00
TABLE OF CONTENTS
Precautions............................................................... 00-i
Precautions ............................................................ 00-1
General Information ................................................... 0-i
General Information ............................................... 0A-1
Maintenance and Lubrication ................................. 0B-1
Engine ......................................................................... 1-i
Precautions .............................................................. 1-1
Engine General Information and Diagnosis ........... 1A-1
Aux. Emission Control Devices .............................. 1B-1
Engine Electrical Devices.......................................1C-1
Engine Mechanical.................................................1D-1
Engine Lubrication System .................................... 1E-1
Engine Cooling System.......................................... 1F-1
Fuel System ...........................................................1G-1
Ignition System.......................................................1H-1
Starting System....................................................... 1I-1
Charging System.....................................................1J-1
Exhaust System ..................................................... 1K-1
Suspension................................................................. 2-i
Precautions .............................................................. 2-1
Suspension General Diagnosis.............................. 2A-1
Front Suspension ................................................... 2B-1
Rear Suspension....................................................2C-1
Wheels and Tires ...................................................2D-1
Driveline / Axle ........................................................... 3-i
Precautions .............................................................. 3-1
Drive Shaft / Axle ................................................... 3A-1
Brakes ......................................................................... 4-i
Precautions .............................................................. 4-1
Brake Control System and Diagnosis .................... 4A-1
Front Brakes........................................................... 4B-1
Rear Brakes ...........................................................4C-1
Parking Brake.........................................................4D-1
ABS ........................................................................ 4E-1
Transmission / Transaxle .......................................... 5-i
Precautions .............................................................. 5-1 1
Manual Transmission/Transaxle ............................5B-1
Clutch .....................................................................5C-1
Automated Manual Transaxle ................................5D-1
Steering ....................................................................... 6-i 2
Precautions .............................................................. 6-1
Steering General Diagnosis ...................................6A-1
Steering Wheel and Column ..................................6B-1
Power Assisted Steering System ...........................6C-1
3
HVAC ........................................................................... 7-i
Precautions .............................................................. 7-1
HVAC System ........................................................7B-1
Restraint...................................................................... 8-i 4
Precautions .............................................................. 8-1
Seat Belts...............................................................8A-1
Air Bag System ......................................................8B-1
Body, Cab and Accessories ...................................... 9-i 5
Precautions .............................................................. 9-1
Wiring Systems ......................................................9A-1
Lighting Systems ....................................................9B-1
Instrumentation / Driver Info. / Horn .......................9C-1
Wipers / Washers ...................................................9D-1 6
Glass / Windows / Mirrors ......................................9E-1
Security and Locks ................................................. 9F-1
Seats ..................................................................... 9G-1
Exterior Trim / Interior Trim ....................................9H-1
Hood / Fenders / Doors .......................................... 9J-1 7
Body Structure .......................................................9K-1
Paint / Coatings ...................................................... 9L-1
Audio Visual / Navigation ...................................... 9O-1
Control Systems....................................................... 10-i 8
Precautions ............................................................ 10-1
Body Electrical Control System ............................10B-1
Immobilizer Control System .................................10C-1
Communication System .......................................10H-1
9
10

Section 00
Precautions
CONTENTS
Precautions ...............................................00-1
Precautions........................................................... 00-1
General Precautions ........................................... 00-1
Precautions for Electrical Circuit Service ............ 00-3
Caution for Fastener ........................................... 00-6
Precautions for Catalytic Converter .................... 00-6
Warning for CNG ................................................ 00-6
Caution for Suspension....................................... 00-6
Caution for Wheel (with Tire) Removal ............... 00-6
Warning for Wheel and Tire ................................ 00-6
Warning for Brake ............................................... 00-7
Table of Contents 00- i
00
Warning for P/S System...................................... 00-7
Warning for Airbag .............................................. 00-7
Warning for Vehicle Equipped with
Supplemental Restraint (Airbag) System .......... 00-7
Precautions for Installing Mobile
Communication Equipment ............................. 00-10
Precautions for CNG Vehicles .......................... 00-10
Repair Instructions ............................................ 00-11
Electrical Circuit Inspection Procedure ............. 00-11
Intermittent Connection and Poor Contact
Inspection........................................................ 00-13
00-1 Precautions:

Precautions
Precautions

Precautions
General Precautions • Do not swallow any service materials.
AENJCA0A0000001 Swallowing them could cause diarrhea,
WARNING and CAUTION describe some general
nausea or other health problems. Be
precautions that you should observe when servicing a
especially careful not to allow children and
vehicle. These general precautions apply to many of the
pets to swallow them.
service procedures, but they will not necessarily be
repeated for every procedure to which they apply. • Keep all service materials out of reach of
children and pets.
! WARNING • Check that the hood is fully closed and
securely latched before driving the vehicle.
Failure to take proper precautions when
If the hood is not fully closed and latched,
servicing a vehicle can cause severe
it can fly up unexpectedly while driving,
personal injury.
obstructing the driver’s view and leading
• Whenever raising a vehicle for service, to an accident.
follow the instructions under “Vehicle
Lifting Points” in Section 0A (Page 0A-8). • Before starting any service work, cover fenders, seats
• If the service work being performed and any other parts that are likely to get scratched or
requires running the engine, check that the stained during servicing. Also, be aware that what you
parking brake is fully set, block drive wear (e.g. buttons) may cause damage to the
wheels and the transaxle is in “Neutral” or vehicle’s finish.
“P” range.
Also keep hands, hair, clothing, tools, etc.
away from the fan and belts while the
engine is running.
• When running the engine indoors, provide
a means to force exhaust gases outdoors.
• Do not perform service work in areas
where combustible materials can come
into contact with a hot exhaust system
component.
• Handle toxic or flammable materials (such
as gasoline and refrigerant) only in a well- I2RH01010025-01

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

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

• When removing the battery, disconnect the negative
(–) cable first and then the positive (+) cable. When
reconnecting the battery, connect the positive (+)
cable first and then the negative (–) cable. Reinstall
the terminal cover.
• Check that all parts used for reassembly are
thoroughly clean.
When the use of a certain type of lubricant, adhesive
or sealant is specified, use only the specified material.
“A”: Sealant 99000-XXXXX (SUZUKI Bond
No.XXXXX)

“A”

I5RS0B150012-01

• Use special tools when instructed.

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

I2RH01010031-01
I5RW0A000002-01
• After servicing any system that is concerned with fuel,
• Do not reuse oil seals, gaskets, packing, O-rings, lock
oil, coolant, vacuum, exhaust gases or brakes, check
washers, split pins, self-locking nuts, and other
all related lines for leakage.
specified parts, but use new ones. Also, before
installing new gaskets, packing, etc., remove any
residual material from the mating surfaces.

I2RH01010033-01
IFFA0B000003-01
• Never disconnect any of the fuel lines between fuel
pump and injectors without first releasing the fuel
pressure, or fuel can be sprayed out under pressure.
00-3 Precautions:

• When performing any work that produces a heat Precautions for Electrical Circuit Service
exceeding 80 °C (176 °F) in the vicinity of the AENJCA0A0000002

electrical parts, remove the heat-sensitive electrical • When replacing a fuse, use a fuse of the specified
part(s) beforehand. capacity. Use of a fuse with a larger capacity will
cause damage to electrical parts and a fire.

I2RH01010034-01

• Do not expose connectors and electrical parts to

water, which will cause trouble to electrical systems. I2RH01010038-01

• Before disconnecting or connecting connectors, do

either of the following depending on the type of power
supply. Otherwise, the electrical parts to which the
power is supplied may be damaged.
– Continuous power supply: Disconnect the negative
(–) cable at the battery.
– Ignition power supply: Set ignition “OFF”.
• When disconnecting connectors, never pull on the
wiring harness. Unlock the connector lock first and
then pull the male and female connectors apart by
holding them.
I2RH01010035-01

• Do not handle electrical components (computers,

relays, etc.) in a rough manner or drop them.

I2RH01010040-01

• When connecting male and female connectors, also

I2RH01010036-01 hold connectors and put them together until they lock
securely (a click is heard).

I2RH01010041-01

• When installing a wiring harness, secure it with
clamps so that no slack is left.
I2RH01010042-01
• When installing vehicle parts, check that they do not
interfere with any wiring harness and they do not
catch any wiring harness under them.
I2RH01010043-01
• Protect the part of harness which may touch any edge
by wrapping it with tape or the like.
I2RH01010044-01
• Be careful not to touch the electrical terminals of parts
which use microcomputers (e.g. electronic control unit
such as ECM, PCM, P/S control module, etc.). The
static electricity from your body can damage these
parts.
I3RM0A000004-01
• Never connect any tester (voltmeter, ohmmeter or
whatever) to terminals of an electronic control unit
when its connector is disconnected. Doing so may
cause damage to the electronic control unit.
Precautions: 00-4
• Never connect an ohmmeter to an electronic control
unit with its connector connected to it. Doing so may
cause damage to electronic control unit and sensors.
• Use only the specified voltmeter / ohmmeter.
Otherwise, accurate measurements may not be
obtained or personal injury may result. Where no
voltmeter type is specified, use a voltmeter with high
impedance (M Ω/V minimum) or a digital type
voltmeter.
• When taking measurements at electrical connectors
using a tester probe, insert the probe (2) from the wire
harness side (backside) of the connector (1).
I2RH01010046-01
• When it is impossible to insert a tester probe from the
harness side of connector, insert a properly sized
male terminal with a lead into the connector and
connect the tester probe to the lead as shown. Do not
insert the probe directly into the connector, or the
female terminal may be deformed.
IAW101000003-01
• When checking connection of terminals, check male
terminals for bend, female terminals for excessive
opening, and both for locking (looseness), corrosion,
dust, etc.
• Before measuring voltage at each terminal, check that
battery voltage is 12 V or more. Terminal voltage
check at low battery voltage will lead to erroneous
results.
I2RH01010048-01
00-5 Precautions:

• For the details of the names and installation positions Twist Pair Wire Harness
of relays and circuit fuses described in this manual,
refer to: NOTE
– “Fuses and the Protected Parts” in Section 9A For locations where twist pair wire harness
(Page 9A-34) are used, refer to “System Circuit Diagram”
in Section 9A (Page 9A-48).
– “J/B Connector Layout” in Section 9A (Page 9A-39)
• A twist (1) in the twist pair wire harnesses except
Wire Color around the connectors (2) should be within 100 mm
• On some connectors, some different circuits use the (3.9 in.). Excessively-loose lines can be affected by
same wire color. electric noise.
In this case, the circuit cannot be identified by wire
color. 2 2
Check the terminal number in the wring diagram to
identify the circuit.

1
IDL10A000001-01
[a]
• Do not connect twist pair line terminals using a bypass
wire (1). Doing so makes the twist pair line receive
electric noise interference.
[a]
IAP70P000002-02

[a]: Identical wire colors. 1

• Some wire harnesses in the same circuit may have

different colors [a] and [b] at both ends of the
intermediate connector.
In this case, the circuit cannot be identified by wire
color.
Check the terminal number in the wring diagram to
identify the circuit.
I4JA01000003-01

Aluminum Wire Harness

If aluminum wire (color LVN: lavender (light purple)) is
[b]
connected to copper wire directly, electrolytic corrosion
may occur and cause faulty electrical continuity, heating
and a fire in the worst case.
[a]
Do not connect aluminum wire to copper wire directly. If
IAP70P000003-01 it is necessary to repair aluminum wire, replace it as wire
harness assembly.
Terminal Number
With some connectors, the numbers are molded into the
connector. However, the numbers may not mean the
terminal numbers which represent the terminal position
described in this manual.
Do not refer to the numbers on the connector for the
terminal numbers.

Caution for Fastener
AENJCA0A0000003
NOTICE
Failure to use correct fasteners or to properly
use fasteners can cause parts or system
damage.
• When fasteners are removed, always
reinstall them at the locations from which
they were removed.
• All fasteners must be replaced with
fasteners having the same part number. If a
fastener of the correct part number is not
available, a fastener of the same size
having equal or higher strength may be
used.
• This manual identifies and indicates
special conditions for all non-reusable
fasteners and fasteners requiring the use
of thread-locking compound. Follow all
instructions, including torque values.
Precautions for Catalytic Converter
AENJCA0A0000004
As this vehicle is equipped with a catalytic converter, use
only unleaded gasoline and be careful not to let a large
amount of unburned gasoline enter the converter, or it
can be damaged.
• Conduct a spark jump test only when necessary to the
shortest possible time without opening the throttle.
• Conduct engine compression checks within the
shortest possible time.
• Avoid any situations which can result in engine misfire
(e.g. starting the engine when the fuel tank is nearly
empty).
Warning for CNG
AENJCA0A0000014
! WARNING
• When removing CNG fuel line components
without relief of CNG pressure, the
removing part may jump out suddenly and
personal injury may result.
Before performing any service work for
CNG fuel line, relieve CNG pressure
referring to “Fuel Pressure Relief
Procedure”: Bi-Fuel CNG in Section 1G
(Page 1G-55).
• Service operation for the fuel system
involves a risk of fire and personal injury if
proper precautions are not taken.
Follow all of the instructions provided in
“Precautions for CNG Vehicles” (Page 00-
10).
Precautions: 00-6
Caution for Suspension
AENJCA0A0000005
! CAUTION
Failure to use proper suspension fasteners
or to perform proper maintenance / repair of
suspension components can cause unsafe
operating conditions.
• Replace suspension fasteners only with
fasteners having the same part number or
their equivalent. Do not use replacement
parts of lesser quality or substitute design.
• Observe the specified torque value for
each fastener to assure proper retention of
components.
• Never repair any suspension part using
heating, quenching, or straightening.
Instead, replace the part with a new one.
Caution for Wheel (with Tire) Removal
AENJCA0A0000006
! CAUTION
A wheel may fall off the axle and cause an
injury if all of the wheel nuts are removed at
the same time.
When removing the last wheel nut, hold the
wheel so that it does not fall off the axle.
Warning for Wheel and Tire
AENJCA0A0000007
! WARNING
Failure to use proper wheel fasteners or to
perform proper maintenance / repair of
wheels can cause unsafe operating
conditions.
• Replace wheel fasteners only with
fasteners having the same part number or
their equivalent. Do not use replacement
parts of lesser quality or substitute design.
• Tighten wheel fasteners to specified
torque value to assure proper retention of
wheels.
• Never repair any wheel by welding.
Excessive heat caused by welding may
damage the wheel.
00-7 Precautions:
Warning for Brake
AENJCA0A0000008
! WARNING
Failure to use proper brake fasteners or to
perform proper maintenance / repair of brake
components can cause unsafe operating
conditions.
• Replace brake fasteners only with
fasteners having the same part number or
their equivalent. Do not use replacement
parts of lesser quality or substitute design.
• Observe the specified torque values when
tightening brake fasteners to assure
proper retention of brake parts.
• Never repair any part by welding.
Excessive heat caused by welding may
damage brake components.
Warning for P/S System
AENJCA0A0000009
! WARNING
Failure to use proper steering gear fasteners
or to perform proper maintenance / repair of
steering components can cause unsafe
operating conditions.
• Replace steering gear fasteners only with
fasteners having the same part number or
their equivalent. Do not use replacement
parts of lesser quality or substitute design.
• Observe the specified torque value for
each fastener to assure proper retention of
components.
Warning for Airbag
AENJCA0A0000011
! WARNING
Failure to take proper precautions when
performing service on or around the airbag
system components or wiring could cause
accidental activation of the airbag system or
render the system inoperative. Either of
these may lead to personal injury.
• Only an authorized SUZUKI dealer should
perform service on or around the airbag
system components or wiring. Refer to
“Airbag System Component, Wiring and
Connector Location” in Section 8B (Page
8B-8) to check whether you are performing
service on or near the airbag system
components or wiring.
• Read and understand all “WARNING”s and
“Precautions for Airbag System Service”
in Section 8B (Page 8B-1) before
performing service on or around the airbag
system components or wiring.
• All service work must be started at least 90
seconds after the ignition has been set
“OFF” and the negative (–) cable has been
disconnected from the battery. Otherwise,
the airbag system may be activated by
reserve energy stored in the Sensing and
Diagnostic Module (SDM).
Warning for Vehicle Equipped with
Supplemental Restraint (Airbag) System
AENJCA0A0000012
! WARNING
Failure to follow the proper procedures when
servicing (removing, reinstalling and
checking) any of airbag system components
could result in personal injury due to
accidental airbag activation, damage to
components, or non-activation of the airbag
system in the event of a collision. (Page
8B-8)
When servicing any of the airbag
components, take the following precautions:
• Follow the procedures described in
“Precautions for Airbag System Service”
in Section 8B (Page 8B-1).
• If the airbag system and another vehicle
system both require repair, repairing the
other system prior to the airbag system
may increase the chance of unintended
activation of the airbag system and
possible personal injury. SUZUKI
recommends that the airbag system be
repaired first.
• Modifying any parts supporting or
surrounding the airbag system
components can adversely affect the
performance of the system and lead to
personal injury.
Do not modify the steering wheel,
dashboard or any other parts that are near
the airbag system components.
• High temperatures over 90 °C (194 °F) may
activate the airbag system or damage its
components.
Before performing paint baking or other
operations that involve high temperatures,
remove the airbag system components
from the vehicle and place them in an area
away from the area where such operations
are to be performed.

Diagnosis
• When troubleshooting the airbag system, follow
“Airbag Diagnostic System Check” in Section 8B
(Page 8B-9).
Bypassing these procedures may result in extended
diagnostic time, incorrect diagnosis, and incorrect
replacement of parts.
• Never use electrical test equipment other than that
specified.
! WARNING
Measuring the resistance of any airbag
(inflator) module or any seat belt
pretensioner with a tester is dangerous, as
the electric current from the tester may
trigger the airbag or pretensioner.
Never measure the resistance of an airbag
(inflator) module or seat belt pretensioner.
IJHA0A000001-01
Servicing and Handling
! WARNING
Airbag (Inflator) Module
Failure to take proper precautions when
servicing and handling airbag (inflator)
modules can cause accidental triggering of
the inflator, which can result in severe
personal injury.
• Always disconnect the “A/B” fuse and
airbag (inflator) modules from the initiator
circuit when instructed in any service
procedure.
• Handle and store a live (non-deployed)
airbag (inflator) module in a dry place
where the ambient temperature is below 65
°C (150 °F), and there are no electric noise
sources.
• Always carry a live airbag (inflator) module
with the airbag’s opening pointing away
from you. Doing so will help reduce the
chance of injury in case of an accidental
deployment of the airbag.
Precautions: 00-8
• Never carry a live airbag (inflator) module
by its wires or connector.
• Always place a live airbag (inflator) module
on a bench or other surface with the bag
side facing up to keep it away from the
surface.
• Do not place anything including another
airbag (inflator) module on top of an airbag
(inflator) module. Allowing for a free space
above the module is essential to minimize
the risk of personal injury in the event of
accidental deployment of the airbag
(inflator) module.
• Never dispose of any live airbag (inflator)
module. Before disposing of any live
airbag (inflator) module, deploy it
according to the applicable procedure
described in “Airbag (Inflator) Module and
Seat Belt Pretensioner Disposal” in
Section 8B (Page 8B-64).
• The airbag (inflator) module is very hot
immediately after deployment. Wait for at
least half an hour to let it cool down before
proceeding to the next step.
• After deployment of an airbag (inflator)
module, there will be a powdery substance
remaining on its surface. This substance
consists primarily of cornstarch that is
used to lubricate the bag as it inflates and
by-products of a chemical reaction. Like
with many other service procedures, wear
gloves and safety glasses to protect the
skin and eyes when handling a deployed
airbag (inflator) module.
[A]
[B]
:[C]
IBP80A000002-01
[A]: Always carry airbag (inflator) module with trim cover (airbag opening)
away from body.
[B]: Always place airbag (inflator) module on workbench with trim cover
(airbag opening) up, away from loose objects.
[C]: Airbag deployment direction
00-9 Precautions:
! WARNING
SDM
Failure to take proper precautions when
servicing and handling the Sensing and
Diagnostic Module (SDM) can cause
accidental triggering of the inflator, which
can result in severe personal injury.
• Always disconnect the “A/B” fuse and
airbag (inflator) modules from the initiator
circuit when instructed in any service
procedure.
• Handle and store an SDM in a dry place
where the ambient temperature is below 65
°C (150 °F), and there are no electric noise
sources.
• Handle the SDM very carefully during all
service procedures. Never strike it with
another object or shake it excessively.
• Never power the airbag system when the
SDM is not rigidly attached to the vehicle.
Unless all fasteners of the SDM mounting
bracket are firmly tightened and the arrow
points toward the front of the vehicle, the
SDM could be accidentally activated when
the airbag system is powered, possibly
causing the airbags to deploy.
! WARNING
Seat Belt Pretensioner
Failure to take proper precautions when
servicing and handling the seat belt
pretensioners can cause accidental
triggering of the pretensioners, which can
result in severe personal injury.
• Always disconnect the “A/B” fuse and seat
belt pretensioners from the initiator circuit
when instructed in any service procedure.
• Handle and store a live (non-activated)
seat belt pretensioner in a dry place where
the ambient temperature is below 65 °C
(150 °F), and there are no electric noise
sources.
• Never carry a live pretensioner by its wires
or connector.
• Never put anything on top of a live
pretensioner placed on a workbench or
similar surface. Any objects on top of the
pretensioner can increase the risk of
personal injury in the event of accidental
activation.
• Never dispose of a live pretensioner.
Before disposing of a live pretensioner,
activate it according to the applicable
procedure described in “Airbag (Inflator)
Module and Seat Belt Pretensioner
Disposal” in Section 8B (Page 8B-64).
• The seat belt pretensioner is very hot
immediately after activation. Wait for at
least half an hour to let it cool down before
proceeding to the next step.
• Like with many other service procedures,
wear gloves and safety glasses when
handling pretensioners to protect the skin
and eyes.
NOTICE
Failure to take proper precautions when
servicing the airbag and seat belt
pretensioner systems may cause faulty
operation or damage to components of the
systems.
• After any accident, even if it was not
severe enough to cause deployment of the
airbags, check the airbag system and other
related components according to the
instructions under “Repair and Inspection
Required after Accident” in Section 8B
(Page 8B-54).
• If any airbag system component is
impacted during service on other
components, remove the airbag system
component before continuing the service.
• Carefully handle the following components
not to drop or otherwise impact them: the
airbag (inflator) modules; the seat belt
pretensioners; the forward and side
sensors; and the SDM. If any of these
components receives an impact, never
disassemble and repair it but replace it
with new one.
• If any of the following components gets
contaminated with such materials as
grease, cleaning solvents, oil or water,
wipe it clean with a dry cloth: the airbag
(inflator) modules and the seat belt
pretensioners.
• The airbag harness is part of the main
harness, instrument panel harness and
floor harness. For easy identification, the
connector-side of each airbag harness
wire is covered with a yellow protection
tube and each connector is yellow in color.
Handle the airbag harness wires and
connectors very carefully.
• When an open wire or damaged connector
/ terminal is found in the airbag harness,
replace the entire harness rather than
replacing only the damaged wire or
connector/terminal.
• Apply power to the airbag system only
when all its components are connected or
a diagnostic procedure requires it. Doing
otherwise will set a DTC.

• Never use airbag system components from
another vehicle.
• When doing any electric welding,
temporarily disable the airbag system
referring to “Disabling Airbag System” in
Section 8B (Page 8B-56).
• Never expose the airbag system
components to extremely hot air (i.e.,
placing the vehicle in an oven to dry it after
painting).
• WARNING / CAUTION labels are affixed to
every airbag system component. Follow
the instructions provided on them.
• After completing repairs on any airbag
system component, perform the
procedures in “Airbag Diagnostic System
Check” in Section 8B (Page 8B-9).
Precautions for Installing Mobile
Communication Equipment
AENJCA0A0000013
When installing mobile communication equipment such
as CB (citizen band) radio or cellular telephone, observe
the following precautions.
Failure to follow these cautions may adversely affect
electronic control system.
• Keep the antenna as far away as possible from the
vehicle’s electronic control unit.
• Keep the antenna feeder more than 20 cm (7.9 in.)
away from any electronic control unit and its wire
harnesses.
• Do not run the antenna feeder parallel with other wire
harnesses.
• Check that the antenna and feeder are correctly
adjusted.
Precautions: 00-10
Precautions for CNG Vehicles
AENJCA0A0000015
CNG Feature
• CNG consists primarily of methane with a small
quantity of ethane and other gaseous paraffinic
hydrocarbons. CNG itself is combustible, odorless,
colorless and invisible gas, but odorant is added by its
manufacturer in order to detect gas leakage easily.
• When CNG leaks, CNG dissipates into the
atmosphere, because CNG is lighter than air.
Condition of Workshop
• Provide the workshop with a gas leak detector or gas
leak detection liquid. Refer to “Fuel Leakage Check
Procedure”: Bi-Fuel CNG in Section 1G (Page 1G-
56).
• Locate vehicle in a well-ventilated area.
• Perform the service work at the place 3 m or more
away from any source 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
shielded from the source of heat.
Servicing and Handling
• 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.
• Relieve CNG pressure before removing CNG pipes or
hoses. Check for fuel leakage after installing them.
• The CNG cylinder, piping and all components of the
system should be checked for corrosion, deterioration
and for any modification affecting compliance, at least
once 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 has passed for more than 20
years from its production should not be used
continuously.
00-11 Precautions:

Repair Instructions
Electrical Circuit Inspection Procedure 4) Perform continuity test or voltage check using the
AENJCA0A0006001 following procedure, to check the wire harness for
While there are various electrical circuit inspection
open circuit and poor connection at its terminals.
methods, the following describes the general methods
using an ohmmeter and a voltmeter to check open and
short circuits.

Open Circuit Check

Possible causes for the open circuit are as listed below.
As defects in connectors or terminals are most often the
causes, they need to be checked particularly and I2RH01010051-01

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

• Loose connection of connector 2. Open

• Poor contact of terminal (caused by dirt, corrosion or

Continuity Test
rust on it, poor contact tension, entry of foreign object,
etc.) 1) Measure resistance between connector terminals at
both ends of the circuit under test (between “A-1”
• Open wire harness
and “C-1” in the figure). If no continuity is indicated
When checking circuits including an electronic control
(infinity or over limit), it means that the circuit is open
unit such as ECM, TCM, ESP® control module, etc., it is
between terminals “A-1” and “C-1”.
important to carefully perform check, starting with items
which are easiest to check.
1) Disconnect negative (–) cable at battery.
2) Check connectors at both ends of the circuit being
checked for loose connection. Also check lock
condition of connectors if equipped with connector
locks.

I2RH01010052-01

2) Disconnect the connector included in the circuit

IFFA0B000002-01
3) Using a male terminal for test use, check terminals
on both ends of the circuit being checked for contact
tension of female terminals. Check each terminal
visually for cause of poor contact (dirt, corrosion,
rust, entry of foreign object, etc.). At the same time,
check that each terminal is held and locked in
connector fully.
(connector-B in the figure) and measure resistance
between terminals “A-1” and “B-1”.
If no continuity is indicated, it means that the circuit
is open between terminals “A-1” and “B-1”. If
continuity is indicated, there is an open circuit
between terminals “B-1” and “C-1” or connector-B is
defective.

I2RH01010053-01
I2RH01010050-01

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


Voltage Check
If the circuit being checked is under voltage, voltage
check can be used to check the circuit.
1) With all connectors connected and voltage applied to
the circuit being checked, measure voltage between
each terminal and ground.
a) If measurements are taken as shown in figure
and results are as listed below, it means that the
circuit is open between terminals “B-1” and “A-1”.
Voltage between
“C-1” and ground: Approx. 5 V
“B-1” and ground: Approx. 5 V
“A-1” and ground: 0 V
b) If measurements are as listed below, it means
that there is an abnormally high resistance
causing the indicated voltage drop in the circuit
between terminals “A-1” and “B-1”.
Voltage between
“C-1” and ground: Approx. 5 V
“B-1” and ground: Approx. 5 V
“A-1” and ground: Approx. 3 V
I5RH01000005-01
Precautions: 00-12
Short Circuit Check (Wire Harness to Ground)
1) Disconnect negative (–) cable at battery.
2) Disconnect connectors at both ends of the circuit to
be checked.
NOTE
If the circuit to be checked is connected to
other parts (1), disconnect all connections to
these parts.
This is essential to having correct check
results.
3) Measure resistance between the terminal at one end
of the circuit (“A-1” terminal in the figure) and
ground. If continuity is indicated, it means that the
circuit is shorted to ground between terminals “A-1”
and “C-1”.
I5RH01000006-01
00-13 Precautions:

4) Disconnect the connector included in circuit • Improperly formed or damaged terminals.

(connector-B) and measure resistance between “A-
1” and ground. If continuity is indicated, the circuit is
shorted to ground between terminals “A-1” and “B-
1”.
Check each connector terminal in circuit with problem
for good contact tension using a corresponding test
terminal.
If contact tension is not enough, correct terminal
shape to increase contact tension or replace harness.

I2RH01010056-01

1. To other parts

Intermittent Connection and Poor Contact

Inspection
AENJCA0A0006002
Most intermittent connections are caused by faulty
electrical connections or wiring, although a sticking relay
or solenoid can occasionally be a cause. When checking
I5RH01000007-01
connections, perform check of suspect circuit for:
1. Check contact tension by inserting and removing just once.
• Poor mating of connector halves, or terminals not fully 2. Check each terminal for bend and proper alignment.
seated in the connector body (backed out).
• Dirt or corrosion on the terminals. The terminals must • Poor connection of terminal and wire.
be clean and free of any foreign material which could Check each wire harness in circuit with problem for
impede proper terminal contact. However, cleaning poor connection by shaking it by hand lightly. If any
the terminal with a sand paper or the like is prohibited. abnormal condition is found, repair or replace
• Damaged connector body, terminals exposed to harness.
moisture and dirt, misalignment of terminals on
component or connector and mating connector.

I2RH01010057-02
I2RH01010059-01
 Precautions: 00-14

• Damaged wire insulation, causing intermittent short

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

I2RH01010060-01
00-15 Precautions:

Section 0
General Information
CONTENTS
General Information ................................ 0A-1
General Description .............................................0A-1
Abbreviations ...................................................... 0A-1
ISO-to-SUZUKI Term .......................................... 0A-2
Symbols .............................................................. 0A-5
Wire Color / Connector Color Symbols ............... 0A-5
Ignition Modes and Ignition Switch Positions ...... 0A-6
Fasteners Information ......................................... 0A-6
Vehicle Lifting Points........................................... 0A-8
Vehicle Identification Number ........................... 0A-11
Identification Plate............................................. 0A-12
Engine Identification Number ............................ 0A-12
CNG Compliance Plate ..................................... 0A-12
Component Location .........................................0A-13
Warning, Caution and Information Location...... 0A-13
Maintenance and Lubrication................. 0B-1
Scheduled Maintenance ......................................0B-1
Maintenance Schedule under Normal Driving
Conditions ......................................................... 0B-1
Maintenance Recommended under Severe
Driving Conditions ............................................. 0B-2
Periodic Maintenance Schedule (Bi-Fuel
CNG Model) ...................................................... 0B-4
Repair Instructions ..............................................0B-5
Accessory Drive Belt Inspection.......................... 0B-5
Accessory Drive Belt Replacement..................... 0B-5
Valve Lash (Clearance) Inspection ..................... 0B-5
Engine Oil and Filter Change .............................. 0B-5
Engine Coolant Change ...................................... 0B-5
Exhaust System Inspection................................. 0B-5
Spark Plug Replacement .................................... 0B-5
Air Cleaner Filter Inspection................................ 0B-6
Air Cleaner Filter Replacement ........................... 0B-6
Fuel Tank, Cap Gasket and Fuel Line
Inspection.......................................................... 0B-6
Special Tools and Equipment ...........................0B-12
Fuel Filter Replacement ...................................... 0B-6
PCV Valve Inspection ......................................... 0B-6
Table of Contents 0- i
0
Fuel Evaporative Emission Control System
Inspection..........................................................0B-6
CNG Leakage Inspection ....................................0B-6
Cooling System Hose Inspection ........................0B-6
CNG System Fastener ........................................0B-6
CNG Fuel Filter Replacement .............................0B-6
Spark Plug Inspection .........................................0B-6
CNG Cylinder Inspection.....................................0B-6
CNG Receptacle Replacement ...........................0B-7
Brake Disc and Pad Inspection ...........................0B-7
Brake Drum and Shoe Inspection .......................0B-7
Brake Hose and Pipe Inspection.........................0B-7
Brake Fluid Inspection.........................................0B-7
Brake Pedal Inspection .......................................0B-7
Brake Fluid Replacement....................................0B-7
Brake Lever and Cable Inspection ......................0B-7
Clutch Pedal Inspection (M/T Model) ..................0B-8
Tire Inspection.....................................................0B-8
Wheel Disc Inspection.........................................0B-8
Wheel Bearing Inspection ...................................0B-8
Drive Shaft (Axle) Boot Inspection ......................0B-8
Suspension System Inspection ...........................0B-9
Steering System Inspection ................................0B-9
Manual Transaxle Oil Inspection (M/T Model) ..0B-10
Manual Transaxle Oil Replacement (M/T
Model) .............................................................0B-10
Auto Gear Shift Transaxle Oil Inspection
(Auto Gear Shift Model) ..................................0B-10
Auto Gear Shift Transaxle Oil Replacement
(Auto Gear Shift Model) ..................................0B-10
Auto Gear Shift Actuator Oil Inspection (Auto
Gear Shift Model) ............................................0B-10
All Latches, Hinges and Locks Inspection.........0B-10
HVAC Air Filter Inspection ................................0B-10
HVAC Air Filter Replacement............................0B-10
Final Inspection for Maintenance Service .........0B-10
Recommended Fluids and Lubricants...............0B-12
0A-1 General Information:

General Information
General Information

General Description
Abbreviations EGT: Exhaust Gas Temperature
AENJCA0A0101001 ELR: Emergency Locking Retractor
A:
ENG A-STOP: Engine Auto Stop and Start
A/B: Airbag
EPS: Electronic Power Steering
ABDC: After Bottom Dead Center
ESP®: Electronic Stability Program
ABS: Anti-lock Brake System
EVAP: Evaporative Emission
AC: Alternating Current
F:
A/C: Air Conditioning
FET: Field-Effect Transistor
A-ELR: Automatic-Emergency Locking Retractor
FWD: Front Wheel Drive
A/F: Air Fuel Ratio
G:
ALR: Automatic Locking Retractor
GND: Ground
API: American Petroleum Institute
GPS: Global Positioning System
APP: Accelerator Pedal Position
H:
A/T: Automatic Transmission, Automatic Transaxle
HVAC: Heating, Ventilating and Air Conditioning
ATDC: After Top Dead Center
HC: Hydrocarbons
ATF: Automatic Transmission Fluid, Automatic
HDD: Hard Disk Drive
Transaxle Fluid
HFC: Hydro Fluorocarbon
AWD: All Wheel Drive
HFO: Hydro Fluoroolefin
B:
HI: High
BARO: Barometric Pressure
HO2S: Heated Oxygen Sensor
BBDC: Before Bottom Dead Center
I:
BCM: Body electrical Control Module
IAC: Idle Air Control
BTDC: Before Top Dead Center
IAT: Intake Air Temperature
B+: Battery Positive Voltage
IMRC: Intake Manifold Runner Control
BB+: Battery Positive Voltage for Backup IMT: Intake Manifold Tuning
C: ISC: Idle Speed Control
CAN: Controller Area Network ISG: Integrated Starter Generator
CKP: Crankshaft Position ISO: International Organization for Standardization
CMP: Camshaft Position J:
CNG: Compressed Natural Gas JIS: Japanese Industrial Standards
CO: Carbon Monoxide J/B: Junction Block
CO2: Carbon Dioxide J/C: Junction Connector
CPP: Clutch Pedal Position L:
CPU: Central Processing Unit L: Left
CVT: Continuously Variable Transmission, LCD: Liquid Crystal Display
Continuously Variable Transaxle LED: Light Emitting Diode
D: LHD: Left Hand Drive vehicle
DC: Direct Current LIN: Local Interconnect Network
D/C: Driving Cycle LO: Low
DLC: Data Link Connector LSD: Limited Slip Differential
DOHC: Double Over Head Camshaft LSPV: Load Sensing Proportioning Valve
DOJ: Double Offset Joint M:
DOT: Department of Transportation MAF: Mass Air Flow
DPF®: Diesel Particulate Filter MAP: Manifold Absolute Pressure
DRL: Daytime Running Light
Max: Maximum
DSBS: Dual Sensor Brake Support
MFI: Multiport Fuel Injection
DTC: Diagnostic Trouble Code (Diagnostic Code)
Min: Minimum
E:
MIL: Malfunction Indicator Lamp (“CHECK ENGINE”
EBD: Electronic Brake Force Distribution
Light or “SERVICE ENGINE SOON” Light)
ECM: Engine Control Module
M/T: Manual Transmission, Manual Transaxle
ECT: Engine Coolant Temperature
N:
ECU: Electronic Control Unit
NOx: Nitrogen Oxides
EEPROM: Electrically Erasable Programmable Read
O:
Only Memory
OBD: On-Board Diagnostic system
EFE Heater: Early Fuel Evaporation Heater
OCM: Occupant Classification Module
EGR: Exhaust Gas Recirculation
 General Information: 0A-2

OCV: Oil Control Valve TCM: Transmission Control Module

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

ISO-to-SUZUKI Term
AENJCA0A0101002
This table lists ISO (International Organization for Standardization) TR15031 terms and abbreviations which may be
used in this manual in compliance with ISO recommendations, as well as their SUZUKI terms.
ISO term
SUZUKI term
Full spelling Abbreviation
A
Accelerator Pedal Position APP Accelerator Pedal Position (APP)
Air Cleaner ACL Air Cleaner
Air Cleaner Element ACL Element Air Cleaner Element
Air Cleaner Housing ACL Housing Air Cleaner Housing
Air Conditioning A/C Air Conditioner (A/C)
Air Conditioning System A/C System Air Conditioning System (A/C system)
Air Fuel Ratio Sensor A/F Sensor Air Fuel Ratio Sensor (A/F sensor)
Automatic Transaxle, Automatic A/T Automatic Transaxle, Automatic Transmission (A/T)
Transmission
B
Barometric Pressure BARO Barometric Pressure (BARO)
Barometric Pressure Sensor BARO Sensor Barometric Pressure Sensor (BARO sensor)
Battery Positive Voltage B+ Battery Positive Voltage (B+)
C
Camshaft Position CMP Camshaft Position
Camshaft Position Sensor CMP Sensor Camshaft Position Sensor (CMP sensor)
Carbon Monoxide CO Carbon Monoxide (CO)
Carbon Dioxide CO2 Carbon Dioxide (CO2)
Clutch Pedal Position Switch CPP Switch Clutch Pedal Position Switch (CPP switch)
Closed Loop CL Closed-Loop
Closed Throttle Position CTP Closed Throttle Position
0A-3 General Information:

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

ISO term
SUZUKI term
Full spelling Abbreviation
Open Loop OL Open Loop
Output Shaft Speed Sensor OSS Sensor Output Shaft Speed Sensor
Oxygen O2 O2
Oxidation catalytic converter OC Oxidation catalytic converter
Oxygen Sensor O2S O2 Sensor, O2S
P
Positive Crankcase Ventilation PCV PCV
Positive Crankcase Ventilation Valve PCV Valve PCV Valve
Power Steering Pressure Switch PSP Switch Power Steering Pressure Switch
Powertrain Control Module PCM PCM
R
Random Access Memory RAM RAM
S
Scan Tool ST Scan Tool
Shift Solenoid SS Shift Solenoid
Shift Solenoid Valve SS Valve Shift Solenoid Valve
T
Third Gear 3GR 3rd Gear
Three Way Catalytic Converter TWC Three-Way Catalytic Converter (TWC)
Throttle Actuator Control TAC Throttle Actuator Control
Throttle Body TB Throttle body
Throttle Position TP Throttle Position, TP
Throttle Position Sensor TP Sensor TP Sensor
Torque Converter Clutch TCC Torque Converter Clutch
Torque Converter Clutch Pressure TCCP Torque Converter Clutch Pressure
Transmission Control Module TCM Transmission Control Module (TCM)
Transmission Fluid Temperature Sensor TFT Sensor Transmission Fluid Temperature Sensor
Transmission Range TR Transmission Range
Transmission Range Sensor TR Sensor Transmission Range Sensor
Transmission Range Switch TR Switch Transmission Range Switch
V
Vehicle Identification Number VIN Vehicle Identification Number, VIN
Vehicle Speed Sensor VSS Vehicle Speed Sensor, VSS
Voltage Regulator VR Voltage Regulator
W
Warm Up Three Way Catalytic Converter WU-TWC Warm Up Three-Way Catalytic Converter
0A-5 General Information:

Symbols
AENJCA0A0101003
Symbol Definition Symbol Definition
Tightening torque Apply SUZUKI BOND NO. 1207B
99000-31140
Apply oil (engine, transmission, transfer, Apply SILICONE SEALANT
differential) 99000-31120
Apply fluid (brake, power steering or Apply SEALING COMPOUND 366E
automatic transmission fluid) 99000-31090
Apply SUZUKI SUPER GREASE A Apply THREAD LOCK 1322
99000-25011 99000-32150
Apply SUZUKI SUPER GREASE C Apply THREAD LOCK 1333B
99000-25030 99000-32020
Apply SUZUKI SUPER GREASE E Apply THREAD LOCK 1342
99000-25050 99000-32050
Apply SUZUKI SUPER GREASE H Do not reuse
99000-25121
Apply SUZUKI SUPER GREASE I Note on reassembly
99000-25210
Apply SUZUKI BOND NO. 1215 Alert
99000-31110
Apply SUZUKI BOND NO. 1207F Do not touch electricity
99000-31250
Apply SUZUKI BOND NO. 1217G Do not repair or disassemble
99000-31260
Apply SUZUKI BOND NO. 1216B Refer to service manual or owner’s
99000-31230 manual

Wire Color / Connector Color Symbols

AENJCA0A0101004
Symbol Wire color / Connector color Symbol Wire color / Connector color
Natural (Plastic material color: Milky
BEG Beige N
white / Light yellow)
BLK Black ORN Orange
BLU Blue RED Red
BRN Brown WHT White
GRN Green YEL Yellow
GRY Gray PNK Pink
LVN Lavender PPL Violet

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

2
1 GRN
GRN/YEL 1
GRN/YEL

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

N 5
6
IDP50B010001-01

5. Connector color
 General Information: 0A-6

Ignition Modes and Ignition Switch Positions Fastener Strength Identification

AENJCA0A0101005 Most commonly used strength classes of metric
In this manual, each ignition switch position (models with
fasteners are 4T, 6.8, 7T and 8.8. Strength class is
a conventional ignition switch system) and the
indicated by a number or radial line(s) embossed on the
corresponding ignition mode (models with a keyless
head of each bolt. Some metric nuts have a inscribed
push start system) are indicated using the following
number, 6 or 8 on their end surfaces. Figure shows
unified word / acronym preceded by “ignition”: START,
different strength markings.
ON, ACC or OFF (e.g. “ignition ON”) unless there is
When replacing metric fasteners, use bolts and nuts of
need to express it otherwise.
the same strength class as or higher class than the
original bolts and nuts. It is also important to select
Fasteners Information replacement fasteners of the correct diameter and
AENJCA0A0101006
Metric Fasteners thread pitch. Correct replacement bolts and nuts are
Most of the fasteners used for this vehicle are JIS- available as SUZUKI spare parts.
defined and ISO-defined metric fasteners. When Metric bolts and nuts: Strength class numbers or marks
replacing any fasteners, it is most important that (The larger the number, the greater the strength).
replacement fasteners are of the correct diameter,
thread pitch and strength.

NOTICE
Combining male and female fasteners with
different thread pitches will damage both
fasteners.
It is important to note that, even when the
nominal diameter (1) of the threads is the
same, JIS-defined and ISO-defined fasteners
may be different in thread pitch (2) or width
across flats (3). Refer to the following table
for these differences.
Before installing a fastener, check it for
correct thread pitch and then, screw it in or
on the mating fastener by hand. If the
fastener is too tight to turn by hand, its
thread pitch may be different from that of the I5RH01010001-01
mating fastener.
1. Nut strength identification

JIS-to-ISO main fasteners comparison table

Nominal diameter
M6 M8 M10 M12 M14
Thread pitch 1.0 1.25 1.25 1.25 1.5
JIS
Width across flats 10 12 14 17 19
Thread pitch 1.0 1.25 1.5 1.5 1.5
ISO
Width across flats 10 13 16 18 21

I4RH0A010005-01
0A-7 General Information:

Standard Tightening Torque

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

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

Tightening torque chart

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

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

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

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

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

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

I2RH01010017-01

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

Vehicle Lifting Points

AENJCA0A0101007
! WARNING
Improperly lifting the vehicle using a hoist could cause serious personal injury and/or damage to the
vehicle.
Take the following precautions when lifting the vehicle with a hoist:
• Before applying the hoist arms to the underbody, keep in mind how the balance of the vehicle will
change when components are removed during the intended service.
• Before lifting up the vehicle, check that the ends of the hoist arms are not in contact with
components such as the brake and fuel lines, and related brackets.
• When using a frame contact hoist, apply the right and left arms to the symmetrically located points
shown in the figure. Lift up the vehicle until all 4 tires are slightly off the ground and check that the
vehicle will not fall off the hoist by rocking the vehicle body back and forth.
Work should be started only after this confirmation.
• Lock the hoist after the vehicle has been raised up to the desired height.

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

[A] [B]

4
4
6 6
1 5

1 5
2
4
2
3 4

3 3

IGSB0A010001-01

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

0A-9 General Information:

When Using Frame Contact Hoist

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

[A] [B]

4 4

“b” “b” “b”

“b”

2 2

[F]

1
1
3

[a] “a”
2
IJCA0A010001-01

[A]: Front side [a]: Wheel center 2. Support position for frame contact hoist and safety stand
[B]: Rear side “a”: Approx. 969 – 1,124 mm (Approx. 3. Gravity center position without load in vehicle
38.15 – 44.25 in.)
[F]: Vehicle front 1. Floor jack position
 General Information: 0A-10

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

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

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

IJCA0A010002-01

“l”

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

Rear
Front

“a” “a”

1
IJCA0A010004-01

Rear

2
IJCA0A010003-01

To perform service with either front or rear vehicle end

jacked up, place safety stands (1) under the body
mounting stays (2) so that vehicle body is securely
“a” “a”
supported. Then check that vehicle body does not slide
on safety stands and the vehicle is held stable. 1
IJCA0A010005-01
NOTICE
Improper placing safety stands to the vehicle
Vehicle Identification Number
may damage body parts such as underbody AENJCA0A0101008
flange. The number (1) is inscribed on the cowl upper panel in
When supporting the vehicle body, check engine compartment.
that there is space “a” between safety stand
and body parts.

IJCA0A010006-01
 General Information: 0A-12

Identification Plate Engine Identification Number

AENJCA0A0101009 AENJCA0A0101010
Identification plate (1) is installed at the center pillar The engine identification number is inscribed on cylinder
lower side on the right side body outer panel. block.
The identification plate has the following information:
• VIN (2)
• Engine identification number (3)

IFRA0B010003-01

CNG Compliance Plate

AENJCA0A0101011
The plate (1) is attached on the inside of fuel filler lid.

3
IFRA0A010008-01

IJCA0A010007-01
0A-13 General Information:

Component Location
Warning, Caution and Information Location
AENJCA0A0103001
The figure shows main labels that are attached to vehicle components.
When servicing and handling components, refer to WARNING / CAUTION instructions printed on labels.
If any WARNING / CAUTION label is found stained or damaged, clean or replace it.

[A]

2 5

3 4

IJCA0A010008-03

[A]: These labels are WARNING/CAUTION labels for 2. Radiator cap label 4. Steering shaft joint cover label
items not related to airbag system.
1. Battery label 3. Engine cooling fan label 5. Jack label
 General Information: 0A-14

[B]
[a]

3
3
2
[a]

IJCA0A010009-01

[B]: These labels are attached on vehicle equipped with airbag system only. 3. Airbag label (printed warning) on sun visor (passenger side)
1. Airbag label on driver airbag (inflator) module 4. Airbag label on SDM
2. Airbag label on passenger airbag (inflator) module (if equipped) 5. Pretensioner label on front seat belt retractor (if equipped)
0A-15 General Information:

CNG Labels

NOTE
These labels are attached on vehicle equipped with bi-fuel CNG system only.

3
2

IJCA0A010010-02

1. CNG label on driver door 3. CNG label on windshield glass

2. CNG label on rear end door glass 4. CNG label on CNG cylinder
 Maintenance and Lubrication: 0B-1

Maintenance and Lubrication

General Information

0B

Scheduled Maintenance
Periodic Maintenance Schedule (Petrol Model)
AENJCA0A0205001
NOTE
• The intervals should be determined based on odometer readings or months, whichever comes first.
• The following table shows the service schedule up to 80,000 km. Beyond 80,000 km, perform the
same maintenance services at the same intervals shown in the table.

km (x 1,000) 1 5 10 20 30 40 50 60 70 80
Interval
months 1 6 12 24 36 48 60 72 84 96
Engine
Water pump drive belt (tension, wear) (I: (Page 0B-4),
— — — — — I — — — R
R: (Page 0B-4))
Engine coolant (level, leakage) (R: (Page 0B-4)) I I I R I R I R I R
Engine oil, engine oil filter and drain plug gasket (Level,
— — R R R R R R R R
Leakage) (R: (Page 0B-4))
Cooling system hoses and connections (leakage,
I I I I I I I I I I
damage)
Engine mounting and manifold fixing (loose, damage) — — I — I — I — I —
Valve clearance (I: (Page 0B-4)) — — — — I — — I — —
Exhaust system (noise, leakage, etc.) (I: (Page 0B-4)) — I — I — I — I — I
Positive crankcase ventilation system (hoses,
— I — I — I — I — I
connections and valve) (I: (Page 0B-5))
Ignition
Ignition wiring (damage, deterioration) — — — I — I — I — I
Spark plug (R: (Page 0B-4)) — — — — — R — — — R
Fuel
Paved road Clean every 5,000 km. Replace every 40,000 km.
Air cleaner filter element (I: (Page 0B-5),
Dusty Clean every 2,500 km or as required. Replace every 40,000
R: (Page 0B-5))
condition km. Replace more frequently if dust condition is severe.
Fuel filter (leakage) (R: (Page 0B-5)) I I I I I R I I I R
Fuel tank cap, fuel lines and connections (leakage,
— — — — — I — — — I
damage) (I: (Page 0B-5))
Clutch and Transmission
Clutch pedal (play) (I: (Page 0B-7)) I I I I I I I I I I
Clutch slipping (dragging or excess damage) I I I I I I I I I I
Manual transmission oil / Auto Gear Shift oil (level,
I I I I I I I I I I
leakage) (I: (Page 0B-9), R: (Page 0B-9))
Gear shifter (Operation) I I I I I I I I I I
Drive Shaft
Drive shaft noise I I I I I I I I I I
Drive shaft boots (damage) (I: (Page 0B-7)) — I I I I I I I I I
Brake
Brake fluid (level, leakage) (I: (Page 0B-6), R: (Page
I I I R I R I R I R
0B-6))
Brake pedal (pedal - carpet clearance) (I: (Page 0B-6)) I I I I I I I I I I
Parking brake lever and cable (play, damage)
I I I I I I I I I I
(I: (Page 0B-6))
Brake discs and pads (wear) (I: (Page 0B-6)) — I I I I I I I I I
Brake drum and shoes (wear) (I: (Page 0B-6)) — — I I I I I I I I
Brake hoses and pipes (fluid leakage, damage)
I I I I I I I I I I
(I: (Page 0B-6))
Master cylinder, wheel cylinder, caliper piston (fluid
I I I I I I I I I I
leakage, boot/seal damage)
Wheel
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
Tires (air pressure, abnormal wear, crack and rotation) I I&O I&O I&O I&O I&O I&O I&O I&O I&O
Wheels (damage) (I: (Page 0B-7)) I I I I I I I I I I
Front / rear wheel bearings (loose, damage)
I I I I I I I I I I
(I: (Page 0B-7))
Front / Rear Suspension
Suspension strut (oil leakage, damage)
I I I I I I I I I I
(I: (Page 0B-8))
Suspension arms / knuckle support and torsion rods
— I I I I I I I I I
(loose, damage) (I: (Page 0B-8))
Rear spring (damage) (I: (Page 0B-8)) I I I I I I I I I I
Shock absorbers (oil leakage, damage)
I I I I I I I I I I
(I: (Page 0B-8))
All bolts and nuts (loose) (I: (Page 0B-8)) — T T T T T T T T T
Steering
Steering wheel (play, loose) (I: (Page 0B-8)) I I I I I I I I I I
All rods and arms (loose, damage, wear)
I I I I I I I I I I
(I: (Page 0B-8))
Tilt steering (operation) (I: (Page 0B-8)) I I I I I I I I I I
Electrical
Battery electrolyte (level, leakage) and voltage
I I I I I I I I I I
(I: (Page 0B-10))
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
Wiper (operation) I I I I I I I I I I
Horn (operation) I I I I I I I I I I
AUX, USB (if equipped) and accessory socket
— I I I I I I I I I
(Operation)
Body
All chassis bolts and nuts (tighten) — T T T T T T T T T
All latches, hinges and locks (function) (I: (Page 0B-9)) I I&L I&L I&L I&L I&L I&L I&L I&L I&L
Road Test
Operation of brakes, gear shifting and speedometer I I I I I I I I I I
Body and chassis noise I I I I I I I I I I
Air Conditioner
Check belt tension (I: (Page 0B-4)) I I I I I I I I I I
Tighten compressor mounting bolts — T T T T T T T T T
All hose joints (check, tighten) I I I I I I I I I I
Check functioning of recirculating flap I I I I I I I I I I
Clean condenser with low pressure water — C C C C C C C C C
Check belt for frayed edges (I: (Page 0B-4)) I I I I I I I I I I
Check all mounting bolts I I I I I I I I I I
Air conditioner filter element (if equipped) (I:(Page 0B-
I I I I R I I R I I
9), R:(Page 0B-9))

NOTE
• “R”: Replace or change
• “I”: Inspect, clean, adjust, lubricate, correct, or replace if necessary.
• “L”: Lubricate
• “T”: Tighten to specified torque wherever applicable
• “C”: Clean
• “O”: Rotate
• For specified spark plug, refer to “Spark Plug Inspection”.
– K10B model: (Page 1H-7)
– K12M model: (Page 1H-17)
 Maintenance and Lubrication: 0B-3

Periodic Maintenance Schedule (Bi-Fuel CNG Model)

AENJCA0A0205003
NOTE
• This table shows services for CNG system only. Make sure to carry out services additionally,
according to the table of “Periodic Maintenance Schedule (Petrol Model)”
• This interval should be judged by odometer reading or months, whichever comes first.
• This table includes service as scheduled up to 100,000 km. Beyond 100,000 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 90 100
Interval
Months 1 6 12 24 36 48 60 72 84 96 108 120
All joints (CNG leakage)
I I I I I I I I I I I I
(I: (Page 0B-5))
Coolant hoses (leakage, damage)
I I I I I I I I I I I I
(I: (Page 0B-5))
All fasteners torque values T T T T T T T T T T T T
CNG low pressure filter
— — — R — R — R — R — R
cartridge with O-Ring
CNG cylinder leak testing and
Every 3 years from the date of initial testing, by govt. approved testing agency
certification
CNG filler receptacle O-ring Replace every 4 years or 300,000 km, whichever comes first

NOTE
• “R”: Replace or change
• “I”: Inspect, clean, adjust, lubricate or replace it if necessary
• “T”: Tighten to specified torque
0B-4 Maintenance and Lubrication:

Repair Instructions
Accessory Drive Belt Inspection Engine Coolant Change
AENJCA0A0206001 AENJCA0A0206005
! WARNING Change engine coolant with new one.
• K10B model:
There is a risk of personal injury if the service
– Draining: (Page 1F-9)
work described below is performed while the
engine is running. – Refilling: (Page 1F-9)
Check that the ENGINE IS NOT RUNNING • K12M model:
before performing the service work – Draining: (Page 1F-27)
described below.
– Refilling: (Page 1F-27)
Check belt for tension, crack, cuts, deformation, wear
and contamination. If any defect is found, replace belt. Exhaust System Inspection
AENJCA0A0206006
• Water pump / generator drive belt: ! CAUTION
– K10B model: (Page 1J-7) Exhaust system components may be hot
– K12M model: (Page 1J-25) enough to cause burns.
– Compressor drive belt: (Page 7B-50) Check that all exhaust system components
have cooled before performing any service
Accessory Drive Belt Replacement work on the exhaust system.
AENJCA0A0206002
Replace accessory drive belt with new one. When carrying out periodic maintenance, or the vehicle
• Water pump / generator drive belt: is hoisted for other service, check exhaust system as
– K10B model: (Page 1J-8) follows:
– K12M model: (Page 1J-26) • Check rubber mountings for damage, deterioration
and dislocation.
• Compressor drive belt: (Page 7B-51)
• Check exhaust system for leakage, loose
connections, dents and damages.
Valve Lash (Clearance) Inspection
AENJCA0A0206003 If bolts or nuts are loose, tighten them to specification.
Check intake and exhaust valve clearances. Adjust them • Check nearby body areas for damaged, missing or ill-
if necessary. placed parts, open seams, holes, loose connections
Refer to “Valve Clearance Inspection and Adjustment” or other defects which could permit exhaust fumes to
for valve clearance inspection and adjustment seep into the vehicle.
procedures.
• Check that exhaust system components have enough
• K10B model: (Page 1D-3) clearance from the underbody to avoid overheating
• K12M model: (Page 1D-79) and possible damage to floor carpet.
– K10B model: (Page 1K-2)
– K12M model: (Page 1K-8)
• Any defects should be fixed at once.

Spark Plug Replacement

AENJCA0A0206007
Replace spark plugs with new ones.
• K10B model: (Page 1H-7)
• K12M model: (Page 1H-17)

I2RH0B020003-02

1. Camshaft 2. Feeler gauge

Engine Oil and Filter Change

AENJCA0A0206004
Change engine oil and filter.
• K10B model: (Page 1E-4)
• K12M model: (Page 1E-19)
 Maintenance and Lubrication: 0B-5

Air Cleaner Filter Inspection Fuel Filter Replacement

AENJCA0A0206008 AENJCA0A0206011
1) Remove air cleaner filter. ! WARNING
• K10B model: (Page 1D-5)
Replacing the fuel filter without adequate
• K12M model: (Page 1D-82) ventilation may lead to a fire.
2) Check that filter is not excessively dirty, damaged or Replace the fuel filter only in a well-ventilated
oily. Clean filter with compressed air from air outlet area away from any open flames (e.g. a gas
side of filter. water heater).

[A] Replace fuel filter.

• Petrol model: (Page 1G-29)
• Bi-fuel CNG model: (Page 1G-64)

PCV Valve Inspection

AENJCA0A0206012
Check PCV valve and hose.
• K10B model:
– PCV valve: (Page 1B-7)
– PCV hose: (Page 1B-6)
• K12M model:
[B]
IHSE0A020001-01
– PCV valve: (Page 1B-13)
[A]: Air outlet (throttle) side [B]: Air inlet (flesh air) side
– PCV hose: (Page 1B-12)

3) Install air cleaner filter. Fuel Evaporative Emission Control System

• K10B model: (Page 1D-5) Inspection
AENJCA0A0206013
• K12M model: (Page 1D-82) Check EVAP canister and fuel vapor hose.
• K10B model:
Air Cleaner Filter Replacement – EVAP canister: (Page 1B-5)
AENJCA0A0206009
Replace air cleaner filter with new one. – EVAP connection hose: (Page 1B-6)
• K10B model: (Page 1D-5) • K12M model:
• K12M model: (Page 1D-82) – EVAP canister: (Page 1B-12)
– EVAP connection hose: (Page 1B-12)
Fuel Tank, Cap Gasket and Fuel Line Inspection
AENJCA0A0206010
CNG Leakage Inspection
• Check fuel tank, fuel filler cap (1) and fuel lines for AENJCA0A0206042
loose connection, deterioration or damage which Check CNG leakage. (Page 1G-57)
could cause leakage. Check that all clamps are
secure. Cooling System Hose Inspection
AENJCA0A0206043
• Check fuel filler cap gasket (2) for an even filler neck
Check cooling system hoses. (Page 1F-7)
imprint or any damage.
Check cooling system leakage. (Page 1F-8)

CNG System Fastener

AENJCA0A0206044
Tighten CNG system parts. (Page 1G-50)
2

CNG Fuel Filter Replacement

AENJCA0A0206045
1 Replace CNG fuel filter. (Page 1G-64)

IDAA0A020001-01 Spark Plug Inspection

• Replace any damaged or deteriorated parts. AENJCA0A0206046
Check spark plugs. (Page 1H-7)
There should be no sign of fuel leakage or moisture at
any fuel connection.
– Petrol model: (Page 1G-15)
CNG Cylinder Inspection
AENJCA0A0206047
– Bi-fuel CNG model: (Page 1G-50) Check CNG cylinder. (Page 1G-74)
0B-6 Maintenance and Lubrication:

CNG Receptacle Replacement ! CAUTION

AENJCA0A0206048
Replace CNG receptacle. (Page 1G-79) Since brake system of this vehicle is factory-
filled with brake fluid indicated on reservoir
Brake Disc and Pad Inspection cap, do not use or mix different type of fluid
AENJCA0A0206014 when refilling; otherwise serious damage will
1) Check lining thickness of outside and inside pads. occur.
(Page 4B-2) Do not use old or used brake fluid, or any
Use scale if necessary. fluid from an unsealed container.
2) Check brake discs for excessive wear, damage and
deflection. (Page 4B-5) Brake fluid specification
Replace parts if necessary. Refer to reservoir cap of brake master cylinder.

Brake Drum and Shoe Inspection Brake Pedal Inspection

AENJCA0A0206015 AENJCA0A0206018
Check rear brake drums and brake linings for excessive Check brake pedal travel.
wear and damage, while wheels and drums are • Brake pedal travel: (Page 4A-11)
removed. At the same time, check wheel cylinders for • Brake pedal play: (Page 4A-11)
leakage. Replace these parts if necessary. (Page 4C-
3) Brake Fluid Replacement
AENJCA0A0206019
Brake Hose and Pipe Inspection Change brake fluid as follows.
AENJCA0A0206016 Drain existing fluid from brake system completely, fill
Perform this inspection where there is enough light and system with specified fluid and carry out air bleeding
use a mirror if necessary. operation.
• Check brake hoses and pipes for improper • Replacement: (Page 4A-5)
connections, leakage, crack, chafing and other • Air bleeding: (Page 4A-6)
damage. (Page 4A-16)
• Check that hoses and pipes are clear of sharp edges Brake Lever and Cable Inspection
and moving parts. AENJCA0A0206020
Replace any of these parts if necessary. 1) Check brake cables for damage and smooth
movement. (Page 4D-2)
NOTICE
Replace deteriorated cable(s).
Air in the brake system will cause poor 2) Check tooth tip of each brake lever ratchet notch for
braking performance and can lead to an damage or wear. If any damage or wear is found,
accident. replace parking brake lever.
After servicing the brake system, completely
bleed all air out of the system. 3) Check parking brake lever for proper operation and
stroke, and adjust it if necessary.
• Check: (Page 4D-2)
Brake Fluid Inspection
AENJCA0A0206017 • Adjust: (Page 4D-2)
1) Check parts around master cylinder and reservoir for
fluid leakage. If any sign of leakage is found, correct
defects.
2) Check fluid level.
If fluid level is lower than the minimum level of
reservoir, refilling is necessary. Fill reservoir with
specified brake fluid.
For the details, refer to to “Brake Fluid Level
Inspection” in Section 4A (Page 4A-4).

IDL10A020003-01
 Maintenance and Lubrication: 0B-7

Clutch Pedal Inspection (M/T Model) Wheel Bearing Inspection

AENJCA0A0206021 AENJCA0A0206026
Check clutch pedal travel. (Page 5C-4) 1) Check front wheel bearings for wear, damage and
abnormal noise. For details, refer to “Front Wheel
Tire Inspection Bearing Check”: Front in Section 3A (Page 3A-10).
AENJCA0A0206024
2) Check rear wheel bearings for wear, damage and
1) Check tires for uneven or excessive wear, or
abnormal noise. For details, refer to “Rear Wheel
damage. If faulty condition is found, replace tire.
Bearing Check”: Rear in Section 3A (Page 3A-17).
Refer to “Tire Inspection” in Section 2D (Page 2D-3)
for details.

IDL10A020004-01

I2RH01020022-01 Drive Shaft (Axle) Boot Inspection

1. Tread wear indicator
2) Check inflation pressure of each tire and adjust
pressure to specification if necessary.
AENJCA0A0206027
Check drive shaft boots (wheel side and differential side)
for leakage, detachment, tear or other damage.
Replace defective parts if necessary.

NOTE
• Tire inflation pressure should be checked
when tires are cool.
• The tire inflation pressure will change due IDAA0A020002-01
to changes in atmospheric pressure,
temperature or tire temperature when
driving.
For details of tire inflation pressure, refer
to “Tire Description” in Section 2D (Page
2D-1).
• Specified tire inflation pressure is
indicated on the “Tire Placard”.

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

Section 2D (Page 2D-5).

Wheel Disc Inspection

AENJCA0A0206025
Refer to “Wheel Inspection” in Section 2D (Page 2D-4)
for details.
0B-8 Maintenance and Lubrication:

Suspension System Inspection • Check dust covers of front suspension arm ball joints
AENJCA0A0206028 for leakage, detachment, tear or any other damage.
• Check front strut assemblies and rear shock For checking procedure, refer to Steps 1) to 10) of
absorbers for sign of oil leakage, dents or any other “Joint” under “Suspension Arm Check” in Section 2B
damage on sleeves. Also check anchor ends for (Page 2B-12).
deterioration.
Replace defective parts, if any.
• Check front and rear suspension systems for
damaged, loose or missing parts. Also check them for
parts showing signs of wear or lack of lubrication.
Repair or replace defective parts, if any.
Front

IAW101020014-01

Steering System Inspection

AENJCA0A0206029
1) Check steering wheel for play and abnormal noise,
holding vehicle straight on ground.
Steering wheel play
“a”: 0 – 30 mm (0 – 1.2 in.)

IJCA0A210001-01

Rear

I2RH01020026-01

2) Check bolts and nuts for tightness and retighten

them if necessary. Repair or replace defective parts.
3) Check steering linkage for looseness and damage.
Repair or replace defective parts.
4) Check boots (1) and (2) of steering linkage and
steering gear case for damage (leakage,
detachment, tear, etc.). Replace defective steering
rack boot(s) or tie-rod end(s) with new one(s).
If any dent is found on steering gear case boots,
correct it to original shape by turning steering wheel
to the right or left as far as it stops and holding it for a
few seconds.
IJCA0A210002-01

5) Check universal joints (3) of steering shaft for
abnormal noise and damage. If abnormal noise or
damage is detected, replace defective part with new
one.
1 2 1 I2RH01020033-01
IFRA0A020001-01
6) Check that steering wheel can be turned fully to the
right and left. Repair or replace defective parts, if
any.
7) Check that steering wheel can be turned fully to the
right and left with smaller force when engine is
running at idle speed than when it is stopped. Repair
power steering system if it provides no assistance.
8) Check wheel alignment referring to “Front Wheel
Alignment Inspection and Adjustment” in Section 2B
(Page 2B-2).
Manual Transaxle Oil Inspection (M/T Model)
AENJCA0A0206030
Check transaxle oil for leakage, contamination and level.
• K10B model: (Page 5B-8)
• K12M model: (Page 5B-49)
Manual Transaxle Oil Replacement (M/T Model)
AENJCA0A0206031
Change transaxle oil with new specified one.
• K10B model: (Page 5B-8)
• K12M model: (Page 5B-49)
Auto Gear Shift Transaxle Oil Inspection (Auto
Gear Shift Model)
AENJCA0A0206039
Check auto gear shift transaxle oil for leakage,
contamination and level. (Page 5D-106)
Auto Gear Shift Transaxle Oil Replacement
(Auto Gear Shift Model)
AENJCA0A0206040
Change auto gear shift transaxle oil with new specified
one. (Page 5D-106)
Auto Gear Shift Actuator Oil Inspection (Auto
Gear Shift Model)
AENJCA0A0206041
Check auto gear shift actuator oil level. (Page 5D-106)
Maintenance and Lubrication: 0B-9
All Latches, Hinges and Locks Inspection
AENJCA0A0206035
Door
Check that each door opens and closes smoothly and
locks securely when closed.
If any malfunction is found, lubricate hinges and latch or
repair door lock system.
Rear End Door
Check that rear end door opens and closes smoothly
and locks securely when closed.
If any malfunction is found, adjust rear end door latch
striker.
Hood
Check that secondary latch operates properly (check
that secondary latch keeps hood from opening all the
way when hood release handle inside vehicle is pulled).
Also check that hood opens and closes smoothly and
properly and hood locks securely when closed.
If any malfunction is found, lubricate hinges and latch, or
repair hood lock system.
HVAC Air Filter Inspection
AENJCA0A0206036
Check HVAC air filter for dirt and dust. If air filter is dirty,
clean or replace it with new one. (Page 7B-49)
HVAC Air Filter Replacement
AENJCA0A0206037
Replace HVAC air filter with new one. (Page 7B-49)
Final Inspection for Maintenance Service
AENJCA0A0206038
! WARNING
If you do not select a suitable route and take
proper precautions when performing a road
test, an accident can occur.
Select a level road with no traffic to minimize
the risk of an accident, and perform the test
extremely carefully.
Seat
Check that each front seat slides smoothly and locks
securely at any position. Also check that reclining
mechanism of each front seat allows the seatback to be
locked at any angle.
0B-10 Maintenance and Lubrication:
Seat Belt
Check seat belt systems including webbing, buckles,
latch plates, retractors and anchors for damage or wear.
Check that each seat belt locks securely. If “REPLACE
BELT” label on seat belt is visible, replace belt.
Battery Check
Battery terminal check
Check battery terminals for looseness, corrosion or
damage.
Battery electrolyte level check
• If battery is equipped with electrolyte level check lines
on the case, check that the electrolyte level of all
battery cells is between the upper and lower level
lines.
• If battery is equipped with built-in indicator, check
battery condition by the indicator.
• If battery is not equipped with check lines and built-in
indicator, it is not necessary to perform electrolyte
level check.
Accelerator Pedal Operation
Check that accelerator pedal operates smoothly without
getting caught by or interfering any other part.
Engine Start
Check the engine starts readily.
! WARNING
If you do not take proper precautions when
performing the engine start check as
described below, the vehicle could move
without warning causing personal injury and/
or property damage.
When performing the engine start check as
described below, take the following
precautions:
• Provide adequate space around the
vehicle.
• Firmly apply both the parking brake and
the foot brake.
• Do not use the accelerator pedal.
• Set ignition “OFF” immediately if the
engine starts.
For auto gear shift vehicles, try to start the engine in
each select lever position. The starting motor should
crank only in N range with brake pedal depressed.
Exhaust System Check
Check for leakage, crack or loose supports.
Clutch (M/T Model)
Check for the following points:
• Clutch is completely released when clutch pedal is
depressed.
• No slipping clutch occurs when releasing pedal and
accelerating.
• Clutch itself is free from any abnormal conditions.
Gear Shift or Select Lever
Check gear shift or select lever for smooth movement to
all positions and for good and correct response of
transaxle in any position.
For auto gear shift models, also check that shift indicator
indicates position correctly according to select lever
position.
Brake
Foot brake
Check the following points:
• Brake pedal has proper travel.
• Brakes work properly.
• Brakes do not generate abnormal noise.
• Vehicle does not pull to one side when brakes are
applied.
• Brakes do not drag.
Parking brake
Check that lever stroke is proper.
! WARNING
If you do not take proper precautions when
testing the parking brake on a slope, the
vehicle could move unexpectedly, causing
personal injury and/or property damage.
When testing the parking brake on a slope,
take the following precautions:
• Check that there is nothing in the way
ahead.
• Apply the foot brake quickly if the vehicle
moves.
Check that parking brake is fully effective when the
vehicle is stopped on a slope by pulling parking brake
lever all the way.
Steering
• Check that steering wheel is not instable and has no
abnormally large resistance to turn.
• Check that vehicle does not wander or pull to one
side.
Engine
• Check that speed changes responsively to
accelerator positions.
• Check that engine is free from abnormal noise and
abnormal vibration.

Body, Wheel and Power Train Components
Check that body, wheels and power train components
are free from any abnormal conditions such as abnormal
noise and vibration.
Meter and Gauge
Check that speedometer, odometer, fuel gauge,
temperature gauge, etc. operate accurately.
Special Tools and Equipment
Recommended Fluids and Lubricants
Engine oil
Engine coolant (Ethylene glycol base coolant)
Brake fluid
Manual transaxle oil (M/T model)
Auto gear shift transaxle oil (auto gear shift model)
Door hinges
Hood latch assembly
Key lock cylinder
Maintenance and Lubrication: 0B-11
Light
Check that all lights operate properly.
Windshield Defroster
Periodically check that air comes out from defroster
outlet when operating heater or air conditioning.
Set mode control lever to defroster position and fan
switch lever to highest position for this check.
AENJCA0A0208001
• K10B model: Refer to “Engine Oil and Filter Change”:
K10B and Bi-Fuel CNG in Section 1E (Page 1E-4).
• K12M model: Refer to “Engine Oil and Filter Change”:
K12M in Section 1E (Page 1E-19)
• K10B model: Refer to “Coolant Description”: K10B and
Bi-Fuel CNG in Section 1F (Page 1F-2)
• K12M model: Refer to “Coolant Description”: K12M in
Section 1F (Page 1F-18)
Refer to reservoir cap of brake master cylinder.
• K10B model: Refer to “Manual Transaxle Oil Change”:
K10B Model in Section 5B (Page 5B-8).
• K12M model: Refer to “Manual Transaxle Oil Change”:
K12M Model in Section 5B (Page 5B-49).
Refer to “Auto Gear Shift Transaxle Oil Change” in
Section 5D (Page 5D-106)
Engine oil or water resistant chassis grease
Engine oil or water resistant chassis grease
Spray lubricant

Section 1
Engine
CONTENTS
Precautions .................................................1-1
Precautions............................................................. 1-1
Precautions for Engine (K10B) ............................. 1-1
Precautions for Engine (K12M) ............................. 1-2
Precautions for Engine (Bi-Fuel CNG) .................. 1-4
Engine General Information and
Diagnosis ................................................. 1A-1
K10B .........................................................................1A-1
General Description .............................................1A-1
Engine Diagnosis General Description ............... 1A-1
OBD System Description .................................... 1A-1
DLC Description .................................................. 1A-4
Engine and Emission Control System
Description ........................................................ 1A-4
Air Intake System Description ............................. 1A-5
Electric Throttle Control System Description....... 1A-5
Electronic Control System Description................ 1A-7
Engine and Emission Control Input / Output
Table ............................................................... 1A-10
Schematic and Routing Diagram......................1A-12
Engine and Emission Control System
Diagram .......................................................... 1A-12
Engine and Emission Control System Flow
Diagram .......................................................... 1A-14
Electronic Control System Circuit Diagram ....... 1A-15
Component Location .........................................1A-17
Electronic Control System Component
Location .......................................................... 1A-17
Diagnostic Information and Procedures..........1A-20
Engine and Emission Control System Check.... 1A-20
MIL Check ......................................................... 1A-22
DTC Check ....................................................... 1A-22
DTC Clearance ................................................. 1A-23
DTC Table......................................................... 1A-24
Fail-Safe Table.................................................. 1A-27
Scan Tool Data ................................................. 1A-30
Visual Inspection ............................................... 1A-35
Engine Basic Inspection.................................... 1A-36
Engine Symptom Diagnosis .............................. 1A-37
MIL Does Not Come ON with Ignition “ON”
and Engine Stopped (but Engine Can Be
Started) ........................................................... 1A-45
MIL Remains ON after Engine Starts................ 1A-45
Table of Contents 1- i
DTC P0031 / P0032 / P0037 / P0038 ...............1A-46
DTC P0106 .......................................................1A-48
DTC P0107 / P0108 ..........................................1A-49
DTC P0112 / P0113 ..........................................1A-51
DTC P0116 .......................................................1A-52
DTC P0117 / P0118 ..........................................1A-53
DTC P0122 / P0123 ..........................................1A-55
DTC P0130 / P0133 ..........................................1A-57
DTC P0136 .......................................................1A-60
DTC P0139 .......................................................1A-62
DTC P0171 / P0172 ..........................................1A-63
DTC P0201 / P0202 / P0203.............................1A-66
DTC P0222 / P0223 ..........................................1A-68
DTC P0300 / P0301 / P0302 / P0303 ...............1A-70
DTC P0327 / P0328 ..........................................1A-72
DTC P0335 / P0336 ..........................................1A-73
DTC P0340 / P0341 ..........................................1A-75
DTC P0420 .......................................................1A-77
DTC P0443 .......................................................1A-80
DTC P0480 .......................................................1A-82
DTC P0500 .......................................................1A-84
DTC P0532 / P0533 ..........................................1A-85
DTC P0602 .......................................................1A-87
DTC P0607 .......................................................1A-87
DTC P0616 / P0617 ..........................................1A-88
DTC P1520 / P1521 ..........................................1A-90
DTC P2101 / P2119 ..........................................1A-92
DTC P2111 .......................................................1A-94
DTC P2122 / P2123 ..........................................1A-95
DTC P2127 / P2128 ..........................................1A-97
DTC P2135 .......................................................1A-99
DTC P2138 .....................................................1A-100
DTC U0073 .....................................................1A-101
DTC U0101 .....................................................1A-101
DTC U0121 .....................................................1A-101
DTC U0140 .....................................................1A-101
DTC U0155 .....................................................1A-101
DTC U2001 .....................................................1A-101
DTC U2021 .....................................................1A-102
Inspection of ECM and Its Circuits ..................1A-103
ECM Power Supply and Ground Circuit
Check ............................................................1A-113
Repair Instructions ..........................................1A-116
Idle Speed Inspection......................................1A-116
Special Tools and Equipment .........................1A-116
1-ii Table of Contents
Special Tool .................................................... 1A-116
K12M.....................................................................1A-117
General Description .........................................1A-117
Engine Diagnosis General Description ........... 1A-117
OBD System Description ................................ 1A-117
DLC Description .............................................. 1A-120
Engine and Emission Control System
Description .................................................... 1A-120
Air Intake System Description ......................... 1A-121
Electric Throttle Control System Description... 1A-122
Electronic Control System Description............ 1A-123
Engine and Emission Control Input / Output
Table ............................................................. 1A-126
Schematic and Routing Diagram....................1A-130
Engine and Emission Control System
Diagram ........................................................ 1A-130
Engine and Emission Control System Flow
Diagram ........................................................ 1A-132
Electronic Control System Circuit Diagram ..... 1A-133
Component Location .......................................1A-135
Electronic Control System Component
Location ........................................................ 1A-135
Diagnostic Information and Procedures........1A-138
Engine and Emission Control System Check.. 1A-138
MIL Check ....................................................... 1A-140
DTC Check...................................................... 1A-140
DTC Clearance ............................................... 1A-141
DTC Table....................................................... 1A-142
Fail-Safe Table................................................ 1A-149
Scan Tool Data ............................................... 1A-153
Visual Inspection ............................................. 1A-158
Engine Basic Inspection.................................. 1A-159
Engine Symptom Diagnosis ............................ 1A-160
MIL Does Not Come ON with Ignition “ON”
and Engine Stopped (but Engine Can Be
Started) ......................................................... 1A-169
MIL Remains ON after Engine Starts.............. 1A-169
DTC P0010 / P2088 / P2089........................... 1A-170
DTC P0011 ..................................................... 1A-172
DTC P0016 ..................................................... 1A-174
DTC P0030 / P0031 / P0032........................... 1A-175
DTC P0036 / P0037 / P0038........................... 1A-177
DTC P0107 / P0108 ........................................ 1A-179
DTC P0112 / P0113 ........................................ 1A-181
DTC P0116 ..................................................... 1A-182
DTC P0117 / P0118 ........................................ 1A-184
DTC P0122 / P0123 ........................................ 1A-185
DTC P0130 ..................................................... 1A-187
DTC P0131 / P0132 ........................................ 1A-189
DTC P0133 ..................................................... 1A-191
DTC P0134 ..................................................... 1A-193
DTC P0137 / P0138 / P0140........................... 1A-195
DTC P0171 / P0172 ........................................ 1A-197
DTC P0201 / P0202 / P0203 / P0204 / P0261
/ P0262 / P0264 / P0265 / P0267 / P0268 /
P0270 / P0271 .............................................. 1A-199
DTC P0222 / P0223 ........................................ 1A-202
DTC P0300 / P0301 / P0302 / P0303 / P0304 1A-204
DTC P0327 / P0328 ........................................ 1A-206
DTC P0335 / P0336 ........................................1A-208
DTC P0340 .....................................................1A-210
DTC P0351 / P0352 / P0353 / P0354 / P2300
/ P2301 / P2303 / P2304 / P2306 / P2307 /
P2309 / P2310 ..............................................1A-212
DTC P0420 .....................................................1A-215
DTC P0443 / P0458 / P0459...........................1A-217
DTC P0480 / P0692 ........................................1A-219
DTC P0481 / P0694 ........................................1A-221
DTC P0500 .....................................................1A-223
DTC P0504 .....................................................1A-225
DTC P0530 .....................................................1A-226
DTC P0560 / P0562 / P0563...........................1A-228
DTC P0602 .....................................................1A-230
DTC P0606 .....................................................1A-230
DTC P0607 .....................................................1A-231
DTC P0645 / P0646 / P0647...........................1A-232
DTC P1520 / P1521 ........................................1A-234
DTC P1693 .....................................................1A-236
DTC P2100 .....................................................1A-237
DTC P2101 / P2119 ........................................1A-239
DTC P2122 / P2123 ........................................1A-241
DTC P2127 / P2128 ........................................1A-243
DTC P2135 .....................................................1A-245
DTC P2138 .....................................................1A-246
DTC P2176 .....................................................1A-248
DTC P2226 / P2227 ........................................1A-249
DTC P2271 .....................................................1A-250
DTC U0073 .....................................................1A-252
DTC U0101 .....................................................1A-252
DTC U0121 .....................................................1A-252
DTC U0140 .....................................................1A-252
DTC U0155 .....................................................1A-252
DTC U2001 .....................................................1A-252
DTC U2021 .....................................................1A-254
Inspection of ECM and Its Circuits ..................1A-254
ECM Power Supply and Ground Circuit
Check ............................................................1A-266
Fuel Cut Operation Inspection ........................1A-270
Repair Instructions ..........................................1A-270
Idle Speed Inspection......................................1A-270
Special Tools and Equipment .........................1A-271
Special Tool ....................................................1A-271
Bi-Fuel CNG .........................................................1A-272
General Description .........................................1A-272
Engine Diagnosis General Description ...........1A-272
OBD System Description ................................1A-272
DLC Description ..............................................1A-274
Engine and Emission Control System
Description ....................................................1A-275
Bi-Fuel CNG System Description ....................1A-275
Bi-Fuel CNG System Construction..................1A-276
Air Intake System Description .........................1A-276
Electric Throttle Control System Description...1A-276
Electronic Control System Description ............1A-276
Engine and Emission Control Input / Output
Table .............................................................1A-277
Schematic and Routing Diagram ....................1A-280

Engine and Emission Control System Flow
Diagram ........................................................ 1A-280
Engine Control System Circuit Diagram.......... 1A-282
Component Location .......................................1A-287
Electronic Control System Component
Location ........................................................ 1A-287
Diagnostic Information and Procedures........1A-291
Engine and Emission Control System Check.. 1A-291
MIL Check ....................................................... 1A-293
CNG Warning Light Check.............................. 1A-293
DTC Check ..................................................... 1A-293
DTC Clearance ............................................... 1A-294
DTC Table....................................................... 1A-295
Fail-Safe Table................................................ 1A-297
Scan Tool Data (ECM) .................................... 1A-298
Scan Tool Data (CNG Control Module)........... 1A-304
Visual Inspection ............................................. 1A-306
Engine Basic Inspection.................................. 1A-308
Engine Symptom Diagnosis ............................ 1A-310
MIL Does Not Come ON with Ignition “ON”
and Engine Stopped (but Engine Can Be
Started) ......................................................... 1A-320
MIL Remains ON after Engine Starts.............. 1A-320
CNG Warning Light Does Not Come ON with
Ignition “ON” and Engine Stopped ................ 1A-320
CNG Warning Light Remains ON after Engine
Starts............................................................. 1A-320
DTC U0108 ..................................................... 1A-320
DTC P0005 / P0007 ........................................ 1A-321
DTC P0182 / P0183 ........................................ 1A-324
DTC P0192 / P0193 ........................................ 1A-326
DTC P0201 / P0202 / P0203 .......................... 1A-328
DTC P0601 ..................................................... 1A-331
DTC P0607 ..................................................... 1A-332
DTC P0612 ..................................................... 1A-334
DTC P062F ..................................................... 1A-337
DTC P1432 / P1433 ........................................ 1A-338
DTC P1601 ..................................................... 1A-340
DTC P2408 ..................................................... 1A-341
DTC P2665 / P2667 ........................................ 1A-343
DTC P2668 ..................................................... 1A-346
DTC U0073 ..................................................... 1A-347
DTC U0100 ..................................................... 1A-347
Inspection of ECM and Its Circuits .................. 1A-347
Inspection of CNG Control Module and Its
Circuit............................................................ 1A-358
ECM Power and Ground Circuit Check........... 1A-362
CNG Control Module Power and Ground
Circuit Check................................................. 1A-363
Repair Instructions ..........................................1A-365
Idle Speed Inspection ..................................... 1A-365
Special Tools and Equipment .........................1A-366
Special Tool .................................................... 1A-366
Aux. Emission Control Devices ............. 1B-1
K10B and Bi-Fuel CNG ...........................................1B-1
Diagnostic Information and Procedures............1B-1
EVAP Canister Purge System Inspection ........... 1B-1
Repair Instructions ..............................................1B-3
Table of Contents 1-iii
EVAP System Components ................................1B-3
EVAP Canister Purge Valve Inspection ..............1B-4
EVAP Canister Removal and Installation (Bi-
Fuel CNG) .........................................................1B-5
EVAP Canister Inspection...................................1B-5
EVAP Connection Hose Inspection.....................1B-6
PCV Hose Inspection ..........................................1B-6
PCV Valve Inspection .........................................1B-7
Fuel Cut Valve Inspection ...................................1B-7
Specifications .......................................................1B-8
Tightening Torque Specifications........................1B-8
Special Tools and Equipment .............................1B-8
Special Tool ........................................................1B-8
K12M.........................................................................1B-9
Diagnostic Information and Procedures ............1B-9
EVAP Canister Purge System Inspection ...........1B-9
Repair Instructions ............................................1B-11
EVAP System Components ..............................1B-11
EVAP Canister Purge Valve Inspection ............1B-11
EVAP Canister Inspection.................................1B-12
EVAP Connection Hose Inspection...................1B-12
PCV Hose Inspection ........................................1B-12
PCV Valve Inspection .......................................1B-13
Fuel Cut Valve Inspection .................................1B-13
Specifications .....................................................1B-14
Tightening Torque Specifications......................1B-14
Special Tools and Equipment ...........................1B-14
Special Tool ......................................................1B-14
Engine Electrical Devices ....................... 1C-1
K10B and Bi-Fuel CNG............................................1C-1
General Description .............................................1C-1
Engine Electrical Devices Description.................1C-1
Engine Electrical Devices Description (Bi-
Fuel CNG) .........................................................1C-2
Component Location ...........................................1C-2
Electronic Control System Component
Location.............................................................1C-2
Repair Instructions ..............................................1C-3
ECM Removal and Installation............................1C-3
Procedure after ECM Replacement ....................1C-4
CNG Control Module Removal and
Installation (Bi-Fuel CNG) .................................1C-4
Electric Throttle Body Assembly On-Vehicle
Inspection..........................................................1C-5
Electric Throttle Control System Calibration .......1C-7
APP Sensor On-Vehicle Inspection ....................1C-7
Accelerator Pedal Assembly (Incorporating
APP Sensor) Removal and Installation .............1C-8
MAP Sensor Removal and Installation................1C-9
MAP Sensor Inspection.......................................1C-9
ECT Sensor On-Vehicle Inspection ..................1C-10
ECT Sensor Removal and Installation ..............1C-10
ECT Sensor Inspection .....................................1C-11
HO2S On-Vehicle Inspection ............................1C-11
HO2S Removal and Installation ........................1C-11
CMP Sensor On-Vehicle Inspection..................1C-12
CMP Sensor Removal and Installation .............1C-12
CMP Sensor Inspection ....................................1C-12
1-iv Table of Contents
CKP Sensor Removal and Installation ..............1C-13
CKP Sensor Inspection .....................................1C-13
Knock Sensor On-Vehicle Inspection................1C-14
Knock Sensor Removal and Installation ...........1C-14
Engine and Emission Control System Relay
Inspection........................................................1C-14
IAT Sensor On-Vehicle Inspection ....................1C-14
IAT Sensor Removal and Installation................1C-14
IAT Sensor Inspection.......................................1C-15
CNG Pressure-and-Temperature Sensor
Removal and Installation (Bi-Fuel CNG) .........1C-16
CNG Pressure-and-Temperature Sensor
Inspection (Bi-Fuel CNG) ................................1C-16
Fuel Filler Lid Switch Removal and
Installation (Bi-Fuel CNG) ...............................1C-17
Fuel Filler Lid Switch Inspection (Bi-Fuel
CNG) ...............................................................1C-17
Fuel Select Switch Removal and Installation
(Bi-Fuel CNG) .................................................1C-18
Fuel Select Switch Inspection (Bi-Fuel CNG) ...1C-18
Specifications.....................................................1C-18
Tightening Torque Specifications......................1C-18
Special Tools and Equipment ...........................1C-19
Special Tool ......................................................1C-19
K12M.......................................................................1C-20
General Description ...........................................1C-20
Engine Electrical Devices Description...............1C-20
Component Location .........................................1C-21
Electronic Control System Component
Location ..........................................................1C-21
Repair Instructions ............................................1C-22
ECM Removal and Installation..........................1C-22
Procedure after ECM Replacement ..................1C-23
Electric Throttle Body Assembly On-Vehicle
Inspection........................................................1C-23
Electric Throttle Control System Calibration .....1C-25
ECM Learning Procedure of Engine Torque .....1C-25
APP Sensor On-Vehicle Inspection ..................1C-25
Accelerator Pedal Assembly (Incorporating
APP Sensor) Removal and Installation ...........1C-26
MAP Sensor Removal and Installation..............1C-27
MAP Sensor Inspection.....................................1C-27
ECT Sensor On-Vehicle Inspection ..................1C-28
ECT Sensor Removal and Installation ..............1C-28
ECT Sensor Inspection .....................................1C-28
HO2S On-Vehicle Inspection ............................1C-29
HO2S Removal and Installation ........................1C-29
CMP Sensor On-Vehicle Inspection..................1C-30
CMP Sensor Removal and Installation .............1C-30
CKP Sensor Removal and Installation ..............1C-31
CKP Sensor Inspection .....................................1C-31
Knock Sensor On-Vehicle Inspection................1C-32
Knock Sensor Removal and Installation ...........1C-32
Engine and Emission Control System Relay
Inspection........................................................1C-32
IAT Sensor On-Vehicle Inspection ....................1C-32
IAT Sensor Removal and Installation................1C-32
IAT Sensor Inspection.......................................1C-33
OCV Inspection .................................................1C-34
Specifications .....................................................1C-34
Tightening Torque Specifications......................1C-34
Special Tools and Equipment ...........................1C-34
Special Tool ......................................................1C-34
Engine Mechanical .................................. 1D-1
K10B and Bi-Fuel CNG............................................1D-1
General Description .............................................1D-1
Engine Construction Description .........................1D-1
Diagnostic Information and Procedures ............1D-1
Compression Check............................................1D-1
Engine Vacuum Check........................................1D-2
Valve Clearance Inspection and Adjustment ......1D-3
Repair Instructions ..............................................1D-5
Air Cleaner Components.....................................1D-5
Air Cleaner Filter Removal and Installation .........1D-5
Air Cleaner Filter Inspection and Cleaning..........1D-6
Air Cleaner Assembly Removal and
Installation .........................................................1D-6
Electric Throttle Body and Intake Manifold
Components......................................................1D-7
Electric Throttle Body On-Vehicle Inspection ......1D-7
Electric Throttle Body Assembly Removal and
Installation .........................................................1D-8
Electric Throttle Body Cleaning...........................1D-8
Intake Manifold Removal and Installation ...........1D-9
Cylinder Head Cover Components ...................1D-10
Cylinder Head Cover Removal and
Installation .......................................................1D-11
Camshaft and Tappet Components ..................1D-14
Camshaft and Tappet Removal and
Installation .......................................................1D-14
Camshaft and Tappet Inspection ......................1D-19
Crankshaft Front Oil Seal Replacement............1D-21
Crankshaft Rear Oil Seal Replacement ............1D-22
Engine Mounting Components..........................1D-23
Engine Assembly Removal and Installation ......1D-24
Timing Chain Cover Components .....................1D-30
Timing Chain Cover Removal and Installation ..1D-31
Timing Chain Cover Inspection .........................1D-33
Flywheel Removal and Installation....................1D-33
Flywheel Inspection...........................................1D-34
Timing Chain and Chain Tensioner
Components....................................................1D-35
Timing Chain and Chain Tensioner Removal
and Installation ................................................1D-36
Timing Chain and Chain Tensioner Inspection ..1D-39
Valve and Cylinder Head Components .............1D-40
Valve and Cylinder Head Removal and
Installation .......................................................1D-41
Cylinder Head Disassembly and Reassembly ..1D-42
Valve and Valve Guide Inspection ....................1D-45
Cylinder Head Inspection ..................................1D-47
Valve Spring Inspection ....................................1D-48
Piston, Piston Ring and Connecting Rod
Components....................................................1D-49
Piston, Piston Ring and Connecting Rod
Removal and Installation.................................1D-50

Piston, Piston Ring and Connecting Rod
Disassembly and Reassembly ........................1D-52
Cylinder, Piston and Piston Ring Inspection .....1D-53
Piston Pin and Connecting Rod Inspection.......1D-55
Crankshaft Pin and Connecting Rod Bearing
Inspection........................................................1D-56
Main Bearing, Crankshaft and Cylinder Block
Components....................................................1D-59
Main Bearing, Crankshaft and Cylinder Block
Removal and Installation.................................1D-60
Crankshaft Inspection .......................................1D-63
Main Bearing Inspection ...................................1D-63
Sensor Plate Inspection ....................................1D-68
Cylinder Block Inspection..................................1D-68
Specifications.....................................................1D-69
Tightening Torque Specifications......................1D-69
Special Tools and Equipment ...........................1D-70
Recommended Service Material .......................1D-70
Special Tool ......................................................1D-70
K12M.......................................................................1D-73
General Description ...........................................1D-73
Engine Construction Description.......................1D-73
VVT System Description ...................................1D-74
Diagnostic Information and Procedures..........1D-77
Compression Check..........................................1D-77
Engine Vacuum Check .....................................1D-78
Valve Clearance Inspection and Adjustment ....1D-79
Repair Instructions ............................................1D-81
Air Cleaner Components...................................1D-81
Air Cleaner Filter Removal and Installation.......1D-82
Air Cleaner Filter Inspection and Cleaning........1D-82
Air Cleaner Assembly Removal and
Installation .......................................................1D-82
Throttle Body and Intake Manifold
Components....................................................1D-84
Throttle Body On-Vehicle Inspection ................1D-84
Electric Throttle Body Assembly Removal and
Installation .......................................................1D-84
Throttle Body Cleaning .....................................1D-85
Intake Manifold Removal and Installation .........1D-85
Cylinder Head Cover Components ...................1D-86
Cylinder Head Cover Removal and
Installation .......................................................1D-86
Camshaft and Tappet Components ..................1D-89
Camshaft and Tappet Removal and
Installation .......................................................1D-89
VVT Actuator, Camshaft and Tappet
Inspection........................................................1D-95
Crankshaft Front Oil Seal Replacement............1D-97
Crankshaft Rear Oil Seal Replacement ............1D-98
Engine Mounting Components..........................1D-99
Engine Assembly Removal and Installation ....1D-100
Timing Chain Cover Components ...................1D-104
Timing Chain Cover Removal and Installation 1D-105
Timing Chain Cover Inspection .......................1D-107
OCV Removal and Installation ........................1D-108
Flywheel Removal and Installation..................1D-108
Flywheel Inspection ........................................1D-109
Table of Contents 1-v
Timing Chain and Chain Tensioner
Components..................................................1D-110
Timing Chain and Chain Tensioner Removal
and Installation ..............................................1D-111
Timing Chain and Chain Tensioner Inspection 1D-114
Valve and Cylinder Head Components ...........1D-115
Valve and Cylinder Head Removal and
Installation .....................................................1D-116
Valve and Cylinder Head Disassembly and
Reassembly ..................................................1D-117
Valve and Valve Guide Inspection ..................1D-121
Venturi Plug Inspection ...................................1D-123
Cylinder Head Inspection ................................1D-123
Cylinder Head Bolt Inspection.........................1D-124
Valve Spring Inspection ..................................1D-124
Piston, Piston Ring and Connecting Rod
Components..................................................1D-125
Piston, Piston Ring and Connecting Rod
Removal and Installation...............................1D-126
Piston, Piston Ring and Connecting Rod
Disassembly and Reassembly ......................1D-128
Cylinder, Piston and Piston Ring Inspection ...1D-129
Piston Pin and Connecting Rod Inspection.....1D-131
Crankshaft Pin and Connecting Rod Bearing
Inspection......................................................1D-132
Main Bearing, Crankshaft and Cylinder Block
Components..................................................1D-135
Main Bearing, Crankshaft and Cylinder Block
Removal and Installation...............................1D-136
Crankshaft Inspection .....................................1D-140
Main Bearing Inspection..................................1D-141
Sensor Plate Inspection ..................................1D-147
Cylinder Block Inspection................................1D-147
Specifications ...................................................1D-148
Tightening Torque Specifications....................1D-148
Special Tools and Equipment .........................1D-149
Recommended Service Material .....................1D-149
Special Tool ....................................................1D-149
Engine Lubrication System .................... 1E-1
K10B and Bi-Fuel CNG............................................1E-1
General Description .............................................1E-1
Engine Lubrication Description ...........................1E-1
Diagnostic Information and Procedures ............1E-3
Oil Pressure Check .............................................1E-3
Repair Instructions ..............................................1E-4
Engine Oil and Filter Change ..............................1E-4
Oil Pressure Switch On-Vehicle Inspection.........1E-5
Oil Pressure Switch Removal and Installation ....1E-6
Oil Pan and Oil Pump Strainer Components.......1E-7
Oil Pan and Oil Pump Strainer Removal and
Installation .........................................................1E-8
Oil Pump Assembly Components .....................1E-11
Oil Pump Assembly Removal and Installation ..1E-11
Oil Pump Assembly Disassembly and
Reassembly ....................................................1E-12
Oil Pump Inspection ..........................................1E-13
Specifications .....................................................1E-14
Tightening Torque Specifications......................1E-14
1-vi Table of Contents
Special Tools and Equipment ........................... 1E-15
Recommended Service Material ....................... 1E-15
Special Tool ......................................................1E-15
K12M....................................................................... 1E-16
General Description ........................................... 1E-16
Engine Lubrication Description .........................1E-16
Diagnostic Information and Procedures.......... 1E-18
Oil Pressure Check ........................................... 1E-18
Repair Instructions ............................................1E-19
Engine Oil and Filter Change ............................1E-19
Oil Pressure Switch On-Vehicle Inspection....... 1E-20
Oil Pressure Switch Removal and Installation ..1E-20
Oil Pan and Oil Pump Strainer Components.....1E-22
Oil Pan and Oil Pump Strainer Removal and
Installation ....................................................... 1E-23
Oil Pump Assembly Components .....................1E-25
Oil Pump Assembly Removal and Installation ..1E-26
Oil Pump Assembly Disassembly and
Reassembly .................................................... 1E-26
Oil Pump Inspection .......................................... 1E-27
Specifications.....................................................1E-28
Tightening Torque Specifications......................1E-28
Special Tools and Equipment ........................... 1E-29
Recommended Service Material ....................... 1E-29
Special Tool ......................................................1E-29
Engine Cooling System ...........................1F-1
K10B and Bi-Fuel CNG ........................................... 1F-1
Precautions........................................................... 1F-1
Precautions for Cooling System.......................... 1F-1
General Description ............................................. 1F-2
Cooling System Description ................................ 1F-2
Coolant Description............................................. 1F-2
Cooling Fan Operation Description ..................... 1F-2
Schematic and Routing Diagram........................ 1F-3
Coolant Circulation.............................................. 1F-3
Radiator Cooling Fan Control System Circuit
Diagram ............................................................ 1F-4
Diagnostic Information and Procedures............ 1F-4
Engine Cooling Symptom Diagnosis................... 1F-4
Radiator Cooling Fan System Check .................. 1F-5
Repair Instructions .............................................. 1F-7
Cooling System Components.............................. 1F-7
Coolant Level Check ........................................... 1F-8
Engine Cooling System Inspection ..................... 1F-8
Cooling System Draining..................................... 1F-9
Cooling System Refilling ..................................... 1F-9
Water Inlet Pipe Removal and Installation ........ 1F-10
Thermostat Removal and Installation................ 1F-11
Thermostat Inspection....................................... 1F-11
Radiator Cooling Fan Assembly On-Vehicle
Inspection........................................................ 1F-12
Radiator Cooling Fan Relay Inspection............. 1F-13
Radiator Cooling Fan Assembly Removal and
Installation ....................................................... 1F-13
Radiator Cooling Fan Disassembly and
Reassembly .................................................... 1F-14
Radiator On-Vehicle Inspection and Cleaning .. 1F-15
Radiator Removal and Installation .................... 1F-15
Water Pump Removal and Installation .............. 1F-16
Water Pump Inspection ..................................... 1F-16
Specifications ..................................................... 1F-17
Tightening Torque Specifications...................... 1F-17
Special Tools and Equipment ........................... 1F-17
Recommended Service Material ....................... 1F-17
Special Tool ...................................................... 1F-17
K12M....................................................................... 1F-18
Precautions......................................................... 1F-18
Precautions for Cooling System ........................ 1F-18
General Description ........................................... 1F-18
Cooling System Description .............................. 1F-18
Coolant Description ........................................... 1F-18
Cooling Fan Operation Description ................... 1F-19
Schematic and Routing Diagram ...................... 1F-19
Coolant Circulation ............................................ 1F-19
Radiator Cooling Fan Control System Circuit
Diagram........................................................... 1F-20
Diagnostic Information and Procedures .......... 1F-21
Engine Cooling Symptom Diagnosis ................. 1F-21
Radiator Cooling Fan System Check ................ 1F-22
Repair Instructions ............................................ 1F-25
Cooling System Components............................ 1F-25
Coolant Level Check ......................................... 1F-26
Engine Cooling System Inspection ................... 1F-26
Cooling System Draining................................... 1F-27
Cooling System Refilling ................................... 1F-27
Water Inlet Pipe Removal and Installation ........ 1F-28
Thermostat Removal and Installation................ 1F-29
Thermostat Inspection....................................... 1F-29
Radiator Cooling Fan Assembly On-Vehicle
Inspection........................................................ 1F-30
Radiator Cooling Fan Relay Inspection............. 1F-31
Radiator Cooling Fan Assembly Removal and
Installation ....................................................... 1F-31
Radiator Cooling Fan Disassembly and
Reassembly .................................................... 1F-32
Radiator On-Vehicle Inspection and Cleaning .. 1F-32
Radiator Removal and Installation .................... 1F-32
Water Pump Removal and Installation .............. 1F-33
Water Pump Inspection ..................................... 1F-34
Specifications ..................................................... 1F-34
Tightening Torque Specifications...................... 1F-34
Special Tools and Equipment ........................... 1F-35
Recommended Service Material ....................... 1F-35
Special Tool ...................................................... 1F-35
Fuel System ............................................. 1G-1
Petrol ....................................................................... 1G-1
Precautions.......................................................... 1G-1
Precautions for Fuel System Service ................. 1G-1
General Description ............................................ 1G-2
Fuel System Description .................................... 1G-2
Fuel Delivery System Description ...................... 1G-2
Fuel Pump Description....................................... 1G-2
Schematic and Routing Diagram ....................... 1G-2
Fuel Delivery System Diagram........................... 1G-2
Fuel Injector Control System Circuit Diagram .... 1G-3

Fuel Pump Control System Circuit Diagram .......1G-5
Diagnostic Information and Procedures............1G-5
Fuel System Inspection.......................................1G-5
Power Balance Test ............................................1G-6
Fuel Injector Circuit Check ..................................1G-7
Fuel Pump and Its Circuit Check.......................1G-10
Fuel Pressure Check ........................................1G-12
Fuel Pressure Basic Check...............................1G-14
Repair Instructions ............................................1G-15
Fuel System Components.................................1G-15
Fuel Hose Disconnection and Reconnection ....1G-16
Fuel Pressure Relief Procedure ........................1G-19
Fuel Leakage Check Procedure .......................1G-20
Fuel Line On-Vehicle Inspection .......................1G-20
Fuel Pipe Removal and Installation ..................1G-20
Fuel Injector On-Vehicle Inspection ..................1G-21
Fuel Injector Removal and Installation ..............1G-22
Fuel Injector Inspection .....................................1G-24
Fuel Filler Cap Inspection .................................1G-26
Fuel Tank Removal and Installation..................1G-26
Fuel Tank Inspection.........................................1G-28
Fuel Tank Flushing Procedure ..........................1G-28
Fuel Pump On-Vehicle Inspection ....................1G-29
Fuel Filter Removal and Installation..................1G-29
Fuel Pump Assembly Removal and
Installation .......................................................1G-29
Fuel Pump Inspection .......................................1G-31
Fuel Level Sensor Removal and Installation.....1G-31
Fuel Level Sensor Inspection............................1G-32
Specifications.....................................................1G-32
Tightening Torque Specifications......................1G-32
Special Tools and Equipment ...........................1G-33
Special Tool ......................................................1G-33
Bi-Fuel CNG ...........................................................1G-34
Precautions.........................................................1G-34
Precautions for Fuel System Service ................1G-34
General Description ...........................................1G-35
Fuel System Description ...................................1G-35
Fuel Delivery System Description .....................1G-35
Fuel Pump Description......................................1G-35
CNG Receptacle Description ............................1G-35
CNG Cylinder Description .................................1G-35
CNG Cylinder Valve Description .......................1G-36
CNG Fuel Filter Description ..............................1G-37
CNG Pressure Regulator Description ...............1G-37
Schematic and Routing Diagram......................1G-38
Fuel Delivery System Diagram..........................1G-38
Fuel Injector Control System Circuit Diagram ...1G-39
Fuel Pump Control System Circuit Diagram .....1G-40
Diagnostic Information and Procedures..........1G-40
Fuel System Inspection.....................................1G-40
Power Balance Test ..........................................1G-41
Fuel Injector Circuit Check ................................1G-41
Fuel Pump and Its Circuit Check.......................1G-46
Fuel Pressure Check ........................................1G-46
Fuel Pressure Basic Check...............................1G-47
Fuel Cut Operation Check ................................1G-47
Repair Instructions ............................................1G-49
Fuel System Components.................................1G-49
Table of Contents 1-vii
Fuel Hose Disconnection and Reconnection ... 1G-54
Fuel Pressure Relief Procedure ....................... 1G-55
Fuel Leakage Check Procedure....................... 1G-56
Fuel Line On-Vehicle Inspection ...................... 1G-58
Fuel Pipe Removal and Installation.................. 1G-58
Fuel Filter Removal and Installation................. 1G-63
Fuel Injector On-Vehicle Inspection ................. 1G-65
Fuel Injector Removal and Installation ............. 1G-65
Fuel Injector Inspection .................................... 1G-66
CNG Pressure Regulator On-Vehicle
Inspection....................................................... 1G-67
CNG Pressure Regulator Removal and
Installation ...................................................... 1G-67
CNG Pressure Regulator Inspection................ 1G-69
CNG Pressure Gauge Removal and
Installation ...................................................... 1G-70
Fuel Filler Cap Inspection ................................ 1G-71
Fuel Tank Removal and Installation................. 1G-71
Fuel Tank Inspection........................................ 1G-73
Fuel Tank Flushing Procedure ......................... 1G-73
Fuel Pump On-Vehicle Inspection.................... 1G-73
Fuel Pump Relay Inspection ............................ 1G-73
CNG Valve Control Relay Inspection ............... 1G-73
Fuel Pump Assembly Removal and
Installation ...................................................... 1G-73
Fuel Pump Inspection ...................................... 1G-73
Fuel Level Sensor Removal and Installation.... 1G-73
Fuel Level Sensor Inspection........................... 1G-73
CNG Cylinder with Valve On-Vehicle
Inspection....................................................... 1G-73
CNG Cylinder with Valve Removal and
Installation ...................................................... 1G-74
CNG Receptacle On-Vehicle Inspection .......... 1G-78
CNG Receptacle Removal and Installation...... 1G-78
CNG Hose Chamber Removal and
Installation ...................................................... 1G-80
Specifications .................................................... 1G-81
Tightening Torque Specifications..................... 1G-81
Special Tools and Equipment .......................... 1G-81
Special Tool ..................................................... 1G-81
Ignition System ........................................ 1H-1
K10B and Bi-Fuel CNG............................................1H-1
General Description .............................................1H-1
Ignition System Construction ..............................1H-1
Schematic and Routing Diagram ........................1H-2
Ignition System Circuit Diagram..........................1H-2
Component Location ...........................................1H-3
Ignition System Component Location .................1H-3
Diagnostic Information and Procedures ............1H-4
Ignition System Check ........................................1H-4
Ignition Spark Test ..............................................1H-6
Repair Instructions ..............................................1H-7
Spark Plug Removal and Installation ..................1H-7
Spark Plug Inspection .........................................1H-7
Ignition Coil Assembly Removal and
Installation .........................................................1H-7
Ignition Coil Assembly Inspection .......................1H-7
Ignition Timing Inspection ...................................1H-8
1-viii Table of Contents
Specifications.......................................................1H-9
Tightening Torque Specifications........................1H-9
Special Tools and Equipment .............................1H-9
Special Tool ........................................................1H-9
K12M.......................................................................1H-10
General Description ...........................................1H-10
Ignition System Construction ............................1H-10
Schematic and Routing Diagram......................1H-11
Ignition System Circuit Diagram........................1H-11
Component Location .........................................1H-12
Ignition System Component Location ...............1H-12
Diagnostic Information and Procedures..........1H-13
Ignition System Check ......................................1H-13
Ignition Spark Test ............................................1H-16
Repair Instructions ............................................1H-17
Spark Plug Removal and Installation ................1H-17
Spark Plug Inspection .......................................1H-17
Ignition Coil Assembly Removal and
Installation .......................................................1H-17
Ignition Coil Assembly Inspection .....................1H-18
Ignition Timing Inspection .................................1H-18
Specifications.....................................................1H-19
Tightening Torque Specifications......................1H-19
Special Tools and Equipment ...........................1H-19
Special Tool ......................................................1H-19
Starting System ......................................... 1I-1
General Description .............................................. 1I-1
Cranking System Description............................... 1I-1
Schematic and Routing Diagram......................... 1I-2
Cranking System Circuit Diagram ........................ 1I-2
Diagnostic Information and Procedures............. 1I-3
Cranking System Symptom Diagnosis................. 1I-3
Repair Instructions ............................................... 1I-5
Starting Motor Control Relay Inspection .............. 1I-5
Starting Motor Removal and Installation .............. 1I-5
Starting Motor Components ................................. 1I-7
Starting Motor Disassembly and Reassembly ..... 1I-8
Starting Motor Inspection ................................... 1I-11
Starter Count Information Clear (M/T Model)..... 1I-15
Specifications...................................................... 1I-16
Cranking System Specifications......................... 1I-16
Tightening Torque Specifications....................... 1I-16
Special Tools and Equipment ............................ 1I-16
Recommended Service Material ........................ 1I-16
Special Tool ....................................................... 1I-16
Charging System ...................................... 1J-1
K10B and Bi-Fuel CNG ........................................... 1J-1
Precautions........................................................... 1J-1
Precautions for Handling Battery ........................ 1J-1
General Description ............................................. 1J-2
Battery Description.............................................. 1J-2
Generator Description ......................................... 1J-2
Diagnostic Information and Procedures............ 1J-4
Battery Inspection ............................................... 1J-4
Generator Symptom Diagnosis ........................... 1J-4
Generator Test .................................................... 1J-5
Repair Instructions .............................................. 1J-6
Jump-Starting in Case of Emergency ................. 1J-6
Battery Removal and Installation ........................ 1J-6
Water Pump / Generator Drive Belt Tension
Inspection and Adjustment................................ 1J-7
Water Pump / Generator Drive Belt Removal
and Installation .................................................. 1J-8
Belt Tensioner Arm and Belt Tensioner Pulley
Removal and Installation................................... 1J-9
Generator Removal and Installation.................. 1J-10
Generator Arm and Generator Bracket
Removal and Installation................................. 1J-11
Belt Tensioner Pulley Inspection ....................... 1J-11
Generator Components..................................... 1J-12
Generator Disassembly and Reassembly ......... 1J-12
Generator Inspection......................................... 1J-16
Specifications ..................................................... 1J-17
Charging System Specifications ....................... 1J-17
Tightening Torque Specifications...................... 1J-18
Special Tools and Equipment ........................... 1J-18
Special Tool ...................................................... 1J-18
K12M....................................................................... 1J-19
Precautions......................................................... 1J-19
Precautions for Handling Battery ...................... 1J-19
General Description ........................................... 1J-20
Battery Description ............................................ 1J-20
Generator Description ....................................... 1J-20
Diagnostic Information and Procedures .......... 1J-22
Battery Inspection ............................................. 1J-22
Generator Symptom Diagnosis ......................... 1J-22
Generator Test .................................................. 1J-23
Repair Instructions ............................................ 1J-24
Jump-Starting in Case of Emergency ............... 1J-24
Battery Removal and Installation ...................... 1J-24
Water Pump / Generator Drive Belt Inspection
and Adjustment ............................................... 1J-25
Water Pump / Generator Drive Belt Removal
and Installation ................................................ 1J-26
Belt Tensioner Arm and Belt Tensioner Pulley
Removal and Installation................................. 1J-27
Generator Removal and Installation.................. 1J-28
Generator Arm and Generator Bracket
Removal and Installation................................. 1J-29
Belt Tensioner Pulley Inspection ....................... 1J-29
Generator Components..................................... 1J-30
Generator Disassembly and Reassembly ......... 1J-30
Generator Inspection......................................... 1J-34
Specifications ..................................................... 1J-35
Charging System Specifications ....................... 1J-35
Tightening Torque Specifications...................... 1J-36
Special Tools and Equipment ........................... 1J-36
Special Tool ...................................................... 1J-36
Exhaust System....................................... 1K-1
K10B and Bi-Fuel CNG............................................1K-1
General Description .............................................1K-1
Exhaust System Description ...............................1K-1
Diagnostic Information and Procedures ............1K-1
Exhaust System Check .......................................1K-1

Repair Instructions ..............................................1K-2
Exhaust System Components............................. 1K-2
Exhaust Manifold Removal and Installation ........ 1K-3
Exhaust Manifold Inspection ............................... 1K-4
Exhaust Pipe and Muffler Removal and
Installation ......................................................... 1K-5
Specifications.......................................................1K-6
Tightening Torque Specifications........................ 1K-6
K12M.........................................................................1K-7
General Description .............................................1K-7
Exhaust System Description ............................... 1K-7
Table of Contents 1-ix
Diagnostic Information and Procedures ............1K-7
Exhaust System Check .......................................1K-7
Repair Instructions ..............................................1K-8
Exhaust System Components.............................1K-8
Exhaust Manifold Removal and Installation ........1K-9
Exhaust Manifold Inspection .............................1K-10
Exhaust Pipe and Muffler Removal and
Installation .......................................................1K-10
Specifications .....................................................1K-11
Tightening Torque Specifications......................1K-11
1-1 Precautions:
Precautions
Engine
Precautions
Precautions for Engine (K10B)
AENJCA0A1000001
Warning for Airbag
Refer to “Warning for Airbag” in Section 00 (Page 00-7).
Precautions for Catalytic Converter
Refer to “Precautions for Catalytic Converter” in Section
00 (Page 00-6).
Precautions for Electrical Circuit Service
Refer to “Precautions for Electrical Circuit Service” in
Section 00 (Page 00-3).
Reassembling Note for Wiring Harness
Observe “Reassembling Note for Wiring Harness” in
Section 9A (Page 9A-132) whenever installing wiring
harness.
Otherwise, electrical trouble may occur.
Precautions for Fuel System Service
Refer to “Precautions for Fuel System Service”: Petrol in
Section 1G (Page 1G-1).
Precautions for Engine Service
• When raising or supporting engine, do not use a jack
under oil pan. Due to small clearance between oil pan
and oil pump strainer, jacking against oil pan may
cause it to be bent against strainer resulting in
damaged oil pick-up unit.
• It should be kept in mind, while working on engine,
that 12-volt electrical system involves danger of
violent and damaging short circuits. When performing
any work where electrical terminals could be
grounded, ground cable of the battery should be
disconnected at battery.
• Any time the air cleaner, throttle body or intake
manifold is removed, the intake opening should be
covered. This will protect against accidental entrance
of foreign material which could follow intake passage
into cylinder and cause extensive damage when
engine is started.
• When disconnecting connectors, do not pull wire
harness but hold connector itself. With lock type
connector, unlock before disconnection.
Attempt to disconnect connector without unlocking
may result in damage to connector. When connecting
lock type connector, insert it till clicking sound is heard
and connect it securely.
IYSQ01110001-01
Precautions for Diagnosing Trouble
• Diagnostic information stored in ECM memory can be
cleared as well as checked using SUZUKI scan tool or
CAN communication OBD-II generic scan tool. Before
using scan tool, read its Operator’s Manual to know
how to use it.
• Not only ECM but also TCM (auto gear shift model in
Section 5D) turns on MIL. It is indistinguishable which
module turns on MIL.
Therefore, for auto gear shift model in Section 5D,
check both ECM and TCM for DTC when MIL lights
up.
• Priorities for diagnosing troubles:
If two or more DTCs are stored, perform DTC
troubleshooting for these DTCs beginning with the
DTC detected earliest and follow the instructions
available in the troubleshooting procedure.
If no instructions are available, troubleshoot DTCs
according to the following priorities.
a. DTC P0300 / P0301 / P0302 / P0303 (Misfire
detected)
b. DTC P0171 / P0172 (Fuel system too lean/too
rich)
c. DTCs other than DTC P0171 / P0172 (Fuel
system too lean/too rich) and DTC P0300 / P0301
/ P0302 / P0303 (Misfire detected)
• Read “Precautions for Electrical Circuit Service” in
Section 00 (Page 00-3) before inspection and observe
what is written there.
• Communication of ECM and other control module are
established via CAN. (For more detail of CAN
communication for ECM, refer to “Communication
System Description” in Section 10H (Page 10H-1).)
• Before performing troubleshooting, read the
“Precautions for ECM Circuit Inspection” (Page 1-2).
• Upon completion of inspection and repair work,
perform “DTC Confirmation Procedure” and check
that the trouble has been repaired.

Precautions for Replacing ECM
• Before replacement of the ECM, check the following
conditions. Neglecting this check may cause damage
to new ECM.
– Resistances of all relays and actuators are as
specified.
– TP sensor, APP sensor, MAP sensor and A/C
refrigerant pressure sensor are in good condition
and none of their power circuits is shorted to
ground.
• Perform “Procedure after ECM Replacement”: K10B
and Bi-Fuel CNG in Section 1C (Page 1C-4).
Precautions for ECM Circuit Inspection
Do not measure circuit voltage and/or pulse signal of
ECM by inserting tester probe into a sealed terminal of
ECM.
When measuring circuit voltage and/or pulse signal of
ECM, connect service wires (5) to terminals of each
sensor / actuator (1) and sensor / actuator connector (2).
Otherwise, sealed terminals, ECM and its circuits may
be damaged.
3
1
2
5 Refer to “Precautions for Fuel System Service”: Petrol in
4
I8C50A110001-02
3. Voltmeter 4. Oscilloscope
Precautions for Electric Throttle Control System
Calibration
Completely closed and opened throttle valve position
data are stored in ECM.
After performing any one of the following services,
calibrate the completely closed and opened throttle
valve position stored in ECM. (Page 1C-7)
• Replacement of ECM
• Clearance of DTC related to ECM
• Replacement of electric throttle body assembly
• Replacement of accelerator pedal assembly
Precautions: 1-2
Precautions for Generator Control System
In connection with generating control of the generator,
the engine speed may rise or drop due to such causal
factors as described below.
• Battery is undercharged or its service life is used up.
• The power for later added accessories is taken
directly from the battery terminal.
• A large amount of electric load is applied.
• One of the following DTCs is detected.
– U2001: LIN Lost Communication With Generator
– U2021: LIN Invalid Data from ECM to Generator
Precautions for Engine (K12M)
AENJCA0A1000003
Warning for Airbag
Refer to “Warning for Airbag” in Section 00 (Page 00-7).
Precautions for Catalytic Converter
Refer to “Precautions for Catalytic Converter” in Section
00 (Page 00-6).
Precautions for Electrical Circuit Service
Refer to “Precautions for Electrical Circuit Service” in
Section 00 (Page 00-3).
Reassembling Note for Wiring Harness
Observe “Reassembling Note for Wiring Harness” in
Section 9A (Page 9A-132) whenever installing wiring
harness.
Otherwise, electrical trouble may occur.
Precautions for Fuel System Service
Section 1G (Page 1G-1).
Precautions for Engine Service
• When raising or supporting engine, do not use a jack
under oil pan. Due to small clearance between oil pan
and oil pump strainer, jacking against oil pan may
cause it to be bent against strainer resulting in
damaged oil pick-up unit.
• It should be kept in mind, while working on engine,
that 12-volt electrical system involves danger of
violent and damaging short circuits. When performing
any work where electrical terminals could be
grounded, ground cable of the battery should be
disconnected at battery.
• Any time the air cleaner, throttle body or intake
manifold is removed, the intake opening should be
covered. This will protect against accidental entrance
of foreign material which could follow intake passage
into cylinder and cause extensive damage when
engine is started.
1-3 Precautions:
• When disconnecting connectors, do not pull wire
harness but hold connector itself. With lock type
connector, unlock before disconnection.
Attempt to disconnect connector without unlocking
may result in damage to connector. When connecting
lock type connector, insert it till clicking sound is heard
and connect it securely.
IYSQ01110001-01
Precautions for Diagnosing Trouble
• Diagnostic information stored in ECM memory can be
cleared and checked using SUZUKI scan tool or CAN
communication OBD-II generic scan tool. Before
using scan tool, read its Operator’s Manual to know
how to use it.
• Not only ECM but also TCM (auto gear shift model in
Section 5D) turns on MIL. It is indistinguishable which
module turns on MIL.
Therefore, for auto gear shift model in Section 5D,
check both ECM and TCM for DTC when MIL lights
up.
• Priorities for diagnosing troubles:
If two or more DTCs are stored, perform DTC
troubleshooting for these DTCs beginning with the
DTC detected earliest and follow the instructions
available in the troubleshooting procedure.
If no instructions are available, troubleshoot DTCs
according to the following priorities.
a. DTC P0300 / P0301 / P0302 / P0303 / P0304
(Misfire detected)
b. DTC P0171 / P0172 (Fuel system too lean/too
rich)
c. DTCs other than DTC P0171 / P0172 (Fuel
system too lean/too rich) and DTC P0300 / P0301
/ P0302 / P0303 / P0304 (Misfire detected)
• Read “Precautions for Electrical Circuit Service” in
Section 00 (Page 00-3) before inspection and observe
what is written there.
• Communication of ECM and other control module are
established via CAN. (For more detail of CAN
communication for ECM, refer to “Communication
System Description” in Section 10H (Page 10H-1).)
• Before performing troubleshooting, read the
“Precautions for ECM Circuit Inspection” (Page 1-3).
• Upon completion of inspection and repair work,
perform “DTC Confirmation Procedure” and check
that the trouble has been repaired.
Precautions for Replacing ECM
• Before replacement of the ECM, check the following
conditions. Neglecting this check may cause damage
to new ECM.
– Resistances of all relays and actuators are as
specified.
– TP sensor, APP sensor, MAP sensor and A/C
refrigerant pressure sensor are in good condition
and none of their power circuits is shorted to
ground.
• Perform “Procedure after ECM Replacement”: K12M
in Section 1C (Page 1C-23).
Precautions for ECM Circuit Inspection
Do not measure circuit voltage and/or pulse signal of
ECM by inserting tester probe into a sealed terminal of
ECM.
When measuring circuit voltage and/or pulse signal of
ECM, connect service wires (5) to terminals of each
sensor / actuator (1) and sensor / actuator connector (2).
Otherwise, sealed terminals, ECM and its circuits may
be damaged.
3
1
2
5
4
I8C50A110001-02
3. Voltmeter 4. Oscilloscope
Precautions for Electric Throttle Control System
Calibration
Completely closed and opened throttle valve position
data are stored in ECM.
After performing any one of the following services,
calibrate the completely closed and opened throttle
valve position stored in ECM. (Page 1C-25)
• Replacement of ECM
• Clearance of DTC related to ECM
• Removal and installation of electric throttle body
assembly (cleaning or replacement)

Precautions for Generator Control System
In connection with generating control of the generator,
the engine speed may rise or drop due to such causal
factors as described below.
• Battery is undercharged or its service life is used up.
• The power for later added accessories is taken
directly from the battery terminal.
• A large amount of electric load is applied.
• One of the following DTCs is detected.
– U2001: LIN Lost Communication With Generator
– U2021: LIN Invalid Data from ECM to Generator
Precautions for Engine (Bi-Fuel CNG)
AENJCA0A1000004
Warning for Airbag
Refer to “Warning for Airbag” in Section 00 (Page 00-7).
Precautions for Catalytic Converter
Refer to “Precautions for Catalytic Converter” in Section
00 (Page 00-6).
Precautions for Electrical Circuit Service
Refer to “Precautions for Electrical Circuit Service” in
Section 00 (Page 00-3).
Reassembling Note for Wiring Harness
Observe “Reassembling Note for Wiring Harness” in
Section 9A (Page 9A-132) whenever installing wiring
harness.
Otherwise, electrical trouble may occur.
Precautions for Fuel System Service
Refer to “Precautions for Fuel System Service”: Bi-Fuel
CNG in Section 1G (Page 1G-34).
Precautions for Engine Service
! WARNING
CNG is combustible and there is a risk of
incidental fire causing personal injury.
Take special precaution when handling CNG
referring to “Warning for CNG” in Section 00
(Page 00-6).
• When raising or supporting engine, do not use a jack
under oil pan. Due to small clearance between oil pan
and oil pump strainer, jacking against oil pan may
cause it to be bent against strainer resulting in
damaged oil pick-up unit.
• It should be kept in mind, while working on engine,
that 12-volt electrical system involves danger of
violent and damaging short circuits. When performing
any work where electrical terminals could be
grounded, ground cable of the battery should be
disconnected at battery.
Precautions: 1-4
• Any time the air cleaner, throttle body or intake
manifold is removed, the intake opening should be
covered. This will protect against accidental entrance
of foreign material which could follow intake passage
into cylinder and cause extensive damage when
engine is started.
• When disconnecting connectors, do not pull wire
harness but hold connector itself. With lock type
connector, unlock before disconnection.
Attempt to disconnect connector without unlocking
may result in damage to connector. When connecting
lock type connector, insert it till clicking sound is heard
and connect it securely.
IYSQ01110001-01
Precautions for Diagnosing Trouble
ECM
Refer to “Precautions for Diagnosing Trouble” under
“Precautions for Engine (K10B)” (Page 1-1).
CNG control module
• Diagnostic information stored in CNG control module
memory can be cleared as well as checked using
SUZUKI scan tool or CAN communication OBD-II
generic scan tool. Before using scan tool, read its
Operator’s Manual to know how to use it.
• Read “Precautions for Electrical Circuit Service” in
Section 00 (Page 00-3) before inspection and observe
what is written there.
• Communication of CNG control module and other
control module are established via CAN. (For more
detail of CAN communication for CNG control module,
refer to “Communication System Description” in
Section 10H (Page 10H-1).)
• Before performing troubleshooting, read the
“Precautions for CNG Control Module Circuit
Inspection” (Page 1-5).
• Upon completion of inspection and repair work,
perform “DTC Confirmation Procedure” and check
that the trouble has been repaired.
Precautions for Replacing ECM
Refer to “Precautions for Replacing ECM” under
“Precautions for Engine (K10B)” (Page 1-1).
Precautions for ECM Circuit Inspection
Refer to “Precautions for ECM Circuit Inspection” under
“Precautions for Engine (K10B)” (Page 1-1).
1-5 Precautions:

Precautions for Replacing CNG Control Module

Before replacement of the CNG control module, check
the following conditions. Neglecting this check may
cause damage to new CNG control module.
• Resistances of all relay and actuators are as
specified.
• CNG pressure-and-temperature sensor and CNG
cylinder pressure sensor are in good condition and
none of their power circuits is shorted to ground.

Precautions for CNG Control Module Circuit

Inspection
Do not measure voltage and/or pulse signal of CNG
control module inserting tester probe in sealed terminal
of CNG control module.
When measuring circuit voltage and/or pulse signal of
CNG control module, be sure to connect service wires
(5) to each sensor (1) and sensor connector (2).
Otherwise, sealed terminal, CNG control module and its
circuits may be damaged.

4
I8C50A110001-02

3. Voltmeter 4. Oscilloscope

Precautions for Electric Throttle Control System

Calibration
Refer to “Precautions for Electric Throttle Control
System Calibration” under “Precautions for Engine
(K10B)” (Page 1-1).

Precautions for Generator Control System

Refer to “Precautions for Generator Control System”
under “Precautions for Engine (K10B)” (Page 1-1).
 Engine General Information and Diagnosis: K10B 1A-1

Engine General Information and Diagnosis

Engine

K10B
General Description
Engine Diagnosis General Description • Not only SUZUKI scan tool (2) but also CAN
AENJCA0A1111002 communication OBD generic scan tool can
The engine and emission control system in this vehicle
communicate with ECM via DLC (3). Diagnostic
are controlled by ECM. ECM has an OBD system which
information can be accessed using a scan tool.
detects a malfunction in this system and abnormality of
those parts that influence the engine exhaust emission.
When diagnosing engine troubles, have full
understanding of the outline of “OBD System
Description”: K10B (Page 1A-1) and each item in 1
“Precautions for Diagnosing Trouble” under “Precautions
for Engine (K10B)” in Section 1 (Page 1-1) and execute
diagnosis according to “Engine and Emission Control
System Check”: K10B (Page 1A-20).
There is a close relationship between the engine
mechanical, engine cooling system, ignition system,
exhaust system, etc. and the engine and emission
control system in their structure and operation. In case of
an engine trouble, even when the MIL does not turn ON,
it should be diagnosed according to “Engine and
Emission Control System Check”: K10B (Page 1A-20).
3
OBD System Description
AENJCA0A1111003
General Description
ECM in this vehicle has the following functions.
• When ignition is “ON” with the engine at a stop, MIL
(1) turns ON to check the circuit of the MIL (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 combination
meter of the instrument panel turn ON or blink
(blinking only when detecting a misfire which can
cause damage to the catalyst) and stores the 2
malfunction area in its memory. IJCA0A111001-01

• For some malfunctions, ECM adopts the 3 driving

cycle detection logic (refer to “3 Driving Cycle
Detection Logic”: K10B (Page 1A-1)) to prevent
erroneous detection.
With this logic, MIL is turned on when the same
malfunction is detected for 3 consecutive driving
cycles.
However, if ECM detects a malfunction only in the first
driving cycle (refer to “Driving Cycle”: K10B (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.
• 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”: K10B (Page 1A-3).
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.
3 Driving Cycle Detection Logic
The malfunction detected in the first driving cycle is
stored in ECM memory (in the form of pending DTC) but
MIL does not light at this time. ECM causes the MIL to
light up when it detects third time the same malfunction
in the next two driving cycles.
1A-2 Engine General Information and Diagnosis: K10B
Pending DTC
“Pending DTC” is relevant to those DTCs to which the “3
driving cycle detection logic” is applied. If such a DTC is
detected and stored temporarily during the first of three
consecutive driving cycles, the DTC is called “pending
DTC”.
Freeze Frame Data
ECM stores the engine and driving conditions at the
moment of the detection of a malfunction in its memory.
This data is called “Freeze frame data”.
Therefore, it is possible to know engine and driving
conditions (e.g. whether the engine was warm or not,
whether the vehicle was running or stopped, whether air/
fuel mixture was lean or rich) at the moment the
malfunction was detected by checking the freeze frame
data. Also, ECM has a function to store each freeze
frame data for three different malfunctions in detecting
order. Utilizing this function, it is possible to know the
detecting order of the malfunctions, and facilitates
recheck and diagnosis of the trouble.
NOTE
• Absolute TP / APP indicates the ratio of the
output voltage to the power supply voltage
of related sensor.
When power supply voltage is 5.0 V and
output voltage is 4.0 V, freeze frame data is
displayed as follows.
– The sensor that the output voltage
increases according to the opening
angle, it displays 80%.
– The sensor that the output voltage
decreases according to the opening
angle, it displays 20%.
• Relative TP indicates value calculated by
formula ((output voltage – output voltage
at closed throttle position) / power supply
voltage).
When power supply voltage is 5.0 V and
output voltage at closed throttle position is
1.0 V, freeze frame data is displayed as
follows.
– At closed throttle position (output
voltage = 1.0 V), it displays 0%.
– At wide open throttle position (output
voltage = 4.0 V), it displays 60%.
However, for systems where the output is
inversely proportional to the input voltage, it
displays 100% minus above-mentioned
formula.
Freeze frame data (For example)
IJHB0B111001-01
 Engine General Information and Diagnosis: K10B 1A-3

Priority of freeze frame data

ECM has 4 freeze frames from 0 to 3 where freeze frame data can be stored.
Frame 0 is a special frame where freeze frame data concerning emission-affecting malfunction has priority over data
related to other (general) malfunctions. If any emission-affecting malfunction is detected while Frame 0 is holding a
data related to general malfunctions (priority “2” data in the following table), then the currently stored data is replaced
by the data concerning the newly detected malfunction (priority “1” data in the following table).
Priority Freeze frame data in frame 0
Data concerning any of the following malfunctions: Misfire Detected (P0300 – P0303), System Too Lean
1
(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 P0532 P0532 data
DTC 3 P0480 P0532 data P0480 data
detection
order 4 P0443 P0443 data P0532 data P0480 data P0443 data
5 P0171 P0171 data P0532 data P0480 data P0443 data
6 P0112 P0171 data P0532 data P0480 data P0443 data
IDLA0A110002-01
—: No freeze frame data

Freeze frame data clearance NOTE

When a DTC is cleared, the freeze frame data for the
malfunction represented by this DTC is also cleared. • The system readiness test status may
change from “Complete” to “Incomplete” if
System Readiness Test any of the following service operations is
The system readiness test is performed for the purpose performed.
of checking that each of the exhaust-emission-related – Disconnection of battery negative (–)
systems fulfills the conditions that allow ECM to detect a cable
malfunction if it occurs and to set the corresponding – Disconnection of ECM connectors
DTC. – Removal of ECM ground cable
The test is carried out by monitoring the specific items
• The items (components) indicated in the
(components) using a scan tool (SUZUKI scan tool or
table below are monitored in the system
CAN communication OBD generic scan tool). When the
readiness test to check the readiness for
test shows that the conditions pre-established for the
detecting the DTCs listed beside each
tested system are met, ECM performs an on-board
monitoring item.
diagnosis of the system, changes the status of the
system readiness test from “Incomplete” to “Complete”, • The “Complete” or “Incomplete” status
and causes the “Complete” status to be displayed on the identified through the system readiness
scan tool. test does NOT mean the “Normal” or
The “Complete” status is maintained until DTC clearance “Abnormal” result of on-board diagnosis.
operation is performed using the scan tool.
Monitoring item of system readiness test table
Monitoring item DTC related to monitoring item
Catalyst P0420
O2 Sensor P0133 P0139*
O2 Sensor Heater —

*: Depending on model
1A-4 Engine General Information and Diagnosis: K10B

DLC Description Engine and Emission Control System

AENJCA0A1111004
DLC (1) is in compliance with SAE J1962 in the shape of
Description
AENJCA0A1111005
connector and pin assignment. The engine and emission control system is divided into 4
OBD CAN High line (6) and Low line (3) (CAN line of ISO major sub-systems: air intake system, fuel delivery
15765-4) are used for SUZUKI scan tool (7) or CAN system, electronic control system and emission control
communication OBD generic scan tool to communicate system.
with ECM and other control modules. Air intake system includes air cleaner, throttle body and
intake manifold.
2 3 Fuel delivery system includes fuel pump, delivery pipe,
16 15 14 13 12 11 10 9 etc.
Electronic control system includes ECM, various sensors
8 7 6 5 4 3 2 1 and controlled devices.
Emission control system includes EVAP and PCV
6 5
1 4 systems.

7
IJCA0A111002-01

2. B + (Continuous battery power)

4. ECM ground (Signal ground)
5. Ground (Chassis ground)
 Engine General Information and Diagnosis: K10B 1A-5

Air Intake System Description

AENJCA0A1111006
The main components of the air intake system are air cleaner (1), air cleaner outlet hose (2), electric throttle body (3)
(For the details, refer to “Electric Throttle Control System Description”: K10B (Page 1A-5).) and intake manifold (4).
The air (by the amount corresponding to throttle valve (5) opening and engine speed) is filtered by the air cleaner,
distributed by the intake manifold, and finally drawn into each combustion chamber. Electric throttle body is not
equipped with IAC valve for idle speed control. Idle speed control is performed by the throttle actuator (6) which opens/
closes the throttle valve. (For the details, refer to “Electric Throttle Control System Description”: K10B (Page 1A-5).)

3
6

I5RW0A110006-02

Electric Throttle Control System Description

AENJCA0A1111008
The electric throttle control system consists of the following items:
• Electric throttle body incorporating the throttle valve, throttle actuator and TP sensors (main/sub)
• Accelerator pedal assembly incorporating APP sensors (main/sub)
• ECM
1A-6 Engine General Information and Diagnosis: K10B

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

5
8

2 9 3 6
10
1
7

13
11

12

I7Y50A110003-01

6. CPU 9. APP sensor (sub) signal circuit 12. Drive circuit of throttle actuator
7. Throttle actuator driver 10. TP sensor (main) signal circuit
8. APP sensor (main) signal circuit 11. TP sensor (sub) signal circuit
 Engine General Information and Diagnosis: K10B 1A-7

Electronic Control System Description

AENJCA0A1111010
Function Construction
ECM controls fuel to be supplied into cylinder adjusting injection timing and injection
time (volume) optimally.
The fuel injection timing and time (volume) are decided by engine start injection control
for the engine starting and after start injection control during the normal driving.
Further, fuel cut is controlled in response to the driving conditions.
Engine start injection control
• Fuel injection timing
ECM has basic injection timing corresponding to coolant temperature and fuel is
injected in sequential order synchronizing with CKP sensor signal.
• Fuel injection time (volume)
For engine start, fuel injection time is decided adding adjustable factors such as
intake air temperature, battery voltage, engine speed (cranking speed) and
atmospheric pressure to the basic injection time programmed in ECM.
And, the lower the coolant temperature, the longer the injection time for good
startability.
After start injection control
• Fuel injection timing
– When the vehicle is running in normal condition, ECM calculates start timing of
the injection to accomplish it in programed finish timing and injects it sequentially.
Fuel injection control system – When deceleration fuel cut returns to normal injection or accelerating rapidly, fuel
is injected into all cylinders temporarily at the same time without synchronizing to
CKP sensor signal.
• Fuel injection time (volume)
ECM has a basic fuel injection time corresponding to intake air volume and engine
speed, and this basic injection time is adjusted adding correction value from each
sensor for the driving conditions optimally.
Fuel cut control
• Fuel cut by engine speed
To prevent the engine over speed, this fuel cut is operated in the following
conditions.
– While vehicle is running: When engine speed goes up to 6,400 rpm or higher.
– While vehicle is stopped: When engine speed goes up to 5,200 rpm or higher.

NOTE
The engine speed of fuel cut is a reference value.

• Fuel cut with deceleration of vehicle

To restrain hydrocarbon (HC) emissions and improve fuel economy, this fuel cut is
operated during deceleration in specified conditions.
1A-8 Engine General Information and Diagnosis: K10B

Function Construction
• Corresponding to vehicle running conditions, ECM controls ignition timing optimally.
• There are three control modes to determine ignition timing, i.e. engine start ignition
control mode, normal driving condition ignition control mode and ignition timing
inspection mode.
Further, energizing time of the spark plug is decided by engine speed and battery
voltage.
Engine start ignition control mode
When engine speed (cranking speed) is below 500 rpm, ECM controls the ignition
timing to BTDC –10° to 10°.
Ignition timing control system Normal driving condition ignition control mode
• At idling
ECM controls ignition timing optimally adding factor of coolant temperature to basic
timing corresponding to engine speed.
• Except idling
ECM controls ignition timing optimally adding correction value to basic timing
determined by factors such as intake air volume, engine speed.
Ignition timing inspection mode
When checking ignition timing with SUZUKI scan tool (Suzuki SDT-II), the timing is
fixed to BTDC 5° at idling.
Receiving dual voltage signals, main and sub, from APP Sensor, ECM calculates a
target degree of throttle opening to bring the throttle opening closer to the target and
activates throttle actuator. Further, the following controls are executed in response to
the vehicle conditions.
Engine start control
For engine start, ECM sets up throttle opening angle according to coolant temperature
to increase intake air for good startability. And, the lower the coolant temperature, the
wider the throttle opening for the same purpose.
Idling control
ECM has stored basic throttle opening angle corresponding to information of coolant
temperature, shift position and A/ C switch and, adding correction value, a target
degree of throttle opening is determined.
Normal condition control
Adding information of accelerator pedal depressing degree, engine load, etc. to basic
throttle opening degree, ECM determines a target degree of throttle opening. If actual
throttle opening angle differs from the target degree, ECM adjusts the throttle opening
to bring it closer to the target.
Deceleration control
Electric throttle body control At the time of deceleration, ECM controls to open throttle valve at specified degree to
system increase intake air and prevents engine speed from excessive falling.
Maximum engine speed limitation control
To prevent engine over speed, ECM restricts the throttle opening under the following
conditions.
• While vehicle is running: Engine speed at 6,200 rpm or higher.
• While vehicle is stopped: Engine speed at 2,800 rpm or higher for specified time.

NOTE
Above engine speed is reference value.

Torque down control (auto gear shift model)

When torque down demand from TCM is inputted, ECM responds to reduce engine
torque controlling throttle opening and ignition timing.
Fail-safe control
When ECM detects a malfunction of throttle control circuit, ECM stops energization to
the throttle actuator. As a result, throttle valve opening is fixed in a default angle or,
movable maximum opening of throttle valve is restricted in a degree equivalent to the
default angle. However, minimum vehicle running is ensured by control of fuel injection
and ignition timing.

Function
Generator control system
HO2S heater control system
Evaporative emission control
system
A/C control system
Radiator cooling fan control
system
Fuel pump control system
Starting motor control system
(M/T model)
Main relay control
CAN communication system
Brake override system
Engine General Information and Diagnosis: K10B 1A-9
Construction
• ECM communicates with generator through LIN. For better startability of engine,
generator is controlled not to generate electric power while cranking engine.
• Receiving information from generator, ECM sends charging system information to
combination meter through CAN and controls ON/OFF of charge warning light.
To quicken startup or maintain activation of HO2S, ECM controls HO2S heater by
using duty cycle pulse signal.
Corresponding to vehicle running conditions, ECM controls ON/OFF of EVAP canister
purge valve to suck in fuel evaporation gas absorbed in canister and feeds it into intake
manifold together with air-fuel mixture to burn.
This function restrains the fuel evaporation gas to be released to atmosphere.
Based on information of A/C switch, refrigerant pressure sensor and vehicle driving
conditions through CAN communication, ECM controls ON/OFF of A/C compressor
relay.
For more detail of A/C control system, refer to “A/C Operation Description” in Section
7B (Page 7B-4).
ECM controls ON/OFF of radiator fan actuating the relay based on information of A/C
switch, vehicle speed, engine speed, coolant temperature and refrigerant pressure.
For more detail of cooling fan operation, refer to “Cooling Fan Operation Description”:
K10B and Bi-Fuel CNG in Section 1F (Page 1F-2).
ECM operates or stops fuel pump controlling fuel pump relay.
ON conditions of fuel pump relay:
• For specified time after ignition “ON”.
• While CKP sensor signal is being inputted to ECM with engine running.
ECM controls starting motor control relay to protect starting motor from damage.
Continuous cranking before engine start exceeds specified time (about 12 seconds),
operation of starting motor is suspended. Before the next cranking, ignition “OFF” is
required. After starting engine, “START” position of ignition will not allow starting motor
to operate.
For more detail of engine cranking, refer to “Cranking System Description” in Section 1I
(Page 1I-1).
• Corresponding to “ON” or “OFF” of ignition mode, ECM controls main relay for
startup or stop of engine control system.
• The main relay controls the following functions.
– Self-shut-off function: ECM supplies power for specified time after ignition “OFF”.
– Battery countercurrent protection function: When the battery terminal is
connected reversely by mistake, the countercurrent is prevented by an internal
circuit of ECM.
ECM transmits / receives information and the data to / from other control modules by
using this system.
For more detail of CAN communication, refer to “Communication System Description”
in Section 10H (Page 10H-1).
When the driver depresses accelerator pedal and brake pedal at the same time, ECM
controls engine output by restricting throttle valve opening and prioritizes braking force.
NOTE
The system may not be activated depending on the following conditions.
• Depressing amount of accelerator pedal and brake pedal
• Vehicle speed
1A-10 Engine General Information and Diagnosis: K10B

Engine and Emission Control Input / Output Table

AENJCA0A1111011
Function Output Input
• Ignition “ON” signal
• Ignition “ST” signal
• ECT sensor
• CKP sensor
• CMP sensor
• TP sensor
• APP sensor
• IAT sensor
Fuel injection control Fuel injector
• MAP sensor
• HO2S-1
• HO2S-2
• Battery voltage
• Brake light switch
• ABS control module (wheel speed signal)
• TCM (gear shift position signal) (auto gear shift model)
• BCM (A/C ON/OFF request signal)
Fuel injector • Ignition “ON” signal
Immobilizer control
Ignition coil assembly • BCM
• Ignition “ON” signal
• Ignition “ST” signal
• ECT sensor
• CKP sensor
• CMP sensor
• TP sensor
• APP sensor
Ignition timing control Ignition coil assembly • IAT sensor
• MAP sensor
• Knock sensor
• Battery voltage
• ABS control module (wheel speed signal)
• Immobilizer control module
• TCM (gear shift position signal) (auto gear shift model)
• BCM (A/C ON/OFF request signal)
• Ignition “ON” signal
• Ignition “ST” signal
• ECT sensor
• CKP sensor
• TP sensor
• APP sensor
• IAT sensor
Idle speed control Throttle actuator
• MAP sensor
• Generator (field coil measured signal)
• BCM (electric load signal)
• ABS control module (wheel speed signal)
• P/S control module
• TCM (gear shift position signal) (auto gear shift model)
• BCM (A/C ON/OFF request signal)
 Engine General Information and Diagnosis: K10B 1A-11

Function Output Input

• Ignition “ON” signal
• CKP sensor
• TP sensor
• APP sensor
Throttle valve control Throttle actuator
• IAT sensor
• A/C refrigerant pressure sensor (A/C model)
• BCM (electric load signal)
• BCM (A/C ON/OFF request signal)
• Ignition “ON” signal
Generator control Generator • Ignition “ST” signal
• CKP sensor
• Ignition “ON” signal
• Ignition “ST” signal
• ECT sensor
HO2S-1
HO2S heater control • CKP sensor
HO2S-2
• TP sensor
• IAT sensor
• Battery voltage
• Ignition “ON” signal
• ECT sensor
• CKP sensor
• TP sensor
EVAP canister purge
EVAP purge control • IAT sensor
valve
• ABS control module (wheel speed signal)
• HO2S-1
• HO2S-2
• BCM (A/C ON/OFF request signal)
• Ignition “ON” signal
• Ignition “ST” signal
• ECT sensor
• CKP sensor
• TP sensor
A/C compressor control A/C compressor relay
• APP sensor
• A/C refrigerant pressure sensor
• BCM (evaporator temperature signal and A/C ON request
signal)
• ABS control module (wheel speed signal)
• Ignition “ON” signal
• ECT sensor
Radiator cooling fan Radiator cooling fan • CKP sensor
control relay • A/C refrigerant pressure sensor
• ABS control module (wheel speed signal)
• BCM (A/C ON/OFF request signal)
• Ignition “ON” signal
Fuel pump control Fuel pump relay
• CKP sensor
Starting motor control Starting motor control
• Ignition “ST” signal
relay control (M/T model) relay
Main relay control Main relay • Ignition “ON” signal
1A-12 Engine General Information and Diagnosis: K10B

Schematic and Routing Diagram

Engine and Emission Control System Diagram
AENJCA0A1112001

20
[B]

21

22
19

33
31
17

18

32
30
18

29
[B]

28
[A]

27

25 26
34

24
23

[A]
15
2

13

14
12
1

16
3

6
4

7
5

11
10
9

IJCA0A111003-03

[A]: M/T model
[B]: Auto gear shift model
1. Air cleaner
2. IAT sensor
3. TP sensor
4. Throttle actuator
5. MAP sensor
6. Ignition coil assembly
7. Fuel injector
8. EVAP canister purge valve
9. EVAP canister
10. Fuel cut valve
Engine General Information and Diagnosis: K10B 1A-13
11. Fuel pump (with pressure regulator) 23. CPP No.2 switch
12. Knock sensor 24. APP sensor
13. ECT sensor 25. CMP sensor
14. HO2S-1 26. CKP sensor
15. HO2S-2 27. Main relay
16. Fuel pump relay 28. Ignition switch
17. Control modules and sensor connected by CAN 29. IG11 relay (with keyless entry system)
18. TCM 30. Starting motor control relay
19. Radiator cooling fan relay 31. Starting motor
20. A/C compressor relay 32. Brake light switch
21. A/C refrigerant pressure sensor 33. Brake light
22. Generator 34. ECM
 CAN communication line Air Vapor

Exhaust gas Fuel

* : if equipped

Air cleaner Electric throttle Intake manifold Engine Exhaust manifold (Threeway catalyst)
outlet hose body assembly
Throttle TP MAP HO2S-1 HO2S-2
IAT sensor CMP CKP Knock Ignition coil
actuator sensor sensor
sensor sensor sensor assembly
Fuel
injector

EVAP canister ECT

purge valve Fuel sensor
Fuel cut valve pump

EVAP
canister Fuel tank
1A-14 Engine General Information and Diagnosis: K10B

Engine and Emission Control System Flow Diagram

Fuel pump relay

Heater Heater
control control
ECM

A/C compressor Main relay *CPP No.2 switch APP sensor

· *TCM Generator
relay
· ABS control module
· P/S control module
· BCM Radiator cooling Starting motor Blower speed A/C refrigerant Brake light switch
· SDM fan relay control relay selector pressure sensor
· Combination meter

Ignition switch

IJCA0A111004-02
AENJCA0A1112002
 Engine General Information and Diagnosis: K10B 1A-15

Electronic Control System Circuit Diagram

AENJCA0A1112003

1
2 28 +B
GRN E01-31 C01-70 LT GRN
3 29
PNK E01-32 C01-75 BRN
GRY E01-33 C01-56 RED
30
BLU E01-40 C01-54 GRN
31
4 GRY E01-41 C01-55 WHT
YEL E01-42 C01-45 BLK
+B C01-44 GRY 65
32
C01-77 PNK
5 C01-78 WHT 33
PPL C01-58
C01-79 RED 34

6
PNK C01-60
GRY 35
C01-40 RED
7 65
+B RED C01-53
GRN C01-37 36
BLU PPL C01-71 E01-38 YEL
BLK PNK +BB
LT GRN C01-32
37
8 65 38
BRN C01-52 E01-22 LT GRN 40
YEL C01-51 BLK BLU
BLU RED C01-76 39
BEG C01-42
41
9 E01-12 GRY
42 43
YEL C01-34 GRY BLU
BEG C01-38
10
WHT C01-33
BLU C01-43

44
11 LT BLU C01-57
C01-17 YEL
BEG C01-35 45
GRY C01-39 C01-18 GRN
12
BLU C01-36 46
13 LT GRN E01-37 C01-19 PNK

BEG E01-54
BLK E01-43

25 C01-31 BLU 47

+BB 48
E01-10 PNK
[A] 14 49
18 E01-56 BLU
GRN E01-20
E01-55 BLU

15
[D] 51
50 52
16 E01-19 WHT
YEL E01-23
17 [C]
IG2
56 53
IG1 54
IG2
[B] 53 ST 55
WHT C01-21
26 IG1 52
RED C01-22
+BB ST 58
20 57 59
WHT E01-18
19 27
RED E01-9 60

[A] E01-11 GRN 63

61
YEL E01-48
21 22 [B] 64
26
23 62
24 E01-24 LT BLU
C01-61 BLK
C01-66 BLK
: 66 : 67 : 12V : 5V
IJCA0A111005-03
1A-16 Engine General Information and Diagnosis: K10B

[A]: M/T model 21. To blower motor 45. Ignition coil assembly No.2
[B]: Auto gear shift model 22. Blower speed switch 46. Ignition coil assembly No.3
[C]: Without keyless entry system 23. A/C switch 47. Generator
[D]: With keyless entry system 24. To BCM 48. Main relay
1. ECM 25. LIN driver 49. “FI” fuse
2. APP sensor 26. TCM 50. “IG” fuse
3. APP sensor (main) 27. CAN driver 51. IG11 relay
4. APP sensor (sub) 28. Electric throttle body assembly 52. “IGN” fuse
5. CMP sensor 29. Throttle actuator 53. Ignition switch
6. CKP sensor 30. TP sensor (main) 54. “KEY” fuse
7. HO2S-1 31. TP sensor (sub) 55. “KEY2” fuse
8. HO2S-2 32. Fuel injector No.1 56. “IG COIL” fuse
9. IAT sensor 33. Fuel injector No.2 57. “ST SIG” fuse (in fuse box)
10. Knock sensor 34. Fuel injector No.3 58. “IGN2” fuse
11. MAP sensor 35. EVAP canister purge valve 59. “ST” fuse
12. ECT sensor 36. Fuel pump relay 60. Starting motor control relay
13. A/C refrigerant pressure sensor 37. Fuel pump 61. Starting motor
14. CPP No.2 switch 38. Radiator cooling fan relay 62. “ST SIG” fuse (in relay box)
15. Brake light switch 39. Radiator cooling fan 63. Main fuse box
16. Brake light 40. “RDTR” fuse 64. Battery
17. To other control module 41. A/C compressor relay 65. Shield wire
18. “STOP” fuse 42. A/C compressor 66. Engine ground
19. DLC 43. “CPRSR” fuse 67. Body ground
20. To other control modules and sensor 44. Ignition coil assembly No.1
connected by CAN

Terminal Arrangement of ECM Connector

NOTE
For circuit names and terminal voltages, refer to “Inspection of ECM and Its Circuits”: K10B (Page 1A-
103).

[A] C01 E01

10 9 8 7 6 5 4 3 2 1
65 64 63 62 61 20 19 18 17 16 15 14 13 12 11
70 69 68 67 66 30 29 28 27 26 25 24 23 22 21
75 74 73 72 71 40 39 38 37 36 35 34 33 32 31
80 79 78 77 76 50 49 48 47 46 45 44 43 42 41
60 59 58 57 56 55 54 53 52 51
[a]
9 8 7 6 5 4 3 2 1
57 56 55 18 17 16 15 14 13 12 11 10
60 59 58 27 26 25 24 23 22 21 20 19
63 62 61 36 35 34 33 32 31 30 29 28
66 65 64 45 44 43 42 41 40 39 38 37
54 53 52 51 50 49 48 47 46

IJCA0A111006-02

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

 Engine General Information and Diagnosis: K10B 1A-17

Component Location
Electronic Control System Component Location
AENJCA0A1113001
Engine Compartment

[a]
[1]

[2]

[c]

[b]
[f]

[e]
[d]

IJCA0A111007-01

Information sensors Control devices Others

1. A/C refrigerant pressure sensor
[a]: Generator [1]: ECM
[b]: A/C compressor relay [2]: Individual circuit fuse box No.1
[c]: Radiator cooling fan relay
[d]: Fuel pump relay
[e]: Main relay
[f]: Starting motor control relay
1A-18 Engine General Information and Diagnosis: K10B

Interior (Around Instrument Panel)

[1]

[a]

[1]

[2]
2

IJCA0A111008-02

Information sensors Control devices Others

1. APP sensor [a]: MIL [1]: Combination meter
2. CPP No.2 switch (M/T model) [2]: DLC
3. Brake light switch
 Engine General Information and Diagnosis: K10B 1A-19

Engine Assembly

[a]
[b]
[f]
[c] [g]
[h]

1 6

2, [d]
7

[e]

8
4
3

5
IJCA0A111009-01

Information sensors Control devices

1. IAT sensor [a]: Ignition coil assembly No.1
2. TP sensor [b]: Ignition coil assembly No.2
3. ECT sensor [c]: Ignition coil assembly No.3
4. HO2S-1 [d]: Electric throttle body assembly
5. HO2S-2 [e]: EVAP canister purge valve
6. CMP sensor [f]: Fuel injector No.3
7. MAP sensor [g]: Fuel injector No.2
8. Knock sensor [h]: Fuel injector No.1
9. CKP sensor
1A-20 Engine General Information and Diagnosis: K10B

Diagnostic Information and Procedures

Engine and Emission Control System Check
AENJCA0A1114001
Refer to the following items for the details of each step.
Step Action Yes No
1 Customer complaint analysis Go to Step 2. Perform customer
1) Perform customer complaint analysis. (Page 1A-21) complaint analysis.

Was customer complaint analysis performed?

2 DTC / freeze frame data check, record and clearance Print DTCs and freeze Go to Step 4.
1) Check for DTCs (including pending DTCs). (Page 1A- frame data or write them
22) down and clear them
referring to “DTC
Is there any DTC(s) / freeze frame data? Clearance”: K10B
(Page 1A-23), and go to
Step 3.
3 Visual inspection Repair or replace Go to Step 5.
1) Perform visual inspection. (Page 1A-22) defective part, and then
go to Step 11.
Is there any faulty condition?
4 Visual inspection Repair or replace Go to Step 8.
1) Perform visual inspection. (Page 1A-22) defective part, and then
go to Step 11.
Is there any faulty condition?
5 Trouble symptom confirmation Go to Step 6. Go to Step 7.
1) Check trouble symptom. (Page 1A-22)

Is trouble symptom identified?

6 Rechecking and recording DTC / freeze frame data Go to Step 9. Go to Step 8.
1) Recheck for DTC and freeze frame data. (Page 1A-22)

Is there any DTC(s)?

7 Rechecking and recording DTC / freeze frame data Go to Step 9. Go to Step 10.
1) Recheck for DTC and freeze frame data. (Page 1A-22)

Is there any DTC(s)?

8 Engine basic inspection and engine symptom diagnosis Go to Step 11. Check and repair
1) Check and repair. (Page 1A-22) defective part(s), and go
to Step 11.
Are check and repair complete?
9 Troubleshooting for DTC Go to Step 11. Check and repair
1) Check and repair according to applicable DTC defective part(s), and go
troubleshooting. (Page 1A-22) to Step 11.

Are check and repair complete?

10 Intermittent problem check Repair or replace Go to Step 11.
1) Check for intermittent problems. (Page 1A-22) defective part(s), and go
to Step 11.
Is there any faulty condition?
11 Final confirmation test Go to Step 6. End.
1) Clear DTC if any.
2) Perform final confirmation test. (Page 1A-22)

Is there any problem symptom, DTC or abnormal condition?

 Engine General Information and Diagnosis: K10B 1A-21

Step 1: Customer Complaint Analysis

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

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

Customer questionnaire form (Example)

I9P60A111042-01
1A-22 Engine General Information and Diagnosis: K10B
Step 2: DTC / Freeze Frame Data Check, Record and
Clearance
First, check DTC (including pending DTC). (Page 1A-
22)
If DTC is indicated, print it and freeze frame data or write
them down and then clear them. (Page 1A-23)
Steps 3 and 4: Visual Inspection
As a preliminary step, perform visual check of the items
that support proper function of the engine. (Page 1A-
35)
Step 5: Trouble Symptom Confirmation
If there is no DTC in Step 2:
Based on information obtained in “Step 1: Customer
Complaint Analysis”: K10B (Page 1A-21) and “Step 2:
DTC / Freeze Frame Data Check, Record and
Clearance”: K10B (Page 1A-22), check trouble
symptoms.
If there is any DTC in Step 2:
Recheck DTC according to “DTC Confirmation
Procedure” described in each DTC troubleshooting.
Steps 6 and 7: Rechecking and Record in DTC /
Freeze Frame Data
Refer to “DTC Check”: K10B (Page 1A-22) for checking
procedure.
Step 8: Engine Basic Inspection and Engine
Symptom Diagnosis
1) Perform basic engine inspection. (Page 1A-36)
2) If there is no faulty part found in inspection
procedure of “Engine basic inspection”, perform
“Engine Symptom Diagnosis”: K10B (Page 1A-37)
based on symptom found in vehicle checking in the
following steps.
• Customer complaint analysis
• Trouble symptom confirmation
Step 9: Troubleshooting for DTC
Perform applicable DTC troubleshooting and repair or
replace faulty parts.
Step 10: Intermittent Problems Check
If there is no DTC in Step 2:
Check for intermittent problem. (Page 00-13)
If there is any DTC in Step 2:
Check parts related to detected DTC (e.g. wire harness,
connector, etc.).
Step 11: Final Confirmation Test
Check that the problem symptom has gone and engine
is free from any abnormal conditions. If what has been
repaired is related to DTC, clear DTC once, perform
DTC confirmation procedure and check that no DTC is
indicated.
MIL Check
AENJCA0A1114002
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)”: K10B
(Page 1A-45) for troubleshooting.
If MIL does not light with ignition “ON” and engine
does not start though it is cranked, go to “ECM
Power Supply and Ground Circuit Check”: K10B
(Page 1A-113).
2) Start engine and check that MIL turns OFF.
If MIL remains ON and no DTC is stored in ECM and
TCM (auto gear shift model in Section 5D), go to
“MIL Remains ON after Engine Starts”: K10B (Page
1A-45) for troubleshooting.
1
IJCA0A111010-01
DTC Check
AENJCA0A1114003
NOTE
In case that MIL turns on, the malfunction(s)
is detected in either ECM or TCM (auto gear
shift model in Section 5D) and it stores the
trouble information (DTC, freeze frame data,
etc.) in its memory.
1) Set ignition “OFF”.
2) Connect SUZUKI scan tool to DLC (1).
Special tool
(A): SUZUKI scan tool (Suzuki SDT-II)
3) Set ignition “ON”.
4) Read DTC, pending DTC and freeze frame data
according to instructions displayed on SUZUKI scan
tool and print them or write them down. Refer to
Operator's Manual of SUZUKI scan tool for further
details.
NOTE
If communication between SUZUKI scan tool
and ECM is not possible, perform the
following checks:
• Check communication condition between
PC and VCI (2) using SUZUKI scan tool
function.
• Check DLC power circuit and ground
circuit.
 Engine General Information and Diagnosis: K10B 1A-23

• 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-15)
• Check ECM power circuit and ground
circuit. (Page 1A-113)
• Check CAN communication system.
(“Control Module Communication Bus Off”
is detected in any control module.) (Page
10H-15)
• Check ECM power circuit and ground
circuit. (Page 1A-113)

2 (A)
IJCA0A111011-01

5) After completing DTC clearance, set ignition “OFF”

(A)
IJCA0A111011-01
5) After completing the check, set ignition “OFF” and
disconnect SUZUKI scan tool from DLC.
DTC Clearance
AENJCA0A1114004
1) Set ignition “OFF”.
2) Connect SUZUKI scan tool to DLC (1).
Special tool
(A): SUZUKI scan tool (Suzuki SDT-II)
3) Set ignition “ON”.
4) Clear DTC and pending DTC according to
instructions displayed on SUZUKI scan tool and print
them or write them down. Refer to Operator's
Manual of SUZUKI scan tool for further details.
and disconnect SUZUKI scan tool from DLC.
NOTE
DTC and freeze frame data stored in ECM
memory are also cleared in the following
case. Be careful not to clear them before
recording them.
• When the same malfunction (DTC) is not
detected again for 40 engine warm-up
cycles. (See “Warm-Up Cycle” under “OBD
System Description”: K10B (Page 1A-1).)
6) Perform electric throttle control system calibration.
(Page 1C-7)

NOTE
If communication between SUZUKI scan tool
and ECM is not possible, perform the
following checks:
• Check communication condition between
PC and VCI (2) using SUZUKI scan tool
function.
• Check DLC power circuit and ground
circuit.
• Check DLC cable. If necessary, check DLC
cable by substituting a known-good DLC
cable.
1A-24 Engine General Information and Diagnosis: K10B

DTC Table
AENJCA0A1114005
NOTE
• When DTC P0300 / P0301 / P0302 / P0303 is detected, MIL blinks or lights up according to detecting
condition. For details, refer to “DTC P0300 / P0301 / P0302 / P0303”: K10B (Page 1A-70).
• With the CAN communication generic scan tool, only DTC with asterisk (*) in the following table can
be read.

DTC
DTC DTC name DTC detecting condition detection MIL
logic
Output voltage of HO2S-1 heater circuit is lower
HO2S Heater Control
*P0031 (Page than specified value for 5 sec. continuously even
Circuit Low (Bank 1 3 D/C Lights up
1A-46) though control duty of HO2S-1 heater is lower than
Sensor 1)
90% with engine running.
Output voltage of HO2S-1 heater circuit is higher
HO2S Heater Control
*P0032 (Page than specified value for 5 sec. continuously even
Circuit High (Bank 1 3 D/C Lights up
1A-46) though control duty of HO2S-1 heater is higher
Sensor 1)
than 10% with engine running.
Output voltage of HO2S-2 heater circuit is lower
HO2S Heater Control
*P0037 (Page than specified value for 5 sec. continuously even
Circuit Low (Bank 1 3 D/C Lights up
1A-46) though control duty of HO2S-2 heater is lower than
Sensor 2)
90% with engine running.
Output voltage of HO2S-2 heater circuit is higher
HO2S Heater Control
*P0038 (Page than specified value for 5 sec. continuously even
Circuit High (Bank 1 3 D/C Lights up
1A-46) though control duty of HO2S-2 heater is higher
Sensor 2)
than 10% with engine running.
Any of the following conditions is met.
• Difference between maximum pressure and
Manifold Absolute
minimum pressure of MAP sensor is out of
*P0106 (Page Pressure / Barometric
specification. 3 D/C Lights up
1A-48) Pressure Circuit Range /
Performance • Difference between MAP sensor and estimated
barometric pressure is out of specification for 5
sec.
Manifold Absolute
*P0107 (Page Output voltage of MAP sensor signal circuit is
Pressure / Barometric 3 D/C Lights up
1A-49) lower than 0.35 V for 5 sec.
Pressure Circuit Low
Manifold Absolute
*P0108 (Page Output voltage of MAP sensor signal circuit is
Pressure / Barometric 3 D/C Lights up
1A-49) higher than 4.88 V for 5 sec.
Pressure Circuit High
Intake Air Temperature
*P0112 (Page Output voltage of IAT sensor signal circuit is lower
Sensor 1 Circuit Low 3 D/C Lights up
1A-51) than 0.02 V for 5 sec.
(Bank 1)
Intake Air Temperature
*P0113 (Page Output voltage of IAT sensor signal circuit is higher
Sensor 1 Circuit High 3 D/C Lights up
1A-51) than 4.98 V for 5 sec.
(Bank 1)
Engine Coolant
Output voltage of ECT sensor signal circuit is
*P0116 (Page Temperature Sensor 1
unchanged for 2 min. when ECT is lower than 70 3 D/C Lights up
1A-52) Circuit Range /
°C (158 °F).
Performance
Engine Coolant
*P0117 (Page Output voltage of ECT sensor signal circuit is lower
Temperature Sensor 1 3 D/C Lights up
1A-53) than 0.02 V for 5 sec.
Circuit Low
Engine Coolant
*P0118 (Page Output voltage of ECT sensor signal circuit is
Temperature Sensor 1 3 D/C Lights up
1A-53) higher than 4.98 V for 5 sec.
Circuit High
Throttle / Pedal Position
*P0122 (Page Output voltage of TP sensor (main) signal circuit is
Sensor / Switch “A” 1 D/C Lights up
1A-55) lower than 0.26 V.
Circuit Low
 Engine General Information and Diagnosis: K10B 1A-25

DTC
DTC DTC name DTC detecting condition detection MIL
logic
Throttle / Pedal Position
*P0123 (Page Output voltage of TP sensor (main) signal circuit is
Sensor / Switch “A” 1 D/C Lights up
1A-55) higher than 4.76 V.
Circuit High
*P0130 (Page O2 Sensor Circuit (Bank Internal resistance of HO2S-1 is higher than
3 D/C Lights up
1A-57) 1 Sensor 1) specified value.
O2 Sensor Circuit Slow
*P0133 (Page Average response time of HO2S-1 output signal is
Response (Bank 1 3 D/C Lights up
1A-57) longer than specified time.
Sensor 1)
*P0136 (Page O2 Sensor Circuit (Bank Internal resistance of HO2S-2 is higher than
3 D/C Lights up
1A-60) 1 Sensor 2) specified value.
O2 Sensor Circuit Slow Shifting time of HO2S signal circuit voltage from
*P0139 (Page
Response (Bank 1 0.5 V to 0.3 V is longer than specified time at fuel 3 D/C Lights up
1A-62)
Sensor 2) cut.
*P0171 (Page System Too Lean (Bank Total fuel trim (short term fuel trim + long term fuel
3 D/C Lights up
1A-63) 1) trim) is higher than specified value for 10 sec.
*P0172 (Page Total fuel trim (short term fuel trim + long term fuel
System Too Rich (Bank 1) 3 D/C Lights up
1A-63) trim) is lower than specified value for 10 sec.
Injector driver No.1 and/or its circuit malfunction
P0201 (Page Injector Circuit / Open –
(open, short to power supply or short to ground) is 3 D/C Lights up
1A-66) Cylinder1
detected.
Injector driver No.2 and/or its circuit malfunction
P0202 (Page Injector Circuit / Open –
(open, short to power supply or short to ground) is 3 D/C Lights up
1A-66) Cylinder2
detected.
Injector driver No.3 and/or its circuit malfunction
P0203 (Page Injector Circuit / Open –
(open, short to power supply or short to ground) is 3 D/C Lights up
1A-66) Cylinder3
detected.
Throttle / Pedal Position
*P0222 (Page Output voltage of TP sensor (sub) signal circuit is
Sensor / Switch “B” 1 D/C Lights up
1A-68) lower than 0.24 V.
Circuit Low
Throttle / Pedal Position
*P0223 (Page Output voltage of TP sensor (sub) signal circuit is
Sensor / Switch “B” 1 D/C Lights up
1A-68) higher than 4.74 V.
Circuit High
Any of the following conditions is met.
• Misfire, which causes catalyst to overheat during
200 engine revolutions, is detected at 2 or more
*P0300 (Page Random / Multiple
cylinders. (MIL blinks as long as misfire lasts.) 3 D/C Lights up
1A-70) Cylinder Misfire Detected
• Misfire, which affects exhaust emission
adversely during 1,000 engine revolutions, is
detected at 2 or more cylinders.
*P0301 (Page Cylinder 1 Misfire Any of the following conditions is met.
3 D/C Lights up
1A-70) Detected • Misfire, which causes catalyst to overheat during
*P0302 (Page Cylinder 2 Misfire 200 engine revolutions, is detected at specific 3 D/C Lights up
1A-70) Detected cylinder. (MIL blinks as long as misfire lasts.)
*P0303 (Page Cylinder 3 Misfire • Misfire, which affects exhaust emission
adversely during 1,000 engine revolutions, is 3 D/C Lights up
1A-70) Detected
detected at specific cylinder.
Knock Sensor 1 Circuit
*P0327 (Page Knock sensor signal is lower than 1.23 V for 5 sec.
Low (Bank 1 or Single 3 D/C Lights up
1A-72) with engine running.
Sensor)
Knock Sensor 1 Circuit
*P0328 (Page Knock sensor signal is higher than 4.9 V for 5 sec.
High (Bank 1 or Single 3 D/C Lights up
1A-72) with engine running.
Sensor)
*P0335 (Page Crankshaft Position Even if CMP sensor signal is input, CKP sensor
1 D/C Lights up
1A-73) Sensor “A” Circuit signal is not input for more than 3 sec.
1A-26 Engine General Information and Diagnosis: K10B

DTC
DTC DTC name DTC detecting condition detection MIL
logic
Crankshaft Position
*P0336 (Page Output signal pulse of CKP sensor is out of
Sensor “A” Circuit Range 1 D/C Lights up
1A-73) specified pattern more than specified times.
/ Performance
Camshaft Position
*P0340 (Page Even if CKP sensor signal is input, CMP sensor
Sensor “A” Circuit (Bank 3 D/C Lights up
1A-75) signal is not input for more than 3 sec.
1 or Single Sensor)
Camshaft Position
*P0341 (Page Sensor “A” Circuit Range Output signal pulse of CMP sensor is out of
3 D/C Lights up
1A-75) / Performance (Bank 1 or specified pattern more than specified times.
Single Sensor)
Delay of shifting cycle between rich and lean of
Catalyst System HO2S-2 signal compared with shifting cycle
*P0420 (Page
Efficiency Below between rich and lean of fuel system feedback is 3 D/C Lights up
1A-77)
Threshold (Bank 1) less than specified time while vehicle is running
with constant speed after warmed up.
Evaporative Emission Measured signal duty of EVAP canister purge
*P0443 (Page
System Purge Control valve control circuit is different from control 3 D/C Lights up
1A-80)
Valve Circuit command duty for 5 sec. (Circuit open or short)
Measured voltage of radiator cooling fan relay
P0480 (Page
Fan 1 Control Circuit output is different from its command signal for 5 3 D/C Off
1A-82)
sec.
Vehicle speed signal is not input, while fuel is cut at
*P0500 (Page
Vehicle Speed Sensor “A” deceleration for 5 sec. continuously with engine 3 D/C Lights up
1A-84)
speed at 3,600 rpm or less.
P0532 (Page A/C Refrigerant Pressure Output voltage of A/C refrigerant pressure sensor
3 D/C Off
1A-85) Sensor “A” Circuit Low signal circuit is lower than 0.15 V for 5 sec.
P0533 (Page A/C Refrigerant Pressure Output voltage of A/C refrigerant pressure sensor
3 D/C Off
1A-85) Sensor “A” Circuit High signal circuit is higher than 4.93 V for 5 sec.
*P0602 (Page Control Module
Data programming error. 1 D/C Lights up
1A-87) Programing Error
P0607 (Page Control Module ECM internal failure related to throttle control
1 D/C Lights up
1A-87) Performance system.
*P0616 (Page No starter switch ON signal is input even if engine
Starter Relay Circuit Low 3 D/C Lights up
1A-88) has been started.
*P0617 (Page Starter switch ON signal is input for more than 180
Starter Relay Circuit High 3 D/C Lights up
1A-88) sec. after engine has been started.
P1520 (Page ECM Starter protection Starting motor control relay drive circuit is shorted
1 D/C Off
1A-90) circuit on error to ground.
P1521 (Page ECM Starter protection Starting motor control relay drive circuit is shorted
1 D/C Off
1A-90) circuit off error to power supply.
Immobilizer ID and/or
P1610 1 D/C Off
Password Not Registered
P1611 Password Not Matched 1 D/C Off
EEPROM Reading /
P1622 1 D/C Off
Writing Error
Immobilizer Refer to “DTC Table” in Section 10C (Page 10C-5).
P1642 Communication Line 1 D/C Off
Error
Immobilizer ID
P1644 1 D/C Off
Mismatched
P1646 ID Code Incorrectness 1 D/C Off
Throttle Actuator “A”
*P2101 (Page Throttle actuator drive circuit malfunction (open or
Control Motor Circuit 1 D/C Lights up
1A-92) excessive temperature of device) is detected.
Range / Performance
During diagnosing throttle valve with ignition
*P2111 (Page Throttle Actuator Control
“OFF”, throttle valve does not close even if throttle 1 D/C Lights up
1A-94) System Stuck Open
valve is opened at specified value.
 Engine General Information and Diagnosis: K10B 1A-27

DTC
DTC DTC name DTC detecting condition detection MIL
logic
Throttle Actuator Control
*P2119 (Page Difference between targeted TP and measured TP
Throttle Body Range / 1 D/C Lights up
1A-92) is out of specified range.
Performance
Throttle / Pedal Position
*P2122 (Page Output voltage of APP sensor (main) signal circuit
Sensor / Switch “D” 1 D/C Lights up
1A-95) is lower than 0.35 V.
Circuit Low
Throttle / Pedal Position
*P2123 (Page Output voltage of APP sensor (main) signal circuit
Sensor / Switch “D” 1 D/C Lights up
1A-95) is higher than 4.63 V.
Circuit High
Throttle / Pedal Position
*P2127 (Page Output voltage of APP sensor (sub) signal circuit is
Sensor / Switch “E” 1 D/C Lights up
1A-97) lower than 0.16 V.
Circuit Low
Throttle / Pedal Position
*P2128 (Page Output voltage of APP sensor (sub) signal circuit is
Sensor / Switch “E” 1 D/C Lights up
1A-97) higher than 3.53 V.
Circuit High
Throttle / Pedal Position Difference between TP (main) and TP (sub) sensor
*P2135 (Page
Sensor / Switch “A” / “B” signal is more than specified value for specified 1 D/C Lights up
1A-99)
Voltage Correlation time.
Throttle / Pedal Position Difference between APP (main) and APP (sub)
*P2138 (Page
Sensor / Switch “D” / “E” sensor signal is more than specified value for 1 D/C Lights up
1A-100)
Voltage Correlation specified time.
U0073 (Page Control Module
1 D/C Off
1A-101) Communication Bus Off
U0101 (Page Lost Communication With
1 D/C Lights up
1A-101) TCM
Lost Communication With
U0121 (Page Refer to “CAN DTC (Lost Communication and
ABS / ESP® Control 1 D/C Lights up
1A-101) Communication Bus Off) Table” in Section 10H
Module
(Page 10H-7).
U0140 (Page Lost Communication With
1 D/C Off
1A-101) Body Control Module
Lost Communication With
U0155 (Page
Instrument Panel Cluster 1 D/C Off
1A-101)
(IPC) Control Module
U2001 (Page LIN Lost Communication
Received data from generator via LIN is faulty. 1 D/C Off
1A-101) With Generator
U2021 (Page LIN Invalid Data from Transmitted data from ECM to generator via LIN is
1 D/C Off
1A-102) ECM to Generator faulty.

Fail-Safe Table
AENJCA0A1114006
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
P0031 (Page HO2S Heater Control Circuit Low (Bank 1
1A-46) Sensor 1)
—
P0032 (Page HO2S Heater Control Circuit High (Bank
1A-46) 1 Sensor 1)
P0037 (Page HO2S Heater Control Circuit Low (Bank 1
1A-46) Sensor 2)
—
P0038 (Page HO2S Heater Control Circuit High (Bank
1A-46) 1 Sensor 2)
P0106 (Page Manifold Absolute Pressure / Barometric
—
1A-48) Pressure Circuit Range / Performance
P0107 (Page Manifold Absolute Pressure / Barometric • ECM calculates manifold absolute pressure according
1A-49) Pressure Circuit Low to throttle valve position and engine speed.
P0108 (Page Manifold Absolute Pressure / Barometric • ECM controls actuators assuming that barometric
1A-49) Pressure Circuit High pressure is 90 kPa.
1A-28 Engine General Information and Diagnosis: K10B

DTC DTC name Fail-safe operation

P0112 (Page Intake Air Temperature Sensor 1 Circuit
1A-51) Low (Bank 1) ECM controls actuators assuming that intake air
P0113 (Page Intake Air Temperature Sensor 1 Circuit temperature is 20 °C (68 °F).
1A-51) High (Bank 1)
P0116 (Page Engine Coolant Temperature Sensor 1
—
1A-52) Circuit Range / Performance
P0117 (Page Engine Coolant Temperature Sensor 1 • ECM controls actuators assuming that engine coolant
1A-53) Circuit Low temperature is 80 °C (176 °F).
P0118 (Page Engine Coolant Temperature Sensor 1
1A-53) Circuit High • ECM operates radiator cooling fan. (high speed)
P0122 (Page Throttle / Pedal Position Sensor / Switch
1A-55) “A” Circuit Low • ECM fixes throttle valve at default position.
P0123 (Page Throttle / Pedal Position Sensor / Switch • ECM performs fuel cut at specified engine speed.
1A-55) “A” Circuit High
P0130 (Page
O2 Sensor Circuit (Bank 1 Sensor 1) ECM stops A/F feedback control.
1A-57)
P0133 (Page O2 Sensor Circuit Slow Response (Bank
—
1A-57) 1 Sensor 1)
P0136 (Page
O2 Sensor Circuit (Bank 1 Sensor 2) —
1A-60)
P0139 (Page O2 Sensor Circuit Slow Response (Bank
—
1A-62) 1 Sensor 2)
P0171 (Page
System Too Lean (Bank 1)
1A-63)
ECM stops EVAP canister purge valve control.
P0172 (Page
System Too Rich (Bank 1)
1A-63)
P0201 (Page • ECM stops fuel injection of No.1 cylinder.
Injector Circuit / Open – Cylinder1
1A-66) • ECM stops A/F feedback control.
P0202 (Page • ECM stops fuel injection of No.2 cylinder.
Injector Circuit / Open – Cylinder2
1A-66) • ECM stops A/F feedback control.
P0203 (Page • ECM stops fuel injection of No.3 cylinder.
Injector Circuit / Open – Cylinder3
1A-66) • ECM stops A/F feedback control.
P0222 (Page Throttle / Pedal Position Sensor / Switch
1A-68) “B” Circuit Low • ECM fixes throttle valve at default position.
P0223 (Page Throttle / Pedal Position Sensor / Switch • ECM performs fuel cut at specified engine speed.
1A-68) “B” Circuit High
P0300 (Page Random / Multiple Cylinder Misfire
1A-70) Detected
P0301 (Page
Cylinder 1 Misfire Detected
1A-70)
—
P0302 (Page
Cylinder 2 Misfire Detected
1A-70)
P0303 (Page
Cylinder 3 Misfire Detected
1A-70)
P0327 (Page Knock Sensor 1 Circuit Low (Bank 1 or
1A-72) Signal Sensor) • ECM stops knock control.
P0328 (Page Knock Sensor 1 Circuit High (Bank 1 or • ECM retards ignition timing.
1A-72) Signal Sensor)
P0335 (Page
Crankshaft Position Sensor “A” Circuit
1A-73)
P0336 (Page Crankshaft Position Sensor “A” Circuit
1A-73) Range / Performance • ECM performs fuel cut at 4,000 rpm.
P0340 (Page Camshaft Position Sensor “A” Circuit
1A-75) (Bank 1 or Signal Sensor) • ECM change cylinder identification method.
Camshaft Position Sensor “A” Circuit
P0341 (Page
Range / Performance (Bank 1 or Signal
1A-75)
Sensor)
 Engine General Information and Diagnosis: K10B 1A-29

DTC DTC name Fail-safe operation

P0420 (Page Catalyst System Efficiency Below
—
1A-77) Threshold (Bank 1)
P0443 (Page Evaporative Emission System Purge
ECM stops EVAP canister purge valve control.
1A-80) Control Valve Circuit
P0480 (Page
Fan 1 Control Circuit —
1A-82)
P0500 (Page ECM controls actuators assuming that vehicle speed is 0
Vehicle Speed Sensor “A”
1A-84) km/h (0 mile/h).
P0532 (Page A/C Refrigerant Pressure Sensor “A”
1A-85) Circuit Low
ECM stops A/C control.
P0533 (Page A/C Refrigerant Pressure Sensor “A”
1A-85) Circuit High
P0602 (Page
Control Module Programing Error —
1A-87)
P0607 (Page • ECM fixes throttle valve at default position.
Control Module Performance
1A-87) • ECM performs fuel cut at specified engine speed.
P0616 (Page
Starter Relay Circuit Low
1A-88)
—
P0617 (Page
Starter Relay Circuit High
1A-88)
P1520 (Page
ECM Starter protection circuit on error
1A-90)
—
P1521 (Page
ECM Starter protection circuit off error
1A-90)
P2101 (Page Throttle Actuator “A” Control Motor Circuit
1A-92) Range / Performance
P2111 (Page Throttle Actuator Control System Stuck • ECM fixes throttle valve at default position.
1A-94) Open • ECM performs fuel cut at specified engine speed.
P2119 (Page Throttle Actuator Control Throttle Body
1A-92) Range / Performance
P2122 (Page Throttle / Pedal Position Sensor / Switch
1A-95) “D” Circuit Low
P2123 (Page Throttle / Pedal Position Sensor / Switch • ECM controls actuators lowering upper limit of throttle
1A-95) “D” Circuit High valve.
P2127 (Page Throttle / Pedal Position Sensor / Switch
1A-97) “E” Circuit Low • ECM performs fuel cut at specified engine speed.
P2128 (Page Throttle / Pedal Position Sensor / Switch
1A-97) “E” Circuit High
P2135 (Page Throttle / Pedal Position Sensor / Switch
1A-99) “A” / “B” Voltage Correlation • ECM fixes throttle valve at default position.
P2138 (Page Throttle / Pedal Position Sensor / Switch • ECM performs fuel cut at specified engine speed.
1A-100) “D” / “E” Voltage Correlation
U0073 (Page
Control Module Communication Bus Off
1A-101)
U0101 (Page
Lost Communication With TCM
1A-101)
U0121 (Page Lost Communication With ABS / ESP®
—
1A-101) Control Module
U0140 (Page Lost Communication With Body Control
1A-101) Module
U0155 (Page Lost Communication With Instrument
1A-101) Panel Cluster (IPC) Control Module
U2001 (Page
LIN Lost Communication With Generator
1A-101)
—
U2021 (Page
LIN Invalid Data from ECM to Generator
1A-102)
1A-30 Engine General Information and Diagnosis: K10B

Scan Tool Data

AENJCA0A1114007
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-8)

NOTE
• If communication between SUZUKI scan tool and ECM is not possible, perform the following
checks:
– Check communication condition between PC and VCI using SUZUKI scan tool function.
– Check DLC power circuit and ground circuit.
– Check DLC cable. If necessary, check DLC cable by substituting a known-good DLC cable.
– Check CAN communication system. (“Control Module Communication Bus Off” is detected in any
control module.) (Page 10H-15)
– Check ECM power circuit and ground circuit. (Page 1A-113)
• With the generic scan tool, only data with asterisk (*) in the following table can be read.
• When checking data with engine running at idle speed or racing, place gear shift lever in “Neutral”
for M/T model or “N” range for auto gear shift model and apply parking brake fully. Also, if nothing
or “no load” is indicated, turn off A/C, all electric loads, P/S and all the other switches.

Normal condition /
Scan tool data Vehicle condition
Reference value
Open loop (OL) control before satisfaction of closed loop
control conditions (ECT >10 °C, HO2S-1, IAT, TP sensor / OL
system = OK)
Open loop (OL) control due to driving conditions (Power
OL-Drive
Fuel System (Page 1A- enrichment, etc.)
*
33) Open loop (OL) control due to fuel system failure OL-Fault
Closed loop (CL) control using HO2S-1 as feedback
CL
sensors for fuel control
Closed loop (CL) control due to fuel system failure CL-Fault
When engine stops with ignition “ON” —
Short Term Fuel Trim
* Engine: Idle speed after warming up Approx. –20 to 20%
(Page 1A-33)
Long Term Fuel Trim
* Engine: Idle speed after warming up Approx. –20 to 20%
(Page 1A-33)
Total Fuel Trim (Page
Engine: Idle speed after warming up Approx. –30 to 30%
1A-33)
Inj Pulse Width (Page
Engine: Idle speed with no load after warming up Approx. 1.6 to 4.0 msec
1A-33)
Ignition Advance (Page
* Engine: Idle speed with no load after warming up –5 to 15° BTDC
1A-33)
Calculated Load (Page
* Engine: Idle speed with no load after warming up Approx. 20 to 40%
1A-33)
Engine: Idle speed after warming up
Radiator cooling fan: Stopped
Engine Speed (Page
* All electrical equipment: OFF 650 to 750 rpm
1A-33)
Gear shift lever: Neutral position (M/T model)
Shift selector: N range (auto gear shift model)
Engine: Idle speed after warming up
Radiator cooling fan: Stopped
Desired Idle (Page 1A-
All electrical equipment: OFF 700 rpm
33)
Gear shift lever: Neutral position (M/T model)
Shift selector: N range (auto gear shift model)
 Engine General Information and Diagnosis: K10B 1A-31

Normal condition /
Scan tool data Vehicle condition
Reference value
Vehicle Speed (Page Almost the same as
* Vehicle running
1A-33) speedometer reading
* MAP (Page 1A-33) Engine: Idle speed after warming up Approx. 20 to 55 kPa
Approx. 80 to 105 °C (176
* ECT (Page 1A-33) Engine: Idle speed after warming up
– 221 °F)
Ambient air temperature –
Intake Air Temperature
* Engine: Idle speed after warming up 5 °C (–9 °F) to ambient air
(Page 1A-33)
temperature +40 °C (72 °F)
Barometric Pres (Page Barometric pressure is
* —
1A-33) displayed.
EVAP Canist Prg Duty
* Engine: Idle speed after warming up 0%
(Page 1A-33)
Engine: Idle speed with no load after warming up Approx. 5 to 30%
IAC Throttle Opening Engine: Idle speed after warming up
(Page 1A-33) A/C: ON Approx. 20 to 50%
Blower speed selector: Max
Ignition: “ON”
0.8 to 1.0 V
TP Sensor 1 Volt (Page Accelerator pedal: Released
1A-33) Ignition: “ON”
4.3 to 4.5 V
Accelerator pedal: Fully depressed
Ignition: “ON”
4.0 to 4.2 V
TP Sensor 2 Volt (Page Accelerator pedal: Released
1A-33) Ignition: “ON”
0.5 to 0.7 V
Accelerator pedal: Fully depressed
Ignition: “ON”
0.7 to 0.8 V
APP Sensor 1 Voltage Accelerator pedal: Released
(Page 1A-34) Ignition: “ON”
4.35 to 4.45 V
Accelerator pedal: Fully depressed
Ignition: “ON”
0.37 to 0.38 V
APP Sensor 2 Voltage Accelerator pedal: Released
(Page 1A-34) Ignition: “ON”
2.15 to 2.25 V
Accelerator pedal: Fully depressed
Ignition: “ON”
0 to 2%
Accelerator Position Accelerator pedal: Released
(Page 1A-34) Ignition: “ON”
90 to 100%
Accelerator pedal: Fully depressed
Ignition: “ON”
0 to 10%
Throttle Position (Page Accelerator pedal: Released
1A-34) Ignition: “ON”
90 to 100%
Accelerator pedal: Fully depressed
Ignition: “ON”
0 to 10%
Target Throttle Posi Accelerator pedal: Released
*
(Page 1A-34) Ignition: “ON”
90 to 100%
Accelerator pedal: Fully depressed
O2S B1 S1 (Page 1A-
* Engine: Idle speed for 2 min. after warming up Approx. 0 to 1.0 V
34)
O2S B1 S2 (Page 1A-
* Engine: 2,000 rpm for 3 min. or more after warming up Approx. 0 to 1.0 V
34)
Battery Voltage (Page
* Engine: Idle speed Approx. 13 to 15 V
1A-34)
Fuel Tank Level (Page
Ignition: “ON” 0 to 100%
1A-34)
Engine: Idle speed
A/C Pressure (Page A/C compressor: Operating
1,180 to 1,520 kPa
1A-34) Blower speed selector: MAX position
Ambient temperature: 30 °C (86 °F)
Generator Field Duty
Engine: Idle speed after warming up Approx. 20 to 100%
(Page 1A-34)
1A-32 Engine General Information and Diagnosis: K10B

Normal condition /
Scan tool data Vehicle condition
Reference value
Generator Reg Volt
Engine: Idle speed 10.6 to 15 V
(Com) (Page 1A-34)
Radiator Fan (Page 1A- Radiator cooling fan: OFF OFF
34) Radiator cooling fan: ON ON
Engine: Running
A/C Comp Relay (Page A/C compressor: Operating ON
1A-34) Blower speed selector: ON
Other than above condition OFF
Fuel Pump (Page 1A- Engine: Running ON
34) Other than above condition OFF
Starter Switch (Page Ignition: “ST” (engine cranking) ON
1A-34) Other than above condition OFF
A/C switch: ON
A/C Switch (Page 1A- ON
Blower speed selector: ON
34)
Other than above condition OFF
Blower Fan (Page 1A- 2nd or higher speed position ON
34) Other than above condition OFF
Brake Switch (Page Brake pedal: Depressed ON
1A-34) Brake pedal: Released OFF
Electric Load (Page 1A- Headlight switch: ON ON
34) Headlight switch: OFF OFF
PNP Signal (Page 1A- Auto gear shift model: D
34) Shift selector: Other than N range
Auto gear shift model:
P/N
Shift selector: N range
M/T model:
Declutch
Clutch Switch (Page Clutch pedal: More than halfway depressed
1A-34) M/T model:
Clutched
Clutch pedal: Released
Engine: Idle speed after warming up OFF
Fuel Cut (Page 1A-34) Accelerator pedal: Released
ON
Engine: 2,000 rpm or more after warming up
Ignition: “ON”
ON
Closed Throttle Pos Accelerator pedal: Released
(Page 1A-34) Ignition: “ON”
OFF
Accelerator pedal: Depressed
O2S B1 S1 Act (Page
Engine: Idle speed after warming up Active
1A-34)
O2S B1 S2 Act (Page
Engine: Idle speed after warming up Active
1A-34)
Starter Count Information M/T model: Starting motor overrun
(Overrun) (Page 1A-34) Ignition: “ON” counter
Starter Count Information
M/T model: Starting motor
(Overcranking) (Page
Ignition: “ON” overcranking counter
1A-35)
Starter Count Information M/T model: Starting motor inching
(Inching) (Page 1A-35) Ignition: “ON” counter
Starter Count Information
(Starter Relay Slow M/T model: Starting motor control relay
Response) (Page 1A- Ignition: “ON” slow response counter
35)
 Engine General Information and Diagnosis: K10B 1A-33

Scan Tool Data Definitions Engine Speed (rpm)

Fuel System (Fuel system status) The engine revolution speed is calculated based on the
This parameter indicates the state of A/F feedback input signal of CKP sensor.
control by ECM.
Desired Idle (Desired idle speed, rpm)
NOTE This parameter indicates target engine idle speed
• Open loop requested by ECM.
Fuel injection time (volume) in the various NOTE
engines states is determined beforehand.
Information from HO2S-1 is not reflected to When performing “Fixed Spark” in “Active
fuel injection control. Test”, actual engine idle speed may not
follow target engine idle speed.
• Closed loop
Information from HO2S-1 is reflected to
fuel injection control. When ECM judges Vehicle Speed (km/h, mph)
that actual air-fuel ratio is higher than This parameter indicates the vehicle speed based on
stoichiometric air-fuel ratio, ECM controls wheel speed sensors sent from ABS control module via
to increase the volume of fuel. On the CAN communication.
contrary, when the actual air-fuel ratio is
lower than stoichiometric air-fuel ratio, MAP (Manifold absolute pressure, kPa, mmHg, inHg,
ECM controls to decrease the volume of psi, inH2O)
fuel. This parameter indicates the calculated MAP based on
input voltage of MAP sensor.
Short Term Fuel Trim (%)
ECT (Engine coolant temperature, °C, °F)
This parameter indicates short term fuel trim value (short
This parameter indicates the calculated ECT based on
term air/fuel mixture correction factor) and changes the
input voltage of ECT sensor.
value corresponding to driving conditions. 0 (zero)
indicates no correction, a value greater than 0 indicates
Intake Air Temperature. (°C, °F)
enrichment correction, and a value less than 0 indicates
This parameter indicates the calculated IAT based on
enleanment correction.
input voltage of IAT sensor.
Long Term Fuel Trim (%)
Barometric Pres (Barometric pressure, kPa, mmHg,
This parameter indicates a median value of short term
inHg, psi, inH2O)
trim learned in A/F feedback control (closed loop). This
This parameter represents barometric air pressure
median value is used by ECM to correct fuel injection
measurement and is used for altitude correction of the
volume appropriately in open loop control avoiding
fuel injection rate.
interference caused by individual difference and aging. 0
(zero) indicates no correction, a value greater than 0
EVAP Canist Prg Duty (EVAP canister purge flow
indicates enrichment correction, and a value less than 0
duty, %)
indicates enleanment correction.
This parameter indicates valve ON (valve open) time
rate within a certain set cycle of EVAP canister purge
Total Fuel Trim (%)
valve.
This parameter indicates the comprehensive fuel trim
computed based on short term and long term fuel trim.
IAC Throttle Opening (Idle air throttle valve opening,
%)
Inj Pulse Width (Fuel injection pulse width, msec.)
This parameter indicates opening% of throttle valve on
This parameter indicates the injector drive pulse width
the assumption that the maximum opening of idle air
(open time) during the injector valve stays open
control is 100%.
commanded by ECM.
TP Sensor 1 Volt (TP sensor (main) output voltage,
Ignition Advance (Ignition timing advance for No.1
V)
cylinder, ° BTDC)
This parameter indicates the input voltage of TP sensor
This parameter indicates the ignition timing of No.1
(main) installed in throttle body.
cylinder commanded by ECM.
TP Sensor 2 Volt (TP sensor (sub) output voltage, V)
Calculated Load (Calculated load value, %)
This parameter indicates the input voltage of TP sensor
This parameter indicates the engine load calculated by
(sub) installed in throttle body.
ECM based on input signals of various sensors as a
percentage.
1A-34 Engine General Information and Diagnosis: K10B
APP Sensor 1 Voltage (APP sensor (main) output
voltage, V)
This parameter indicates the input voltage of APP
sensor (main) installed in accelerator pedal.
APP Sensor 2 Voltage (APP sensor (sub) output
voltage, V)
This parameter indicates the input voltage of APP
sensor (sub) installed in accelerator pedal.
Accelerator Position (Absolute accelerator pedal
position, %)
This parameter indicates the depressing amount of
accelerator pedal that ECM calculated based on the
input signals of APP sensor (main and sub) in
percentage.
Throttle Position (Absolute throttle position, %)
This parameter indicates the calculated throttle valve
opening in percentage based on input signal from TP
sensor.
Target Throttle Posi (Target throttle valve position,
%)
This parameter indicates the target throttle position
requested by ECM.
O2S B1 S1 (HO2S-1, V)
This parameter indicates output voltage of HO2S-1
installed on exhaust manifold (pre-TWC).
O2S B1 S2 (HO2S-2, V)
This parameter indicates output voltage of HO2S-2
installed on exhaust manifold (post-TWC). It is used to
detect catalyst deterioration.
Battery Voltage (V)
This parameter indicates battery positive voltage
inputted from main relay to ECM.
Fuel Tank Level (%)
This parameter indicates the information of fuel level
inputted via combination meter. The fuel level data is
provided as a percentage from 0 to 100%.
A/C Pressure (A/C refrigerant absolute pressure,
kPa, mmHg, inHg, psi, inH2O)
This parameter indicates A/C refrigerant pressure
calculated by ECM based on A/C refrigerant pressure
sensor voltage.
Generator Field Duty (%)
This parameter indicates operation rate (generation
condition) of generator using operation duty of generator
field coil.
Generator Reg Volt (Com) (Generator regulated
voltage (Com) (V))
This parameter indicates commanded generator
regulated voltage.
Radiator Fan (Radiator cooling fan control relay, ON/
OFF)
This parameter indicates the state that ECM operates
radiator cooling fan relay.
A/C Comp Relay (A/C compressor relay, ON/OFF)
This parameter indicates the state that ECM operates A/
C compressor relay.
Fuel Pump (ON/OFF)
This parameter indicates the state that ECM operates
fuel pump relay.
Starter Switch (ON/OFF)
This parameter indicates state of starting motor control
relay output.
A/C Switch (ON/OFF)
This parameter indicates the state that ECM operates A/
C by request from BCM.
Blower Fan (ON/OFF)
This parameter indicates the signal state of the blower
fan motor inputted into ECM.
Brake Switch (ON/OFF)
This parameter indicates operating state of the brake
switch.
Electric Load (ON/OFF)
This parameter indicates the state of electric load signal
inputted into ECM.
PNP Signal (P/N or D range) (auto gear shift model)
This parameter indicates shift position informed from
TCM via CAN communication.
Clutch Switch (Declutch / Clutched) (M/T model)
This parameter indicates operating state of CPP No.2
switch.
Fuel Cut (ON/OFF)
This parameter indicates the operating state of fuel cut.
Closed Throttle Pos (Closed throttle position, ON/
OFF)
This parameter monitors idle state for engine control.
O2S B1 S1 Act (HO2S-1, Active / Inactive)
This parameter indicates the activation condition of
HO2S-1.
O2S B1 S2 Act (HO2S-2, Active / Inactive)
This parameter indicates the activation condition of
HO2S-2.
Starter Count Information (Overrun) (times) (M/T
model)
This parameter indicates the starter count information
(overrun).
 Engine General Information and Diagnosis: K10B 1A-35

Starter Count Information (Overcranking) (times) (M/ Starter Count Information (Starter Relay Slow
T model) Response) (times) (M/T model)
This parameter indicates the starter count information This parameter indicates the starter count information
(overcranking). (starter relay slow response).

Starter Count Information (Inching) (times) (M/T

model)
This parameter indicates the starter count information
(Inching).

Visual Inspection
AENJCA0A1114008
Visually check the following parts and systems.
Inspection item Referring section
“Engine Oil and Filter Change” in Section 0B
Level
Engine oil (Page 0B-5)
Leakage —
“Coolant Level Check”: K10B and Bi-Fuel
Level
CNG in Section 1F (Page 1F-8)
Engine coolant
“Engine Cooling System Inspection”: K10B
Leakage
and Bi-Fuel CNG in Section 1F (Page 1F-8)
Level —
Fuel “Fuel Leakage Check Procedure”: Petrol in
Leakage
Section 1G (Page 1G-20)
“Manual Transaxle Oil Level Check”: K10B
Level
Manual transaxle oil Model in Section 5B (Page 5B-8)
Leakage —
“Auto Gear Shift Transaxle Oil Level Check”
Level
Auto gear shift oil in Section 5D (Page 5D-98)
Leakage —
Dirt “Air Cleaner Filter Inspection and Cleaning”:
Air cleaner filter K10B and Bi-Fuel CNG in Section 1D (Page
Clogging
1D-6)
“Battery Inspection”: K10B and Bi-Fuel CNG
Battery Corrosion of terminal
in Section 1J (Page 1J-4)
Tension “Water Pump / Generator Drive Belt Tension
Accessory drive belt Inspection and Adjustment”: K10B and Bi-
Damage
Fuel CNG in Section 1J (Page 1J-7)
Throttle valve Operating sound —
Disconnection —
Looseness —
Vacuum hoses of air intake system
Deterioration —
Bend —
Disconnection —
Connectors of electric wire harness
Friction / pinch —
Fuses Blown —
Installation —
Parts
Deformation —
Bolt Looseness —

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

Inspection item Referring section
MIL Operation “MIL Check”: K10B (Page 1A-22)
“Generator Symptom Diagnosis”: K10B and
Charging light Operation
Bi-Fuel CNG in Section 1J (Page 1J-4)
“Oil Pressure Switch On-Vehicle Inspection”:
Engine oil pressure light Operation K10B and Bi-Fuel CNG in Section 1E (Page
1E-5)
Engine coolant temperature warning “ECT Sensor Inspection”: K10B and Bi-Fuel
Operation
light CNG in Section 1C (Page 1C-11)
1A-36 Engine General Information and Diagnosis: K10B

Inspection item Referring section

“Fuel Level Sensor Inspection”: Petrol in
Fuel level sensor Operation
Section 1G (Page 1G-32)
“Exhaust System Check”: K10B and Bi-Fuel
Exhaust system Leakage of exhaust gas, noise
CNG in Section 1K (Page 1K-1)
Abnormal air being inhaled at air intake system —
Other parts that can be checked visually —

Engine Basic Inspection

AENJCA0A1114009
This check is very important for troubleshooting when ECM has detected no DTC and no abnormality has been found
in “Visual Inspection”: K10B (Page 1A-35).
Follow the flow carefully.
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K10B
(Page 1A-20).
2 Check battery voltage Go to Step 3. Charge or replace
battery.
Is it 12 V or more?
3 Can engine be cranked? Go to Step 4. Go to “Cranking System
Symptom Diagnosis” in
Section 1I (Page 1I-3).
4 Does engine start? Go to Step 5. Go to Step 7.
5 Check idle speed Go to Step 6. Go to “Engine Symptom
1) Check engine idle speed. (Page 1A-116) Diagnosis”: K10B (Page
1A-37).
Is check result OK?
6 Check ignition system Go to “Engine Symptom Repair or replace
1) Check ignition system. (Page 1H-4) Diagnosis”: K10B (Page defective parts.
1A-37).
Is check result OK?
7 Check immobilizer system Go to Step 8. Immobilizer control
1) Check immobilizer control system. (Page 10C-4) system malfunction.

Is check result OK?

8 Check fuel supply Go to Step 9. Repair or replace
1) Check fuel supply. (Page 1G-29) defective parts.

Is check result OK?

9 Check fuel injector circuit Go to “Engine Symptom Repair or replace
1) Check fuel injector circuit referring to “Fuel Injector Diagnosis”: K10B (Page defective parts.
Circuit Check”: Petrol in Section 1G (Page 1G-7). 1A-37).

Is check result OK?

 Engine General Information and Diagnosis: K10B 1A-37
Engine Symptom Diagnosis
Perform troubleshooting referring to the following points when ECM has detected no DTC and no abnormality has
been found in “Visual Inspection”: K10B (Page 1A-35) and “Engine Basic Inspection”: K10B (Page 1A-36).
Condition Possible cause
Hard starting (Engine can Faulty spark plug
be cranked)
Faulty ignition coil
Dirty or clogged fuel hoses or pipes
Malfunctioning fuel pump
Air drawn in through intake manifold
gasket or throttle body gasket
Faulty electric throttle body assembly
Faulty APP sensor
Faulty ECT sensor or MAP sensor
Faulty ECM
Low compression
Poor spark plug tightening or faulty
gasket
Compression leakage from valve seat
Sticky valve stem
Weak or damaged valve springs
Compression leakage at cylinder head
gasket
Sticky or damaged piston ring
Worn piston, piston ring or cylinder
Malfunctioning PCV valve
Low oil pressure Improper oil viscosity
Malfunctioning oil pressure switch
Clogged oil strainer
Functional deterioration of oil pump
Worn oil pump relief valve
Excessive clearance in various sliding
parts
AENJCA0A1114010
Correction / Reference Item
“Spark Plug Inspection”: K10B and Bi-Fuel
CNG in Section 1H (Page 1H-7)
“Ignition Coil Assembly Inspection”: K10B and
Bi-Fuel CNG in Section 1H (Page 1H-7)
“Fuel Pressure Check”: Petrol in Section 1G
(Page 1G-12)
“Fuel Pump and Its Circuit Check”: Petrol in
Section 1G (Page 1G-10)
Check air intake system.
“Electric Throttle Body Assembly On-Vehicle
Inspection”: K10B and Bi-Fuel CNG in Section
1C (Page 1C-5)
“APP Sensor On-Vehicle Inspection”: K10B
and Bi-Fuel CNG in Section 1C (Page 1C-7)
“ECT Sensor Inspection”: K10B and Bi-Fuel
CNG in Section 1C (Page 1C-11) or “MAP
Sensor Inspection”: K10B and Bi-Fuel CNG in
Section 1C (Page 1C-9)
“Inspection of ECM and Its Circuits”: K10B
(Page 1A-103)
“Compression Check”: K10B and Bi-Fuel CNG
in Section 1D (Page 1D-1)
“Spark Plug Removal and Installation”: K10B
and Bi-Fuel CNG in Section 1H (Page 1H-7)
“Valve and Valve Guide Inspection”: K10B and
Bi-Fuel CNG in Section 1D (Page 1D-45)
“Valve and Valve Guide Inspection”: K10B and
Bi-Fuel CNG in Section 1D (Page 1D-45)
“Valve Spring Inspection”: K10B and Bi-Fuel
CNG in Section 1D (Page 1D-48)
“Cylinder Head Inspection”: K10B and Bi-Fuel
CNG in Section 1D (Page 1D-47)
“Cylinder, Piston and Piston Ring Inspection”:
K10B and Bi-Fuel CNG in Section 1D (Page
1D-53)
“Cylinder, Piston and Piston Ring Inspection”:
K10B and Bi-Fuel CNG in Section 1D (Page
1D-53)
“PCV Valve Inspection”: K10B and Bi-Fuel
CNG in Section 1B (Page 1B-7)
“Engine Oil and Filter Change” in Section 0B
(Page 0B-5)
“Oil Pressure Switch On-Vehicle Inspection”:
K10B and Bi-Fuel CNG in Section 1E (Page
1E-5)
Check oil strainer for clog.
“Oil Pump Inspection”: K10B and Bi-Fuel CNG
in Section 1E (Page 1E-13)
“Oil Pump Inspection”: K10B and Bi-Fuel CNG
in Section 1E (Page 1E-13)
—
1A-38 Engine General Information and Diagnosis: K10B

Condition Possible cause Correction / Reference Item

Engine noise – Valve Improper valve lash “Camshaft and Tappet Inspection”: K10B and
noise Bi-Fuel CNG in Section 1D (Page 1D-19)
Worn valve stem and guide “Valve and Valve Guide Inspection”: K10B and
NOTE Bi-Fuel CNG in Section 1D (Page 1D-45)
Before checking Weak or broken valve spring “Valve Spring Inspection”: K10B and Bi-Fuel
mechanical noise, check CNG in Section 1D (Page 1D-48)
that: Warped or bent valve “Valve and Valve Guide Inspection”: K10B and
• Specified spark plug is Bi-Fuel CNG in Section 1D (Page 1D-45)
used.
• Specified fuel is used.

Engine noise – Piston, Worn piston, piston ring and cylinder “Cylinder, Piston and Piston Ring Inspection”:
piston ring and cylinder bore K10B and Bi-Fuel CNG in Section 1D (Page
noise 1D-53)

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

Engine noise – Worn piston, piston ring and cylinder “Cylinder, Piston and Piston Ring Inspection”:
Connecting rod noise bore K10B and Bi-Fuel CNG in Section 1D (Page
1D-53)
NOTE Worn connecting rod bearing “Crankshaft Pin and Connecting Rod Bearing
Before checking Inspection”: K10B and Bi-Fuel CNG in Section
mechanical noise, check 1D (Page 1D-56)
that: Worn crankshaft pin “Crankshaft Pin and Connecting Rod Bearing
• Specified spark plug is Inspection”: K10B and Bi-Fuel CNG in Section
used. 1D (Page 1D-56)
Loose connecting rod bolts “Piston, Piston Ring and Connecting Rod
• Specified fuel is used.
Removal and Installation”: K10B and Bi-Fuel
CNG in Section 1D (Page 1D-50)
Low oil pressure Condition “Low oil pressure”
Engine noise – Low oil pressure Condition “Low oil pressure”
Crankshaft noise Worn main bearing “Main Bearing Inspection”: K10B and Bi-Fuel
CNG in Section 1D (Page 1D-63)
NOTE Worn crankshaft journal “Crankshaft Inspection”: K10B and Bi-Fuel
Before checking CNG in Section 1D (Page 1D-63)
mechanical noise, check Loose bearing cap bolts “Main Bearing, Crankshaft and Cylinder Block
that: Removal and Installation”: K10B and Bi-Fuel
• Specified spark plug is CNG in Section 1D (Page 1D-60)
used. Excessive crankshaft thrust play “Crankshaft Inspection”: K10B and Bi-Fuel
CNG in Section 1D (Page 1D-63)
• Specified fuel is used.
 Engine General Information and Diagnosis: K10B 1A-39
Condition Possible cause
Engine overheating Inoperative thermostat
Poor water pump performance
Clogged or leaky radiator
Improper engine oil grade
Clogged oil filter or oil strainer
Poor oil pump performance
Faulty radiator cooling fan control
system
Dragging brakes
Slipping clutch (M/T model)
Slipping clutch (auto gear shift model) “Clutch Cover and Clutch Disc Inspection” in
Blown cylinder head gasket
Air mixed in cooling system
Poor fuel mileage Faulty spark plug (improper gap, heavy “Spark Plug Inspection”: K10B and Bi-Fuel
deposits and burned electrodes, etc.)
High idle speed
Poor performance of ECT sensor or
MAP sensor
Faulty electric throttle body assembly “Electric Throttle Body Assembly On-Vehicle
Faulty APP sensor
Faulty fuel injector(s)
Faulty ECM
Low compression
Poor valve seating
Dragging brakes
Slipping clutch (M/T model)
Slipping clutch (auto gear shift model) “Clutch Cover and Clutch Disc Inspection” in
Thermostat out of order
Improper tire pressure
Correction / Reference Item
“Thermostat Inspection”: K10B and Bi-Fuel
CNG in Section 1F (Page 1F-11)
“Water Pump Inspection”: K10B and Bi-Fuel
CNG in Section 1F (Page 1F-16)
“Radiator On-Vehicle Inspection and
Cleaning”: K10B and Bi-Fuel CNG in Section
1F (Page 1F-15)
“Engine Oil and Filter Change” in Section 0B
(Page 0B-5)
“Oil Pressure Check”: K10B and Bi-Fuel CNG
in Section 1E (Page 1E-3)
“Oil Pressure Check”: K10B and Bi-Fuel CNG
in Section 1E (Page 1E-3)
“Radiator Cooling Fan System Check”: K10B
and Bi-Fuel CNG in Section 1F (Page 1F-5)
Condition “Dragging brakes” in “Brake
Symptom Diagnosis” in Section 4A (Page 4A-
2)
Condition “Slipping clutch” in “Clutch System
Symptom Diagnosis” in Section 5C (Page 5C-
1)
Section 5D (Page 5D-146)
“Cylinder Head Inspection”: K10B and Bi-Fuel
CNG in Section 1D (Page 1D-47)
“Cooling System Refilling”: K10B and Bi-Fuel
CNG in Section 1F (Page 1F-9)
CNG in Section 1H (Page 1H-7)
Condition “Improper engine idling or engine
fails to idle”
“ECT Sensor Inspection”: K10B and Bi-Fuel
CNG in Section 1C (Page 1C-11) or “MAP
Sensor Inspection”: K10B and Bi-Fuel CNG in
Section 1C (Page 1C-9)
Inspection”: K10B and Bi-Fuel CNG in Section
1C (Page 1C-5)
“APP Sensor On-Vehicle Inspection”: K10B
and Bi-Fuel CNG in Section 1C (Page 1C-7)
“Fuel Injector Circuit Check”: Petrol in Section
1G (Page 1G-7)
“Inspection of ECM and Its Circuits”: K10B
(Page 1A-103)
“Compression Check”: K10B and Bi-Fuel CNG
in Section 1D (Page 1D-1)
“Valve and Valve Guide Inspection”: K10B and
Bi-Fuel CNG in Section 1D (Page 1D-45)
Condition “Dragging brakes” in “Brake
Symptom Diagnosis” in Section 4A (Page 4A-
2)
Condition “Slipping clutch” in “Clutch System
Symptom Diagnosis” in Section 5C (Page 5C-
1)
Section 5D (Page 5D-146)
“Thermostat Inspection”: K10B and Bi-Fuel
CNG in Section 1F (Page 1F-11)
“Tire Description” in Section 2D (Page 2D-1)
1A-40 Engine General Information and Diagnosis: K10B

Condition Possible cause Correction / Reference Item

Excessive engine oil Broken cylinder head gasket “Cylinder Head Inspection”: K10B and Bi-Fuel
consumption – Oil CNG in Section 1D (Page 1D-47)
leakage Leaky crankshaft pulley oil seal “Camshaft and Tappet Inspection”: K10B and
Bi-Fuel CNG in Section 1D (Page 1D-19)
Leaky crankshaft rear oil seal “Main Bearing, Crankshaft and Cylinder Block
Removal and Installation”: K10B and Bi-Fuel
CNG in Section 1D (Page 1D-60)
Leaky cylinder head cover gasket “Cylinder Head Cover Components”: K10B
and Bi-Fuel CNG in Section 1D (Page 1D-10)
Excessive engine oil Sticky piston ring “Cylinder, Piston and Piston Ring Inspection”:
consumption – Oil K10B and Bi-Fuel CNG in Section 1D (Page
entering combustion 1D-53)
chamber Worn piston and cylinder “Cylinder, Piston and Piston Ring Inspection”:
K10B and Bi-Fuel CNG in Section 1D (Page
1D-53)
Worn piston ring groove and ring “Cylinder, Piston and Piston Ring Inspection”:
K10B and Bi-Fuel CNG in Section 1D (Page
1D-53)
Improper location of piston ring gap “Piston, Piston Ring and Connecting Rod
Disassembly and Reassembly”: K10B and Bi-
Fuel CNG in Section 1D (Page 1D-52)
Worn or damaged valve stem seal “Valve and Valve Guide Inspection”: K10B and
Bi-Fuel CNG in Section 1D (Page 1D-45)
Worn valve stem “Valve and Valve Guide Inspection”: K10B and
Bi-Fuel CNG in Section 1D (Page 1D-45)
Engine hesitation – Spark plug faulty or plug gap out of “Spark Plug Inspection”: K10B and Bi-Fuel
Momentary lack of adjustment CNG in Section 1H (Page 1H-7)
response as accelerator Fuel pressure out of specification “Fuel Pressure Basic Check”: Petrol in Section
is depressed. Can occur 1G (Page 1G-14)
at all vehicle speeds. Poor performance of ECT sensor or “ECT Sensor Inspection”: K10B and Bi-Fuel
Usually severest when MAP sensor CNG in Section 1C (Page 1C-11) or “MAP
moving out from a stop at Sensor Inspection”: K10B and Bi-Fuel CNG in
stop signal etc. Section 1C (Page 1C-9)
Faulty electric throttle body assembly “Electric Throttle Body Assembly On-Vehicle
Inspection”: K10B and Bi-Fuel CNG in Section
1C (Page 1C-5)
Faulty APP sensor “APP Sensor On-Vehicle Inspection”: K10B
and Bi-Fuel CNG in Section 1C (Page 1C-7)
Faulty fuel injector “Fuel Injector Circuit Check”: Petrol in Section
1G (Page 1G-7)
Faulty ECM “Inspection of ECM and Its Circuits”: K10B
(Page 1A-103)
Engine overheating Condition “Engine overheating”
Low compression “Compression Check”: K10B and Bi-Fuel CNG
in Section 1D (Page 1D-1)

Condition
Surge – Engine power
variation under steady
throttle or cruise. Vehicle
speed changes up and
down with no change in
accelerator pedal
position.
Excessive detonation –
Engine continuously
generates sharp, metallic
knocking sound that
changes with throttle
opening.
Engine General Information and Diagnosis: K10B 1A-41
Possible cause
Faulty spark plug (excessive carbon
deposits, improper gap, burned
electrodes, etc.)
Variable fuel pressure
Kinky or damaged fuel lines
Faulty fuel pump (clogged fuel suction
filter)
Poor performance of MAP sensor
Faulty fuel injector
Faulty ECM
Faulty electric throttle body assembly
Faulty APP sensor
Faulty spark plug
Engine overheating
Clogged fuel filter or fuel lines
Air drawn in through intake manifold or Check air intake system.
throttle body gasket
Poor performance of knock sensor, ECT “Knock Sensor On-Vehicle Inspection”: K10B
sensor or MAP sensor
Faulty fuel injector(s)
Faulty ECM
Excessive combustion chamber
deposits
Correction / Reference Item
“Spark Plug Inspection”: K10B and Bi-Fuel
CNG in Section 1H (Page 1H-7)
“Fuel Pressure Check”: Petrol in Section 1G
(Page 1G-12)
“Fuel Pressure Check”: Petrol in Section 1G
(Page 1G-12)
“Fuel Pump Inspection”: Petrol in Section 1G
(Page 1G-31)
“MAP Sensor Inspection”: K10B and Bi-Fuel
CNG in Section 1C (Page 1C-9)
“Fuel Injector Circuit Check”: Petrol in Section
1G (Page 1G-7)
“Inspection of ECM and Its Circuits”: K10B
(Page 1A-103)
“Electric Throttle Body Assembly On-Vehicle
Inspection”: K10B and Bi-Fuel CNG in Section
1C (Page 1C-5)
“APP Sensor On-Vehicle Inspection”: K10B
and Bi-Fuel CNG in Section 1C (Page 1C-7)
“Spark Plug Inspection”: K10B and Bi-Fuel
CNG in Section 1H (Page 1H-7)
Condition “Engine overheating”
“Fuel Pressure Check”: Petrol in Section 1G
(Page 1G-12)
and Bi-Fuel CNG in Section 1C (Page 1C-14),
“ECT Sensor Inspection”: K10B and Bi-Fuel
CNG in Section 1C (Page 1C-11) or “MAP
Sensor Inspection”: K10B and Bi-Fuel CNG in
Section 1C (Page 1C-9)
“Fuel Injector Circuit Check”: Petrol in Section
1G (Page 1G-7) or “Fuel Injector Inspection”:
Petrol in Section 1G (Page 1G-24)
“Inspection of ECM and Its Circuits”: K10B
(Page 1A-103)
“Cylinder Head Inspection”: K10B and Bi-Fuel
CNG in Section 1D (Page 1D-47) and
“Cylinder, Piston and Piston Ring Inspection”:
K10B and Bi-Fuel CNG in Section 1D (Page
1D-53)
1A-42 Engine General Information and Diagnosis: K10B
Condition Possible cause
Poor engine power Faulty spark plug
Faulty ignition coil assembly
Faulty knock sensor
Clogged fuel hoses or pipes
Malfunctioning fuel pump
Air drawn in through intake manifold
gasket or throttle body gasket
Engine overheating
Poor performance of ECT sensor or
MAP sensor
Faulty electric throttle body assembly
Faulty APP sensor
Faulty fuel injector(s)
Faulty ECM
Dragging brakes
Slipping clutch (M/T model)
Slipping clutch (auto gear shift model)
Low compression
Correction / Reference Item
“Spark Plug Inspection”: K10B and Bi-Fuel
CNG in Section 1H (Page 1H-7)
“Ignition Coil Assembly Inspection”: K10B and
Bi-Fuel CNG in Section 1H (Page 1H-7)
“Knock Sensor On-Vehicle Inspection”: K10B
and Bi-Fuel CNG in Section 1C (Page 1C-14)
“Fuel Pressure Check”: Petrol in Section 1G
(Page 1G-12)
“Fuel Pump and Its Circuit Check”: Petrol in
Section 1G (Page 1G-10)
Check air intake system.
Condition “Engine overheating”
“ECT Sensor Inspection”: K10B and Bi-Fuel
CNG in Section 1C (Page 1C-11) or “MAP
Sensor Inspection”: K10B and Bi-Fuel CNG in
Section 1C (Page 1C-9)
“Electric Throttle Body Assembly On-Vehicle
Inspection”: K10B and Bi-Fuel CNG in Section
1C (Page 1C-5)
“APP Sensor On-Vehicle Inspection”: K10B
and Bi-Fuel CNG in Section 1C (Page 1C-7)
“Fuel Injector Circuit Check”: Petrol in Section
1G (Page 1G-7) or “Fuel Injector Inspection”:
Petrol in Section 1G (Page 1G-24)
“Inspection of ECM and Its Circuits”: K10B
(Page 1A-103)
Condition “Dragging brakes” in “Brake
Symptom Diagnosis” in Section 4A (Page 4A-
2)
Condition “Slipping clutch” in “Clutch System
Symptom Diagnosis” in Section 5C (Page 5C-
1)
“Clutch Cover and Clutch Disc Inspection” in
Section 5D (Page 5D-146)
“Compression Check”: K10B and Bi-Fuel CNG
in Section 1D (Page 1D-1)
 Engine General Information and Diagnosis: K10B 1A-43

Condition Possible cause Correction / Reference Item

Improper engine idling or Faulty spark plug
engine fails to idle
Faulty ignition coil assembly
Fuel pressure out of specification
Leaky manifold, throttle body, or cylinder Check air intake system.
head gasket
Faulty evaporative emission control
system
Faulty fuel injector(s)
Poor performance of ECT sensor or
MAP sensor
Faulty electric throttle body assembly
Faulty APP sensor
Faulty ECM
Loose connection or disconnection of
vacuum hoses
Malfunctioning PCV valve
Engine overheating
Low compression
Faulty generator and/or its circuit
“Spark Plug Inspection”: K10B and Bi-Fuel
CNG in Section 1H (Page 1H-7)
“Ignition Coil Assembly Inspection”: K10B and
Bi-Fuel CNG in Section 1H (Page 1H-7)
“Fuel Pressure Basic Check”: Petrol in Section
1G (Page 1G-14)
“EVAP Canister Purge System Inspection”:
K10B and Bi-Fuel CNG in Section 1B (Page
1B-1)
“Fuel Injector Circuit Check”: Petrol in Section
1G (Page 1G-7) or “Fuel Injector Inspection”:
Petrol in Section 1G (Page 1G-24)
“ECT Sensor Inspection”: K10B and Bi-Fuel
CNG in Section 1C (Page 1C-11) or “MAP
Sensor Inspection”: K10B and Bi-Fuel CNG in
Section 1C (Page 1C-9)
“Electric Throttle Body Assembly On-Vehicle
Inspection”: K10B and Bi-Fuel CNG in Section
1C (Page 1C-5)
“APP Sensor On-Vehicle Inspection”: K10B
and Bi-Fuel CNG in Section 1C (Page 1C-7)
“Inspection of ECM and Its Circuits”: K10B
(Page 1A-103)
Check connection of vacuum hoses.
“PCV Valve Inspection”: K10B and Bi-Fuel
CNG in Section 1B (Page 1B-7)
Condition “Engine overheating”
“Compression Check”: K10B and Bi-Fuel CNG
in Section 1D (Page 1D-1)
“Generator Test”: K10B and Bi-Fuel CNG in
Section 1J (Page 1J-5)
1A-44 Engine General Information and Diagnosis: K10B
Condition Possible cause
Excessive hydrocarbon Faulty spark plug
(HC) emission or carbon
monoxide (CO) emission Faulty ignition coil assembly
Low compression
Lead contamination of three-way
catalytic converter
Faulty evaporative emission control
system
Fuel pressure out of specification
Faulty closed loop system (A/F
feedback compensation) (Poor
performance of ECT sensor or MAP
sensor)
Faulty electric throttle body assembly
Faulty APP sensor
Faulty injector(s)
Faulty ECM
Engine not at normal operating
temperature
Clogged air cleaner
Vacuum leaks
Excessive nitrogen Improper ignition timing
oxides (NOx) emission
Lead contamination of three-way
catalytic converter
Fuel pressure out of specification
Faulty closed loop system (A/F
feedback compensation) (Poor
performance of ECT sensor or MAP
sensor)
Faulty electric throttle body assembly
Faulty APP sensor
Faulty injector(s)
Faulty ECM
Correction / Reference Item
“Spark Plug Inspection”: K10B and Bi-Fuel
CNG in Section 1H (Page 1H-7)
“Ignition Coil Assembly Inspection”: K10B and
Bi-Fuel CNG in Section 1H (Page 1H-7)
“Compression Check”: K10B and Bi-Fuel CNG
in Section 1D (Page 1D-1)
Check for absence of filler neck restrictor.
“EVAP Canister Purge System Inspection”:
K10B and Bi-Fuel CNG in Section 1B (Page
1B-1)
“Fuel Pressure Basic Check”: Petrol in Section
1G (Page 1G-14)
“ECT Sensor Inspection”: K10B and Bi-Fuel
CNG in Section 1C (Page 1C-11) or “MAP
Sensor Inspection”: K10B and Bi-Fuel CNG in
Section 1C (Page 1C-9)
“Electric Throttle Body Assembly On-Vehicle
Inspection”: K10B and Bi-Fuel CNG in Section
1C (Page 1C-5)
“APP Sensor On-Vehicle Inspection”: K10B
and Bi-Fuel CNG in Section 1C (Page 1C-7)
“Fuel Injector Circuit Check”: Petrol in Section
1G (Page 1G-7)
“Inspection of ECM and Its Circuits”: K10B
(Page 1A-103)
—
“Air Cleaner Filter Inspection and Cleaning”:
K10B and Bi-Fuel CNG in Section 1D (Page
1D-6)
“Engine Vacuum Check”: K10B and Bi-Fuel
CNG in Section 1D (Page 1D-2)
“Ignition Timing Inspection”: K10B and Bi-Fuel
CNG in Section 1H (Page 1H-8)
Check for absence of filler neck restrictor.
“Fuel Pressure Basic Check”: Petrol in Section
1G (Page 1G-14)
“ECT Sensor Inspection”: K10B and Bi-Fuel
CNG in Section 1C (Page 1C-11) or “MAP
Sensor Inspection”: K10B and Bi-Fuel CNG in
Section 1C (Page 1C-9)
“Electric Throttle Body Assembly On-Vehicle
Inspection”: K10B and Bi-Fuel CNG in Section
1C (Page 1C-5)
“APP Sensor On-Vehicle Inspection”: K10B
and Bi-Fuel CNG in Section 1C (Page 1C-7)
“Fuel Injector Circuit Check”: Petrol in Section
1G (Page 1G-7) or “Fuel Injector Inspection”:
Petrol in Section 1G (Page 1G-24)
“Inspection of ECM and Its Circuits”: K10B
(Page 1A-103)
 Engine General Information and Diagnosis: K10B 1A-45

MIL Does Not Come ON with Ignition “ON” and Engine Stopped (but Engine Can Be Started)
AENJCA0A1114011
Troubleshooting
Step Action Yes No
1 DTC check Go to troubleshooting Go to Step 2.
1) Check DTC related to CAN communication. for applicable DTC.

Is there any CAN-DTC(s) detected?

2 DTC check Go to troubleshooting Replace ECM and
1) Check combination meter for DTC. for applicable DTC. recheck MIL operation.
(Page 1C-3)
Is there any DTC(s) detected?

MIL Remains ON after Engine Starts

AENJCA0A1114012
Troubleshooting
Step Action Yes No
1 DTC check Go to troubleshooting Replace combination
1) Start engine and recheck DTC of ECM while engine for applicable DTC. meter and recheck MIL
running. operation. (Page 9C-
25)
Is there any DTC(s)?
If MIL still remains ON,
replace ECM and
recheck MIL operation.
(Page 1C-3)
1A-46 Engine General Information and Diagnosis: K10B

DTC P0031 / P0032 / P0037 / P0038

AENJCA0A1114013
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0031: HO2S Heater Control Circuit Low (Bank 1 Sensor 1) • HO2S-1 heater and/or its circuit
Output voltage of HO2S-1 heater circuit is lower than specified • HO2S-2 heater and/or its circuit
value for 5 sec. continuously even though control duty of
• ECM
HO2S-1 heater is lower than 90% with engine running.
(3 D/C detection logic)
P0032: HO2S Heater Control Circuit High (Bank 1 Sensor 1)
Output voltage of HO2S-1 heater circuit is higher than specified
value for 5 sec. continuously even though control duty of
HO2S-1 heater is higher than 10% with engine running.
(3 D/C detection logic)
P0037: HO2S Heater Control Circuit Low (Bank 1 Sensor 2)
Output voltage of HO2S-2 heater circuit is lower than specified
value for 5 sec. continuously even though control duty of
HO2S-2 heater is lower than 90% with engine running.
(3 D/C detection logic)
P0038: HO2S Heater Control Circuit High (Bank 1 Sensor 2)
Output voltage of HO2S-2 heater circuit is higher than specified
value for 5 sec. continuously even though control duty of
HO2S-2 heater is higher than 10% with engine running.
(3 D/C detection logic)

Circuit Diagram

4
+B
1
3 A2
RED C01-53
BLU A3
GRN C01-37
LT GRN C01-32
PPL C01-71
A4
A1
2
3 B2
BRN C01-52
B3
YEL C01-51
BEG C01-42
RED C01-76
B4
B1

[A] C01 E01

10 9 8 7 6 5 4 3 2 1
65 64 63 62 61 20 19 18 17 16 15 14 13 12 11
70 69 68 67 66 30 29 28 27 26 25 24 23 22 21
75 74 73 72 71 40 39 38 37 36 35 34 33 32 31
80 79 78 77 76 50 49 48 47 46 45 44 43 42 41
60 59 58 57 56 55 54 53 52 51
[a]
9 8 7 6 5 4 3 2 1
57 56 55 18 17 16 15 14 13 12 11 10
60 59 58 27 26 25 24 23 22 21 20 19
63 62 61 36 35 34 33 32 31 30 29 28
66 65 64 45 44 43 42 41 40 39 38 37
54 53 52 51 50 49 48 47 46

IJCA0A111012-02

[A]: ECM connector (View: [a]) B1: HO2S-2 heater power supply circuit 2. HO2S-2
A1: HO2S-1 heater power supply circuit B2: HO2S-2 signal circuit 3. Shield wire
A2: HO2S-1 signal circuit B3: HO2S-2 ground circuit 4. ECM
A3: HO2S-1 ground circuit B4: HO2S-2 heater drive circuit
A4: HO2S-1 heater drive circuit 1. HO2S-1
 Engine General Information and Diagnosis: K10B 1A-47

DTC Confirmation Procedure

NOTE
Check that the following condition is met in this “DTC Confirmation Procedure”.
• 15 V > Battery voltage > 10.7 V

1) Run engine at idle speed for 1 min.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K10B
(Page 1A-20).
2 HO2S heater power supply circuit check Go to Step 3. Repair or replace
1) When ignition is “OFF”, disconnect connector from defective wire harness.
HO2S related DTC.
2) Check for proper terminal connection to HO2S
connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between “A1” or “B1” circuit and
ground is battery voltage.

Is check result OK?

3 HO2S heater 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 connection to “C01” and “E01”
connectors.
3) If connections are OK, check the following points.
• Resistance of “A4” or “B4” circuit: less than 1 Ω
• Resistance between “A4” or “B4” circuit and ground:
infinity
• Resistance between “A4” or “B4” circuit terminal and
other terminal at HO2S connector: infinity
• Voltage of “A4” or “B4” circuit: 0 to 1 V (When ignition
is “ON”)

Is check result OK?

4 HO2S check Replace ECM and Replace HO2S-1 or
1) Check HO2S heater. (Page 1C-11) recheck DTC. (Page HO2S-2.
1C-3)
Is check result OK?
1A-48 Engine General Information and Diagnosis: K10B

DTC P0106
AENJCA0A1114014
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0106: Manifold Absolute Pressure / Barometric • MAP sensor and/or its circuit
Pressure Circuit Range / Performance • Air intake system
Any of the following conditions is met.
• ECM
• Difference between maximum pressure and minimum
pressure of MAP sensor is out of specification.
• Difference between MAP sensor and estimated
barometric pressure is out of specification for 5 sec.
(3 D/C detection logic)

Circuit Diagram

2
A1
LT BLU C01-57
1 A2
BEG C01-35
GRY C01-39
A3

[A] C01 E01

10 9 8 7 6 5 4 3 2 1
65 64 63 62 61 20 19 18 17 16 15 14 13 12 11
70 69 68 67 66 30 29 28 27 26 25 24 23 22 21
75 74 73 72 71 40 39 38 37 36 35 34 33 32 31
80 79 78 77 76 50 49 48 47 46 45 44 43 42 41
60 59 58 57 56 55 54 53 52 51
[a]
9 8 7 6 5 4 3 2 1
57 56 55 18 17 16 15 14 13 12 11 10
60 59 58 27 26 25 24 23 22 21 20 19
63 62 61 36 35 34 33 32 31 30 29 28
66 65 64 45 44 43 42 41 40 39 38 37
54 53 52 51 50 49 48 47 46

IJCA0A111013-02

[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 Confirmation Procedure

NOTE
• Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.
• Check that the following condition is met in this “DTC Confirmation Procedure”.
– DTC P0107, P0108, P0112, P0113, P0117 and P0118 are not detected.

1) Warm up engine to normal operating temperature.

2) Run engine at idle speed for 1 min.
 Engine General Information and Diagnosis: K10B 1A-49

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”: K10B
(Page 1A-20).
2 Air intake system check Go to Step 3. Repair or replace air
1) Check air intake system for clogging or leakage. intake system.

Is check result OK?

3 MAP sensor circuit check Go to Step 4. Repair or replace
1) Check MAP sensor circuits according to Step 2 – 4 defective wire harness.
under “DTC P0107 / P0108”: K10B (Page 1A-49).

Is check result OK?

4 MAP sensor check Replace ECM and Replace MAP sensor.
1) Check MAP sensor. (Page 1C-9) recheck DTC. (Page
1C-3)
Is check result OK?

DTC P0107 / P0108

AENJCA0A1114015
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0107: Manifold Absolute Pressure / Barometric Pressure Circuit Low • MAP sensor and/or its circuit
Output voltage of MAP sensor signal circuit is lower than 0.35 V for 5 sec. • ECM
(3 D/C detection logic)
P0108: Manifold Absolute Pressure / Barometric Pressure Circuit High
Output voltage of MAP sensor signal circuit is higher than 4.88 V for 5 sec.
(3 D/C detection logic)

Circuit Diagram

2
A1
LT BLU C01-57
1 A2
BEG C01-35
GRY C01-39
A3

[A] C01 E01

10 9 8 7 6 5 4 3 2 1
65 64 63 62 61 20 19 18 17 16 15 14 13 12 11
70 69 68 67 66 30 29 28 27 26 25 24 23 22 21
75 74 73 72 71 40 39 38 37 36 35 34 33 32 31
80 79 78 77 76 50 49 48 47 46 45 44 43 42 41
60 59 58 57 56 55 54 53 52 51
[a]
9 8 7 6 5 4 3 2 1
57 56 55 18 17 16 15 14 13 12 11 10
60 59 58 27 26 25 24 23 22 21 20 19
63 62 61 36 35 34 33 32 31 30 29 28
66 65 64 45 44 43 42 41 40 39 38 37
54 53 52 51 50 49 48 47 46

IJCA0A111013-02

[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 Confirmation Procedure

1) Run engine at idle speed for 1 min.
1A-50 Engine General Information and Diagnosis: K10B

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”: K10B
(Page 1A-20).
2 MAP sensor power supply circuit check Go to Step 4. Go to Step 3.
1) When ignition is “OFF”, disconnect MAP sensor
connector.
2) Check for proper terminal connection to MAP sensor
connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between “A1” and “A3” is approx. 5 V.

Is check result OK?

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

Is check result OK?

5 MAP sensor check Replace ECM and Replace MAP sensor.
1) Check MAP sensor. (Page 1C-9) recheck DTC. (Page
1C-3)
Is check result OK?
 Engine General Information and Diagnosis: K10B 1A-51

DTC P0112 / P0113

AENJCA0A1114016
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0112: Intake Air Temperature Sensor 1 Circuit Low (Bank 1) • IAT sensor and/or its circuit
Output voltage of IAT sensor signal circuit is lower than 0.02 V for 5 sec. • ECM
(3 D/C detection logic)
P0113: Intake Air Temperature Sensor 1 Circuit High (Bank 1)
Output voltage of IAT sensor signal circuit is higher than 4.98 V for 5 sec.
(3 D/C detection logic)

Circuit Diagram

1 A1
YEL C01-34

BEG C01-38
A2

[A] C01 E01

10 9 8 7 6 5 4 3 2 1
65 64 63 62 61 20 19 18 17 16 15 14 13 12 11
70 69 68 67 66 30 29 28 27 26 25 24 23 22 21
75 74 73 72 71 40 39 38 37 36 35 34 33 32 31
80 79 78 77 76 50 49 48 47 46 45 44 43 42 41
60 59 58 57 56 55 54 53 52 51
[a]
9 8 7 6 5 4 3 2 1
57 56 55 18 17 16 15 14 13 12 11 10
60 59 58 27 26 25 24 23 22 21 20 19
63 62 61 36 35 34 33 32 31 30 29 28
66 65 64 45 44 43 42 41 40 39 38 37
54 53 52 51 50 49 48 47 46

IJCA0A111014-02

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

DTC Confirmation Procedure

1) Run engine at idle speed for 1 min.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K10B
(Page 1A-20).
2 IAT sensor signal circuit and ground circuit check Go to Step 3. Repair or replace
1) When ignition is “OFF”, disconnect “C01” and “E01” defective wire harness.
connectors of ECM and IAT sensor connector.
2) Check for proper terminal connection to “C01” and “E01”
connectors and IAT sensor connector.
3) If connections are OK, check the following points.
• Resistance of “A1” and “A2” circuits: less than 1 Ω
• Resistance between each of “A1” and “A2” circuits
and ground: infinity
• Resistance between “A1” circuit terminal and “A2”
circuit terminal at IAT sensor connector: infinity
• Voltage of “A1” and “A2” circuits: 0 to 1 V (When
ignition is “ON”)

Is check result OK?

1A-52 Engine General Information and Diagnosis: K10B

Step Action Yes No

3 IAT sensor check Replace ECM and Replace IAT sensor.
1) Check IAT sensor. (Page 1C-15) recheck DTC. (Page
1C-3)
Is check result OK?

DTC P0116
AENJCA0A1114017
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0116: Engine Coolant Temperature Sensor 1 Circuit • ECT sensor and/or its circuit
Range / Performance • Thermostat
Output voltage of ECT sensor signal circuit is unchanged
• Cooling system
for 2 min. when ECT is lower than 70 °C (158 °F).
(3 D/C detection logic) • ECM

Circuit Diagram

2
3
1 A1
BLU C01-36

GRY C01-39
A2

[A] C01 E01

10 9 8 7 6 5 4 3 2 1
65 64 63 62 61 20 19 18 17 16 15 14 13 12 11
70 69 68 67 66 30 29 28 27 26 25 24 23 22 21
75 74 73 72 71 40 39 38 37 36 35 34 33 32 31
80 79 78 77 76 50 49 48 47 46 45 44 43 42 41
60 59 58 57 56 55 54 53 52 51
[a]
9 8 7 6 5 4 3 2 1
57 56 55 18 17 16 15 14 13 12 11 10
60 59 58 27 26 25 24 23 22 21 20 19
63 62 61 36 35 34 33 32 31 30 29 28
66 65 64 45 44 43 42 41 40 39 38 37
54 53 52 51 50 49 48 47 46

IJCA0A111015-02

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

DTC Confirmation Procedure

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

NOTE
• Limit the driving permissible in road conditions and regulations.
• Check that the following condition is met in this “DTC Confirmation Procedure”.
– DTC P0117 and P0118 are not detected.

1) Warm up engine to normal operating temperature.

2) Drive vehicle at 60 to 80 km/h (37 to 50 mile/h) for 5 min. or more.
 Engine General Information and Diagnosis: K10B 1A-53

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”: K10B
(Page 1A-20).
2 Coolant level check Go to Step 3. Add coolant and
1) Check coolant level. (Page 1F-8) recheck DTC.

Is check result OK?

3 ECT sensor circuit check Go to Step 4. Repair or replace
1) Check ECT sensor circuits according to Step 2 under defective wire harness.
“DTC P0117 / P0118”: K10B (Page 1A-53).

Is check result OK?

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

Is check result OK?

5 Thermostat check Replace ECM and Replace thermostat.
1) Check thermostat. (Page 1F-11) recheck DTC. (Page (Page 1F-11)
1C-3)
Is check result OK?

DTC P0117 / P0118

AENJCA0A1114018
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0117: Engine Coolant Temperature Sensor 1 Circuit Low • ECT sensor and/or its circuit
Output voltage of ECT sensor signal circuit is lower than 0.02 V for 5 sec. • ECM
(3 D/C detection logic)
P0118: Engine Coolant Temperature Sensor 1 Circuit High
Output voltage of ECT sensor signal circuit is higher than 4.98 V for 5 sec.
(3 D/C detection logic)

Circuit Diagram

2
3
1 A1
BLU C01-36

GRY C01-39
A2

[A] C01 E01

10 9 8 7 6 5 4 3 2 1
65 64 63 62 61 20 19 18 17 16 15 14 13 12 11
70 69 68 67 66 30 29 28 27 26 25 24 23 22 21
75 74 73 72 71 40 39 38 37 36 35 34 33 32 31
80 79 78 77 76 50 49 48 47 46 45 44 43 42 41
60 59 58 57 56 55 54 53 52 51
[a]
9 8 7 6 5 4 3 2 1
57 56 55 18 17 16 15 14 13 12 11 10
60 59 58 27 26 25 24 23 22 21 20 19
63 62 61 36 35 34 33 32 31 30 29 28
66 65 64 45 44 43 42 41 40 39 38 37
54 53 52 51 50 49 48 47 46

IJCA0A111015-02

[A]: ECM connector (View: [a]) A2: ECT sensor ground circuit 2. ECM
A1: ECT sensor signal circuit 1. ECT sensor 3. To MAP sensor
1A-54 Engine General Information and Diagnosis: K10B

DTC Confirmation Procedure

1) Run engine at idle speed for 1 min.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K10B
(Page 1A-20).
2 ECT sensor signal circuit and ground circuit check Go to Step 3. Repair or replace
1) When ignition is “OFF”, disconnect “C01” and “E01” defective wire harness.
connectors of ECM and ECT sensor connector.
2) Check for proper terminal connection to “C01” and “E01”
connectors and ECT sensor connector.
3) If connections are OK, check the following points.
• Resistance of “A1” and “A2” circuits: less than 1 Ω
• Resistance between each of “A1” and “A2” circuits
and ground: infinity
• Resistance between “A1” circuit terminal and “A2”
circuit terminal at ECT sensor connector: infinity
• Voltage of “A1” and “A2” circuits: 0 to 1 V (When
ignition is “ON”)

Is check result OK?

3 ECT sensor check Replace ECM and Replace ECT sensor.
1) Check ECT sensor. (Page 1C-11) recheck DTC. (Page
1C-3)
Is check result OK?
 Engine General Information and Diagnosis: K10B 1A-55

DTC P0122 / P0123

AENJCA0A1114019
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0122: Throttle / Pedal Position Sensor / Switch “A” Circuit Low • TP sensor (main) and/or its circuit
Output voltage of TP sensor (main) signal circuit is lower than 0.26 V. • ECM
(1 D/C detection logic)
P0123: Throttle / Pedal Position Sensor / Switch “A” Circuit High
Output voltage of TP sensor (main) signal circuit is higher than 4.76 V.
(1 D/C detection logic)

Circuit Diagram

5
1
A1
C01-70 LT GRN
A2
C01-75 BRN 4
B1
C01-56 RED B2 2
C01-54 GRN
B3 3
C01-55 WHT
C01-45 BLK
B4
C01-44 GRY

[A] C01 E01

10 9 8 7 6 5 4 3 2 1
65 64 63 62 61 20 19 18 17 16 15 14 13 12 11
70 69 68 67 66 30 29 28 27 26 25 24 23 22 21
75 74 73 72 71 40 39 38 37 36 35 34 33 32 31
80 79 78 77 76 50 49 48 47 46 45 44 43 42 41
60 59 58 57 56 55 54 53 52 51
[a]
9 8 7 6 5 4 3 2 1
57 56 55 18 17 16 15 14 13 12 11 10
60 59 58 27 26 25 24 23 22 21 20 19
63 62 61 36 35 34 33 32 31 30 29 28
66 65 64 45 44 43 42 41 40 39 38 37
54 53 52 51 50 49 48 47 46

IJCA0A111016-02

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

DTC Confirmation Procedure

1) Run engine at idle speed for 1 min.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K10B
(Page 1A-20).
2 TP sensor power supply circuit check Go to Step 4. Go to Step 3.
1) When ignition is “OFF”, disconnect electric throttle body
assembly connector.
2) Check for proper terminal connection to electric throttle
body assembly connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between “B1” and “B4” is approx. 5 V.

Is check result OK?

1A-56 Engine General Information and Diagnosis: K10B

Step Action Yes No

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

Is check result OK?

5 TP sensor check Replace ECM and Replace electric throttle
1) Check TP sensor referring to “TP Sensor Performance recheck DTC. (Page body assembly.
Check” under “Electric Throttle Body Assembly On- 1C-3)
Vehicle Inspection”: K10B and Bi-Fuel CNG in Section
1C (Page 1C-5).

Is check result OK?

 Engine General Information and Diagnosis: K10B 1A-57

DTC P0130 / P0133

AENJCA0A1114020
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0130: O2 Sensor Circuit (Bank 1 Sensor 1) • HO2S-1 and/or its circuit
Internal resistance of HO2S-1 is higher than specified value. • HO2S-1 heater and/or its circuit
(3 D/C detection logic)
• Air intake system
P0133: O2 Sensor Circuit Slow Response (Bank 1 Sensor 1)
Average response time of HO2S-1 output signal is longer than specified time. • Exhaust system
(3 D/C detection logic) • Fuel system
• ECM

Circuit Diagram

4
+B
1
3 A2
RED C01-53
BLU A3
GRN C01-37
LT GRN C01-32
PPL C01-71
A4
A1
2
3 B2
BRN C01-52
B3
YEL C01-51
BEG C01-42
RED C01-76
B4
B1

[A] C01 E01

10 9 8 7 6 5 4 3 2 1
65 64 63 62 61 20 19 18 17 16 15 14 13 12 11
70 69 68 67 66 30 29 28 27 26 25 24 23 22 21
75 74 73 72 71 40 39 38 37 36 35 34 33 32 31
80 79 78 77 76 50 49 48 47 46 45 44 43 42 41
60 59 58 57 56 55 54 53 52 51
[a]
9 8 7 6 5 4 3 2 1
57 56 55 18 17 16 15 14 13 12 11 10
60 59 58 27 26 25 24 23 22 21 20 19
63 62 61 36 35 34 33 32 31 30 29 28
66 65 64 45 44 43 42 41 40 39 38 37
54 53 52 51 50 49 48 47 46

IJCA0A111012-02

[A]: ECM connector (View: [a]) B1: HO2S-2 heater power supply circuit 2. HO2S-2
A1: HO2S-1 heater power supply circuit B2: HO2S-2 signal circuit 3. Shield wire
A2: HO2S-1 signal circuit B3: HO2S-2 ground circuit 4. ECM
A3: HO2S-1 ground circuit B4: HO2S-2 heater drive circuit
A4: HO2S-1 heater drive circuit 1. HO2S-1
1A-58 Engine General Information and Diagnosis: K10B

DTC Confirmation Procedure

P0130

NOTE
• Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.
• Check that the following conditions are met in this “DTC Confirmation Procedure”.
– Battery voltage > 10.6 V
– DTC P0107, P0108, P0112, P0113, P0117 and P0118 are not detected.

1) Warm up engine to normal operating temperature.

2) Run engine at idle speed for 5 min.

P0133

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

NOTE
• Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.
• Limit the driving permissible in road conditions and regulations.
• Check that the following condition is met in this “DTC Confirmation Procedure”.
– DTC P0107, P0108, P0112, P0113, P0117, P0118, P0171, P0172 and P0500 are not detected.

1) Warm up engine to normal operating temperature.

2) Drive vehicle at 60 to 80 km/h (37 to 50 mile/h) constantly for 5 min. or more.
3) Check whether O2 sensor readiness / monitoring test has completed or not using scan tool. If O2 sensor
readiness / monitoring test has not completed, check vehicle conditions (environmental) and repeat Step 2).

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”: K10B
(Page 1A-20).
2 DTC check Go to troubleshooting Go to Step 3.
for applicable DTC.
Is there any DTC(s) other than P0130 and 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 the following points related to fuel system. defective part.
• Fuel pressure: (Page 1G-12)
• Fuel injector circuit: (Page 1G-7)
• Fuel injector: (Page 1G-24)

Is check result OK?

 Engine General Information and Diagnosis: K10B 1A-59

Step Action Yes No

5 HO2S-1 signal circuit check Go to Step 6. Repair or replace
1) When ignition is “OFF”, disconnect “C01” and “E01” defective wire harness.
connectors of ECM and HO2S-1 connector.
2) Check for proper terminal connection to “C01” and “E01”
connectors and HO2S-1 connector.
3) If connections are OK, check the following points.
• Resistance of “A2” circuit: less than 1 Ω
• Resistance between “A2” circuit and ground: infinity
• Resistance between “A2” circuit terminal and other
terminal at HO2S-1 connector: infinity
• Voltage of “A2” circuit: 0 to 1 V (When ignition is “ON”)

Is check result OK?

6 HO2S-1 ground circuit check Go to Step 7. Repair or replace
1) When ignition is “OFF”, check the following points. defective wire harness.
• Resistance of “A3” circuit: less than 1 Ω
• Resistance between “A3” circuit and ground: infinity
• Resistance between “A3” circuit terminal and other
terminal at HO2S-1 sensor connector: infinity
• Voltage of “A3” circuit: 0 to 1 V (When ignition is “ON”)

Is check result OK?

7 HO2S-1 heater check Go to Step 8. Replace HO2S-1.
1) Check HO2S-1 heater. (Page 1C-11)

Is check result OK?

8 DTC recheck Replace ECM and End.
1) Replace HO2S-1. (Page 1C-11) recheck DTC. (Page
1C-3)
2) Clear DTC. (Page 1A-23)
3) Set ignition “OFF”.
4) Perform DTC confirmation procedure and check DTC.

Is DTC P0130 or P0133 still detected?

1A-60 Engine General Information and Diagnosis: K10B

DTC P0136
AENJCA0A1114058
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0136: O2 Sensor Circuit (Bank 1 Sensor 2) • HO2S-2 and/or its circuit
Internal resistance of HO2S-2 is higher than specified value. • HO2S-2 heater and/or its circuit
(3 D/C detection logic)
• ECM

Circuit Diagram

4
+B
1
3 A2
RED C01-53
BLU A3
GRN C01-37
LT GRN C01-32
PPL C01-71
A4
A1
2
3 B2
BRN C01-52
B3
YEL C01-51
BEG C01-42
RED C01-76
B4
B1

[A] C01 E01

10 9 8 7 6 5 4 3 2 1
65 64 63 62 61 20 19 18 17 16 15 14 13 12 11
70 69 68 67 66 30 29 28 27 26 25 24 23 22 21
75 74 73 72 71 40 39 38 37 36 35 34 33 32 31
80 79 78 77 76 50 49 48 47 46 45 44 43 42 41
60 59 58 57 56 55 54 53 52 51
[a]
9 8 7 6 5 4 3 2 1
57 56 55 18 17 16 15 14 13 12 11 10
60 59 58 27 26 25 24 23 22 21 20 19
63 62 61 36 35 34 33 32 31 30 29 28
66 65 64 45 44 43 42 41 40 39 38 37
54 53 52 51 50 49 48 47 46

IJCA0A111012-02

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

DTC Confirmation Procedure

NOTE
Check that the following conditions are met in this “DTC Confirmation Procedure”.
• Battery voltage > 10.6 V
• DTC P0037 and P0038 are not detected.

1) Warm up engine to normal operating temperature.

2) Run engine at idle speed for 5 min.
 Engine General Information and Diagnosis: K10B 1A-61

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”: K10B
(Page 1A-20).
2 DTC check Go to troubleshooting Go to Step 3.
1) Check DTC. (Page 1A-22) for applicable DTC.

Is there any DTC(s) other than P0136?

3 HO2S-2 signal circuit and ground circuit check Go to Step 4. Repair or replace
1) When ignition is “OFF”, disconnect “C01” and “E01” defective wire harness.
connectors of ECM and HO2S-2 connector.
2) Check for proper terminal connection to “C01” and “E01”
connectors and HO2S-2 connector.
3) If connections are OK, check the following points.
• Resistance of “B2” and “B3” circuits: less than 1 Ω
• Resistance between each of “B2” and “B3” circuits
and ground: infinity
• Resistance between “B2” circuit terminal and other
terminal at HO2S-2 connector: infinity
• Resistance between “B3” circuit terminal and other
terminal at HO2S-2 connector: infinity
• Voltage of “B2” and “B3” circuits: 0 to 1 V (When
ignition is “ON”)

Is check result OK?

4 HO2S-1 heater check Go to Step 5. Replace HO2S-1.
1) Check HO2S-1 heater. (Page 1C-11)

Is check result OK?

5 DTC recheck Replace ECM and End.
1) Replace HO2S-2. (Page 1C-11) recheck DTC. (Page
1C-3)
2) Clear DTC. (Page 1A-23)
3) Set ignition “OFF”.
4) Perform DTC confirmation procedure and check DTC.

Is DTC P0136 still detected?

1A-62 Engine General Information and Diagnosis: K10B

DTC P0139
AENJCA0A1114060
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0139: O2 Sensor Circuit Slow Response (Bank 1 Sensor 2) • HO2S-2 and/or its circuit
Shifting time of HO2S signal circuit voltage from 0.5 V to 0.3 V is • ECM
longer than specified time at fuel cut.
(3 D/C detection logic)

Circuit Diagram

4
+B
1
3 A2
RED C01-53
BLU A3
GRN C01-37
LT GRN C01-32
PPL C01-71
A4
A1
2
3 B2
BRN C01-52
B3
YEL C01-51
BEG C01-42
RED C01-76
B4
B1

[A] C01 E01

10 9 8 7 6 5 4 3 2 1
65 64 63 62 61 20 19 18 17 16 15 14 13 12 11
70 69 68 67 66 30 29 28 27 26 25 24 23 22 21
75 74 73 72 71 40 39 38 37 36 35 34 33 32 31
80 79 78 77 76 50 49 48 47 46 45 44 43 42 41
60 59 58 57 56 55 54 53 52 51
[a]
9 8 7 6 5 4 3 2 1
57 56 55 18 17 16 15 14 13 12 11 10
60 59 58 27 26 25 24 23 22 21 20 19
63 62 61 36 35 34 33 32 31 30 29 28
66 65 64 45 44 43 42 41 40 39 38 37
54 53 52 51 50 49 48 47 46

IJCA0A111012-02

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

DTC Confirmation Procedure

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

NOTE
• Limit the driving permissible in road conditions and regulations.
• Check that the following DTCs are not detected in this “DTC Confirmation Procedure”.
– HO2S-1 (P0037 and P0038)

1) Warm up engine to normal operating temperature.

 Engine General Information and Diagnosis: K10B 1A-63

2) Drive vehicle at 60 to 80 km/h (37 to 50 mile/h) constantly for 10 min. or more. (Keep throttle valve opening
constant in this step)
3) Release accelerator pedal, and let vehicle coast under effect of engine braking to produce fuel cut condition.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K10B
(Page 1A-20).
2 DTC check Go to troubleshooting Go to Step 3.
1) Check DTC. (Page 1A-22) for applicable DTC.

Is there any DTC(s) other than P0139?

3 HO2S-2 signal and ground circuit check Go to Step 4. Repair or replace
1) Check “B2” and “B3” circuits according to Step 3 under defective parts.
“DTC P0136”: K10B (Page 1A-60).

Is check result OK?

4 DTC recheck Replace ECM and End.
1) Replace HO2S-2. (Page 1C-11) recheck DTC. (Page
1C-3)
2) Clear DTC. (Page 1A-23)
3) Set ignition “OFF”.
4) Perform “DTC Confirmation Procedure” and check DTC.
(Page 1A-22)

Is DTC P0139 still detected?

DTC P0171 / P0172

AENJCA0A1114023
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0171: System Too Lean (Bank 1) • Fuel system
Total fuel trim (short term fuel trim + long term fuel trim) is • Air intake system
higher than specified value for 10 sec.
• Exhaust system
(3 D/C detection logic)
P0172: System Too Rich (Bank 1) • HO2S-1 and/or its circuit
Total fuel trim (short term fuel trim + long term fuel trim) is • Emission control system
lower than specified value for 10 sec. • ECM
(3 D/C detection logic)
1A-64 Engine General Information and Diagnosis: K10B

Circuit Diagram

4
+B
1
3 A2
RED C01-53
BLU A3
GRN C01-37
LT GRN C01-32
PPL C01-71
A4
A1
2
3 B2
BRN C01-52
B3
YEL C01-51
BEG C01-42
RED C01-76
B4
B1

[A] C01 E01

10 9 8 7 6 5 4 3 2 1
65 64 63 62 61 20 19 18 17 16 15 14 13 12 11
70 69 68 67 66 30 29 28 27 26 25 24 23 22 21
75 74 73 72 71 40 39 38 37 36 35 34 33 32 31
80 79 78 77 76 50 49 48 47 46 45 44 43 42 41
60 59 58 57 56 55 54 53 52 51
[a]
9 8 7 6 5 4 3 2 1
57 56 55 18 17 16 15 14 13 12 11 10
60 59 58 27 26 25 24 23 22 21 20 19
63 62 61 36 35 34 33 32 31 30 29 28
66 65 64 45 44 43 42 41 40 39 38 37
54 53 52 51 50 49 48 47 46

IJCA0A111012-02

[A]: ECM connector (View: [a]) B1: HO2S-2 heater power supply circuit 2. HO2S-2
A1: HO2S-1 heater power supply circuit B2: HO2S-2 signal circuit 3. Shield wire
A2: HO2S-1 signal circuit B3: HO2S-2 ground circuit 4. ECM
A3: HO2S-1 ground circuit B4: HO2S-2 heater drive circuit
A4: HO2S-1 heater drive circuit 1. HO2S-1
 Engine General Information and Diagnosis: K10B 1A-65

DTC Confirmation Procedure

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

NOTE
• Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.
• Limit the driving permissible in road conditions and regulations.
• Check that the following conditions are met in this “DTC Confirmation Procedure”.
– A/F feedback (closed loop) control is activated.
– DTC P0107, P0108, P0112, P0113, P0117 and P0118 are not detected.

1) Warm up engine to normal operating temperature.

2) Drive vehicle at 60 to 80 km/h (37 to 50 mile/h) constantly for 5 min. or more. (Keep throttle valve opening constant
in this step.)

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”: K10B
(Page 1A-20).
2 DTC check Go to troubleshooting Go to Step 3.
for applicable DTC.
Is there any DTC(s) other than P0171 and P0172?
3 Fuel system and emission system check Go to Step 4. Repair or replace
1) Check the following points related to fuel and emission defective parts.
control systems.
• Fuel pressure: (Page 1G-14)
• Fuel injector circuit: (Page 1G-7)
• Fuel injector: (Page 1G-24)
• MAP sensor: (Page 1C-9)
• EVAP canister purge valve: (Page 1B-4)
• PCV valve: (Page 1B-7)

Is check result OK?

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

Is check result OK?

5 HO2S-1 signal circuit and ground circuit check Go to Step 6. Repair or replace
1) Check “A2” and “A3” circuits according to Step 5 – 6 defective wire harness.
under “DTC P0130 / P0133”: K10B (Page 1A-57).

Is check result OK?

1A-66 Engine General Information and Diagnosis: K10B

Step Action Yes No

6 DTC recheck Replace ECM and End.
1) Replace HO2S-1. (Page 1C-11) recheck DTC. (Page
1C-3)
2) Clear DTC. (Page 1A-23)
3) Set ignition “OFF”.
4) Perform DTC confirmation procedure and check DTC.

Is DTC P0171 or P0172 still detected?

DTC P0201 / P0202 / P0203

AENJCA0A1114024
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0201: Injector Circuit / Open – Cylinder1 • Fuel injector and/or its circuit
Injector driver No.1 and/or its circuit malfunction (open, • ECM
short to power supply or short to ground) is detected.
(3 D/C detection logic)
P0202: Injector Circuit / Open – Cylinder2
Injector driver No.2 and/or its circuit malfunction (open,
short to power supply or short to ground) is detected.
(3 D/C detection logic)
P0203: Injector Circuit / Open – Cylinder3
Injector driver No.3 and/or its circuit malfunction (open,
short to power supply or short to ground) is detected.
(3 D/C detection logic)

Circuit Diagram

+B
4 A2 A1
1
C01-77 PNK
B2 B1
2
C01-78 WHT
C2 C1
3
C01-79 RED

[A] C01 E01

10 9 8 7 6 5 4 3 2 1
65 64 63 62 61 20 19 18 17 16 15 14 13 12 11
70 69 68 67 66 30 29 28 27 26 25 24 23 22 21
75 74 73 72 71 40 39 38 37 36 35 34 33 32 31
80 79 78 77 76 50 49 48 47 46 45 44 43 42 41
60 59 58 57 56 55 54 53 52 51
[a]
9 8 7 6 5 4 3 2 1
57 56 55 18 17 16 15 14 13 12 11 10
60 59 58 27 26 25 24 23 22 21 20 19
63 62 61 36 35 34 33 32 31 30 29 28
66 65 64 45 44 43 42 41 40 39 38 37
54 53 52 51 50 49 48 47 46

IJCA0A111017-02

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

DTC Confirmation Procedure

1) Run engine at idle speed for 1 min.
 Engine General Information and Diagnosis: K10B 1A-67

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”: K10B
(Page 1A-20).
2 Fuel injector power supply circuit check Go to Step 3. Repair or replace
1) With ignition “OFF”, disconnect connector(s) from fuel defective wire harness.
injector related to DTC(s).
2) Check for proper terminal connection to fuel injector
connector(s).
3) If connections are OK, set ignition “ON”.
4) Check that voltage between “A1”, “B1” or “C1” and
ground is battery voltage.

Is check result OK?

3 Fuel injector drive circuit check Go to Step 4. Repair or replace
1) With ignition “OFF”, disconnect “C01” and “E01” defective wire harness.
connectors from ECM.
2) Check for proper terminal connection to “C01” and “E01”
connectors.
3) If connections are OK, check the following points.
• Resistance of “A2”, “B2” or “C2” circuit: less than 1 Ω
• Resistance between each of “A2”, “B2” and “C2”
circuit and ground: infinity
• Resistance between “A1” circuit terminal and “A2”
circuit terminal at fuel injector connector: infinity
• Resistance between “B1” circuit terminal and “B2”
circuit terminal at fuel injector connector: infinity
• Resistance between “C1” circuit terminal and “C2”
circuit terminal at fuel injector connector: infinity
• Voltage of “A2”, “B2” or “C2” circuit: 0 to 1 V (When
ignition is “ON”)

Is check result OK?

4 Fuel injector check Replace ECM and Replace fuel injector(s)
1) Check fuel injector(s) related to DTC(s). (Page 1G-24) recheck DTC. (Page related to DTC(s).
1C-3) (Page 1G-22)
Is check result OK?
1A-68 Engine General Information and Diagnosis: K10B

DTC P0222 / P0223

AENJCA0A1114025
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0222: Throttle / Pedal Position Sensor / Switch “B” Circuit Low • TP sensor (sub) and/or its circuit
Output voltage of TP sensor (sub) signal circuit is lower than 0.24 V. • ECM
(1 D/C detection logic)
P0223: Throttle / Pedal Position Sensor / Switch “B” Circuit High
Output voltage of TP sensor (sub) signal circuit is higher than 4.74 V.
(1 D/C detection logic)

Circuit Diagram

5
1
A1
C01-70 LT GRN
A2
C01-75 BRN 4
B1
C01-56 RED B2 2
C01-54 GRN
B3 3
C01-55 WHT
C01-45 BLK
B4
C01-44 GRY

[A] C01 E01

10 9 8 7 6 5 4 3 2 1
65 64 63 62 61 20 19 18 17 16 15 14 13 12 11
70 69 68 67 66 30 29 28 27 26 25 24 23 22 21
75 74 73 72 71 40 39 38 37 36 35 34 33 32 31
80 79 78 77 76 50 49 48 47 46 45 44 43 42 41
60 59 58 57 56 55 54 53 52 51
[a]
9 8 7 6 5 4 3 2 1
57 56 55 18 17 16 15 14 13 12 11 10
60 59 58 27 26 25 24 23 22 21 20 19
63 62 61 36 35 34 33 32 31 30 29 28
66 65 64 45 44 43 42 41 40 39 38 37
54 53 52 51 50 49 48 47 46

IJCA0A111016-02

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

DTC Confirmation Procedure

1) Run engine at idle speed for 1 min.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K10B
(Page 1A-20).
2 TP sensor power supply circuit check Go to Step 4. Go to Step 3.
1) When ignition is “OFF”, disconnect electric throttle body
assembly connector.
2) Check for proper terminal connection to electric throttle
body assembly connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between “B1” and “B4” is approx. 5 V.

Is check result OK?

 Engine General Information and Diagnosis: K10B 1A-69

Step Action Yes No

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

Is check result OK?

5 TP sensor check Replace ECM and Replace electric throttle
1) Check TP sensor referring to “TP Sensor Performance recheck DTC. (Page body assembly.
Check” under “Electric Throttle Body Assembly On- 1C-3)
Vehicle Inspection”: K10B and Bi-Fuel CNG in Section
1C (Page 1C-5).

Is check result OK?

1A-70 Engine General Information and Diagnosis: K10B

DTC P0300 / P0301 / P0302 / P0303

AENJCA0A1114026
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0300: Random / Multiple Cylinder Misfire Detected • Exhaust system
Any of the following conditions is met. • Air intake system
• Misfire, which causes catalyst to overheat during 200 engine revolutions, • Ignition system
is detected at 2 or more cylinders. (MIL blinks as long as misfire lasts.)
• Fuel system
• Misfire, which affects exhaust emission adversely during 1,000 engine
• Engine compression
revolutions, is detected at 2 or more cylinders.
(3 D/C detection logic) • Valve clearance
• Valve timing
• ECM
P0301: Cylinder 1 Misfire Detected • Ignition system
P0302: Cylinder 2 Misfire Detected • Engine compression
P0303: Cylinder 3 Misfire Detected
• Valve clearance
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. (MIL blinks as long as misfire lasts.) • ECM
• Misfire, which affects exhaust emission adversely during 1,000 engine
revolutions, is detected at specific cylinder.
(3 D/C detection logic)

DTC Confirmation Procedure

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

NOTE
• Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.
• Limit the driving permissible in road conditions and regulations.
• Check that the following condition is met in this “DTC Confirmation Procedure”.
– DTC P0107, P0108, P0335 and P0340 are not detected.

1) Warm up engine to normal operating temperature.

2) Drive vehicle at 60 to 80 km/h (37 to 50 mile/h) constantly for 5 min. or more. (Keep throttle valve opening constant
in this step.)
 Engine General Information and Diagnosis: K10B 1A-71

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”: K10B
(Page 1A-20).
2 Fuel level check Add fuel and recheck Go to Step 3.
1) Check fuel level by fuel level meter. DTC.

Does it indicate “E” level (empty)?

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

Is check result OK?

5 Ignition system check Go to Step 6. Repair or replace
1) Check ignition system. (Page 1H-4) defective 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: (Page 1G-14)
• Fuel injector circuit: (Page 1G-7)
• Fuel injector: (Page 1G-24)

Is check result OK?

7 Engine mechanical system check Check ECM power Repair or replace
1) Check the following points which can be cause of rough supply and ground defective parts.
idling or poor performance. circuits. (Page 1A-
113)
• Engine compression: (Page 1D-1)
• Valve clearance: (Page 1D-3) If circuit is OK, replace
ECM and recheck DTC.
• Valve timing: (Page 1D-36) (Page 1C-3)
Is check result OK?
1A-72 Engine General Information and Diagnosis: K10B

DTC P0327 / P0328

AENJCA0A1114027
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0327: Knock Sensor 1 Circuit Low (Bank 1 or Single Sensor) • Knock sensor and/or its circuit
Knock sensor signal is lower than 1.23 V for 5 sec. with engine running. • ECM
(3 D/C detection logic)
P0328: Knock Sensor 1 Circuit High (Bank 1 or Single Sensor)
Knock sensor signal is higher than 4.9 V for 5 sec. with engine running.
(3 D/C detection logic)

Circuit Diagram

2
1 A1
WHT C01-33
BLU C01-43
B1

[A] C01 E01

10 9 8 7 6 5 4 3 2 1
65 64 63 62 61 20 19 18 17 16 15 14 13 12 11
70 69 68 67 66 30 29 28 27 26 25 24 23 22 21
75 74 73 72 71 40 39 38 37 36 35 34 33 32 31
80 79 78 77 76 50 49 48 47 46 45 44 43 42 41
60 59 58 57 56 55 54 53 52 51
[a]
9 8 7 6 5 4 3 2 1
57 56 55 18 17 16 15 14 13 12 11 10
60 59 58 27 26 25 24 23 22 21 20 19
63 62 61 36 35 34 33 32 31 30 29 28
66 65 64 45 44 43 42 41 40 39 38 37
54 53 52 51 50 49 48 47 46

IJCA0A111018-02

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

DTC Confirmation Procedure

1) Warm up engine to normal operating temperature.
2) Run engine at idle speed for 1 min.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K10B
(Page 1A-20).
2 Knock sensor signal circuit and ground circuit check Go to Step 3. Repair or replace
1) When ignition is “OFF”, disconnect “C01” and “E01” defective wire harness.
connectors of ECM and knock sensor connector.
2) Check for proper terminal connection to “C01” and “E01”
connectors and knock sensor connector.
3) If connections are OK, check the following points.
• Resistance of “A1” and “B1” circuits: less than 1 Ω
• Resistance between each of “A1” and “B1” circuits
and ground: infinity
• Resistance between “A1” circuit terminal and “B1”
circuit terminal at knock sensor connector: infinity
• Voltage of “A1” and “B1” circuits: 0 to 1 V (When
ignition is “ON”)

Is check result OK?

 Engine General Information and Diagnosis: K10B 1A-73

Step Action Yes No

3 Knock sensor check Go to Step 4. Replace knock sensor.
1) Check knock sensor. (Page 1C-14)

Is check result OK?

4 Troubleshooting of other DTC(s) at the same time Go to troubleshooting Replace ECM and
for applicable DTC. recheck DTC. (Page
Is other DTC(s) detected together? 1C-3)

DTC P0335 / P0336

AENJCA0A1114028
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0335: Crankshaft Position Sensor “A” Circuit • CKP sensor and/or its circuit
Even if CMP sensor signal is input, CKP sensor signal is not input for more • Sensor plate
than 3 sec.
• ECM
(1 D/C detection logic)
P0336: Crankshaft Position Sensor “A” Circuit Range / Performance
Output signal pulse of CKP sensor is out of specified pattern more than
specified times.
(1 D/C detection logic)

Circuit Diagram

+B 3
A1 A2
BLU
1
PPL C01-58

A3
B1 B2
2
PNK C01-60
GRY
B3

[A] C01 E01

10 9 8 7 6 5 4 3 2 1
65 64 63 62 61 20 19 18 17 16 15 14 13 12 11
70 69 68 67 66 30 29 28 27 26 25 24 23 22 21
75 74 73 72 71 40 39 38 37 36 35 34 33 32 31
80 79 78 77 76 50 49 48 47 46 45 44 43 42 41
60 59 58 57 56 55 54 53 52 51
[a]
9 8 7 6 5 4 3 2 1
57 56 55 18 17 16 15 14 13 12 11 10
60 59 58 27 26 25 24 23 22 21 20 19
63 62 61 36 35 34 33 32 31 30 29 28
66 65 64 45 44 43 42 41 40 39 38 37
54 53 52 51 50 49 48 47 46

IJCA0A111019-02

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

DTC Confirmation Procedure

NOTE
• Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.
• Check that the following condition is met in this “DTC Confirmation Procedure”.
– P0335:
DTC P0616 and P0617 are not detected.

1) Run engine at idle speed for 1 min.

1A-74 Engine General Information and Diagnosis: K10B

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”: K10B
(Page 1A-20).
2 CKP sensor power supply circuit check Go to Step 4. Go to Step 3.
1) When ignition is “OFF”, disconnect CKP sensor
connector.
2) Check for proper terminal connection to CKP sensor
connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between “B1” and “B3” is battery
voltage.

Is check result OK?

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

Is check result OK?

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

Is check result OK?

5 CKP sensor and sensor plate check Replace ECM and Repair or replace
1) Check CKP sensor and sensor plate. recheck DTC. (Page defective parts.
1C-3)
• CKP sensor: (Page 1C-13)
• Sensor plate: (Page 1D-68)

Is check result OK?

 Engine General Information and Diagnosis: K10B 1A-75

DTC P0340 / P0341

AENJCA0A1114029
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0340: Camshaft Position Sensor “A” Circuit (Bank 1 • CMP sensor and/or its circuit
or Single Sensor) • Signal rotor
Even if CKP sensor signal is input, CMP sensor signal is
• ECM
not input for more than 3 sec.
(3 D/C detection logic)
P0341: Camshaft Position Sensor “A” Circuit Range /
Performance (Bank 1 or Single Sensor)
Output signal pulse of CMP sensor is out of specified
pattern more than specified times.
(3 D/C detection logic)

Circuit Diagram

+B 3
A1 A2
BLU
1
PPL C01-58

A3
B1 B2
2
PNK C01-60
GRY
B3

[A] C01 E01

10 9 8 7 6 5 4 3 2 1
65 64 63 62 61 20 19 18 17 16 15 14 13 12 11
70 69 68 67 66 30 29 28 27 26 25 24 23 22 21
75 74 73 72 71 40 39 38 37 36 35 34 33 32 31
80 79 78 77 76 50 49 48 47 46 45 44 43 42 41
60 59 58 57 56 55 54 53 52 51
[a]
9 8 7 6 5 4 3 2 1
57 56 55 18 17 16 15 14 13 12 11 10
60 59 58 27 26 25 24 23 22 21 20 19
63 62 61 36 35 34 33 32 31 30 29 28
66 65 64 45 44 43 42 41 40 39 38 37
54 53 52 51 50 49 48 47 46

IJCA0A111019-02

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

DTC Confirmation Procedure

NOTE
• Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.
• Check that the following condition is met in this “DTC Confirmation Procedure”.
– P0340:
DTC P0335 is not detected.

1) Run engine at idle speed for 1 min.

1A-76 Engine General Information and Diagnosis: K10B

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”: K10B
(Page 1A-20).
2 CMP sensor power supply circuit check Go to Step 4. Go to Step 3.
1) When ignition is “OFF”, disconnect CMP sensor
connector.
2) Check for proper terminal connection to CMP sensor
connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between “A1” and “A3” is battery
voltage.

Is check result OK?

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

Is check result OK?

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

Is check result OK?

5 CMP sensor and signal rotor check Replace ECM and Repair or replace
1) Check CMP sensor and signal rotor. recheck DTC. (Page defective parts.
1C-3)
• CMP sensor: (Page 1C-12)
• Signal rotor: (Page 1D-19)

Is check result OK?

 Engine General Information and Diagnosis: K10B 1A-77

DTC P0420
AENJCA0A1114030
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0420: Catalyst System Efficiency Below Threshold (Bank 1) • Exhaust system
Delay of shifting cycle between rich and lean of HO2S-2 signal • HO2S-1 and/or its circuit
compared with shifting cycle between rich and lean of fuel system
• HO2S-2 and/or its circuit
feedback is less than specified time while vehicle is running with
constant speed after warmed up. • TWC
(3 D/C detection logic) • ECM

Circuit Diagram

2 RED C01-53
GRN C01-37
3

BRN C01-52
YEL C01-51

[A] C01 E01

10 9 8 7 6 5 4 3 2 1
65 64 63 62 61 20 19 18 17 16 15 14 13 12 11
70 69 68 67 66 30 29 28 27 26 25 24 23 22 21
75 74 73 72 71 40 39 38 37 36 35 34 33 32 31
80 79 78 77 76 50 49 48 47 46 45 44 43 42 41
60 59 58 57 56 55 54 53 52 51
[a]
9 8 7 6 5 4 3 2 1
57 56 55 18 17 16 15 14 13 12 11 10
60 59 58 27 26 25 24 23 22 21 20 19
63 62 61 36 35 34 33 32 31 30 29 28
66 65 64 45 44 43 42 41 40 39 38 37
54 53 52 51 50 49 48 47 46

IJCA0A111020-02

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

1. HO2S-1 3. HO2S-2
1A-78 Engine General Information and Diagnosis: K10B

DTC Confirmation Procedure

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

NOTE
• Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.
• Limit the driving permissible in road conditions and regulations.
• Check that the following DTCs are not detected in this “DTC Confirmation Procedure”.
– HO2S-2 (P0136)
– IAT sensor (P0112 / P0113)
– MAP sensor (P0107 / P0108)
– ECT sensor (P0117 / P0118)
– Wheel speed sensor (P0500)
– Misfire (P0300 / P0301 / P0302 / P0303)

1) Warm up engine to normal operating temperature.

2) Drive vehicle at 60 to 80 km/h (37 to 50 mile/h) constantly for 5 min. or more.
3) Check whether O2 sensor readiness / monitoring test has completed or not using scan tool. If O2 sensor
readiness / monitoring test has not completed, check vehicle conditions (environmental) and repeat Step 2).
 Engine General Information and Diagnosis: K10B 1A-79

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”: K10B
(Page 1A-20).
2 DTC check Go to troubleshooting Go to Step 3.
1) Check DTC. for applicable DTC.

Is there DTC(s) detected other than P0420?

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

Is check result OK?

4 HO2S-2 signal circuit and ground circuit check Go to Step 5. Repair or replace
1) Check HO2S-2 signal and ground circuits according to defective wire harness.
Step 3 under “DTC P0136”: K10B (Page 1A-60).

Is check result OK?

5 HO2S-1 signal circuit and ground circuit check Go to Step 6. Repair or replace
1) Check HO2S-1 signal and ground circuit according to defective wire harness.
Step 5 and 6 under “DTC P0130 / P0133”: K10B (Page
1A-57).

Is check result OK?

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

Is DTC P0420 still detected?

7 DTC recheck Go to Step 8. End.
1) Replace HO2S-2. (Page 1C-11)
2) Clear DTC. (Page 1A-23)
3) Set ignition “OFF”.
4) Perform DTC confirmation procedure and check DTC.

Is DTC P0420 still detected?

8 DTC recheck Replace ECM and End.
1) Replace HO2S-1. (Page 1C-11) recheck DTC. (Page
1C-3)
2) Clear DTC. (Page 1A-23)
3) Set ignition “OFF”.
4) Perform DTC confirmation procedure and check DTC.

Is DTC P0420 still detected?

1A-80 Engine General Information and Diagnosis: K10B

DTC P0443
AENJCA0A1114031
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0443: Evaporative Emission System Purge Control Valve Circuit • EVAP canister purge valve and/or its
Measured signal duty of EVAP canister purge valve control circuit is circuit
different from control command duty for 5 sec. (Circuit open or short) • ECM
(3 D/C detection logic)

Circuit Diagram

3
B1 A1

1
C01-40 RED BLU 2

[A] C01 E01

10 9 8 7 6 5 4 3 2 1
65 64 63 62 61 20 19 18 17 16 15 14 13 12 11
70 69 68 67 66 30 29 28 27 26 25 24 23 22 21
75 74 73 72 71 40 39 38 37 36 35 34 33 32 31
80 79 78 77 76 50 49 48 47 46 45 44 43 42 41
60 59 58 57 56 55 54 53 52 51
[a]
9 8 7 6 5 4 3 2 1
57 56 55 18 17 16 15 14 13 12 11 10
60 59 58 27 26 25 24 23 22 21 20 19
63 62 61 36 35 34 33 32 31 30 29 28
66 65 64 45 44 43 42 41 40 39 38 37
54 53 52 51 50 49 48 47 46

IJCA0A111021-02

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

DTC Confirmation Procedure

NOTE
• Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.
• Check that the following condition is met in this “DTC Confirmation Procedure”.
– Battery voltage > 10.7 V

1) Run engine at idle speed for 1 min.

 Engine General Information and Diagnosis: K10B 1A-81

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”: K10B
(Page 1A-20).
2 EVAP canister purge valve power supply circuit check Go to Step 3. Repair or replace
1) When ignition is “OFF”, disconnect EVAP canister purge defective wire harness.
valve connector.
2) Check for proper terminal connection to EVAP canister
purge valve connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between “A1” and ground is battery
voltage.

Is check result OK?

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

Is check result OK?

4 EVAP canister purge valve check Replace ECM and Replace EVAP canister
1) Check EVAP canister purge valve for resistance. recheck DTC. (Page purge valve.
(Page 1B-4) 1C-3)

Is check result OK?

1A-82 Engine General Information and Diagnosis: K10B

DTC P0480
AENJCA0A1114032
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0480: Fan 1 Control Circuit • Radiator cooling fan relay and/or its circuit
Measured voltage of radiator cooling fan relay output is • ECM
different from its command signal for 5 sec.
(3 D/C detection logic but MIL does not light up)

Circuit Diagram

4
A1 A2

1
5 BLU LT GRN E01-22
6 GRY BLU 2 BLK
3

[A] C01 E01

10 9 8 7 6 5 4 3 2 1
65 64 63 62 61 20 19 18 17 16 15 14 13 12 11
70 69 68 67 66 30 29 28 27 26 25 24 23 22 21
75 74 73 72 71 40 39 38 37 36 35 34 33 32 31
80 79 78 77 76 50 49 48 47 46 45 44 43 42 41
60 59 58 57 56 55 54 53 52 51
[a]
9 8 7 6 5 4 3 2 1
57 56 55 18 17 16 15 14 13 12 11 10
60 59 58 27 26 25 24 23 22 21 20 19
63 62 61 36 35 34 33 32 31 30 29 28
66 65 64 45 44 43 42 41 40 39 38 37
54 53 52 51 50 49 48 47 46

IJCA0A111022-02

[A]: ECM connector (View: [a]) 1. Radiator cooling fan relay 4. ECM
A1: Radiator cooling fan relay power supply circuit (coil side) 2. Radiator cooling fan 5. To main relay
A2: Radiator cooling fan relay drive circuit 3. “RDTR” fuse 6. To main fuse box

DTC Confirmation Procedure

NOTE
• Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.
• Check that the following condition is met in this “DTC Confirmation Procedure”.
– 10 V < Battery voltage < 16 V

1) Connect SUZUKI scan tool to DLC.

2) Display “ECT” of “Data List” mode on SUZUKI scan tool.
3) Keep engine at idle speed until engine coolant temperature reaches 97 °C (207 °F) or more.
4) Stop engine.
5) Repeat Step 2) – 4) 2 times.
 Engine General Information and Diagnosis: K10B 1A-83

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”: K10B
(Page 1A-20).
2 Radiator cooling fan relay power supply circuit (coil Go to Step 3. Repair or replace
side) check defective wire harness.
1) When ignition is “OFF”, remove radiator cooling fan
relay.
2) Check for proper terminal connection to radiator cooling
fan relay connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between “A1” and ground is battery
voltage.

Is check result OK?

3 Radiator cooling fan relay check Go to Step 4. Replace radiator cooling
1) Check radiator cooling fan relay. (Page 1F-13) fan relay.

Is check result OK?

4 Radiator cooling fan relay drive circuit check Replace ECM and Repair or replace
1) When ignition is “OFF”, disconnect “C01” and “E01” recheck DTC. (Page defective wire harness.
connectors from ECM. 1C-3)
2) Check for proper terminal connection to “C01” and “E01”
connectors.
3) If connections are OK, check the following points.
• Resistance of “A2” circuit: less than 1 Ω
• Resistance between “A2” circuit and ground: infinity
• Resistance between “A2” circuit terminal and other
terminal at radiator cooling fan relay connector: infinity
• Voltage of “A2” circuit: 0 to 1 V (When ignition is “ON”)

Is check result OK?

1A-84 Engine General Information and Diagnosis: K10B

DTC P0500
AENJCA0A1114033
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0500: Vehicle Speed Sensor “A” • CAN communication line
Vehicle speed signal is not input, while fuel is cut at deceleration for • Wheel speed sensor and/or its circuit
5 sec. continuously with engine speed at 3,600 rpm or less.
• ABS control module
(3 D/C detection logic)
• ECM

Circuit Diagram

2 1

4 RED E01-9
7 7
WHT E01-18
5

[A] C01 E01

10 9 8 7 6 5 4 3 2 1
65 64 63 62 61 20 19 18 17 16 15 14 13 12 11
70 69 68 67 66 30 29 28 27 26 25 24 23 22 21
75 74 73 72 71 40 39 38 37 36 35 34 33 32 31
80 79 78 77 76 50 49 48 47 46 45 44 43 42 41
60 59 58 57 56 55 54 53 52 51
[a]
9 8 7 6 5 4 3 2 1
57 56 55 18 17 16 15 14 13 12 11 10
60 59 58 27 26 25 24 23 22 21 20 19
63 62 61 36 35 34 33 32 31 30 29 28
66 65 64 45 44 43 42 41 40 39 38 37
54 53 52 51 50 49 48 47 46

IJCA0A111023-02

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

DTC Confirmation Procedure

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

NOTE
Limit the driving permissible in road conditions and regulations.

1) Warm up engine to normal operating temperature.

2) Drive vehicle at 3,600 rpm (engine speed) for 5 sec. or more.
3) Release accelerator pedal, and keep vehicle coasting for 10 sec. with engine brakes applied (fuel cut condition).
 Engine General Information and Diagnosis: K10B 1A-85

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”: K10B
(Page 1A-20).
2 DTC check Go to troubleshooting Go to Step 3.
for CAN-DTC. (Page
Is there any CAN-DTC detected? 10H-7)
3 DTC check Go to troubleshooting Replace ECM and
1) Check ABS / ESP® control module for DTC. for applicable DTC. recheck DTC. (Page
1C-3)
Is there any DTC(s) detected?

DTC P0532 / P0533

AENJCA0A1114035
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0532: A/C Refrigerant Pressure Sensor “A” Circuit Low • A/C refrigerant pressure sensor and/or its circuit
Output voltage of A/C refrigerant pressure sensor signal circuit • ECM
is lower than 0.15 V for 5 sec.
(3 D/C detection logic but MIL does not light up)
P0533: A/C Refrigerant Pressure Sensor “A” Circuit High
Output voltage of A/C refrigerant pressure sensor signal circuit
is higher than 4.93 V for 5 sec.
(3 D/C detection logic but MIL does not light up)

Circuit Diagram

2
A1
LT GRN E01-37
1 A2
BEG E01-54
BLK E01-43
A3

[A] C01 E01

10 9 8 7 6 5 4 3 2 1
65 64 63 62 61 20 19 18 17 16 15 14 13 12 11
70 69 68 67 66 30 29 28 27 26 25 24 23 22 21
75 74 73 72 71 40 39 38 37 36 35 34 33 32 31
80 79 78 77 76 50 49 48 47 46 45 44 43 42 41
60 59 58 57 56 55 54 53 52 51
[a]
9 8 7 6 5 4 3 2 1
57 56 55 18 17 16 15 14 13 12 11 10
60 59 58 27 26 25 24 23 22 21 20 19
63 62 61 36 35 34 33 32 31 30 29 28
66 65 64 45 44 43 42 41 40 39 38 37
54 53 52 51 50 49 48 47 46

IJCA0A111024-02

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

DTC Confirmation Procedure

1) Start engine and operate A/C system for 10 sec. or more.
1A-86 Engine General Information and Diagnosis: K10B

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”: K10B
(Page 1A-20).
2 A/C refrigerant pressure sensor power supply circuit Go to Step 4. Go to Step 3.
check
1) With ignition “OFF”, disconnect A/C refrigerant pressure
sensor connector.
2) Check for proper terminal connection to A/C refrigerant
pressure sensor connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between “A1” and “A3” is approx. 5 V.

Is check result OK?

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

Is check result OK?

5 A/C refrigerant pressure sensor check Replace ECM and Replace A/C refrigerant
1) Check A/C refrigerant pressure sensor. (Page 7B-47) recheck DTC. (Page pressure sensor.
1C-3) (Page 7B-48)
Is check result OK?
 Engine General Information and Diagnosis: K10B 1A-87

DTC P0602
AENJCA0A1114038
DTC Detecting Condition and Trouble Area

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

DTC detecting condition Trouble area

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

DTC Confirmation Procedure

1) Set ignition “ON” for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 DTC recheck Go to Step 2. Check for intermittent
1) Clear DTC. (Page 1A-23) trouble. (Page 00-13)
2) Set ignition “OFF”.
3) Perform DTC confirmation procedure and check DTC.

Is DTC P0602 still detected?

2 ECM reprogramming check Execute reprogramming Go to Step 3.
of ECM correctly once
Was reprogramming of ECM executed? again.
3 ECM power supply and ground circuit check Replace ECM and Repair or replace
1) Check ECM power supply and ground circuits. (Page recheck DTC. (Page defective wire harness.
1A-113) 1C-3)

Is check result OK?

DTC P0607
AENJCA0A1114037
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0607: Control Module Performance • ECM power supply circuit and/or ground circuit
ECM internal failure related to throttle control system. • ECM
(1 D/C detection logic)

DTC Confirmation Procedure

1) Set ignition “ON”.
2) Start engine, if possible.

DTC Troubleshooting
Step Action Yes No
1 DTC recheck Go to Step 2. Check for intermittent
1) Clear DTC. (Page 1A-23) trouble. (Page 00-13)
2) Set ignition “OFF”.
3) Perform DTC confirmation procedure and check DTC.

Is DTC P0607 still detected?

2 ECM power supply and ground circuit check Replace ECM and Repair defective wire
1) Check ECM power supply and ground circuits. (Page recheck DTC. (Page harness.
1A-113) 1C-3)

Is check result OK?

1A-88 Engine General Information and Diagnosis: K10B

DTC P0616 / P0617

AENJCA0A1114039
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0616: Starter Relay Circuit Low • Starting motor control relay and/or its circuit
No starter switch ON signal is input even if engine has been started. • ECM
(3 D/C detection logic)
P0617: Starter Relay Circuit High
Starter switch ON signal is input for more than 180 sec. after engine
has been started.
(3 D/C detection logic)

Circuit Diagram

8
[A] B2
E01-11 GRN B1
3 2 1

[B]
4 5

E01-24 LT BLU
6

7
A1

[C] C01 E01

10 9 8 7 6 5 4 3 2 1
65 64 63 62 61 20 19 18 17 16 15 14 13 12 11
70 69 68 67 66 30 29 28 27 26 25 24 23 22 21
75 74 73 72 71 40 39 38 37 36 35 34 33 32 31
80 79 78 77 76 50 49 48 47 46 45 44 43 42 41
60 59 58 57 56 55 54 53 52 51
[a]
9 8 7 6 5 4 3 2 1
57 56 55 18 17 16 15 14 13 12 11 10
60 59 58 27 26 25 24 23 22 21 20 19
63 62 61 36 35 34 33 32 31 30 29 28
66 65 64 45 44 43 42 41 40 39 38 37
54 53 52 51 50 49 48 47 46

IJCA0A111025-04

[A]: M/T model B2: Starting motor control relay drive circuit 5. “ST” fuse
[B]: Auto gear shift model 1. Ignition switch 6. “ST SIG” fuse (in relay box)
[C]: ECM connector (View: [a]) 2. “ST SIG” fuse (in fuse box) (without keyless 7. Starting motor
entry system)
A1: Starting motor control relay signal circuit 3. Starting motor control relay 8. ECM
B1: Starting motor control relay power supply 4. TCM
circuit (coil side)

DTC Confirmation Procedure

1) Run engine at idle speed for 3 min.
 Engine General Information and Diagnosis: K10B 1A-89

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”: K10B
(Page 1A-20).
2 Starting motor control relay check Go to Step 3. Replace starting motor
1) With ignition “OFF”, remove starting motor control relay. control relay.
2) Check for proper terminal connection to starting motor
control relay connector.
3) If connections are OK, check starting motor control relay.
(Page 1I-5)

Is check result OK?

3 Starting motor control relay signal circuit check Replace ECM and Repair or replace
1) Disconnect “C01” and “E01” connectors from ECM. recheck DTC. (Page defective wire harness.
1C-3)
2) Check for proper terminal connection to “C01” and “E01”
connectors.
3) If connections are OK, check the following points.
• Resistance of “A1” circuit: less than 1 Ω
• Resistance between “A1” circuit and ground: infinity
• Resistance between “A1” circuit terminal and other
terminal at starting motor control relay connector:
infinity
• Voltage of “A1” circuit: 0 to 1 V (When ignition is “ON”)

Is check result OK?

1A-90 Engine General Information and Diagnosis: K10B

DTC P1520 / P1521

AENJCA0A1114059
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P1520: ECM Starter protection circuit on error • Starting motor control relay and/or its circuit
Starting motor control relay drive circuit is shorted to ground. • ECM
(1 D/C detection logic but MIL does not light up)
P1521: ECM Starter protection circuit off error
Starting motor control relay drive circuit is shorted to power supply.
(1 D/C detection logic but MIL does not light up)

Circuit Diagram

8
[A] B2
E01-11 GRN B1
3 2 1

[B]
4 5

E01-24 LT BLU
6

7
A1

[C] C01 E01

10 9 8 7 6 5 4 3 2 1
65 64 63 62 61 20 19 18 17 16 15 14 13 12 11
70 69 68 67 66 30 29 28 27 26 25 24 23 22 21
75 74 73 72 71 40 39 38 37 36 35 34 33 32 31
80 79 78 77 76 50 49 48 47 46 45 44 43 42 41
60 59 58 57 56 55 54 53 52 51
[a]
9 8 7 6 5 4 3 2 1
57 56 55 18 17 16 15 14 13 12 11 10
60 59 58 27 26 25 24 23 22 21 20 19
63 62 61 36 35 34 33 32 31 30 29 28
66 65 64 45 44 43 42 41 40 39 38 37
54 53 52 51 50 49 48 47 46

IJCA0A111025-04

[A]: M/T model B2: Starting motor control relay drive circuit 5. “ST” fuse
[B]: Auto gear shift model 1. Ignition switch 6. “ST SIG” fuse (in relay box)
[C]: ECM connector (View: [a]) 2. “ST SIG” fuse (in fuse box) (without keyless 7. Starting motor
entry system)
A1: Starting motor control relay signal circuit 3. Starting motor control relay 8. ECM
B1: Starting motor control relay power supply 4. TCM
circuit (coil side)

DTC Confirmation Procedure

1) Start engine and leave ignition “ON” for 5 sec. or more.
 Engine General Information and Diagnosis: K10B 1A-91

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”: K10B
(Page 1A-20).
2 Starting motor control relay power supply circuit (coil Go to Step 3. Repair or replace
side) check defective wire harness.
1) With ignition “OFF”, remove starting motor control relay.
2) Check for proper terminal connection to starting motor
control relay connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between “B1” and ground is battery
voltage.

Is check result OK?

3 Starting motor control relay check Go to Step 4. Replace starting motor
1) Check starting motor control relay. (Page 1I-5) control relay.

Is check result OK?

4 Starting motor control relay drive circuit check Replace ECM and Repair or replace
1) When ignition is “OFF”, disconnect “C01” and “E01” recheck DTC. (Page defective wire harness.
connectors of ECM. 1C-3)
2) Check for proper terminal connection to “C01” and “E01”
connectors.
3) If connections are OK, check the following points.
• Resistance of “B2” circuit: less than 1 Ω
• Resistance between “B2” circuit and ground: infinity
• Resistance between “B2” circuit terminal and other
terminal at starting motor control relay connector:
infinity
• Voltage of “B2” circuit: 0 to 1 V (When ignition is “ON”)

Is check result OK?

1A-92 Engine General Information and Diagnosis: K10B

DTC P2101 / P2119

AENJCA0A1114041
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P2101: Throttle Actuator “A” Control Motor Circuit Range / Performance • Throttle actuator and/or its circuit
Throttle actuator drive circuit malfunction (open or excessive temperature of • TP sensor and/or its circuit
device) is detected.
• Electric throttle body assembly
(1 D/C detection logic)
P2119: Throttle Actuator Control Throttle Body Range / Performance • ECM
Difference between targeted TP and measured TP is out of specified range.
(1 D/C detection logic)

Circuit Diagram

5
1
A1
C01-70 LT GRN
A2
C01-75 BRN 4
B1
C01-56 RED B2 2
C01-54 GRN
B3 3
C01-55 WHT
C01-45 BLK
B4
C01-44 GRY

[A] C01 E01

10 9 8 7 6 5 4 3 2 1
65 64 63 62 61 20 19 18 17 16 15 14 13 12 11
70 69 68 67 66 30 29 28 27 26 25 24 23 22 21
75 74 73 72 71 40 39 38 37 36 35 34 33 32 31
80 79 78 77 76 50 49 48 47 46 45 44 43 42 41
60 59 58 57 56 55 54 53 52 51
[a]
9 8 7 6 5 4 3 2 1
57 56 55 18 17 16 15 14 13 12 11 10
60 59 58 27 26 25 24 23 22 21 20 19
63 62 61 36 35 34 33 32 31 30 29 28
66 65 64 45 44 43 42 41 40 39 38 37
54 53 52 51 50 49 48 47 46

IJCA0A111016-02

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

DTC Confirmation Procedure

1) Warm up engine to normal operating temperature.
2) Stop engine and then set ignition “ON”.
3) Keep accelerator pedal at fully depressed position for 1 min.
4) Release accelerator pedal for 1 min.
5) Set ignition “OFF” for 1 min. and then “ON”.
 Engine General Information and Diagnosis: K10B 1A-93

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”: K10B
(Page 1A-20).
2 DTC recheck Go to Step 3. End.
1) Clear DTC.
2) Perform electric throttle control system calibration.
(Page 1C-7)
3) Recheck DTC.

Is DTC P2101 or P2119 still detected?

3 Throttle actuator control circuit check Go to Step 4. Repair or replace
1) When ignition is “OFF”, disconnect “C01” and “E01” defective wire harness.
connectors of ECM and electric throttle body assembly
connector.
2) Check for proper terminal connection to “C01” and “E01”
connectors and electric throttle body assembly
connector.
3) If connections are OK, check the following points.
• Resistance of “A1” and “A2” circuits: less than 1 Ω
• Resistance between each of “A1” and “A2” circuits
and ground: infinity
• Resistance between “A1” circuit terminal and other
terminal at electric throttle body assembly connector:
infinity
• Resistance between “A2” circuit terminal and other
terminal at electric throttle body assembly connector:
infinity
• Voltage of “A1” and “A2” circuits: 0 to 1 V (When
ignition is “ON”)

Is check result OK?

4 Electric throttle body assembly check Replace ECM and Replace electric throttle
1) Check electric throttle body assembly for performance. recheck DTC. (Page body assembly.
(Page 1C-5) 1C-3)

Is check result OK?

1A-94 Engine General Information and Diagnosis: K10B

DTC P2111
AENJCA0A1114043
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P2111: Throttle Actuator Control System Stuck Open • Throttle actuator
During diagnosing throttle valve with ignition “OFF”, throttle valve • ECM
does not close even if throttle valve is opened at specified value.
(1 D/C detection logic)

Circuit Diagram

5
1
A1
C01-70 LT GRN
A2
C01-75 BRN 4
B1
C01-56 RED B2 2
C01-54 GRN
B3 3
C01-55 WHT
C01-45 BLK
B4
C01-44 GRY

[A] C01 E01

10 9 8 7 6 5 4 3 2 1
65 64 63 62 61 20 19 18 17 16 15 14 13 12 11
70 69 68 67 66 30 29 28 27 26 25 24 23 22 21
75 74 73 72 71 40 39 38 37 36 35 34 33 32 31
80 79 78 77 76 50 49 48 47 46 45 44 43 42 41
60 59 58 57 56 55 54 53 52 51
[a]
9 8 7 6 5 4 3 2 1
57 56 55 18 17 16 15 14 13 12 11 10
60 59 58 27 26 25 24 23 22 21 20 19
63 62 61 36 35 34 33 32 31 30 29 28
66 65 64 45 44 43 42 41 40 39 38 37
54 53 52 51 50 49 48 47 46

IJCA0A111016-02

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

DTC Confirmation Procedure

NOTE
Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Set ignition “ON”.

2) Set ignition “OFF” for 1 min.
3) Repeat Step 1) – 2) 3 times.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K10B
(Page 1A-20).
2 DTC check Go to troubleshooting Go to Step 3.
for applicable DTC.
Is there DTC(s) other than P2111?
3 Electric throttle body assembly check Replace ECM and Replace electric throttle
1) Check electric throttle body assembly for performance. recheck DTC. (Page body assembly.
(Page 1C-5) 1C-3)

Is check result OK?

 Engine General Information and Diagnosis: K10B 1A-95

DTC P2122 / P2123

AENJCA0A1114044
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P2122: Throttle / Pedal Position Sensor / Switch “D” Circuit Low • APP sensor (main) and/or its circuit
Output voltage of APP sensor (main) signal circuit is lower than 0.35 V. • ECM
(1 D/C detection logic)
P2123: Throttle / Pedal Position Sensor / Switch “D” Circuit High
Output voltage of APP sensor (main) signal circuit is higher than 4.63 V.
(1 D/C detection logic)

Circuit Diagram

A1
GRN E01-31
A2
1 PNK E01-32
A3
GRY E01-33
B1
BLU E01-40
B2
2 GRY E01-41
B3
YEL E01-42

[A] C01 E01

10 9 8 7 6 5 4 3 2 1
65 64 63 62 61 20 19 18 17 16 15 14 13 12 11
70 69 68 67 66 30 29 28 27 26 25 24 23 22 21
75 74 73 72 71 40 39 38 37 36 35 34 33 32 31
80 79 78 77 76 50 49 48 47 46 45 44 43 42 41
60 59 58 57 56 55 54 53 52 51
[a]
9 8 7 6 5 4 3 2 1
57 56 55 18 17 16 15 14 13 12 11 10
60 59 58 27 26 25 24 23 22 21 20 19
63 62 61 36 35 34 33 32 31 30 29 28
66 65 64 45 44 43 42 41 40 39 38 37
54 53 52 51 50 49 48 47 46

IJCA0A111026-02

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

DTC Confirmation Procedure

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

1) Run engine at idle speed for 1 min.

1A-96 Engine General Information and Diagnosis: K10B

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”: K10B
(Page 1A-20).
2 Accelerator pedal assembly (incorporating APP sensor) Go to Step 3. Reinstall accelerator
mounting check pedal assembly
1) Check that accelerator pedal assembly (incorporating (incorporating APP
APP sensor) has been mounted to vehicle body properly sensor) properly.
(no pinched floor carpet, etc.). (Page 1C-8)

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.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between “A1” and “A3” is approx. 5 V.

Is check result OK?

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

Is check result OK?

6 APP sensor check Replace ECM and Replace accelerator
1) Check APP sensor. (Page 1C-7) recheck DTC. (Page pedal assembly
1C-3) (incorporating APP
Is check result OK? sensor).
 Engine General Information and Diagnosis: K10B 1A-97

DTC P2127 / P2128

AENJCA0A1114045
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P2127: Throttle / Pedal Position Sensor / Switch “E” Circuit Low • APP sensor (sub) and/or its circuit
Output voltage of APP sensor (sub) signal circuit is lower than 0.16 V. • ECM
(1 D/C detection logic)
P2128: Throttle / Pedal Position Sensor / Switch “E” Circuit High
Output voltage of APP sensor (sub) signal circuit is higher than 3.53 V.
(1 D/C detection logic)

Circuit Diagram

A1
GRN E01-31
A2
1 PNK E01-32
A3
GRY E01-33
B1
BLU E01-40
B2
2 GRY E01-41
B3
YEL E01-42

[A] C01 E01

10 9 8 7 6 5 4 3 2 1
65 64 63 62 61 20 19 18 17 16 15 14 13 12 11
70 69 68 67 66 30 29 28 27 26 25 24 23 22 21
75 74 73 72 71 40 39 38 37 36 35 34 33 32 31
80 79 78 77 76 50 49 48 47 46 45 44 43 42 41
60 59 58 57 56 55 54 53 52 51
[a]
9 8 7 6 5 4 3 2 1
57 56 55 18 17 16 15 14 13 12 11 10
60 59 58 27 26 25 24 23 22 21 20 19
63 62 61 36 35 34 33 32 31 30 29 28
66 65 64 45 44 43 42 41 40 39 38 37
54 53 52 51 50 49 48 47 46

IJCA0A111026-02

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

DTC Confirmation Procedure

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

1) Run engine at idle speed for 1 min.

1A-98 Engine General Information and Diagnosis: K10B

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”: K10B
(Page 1A-20).
2 Accelerator pedal assembly (incorporating APP sensor) Go to Step 3. Reinstall accelerator
mounting check pedal assembly
1) Check that accelerator pedal assembly (incorporating (incorporating APP
APP sensor) has been mounted to vehicle body properly sensor) properly.
(no pinched floor carpet, etc.). (Page 1C-8)

Is check result OK?

3 APP sensor (sub) 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.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between “B1” and “B3” is approx. 5 V.

Is check result OK?

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

Is check result OK?

6 APP sensor check Replace ECM and Replace accelerator
1) Check APP sensor. (Page 1C-7) recheck DTC. (Page pedal assembly
1C-3) (incorporating APP
Is check result OK? sensor).
 Engine General Information and Diagnosis: K10B 1A-99

DTC P2135
AENJCA0A1114046
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P2135: Throttle / Pedal Position Sensor / Switch “A”/ • TP sensor and/or its circuit
“B” Voltage Correlation • ECM
Difference between TP (main) and TP (sub) sensor signal
is more than specified value for specified time.
(1 D/C detection logic)

Circuit Diagram

5
1
A1
C01-70 LT GRN
A2
C01-75 BRN 4
B1
C01-56 RED B2 2
C01-54 GRN
B3 3
C01-55 WHT
C01-45 BLK
B4
C01-44 GRY

[A] C01 E01

10 9 8 7 6 5 4 3 2 1
65 64 63 62 61 20 19 18 17 16 15 14 13 12 11
70 69 68 67 66 30 29 28 27 26 25 24 23 22 21
75 74 73 72 71 40 39 38 37 36 35 34 33 32 31
80 79 78 77 76 50 49 48 47 46 45 44 43 42 41
60 59 58 57 56 55 54 53 52 51
[a]
9 8 7 6 5 4 3 2 1
57 56 55 18 17 16 15 14 13 12 11 10
60 59 58 27 26 25 24 23 22 21 20 19
63 62 61 36 35 34 33 32 31 30 29 28
66 65 64 45 44 43 42 41 40 39 38 37
54 53 52 51 50 49 48 47 46

IJCA0A111016-02

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

DTC Confirmation Procedure

1) Run engine at idle speed for 1 min.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K10B
(Page 1A-20).
2 Wire harness check Go to Step 3. Repair or replace
1) Check the following points. defective wire harness.
• “B2” circuit: Refer to Step 4 under “DTC P0122 /
P0123”: K10B (Page 1A-55).
• “B3” circuit: Refer to Step 4 under “DTC P0222 /
P0223”: K10B (Page 1A-68).

Is check result OK?

1A-100 Engine General Information and Diagnosis: K10B

Step Action Yes No

3 TP sensor check Replace ECM and Replace electric throttle
1) Check TP sensor for performance referring to “Throttle recheck DTC. (Page body assembly.
Position (TP) Sensor Performance Check” under 1C-3)
“Electric Throttle Body Assembly On-Vehicle Inspection”:
K10B and Bi-Fuel CNG in Section 1C (Page 1C-5).

Is check result OK?

DTC P2138
AENJCA0A1114047
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P2138: Throttle / Pedal Position Sensor / Switch “D”/ • APP sensor and/or its circuit
“E” Voltage Correlation • ECM
Difference between APP (main) and APP (sub) sensor
signal is more than specified value for specified time.
(1 D/C detection logic)

Circuit Diagram

A1
GRN E01-31
A2
1 PNK E01-32
A3
GRY E01-33
B1
BLU E01-40
B2
2 GRY E01-41
B3
YEL E01-42

[A] C01 E01

10 9 8 7 6 5 4 3 2 1
65 64 63 62 61 20 19 18 17 16 15 14 13 12 11
70 69 68 67 66 30 29 28 27 26 25 24 23 22 21
75 74 73 72 71 40 39 38 37 36 35 34 33 32 31
80 79 78 77 76 50 49 48 47 46 45 44 43 42 41
60 59 58 57 56 55 54 53 52 51
[a]
9 8 7 6 5 4 3 2 1
57 56 55 18 17 16 15 14 13 12 11 10
60 59 58 27 26 25 24 23 22 21 20 19
63 62 61 36 35 34 33 32 31 30 29 28
66 65 64 45 44 43 42 41 40 39 38 37
54 53 52 51 50 49 48 47 46

IJCA0A111026-02

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

DTC Confirmation Procedure

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

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K10B
(Page 1A-20).
 Engine General Information and Diagnosis: K10B 1A-101

Step Action Yes No

2 Wire harness check Go to Step 3. Repair or replace
1) Check the following points. defective wire harness.
• “A1”, “A2” and “A3” circuits: Refer to Step 3 – 5 under
“DTC P2122 / P2123”: K10B (Page 1A-95).
• “B1”, “B2” and “B3” circuits: Refer to Step 3 – 5 under
“DTC P2127 / P2128”: K10B (Page 1A-97).

Is check result OK?

3 APP sensor check Replace ECM and Replace accelerator
1) Check APP sensor for performance. (Page 1C-7) recheck DTC. (Page pedal assembly
1C-3) (incorporating APP
Is check result OK? sensor).

DTC U0073 Refer to “Troubleshooting for Lost Communication” in

AENJCA0A1114048 Section 10H (Page 10H-9).
Refer to “Troubleshooting for Communication Bus Off” in
Section 10H (Page 10H-15).
DTC U0140
AENJCA0A1114052
DTC U0101 Refer to “Troubleshooting for Lost Communication” in
AENJCA0A1114049 Section 10H (Page 10H-9).
Refer to “Troubleshooting for Lost Communication” in
Section 10H (Page 10H-9).
DTC U0155
AENJCA0A1114053
DTC U0121 Refer to “Troubleshooting for Lost Communication” in
AENJCA0A1114050 Section 10H (Page 10H-9).

DTC U2001
AENJCA0A1114054
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
U2001: LIN Lost Communication With Generator • Generator LIN communication circuit
Received data from generator via LIN is faulty. • Regulator
(1 D/C detection logic but MIL does not light up)
• ECM

Circuit Diagram

1 3

A1

2 BLU C01-31 4

[A] C01 E01

10 9 8 7 6 5 4 3 2 1
65 64 63 62 61 20 19 18 17 16 15 14 13 12 11
70 69 68 67 66 30 29 28 27 26 25 24 23 22 21
75 74 73 72 71 40 39 38 37 36 35 34 33 32 31
80 79 78 77 76 50 49 48 47 46 45 44 43 42 41
60 59 58 57 56 55 54 53 52 51
[a]
9 8 7 6 5 4 3 2 1
57 56 55 18 17 16 15 14 13 12 11 10
60 59 58 27 26 25 24 23 22 21 20 19
63 62 61 36 35 34 33 32 31 30 29 28
66 65 64 45 44 43 42 41 40 39 38 37
54 53 52 51 50 49 48 47 46

IJCA0A111027-02

[A]: ECM connector (View: [a]) 1. Generator 3. ECM

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

DTC Confirmation Procedure

1) Run engine at idle speed for 1 min.
1A-102 Engine General Information and Diagnosis: K10B

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”: K10B
(Page 1A-20).
2 Generator LIN communication circuit check Go to Step 3. Repair or replace
1) When ignition is “OFF”, disconnect “C01” and “E01” defective wire harness.
connectors of ECM and generator connector.
2) Check for proper terminal connection to “C01” and “E01”
connectors and generator connector.
3) If connections are OK, check the following points.
• Resistance of “A1” circuit: less than 1 Ω
• Resistance between “A1” circuit and ground: infinity
• Resistance between “A1” circuit terminal and other
terminal at ECM connector: infinity
• Voltage of “A1” circuit: 0 to 1 V (When ignition is “ON”)

Is check result OK?

3 DTC recheck Replace ECM and End.
1) Replace regulator assembly. (Page 1J-12) recheck DTC. (Page
1C-3)
2) Clear DTC. (Page 1A-23)
3) Set ignition “OFF”.
4) Perform DTC confirmation procedure and check DTC.

Is DTC U2001 still detected?

DTC U2021
AENJCA0A1114055
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
U2021: LIN Invalid Data from ECM to Generator • ECM power supply circuit and/or ground circuit
Transmitted data from ECM to generator via LIN is faulty. • ECM
(1 D/C detection logic but MIL does not light up)

DTC Confirmation Procedure

1) Run engine at idle speed for 1 min.

DTC Troubleshooting
Step Action Yes No
1 DTC recheck Go to Step 2. Check for intermittent
1) Clear DTC. (Page 1A-23) trouble. (Page 00-13)
2) Set ignition “OFF”.
3) Perform DTC confirmation procedure and check DTC.

Is DTC U2021 still detected?

2 ECM power supply and ground circuit check Replace ECM and Repair ECM power
1) Check ECM power supply and ground circuits. (Page recheck DTC. (Page supply and ground
1A-113) 1C-3) circuits.

Is check result OK?

 Engine General Information and Diagnosis: K10B 1A-103

Inspection of ECM and Its Circuits

AENJCA0A1114056
Voltage Check

NOTE
• As each terminal voltage is affected by battery voltage, check that it is 12 V or more when ignition is
“ON”.
• Voltage of terminals with asterisk (*) cannot be measured with voltmeter because it is pulse signal.
Use oscilloscope for its check.
• Before performing this inspection, read “Precautions for ECM Circuit Inspection” under
“Precautions for Engine (K10B)” in Section 1 (Page 1-1).

[A] C01 E01

10 9 8 7 6 5 4 3 2 1
65 64 63 62 61 20 19 18 17 16 15 14 13 12 11
70 69 68 67 66 30 29 28 27 26 25 24 23 22 21
75 74 73 72 71 40 39 38 37 36 35 34 33 32 31
80 79 78 77 76 50 49 48 47 46 45 44 43 42 41
60 59 58 57 56 55 54 53 52 51
[a]
9 8 7 6 5 4 3 2 1
57 56 55 18 17 16 15 14 13 12 11 10
60 59 58 27 26 25 24 23 22 21 20 19
63 62 61 36 35 34 33 32 31 30 29 28
66 65 64 45 44 43 42 41 40 39 38 37
54 53 52 51 50 49 48 47 46

IJCA0A111006-02

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

“C01” connector
Terminal No. Wire color Circuit Normal voltage Condition
C01-1 — — — —
C01-2 — — — —
C01-3 — — — —
C01-4 — — — —
C01-5 — — — —
C01-6 — — — —
C01-7 — — — —
C01-8 — — — —
C01-9 — — — —
C01-10 — — — —
C01-11 — — — —
C01-12 — — — —
C01-13 — — — —
C01-14 — — — —
C01-15 — — — —
C01-16 — — — —
Refer to reference waveform.
Ignition coil No.1 drive • “Ignition coil signal”: K10B (Page 1A-110)
C01-17* YEL
circuit • “Fuel injector No.1 signal and ignition coil No.1 signal”: K10B
(Page 1A-108)
Refer to reference waveform.
Ignition coil No.2 drive • “Ignition coil signal”: K10B (Page 1A-110)
C01-18* GRN
circuit • “Fuel injector No.2 signal and ignition coil No.2 signal”: K10B
(Page 1A-108)
Refer to reference waveform.
Ignition coil No.3 drive • “Ignition coil signal”: K10B (Page 1A-110)
C01-19* PNK
circuit • “Fuel injector No.3 signal and ignition coil No.3 signal”: K10B
(Page 1A-109)
C01-20 — — — —
CAN (low) Refer to reference waveform.
C01-21* WHT
communication circuit “CAN communication signal”: K10B (Page 1A-112)
1A-104 Engine General Information and Diagnosis: K10B

Terminal No. Wire color Circuit Normal voltage Condition

CAN (high) Refer to reference waveform.
C01-22* RED
communication circuit “CAN communication signal”: K10B (Page 1A-112)
C01-23 — — — —
C01-24 — — — —
C01-25 — — — —
C01-26 — — — —
C01-27 — — — —
C01-28 — — — —
C01-29 — — — —
C01-30 — — — —
Generator LIN Refer to reference waveform.
C01-31* BLU
communication circuit “Generator LIN communication signal”: K10B (Page 1A-110)
HO2S-1 shield ground
C01-32 LT GRN Below 0.3 V Ignition: “ON”
circuit
Approx. 2.5 V Engine: Idle speed
Knock sensor signal
C01-33* WHT Refer to reference waveform.
circuit
“Knock sensor signal”: K10B (Page 1A-110)
Ignition: “ON”
3.2 to 3.6 V
IAT: 0 °C (32 °F)
Ignition: “ON”
C01-34 YEL IAT sensor signal circuit 1.3 to 1.7 V
IAT: 40 °C (104 °F)
Ignition: “ON”
0.4 to 0.8 V
IAT: 80 °C (176 °F)
4.0 to 4.2 V Ignition: “ON”
Engine: Idle speed after warming up
1.5 to 1.8 V Barometric pressure: 100 kPa, 760
C01-35 BRN MAP sensor signal circuit
mmHg
Refer to reference waveform.
“MAP sensor signal”: K10B (Page 1A-111)
Ignition: “ON”
3.2 to 3.6 V
ECT: 0 °C (32 °F)
Ignition: “ON”
C01-36 BLU ECT sensor signal circuit 1.0 to 1.4 V
ECT: 50 °C (122 °F)
Ignition: “ON”
0.2 to 0.5 V
ECT: 100 °C (212 °F)
C01-37 GRN HO2S-1 ground circuit Below 0.3 V Ignition: “ON”
C01-38 BEG IAT sensor ground circuit Below 0.3 V Ignition: “ON”
ECT sensor and MAP
C01-39 GRY Below 0.3 V Ignition: “ON”
sensor ground circuit
10 to 14 V Ignition: “ON”
EVAP canister purge
C01-40* RED Refer to reference waveform.
valve drive circuit
“EVAP canister purge valve signal”: K10B (Page 1A-112)
C01-41 — — — —
HO2S-2 shield ground
C01-42 BEG Below 0.3 V Ignition: “ON”
circuit
Knock sensor ground
C01-43 BLU Below 0.3 V Ignition: “ON”
circuit
TP sensor shield ground
C01-44 GRY Below 0.3 V Ignition: “ON”
circuit
C01-45 BLK TP sensor ground circuit Below 0.3 V Ignition: “ON”
C01-46 — — — —
C01-47 — — — —
C01-48 — — — —
C01-49 — — — —
C01-50 — — — —
C01-51 YEL HO2S-2 ground circuit Below 0.3 V Ignition: “ON”
Refer to reference waveform.
C01-52* BRN HO2S-2 signal circuit
“HO2S-2 signal”: K10B (Page 1A-110)
 Engine General Information and Diagnosis: K10B 1A-105

Terminal No. Wire color Circuit Normal voltage Condition

Refer to reference waveform.
C01-53* RED HO2S-1 signal circuit
“HO2S-1 signal”: K10B (Page 1A-111)
Ignition: “ON”
0.8 to 1.0 V
TP sensor (main) signal Accelerator pedal: Released
C01-54 GRN
circuit Ignition: “ON”
4.3 to 4.5 V
Accelerator pedal: Fully depressed
Ignition: “ON”
4.0 to 4.2 V
TP sensor (sub) signal Accelerator pedal: Released
C01-55 WHT
circuit Ignition: “ON”
0.5 to 0.7 V
Accelerator pedal: Fully depressed
TP sensor power supply
C01-56 RED 4.5 to 5.5 V Ignition: “ON”
circuit
MAP sensor power
C01-57 LT BLU 4.5 to 5.5 V Ignition: “ON”
supply circuit
Approx. 0 V or 4 to 5 V Ignition: “ON”
Refer to reference waveform.
C01-58* PPL CMP sensor signal circuit
“CMP sensor signal and CKP sensor signal”: K10B (Page 1A-
111)
C01-59 — — — —
Approx. 0 V or 4 to 5 V Ignition: “ON”
Refer to reference waveform.
C01-60* PNK CKP sensor signal circuit
“CMP sensor signal and CKP sensor signal”: K10B (Page 1A-
111)
C01-61 BLK ECM ground circuit 1 Below 0.3 V Ignition: “ON”
C01-62 — — — —
C01-63 — — — —
C01-64 — — — —
C01-65 — — — —
C01-66 BLK ECM ground circuit 2 Below 0.3 V Ignition: “ON”
C01-67 — — — —
C01-68 — — — —
C01-69 — — — —
Throttle actuator control Refer to reference waveform.
C01-70* LT GRN
circuit (close) “Throttle actuator signal”: K10B (Page 1A-109)
HO2S-1 heater drive Refer to reference waveform.
C01-71* PPL
circuit “HO2S-1 and HO2S-2 heater signal”: K10B (Page 1A-111)
C01-72 — — — —
C01-73 — — — —
C01-74 — — — —
Throttle actuator control Refer to reference waveform.
C01-75* BRN
circuit (open) “Throttle actuator signal”: K10B (Page 1A-109)
HO2S-2 heater drive Refer to reference waveform.
C01-76* RED
circuit “HO2S-1 and HO2S-2 heater signal”: K10B (Page 1A-111)
10 to 14 V Ignition: “ON”
Refer to reference waveform.
Fuel injector No.1 drive
C01-77* PNK • “Fuel injector signal”: K10B (Page 1A-108)
circuit
• “Fuel injector No.1 signal and ignition coil No.1 signal”: K10B
(Page 1A-108)
10 to 14 V Ignition: “ON”
Refer to reference waveform.
Fuel injector No.2 drive
C01-78* WHT • “Fuel injector signal”: K10B (Page 1A-108)
circuit
• “Fuel injector No.2 signal and ignition coil No.2 signal”: K10B
(Page 1A-108)
1A-106 Engine General Information and Diagnosis: K10B

Terminal No. Wire color Circuit Normal voltage Condition

10 to 14 V Ignition: “ON”
Refer to reference waveform.
Fuel injector No.3 drive
C01-79* RED • “Fuel injector signal”: K10B (Page 1A-108)
circuit
• “Fuel injector No.3 signal and ignition coil No.3 signal”: K10B
(Page 1A-109)
C01-80 — — — —

“E01” connector
Terminal No. Wire color Circuit Normal voltage Condition
E01-1 — — — —
E01-2 — — — —
E01-3 — — — —
E01-4 — — — —
E01-5 — — — —
E01-6 — — — —
E01-7 — — — —
E01-8 — — — —
CAN (high) Refer to reference waveform.
E01-9* RED
communication circuit “CAN communication signal”: K10B (Page 1A-112)
0 to 1 V Ignition: “ON”
E01-10 PNK Main relay drive circuit
10 to 14 V Ignition: 3 sec. after ignition “OFF”
Starting motor control Approx. 0 V Starting motor: Operating
E01-11 GRN relay drive circuit (M/T Refer to reference waveform.
model) “Starting motor control relay signal”: K10B (Page 1A-112)
A/C compressor relay 10 to 14 V A/C compressor: Not operating
E01-12 GRY
drive circuit 0 to 1 V A/C compressor: Operating
E01-13 — — — —
E01-14 — — — —
E01-15 — — — —
E01-16 — — — —
E01-17 — — — —
CAN (low) Refer to reference waveform.
E01-18* WHT
communication circuit “CAN communication signal”: K10B (Page 1A-112)
Approx. 0 V Ignition: “OFF”, “ACC”
E01-19 WHT Ignition signal circuit
10 to 14 V Ignition: “ON”
Ignition: “ON”
0 to 1 V
CPP No.2 switch signal Clutch pedal: Halfway depressed
E01-20 GRN
circuit (M/T model) Ignition: “ON”
10 to 14 V
Clutch pedal: Released
E01-21 — — — —
Engine: Idle speed
10 to 14 V ECT < 95 °C (203 °F)
Radiator cooling fan A/C switch: OFF
E01-22 LT GRN
relay drive circuit Engine: Idle speed
0 to 1 V ECT > 97 °C (207 °F)
A/C switch: OFF
Brake light switch signal 0 to 1 V Brake pedal: Released
E01-23 YEL
circuit 10 to 14 V Brake pedal: Fully depressed
Starting motor control 0 to 1 V Ignition: “ON”
E01-24 LT BLU
relay signal circuit 6 to 12 V Ignition: “START”
E01-25 — — — —
E01-26 — — — —
E01-27 — — — —
E01-28 — — — —
E01-29 — — — —
E01-30 — — — —
APP sensor (main)
E01-31 GRN 4.5 to 5.5 V Ignition: “ON”
power supply circuit
 Engine General Information and Diagnosis: K10B 1A-107

Terminal No. Wire color Circuit Normal voltage Condition

Ignition: “ON”
0.70 to 0.80 V
APP sensor (main) signal Accelerator pedal: Released
E01-32 PNK
circuit Ignition: “ON”
4.35 to 4.45 V
Accelerator pedal: Fully depressed
APP sensor (main)
E01-33 GRY Below 0.3 V Ignition: “ON”
ground circuit
E01-34 — — — —
E01-35 — — — —
E01-36 — — — —
A/C refrigerant pressure
E01-37 LT GRN sensor power supply 4.5 to 5.5 V Ignition: “ON”
circuit
Fuel pump relay drive Refer to reference waveform.
E01-38 YEL
circuit “Fuel pump relay signal”: K10B (Page 1A-112)
E01-39 — — — —
APP sensor (sub) power
E01-40 BLU 4.5 to 5.5 V Ignition: “ON”
supply circuit
Ignition: “ON”
0.37 to 0.38 V
APP sensor (sub) signal Accelerator pedal: Released
E01-41 GRY
circuit Ignition: “ON”
2.15 to 2.25 V
Accelerator pedal: Fully depressed
APP sensor (sub) ground
E01-42 YEL Below 0.3 V Ignition: “ON”
circuit
A/C refrigerant pressure
E01-43 BLK Below 0.3 V Ignition: “ON”
sensor ground circuit
E01-44 — — — —
E01-45 — — — —
E01-46 — — — —
E01-47 — — — —
Ignition: “ON”
Approx. 0 V
Blower speed switch: 2nd or more
Blower motor signal Ignition: “ON”
E01-48 YEL 5 to 7 V
circuit Blower speed switch: 1st position
Ignition: “ON”
10 to 14 V
Blower speed switch: OFF
E01-49 — — — —
E01-50 — — — —
E01-51 — — — —
E01-52 — — — —
E01-53 — — — —
Engine: Running
0.9 to 1.3 V
A/C refrigerant pressure A/C compressor: Not operating
E01-54 BEG
sensor signal circuit Engine: Running
1.3 to 2.2 V
A/C compressor: Operating
Main power supply circuit
E01-55 BLU 10 to 14 V Ignition: “ON”
1
Main power supply circuit
E01-56 BLU 10 to 14 V Ignition: “ON”
2
E01-57 — — — —
E01-58 — — — —
E01-59 — — — —
E01-60 — — — —
E01-61 — — — —
E01-62 — — — —
E01-63 — — — —
E01-64 — — — —
E01-65 — — — —
E01-66 — — — —
1A-108 Engine General Information and Diagnosis: K10B

Reference Waveform Fuel injector No.1 signal and ignition coil No.1 signal
Oscilloscope display
Shown below is typical waveform display provided using Fuel injector No.1 signal (1)
oscilloscope. Channel Probe Terminal No.
+ C01-77
NOTE 1
– C01-61
• Display includes the following types of
data: Ignition coil No.1 signal (2)
Channel Probe Terminal No.
+ C01-17
2
– C01-61

CMP sensor signal (3)

Channel Probe Terminal No.
+ C01-58
3
– C01-61

CKP sensor signal (4)

Channel Probe Terminal No.
+ C01-60
4
– C01-61

ICP70A110009-01 Measurement condition

[A]: Waveform of channel 1 [C]: VOLT/DIV of each channel • Engine: Idle speed after warming up
[B]: Ground level of each channel [D]: TIME/DIV

• Waveform varies depending on

measurement condition and vehicle spec.

Fuel injector signal

Channel Probe Terminal No.
C01-77 (No.1)
+ C01-78 (No.2)
1
C01-79 (No.3)
– C01-61
I7V10A111011-05
Measurement condition
5. Camshaft 360°angle 6. Crankshaft 720°angle
• Engine: Idle speed after warming up
Fuel injector No.2 signal and ignition coil No.2 signal

Fuel injector No.2 signal (1)

Channel Probe Terminal No.
+ C01-78
1
– C01-61

Ignition coil No.2 signal (2)

Channel Probe Terminal No.
+ C01-18
2
– C01-61
IDLA0A110027-01

1. Fuel injector signal CMP sensor signal (3)

Channel Probe Terminal No.
+ C01-58
3
– C01-61

CKP sensor signal (4)

Channel Probe Terminal No.
+ C01-60
4
– C01-61
 Engine General Information and Diagnosis: K10B 1A-109

Measurement condition Throttle actuator signal

• Engine: Idle speed after warming up
Throttle actuator signal (Open) (1)
Channel Probe Terminal No.
+ C01-70
1
– C01-61

Throttle actuator signal (Close) (2)

Channel Probe Terminal No.
+ C01-75
2
– C01-61

Measurement condition
• Engine: Idle speed after warming up
I7V10A111015-01

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

Fuel injector No.3 signal and ignition coil No.3 signal

Fuel injector No.3 signal (1)

Channel Probe Terminal No.
+ C01-79
1
– C01-61

Ignition coil No.3 signal (2)

Channel Probe Terminal No. IJCA0A111028-01
+ C01-19
2 Measurement condition
– C01-61
• Engine: Running after warming up (Momentarily at
CMP sensor signal (3) accelerator pedal depressed)
Channel Probe Terminal No.
+ C01-58
3
– C01-61

CKP sensor signal (4)

Channel Probe Terminal No.
+ C01-60
4
– C01-61

Measurement condition
• Engine: Idle speed after warming up
IJCA0A111029-01

I7V10A111016-01

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

1A-110 Engine General Information and Diagnosis: K10B

Ignition coil signal Generator LIN communication signal

Channel Probe Terminal No. Channel Probe Terminal No.
C01-17 (No.1) + C01-31
1
+ C01-18 (No.2) – C01-61
1
C01-19 (No.3)
– C01-61 Measurement condition
• Engine: Idle speed after warming up
Measurement condition
• Engine: Idle speed after warming up

ICV00P111021-02

1. Generator LIN communication signal

IDLA0A110030-01

1. Ignition coil signal

HO2S-2 signal
Knock sensor signal Channel Probe Terminal No.
+ C01-52
Channel Probe Terminal No. 1
– C01-61
+ C01-33
1
– C01-61 Measurement condition
Measurement condition • Engine: Racing after warming up
• Engine: Running at 3,000 rpm after warming up

IJCA0A111031-01

1. Engine: Racing 2. Engine: Idle speed

IJCA0A111030-01
 Engine General Information and Diagnosis: K10B 1A-111

HO2S-1 signal CMP sensor signal and CKP sensor signal

Channel Probe Terminal No.
+ C01-53 CMP sensor signal (1)
1 Channel Probe Terminal No.
– C01-61
+ C01-58
1
Measurement condition – C01-61
• Engine: Idle speed after warming up
CKP sensor signal (2)
Channel Probe Terminal No.
+ C01-60
2
– C01-61

Measurement condition
• Engine: Idle speed after warming up

IJCA0A111032-01

MAP sensor signal

Channel Probe Terminal No.
+ C01-35
1
– C01-61

Measurement condition I8C50B111039-01

• Engine: Racing after warming up

HO2S-1 and HO2S-2 heater signal

HO2S-1 heater signal (1)

Channel Probe Terminal No.
+ C01-71
1
– C01-61

HO2S-2 heater signal (2)

Channel Probe Terminal No.
+ C01-76
2
– C01-61

IBV10A111022-01 Measurement condition

1. Engine: Racing 2. Engine: Idle speed • Engine: Idle speed after warming up

IDLA0A110032-01
1A-112 Engine General Information and Diagnosis: K10B

EVAP canister purge valve signal Fuel pump relay signal

Channel Probe Terminal No. Channel Probe Terminal No.
+ C01-40 + E01-35
1 1
– C01-61 – C01-61

Measurement condition Measurement condition

• EVAP canister purge valve: 10% open • Ignition: “OFF”→“ON”→“START”
(using active test of SUZUKI scan tool)

IAW101110042-01

I7V20A111065-02 1. Fuel pump relay signal 3. Ignition: “ON”

1. EVAP canister purge valve signal 2. Ignition: “OFF” 4. Ignition: “START”

CAN communication signal Starting motor control relay signal

CAN communication signal (High) (1) Ignition ON signal (1)

Channel Probe Terminal No. Channel Probe Terminal No.
C01-22 + E01-19
+ 1
1 E01-9 – C01-61
– C01-61
Starting motor control relay signal (2)
CAN communication signal (Low) (2) Channel Probe Terminal No.
Channel Probe Terminal No. + E01-11
2
C01-21 – C01-61
+
2 E01-18
– C01-61 Fuel pump relay signal (3)
Channel Probe Terminal No.
Measurement condition + E01-38
3
– C01-61
• Ignition: “ON”
Measurement condition
• Ignition: “OFF” → “ON” → “START”

I8C50B111041-01

IJCA0A111033-01

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

5. Ignition: “ON” 7. Starting motor: Operation prohibited
 Engine General Information and Diagnosis: K10B 1A-113

ECM Power Supply and Ground Circuit Check

AENJCA0A1114057
Circuit Diagram

7
C01-70 LT GRN
8
C01-751 BRN M
2 A1 D1
GRN E01-31 C01-56 RED
3 9
PNK E01-32 C01-54 GRN
GRY E01-33 10
C01-55 WHT
A2 C01-45 BLK
BLU E01-40
C01-44 GRY
4 GRY E01-41
YEL E01-42 E1 11 F1
B1 E01-10 PNK 12
5 E01-56 BLU
LT BLU C01-57 E2 F2
BEG C01-35 E01-55 BLU
GRY C01-39 E3 14
13 15
E01-19 WHT
C1
G1
LT GRN E01-37 16
6
BEG E01-54
BLK E01-43
H1 17
C01-61 BLK
H2
C01-66 BLK

[A] C01 E01

10 9 8 7 6 5 4 3 2 1
65 64 63 62 61 20 19 18 17 16 15 14 13 12 11
70 69 68 67 66 30 29 28 27 26 25 24 23 22 21
75 74 73 72 71 40 39 38 37 36 35 34 33 32 31
80 79 78 77 76 50 49 48 47 46 45 44 43 42 41
60 59 58 57 56 55 54 53 52 51
[a]
9 8 7 6 5 4 3 2 1
57 56 55 18 17 16 15 14 13 12 11 10
60 59 58 27 26 25 24 23 22 21 20 19
63 62 61 36 35 34 33 32 31 30 29 28
66 65 64 45 44 43 42 41 40 39 38 37
54 53 52 51 50 49 48 47 46

IJCA0A111034-02

[A]: ECM connector (View: [a]) G1: Ignition “ON” signal circuit 9. TP sensor (main)
A1: APP sensor (main) power supply circuit H1: ECM ground circuit 1 10. TP sensor (sub)
A2: APP sensor (sub) power supply circuit H2: ECM ground circuit 2 11. Main relay
B1: MAP sensor power supply circuit 1. ECM 12. “FI” fuse
C1: A/C refrigerant pressure sensor power 2. APP sensor 13. “IG COIL” fuse (without keyless entry system) or
supply circuit “IG” fuse (with keyless entry system)
D1: TP sensor power supply circuit 3. APP sensor (main) 14. Ignition switch (without keyless entry system) or
IG11 relay (with keyless entry system)
E1: Main relay drive circuit 4. APP sensor (sub) 15. “IGN” fuse
E2: Main power supply circuit 2 5. MAP sensor 16. Main fuse box
E3: Main power supply circuit 1 6. A/C refrigerant pressure sensor 17. Battery
F1: Main relay power supply circuit (coil side) 7. Electric throttle body assembly
F2: Main relay power supply circuit (switch side) 8. Throttle actuator

Circuit Description
When ignition is set to “ON”, the main relay turns ON (contacts close) and the main power is supplied to ECM. ECM
then supplies 5 V power to the following sensors: A/C refrigerant pressure sensor, APP sensor, TP sensor and MAP
sensor.
1A-114 Engine General Information and Diagnosis: K10B

Troubleshooting

NOTE
• Before troubleshooting, read “Precautions for ECM Circuit Inspection” under “Precautions for
Engine (K10B)” in Section 1 (Page 1-1).
• Before performing, check that related fuses of ECM power circuit have not blown out.
If any fuse has blown out, replace the fuse and check circuits connected to the blown fuse for short
circuit to ground.

Step Action Yes No

1 Battery check Go to Step 2. Check battery and
1) Check that battery voltage is 12 V or more. generator referring to
“Battery Inspection”:
Is check result OK? K10B and Bi-Fuel CNG
in Section 1J (Page 1J-
4) and “Generator Test”:
K10B and Bi-Fuel CNG
in Section 1J (Page 1J-
5).
2 Main relay power supply check Go to Step 3. Check that “FI” fuse has
1) When ignition is “OFF”, remove main relay (1) from not blown. If check
individual circuit fuse box No.1. result is OK, repair or
replace defective wire
harness.

IJCA0A111035-01

2) Check for proper terminal connection to main relay

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

Is check result OK?

3 Main relay check Go to Step 4. Replace main relay.
1) Check main relay. (Page 1C-14)

Is check result OK?

 Engine General Information and Diagnosis: K10B 1A-115

Step Action Yes No

4 Ignition mode circuit check Go to Step 5. Check that “IG COIL”
1) When ignition is “OFF”, install main relay to individual fuse (without keyless
circuit fuse box No.1. entry system), “IG” fuse
(with keyless entry
2) Disconnect “C01” and “E01” connectors from ECM.
system) or “IGN” fuse
3) Check for proper terminal connection to “C01” and “E01” has not blown. If check
connectors. result is OK, repair or
4) If connections are OK, set ignition “ON”. replace defective wire
5) Check that voltage between “G1” and ground is battery harness.
voltage.

Is check result OK?

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

Is check result OK?

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

Is check result OK?

7 ECM ground circuit check Go to Step 8. Repair or replace
1) Set ignition “OFF”. defective wire harness.
2) Check that resistance between each of “H1” and “H2”
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. (Page
4) If connections are OK, set ignition “ON”. 1C-3)
5) Check that voltage between each of the following circuits
and ground is approx. 5 V.
• A1
• A2
• B1
• C1
• D1

Is check result OK?

1A-116 Engine General Information and Diagnosis: K10B

Repair Instructions
Idle Speed Inspection Special tool
AENJCA0A1116001 (A): SUZUKI scan tool (Suzuki SDT-II)
Before idle speed check, check the following points.
• Lead wires and hoses of electronic fuel injection and
engine and emission control systems are connected
securely.
• Valve lash is checked according to maintenance
schedule.
1
• 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
condition.
• There is no air abnormally drawn in from air intake
system.
• There is no obstruction in PCV valve or its hoses.
• There is no DTCs in ECM.
• The following items are turned OFF as checked using
“Data List” mode of scan tool. (A)
– A/C Comp Relay IJCA0A181004-01

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

– Blower Fan 3) Check engine idle speed using “Data List” mode on
– Brake Switch scan tool.
– Electric Load 4) If check result is not as specified, check engine idle
After checking all items, check idle speed as follows. speed referring to “Improper engine idling or engine
fails to idle” under “Engine Symptom Diagnosis”:
NOTE K10B (Page 1A-37).
Before starting engine, place gear shift lever Engine idle speed
in “Neutral” for M/T model or “N” range for A/C OFF: 650 to 750 rpm
auto gear shift model apply parking brake A/C ON: 800 to 900 rpm
and block drive wheels.

1) With ignition “OFF”, connect SUZUKI scan tool to

DLC (1).

Special Tools and Equipment

Special Tool
AENJCA0A1118001
SUZUKI scan tool (Suzuki
SDT-II)
—
(Page 1A-22) /
(Page 1A-23) /
(Page 1A-116)
 Engine General Information and Diagnosis: K12M 1A-117

K12M
General Description
Engine Diagnosis General Description • Not only SUZUKI scan tool (2) but also CAN
AENJCA0A1121002 communication OBD-II generic scan tool can
The engine and emission control system in this vehicle is
communicate with ECM via DLC (3). (Diagnostic
controlled by ECM. ECM has an OBD system which
information can be accessed using a scan tool.)
detects a malfunction in this system and abnormality of
those parts that influence the engine exhaust emission. [A]
When diagnosing engine troubles, have full
understanding of the outline of “OBD System
Description”: K12M (Page 1A-117) and each item in
1
“Precautions for Diagnosing Trouble” under “Precautions
for Engine (K12M)” in Section 1 (Page 1-2) and execute
diagnosis according to “Engine and Emission Control
System Check”: K12M (Page 1A-138).
There is a close relationship between the engine
mechanical, engine cooling system, ignition system,
exhaust system, etc. and the engine and emission
control system in their structure and operation. In case of [B]

an engine trouble, even when the MIL does not turn on,
it should be diagnosed according to “Engine and
Emission Control System Check”: K12M (Page 1A-138). 1

OBD System Description

AENJCA0A1121003
General Description
The ECM has the following functions.
• When ignition is “ON” with the engine at a stop, the
ECM turns on the MIL (1) to check the circuit of the
MIL.
• When ECM detects a malfunction which gives an
adverse effect to vehicle emission while the engine is
running, ECM makes the MIL in the combination
meter of the instrument panel turn on or blink (blinking 3
only when detecting a misfire which can cause
damage to the catalyst) and stores the malfunction
area in its memory.
(If ECM detects a malfunction only in the first driving
cycle (refer to “Driving Cycle”: K12M (Page 1A-118))
but does not detect the same malfunction in the next 2
consecutive driving cycles, ECM does not turn on MIL
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”: K12M (Page 1A-118)) to prevent
erroneous detection. 2
With this logic, MIL is turned on when the same IJCA0A112001-01
malfunction is detected for 3 consecutive driving
[A]: Without tachometer [B]: With tachometer
cycles.
• When a malfunction is detected, engine and driving Warm-Up Cycle
conditions at the moment the malfunction was A “Warm-Up Cycle” means sufficient vehicle operation
detected are stored in ECM memory as freeze frame such that the coolant temperature has risen by at least
data. (For the details, refer to description on “Freeze 22 °C (40 °F) from engine starting and reaches a
frame data clearance”: K12M (Page 1A-119).) minimum temperature of at least 70 °C (160 °F).
1A-118 Engine General Information and Diagnosis: K12M
Driving Cycle
A “Driving Cycle” is a duration from an engine startup to
the following engine shutoff.
3 Driving Cycle Detection Logic
The malfunction detected in the first driving cycle is
stored in ECM memory (in the form of pending DTC) but
MIL does not light at this time. ECM causes the MIL to
light up when it detects third time the same malfunction
in the next two driving cycles.
Pending DTC
“Pending DTC” is relevant to those DTCs to which the 3
driving cycle detection logic is applied. If such a DTC is
detected and stored temporarily during the first of three
consecutive driving cycles, the DTC is called pending
DTC.
Freeze Frame Data
ECM stores the engine and driving conditions at the
moment of the detection of a malfunction in its memory.
This data is called “Freeze Frame Data”.
Therefore, it is possible to know engine and driving
conditions (e.g. whether the engine was warm or not,
whether the vehicle was running or stopped, whether air/
fuel mixture was lean or rich) at the moment the
malfunction was detected by checking the freeze frame
data. Also, ECM has a function to store each freeze
frame data for three different malfunctions in detecting
order. Utilizing this function, it is possible to know the
detecting order of the malfunctions, and facilitates
recheck and diagnosis of the trouble.
NOTE
• Absolute TP / APP indicates the ratio of the
output voltage to the power supply voltage
of related sensor.
When power supply voltage is 5.0 V and
output voltage is 4.0 V, freeze frame data is
displayed as follows.
– The sensor that the output voltage
increases according to the opening
angle, it displays 80%.
– The sensor that the output voltage
decreases according to the opening
angle, it displays 20%.
• Relative TP indicates value calculated by
formula ((output voltage – output voltage
at closed throttle position) / power supply
voltage).
When power supply voltage is 5.0 V and
output voltage at closed throttle position is
1.0 V, freeze frame data is displayed as
follows.
– At closed throttle position (output
voltage = 1.0 V), it displays 0%.
– At wide open throttle position (output
voltage = 4.0 V), it displays 60%.
However, for systems where the output is
inversely proportional to the input voltage, it
displays 100% minus the above-mentioned
formula.
Freeze frame data (For example)
IJHB0B111001-01
 Engine General Information and Diagnosis: K12M 1A-119

Priority of freeze frame data

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

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

Frame 0 Frame 1 Frame 2 Frame 3

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

Freeze frame data clearance NOTE

When a DTC is cleared, the freeze frame data for the
malfunction represented by this DTC is also cleared. • The system readiness test status may
change from “Complete” to “Incomplete” if
System Readiness Test any of the following service operations is
The system readiness test is performed for the purpose performed.
of checking that each of the exhaust-emission-related – Disconnection of battery negative (–)
systems fulfills the conditions that allow ECM to detect a cable
malfunction if it occurs and to set the corresponding – Disconnection of ECM connectors
DTC. – Removal of ECM ground cable
The test is carried out by monitoring the specific items
• The items (components) indicated in the
(components) using a scan tool (SUZUKI scan tool or
table below are monitored in the system
CAN communication OBD-II generic scan tool). When
readiness test to check the readiness for
the test shows that the conditions pre-established for the
detecting the DTCs listed beside each
tested system are met, ECM performs an on-board
monitoring item.
diagnosis of the system, changes the status of the
system readiness test from “Incomplete” to “Complete”, • The “Complete” or “Incomplete” status
and causes the “Complete” status to be displayed on the identified through the system readiness
scan tool. test does NOT mean the “Normal” or
The “Complete” status is maintained until DTC clearance “Abnormal” result of on-board diagnosis.
operation is performed using the scan tool.
Monitoring item of system readiness test
Monitoring item DTC related to monitoring item
Catalyst P0420 —
O2 Sensor P0133 P2271
O2 Sensor Heater — —
VVT system P0011 —
1A-120 Engine General Information and Diagnosis: K12M

DLC Description Engine and Emission Control System

AENJCA0A1121004
DLC (1) is in compliance with SAE J1962 in the shape of
Description
AENJCA0A1121005
connector and pin assignment. The engine and emission control system is divided into 4
OBD CAN High line (6) and Low line (3) (CAN line of ISO major sub-systems: air intake system, fuel delivery
15765-4) are used for SUZUKI scan tool (Suzuki SDT-II) system, electronic control system and emission control
(7) or CAN communication OBD-II generic scan tool to system.
communicate with ECM. Air intake system includes air cleaner, throttle body and
intake manifold.
2 Fuel delivery system includes fuel pump, delivery pipe,
3
etc.
1 2 3 4 5 6 7 8
Electronic control system includes ECM, various sensors
9 10 11 12 13 14 15 16 and controlled devices.
Emission control system includes EVAP and PCV
6 5 systems.
4
1
IGSB0A113002-01

7
IJCA0A112002-01

2. B + (Continuous battery power)

4. ECM ground (Signal ground)
5. Ground (Chassis ground)
 Engine General Information and Diagnosis: K12M 1A-121

Air Intake System Description

AENJCA0A1121006
The main components of the air intake system are the air cleaner assembly (1), the air cleaner outlet hose (2), the
electric throttle body assembly (3) and the intake manifold (4).
For the details of the electric throttle assembly, refer to “Electric Throttle Control System Description”: K12M (Page 1A-
122).
The intake air, which the amount varies corresponding to the throttle valve (5) opening and the engine speed, is
filtered by the air cleaner, distributed by the intake manifold, and finally drawn into each combustion chamber. The
electric throttle body assembly is not equipped with the IAC valve for idle speed control. The idle speed is controlled by
the throttle actuator (6) which opens/closes the throttle valve. For the details, refer to “Electric Throttle Control System
Description”: K12M (Page 1A-122).

3
6
7

IFRA0A111004-02

7. IAT sensor 8. MAP sensor

1A-122 Engine General Information and Diagnosis: K12M

Electric Throttle Control System Description

AENJCA0A1121007
The electric throttle control system consists of the following items:
• Electric throttle body assembly incorporating the throttle valve, throttle actuator and TP sensors (main and sub)
• Accelerator pedal assembly incorporating APP sensors (main and sub)
• ECM

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

5
8

2 9 3 6
10
1
7

13
11

12

I7Y50A110003-01

6. CPU 9. APP sensor (sub) signal circuit 12. Drive circuit of throttle actuator
7. Throttle actuator driver 10. TP sensor (main) signal circuit
8. APP sensor (main) signal circuit 11. TP sensor (sub) signal circuit
 Engine General Information and Diagnosis: K12M 1A-123

Electronic Control System Description

AENJCA0A1121009
Function Construction
ECM controls fuel to be supplied into cylinder adjusting injection timing and injection
time (volume) optimally.
The fuel injection timing and time (volume) are decided by engine start injection control
for the engine starting and after start injection control during the normal driving.
Further, fuel cut is controlled in response to the driving conditions.
Engine start injection control
• Fuel injection timing
ECM has basic injection timing corresponding to coolant temperature and fuel is
injected in sequential order synchronizing with CKP sensor signal.
• Fuel injection time (volume)
For engine start, fuel injection time is decided adding adjustable factors such as
intake air temperature, battery voltage, engine speed (cranking speed) and
atmospheric pressure to the basic injection time programmed in ECM.
And, the lower the coolant temperature, the longer the injection time for good
startability.
After start injection control
• Fuel injection timing
– When the vehicle is running in normal condition, ECM calculates start timing of
the injection to accomplish it in programed finish timing and injects it sequentially.
Fuel injection control system – When deceleration fuel cut returns to normal injection or accelerating rapidly, fuel
is injected into all cylinders temporarily at the same time without synchronizing to
CKP sensor signal.
• Fuel injection time (volume)
ECM has a basic fuel injection time corresponding to intake air volume and engine
speed, and this basic injection time is adjusted adding correction value from each
sensor for the driving conditions optimally.
Fuel cut control
• Fuel cut by engine speed
To prevent the engine over speed, this fuel cut is operated in the following
conditions.
– While vehicle is running: Engine speed at 6,200 rpm or higher.
– While vehicle is stopped: Engine speed beyond 3,200 rpm continues for more
than 150 seconds.

NOTE
The engine speed of fuel cut is a reference value.

• Fuel cut with deceleration of vehicle

To restrain hydrocarbon (HC) emissions and improve fuel economy, this fuel cut is
operated during deceleration in specified conditions.
1A-124 Engine General Information and Diagnosis: K12M

Function Construction
• Corresponding to vehicle running conditions, ECM controls ignition timing optimally.
• There are three control modes to determine ignition timing, i.e. engine start ignition
control mode, normal driving condition ignition control mode and ignition timing
inspection mode.
Further, energizing time of the spark plug is decided by engine speed and battery
voltage.
Engine start ignition control mode
When engine speed (cranking speed) is below 560 rpm, ECM controls the ignition
timing to BTDC –10° to 10°.
Ignition control system Normal driving condition ignition control mode
• At idling
ECM controls ignition timing optimally adding factor of coolant temperature to basic
timing corresponding to engine speed.
• Except idling
ECM controls ignition timing optimally adding correction value to basic timing
determined by factors such as intake air volume, engine speed and state of VVT.
Ignition timing inspection mode
When checking ignition timing with SUZUKI scan tool (Suzuki SDT-II), the timing is
fixed to BTDC 5° at idling.
Receiving dual voltage signals, main and sub, from APP Sensor, ECM calculates a
target degree of throttle opening to bring the throttle opening closer to the target and
activates throttle actuator. Further, the following controls are executed in response to
the vehicle conditions.
Engine start control
For engine start, ECM sets up throttle opening angle according to coolant temperature
to increase intake air for good startability. And, the lower the coolant temperature, the
wider the throttle opening for the same purpose.
Idling control
ECM has stored basic throttle opening angle corresponding to information of coolant
temperature, shift position and A/ C switch and, adding correction value, a target
degree of throttle opening is determined.
Normal condition control
Adding information of accelerator pedal depressing degree, engine load, etc. to basic
throttle opening degree, ECM determines a target degree of throttle opening. If actual
throttle opening angle differs from the target degree, ECM adjusts the throttle opening
to bring it closer to the target.
Deceleration control
Electric throttle body control At the time of deceleration, ECM controls to open throttle valve at specified degree to
system increase intake air and prevents engine speed from excessive falling.
Maximum engine speed limitation control
To prevent engine over speed, ECM restricts the throttle opening under the following
conditions.
• While vehicle is running: Engine speed at 6,200 rpm or higher.
• While vehicle is stopped: Engine speed at 3,200 rpm or higher for specified time.

NOTE
Above engine speed is reference value.

Torque down control (auto gear shift model)

When torque down demand from TCM is inputted, ECM responds to reduce engine
torque controlling throttle opening and ignition timing.
Fail-safe control
When ECM detects a malfunction of throttle control circuit, ECM stops energization to
the throttle actuator. As a result, throttle valve opening is fixed in a default angle or,
movable maximum opening of throttle valve is restricted in a degree equivalent to the
default angle. However, minimum vehicle running is ensured by control of fuel injection
and ignition timing.

Function
VVT system
Generator control system
HO2S heater control system
Evaporative emission control
system
A/C control system
Radiator cooling fan control
system
Fuel pump control system
Starting motor control system
(M/T model)
Main relay control
CAN communication system
Engine General Information and Diagnosis: K12M 1A-125
Construction
ECM controls OCV optimally for driving conditions corresponding to engine speed,
volume of intake air, degree of throttle opening and coolant temperature. The valve
timing is brought closer to the engine command by feedback control detecting actual
advance angle of the valve via CKP sensor.
For more detail of VVT system, refer to “VVT System Description”: K12M in Section 1D
(Page 1D-74).
• ECM communicates with generator through LIN. For better startability of engine,
generator is controlled not to generate electric power while cranking engine.
• Receiving information from generator, ECM sends charging system information to
combination meter through CAN and controls ON/OFF of charge warning light.
To quicken startup or maintain activation of HO2S, ECM controls HO2S heater by
using duty cycle pulse signal.
Corresponding to vehicle running conditions, ECM controls ON/OFF of EVAP canister
purge valve to suck in fuel evaporation gas absorbed in canister and feeds it into intake
manifold together with air-fuel mixture to burn.
This function restrains the fuel evaporation gas to be released to atmosphere.
Based on information of A/C switch, refrigerant pressure sensor and vehicle driving
conditions through CAN communication, ECM controls ON/OFF of A/C compressor
relay.
For more detail of A/C control system, refer to “A/C Operation Description” in Section
7B (Page 7B-4).
Based on information of A/C switch, vehicle speed, engine speed, coolant temperature
and refrigerant pressure, ECM controls radiator fan actuating the relay No.1, No.2 and
No.3 for fan speed of LO, HI or stop.
For more detail of cooling fan operation, refer to “Cooling Fan Operation Description”:
K12M in Section 1F (Page 1F-19).
ECM operates or stops fuel pump controlling fuel pump relay.
ON conditions of fuel pump relay:
• For specified time after ignition “ON”.
• While CKP sensor signal is being inputted to ECM with engine running.
ECM controls starting motor control relay to protect starting motor from damage.
Continuous cranking before engine start exceeds specified time (about 12 seconds),
operation of starting motor is suspended. Before the next cranking, ignition “OFF” is
required. After starting engine, “START” position of ignition will not allow starting motor
to operate.
For more detail of engine cranking, refer to “Cranking System Description” in Section 1I
(Page 1I-1).
• Corresponding to “ON” or “OFF” of ignition mode, ECM controls main relay for
startup or stop of engine control system.
• The main relay controls the following functions.
– Self-shut-off function: ECM supplies power for specified time after ignition “OFF”.
– Battery countercurrent protection function: When the battery terminal is
connected reversely by mistake, the countercurrent is prevented by an internal
circuit of ECM.
ECM transmits / receives information and the data to / from other control modules by
using this system.
For more detail of CAN communication, refer to “Communication System Description”
in Section 10H (Page 10H-1).
1A-126 Engine General Information and Diagnosis: K12M

Function Construction
When the driver depresses accelerator pedal and brake pedal at the same time, ECM
controls engine output by restricting throttle valve opening and prioritizes braking force.

NOTE
• The system may not be activated depending on the following
Brake override system conditions.
– Depressing amount of accelerator pedal and brake pedal
– Vehicle speed
• The system restricts throttle valve opening mainly. Therefore, ignition
timing control and VVT system are affected by this system.

Engine and Emission Control Input / Output Table

AENJCA0A1121010
Function Output Input
• Ignition “ON” signal
• Ignition “ST” signal
• ECT sensor
• CKP sensor
• CMP sensor
• TP sensor
• APP sensor
• MAP sensor
• IAT sensor
Injection control Fuel injector • HO2S-1
• HO2S-2
• Barometric pressure sensor
• A/C refrigerant pressure sensor
• Battery voltage
• Brake light switch
• BCM (A/C switch status signal)
• ABS control module (wheel speed signal)
• P/S control module
• TCM (gear shift position signal) (auto gear shift model)
Fuel injector • Ignition “ON” signal
Immobilizer control
Ignition coil assembly • BCM
• Ignition “ON” signal
• Ignition “ST” signal
• ECT sensor
• CKP sensor
• CMP sensor
• TP sensor
• APP sensor
Ignition control Ignition coil assembly • MAP sensor
• IAT sensor
• Knock sensor
• Barometric pressure sensor
• Battery voltage
• BCM (electric load signal and A/C switch status signal)
• ABS control module (wheel speed signal)
• TCM (gear shift position signal) (auto gear shift model)
 Engine General Information and Diagnosis: K12M 1A-127

Function Output Input

• Ignition “ON” signal
• Ignition “ST” signal
• ECT sensor
• CKP sensor
• TP sensor
• APP sensor
• MAP sensor
• IAT sensor
• HO2S-1
Idle speed control Throttle actuator
• HO2S-2
• Barometric pressure sensor
• A/C refrigerant pressure sensor
• Brake light switch
• Generator (field coil measured signal)
• BCM (electric load signal and A/C switch status signal)
• ABS control module (wheel speed signal)
• P/S control module
• TCM (gear shift position signal) (auto gear shift model)
• Ignition “ON” signal
• Ignition “ST” signal
• ECT sensor
• CKP sensor
• TP sensor
• APP sensor
• MAP sensor
Throttle valve control Throttle actuator • IAT sensor
• HO2S-1
• HO2S-2
• Barometric pressure sensor
• A/C refrigerant pressure sensor
• Brake light switch
• Generator (field coil measured signal)
• BCM (electric load signal and A/C switch status signal)
• Ignition “ON” signal
Generator control Generator • Ignition “ST” signal
• CKP sensor
• Ignition “ON” signal
• Ignition “ST” signal
• ECT sensor
• TP sensor
HO2S-1 heater control HO2S-1 • MAP sensor
• IAT sensor
• Barometric pressure sensor
• CKP sensor
• Battery voltage
1A-128 Engine General Information and Diagnosis: K12M

Function Output Input

• Ignition “ON” signal
• Ignition “ST” signal
• ECT sensor
• TP sensor
HO2S-2 heater control HO2S-2 • MAP sensor
• IAT sensor
• Barometric pressure sensor
• CKP sensor
• Battery voltage
• Ignition “ON” signal
• ECT sensor
• CKP sensor
• TP sensor
• MAP sensor
EVAP canister purge
EVAP purge control • IAT sensor
valve
• HO2S-1
• HO2S-2
• Barometric pressure sensor
• ABS control module (wheel speed signal)
• BCM (electric load signal and A/C switch status signal)
• Ignition “ON” signal
• ECT sensor
• CKP sensor
• CMP sensor
VVT control OCV • IAT sensor
• MAP sensor
• TP sensor
• Brake light switch
• ABS control module (wheel speed signal)
• Ignition “ON” signal
• Ignition “ST” signal
• ECT sensor
• CKP sensor
• TP sensor
A/C compressor control A/C compressor relay
• APP sensor
• A/C refrigerant pressure sensor
• BCM (evaporator temperature signal and A/C ON request
signal)
• ABS control module (wheel speed signal)
• Ignition “ON” signal
• ECT sensor
Radiator cooling fan Radiator cooling fan • CKP sensor
control relay • A/C refrigerant pressure sensor
• BCM (electric load signal and A/C switch status signal)
• ABS control module (wheel speed signal)
• Ignition “ON” signal
Fuel pump control Fuel pump relay • Ignition “ST” signal
• CKP sensor
 Engine General Information and Diagnosis: K12M 1A-129

Function Output Input

Starting motor control Starting motor control
• Ignition “ST” signal
relay control (M/T model) relay
Main relay control Main relay • Ignition “ON” signal
1A-130 Engine General Information and Diagnosis: K12M

Schematic and Routing Diagram

Engine and Emission Control System Diagram
AENJCA0A1122001

27

34
28
20

21

30
36

18

19

29
31
[B]

32

33
[A]

26
25

24
17

35

23
15
2

16

13

14

22
12
1

6
4

7
5

11
8

10
9

IJCA0A112003-02
 Engine General Information and Diagnosis: K12M 1A-131

[A]: M/T model 12. Knock sensor 25. CMP sensor

[B]: Auto gear shift model 13. ECT sensor 26. CKP sensor
1. Air cleaner 14. HO2S-1 27. Brake light
2. IAT sensor 15. HO2S-2 28. Brake light switch
3. TP sensor 16. OCV 29. Starting motor control relay
4. Throttle actuator 17. ECM 30. Ignition switch
5. MAP sensor 18. Radiator cooling fan relay No.1, 2 and 3 31. TCM
6. Ignition coil assembly 19. A/C compressor relay 32. IG11 relay
7. Fuel injector 20. A/C refrigerant pressure sensor 33. Main relay
8. EVAP canister purge valve 21. Generator 34. Starting motor
9. EVAP canister 22. Fuel pump relay 35. Barometric pressure sensor
10. Fuel cut valve 23. CPP No.2 switch (M/T model) 36. Control modules and sensor connected by CAN
11. Fuel pump (with pressure regulator) 24. APP sensor
 CAN communication line Air Vapor

Exhaust gas Fuel

*: If equipped

Electric throttle Intake manifold

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

EVAP canister ECT

purge valve Fuel sensor
Fuel cut valve pump

EVAP Fuel
Fuel tank pump
canister
relay
Engine and Emission Control System Flow Diagram
1A-132 Engine General Information and Diagnosis: K12M

Heater Heater
control control
ECM Barometric pressure sensor

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

A/C compressor Starting motor Brake light switch Main relay

relay control relay

IJCA0A112004-01
AENJCA0A1122002
 Engine General Information and Diagnosis: K12M 1A-133

Electronic Control System Circuit Diagram

AENJCA0A1122003

1
2 28 +B
GRN E02-20 C02-51 LT GRN
3 29
PNK E02-16 C02-54 BRN
GRY E02-19 C02-13 RED
30
BLU E02-6 C02-26 GRN
31
4 GRY E02-3 C02-16 WHT
YEL E02-5 C02-15 BLK
+B C02-17 BLK 68
32
C02-31 PNK
5 C02-11 WHT 33
PPL C02-30
C02-10 RED 34

6 C02-12 GRN 35
PNK C02-39
GRY 36
C02-41 GRY
7 68
+B 37
RED C02-6 C02-42 GRN
GRN C02-7 38
BLU PPL C02-49 E02-24 YEL
BLK PNK +BB
LT GRN C02-55
39 40
8 68
YEL C02-8 E02-2 LT GRN 44
BLU
BRN C02-19
BLU RED C02-52 GRN
BEG BLU
C02-56 42
L+ GRY
E02-27 GRN 43
H+
9 L-
YEL C02-22 BLK H- 41
LT BLU
BEG C02-5 45
10 E02-41 GRY
WHT C02-25 46 47
GRY BLU
BLU C02-37

48
11 LT BLU C02-14
C02-44 YEL
BRN C02-27 49
GRY C02-4 C02-33 GRN
12
BLU C02-20 50
13 LT GRN E02-14 C02-34 PNK
51
BEG E02-33
C02-35 BEG
BLK E02-9

25 C02-1 BLU 52

+BB 53
E02-49 PNK
[A] 14 54
18 E02-55 BLU
GRN E02-42
E02-56 BLU

15
26
16 YEL E02-18
17 55 56
57
E02-1 WHT

IG2
[B] 58
WHT C02-2 IG1 59
63
RED C02-3
+BB ST 60
20 61
WHT E02-29
19 27
RED E02-28 62

[A] E02-38 GRN 66

64
YEL E02-21
21 22 [B] 67
63
23 65
24 E02-43 LT BLU
C02-50 BLK
C02-53 BLK
: 69 : 70 : 12V : 5V : 3.3V
IJCA0A112005-01
1A-134 Engine General Information and Diagnosis: K12M

[A]: M/T model 23. A/C switch 47. “CPRSR” fuse

[B]: Auto gear shift model 24. To BCM 48. Ignition coil assembly No.1
1. ECM 25. LIN driver 49. Ignition coil assembly No.2
2. APP sensor 26. Barometric pressure sensor 50. Ignition coil assembly No.3
3. APP sensor (main) 27. CAN driver 51. Ignition coil assembly No.4
4. APP sensor (sub) 28. Electric throttle body assembly 52. Generator
5. CMP sensor 29. Throttle actuator 53. Main relay
6. CKP sensor 30. TP sensor (main) 54. “FI” fuse
7. HO2S-1 31. TP sensor (sub) 55. “IG” fuse
8. HO2S-2 32. Fuel injector No.1 56. IG11 relay
9. IAT sensor 33. Fuel injector No.2 57. “IGN” fuse
10. Knock sensor 34. Fuel injector No.3 58. Ignition switch
11. MAP sensor 35. Fuel injector No.4 59. “KEY” fuse
12. ECT sensor 36. EVAP canister purge valve 60. “KEY2” fuse
13. A/C refrigerant pressure sensor 37. OCV 61. “ST” fuse
14. CPP No.2 switch 38. Fuel pump relay 62. Starting motor control relay
15. Brake light switch 39. Fuel pump 63. TCM
16. Brake light 40. Radiator cooling fan relay No.1 64. Starting motor
17. To other control modules 41. Radiator cooling fan relay No.2 65. “ST SIG” fuse
18. “STOP” fuse 42. Radiator cooling fan relay No.3 66. Main fuse box
19. DLC 43. Radiator cooling fan 67. Battery
20. To other control modules and sensor 44. “RDTR” fuse 68. Shield wire
connected by CAN
21. To blower motor 45. A/C compressor relay 69. Engine ground
22. Blower speed switch 46. A/C compressor 70. Body ground

Terminal Arrangement of ECM Connector

NOTE
For circuit names and terminal voltages, refer to “Inspection of ECM and Its Circuits”: K12M (Page 1A-
254).

[A] C02 E02

[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

IGSB0A112007-01

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

 Engine General Information and Diagnosis: K12M 1A-135

Component Location
Electronic Control System Component Location
AENJCA0A1123001
Engine Compartment

[a]

[1]

[2]

[d] [e]
[b]
[c]

[h]

[g]
[f]

IJCA0A112006-01

Information sensors Control devices Others

1. A/C refrigerant pressure sensor
[a]: Generator [1]: ECM
[b]: A/C compressor relay [2]: Individual circuit fuse box No.1
[c]: Radiator cooling fan relay No.2
[d]: Radiator cooling fan relay No.1
[e]: Radiator cooling fan relay No.3
[f]: Fuel pump relay
[g]: Main relay
[h]: Starting motor control relay
1A-136 Engine General Information and Diagnosis: K12M

Interior (Around Instrument Panel)

[A] [B]
[1] [1]

[a] [a]

[1]

[2]
2

IJCA0A112007-01

Information sensors Control devices Others

1. APP sensor [a]: MIL [A]: Without tachometer
2. CPP No.2 switch (M/T model) [B]: With tachometer
3. Brake light switch [1]: Combination meter
[2]: DLC
 Engine General Information and Diagnosis: K12M 1A-137

Engine Assembly

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

2, [e]

[m]

[f]
8
4 3

5
IJCA0A112008-01

Information sensors Control devices

1. IAT sensor [a]: Ignition coil assembly No.1
2. TP sensor [b]: Ignition coil assembly No.2
3. ECT sensor [c]: Ignition coil assembly No.3
4. HO2S-1 [d]: Ignition coil assembly No.4
5. HO2S-2 [e]: Electric throttle body assembly
6. MAP sensor [f]: EVAP canister purge valve
7. CMP sensor [g]: Fuel injector No.4
8. Knock sensor [h]: Fuel injector No.3
9. CKP sensor [i]: Fuel injector No.2
[k]: Fuel injector No.1
[m]: OCV
1A-138 Engine General Information and Diagnosis: K12M

Diagnostic Information and Procedures

Engine and Emission Control System Check
AENJCA0A1124001
Refer to the following items for the details of each step.
Step Action Yes No
1 Customer complaint analysis Go to Step 2. Perform customer
1) Perform customer complaint analysis. (Page 1A-139) complaint analysis.

Was customer complaint analysis performed?

2 DTC / freeze frame data check, record and clearance Print DTCs and freeze Go to Step 4.
1) Check for DTCs (including pending DTCs). (Page 1A- frame data or write them
140) down and clear them
referring to “DTC
Is there any DTC(s) / freeze frame data? Clearance”: K12M
(Page 1A-141), and go
to Step 3.
3 Visual inspection Repair or replace Go to Step 5.
1) Perform visual inspection. (Page 1A-140) defective part, and then
go to Step 11.
Is there any faulty condition?
4 Visual inspection Repair or replace Go to Step 8.
1) Perform visual inspection. (Page 1A-140) defective part, and then
go to Step 11.
Is there any faulty condition?
5 Trouble symptom confirmation Go to Step 6. Go to Step 7.
1) Check trouble symptom. (Page 1A-140)

Is trouble symptom identified?

6 Rechecking and recording DTC / freeze frame data Go to Step 9. Go to Step 8.
1) Recheck for DTC and freeze frame data. (Page 1A-
140)

Is there any DTC(s)?

7 Rechecking and recording DTC / freeze frame data Go to Step 9. Go to Step 10.
1) Recheck for DTC and freeze frame data. (Page 1A-
140)

Is there any DTC(s)?

8 Engine basic inspection and engine symptom diagnosis Go to Step 11. Check and repair
1) Check and repair. (Page 1A-140) defective part(s), and go
to Step 11.
Are check and repair complete?
9 Troubleshooting for DTC Go to Step 11. Check and repair
1) Check and repair according to applicable DTC defective part(s), and go
troubleshooting. (Page 1A-140) to Step 11.

Are check and repair complete?

10 Intermittent problem check Repair or replace Go to Step 11.
1) Check for intermittent problems. (Page 1A-140) defective part(s), and go
to Step 11.
Is there any faulty condition?
11 Final confirmation test Go to Step 6. End.
1) Clear DTC if any.
2) Perform final confirmation test. (Page 1A-140)

Is there any problem symptom, DTC or abnormal condition?

 Engine General Information and Diagnosis: K12M 1A-139

Step 1: Customer Complaint Analysis

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

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

Customer questionnaire form (Example)

I9P60A111042-01
1A-140 Engine General Information and Diagnosis: K12M

Step 2: DTC / Freeze Frame Data Check, Record and MIL Check
Clearance AENJCA0A1124002

First, check DTC (including pending DTC). (Page 1A-
140)
If DTC is indicated, print it and freeze frame data or write
them down and then clear them. (Page 1A-141)
Steps 3 and 4: Visual Inspection
As a preliminary step, perform visual check of the items
that support proper function of the engine. (Page 1A-
158)
Step 5: Trouble Symptom Confirmation
If there is no DTC in Step 2:
Based on information obtained in “Step 1: Customer
Complaint Analysis”: K12M (Page 1A-139) and “Step 2:
DTC / Freeze Frame Data Check, Record and
Clearance”: K12M (Page 1A-140), check trouble
symptoms.
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)”: K12M
(Page 1A-169) for troubleshooting.
If MIL does not light with ignition “ON” and engine
does not start though it is cranked, go to “ECM
Power Supply and Ground Circuit Check”: K12M
(Page 1A-267).
2) Start engine and check that MIL turns off.
If MIL remains on and no DTC is stored in ECM and
TCM (auto gear shift model in Section 5D), go to
“MIL Remains ON after Engine Starts”: K12M (Page
1A-169) for troubleshooting.
[A]

If there is any DTC in Step 2:

Recheck DTC according to “DTC Confirmation 1
Procedure” described in each DTC troubleshooting.

Steps 6 and 7: Rechecking and Recording DTC /

Freeze Frame Data
Refer to “DTC Check”: K12M (Page 1A-140) for
checking procedure.
[B]
Step 8: Engine Basic Inspection and Engine
Symptom Diagnosis
1) Perform engine basic inspection. (Page 1A-159)
1
2) If there is no faulty part found in inspection
procedure of “Engine Basic Inspection”, perform
“Engine Symptom Diagnosis”: K12M (Page 1A-160)
based on symptom found in vehicle checking in the
following steps.
• Customer complaint analysis
IJCA0A112009-01
• Trouble symptom confirmation
[A]: Without tachometer [B]: With tachometer

Step 9: Troubleshooting for DTC

Perform applicable DTC troubleshooting and repair or DTC Check
AENJCA0A1124003
replace faulty parts.
NOTE
Step 10: Intermittent Problem Check In case that MIL turns on, the malfunction(s)
If there is no DTC in Step 2: is detected in either ECM or TCM (auto gear
Check for intermittent problem. (Page 00-13) shift model in Section 5D) and it stores the
trouble information (DTC, freeze frame data,
If there is any DTC in Step 2: etc.) in its memory.
Check parts related to detected DTC (e.g. wire harness,
connector, etc.). 1) Set ignition “OFF”.
2) Connect SUZUKI scan tool to DLC (1).
Step 11: Final Confirmation Test Special tool
Check that the problem symptom has gone and engine (A): SUZUKI scan tool (Suzuki SDT-II)
is free from any abnormal conditions. If what has been
repaired is related to DTC, clear DTC once, perform 3) Set ignition “ON”.
DTC confirmation procedure and check that no DTC is
indicated.
 Engine General Information and Diagnosis: K12M 1A-141
4) Read DTC, pending DTC and freeze frame data
according to instructions displayed on SUZUKI scan
tool and print them or write them down. Refer to
Operator's Manual of SUZUKI scan tool for further
details.
NOTE
If communication between SUZUKI scan tool
and ECM is not possible, perform the
following checks:
• Check communication condition between
PC and VCI (2) using SUZUKI scan tool
function.
• Check DLC power circuit and ground
circuit.
• Check DLC cable. If necessary, check DLC
cable by substituting a known-good DLC
cable.
• Check CAN communication system.
(“Control Module Communication Bus Off”
is detected in any control module.) (Page
10H-15)
• Check ECM power circuit and ground
circuit. (Page 1A-267)
1
(A)
IJCA0A111011-01
5) After completing the check, set ignition “OFF” and
disconnect SUZUKI scan tool from DLC.
DTC Clearance
AENJCA0A1124004
1) Set ignition “OFF”.
2) Connect SUZUKI scan tool to DLC (1).
Special tool
(A): SUZUKI scan tool (Suzuki SDT-II)
3) Set ignition “ON”.
4) Clear DTC and pending DTC according to
instructions displayed on SUZUKI scan tool and print
them or write them down. Refer to Operator's
Manual of SUZUKI scan tool for further details.
NOTE
If communication between SUZUKI scan tool
and ECM is not possible, perform the
following checks:
• Check communication condition between
PC and VCI (2) using SUZUKI scan tool
function.
• Check DLC power circuit and ground
circuit.
• Check DLC cable. If necessary, check DLC
cable by substituting a known-good DLC
cable.
• Check CAN communication system.
(“Control Module Communication Bus Off”
is detected in any control module.) (Page
10H-15)
• Check ECM power circuit and ground
circuit. (Page 1A-267)
2
(A)
IJCA0A111011-01
5) After completing DTC clearance, set ignition “OFF”
and disconnect SUZUKI scan tool from DLC.
1A-142 Engine General Information and Diagnosis: K12M

NOTE
DTC and freeze frame data stored in ECM
memory are also cleared in the following
case. Be careful not to clear them before
recording them.
• When the same malfunction (DTC) is not
detected again for 40 engine warm-up
cycles. (See “Warm-Up Cycle” under “OBD
System Description”: K12M (Page 1A-
117).)

6) Perform “Electric Throttle Control System

Calibration”: K12M in Section 1C (Page 1C-25).

DTC Table
AENJCA0A1124005
NOTE
• When DTC P0300 / P0301 / P0302 / P0303 / P0304 is detected, MIL blinks or lights up according to
detecting condition. For details, refer to “DTC P0300 / P0301 / P0302 / P0303 / P0304”: K12M (Page
1A-204).
• With the CAN communication generic scan tool, only DTC with asterisk (*) in the following table can
be read.
• “1 D/C / 3 D/C” in “DTC detection logic” column of table below means DTC detecting logic varies
depending on DTC detecting condition.
For details, refer to each “DTC Detecting Condition and Trouble Area”.
• “Lights up / Off” in “MIL” column of table below means MIL operation varies depending on DTC
detection condition.
For details, refer to each “DTC Detecting Condition and Trouble Area”.

DTC
DTC DTC name DTC detecting condition MIL
detection logic
*P0010 “A” Camshaft Position
(Page 1A- Actuator Circuit / Open (Bank OCV drive circuit is open. 3 D/C Lights up
170) 1)
“A” Camshaft Position Timing
*P0011 (Page Measured CMP does not reach target
Over Advanced or System 3 D/C Lights up
1A-172) CMP for specified time.
Performance (Bank 1)
*P0016 Crankshaft Position - Difference between camshaft position
(Page 1A- Camshaft Position and crankshaft position is out of specified 3 D/C Lights up
174) Correlation (Bank1 SensorA) range.
*P0030
HO2S Heater Control Circuit
(Page 1A- HO2S-1 heater drive circuit is open. 3 D/C Lights up
(Bank 1 Sensor 1)
175)
*P0031
HO2S Heater Control Circuit HO2S-1 heater drive circuit is shorted to
(Page 1A- 3 D/C Lights up
Low (Bank 1 Sensor 1) ground.
175)
*P0032
HO2S Heater Control Circuit HO2S-1 heater drive circuit is shorted to
(Page 1A- 3 D/C Lights up
High (Bank 1 Sensor 1) power supply.
175)
*P0036
HO2S Heater Control Circuit
(Page 1A- HO2S-2 heater drive circuit is open. 3 D/C Lights up
(Bank 1 Sensor 2)
177)
*P0037
HO2S Heater Control Circuit HO2S-2 heater drive circuit is shorted to
(Page 1A- 3 D/C Lights up
Low (Bank 1 Sensor 2) ground.
177)
*P0038
HO2S Heater Control Circuit HO2S-2 heater drive circuit is shorted to
(Page 1A- 3 D/C Lights up
High (Bank 1 Sensor 2) power supply.
177)
 Engine General Information and Diagnosis: K12M 1A-143

DTC
DTC DTC name DTC detecting condition MIL
detection logic
*P0107 Manifold Absolute Pressure /
Output voltage of MAP sensor signal
(Page 1A- Barometric Pressure Circuit 3 D/C Lights up
circuit is lower than 0.1 V for 5 sec.
179) Low
*P0108 Manifold Absolute Pressure /
Output voltage of MAP sensor signal
(Page 1A- Barometric Pressure Circuit 3 D/C Lights up
circuit is higher than 4.8 V for 5 sec.
179) High
Intake Air Temperature
*P0112 (Page Output voltage of IAT sensor signal circuit
Sensor 1 Circuit Low (Bank 3 D/C Lights up
1A-181) is lower than 0.02 V for 5 sec.
1)
Intake Air Temperature
*P0113 (Page Output voltage of IAT sensor signal circuit
Sensor 1 Circuit High (Bank 3 D/C Lights up
1A-181) is higher than 4.9 V for 5 sec.
1)
Difference between measured ECT and
Engine Coolant Temperature
*P0116 (Page estimated ECT is more than specified
Sensor 1 Circuit Range / 3 D/C Lights up
1A-182) value for specified time with engine
Performance
running.
*P0117 (Page Engine Coolant Temperature Output voltage of ECT sensor signal
3 D/C Lights up
1A-184) Sensor 1 Circuit Low circuit is lower than 0.02 V for 5 sec.
*P0118 (Page Engine Coolant Temperature Output voltage of ECT sensor signal
3 D/C Lights up
1A-184) Sensor 1 Circuit High circuit is higher than 4.9 V for 5 sec.
*P0122 Throttle / Pedal Position
Output voltage of TP sensor (main) signal
(Page 1A- Sensor / Switch “A” Circuit 1 D/C Lights up
circuit is lower than 0.2 V.
185) Low
*P0123 Throttle / Pedal Position
Output voltage of TP sensor (main) signal
(Page 1A- Sensor / Switch “A” Circuit 1 D/C Lights up
circuit is higher than 4.8 V.
185) High
Any of the following conditions is met.
• HO2S-1 signal voltage is between 0.06
*P0130 V and 0.4 V even if HO2S-2 signal
O2 Sensor Circuit (Bank 1
(Page 1A- voltage is higher than 0.6 V for 25 sec. 3 D/C Lights up
Sensor 1)
187) • HO2S-1 signal voltage is between 0.6
V and 1.25 V even if HO2S-2 signal
voltage is lower than 0.1 V for 25 sec.
*P0131 Output voltage of HO2S-1 circuit is lower
O2 Sensor Circuit Low
(Page 1A- than 0.06 V and output voltage of HO2S-2 3 D/C Lights up
Voltage (Bank 1 Sensor 1)
189) circuit is higher than 0.6 V for 25 sec.
*P0132
O2 Sensor Circuit High Output voltage of HO2S-1 circuit is higher
(Page 1A- 3 D/C Lights up
Voltage (Bank 1 Sensor 1) than 1.25 V for 25 sec.
189)
*P0133 Cycle duration from rich to lean and lean
O2 Sensor Circuit Slow
(Page 1A- to rich of HO2S-1 is longer than specified 3 D/C Lights up
Response (Bank 1 Sensor 1)
191) time.
*P0134
O2 Sensor Circuit No Activity Output voltage of HO2S-1 circuit stays
(Page 1A- 3 D/C Lights up
Detected (Bank 1 Sensor 1) between 0.4 and 0.6 V for 24 sec.
193)
*P0137
O2 Sensor Circuit Low Output voltage of HO2S-2 circuit is lower
(Page 1A- 3 D/C Lights up
Voltage (Bank 1 Sensor 2) than 0.06 V for 25 sec. after warming up.
195)
*P0138
O2 Sensor Circuit High Output voltage of HO2S-2 signal circuit is
(Page 1A- 3 D/C Lights up
Voltage (Bank 1 Sensor 2) higher than 1.25 V for 25 sec.
195)
*P0140
O2 Sensor Circuit No Activity Output voltage of HO2S-2 circuit stays
(Page 1A- 3 D/C Lights up
Detected (Bank 1 Sensor 2) between 0.4 and 0.6 V for 24 sec.
195)
*P0171 Fuel trim correction is higher than
(Page 1A- System Too Lean (Bank 1) specified value for specified time under 3 D/C Lights up
197) specified vehicle condition.
1A-144 Engine General Information and Diagnosis: K12M

DTC
DTC DTC name DTC detecting condition MIL
detection logic
*P0172 Fuel trim correction is lower than
(Page 1A- System Too Rich (Bank 1) specified value for specified time under 3 D/C Lights up
197) specified vehicle condition.
*P0201
Injector Circuit / Open – Fuel injector No.1 and/or its circuit is open
(Page 1A- 3 D/C Lights up
Cylinder 1 with engine running.
199)
*P0202
Injector Circuit / Open – Fuel injector No.2 and/or its circuit is open
(Page 1A- 3 D/C Lights up
Cylinder 2 with engine running.
199)
*P0203
Injector Circuit / Open – Fuel injector No.3 and/or its circuit is open
(Page 1A- 3 D/C Lights up
Cylinder 3 with engine running.
199)
*P0204
Injector Circuit / Open – Fuel injector No.4 and/or its circuit is open
(Page 1A- 3 D/C Lights up
Cylinder 4 with engine running.
199)
*P0222 Throttle / Pedal Position
Output voltage of TP sensor (sub) signal
(Page 1A- Sensor / Switch “B” Circuit 1 D/C Lights up
circuit is lower than 0.2 V.
202) Low
*P0223 Throttle / Pedal Position
Output voltage of TP sensor (sub) signal
(Page 1A- Sensor / Switch “B” Circuit 1 D/C Lights up
circuit is higher than 4.8 V.
202) High
*P0261
Cylinder 1 Injector Circuit Fuel injector No.1 drive circuit is shorted
(Page 1A- 3 D/C Lights up
Low to ground with engine running.
199)
*P0262
Cylinder 1 Injector Circuit Fuel injector No.1 drive circuit is shorted
(Page 1A- 3 D/C Lights up
High to power supply with engine running.
199)
*P0264
Cylinder 2 Injector Circuit Fuel injector No.2 drive circuit is shorted
(Page 1A- 3 D/C Lights up
Low to ground with engine running.
199)
*P0265
Cylinder 2 Injector Circuit Fuel injector No.2 drive circuit is shorted
(Page 1A- 3 D/C Lights up
High to power supply with engine running.
199)
*P0267
Cylinder 3 Injector Circuit Fuel injector No.3 drive circuit is shorted
(Page 1A- 3 D/C Lights up
Low to ground with engine running.
199)
*P0268
Cylinder 3 Injector Circuit Fuel injector No.3 drive circuit is shorted
(Page 1A- 3 D/C Lights up
High to power supply with engine running.
199)
*P0270
Cylinder 4 Injector Circuit Fuel injector No.4 drive circuit is shorted
(Page 1A- 3 D/C Lights up
Low to ground with engine running.
199)
*P0271
Cylinder 4 Injector Circuit Fuel injector No.4 drive circuit is shorted
(Page 1A- 3 D/C Lights up
High to power supply with engine running.
199)
Any of the following conditions is met.
• Misfire, which causes catalyst to
overheat during 200 engine
revolutions, is detected at 2 or more
*P0300
Random / Multiple Cylinder cylinders. (MIL blinks as long as misfire
(Page 1A- 3 D/C Lights up
Misfire Detected lasts.)
204)
• Misfire, which affects exhaust emission
adversely during 1,000 engine
revolutions, is detected at 2 or more
cylinders.
 Engine General Information and Diagnosis: K12M 1A-145

DTC
DTC DTC name DTC detecting condition MIL
detection logic
*P0301
(Page 1A- Cylinder 1 Misfire Detected Any of the following conditions is met. 3 D/C Lights up
204) • Misfire, which causes catalyst to
*P0302 overheat during 200 engine
(Page 1A- Cylinder 2 Misfire Detected revolutions, is detected at specific 3 D/C Lights up
204) cylinder. (MIL blinks as long as misfire
*P0303 lasts.)
(Page 1A- Cylinder 3 Misfire Detected • Misfire, which affects exhaust emission 3 D/C Lights up
204) adversely during 1,000 engine
*P0304 revolutions, is detected at specific
(Page 1A- Cylinder 4 Misfire Detected cylinder. 3 D/C Lights up
204)
*P0327 Output voltage of knock sensor signal
Knock Sensor 1 Circuit Low
(Page 1A- circuit is lower than specified value for 3 D/C Lights up
(Bank 1 or Single Sensor)
206) specified time with engine running.
*P0328 Output voltage of knock sensor signal
Knock Sensor 1 Circuit High
(Page 1A- circuit is higher than specified value for 3 D/C Lights up
(Bank 1 or Single Sensor)
206) specified time with engine running.
*P0335
Crankshaft Position Sensor CKP sensor signal is not inputted while
(Page 1A- 3 D/C Lights up
“A” Circuit CMP sensor signal is being inputted.
208)
Any of the following conditions is met.
• Signal detecting time is longer than
*P0336 Crankshaft Position Sensor specification.
(Page 1A- “A” Circuit Range/ • Number of teeth between gaps is more 3 D/C Lights up
208) Performance than specification.
• Time between adjacent two teeth is
longer than specification.
Any of the following conditions is met.
• CMP sensor signal is not inputted
*P0340 Camshaft Position Sensor
while CKP sensor signal is being
(Page 1A- “A” Circuit (Bank 1 or Single 3 D/C Lights up
inputted.
210) Sensor)
• CMP sensor signal pattern is not equal
to the expected pattern.
*P0351
Ignition Coil “A” Primary / Ignition coil assembly No.1 and/or its
(Page 1A- 3 D/C Lights up
Secondary Circuit circuit is open with engine running.
212)
*P0352
Ignition Coil “B” Primary / Ignition coil assembly No.2 and/or its
(Page 1A- 3 D/C Lights up
Secondary Circuit circuit is open with engine running.
212)
*P0353
Ignition Coil “C” Primary / Ignition coil assembly No.3 and/or its
(Page 1A- 3 D/C Lights up
Secondary Circuit circuit is open with engine running.
212)
*P0354
Ignition Coil “D” Primary / Ignition coil assembly No.4 and/or its
(Page 1A- 3 D/C Lights up
Secondary Circuit circuit is open with engine running.
212)
*P0420 Average amplitude of HO2S-2 signal is
Catalyst System Efficiency
(Page 1A- more than specified value for 60 sec. 3 D/C Lights up
Below Threshold (Bank 1)
215) under specified vehicle condition.
*P0443 Evaporative Emission
EVAP canister purge valve drive circuit is
(Page 1A- System Purge Control Valve 3 D/C Lights up
open with engine running.
217) Circuit
*P0458 Evaporative Emission
EVAP canister purge valve drive circuit is
(Page 1A- System Purge Control Valve 3 D/C Lights up
shorted to ground with engine running.
217) Circuit Low
1A-146 Engine General Information and Diagnosis: K12M

DTC
DTC DTC name DTC detecting condition MIL
detection logic
*P0459 Evaporative Emission EVAP canister purge valve drive circuit is
(Page 1A- System Purge Control Valve shorted to power supply with engine 3 D/C Lights up
217) Circuit High running.
P0480 (Page Radiator cooling fan relay No.1 drive
Fan 1 Control Circuit 3 D/C Off
1A-219) circuit is shorted to ground or open.
Radiator cooling fan relay No.2 and/or
P0481 (Page
Fan 2 Control Circuit No.3 drive circuit is shorted to ground or 3 D/C Off
1A-221)
open.
*P0500
Vehicle speed is slower than 4 km/h (2
(Page 1A- Vehicle Speed Sensor “A” 3 D/C Lights up
mile/h) for 5 sec. at fuel cut condition.
223)
*P0504
Brake Switch “A”/“B” Brake light switch signal does not
(Page 1A- 1 D/C Lights up
Correlation correlate with brake switch signal.
225)
Any of the following conditions is met.
• Output voltage of A/C refrigerant
pressure sensor signal circuit is lower
P0530 (Page A/C Refrigerant Pressure
than 0.15 V. 3 D/C Off
1A-226) Sensor “A” Circuit
• Output voltage of A/C refrigerant
pressure sensor signal circuit is higher
than 4.93 V.
*P0560
Main power supply voltage is lower than
(Page 1A- System Voltage 3 D/C Lights up
2.54 V for 10 sec.
228)
*P0562
Main power supply circuit voltage is lower
(Page 1A- System Voltage Low 3 D/C Lights up
than 9.8 V for 10 sec.
228)
*P0563
Main power supply circuit voltage is
(Page 1A- System Voltage High 3 D/C Lights up
higher than 18.0 V for 10 sec.
228)
*P0602
Control Module Programming ECM internal failure (data programming
(Page 1A- 1 D/C Lights up
Error error).
230)
*P0606
(Page 1A- Control Module Processor ECM internal processor failure 3 D/C Lights up
230)
*P0607
Lights up /
(Page 1A- Control Module Performance Internal failure in ECM is detected. 1 D/C or 3 D/C
Off
231)
P0645 (Page A/C Clutch Relay Control A/C compressor relay drive circuit is
3 D/C Off
1A-232) Circuit open.
P0646 (Page A/C Clutch Relay Control A/C compressor relay drive circuit is
3 D/C Off
1A-232) Circuit Low shorted to ground.
P0647 (Page A/C Clutch Relay Control A/C compressor relay drive circuit is
3 D/C Off
1A-232) Circuit High shorted to power supply.
P0692 (Page Radiator cooling fan relay No.1 drive
Fan 1 Control Circuit High 3 D/C Off
1A-219) circuit is shorted to power supply.
Radiator cooling fan relay No.2 and/or
P0694 (Page
Fan 2 Control Circuit High No.3 drive circuit is shorted to power 3 D/C Off
1A-221)
supply.
P1520 (Page ECM Starter protection circuit Starting motor control relay drive circuit is
1 D/C Off
1A-234) on error shorted to ground.
P1521 (Page ECM Starter protection circuit Starting motor control relay drive circuit is
1 D/C Off
1A-234) off error shorted to power supply.
 Engine General Information and Diagnosis: K12M 1A-147

DTC
DTC DTC name DTC detecting condition MIL
detection logic
Immobilizer ID and/or
P1610 1 D/C Off
Password Not Registered
P1611 Password Not Matched 1 D/C Off
EEPROM Reading / Writing
P1622 Refer to “DTC Table” in Section 10C 1 D/C Off
Error
(Page 10C-5).
Immobilizer Communication
P1642 1 D/C Off
Line Error
P1644 Immobilizer ID Mismatched 1 D/C Off
P1646 ID Code Incorrectness 1 D/C Off
ECM detects incorrect vehicle variant
P1693 (Page Equipment Information
data from ABS control module and 1 D/C Off
1A-236) Mismatched
combination meter is mismatched.
*P2088 “A” Camshaft Position
(Page 1A- Actuator Control Circuit Low OCV drive circuit is shorted to ground. 3 D/C Lights up
170) (Bank 1)
*P2089 “A” Camshaft Position
OCV drive circuit is shorted to power
(Page 1A- Actuator Control Circuit High 3 D/C Lights up
supply.
170) (Bank 1)
*P2100 Throttle actuator and/or its circuit
Throttle Actuator “A” Control
(Page 1A- malfunction (open, short to power supply 1 D/C Lights up
Motor Circuit / Open
237) or short to ground) is detected.
Any of the following conditions is met.
• Difference between measured throttle
valve position and targeted throttle
*P2101 Throttle Actuator “A” Control
valve position is more than specified
(Page 1A- Motor Circuit Range / 1 D/C Lights up
value.
239) Performance
• Duty ratio of throttle actuator signal is
out of specified range for specified
time.
Any of the following conditions is met.
• Time taken by throttle valve to return
from partially open position to
Throttle Actuator Control mechanical default position is more
*P2119 (Page
Throttle Body Range / than specified time during return spring 1 D/C Lights up
1A-239)
Performance check process after setting ignition
“OFF”.
• Measured default throttle position is
out of specified range.
*P2122 Throttle / Pedal Position
Output voltage of APP sensor (main)
(Page 1A- Sensor / Switch “D” Circuit 1 D/C Lights up
signal circuit is lower than 0.4 V.
241) Low
*P2123 Throttle / Pedal Position
Output voltage of APP sensor (main)
(Page 1A- Sensor / Switch “D” Circuit 1 D/C Lights up
signal circuit is higher than 4.8 V.
241) High
*P2127 Throttle / Pedal Position
Output voltage of APP sensor (sub)
(Page 1A- Sensor / Switch “E” Circuit 1 D/C Lights up
signal circuit is lower than 0.2 V.
243) Low
*P2128 Throttle / Pedal Position
Output voltage of APP sensor (sub)
(Page 1A- Sensor / Switch “E” Circuit 1 D/C Lights up
signal circuit is higher than 2.4 V.
243) High
*P2135 Throttle / Pedal Position Difference between TP sensor (main)
(Page 1A- Sensor / Switch “A” / “B” signal voltage and TP sensor (sub) signal 1 D/C Lights up
245) Voltage Correlation voltage is higher than specified value.
*P2138 Throttle / Pedal Position Difference between half of APP (main)
(Page 1A- Sensor / Switch “D” / “E” sensor signal and APP (sub) sensor 1 D/C Lights up
246) Voltage Correlation signal is more than specified value.
1A-148 Engine General Information and Diagnosis: K12M

DTC
DTC DTC name DTC detecting condition MIL
detection logic
Any of the following conditions is met.
• TP sensor (main) or TP sensor (sub)
*P2176 Throttle Actuator Control
signal voltage at default position is out
(Page 1A- System – Idle Position Not 1 D/C Lights up
of specified range for specified time.
248) Learned
• Electric throttle control system
calibration is not completed.
*P2226 Barometric pressure sensor and/or its
Barometric Pressure Sensor
(Page 1A- circuit malfunction (open, short to power 3 D/C Lights up
“A” Circuit
249) supply or short to ground) is detected.
Any of the following conditions is met.
• BARO sensor signal is out of specified
range.
*P2227 Barometric Pressure Sensor
(Page 1A- “A” Circuit Range / • Difference between actual and 3 D/C Lights up
249) Performance expected ambient pressure is more
than the specified value and the
fluctuation of ambient pressure is more
than the specified value.
Output voltage of HO2S-2 signal circuit is
*P2271
O2 Sensor Signal Biased / higher than 0.3 V for specified time after
(Page 1A- 3 D/C Lights up
Stuck Rich (Bank1 Sensor2) warming up even when vehicle is in fuel
250)
cut driving condition.
*P2300
Ignition Coil “A” Primary Ignition coil assembly No.1 drive circuit is
(Page 1A- 3 D/C Lights up
Control Circuit Low shorted to ground with engine running.
212)
*P2301 Ignition coil assembly No.1 drive circuit is
Ignition Coil “A” Primary
(Page 1A- shorted to power supply with engine 3 D/C Lights up
Control Circuit High
212) running.
*P2303
Ignition Coil “B” Primary Ignition coil assembly No.2 drive circuit is
(Page 1A- 3 D/C Lights up
Control Circuit Low shorted to ground with engine running.
212)
*P2304 Ignition coil assembly No.2 drive circuit is
Ignition Coil “B” Primary
(Page 1A- shorted to power supply with engine 3 D/C Lights up
Control Circuit High
212) running.
*P2306
Ignition Coil “C” Primary Ignition coil assembly No.3 drive circuit is
(Page 1A- 3 D/C Lights up
Control Circuit Low shorted to ground with engine running.
212)
*P2307 Ignition coil assembly No.3 drive circuit is
Ignition Coil “C” Primary
(Page 1A- shorted to power supply with engine 3 D/C Lights up
Control Circuit High
212) running.
*P2309
Ignition Coil “D” Primary Ignition coil assembly No.4 drive circuit is
(Page 1A- 3 D/C Lights up
Control Circuit Low shorted to ground with engine running.
212)
*P2310 Ignition coil assembly No.4 drive circuit is
Ignition Coil “D” Primary
(Page 1A- shorted to power supply with engine 3 D/C Lights up
Control Circuit High
212) running.
Control Module
U0073 1 D/C Off
Communication Bus Off
Lost Communication With
*U0101 1 D/C Lights up
TCM
Lost Communication With Refer to “CAN DTC (Lost Communication
*U0121 1 D/C Lights up
ABS / ESP® Control Module and Communication Bus Off) Table” in
Lost Communication With Section 10H (Page 10H-7).
U0140 1 D/C Off
Body Control Module
Lost Communication With
U0155 Instrument Panel Cluster 1 D/C Off
(IPC) Control Module
 Engine General Information and Diagnosis: K12M 1A-149

DTC
DTC DTC name DTC detecting condition MIL
detection logic
U2001 (Page LIN Lost Communication Received data from generator via LIN is
1 D/C Off
1A-252) With Generator faulty.
U2021 (Page LIN Invalid Data from ECM to Transmitted data from ECM to generator
1 D/C Off
1A-254) Generator via LIN is faulty.

Fail-Safe Table
AENJCA0A1124006
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 1A- “A” Camshaft Position Actuator Circuit /
170) Open (Bank 1)
P0011 (Page 1A- “A” Camshaft Position Timing Over
ECM stops VVT actuator control.
172) Advanced or System Performance (Bank 1)
P0016 (Page 1A- Crankshaft Position - Camshaft Position
174) Correlation (Bank1 SensorA)
P0030 (Page 1A- HO2S Heater Control Circuit (Bank 1
175) Sensor 1)
P0031 (Page 1A- HO2S Heater Control Circuit Low (Bank 1
175) Sensor 1)
P0032 (Page 1A- HO2S Heater Control Circuit High (Bank 1
175) Sensor 1)
—
P0036 (Page 1A- HO2S Heater Control Circuit (Bank 1
177) Sensor 2)
P0037 (Page 1A- HO2S Heater Control Circuit Low (Bank 1
177) Sensor 2)
P0038 (Page 1A- HO2S Heater Control Circuit High (Bank 1
177) Sensor 2)
P0107 (Page 1A- Manifold Absolute Pressure / Barometric
179) Pressure Circuit Low
ECM calculates MAP based on TP sensor signal.
P0108 (Page 1A- Manifold Absolute Pressure / Barometric
179) Pressure Circuit High
P0112 (Page 1A- Intake Air Temperature Sensor 1 Circuit
181) Low (Bank 1) ECM controls actuators assuming that intake air
P0113 (Page 1A- Intake Air Temperature Sensor 1 Circuit temperature is 20 °C (68 °F).
181) High (Bank 1)
P0116 (Page 1A- Engine Coolant Temperature Sensor 1
182) Circuit Range / Performance
P0117 (Page 1A- Engine Coolant Temperature Sensor 1 • ECM calculates ECT value from engine load.
184) Circuit Low • ECM operates radiator cooling fan. (high speed)
P0118 (Page 1A- Engine Coolant Temperature Sensor 1
184) Circuit High
P0122 (Page 1A- Throttle / Pedal Position Sensor / Switch
185) “A” Circuit Low • ECM performs fuel cut at specified engine speed.
P0123 (Page 1A- Throttle / Pedal Position Sensor / Switch • ECM stops VVT actuator control.
185) “A” Circuit High
P0130 (Page 1A-
O2 Sensor Circuit (Bank 1 Sensor 1)
187)
P0131 (Page 1A- O2 Sensor Circuit Low Voltage (Bank 1
ECM stops A/F feedback (closed loop) control.
189) Sensor 1)
P0132 (Page 1A- O2 Sensor Circuit High Voltage (Bank 1
189) Sensor 1)
P0133 (Page 1A- O2 Sensor Circuit Slow Response (Bank 1
—
191) Sensor 1)
P0134 (Page 1A- O2 Sensor Circuit No Activity Detected
ECM stops A/F feedback (closed loop) control.
193) (Bank 1 Sensor 1)
1A-150 Engine General Information and Diagnosis: K12M

DTC DTC name Fail-safe operation

P0137 (Page 1A- O2 Sensor Circuit Low Voltage (Bank 1
195) Sensor 2)
P0138 (Page 1A- O2 Sensor Circuit High Voltage (Bank 1
195) Sensor 2)
P0140 (Page 1A- O2 Sensor Circuit No Activity Detected
—
195) (Bank 1 Sensor 2)
P0171 (Page 1A-
System Too Lean (Bank 1)
197)
P0172 (Page 1A-
System Too Rich (Bank 1)
197)
P0201 (Page 1A- • ECM stops fuel injector No.1 control.
Injector Circuit / Open – Cylinder 1
199) • ECM stops A/F feedback (closed loop) control.
P0202 (Page 1A- • ECM stops fuel injector No.2 control.
Injector Circuit / Open – Cylinder 2
199) • ECM stops A/F feedback (closed loop) control.
P0203 (Page 1A- • ECM stops fuel injector No.3 control.
Injector Circuit / Open – Cylinder 3
199) • ECM stops A/F feedback (closed loop) control.
P0204 (Page 1A- • ECM stops fuel injector No.4 control.
Injector Circuit / Open – Cylinder 4
199) • ECM stops A/F feedback (closed loop) control.
P0222 (Page 1A- Throttle / Pedal Position Sensor / Switch
202) “B” Circuit Low • ECM performs fuel cut at specified engine speed.
P0223 (Page 1A- Throttle / Pedal Position Sensor / Switch • ECM stops VVT actuator control.
202) “B” Circuit High
P0261 (Page 1A-
Cylinder 1 Injector Circuit Low • ECM stops fuel injector No.1 control.
199)
P0262 (Page 1A- • ECM stops A/F feedback (closed loop) control.
Cylinder 1 Injector Circuit High
199)
P0264 (Page 1A-
Cylinder 2 Injector Circuit Low • ECM stops fuel injector No.2 control.
199)
P0265 (Page 1A- • ECM stops A/F feedback (closed loop) control.
Cylinder 2 Injector Circuit High
199)
P0267 (Page 1A-
Cylinder 3 Injector Circuit Low • ECM stops fuel injector No.3 control.
199)
P0268 (Page 1A- • ECM stops A/F feedback (closed loop) control.
Cylinder 3 Injector Circuit High
199)
P0270 (Page 1A-
Cylinder 4 Injector Circuit Low • ECM stops fuel injector No.4 control.
199)
P0271 (Page 1A- • ECM stops A/F feedback (closed loop) control.
Cylinder 4 Injector Circuit High
199)
P0300 (Page 1A- Random / Multiple Cylinder Misfire
—
204) Detected
P0301 (Page 1A- ECM stops fuel injector No.1 control for catalyst
Cylinder 1 Misfire Detected
204) damaging levels of misfire.
P0302 (Page 1A- ECM stops fuel injector No.2 control for catalyst
Cylinder 2 Misfire Detected
204) damaging levels of misfire.
P0303 (Page 1A- ECM stops fuel injector No.3 control for catalyst
Cylinder 3 Misfire Detected
204) damaging levels of misfire.
P0304 (Page 1A- ECM stops fuel injector No.4 control for catalyst
Cylinder 4 Misfire Detected
204) damaging levels of misfire.
P0327 (Page 1A- Knock Sensor 1 Circuit Low (Bank 1 or
206) Single Sensor)
ECM retards ignition timing.
P0328 (Page 1A- Knock Sensor 1 Circuit High (Bank 1 or
206) Single Sensor)
P0335 (Page 1A-
Crankshaft Position Sensor “A” Circuit
208)
ECM calculates CKP based on CMP sensor signal.
P0336 (Page 1A- Crankshaft Position Sensor “A” Circuit
208) Range/Performance
P0340 (Page 1A- Camshaft Position Sensor “A” Circuit (Bank • ECM stops VVT actuator control.
210) 1 or Single Sensor) • ECM retards ignition timing.
 Engine General Information and Diagnosis: K12M 1A-151

DTC DTC name Fail-safe operation

P0351 (Page 1A-
Ignition Coil “A” Primary / Secondary Circuit
212)
P0352 (Page 1A-
Ignition Coil “B” Primary / Secondary Circuit
212)
—
P0353 (Page 1A-
Ignition Coil “C” Primary / Secondary Circuit
212)
P0354 (Page 1A-
Ignition Coil “D” Primary / Secondary Circuit
212)
P0420 (Page 1A- Catalyst System Efficiency Below
—
215) Threshold (Bank 1)
P0443 (Page 1A- Evaporative Emission System Purge
217) Control Valve Circuit
P0458 (Page 1A- Evaporative Emission System Purge
—
217) Control Valve Circuit Low
P0459 (Page 1A- Evaporative Emission System Purge
217) Control Valve Circuit High
P0480 (Page 1A-
Fan 1 Control Circuit
219)
—
P0481 (Page 1A-
Fan 2 Control Circuit
221)
P0500 (Page 1A- ECM controls actuators assuming that vehicle
Vehicle Speed Sensor “A”
223) speed is 0 km/h (0 mile/h).
P0504 (Page 1A-
Brake Switch “A”/“B” Correlation —
225)
P0530 (Page 1A-
A/C Refrigerant Pressure Sensor “A” Circuit ECM stops A/C compressor relay control.
226)
P0560 (Page 1A- ECM controls actuators assuming that system
System Voltage
228) voltage is 13.5 V.
P0562 (Page 1A-
System Voltage Low
228)
—
P0563 (Page 1A-
System Voltage High
228)
P0602 (Page 1A-
Control Module Programming Error
230)
—
P0606 (Page 1A-
Control Module Processor
230)
Any one of the following operations will be taken:
• ECM performs fuel cut at specified engine speed.
P0607 (Page 1A-
Control Module Performance • ECM stops throttle valve control and all injector
231)
control.
• ECM resets internal memory.
P0645 (Page 1A-
A/C Clutch Relay Control Circuit
232)
P0646 (Page 1A-
A/C Clutch Relay Control Circuit Low —
232)
P0647 (Page 1A-
A/C Clutch Relay Control Circuit High
232)
P0692 (Page 1A-
Fan 1 Control Circuit High
219)
—
P0694 (Page 1A-
Fan 2 Control Circuit High
221)
P1520 (Page 1A-
ECM Starter protection circuit on error —
234)
P1521 (Page 1A-
ECM Starter protection circuit off error —
234)
P1693 (Page 1A-
Equipment Information Mismatched —
236)
1A-152 Engine General Information and Diagnosis: K12M

DTC DTC name Fail-safe operation

P2088 (Page 1A- “A” Camshaft Position Actuator Control
170) Circuit Low (Bank 1)
ECM stops VVT actuator control.
P2089 (Page “A” Camshaft Position Actuator Control
1A-170) Circuit High (Bank 1)
P2100 (Page 1A- Throttle Actuator “A” Control Motor Circuit /
237) Open
P2101 (Page 1A- Throttle Actuator “A” Control Motor Circuit
ECM performs fuel cut at specified engine speed.
239) Range / Performance
P2119 (Page 1A- Throttle Actuator Control Throttle Body
239) Range / Performance
P2122 (Page 1A- Throttle / Pedal Position Sensor / Switch
ECM limits APP signal within specified range. If
241) “D” Circuit Low
DTC P2127 or P2128 is detected at the same time,
P2123 (Page 1A- Throttle / Pedal Position Sensor / Switch
ECM controls engine speed at specified value.
241) “D” Circuit High
P2127 (Page 1A- Throttle / Pedal Position Sensor / Switch
ECM limits APP signal within specified range. If
243) “E” Circuit Low
DTC P2122 or P2123 is detected at the same time,
P2128 (Page 1A- Throttle / Pedal Position Sensor / Switch
ECM controls engine speed at specified value.
243) “E” Circuit High
P2135 (Page 1A- Throttle / Pedal Position Sensor / Switch • ECM performs fuel cut at specified engine speed.
245) “A” / “B” Voltage Correlation • ECM stops VVT actuator control.
P2138 (Page 1A- Throttle / Pedal Position Sensor / Switch
ECM limits APP signal within specified range.
246) “D” / “E” Voltage Correlation
Any one of the following operations will be taken:
P2176 (Page 1A- Throttle Actuator Control System – Idle • ECM performs fuel cut at specified engine speed.
248) Position Not Learned • ECM fixes minimum throttle valve position to
specified throttle valve position.
P2226 (Page 1A-
Barometric Pressure Sensor “A” Circuit
249) ECM controls actuators assuming that barometric
P2227 (Page 1A- Barometric Pressure Sensor “A” Circuit pressure is specified value.
249) Range / Performance
P2271 (Page 1A- O2 Sensor Signal Biased / Stuck Rich
—
250) (Bank1 Sensor2)
P2300 (Page 1A-
Ignition Coil “A” Primary Control Circuit Low
212)
P2301 (Page 1A- Ignition Coil “A” Primary Control Circuit
212) High
P2303 (Page 1A-
Ignition Coil “B” Primary Control Circuit Low —
212)
P2304 (Page 1A- Ignition Coil “B” Primary Control Circuit
212) High
P2306 (Page 1A-
Ignition Coil “C” Primary Control Circuit Low
212)
P2307 (Page 1A- Ignition Coil “C” Primary Control Circuit
212) High
P2309 (Page 1A-
Ignition Coil “D” Primary Control Circuit Low —
212)
P2310 (Page 1A- Ignition Coil “D” Primary Control Circuit
212) High
U0073 (Page 1A-
Control Module Communication Bus Off
252)
U0101 (Page 1A-
Lost Communication With TCM
252)
U0121 (Page 1A- Lost Communication With ABS / ESP®
—
252) Control Module
U0140 (Page 1A- Lost Communication With Body Control
252) Module
U0155 (Page 1A- Lost Communication With Instrument Panel
252) Cluster (IPC) Control Module
 Engine General Information and Diagnosis: K12M 1A-153

DTC DTC name Fail-safe operation

U2001 (Page 1A-
LIN Lost Communication With Generator
252)
ECM stops generator control.
U2021 (Page 1A-
LIN Invalid Data from ECM to Generator
254)

Scan Tool Data

AENJCA0A1124007

NOTE
• If communication between SUZUKI scan tool and ECM is not possible, perform the following
checks:
– Check communication condition between PC and VCI using SUZUKI scan tool function.
– Check DLC power circuit and ground circuit.
– Check DLC cable. If necessary, check DLC cable by substituting a known-good DLC cable.
– Check CAN communication system. (“Control Module Communication Bus Off” is detected in any
control module.) (Page 10H-15)
– Check ECM power circuit and ground circuit. (Page 1A-267)
• With a generic scan tool, only data with asterisk (*) in the following table can be read.
• When checking data with engine running at idle or racing, place gear shift lever in neutral position
(M/T model) or shift selector N range (auto gear shift model) and apply parking brake fully. Also, if
nothing or “no load” is indicated, turn off A/C, all electric loads, P/S and all the other switches.

Normal condition /
Scan tool data Vehicle condition
Reference value
Open loop (OL) control before satisfaction of closed loop
control conditions (ECT >10 °C, HO2S-1, IAT, TP sensor OL
/ system = OK)
Open loop (OL) control due to driving conditions (Power
OL-Drive
Fuel System (Page 1A- enrichment, etc.)
*
156) Open loop (OL) control due to fuel system failure OL-Fault
Closed loop (CL) control using HO2S-1 as feedback
CL
sensors for fuel control
Closed loop (CL) control due to fuel system failure CL-Fault
When engine stops with ignition “ON” —
Short Term Fuel Trim
* Engine: Idle speed after warming up Approx. –20 to 20%
(Page 1A-156)
Long Term Fuel Trim
* Engine: Idle speed after warming up Approx. –20 to 20%
(Page 1A-156)
Total Fuel Trim (Page
Engine: Idle speed after warming up Approx. –30 to 30%
1A-156)
Inj Pulse Width (Page
Engine: Idle speed with no load after warming up Approx. 1.6 to 4.0 msec.
1A-156)
Ignition Advance (Page
* Engine: Idle speed with no load after warming up –10 to 10° BTDC
1A-156)
Calculated Load (Page
* Engine: Idle speed with no load after warming up Approx. 20 to 40%
1A-156)
Engine: Idle speed after warming up
Radiator cooling fan: Stopped
All electrical equipment: OFF
Engine Speed (Page 1A-
* M/T model: 600 to 750 rpm
156)
Gear shift lever: Neutral position
Auto gear shift model:
Shift selector: N range
1A-154 Engine General Information and Diagnosis: K12M

Normal condition /
Scan tool data Vehicle condition
Reference value
Engine: Idle speed after warming up
Radiator cooling fan: Stopped
All electrical equipment: OFF
Desired Idle (Page 1A-
M/T model: 600 to 750 rpm
156)
Gear shift lever: Neutral position
Auto gear shift model:
Shift selector: N range
Vehicle Speed (Page 1A- Almost the same as
* Vehicle running
156) speedometer reading
* MAP (Page 1A-156) Engine: Idle speed after warming up Approx. 20 to 55 kPa
Approx. 80 to 105 °C (176
* ECT (Page 1A-156) 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-156) to 40 °C (72 °F) +
environmental temperature
Barometric Pres (Page Barometric pressure is
* —
1A-156) displayed.
EVAP Canist Prg Duty
* Engine: Idle speed after warming up 0%
(Page 1A-156)
VVT Gap (Page 1A-157) Engine: Idle speed after warming up –1.0 to 1.0° CA
Engine: Idle speed with no load after warming up Approx. 1 to 45%
IAC Throttle Opening Engine: Idle speed after warming up
(Page 1A-157) A/C compressor: Operating Approx. 10 to 70%
Blower speed selector: Max position
Ignition: “ON”
0.8 to 1.0 V
TP Sensor 1 Volt (Page Accelerator pedal: Released
1A-157) Ignition: “ON”
4.3 to 4.5 V
Accelerator pedal: Fully depressed
Ignition: “ON”
4.0 to 4.2 V
TP Sensor 2 Volt (Page Accelerator pedal: Released
1A-157) Ignition: “ON”
0.5 to 0.7 V
Accelerator pedal: Fully depressed
Ignition: “ON”
0.70 to 0.80 V
APP Sensor 1 Voltage Accelerator pedal: Released
(Page 1A-157) Ignition: “ON”
4.35 to 4.45 V
Accelerator pedal: Fully depressed
Ignition: “ON”
0.37 to 0.38 V
APP Sensor 2 Voltage Accelerator pedal: Released
(Page 1A-157) Ignition: “ON”
2.15 to 2.25 V
Accelerator pedal: Fully depressed
Ignition: “ON”
0 to 2%
Accelerator Position Accelerator pedal: Released
(Page 1A-157) Ignition: “ON”
90 to 100%
Accelerator pedal: Fully depressed
Ignition: “ON”
0 to 10%
Throttle Position (Page Accelerator pedal: Released
1A-157) Ignition: “ON”
90 to 100%
Accelerator pedal: Fully depressed
Ignition: “ON”
0 to 15%
Target Throttle Posi Accelerator pedal: Released
*
(Page 1A-157) Ignition: “ON”
90 to 100%
Accelerator pedal: Fully depressed
O2S B1 S1 (Page 1A-
* Engine: Idle speed after warming up Approx. 0 to 1.0 V
157)
O2S B1 S2 (Page 1A-
* Engine: 2,000 rpm for 3 min. or more after warming up Approx. 0 to 1.0 V
157)
 Engine General Information and Diagnosis: K12M 1A-155

Normal condition /
Scan tool data Vehicle condition
Reference value
Battery Voltage (Page
* Engine: Idle speed 10.7 to 16.0 V
1A-157)
Fuel Tank Level (Page
Ignition: “ON” 0 to 100%
1A-157)
Engine: Idle speed
A/C Pressure (Page 1A- A/C compressor: Operating
1,100 to 1,470 kPa
157) Blower speed selector: Max position
Ambient temperature: 30 °C (86 °F)
Generator Reg Volt (Com)
Engine: Idle speed 10.7 to 16.0 V
(Page 1A-157)
Radiator cooling fan: Off Off
Radiator Fan (Page 1A-
Radiator cooling fan: Low speed Low
157)
Radiator cooling fan: High speed High
Engine: Running
A/C Comp Relay (Page A/C compressor: Operating ON
1A-157) Blower speed selector: ON
Other than above condition OFF
Fuel Pump (Page 1A- Engine: Running ON
157) Other than above condition OFF
Starter Switch (Page 1A- Ignition: “ST” (engine cranking) ON
157) Other than above condition OFF
A/C switch: ON
A/C Switch (Page 1A- ON
Blower speed selector: ON
157)
Other than above condition OFF
Blower Fan (Page 1A- 2nd or higher speed position ON
157) Other than above condition OFF
Brake Switch (Page 1A- Brake pedal: Depressed ON
157) Brake pedal: Released OFF
Electric Load (Page 1A- Headlight: ON ON
157) Headlight: OFF OFF
Auto gear shift model:
Engine: Running D
PNP Signal (Page 1A- Shift selector: Other than N range
157) Auto gear shift model:
Engine: Running P/N
Shift selector: N range
M/T model:
Declutch
Clutch Switch (Page 1A- Clutch pedal: More than halfway depressed
157) M/T model:
Clutched
Clutch pedal: Released
Engine: Idle speed after warming up OFF
Fuel Cut (Page 1A-157) Accelerator pedal: Released
ON
Engine condition: 2,000 rpm or more after warming up
Ignition: “ON”
ON
Closed Throttle Pos Accelerator pedal: Released
(Page 1A-158) Ignition: “ON”
OFF
Accelerator pedal: Fully depressed
O2S B1 S1 Act (Page
Engine: Idle speed after warming up Active
1A-158)
O2S B1 S2 Act (Page
Engine: Idle speed after warming up Active
1A-158)
Starter Count Information M/T model: Starting motor overrun
(Overrun) (Page 1A-158) Ignition: “ON” counter
Starter Count Information
M/T model: Starting motor
(Overcranking) (Page
Ignition: “ON” overcranking counter
1A-158)
Starter Count Information M/T model: Starting motor inching
(Inching) (Page 1A-158) Ignition: “ON” counter
1A-156 Engine General Information and Diagnosis: K12M

Normal condition /
Scan tool data Vehicle condition
Reference value
Starter Count Information
(Starter Relay Slow M/T model: Starting motor control relay
Response) (Page 1A- Ignition: “ON” slow response counter
158)

Scan Tool Data Definitions Ignition Advance (Ignition timing advance for No.1
Fuel System (Fuel system status) cylinder, ° BTDC)
This parameter indicates the state of A/F feedback This parameter indicates the ignition timing of No.1
control by ECM. cylinder commanded by ECM.

NOTE Calculated Load (Calculated load value, %)

• Open loop This parameter indicates the engine load calculated by
Fuel injection time (volume) in the various ECM based on input signals of various sensors as a
engines states is determined beforehand. percentage.
Information from HO2S-1 is not reflected to
fuel injection control. Engine Speed (rpm)
The engine revolution speed is calculated based on the
• Closed loop
input signal of CKP sensor.
Information from HO2S-1 is reflected to
fuel injection control. When ECM judges
Desired Idle (Desired idle speed, rpm)
that actual air-fuel ratio is higher than
This parameter indicates target engine idle speed
stoichiometric air-fuel ratio, ECM controls
requested by ECM.
to increase the volume of fuel. On the
contrary, when the actual air-fuel ratio is NOTE
lower than stoichiometric air-fuel ratio,
When performing “Fixed Spark” in “Active
ECM controls to decrease the volume of
Test”, actual engine idle speed may not
fuel.
follow target engine idle speed.

Short Term Fuel Trim (%)

Vehicle Speed (km/h, mph)
This parameter indicates short term fuel trim value (short
This parameter indicates the vehicle speed based on
term air/fuel mixture correction factor) and changes the
wheel speed sensors sent from ABS control module via
value corresponding to driving conditions. 0 (zero)
CAN communication.
indicates no correction, a value greater than 0 indicates
enrichment correction, and a value less than 0 indicates
MAP (Manifold absolute pressure, kPa, mmHg, inHg,
enleanment correction.
psi, inH2O)
This parameter indicates the calculated MAP based on
Long Term Fuel Trim (%)
input voltage of MAP sensor.
This parameter indicates a median value of short term
trim learned in A/F feedback control (closed loop). This
ECT (Engine coolant temperature, °C, °F)
median value is used by ECM to correct fuel injection
This parameter indicates the calculated ECT based on
volume appropriately in open loop control avoiding
input voltage of ECT sensor.
interference caused by individual difference and aging. 0
(zero) indicates no correction, a value greater than 0
Intake Air Temperature. (°C, °F)
indicates enrichment correction, and a value less than 0
This parameter indicates the calculated IAT based on
indicates enleanment correction.
input voltage of IAT sensor.
Total Fuel Trim (%)
Barometric Pres (Barometric pressure, kPa, mmHg,
This parameter indicates the comprehensive fuel trim
inHg, psi, inH2O)
computed based on short term and long term fuel trim.
This parameter indicates the calculated barometric air
pressure by barometric pressure sensor in ECM.
Inj Pulse Width (Fuel injection pulse width, msec.)
This parameter indicates the injector drive pulse width
EVAP Canist Prg Duty (EVAP canister purge flow
(open time) during the injector valve stays open
duty, %)
commanded by ECM.
This parameter indicates valve ON (valve open) time
rate within a certain set cycle of EVAP canister purge
valve.
 Engine General Information and Diagnosis: K12M 1A-157
VVT Gap (Variable valve timing difference between
target and actual position, °)
This parameter indicates difference between target
camshaft position (intake side) and actual camshaft
position (intake side).
IAC Throttle Opening (Idle air throttle valve opening,
%)
This parameter indicates opening% of throttle valve on
the assumption that the maximum opening of idle air
control is 100%.
TP Sensor 1 Volt (TP sensor (main) output voltage,
V)
This parameter indicates the input voltage of TP sensor
(main) installed in throttle body.
TP Sensor 2 Volt (TP sensor (sub) output voltage, V)
This parameter indicates the input voltage of TP sensor
(sub) installed in throttle body.
APP Sensor 1 Voltage (APP sensor (main) output
voltage, V)
This parameter indicates the input voltage of APP
sensor (main) installed in accelerator pedal.
APP Sensor 2 Voltage (APP sensor (sub) output
voltage, V)
This parameter indicates the input voltage of APP
sensor (sub) installed in accelerator pedal.
Accelerator Position (Absolute accelerator pedal
position, %)
This parameter indicates the depressing amount of
accelerator pedal that ECM calculated based on the
input signals of APP sensor (main and sub) in
percentage.
Throttle Position (Absolute throttle position, %)
This parameter indicates the calculated throttle valve
opening in percentage based on input signal from TP
sensor.
Target Throttle Posi (Target throttle valve position,
%)
This parameter indicates the target throttle position
requested by ECM.
O2S B1 S1 (HO2S-1, V)
This parameter indicates output voltage of HO2S-1
installed on exhaust manifold (pre-TWC).
O2S B1 S2 (HO2S-2, V)
This parameter indicates output voltage of HO2S-2
installed on exhaust manifold (post-TWC). It is used to
detect catalyst deterioration.
Battery Voltage (V)
This parameter indicates battery positive voltage
inputted from main relay to ECM.
Fuel Tank Level (%)
This parameter indicates the information of fuel level
inputted via combination meter. The fuel level data is
provided as a percentage from 0 to 100%.
A/C Pressure (A/C refrigerant absolute pressure,
kPa, mmHg, inHg, psi, inH2O)
This parameter indicates A/C refrigerant pressure
calculated by ECM based on A/C refrigerant pressure
sensor voltage.
Generator Reg Volt (Com) (Generator regulated
voltage (Com) (V))
This parameter indicates commanded generator
regulated voltage.
Radiator Fan (Radiator cooling fan control relay, ON/
OFF)
This parameter indicates the state that ECM operates
radiator cooling fan relay.
A/C Comp Relay (A/C compressor relay, ON/OFF)
This parameter indicates the state that ECM operates A/
C compressor relay.
Fuel Pump (ON/OFF)
This parameter indicates the state that ECM operates
fuel pump relay.
Starter Switch (ON/OFF)
This parameter indicates state of starting motor control
relay output.
A/C Switch (ON/OFF)
This parameter indicates the state that ECM operates A/
C by request from BCM.
Blower Fan (ON/OFF)
This parameter indicates the signal state of the blower
fan motor inputted into ECM.
Brake Switch (ON/OFF)
This parameter indicates operating state of the brake
switch.
Electric Load (ON/OFF)
This parameter indicates the state of electric load signal
inputted into ECM.
PNP Signal (P/N or D range) (auto gear shift model)
This parameter indicates shift position informed from
TCM via CAN communication.
Clutch Switch (Declutch / Clutched) (M/T model)
This parameter indicates operating state of CPP No.2
switch.
Fuel Cut (ON/OFF)
This parameter indicates the operating state of fuel cut.
1A-158 Engine General Information and Diagnosis: K12M

Closed Throttle Pos (Closed throttle position, ON/
OFF)
This parameter monitors idle state for engine control.
O2S B1 S1 ACT (HO2S-1, Active / Inactive)
This parameter indicates the activation condition of
HO2S-1.
O2S B1 S2 ACT (HO2S-2, Active / Inactive)
This parameter indicates the activation condition of
HO2S-2.
Starter Count Information (Overrun) (times) (M/T
model)
This parameter indicates the starter count information
(overrun).
Starter Count Information (Overcranking) (times) (M/
T model)
This parameter indicates the starter count information
(overcranking).
Starter Count Information (Inching) (times) (M/T
model)
This parameter indicates the starter count information
(Inching).
Starter Count Information (Starter Relay Slow
Response) (times) (M/T model)
This parameter indicates the starter count information
(starter relay slow response).

Visual Inspection
AENJCA0A1124008
Visually check the following parts and systems.
Inspection item Referring section
• Engine oil – Level, leakage “Engine Oil and Filter Change” in Section 0B (Page 0B-5)
• “Coolant Level Check”: K12M in Section 1F (Page 1F-26)
• Engine coolant – Level, leakage • “Engine Cooling System Inspection”: K12M in Section 1F
(Page 1F-26)
“Fuel Leakage Check Procedure”: Petrol in Section 1G
• Fuel – Level, leakage
(Page 1G-20)
“Auto Gear Shift Transaxle Oil Level Check” in Section 5D
• Auto gear shift oil – Level, leakage
(Page 5D-98)
“Air Cleaner Filter Inspection and Cleaning”: K12M in
• Air cleaner filter – Dirt, clogging
Section 1D (Page 1D-82)
• Battery – Corrosion of terminal “Battery Inspection”: K12M in Section 1J (Page 1J-22)
“Water Pump / Generator Drive Belt Inspection and
• Accessory drive belt – Tension, damage
Adjustment”: K12M in Section 1J (Page 1J-25)
• Throttle valve – Operating sound —
• Vacuum hoses of air intake system – Disconnection,
—
looseness, deterioration, bend
• Connectors of electric wire harness – Disconnection,
—
friction, pinch
• Fuses – Blown —
• Parts – Installation, deformation —
• Bolts and nuts – Looseness —

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

Inspection item Referring section
• MIL – Operation “MIL Check”: K12M (Page 1A-140)
“Generator Symptom Diagnosis”: K12M in Section 1J (Page
• Charging light – Operation
1J-22)
“Oil Pressure Switch On-Vehicle Inspection”: K12M in
• Engine oil pressure light – Operation
Section 1E (Page 1E-20)
• Engine coolant temperature warning light – Operation “ECT Sensor Inspection”: K12M in Section 1C (Page 1C-28)
“Fuel Level Sensor Inspection”: Petrol in Section 1G (Page
• Fuel level sensor – Operation
1G-32)
• Tachometer – Operation Section 9C
• Exhaust system – Leakage of exhaust gas, noise “Exhaust System Check”: K12M in Section 1K (Page 1K-7)
• Abnormal air being inhaled at air intake system —
• Other parts that can be checked visually —
 Engine General Information and Diagnosis: K12M 1A-159

Engine Basic Inspection

AENJCA0A1124009
This check is very important for troubleshooting when ECM has detected no DTC and no abnormality has been found
in “Visual Inspection”: K12M (Page 1A-158).
Follow the flow carefully.
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K12M
(Page 1A-138).
2 Check battery voltage Go to Step 3. Charge or replace
battery.
Is it 12 V or more?
3 Is engine cranked? Go to Step 4. Go to “Cranking System
Symptom Diagnosis” in
Section 1I (Page 1I-3).
4 Does engine start? Go to Step 5. Go to Step 7.
5 Check idle speed Go to Step 6. Go to “Engine Symptom
1) Check engine idle speed. (Page 1A-270) Diagnosis”: K12M
(Page 1A-160).
Is check result OK?
6 Check ignition system Go to “Engine Symptom Repair or replace
1) Check ignition system. (Page 1H-13) Diagnosis”: K12M defective parts.
(Page 1A-160).
Is check result OK?
7 Check immobilizer system Go to Step 8. Immobilizer control
1) Check immobilizer control system. (Page 10C-4) system malfunction.

Is check result OK?

8 Check fuel supply Go to Step 9. Repair or replace
1) Check fuel supply. (Page 1G-29) defective parts.

Is check result OK?

9 Check fuel injector circuit Go to “Engine Symptom Repair or replace
1) Check fuel injector circuit. (Page 1G-7) Diagnosis”: K12M defective parts.
(Page 1A-160).
Is check result OK?
1A-160 Engine General Information and Diagnosis: K12M
Engine Symptom Diagnosis
Perform troubleshooting referring to the following points when ECM has detected no DTC and no abnormality has
been found in “Visual Inspection”: K12M (Page 1A-158) and “Engine Basic Inspection”: K12M (Page 1A-159).
Condition Possible cause
Hard starting (Engine can Faulty spark plug
be cranked)
Faulty ignition coil
Dirty or clogged fuel hoses or pipes
Malfunctioning fuel pump
Air drawn in through intake manifold
gasket or throttle body gasket
Faulty electric throttle body assembly
Faulty APP sensor
Faulty ECT sensor or MAP sensor
Faulty ECM
Low compression
Poor spark plug tightening or faulty
gasket
Compression leakage from valve seat
Sticky valve stem
Weak or damaged valve springs
Compression leakage at cylinder head
gasket
Sticky or damaged piston ring
Worn piston, piston ring or cylinder
Malfunctioning PCV valve
VVT system out of order
AENJCA0A1124010
Correction / Reference Item
“Spark Plug Inspection”: K12M in Section 1H
(Page 1H-17)
“Ignition Coil Assembly Inspection”: K12M in
Section 1H (Page 1H-18)
“Fuel Pressure Check”: Petrol in Section 1G
(Page 1G-12)
“Fuel Pump and Its Circuit Check”: Petrol in
Section 1G (Page 1G-10)
Check air intake system.
“Electric Throttle Body Assembly On-Vehicle
Inspection”: K12M in Section 1C (Page 1C-23)
“APP Sensor On-Vehicle Inspection”: K12M in
Section 1C (Page 1C-25)
“ECT Sensor Inspection”: K12M in Section 1C
(Page 1C-28) or “MAP Sensor Inspection”:
K12M in Section 1C (Page 1C-27)
“Inspection of ECM and Its Circuits”: K12M
(Page 1A-254)
“Compression Check”: K12M in Section 1D
(Page 1D-77)
“Spark Plug Removal and Installation”: K12M
in Section 1H (Page 1H-17)
“Valve and Valve Guide Inspection”: K12M in
Section 1D (Page 1D-121)
“Valve and Valve Guide Inspection”: K12M in
Section 1D (Page 1D-121)
“Valve Spring Inspection”: K12M in Section 1D
(Page 1D-124)
“Cylinder Head Inspection”: K12M in Section
1D (Page 1D-123)
“Cylinder, Piston and Piston Ring Inspection”:
K12M in Section 1D (Page 1D-129)
“Cylinder, Piston and Piston Ring Inspection”:
K12M in Section 1D (Page 1D-129)
“PCV Valve Inspection”: K12M in Section 1B
(Page 1B-13)
• VVT actuator: “VVT Actuator, Camshaft and
Tappet Inspection”: K12M in Section 1D
(Page 1D-95)
• Valve timing: “Timing Chain and Chain
Tensioner Inspection”: K12M in Section 1D
(Page 1D-114)
• OCV oil circuit: “Timing Chain Cover
Inspection”: K12M in Section 1D (Page 1D-
107)
 Engine General Information and Diagnosis: K12M 1A-161

Condition Possible cause Correction / Reference Item

Low oil pressure Improper oil viscosity
Malfunctioning oil pressure switch
Clogged oil strainer
Functional deterioration of oil pump
Worn oil pump relief valve
Excessive clearance in various sliding
parts
Engine noise – Valve Improper valve clearance
noise
Worn valve stem and guide
NOTE
Before checking Weak or broken valve spring
mechanical noise, check
that: Warped or bent valve
• Specified spark plug is
used.
• Specified fuel is used.
“Engine Oil and Filter Change” in Section 0B
(Page 0B-5)
“Oil Pressure Switch On-Vehicle Inspection”:
K12M in Section 1E (Page 1E-20)
Check oil strainer for clog.
“Oil Pump Inspection”: K12M in Section 1E
(Page 1E-27)
“Oil Pump Inspection”: K12M in Section 1E
(Page 1E-27)
—
“Valve Clearance Inspection and Adjustment”:
K12M in Section 1D (Page 1D-79)
“Valve and Valve Guide Inspection”: K12M in
Section 1D (Page 1D-121)
“Valve Spring Inspection”: K12M in Section 1D
(Page 1D-124)
“Valve and Valve Guide Inspection”: K12M in
Section 1D (Page 1D-121)

Engine noise – Piston, Worn piston, piston ring and cylinder “Cylinder, Piston and Piston Ring Inspection”:
piston ring and cylinder bore K12M in Section 1D (Page 1D-129)
noise

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

Engine noise – Worn piston, piston ring and cylinder “Cylinder, Piston and Piston Ring Inspection”:
Connecting rod noise bore K12M in Section 1D (Page 1D-129)
Worn connecting rod bearing “Crankshaft Pin and Connecting Rod Bearing
NOTE Inspection”: K12M in Section 1D (Page 1D-
Before checking 132)
mechanical noise, check Worn crankshaft pin “Crankshaft Pin and Connecting Rod Bearing
that: Inspection”: K12M in Section 1D (Page 1D-
• Specified spark plug is 132)
used. Loose connecting rod bolts “Piston, Piston Ring and Connecting Rod
Removal and Installation”: K12M in Section 1D
• Specified fuel is used.
(Page 1D-126)
Low oil pressure Condition “Low oil pressure”
Engine noise – Low oil pressure Condition “Low oil pressure”
Crankshaft noise Worn main bearing “Main Bearing Inspection”: K12M in Section 1D
(Page 1D-141)
NOTE Worn crankshaft journal “Crankshaft Inspection”: K12M in Section 1D
Before checking (Page 1D-140)
mechanical noise, check Loose bearing cap bolts “Main Bearing, Crankshaft and Cylinder Block
that: Removal and Installation”: K12M in Section 1D
• Specified spark plug is (Page 1D-136)
used. Excessive crankshaft thrust play “Crankshaft Inspection”: K12M in Section 1D
(Page 1D-140)
• Specified fuel is used.
1A-162 Engine General Information and Diagnosis: K12M
Condition Possible cause
Engine overheating Inoperative thermostat
Poor water pump performance
Clogged or leaky radiator
Improper engine oil grade
Clogged oil filter or oil strainer
Poor oil pump performance
Faulty radiator cooling fan control
system
Dragging brakes
Slipping clutch (M/T model)
Slipping clutch (auto gear shift model)
Blown cylinder head gasket
Air mixed in cooling system
Correction / Reference Item
“Thermostat Inspection”: K12M in Section 1F
(Page 1F-29)
“Water Pump Inspection”: K12M in Section 1F
(Page 1F-34)
“Radiator On-Vehicle Inspection and
Cleaning”: K12M in Section 1F (Page 1F-32)
“Engine Oil and Filter Change” in Section 0B
(Page 0B-5)
“Oil Pressure Check”: K12M in Section 1E
(Page 1E-18)
“Oil Pressure Check”: K12M in Section 1E
(Page 1E-18)
“Radiator Cooling Fan System Check”: K12M
in Section 1F (Page 1F-22)
Condition “Dragging brakes” in “Brake
Symptom Diagnosis” in Section 4A (Page 4A-
2)
Condition “Slipping” in “Clutch System
Symptom Diagnosis” in Section 5C (Page 5C-
1)
“Auto Gear Shift Symptom Diagnosis” in
Section 5D (Page 5D-42)
“Cylinder Head Inspection”: K12M in Section
1D (Page 1D-123)
“Cooling System Refilling”: K12M in Section 1F
(Page 1F-27)
 Engine General Information and Diagnosis: K12M 1A-163

Condition Possible cause Correction / Reference Item

Poor fuel mileage Faulty spark plug (improper gap, heavy “Spark Plug Inspection”: K12M in Section 1H
deposits and burned electrodes, etc.)
High idle speed
Poor performance of ECT sensor or
MAP sensor
Faulty electric throttle body assembly “Electric Throttle Body Assembly On-Vehicle
Faulty APP sensor
Faulty fuel injector
Faulty ECM
Low compression
Poor valve seating
Dragging brakes
Slipping clutch (M/T model)
Slipping clutch (auto gear shift model) “Auto Gear Shift Symptom Diagnosis” in
Thermostat out of order
Improper tire pressure
VVT system out of order
Excessive engine oil Broken cylinder head gasket
consumption – Oil
leakage Leaky crankshaft pulley oil seal
Leaky crankshaft rear oil seal
Leaky cylinder head cover gasket
(Page 1H-17)
Condition “Improper engine idling or engine
fails to idle”
“ECT Sensor Inspection”: K12M in Section 1C
(Page 1C-28) or “MAP Sensor Inspection”:
K12M in Section 1C (Page 1C-27)
Inspection”: K12M in Section 1C (Page 1C-23)
“APP Sensor On-Vehicle Inspection”: K12M in
Section 1C (Page 1C-25)
“Fuel Injector Circuit Check”: Petrol in Section
1G (Page 1G-7)
“Inspection of ECM and Its Circuits”: K12M
(Page 1A-254)
“Compression Check”: K12M in Section 1D
(Page 1D-77)
“Valve and Valve Guide Inspection”: K12M in
Section 1D (Page 1D-121)
Condition “Dragging brakes” in “Brake
Symptom Diagnosis” in Section 4A (Page 4A-
2)
Condition “Slipping” in “Clutch System
Symptom Diagnosis” in Section 5C (Page 5C-
1)
Section 5D (Page 5D-42)
“Thermostat Inspection”: K12M in Section 1F
(Page 1F-29)
“Tire Description” in Section 2D (Page 2D-1)
• VVT actuator: “VVT Actuator, Camshaft and
Tappet Inspection”: K12M in Section 1D
(Page 1D-95)
• Valve timing: “Timing Chain and Chain
Tensioner Inspection”: K12M in Section 1D
(Page 1D-114)
• OCV oil circuit: “Timing Chain Cover
Inspection”: K12M in Section 1D (Page 1D-
107)
“Cylinder Head Inspection”: K12M in Section
1D (Page 1D-123)
“Timing Chain Cover Inspection”: K12M in
Section 1D (Page 1D-107)
“Main Bearing, Crankshaft and Cylinder Block
Removal and Installation”: K12M in Section 1D
(Page 1D-136)
“Cylinder Head Cover Components”: K12M in
Section 1D (Page 1D-86)
1A-164 Engine General Information and Diagnosis: K12M

Condition Possible cause Correction / Reference Item

Excessive engine oil Sticky piston ring “Cylinder, Piston and Piston Ring Inspection”:
consumption – Oil K12M in Section 1D (Page 1D-129)
entering combustion Worn piston and cylinder “Cylinder, Piston and Piston Ring Inspection”:
chamber K12M in Section 1D (Page 1D-129)
Worn piston ring groove and ring “Cylinder, Piston and Piston Ring Inspection”:
K12M in Section 1D (Page 1D-129)
Improper location of piston ring gap “Piston, Piston Ring and Connecting Rod
Disassembly and Reassembly”: K12M in
Section 1D (Page 1D-128)
Worn or damaged valve stem seal “Valve and Cylinder Head Disassembly and
Reassembly”: K12M in Section 1D (Page 1D-
117)
Worn valve stem “Valve and Valve Guide Inspection”: K12M in
Section 1D (Page 1D-121)
Engine hesitates – Faulty spark plug or plug gap out of “Spark Plug Inspection”: K12M in Section 1H
Momentary lack of adjustment (Page 1H-17)
response as accelerator Fuel pressure out of specification “Fuel Pressure Check”: Petrol in Section 1G
is depressed. Can occur (Page 1G-12)
at all vehicle speeds. Poor performance of ECT sensor or “ECT Sensor Inspection”: K12M in Section 1C
Usually severest when MAP sensor (Page 1C-28) or “MAP Sensor Inspection”:
moving out from a stop at K12M in Section 1C (Page 1C-27)
stop signal etc. Faulty electric throttle body assembly “Electric Throttle Body Assembly On-Vehicle
Inspection”: K12M in Section 1C (Page 1C-23)
Faulty APP sensor “APP Sensor On-Vehicle Inspection”: K12M in
Section 1C (Page 1C-25)
Faulty fuel injector “Fuel Injector Circuit Check”: Petrol in Section
1G (Page 1G-7)
Faulty ECM “Inspection of ECM and Its Circuits”: K12M
(Page 1A-254)
Engine overheating Condition “Engine overheating”
Low compression “Compression Check”: K12M in Section 1D
(Page 1D-77)
 Engine General Information and Diagnosis: K12M 1A-165
Condition Possible cause
Surge – Engine power Faulty spark plug (excessive carbon
variation under steady deposits, improper gap, burned
throttle. Vehicle speed electrodes, etc.)
changes up and down Variable fuel pressure
with no change in
accelerator pedal Kinky or damaged fuel lines
position.
Faulty fuel pump (clogged fuel suction
filter)
Poor performance of MAP sensor
Faulty fuel injector
Faulty ECM
Faulty electric throttle body assembly
Faulty APP sensor
VVT system out of order
Excessive detonation – Faulty spark plug
Engine continuously
generates sharp, metallic Engine overheating
knocking sound that Clogged fuel filter or fuel lines
changes with throttle
opening. Air drawn in through intake manifold or Check air intake system.
throttle body gasket
Poor performance of knock sensor, ECT “Knock Sensor On-Vehicle Inspection”: K12M
sensor or MAP sensor
Faulty fuel injector
Faulty ECM
Excessive combustion chamber
deposits
VVT system out of order
Correction / Reference Item
“Spark Plug Inspection”: K12M in Section 1H
(Page 1H-17)
“Fuel Pressure Check”: Petrol in Section 1G
(Page 1G-12)
“Fuel Pressure Check”: Petrol in Section 1G
(Page 1G-12)
“Fuel Pump Inspection”: Petrol in Section 1G
(Page 1G-31)
“MAP Sensor Inspection”: K12M in Section 1C
(Page 1C-27)
“Fuel Injector Circuit Check”: Petrol in Section
1G (Page 1G-7)
“Inspection of ECM and Its Circuits”: K12M
(Page 1A-254)
“Electric Throttle Body Assembly On-Vehicle
Inspection”: K12M in Section 1C (Page 1C-23)
“APP Sensor On-Vehicle Inspection”: K12M in
Section 1C (Page 1C-25)
• VVT actuator: “VVT Actuator, Camshaft and
Tappet Inspection”: K12M in Section 1D
(Page 1D-95)
• Valve timing: “Timing Chain and Chain
Tensioner Inspection”: K12M in Section 1D
(Page 1D-114)
• OCV oil circuit: “Timing Chain Cover
Inspection”: K12M in Section 1D (Page 1D-
107)
“Spark Plug Inspection”: K12M in Section 1H
(Page 1H-17)
Condition “Engine overheating”
“Fuel Pressure Check”: Petrol in Section 1G
(Page 1G-12)
in Section 1C (Page 1C-32), “ECT Sensor
Inspection”: K12M in Section 1C (Page 1C-28)
or “MAP Sensor Inspection”: K12M in Section
1C (Page 1C-27)
“Fuel Injector Circuit Check”: Petrol in Section
1G (Page 1G-7) or “Fuel Injector Inspection”:
Petrol in Section 1G (Page 1G-24)
“Inspection of ECM and Its Circuits”: K12M
(Page 1A-254)
“Cylinder Head Inspection”: K12M in Section
1D (Page 1D-123) and “Cylinder, Piston and
Piston Ring Inspection”: K12M in Section 1D
(Page 1D-129)
• VVT actuator: “VVT Actuator, Camshaft and
Tappet Inspection”: K12M in Section 1D
(Page 1D-95)
• Valve timing: “Timing Chain and Chain
Tensioner Inspection”: K12M in Section 1D
(Page 1D-114)
• OCV oil circuit: “Timing Chain Cover
Inspection”: K12M in Section 1D (Page 1D-
107)
1A-166 Engine General Information and Diagnosis: K12M

Condition Possible cause Correction / Reference Item

Poor engine power Faulty spark plug
Faulty ignition coil assembly
Faulty knock sensor
Clogged fuel hoses or pipes
Malfunctioning fuel pump
Air drawn in through intake manifold
gasket or throttle body gasket
Engine overheating
Poor performance of ECT sensor or
MAP sensor
Faulty electric throttle body assembly
Faulty APP sensor
Faulty fuel injector
Faulty ECM
Dragging brakes
Slipping clutch (M/T model)
Slipping clutch (auto gear shift model)
Low compression
VVT system out of order
“Spark Plug Inspection”: K12M in Section 1H
(Page 1H-17)
“Ignition Coil Assembly Inspection”: K12M in
Section 1H (Page 1H-18)
“Knock Sensor On-Vehicle Inspection”: K12M
in Section 1C (Page 1C-32)
“Fuel Pressure Check”: Petrol in Section 1G
(Page 1G-12)
“Fuel Pump and Its Circuit Check”: Petrol in
Section 1G (Page 1G-10)
Check air intake system.
Condition “Engine overheating”
“ECT Sensor Inspection”: K12M in Section 1C
(Page 1C-28) or “MAP Sensor Inspection”:
K12M in Section 1C (Page 1C-27)
“Electric Throttle Body Assembly On-Vehicle
Inspection”: K12M in Section 1C (Page 1C-23)
“APP Sensor On-Vehicle Inspection”: K12M in
Section 1C (Page 1C-25)
“Fuel Injector Circuit Check”: Petrol in Section
1G (Page 1G-7) or “Fuel Injector Inspection”:
Petrol in Section 1G (Page 1G-24)
“Inspection of ECM and Its Circuits”: K12M
(Page 1A-254)
Condition “Dragging brakes” in “Brake
Symptom Diagnosis” in Section 4A (Page 4A-
2)
Condition “Slipping” in “Clutch System
Symptom Diagnosis” in Section 5C (Page 5C-
1)
“Auto Gear Shift Symptom Diagnosis” in
Section 5D (Page 5D-42)
“Compression Check”: K12M in Section 1D
(Page 1D-77)
• VVT actuator: “VVT Actuator, Camshaft and
Tappet Inspection”: K12M in Section 1D
(Page 1D-95)
• Valve timing: “Timing Chain and Chain
Tensioner Inspection”: K12M in Section 1D
(Page 1D-114)
• OCV oil circuit: “Timing Chain Cover
Inspection”: K12M in Section 1D (Page 1D-
107)
 Engine General Information and Diagnosis: K12M 1A-167

Condition Possible cause Correction / Reference Item

Improper engine idling or Faulty spark plug
engine fails to idle
Faulty ignition coil assembly
Fuel pressure out of specification
Leaky manifold, throttle body or cylinder Check air intake system.
head gasket
Faulty evaporative emission control
system
Faulty fuel injector
Poor performance of ECT sensor or
MAP sensor
Faulty electric throttle body assembly
Faulty APP sensor
Faulty ECM
Loose connection or disconnection of
vacuum hoses
Malfunctioning PCV valve
Engine overheating
Low compression
Faulty generator and/or its circuit
VVT system out of order
“Spark Plug Inspection”: K12M in Section 1H
(Page 1H-17)
“Ignition Coil Assembly Inspection”: K12M in
Section 1H (Page 1H-18)
“Fuel Pressure Check”: Petrol in Section 1G
(Page 1G-12)
“EVAP Canister Purge System Inspection”:
K12M in Section 1B (Page 1B-9)
“Fuel Injector Circuit Check”: Petrol in Section
1G (Page 1G-7) or “Fuel Injector Inspection”:
Petrol in Section 1G (Page 1G-24)
“ECT Sensor Inspection”: K12M in Section 1C
(Page 1C-28) or “MAP Sensor Inspection”:
K12M in Section 1C (Page 1C-27)
“Electric Throttle Body Assembly On-Vehicle
Inspection”: K12M in Section 1C (Page 1C-23)
“APP Sensor On-Vehicle Inspection”: K12M in
Section 1C (Page 1C-25)
“Inspection of ECM and Its Circuits”: K12M
(Page 1A-254)
Check connection of vacuum hoses.
“PCV Valve Inspection”: K12M in Section 1B
(Page 1B-13)
Condition “Engine overheating”
“Compression Check”: K12M in Section 1D
(Page 1D-77)
“Generator Test”: K12M in Section 1J (Page
1J-23)
• VVT actuator: “VVT Actuator, Camshaft and
Tappet Inspection”: K12M in Section 1D
(Page 1D-95)
• Valve timing: “Timing Chain and Chain
Tensioner Inspection”: K12M in Section 1D
(Page 1D-114)
• OCV oil circuit: “Timing Chain Cover
Inspection”: K12M in Section 1D (Page 1D-
107)
1A-168 Engine General Information and Diagnosis: K12M
Condition Possible cause
Excessive hydrocarbon Faulty spark plug
(HC) emission or carbon
monoxide (CO) emission Faulty ignition coil assembly
Low compression
Lead contamination of TWC
Faulty evaporative emission control
system
Fuel pressure out of specification
Faulty closed loop system (A/F
feedback compensation) (Poor
performance of ECT sensor or MAP
sensor)
Faulty electric throttle body assembly
Faulty APP sensor
Faulty fuel injector
Faulty ECM
Engine not at normal operating
temperature
Clogged air cleaner
Vacuum leakage
VVT system out of order
Correction / Reference Item
“Spark Plug Inspection”: K12M in Section 1H
(Page 1H-17)
“Ignition Coil Assembly Inspection”: K12M in
Section 1H (Page 1H-18)
“Compression Check”: K12M in Section 1D
(Page 1D-77)
Check for absence of filler neck restrictor.
“EVAP Canister Purge System Inspection”:
K12M in Section 1B (Page 1B-9)
“Fuel Pressure Check”: Petrol in Section 1G
(Page 1G-12)
“ECT Sensor Inspection”: K12M in Section 1C
(Page 1C-28) or “MAP Sensor Inspection”:
K12M in Section 1C (Page 1C-27)
“Electric Throttle Body Assembly On-Vehicle
Inspection”: K12M in Section 1C (Page 1C-23)
“APP Sensor On-Vehicle Inspection”: K12M in
Section 1C (Page 1C-25)
“Fuel Injector Circuit Check”: Petrol in Section
1G (Page 1G-7)
“Inspection of ECM and Its Circuits”: K12M
(Page 1A-254)
—
“Air Cleaner Filter Inspection and Cleaning”:
K12M in Section 1D (Page 1D-82)
“Engine Vacuum Check”: K12M in Section 1D
(Page 1D-78)
• VVT actuator: “VVT Actuator, Camshaft and
Tappet Inspection”: K12M in Section 1D
(Page 1D-95)
• Valve timing: “Timing Chain and Chain
Tensioner Inspection”: K12M in Section 1D
(Page 1D-114)
• OCV oil circuit: “Timing Chain Cover
Inspection”: K12M in Section 1D (Page 1D-
107)
 Engine General Information and Diagnosis: K12M 1A-169

Condition Possible cause Correction / Reference Item

Excessive nitrogen Improper ignition timing
oxides (NOx) emission
Lead contamination of TWC
Fuel pressure out of specification
Faulty closed loop system (A/F
feedback compensation) (Poor
performance of ECT sensor or MAP
sensor)
Faulty electric throttle body assembly
Faulty APP sensor
Faulty fuel injector
Faulty ECM
VVT system out of order
“Ignition Timing Inspection”: K12M in Section
1H (Page 1H-18)
Check for absence of filler neck restrictor.
“Fuel Pressure Check”: Petrol in Section 1G
(Page 1G-12)
“ECT Sensor Inspection”: K12M in Section 1C
(Page 1C-28) or “MAP Sensor Inspection”:
K12M in Section 1C (Page 1C-27)
“Electric Throttle Body Assembly On-Vehicle
Inspection”: K12M in Section 1C (Page 1C-23)
“APP Sensor On-Vehicle Inspection”: K12M in
Section 1C (Page 1C-25)
“Fuel Injector Circuit Check”: Petrol in Section
1G (Page 1G-7) or “Fuel Injector Inspection”:
Petrol in Section 1G (Page 1G-24)
“Inspection of ECM and Its Circuits”: K12M
(Page 1A-254)
• VVT actuator: “VVT Actuator, Camshaft and
Tappet Inspection”: K12M in Section 1D
(Page 1D-95)
• Valve timing: “Timing Chain and Chain
Tensioner Inspection”: K12M in Section 1D
(Page 1D-114)
• OCV oil circuit: “Timing Chain Cover
Inspection”: K12M in Section 1D (Page 1D-
107)

MIL Does Not Come ON with Ignition “ON” and Engine Stopped (but Engine Can Be Started)
AENJCA0A1124011
Troubleshooting
Step Action Yes No
1 DTC check Go to troubleshooting Go to Step 2.
1) Check DTC related to CAN communication. for applicable DTC.

Is there any CAN-DTC(s) detected?

2 DTC check Go to troubleshooting Replace ECM and
1) Check combination meter for DTC. for applicable DTC. recheck MIL operation.
(Page 1C-22)
Is there any DTC(s) detected?

MIL Remains ON after Engine Starts

AENJCA0A1124012
Troubleshooting
Step Action Yes No
1 DTC check Go to troubleshooting Substitute a known-
1) Start engine and recheck DTC of ECM and TCM (auto for applicable DTC. good combination meter
gear shift model) while engine running. and recheck MIL
operation. (Page 9C-
Is there any DTC(s)? 25)
If MIL still remains ON,
replace ECM and
recheck MIL operation.
(Page 1C-22)
1A-170 Engine General Information and Diagnosis: K12M

DTC P0010 / P2088 / P2089

AENJCA0A1124013
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0010: “A” Camshaft Position Actuator Circuit / Open (Bank 1) • OCV and/or its circuit
OCV drive circuit is open. • ECM
(3 D/C detection logic)
P2088: “A” Camshaft Position Actuator Control Circuit Low (Bank 1)
OCV drive circuit is shorted to ground.
(3 D/C detection logic)
P2089: “A” Camshaft Position Actuator Control Circuit High (Bank 1)
OCV drive circuit is shorted to power supply.
(3 D/C detection logic)

Circuit Diagram

1 A1
C02-42 GRN 3
B1

[A] C02 E02

[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

IJCA0A112010-01

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

DTC Confirmation Procedure

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

1) Run engine at idle speed for 10 sec.

 Engine General Information and Diagnosis: K12M 1A-171

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”: K12M
(Page 1A-138).
2 OCV power supply circuit check Go to Step 3. Repair or replace
1) With ignition “OFF”, disconnect connector from OCV. defective wire harness.
2) Check for proper terminal connection to OCV connector.
3) If connection is OK, set ignition “ON”.
4) Check that voltage between “A1” and ground is battery
voltage.

Is check result OK?

3 OCV drive circuit check Go to Step 4. Repair or replace
1) With ignition “OFF”, disconnect “C02” and “E02” defective wire harness.
connectors from ECM.
2) Check for proper terminal connections to “C02” and
“E02” connectors.
3) If connections are OK, check the following points.
• Resistance of “B1” circuit: less than 1 Ω
• Resistance between “B1” circuit and ground: infinity
• Resistance between “A1” circuit terminal and “B1”
circuit terminal at OCV connector: infinity
• Voltage of “B1” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

4 OCV check Go to Step 5. Replace OCV.
1) Check OCV. (Page 1C-34)

Is check result OK?

5 Troubleshooting of other DTC(s) at the same time Go to troubleshooting Replace ECM and
for applicable DTC. recheck DTC. (Page
Is other DTC(s) detected together? 1C-22)
1A-172 Engine General Information and Diagnosis: K12M

DTC P0011
AENJCA0A1124014
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0011: “A” Camshaft Position Timing Over Advanced or • OCV and/or its circuit
System Performance (Bank 1) • CKP sensor and sensor plate
Measured CMP does not reach target CMP for specified time.
• CMP sensor and signal rotor
(3 D/C detection logic)
• OCV oil passage
• VVT actuator
• Valve timing
• ECM

Circuit Diagram

1 A1
C02-42 GRN 3
B1

[A] C02 E02

[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

IJCA0A112010-01

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

DTC Confirmation Procedure

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

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

1) Warm up engine and repeat acceleration and deceleration between 30 and 80 km/h (19 and 50 mile/h) more than
10 times.
 Engine General Information and Diagnosis: K12M 1A-173

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”: K12M
(Page 1A-138).
2 DTC check Go to troubleshooting Go to Step 3.
1) Check DTC. for applicable DTC.

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 “B1” circuits according to Step 2 – 3 defective wire harness.
under “DTC P0010 / P2088 / P2089”: K12M (Page 1A-
170).

Is check result OK?

4 Oil pressure check Go to Step 5. Repair or replace
1) Check oil pressure. (Page 1E-18) 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-86) defective parts.
2) Check oil pressure leakage from OCV oil circuit.

Is check result OK?

6 CKP sensor and sensor plate check Go to Step 7. Repair or replace
1) Check CKP sensor and sensor plate. defective parts.
• CKP sensor: (Page 1C-31)
• Sensor plate: (Page 1D-147)

Is check result OK?

7 CMP sensor and signal rotor check Go to Step 8. Repair or replace
1) Check CMP sensor and signal rotor. defective parts.
• CMP sensor: (Page 1C-30)
• Signal rotor: (Page 1D-95)

Is check result OK?

8 OCV check Go to Step 9. Replace OCV. (Page
1) Check OCV. (Page 1C-34) 1D-108)

Is check result OK?

9 VVT actuator check Go to Step 10. Replace VVT actuator.
1) Check VVT actuator. (Page 1D-95) (Page 1D-89)

Is check result OK?

10 Valve timing check Replace ECM and Reinstall parts related to
1) Check parts related to timing chain and their installing recheck DTC. (Page timing chain correctly, or
condition. (Page 1D-111) 1C-22) replace defective parts.

Is check result OK?

1A-174 Engine General Information and Diagnosis: K12M

DTC P0016
AENJCA0A1124070
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0016: Crankshaft Position - Camshaft Position • CMP sensor and signal rotor
Correlation (Bank1 SensorA) • CKP sensor and sensor plate
Difference between camshaft position and crankshaft
• Timing chain
position is out of specified range.
(3 D/C detection logic) • Timing chain tensioner
• Timing chain tensioner adjuster
• VVT actuator
• ECM

DTC Confirmation Procedure

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

NOTE
• Limit the driving speed permissible in road conditions and regulations.
• Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.
• Check that the following DTCs are not detected in this “DTC Confirmation Procedure”.
– OCV (P0010)
– CKP sensor (P0335 and P0336)
– CMP sensor (P0340)

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

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K12M
(Page 1A-138).
2 CMP sensor and its circuit check Go to Step 3. Repair or replace
1) Check CMP sensor, signal rotor and its circuit related to defective part.
DTC according to Step 2 – 5 under “DTC P0340”: K12M
(Page 1A-210).

Is check result OK?

3 CKP sensor and its circuit check Go to Step 4. Repair or replace
1) Check CKP sensor, sensor plate and its circuit related to defective part.
DTC according to Step 2 – 5 under “DTC P0335 /
P0336”: K12M (Page 1A-208).

Is check result OK?

 Engine General Information and Diagnosis: K12M 1A-175

Step Action Yes No

4 Engine mechanical system check Go to Step 5. Repair or replace
1) Remove timing chain cover. (Page 1D-105) defective part.
2) Check the following items.
• Timing chain, timing chain tensioner and timing chain
tensioner adjuster: (Page 1D-114)
• VVT actuator: (Page 1D-95)

Is check result OK?

5 Troubleshooting of other DTC(s) at the same time Go to troubleshooting Replace ECM and
for applicable DTC. recheck for DTC.
Is other DTC(s) detected together? (Page 1C-22)

DTC P0030 / P0031 / P0032

AENJCA0A1124015
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0030: HO2S Heater Control Circuit (Bank 1 Sensor 1) • HO2S-1 heater and/or its circuit
HO2S-1 heater drive circuit is open. • ECM
(3 D/C detection logic)
P0031: HO2S Heater Control Circuit Low (Bank 1 Sensor 1)
HO2S-1 heater drive circuit is shorted to ground.
(3 D/C detection logic)
P0032: HO2S Heater Control Circuit High (Bank 1 Sensor 1)
HO2S-1 heater drive circuit is shorted to power supply.
(3 D/C detection logic)

Circuit Diagram

3
5V
+B 1 4 A3
RED C02-6
A2
GRN C02-7
A4
BLU PPL C02-49
A1 LT GRN C02-55
5V
2 4 B3
YEL C02-8
B2
BRN C02-19
B4
BLU RED C02-52
B1 BEG C02-56

[A] C02 E02

[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

IGSB0A112013-01

[A]: ECM connector (View: [a]) B1: HO2S-2 heater power supply circuit 2. HO2S-2
A1: HO2S-1 heater power supply circuit B2: HO2S-2 signal circuit 3. ECM
A2: HO2S-1 signal circuit B3: HO2S-2 ground circuit 4. Shield wire
A3: HO2S-1 ground circuit B4: HO2S-2 heater drive circuit
A4: HO2S-1 heater drive circuit 1. HO2S-1
1A-176 Engine General Information and Diagnosis: K12M

DTC Confirmation Procedure

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

1) Warm up engine to normal operating temperature.

2) Run engine at idle speed for 1 min.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K12M
(Page 1A-138).
2 HO2S-1 heater power supply circuit check Go to Step 3. Repair or replace
1) With ignition “OFF”, disconnect HO2S-1 connector. defective wire harness.
2) Check for proper terminal connection to HO2S-1
connector.
3) If connection is OK, set ignition “ON”.
4) Check that voltage between “A1” circuit and ground is
battery voltage.

Is check result OK?

3 HO2S-1 heater drive circuit check Go to Step 4. Repair or replace
1) With ignition “OFF”, disconnect “C02” and “E02” defective wire harness.
connectors from ECM.
2) Check for proper terminal connection to “C02” and “E02”
connectors.
3) If connections are OK, check the following points.
• Resistance of “A4” circuit: less than 1 Ω
• Resistance between “A4” circuit and ground: infinity
• Resistance between “A4” circuit terminal and other
terminal at HO2S-1 connector: infinity
• Voltage of “A4” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

4 HO2S-1 heater check Replace ECM and Replace HO2S-1.
1) Check HO2S-1 heater. (Page 1C-29) recheck DTC. (Page (Page 1C-29)
1C-22)
Is check result OK?
 Engine General Information and Diagnosis: K12M 1A-177

DTC P0036 / P0037 / P0038

AENJCA0A1124016
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0036: HO2S Heater Control Circuit (Bank 1 Sensor 2) • HO2S-2 heater and/or its circuit
HO2S-2 heater drive circuit is open. • ECM
(3 D/C detection logic)
P0037: HO2S Heater Control Circuit Low (Bank 1 Sensor 2)
HO2S-2 heater drive circuit is shorted to ground.
(3 D/C detection logic)
P0038: HO2S Heater Control Circuit High (Bank 1 Sensor 2)
HO2S-2 heater drive circuit is shorted to power supply.
(3 D/C detection logic)

Circuit Diagram

3
5V
+B 1 4 A3
RED C02-6
A2
GRN C02-7
A4
BLU PPL C02-49
A1 LT GRN C02-55
5V
2 4 B3
YEL C02-8
B2
BRN C02-19
B4
BLU RED C02-52
B1 BEG C02-56

[A] C02 E02

[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

IGSB0A112013-01

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

DTC Confirmation Procedure

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

1) Warm up engine to normal operating temperature.

2) Run engine at idle speed for 1 min.
1A-178 Engine General Information and Diagnosis: K12M

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”: K12M
(Page 1A-138).
2 HO2S-2 heater power supply circuit check Go to Step 3. Repair or replace
1) With ignition “OFF”, disconnect HO2S-2 connector. defective wire harness.
2) Check for proper terminal connection to HO2S-2
connector.
3) If connection is OK, set ignition “ON”.
4) Check that voltage between “B1” circuit and ground is
battery voltage.

Is check result OK?

3 HO2S-2 heater drive circuit check Go to Step 4. Repair or replace
1) With ignition “OFF”, disconnect “C02” and “E02” defective wire harness.
connectors from ECM.
2) Check for proper terminal connection to “C02” and “E02”
connectors.
3) If connections are OK, check the following points.
• Resistance of “B4” circuit: less than 1 Ω
• Resistance between “B4” circuit and ground: infinity
• Resistance between “B4” circuit terminal and other
terminal at HO2S-2 connector: infinity
• Voltage of “B4” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

4 HO2S-2 check Replace ECM and Replace HO2S-2.
1) Check HO2S-2 heater. (Page 1C-29) recheck DTC. (Page (Page 1C-29)
1C-22)
Is check result OK?
 Engine General Information and Diagnosis: K12M 1A-179

DTC P0107 / P0108

AENJCA0A1124017
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0107: Manifold Absolute Pressure / Barometric Pressure Circuit Low • MAP sensor and/or its circuit
Output voltage of MAP sensor signal circuit is lower than 0.1 V for 5 sec. • ECM
(3 D/C detection logic)
P0108: Manifold Absolute Pressure / Barometric Pressure Circuit High
Output voltage of MAP sensor signal circuit is higher than 4.8 V for 5 sec.
(3 D/C detection logic)

Circuit Diagram

1 5V
A1
LT BLU C02-14

A2
BRN C02-27
A3
GRY C02-4

[A] C02 E02

[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

IJCA0A112011-01

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

DTC Confirmation Procedure

1) Run engine at idle speed for 10 sec.
1A-180 Engine General Information and Diagnosis: K12M

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”: K12M
(Page 1A-138).
2 MAP sensor power supply circuit check Go to Step 4. Go to Step 3.
1) With ignition “OFF”, disconnect MAP sensor connector.
2) Check for proper terminal connection to MAP sensor
connector.
3) If connection is OK, set ignition “ON”.
4) Check that voltage between “A1” and “A3” is approx. 5 V.

Is check result OK?

3 MAP 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 or replace found, repair or replace
“A3” circuit. “A1” circuit.
Is check result OK?
If circuit is OK, replace If circuit is OK, replace
ECM and recheck DTC. ECM and recheck DTC.
(Page 1C-22) (Page 1C-22)
4 MAP sensor signal circuit check Go to Step 5. Repair or replace
1) With ignition “OFF”, disconnect “C02” and “E02” defective wire harness.
connectors from ECM.
2) Check for proper terminal connection to “C02” and “E02”
connectors.
3) If connections are OK, check the following points.
• Resistance of “A2” circuit: less than 1 Ω
• Resistance between “A2” circuit and ground: infinity
• Resistance between “A2” circuit terminal and other
terminal at MAP sensor connector: infinity
• Voltage of “A2” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

5 MAP sensor check Replace ECM and Replace MAP sensor.
1) Check MAP sensor. (Page 1C-27) recheck DTC. (Page (Page 1C-27)
1C-22)
Is check result OK?
 Engine General Information and Diagnosis: K12M 1A-181

DTC P0112 / P0113

AENJCA0A1124018
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0112: Intake Air Temperature Sensor 1 Circuit Low (Bank 1) • IAT sensor and/or its circuit
Output voltage of IAT sensor signal circuit is lower than 0.02 V for 5 sec. • ECM
(3 D/C detection logic)
P0113: Intake Air Temperature Sensor 1 Circuit High (Bank 1)
Output voltage of IAT sensor signal circuit is higher than 4.9 V for 5 sec.
(3 D/C detection logic)

Circuit Diagram

2
A1 5V
1
YEL C02-22

BEG C02-5
A2

[A] C02 E02

[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

IJCA0A112012-01

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

DTC Confirmation Procedure

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

1) Run engine at idle speed for 10 sec.

1A-182 Engine General Information and Diagnosis: K12M

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”: K12M
(Page 1A-138).
2 IAT sensor signal circuit and ground circuit check Go to Step 3. Repair or replace
1) With ignition “OFF”, disconnect “C02” and “E02” defective wire harness.
connectors of ECM and IAT sensor connector.
2) Check for proper terminal connection to “C02” and “E02”
connectors and IAT sensor connector.
3) If connections are OK, check the following points.
• Resistance of “A1” and “A2” circuits: less than 1 Ω
• Resistance between each of “A1” and “A2” circuits
and ground: infinity
• Resistance between “A1” circuit terminal and “A2”
circuit terminal at IAT sensor connector: infinity
• Voltage of “A1” and “A2” circuits: approx. 0 V (When
ignition is “ON”)

Is check result OK?

3 IAT sensor check Replace ECM and Replace IAT sensor.
1) Check IAT sensor. (Page 1C-33) recheck DTC. (Page
1C-22)
Is check result OK?

DTC P0116
AENJCA0A1124019
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0116: Engine Coolant Temperature Sensor 1 Circuit • ECT sensor and/or its circuit
Range / Performance • Thermostat
Difference between measured ECT and estimated ECT is more
• Cooling system
than specified value for specified time with engine running.
(3 D/C detection logic) • ECM

Circuit Diagram

3
A1 5V
1
BLU C02-20
GRY C02-4
2
A2

[A] C02 E02

[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

IGSB0A112019-01

[A]: ECM connector (View: [a]) A2: MAP sensor and ECT sensor ground circuit 2. To MAP sensor ground circuit
A1: ECT sensor signal circuit 1. ECT sensor 3. ECM
 Engine General Information and Diagnosis: K12M 1A-183

DTC Confirmation Procedure

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

NOTE
• Limit the driving permissible in road conditions and regulations.
• Check that the following DTC is not detected in this “DTC Confirmation Procedure”.
– ECT sensor (P0118)

1) Warm up engine to normal operating temperature.

2) Drive vehicle at 60 to 80 km/h (37 to 50 mile/h) for 20 min.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K12M
(Page 1A-138).
2 Coolant level check Go to Step 3. Add coolant and
1) Check coolant level. (Page 1F-26) recheck DTC.

Is check result OK?

3 ECT sensor circuit check Go to Step 4. Repair or replace
1) Check ECT sensor circuits according to Step 2 under defective wire harness.
“DTC P0117 / P0118”: K12M (Page 1A-184).

Is check result OK?

4 ECT sensor check Go to Step 5. Replace ECT sensor.
1) Check ECT sensor. (Page 1C-28) (Page 1C-28)

Is check result OK?

5 Thermostat check Replace ECM and Replace thermostat.
1) Check thermostat. (Page 1F-29) recheck DTC. (Page (Page 1F-29)
1C-22)
Is check result OK?
1A-184 Engine General Information and Diagnosis: K12M

DTC P0117 / P0118

AENJCA0A1124020
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0117: Engine Coolant Temperature Sensor 1 Circuit Low • ECT sensor and/or its circuit
Output voltage of ECT sensor signal circuit is lower than 0.02 V for 5 sec. • ECM
(3 D/C detection logic)
P0118: Engine Coolant Temperature Sensor 1 Circuit High
Output voltage of ECT sensor signal circuit is higher than 4.9 V for 5 sec.
(3 D/C detection logic)

Circuit Diagram

3
A1 5V
1
BLU C02-20
GRY C02-4
2
A2

[A] C02 E02

[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

IGSB0A112019-01

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

DTC Confirmation Procedure

1) Set ignition “ON” for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K12M
(Page 1A-138).
2 ECT sensor signal circuit and ground circuit check Go to Step 3. Repair or replace
1) With ignition “OFF”, disconnect “C02” and “E02” defective wire harness.
connectors of ECM and ECT sensor connector.
2) Check for proper terminal connection to “C02” and “E02”
connectors and ECT sensor connector.
3) If connections are OK, check the following points.
• Resistance of “A1” and “A2” circuits: less than 1 Ω
• Resistance between each of “A1” and “A2” circuits
and ground: infinity
• Resistance between “A1” circuit terminal and “A2”
circuit terminal at ECT sensor connector: infinity
• Voltage of “A1” and “A2” circuits: approx. 0 V (When
ignition is “ON”)

Is check result OK?

 Engine General Information and Diagnosis: K12M 1A-185

Step Action Yes No

3 ECT sensor check Replace ECM and Replace ECT sensor.
1) Check ECT sensor. (Page 1C-28) recheck DTC. (Page (Page 1C-28)
1C-22)
Is check result OK?

DTC P0122 / P0123

AENJCA0A1124021
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0122: Throttle / Pedal Position Sensor / Switch “A” Circuit Low • TP sensor (main) and/or its circuit
Output voltage of TP sensor (main) signal circuit is lower than 0.2 V. • ECM
(1 D/C detection logic)
P0123: Throttle / Pedal Position Sensor / Switch “A” Circuit High
Output voltage of TP sensor (main) signal circuit is higher than 4.8 V.
(1 D/C detection logic)

Circuit Diagram

5
12V
A1 1
C02-51 LT GRN
4
C02-54 BRN M
5V A2 B1
C02-13 RED
B2 2
C02-26 GRN
B3 3
C02-16 WHT
B4
C02-15 BLK
C02-17 BLK 6

[A] C02 E02

[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

IJCA0A112013-01

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

DTC Confirmation Procedure

P0122

NOTE
Check that the following DTC is not detected in this “DTC Confirmation Procedure”.
• TP sensor (P0123)

1) Set ignition “ON” for 10 sec.

2) Keep accelerator pedal at fully depressed position for 2 sec.
3) Release accelerator pedal for 2 sec.
4) Repeat Step 2) – 3) 3 times.
1A-186 Engine General Information and Diagnosis: K12M

P0123
1) Set ignition “ON” for 10 sec.
2) Keep accelerator pedal at fully depressed position for 2 sec.
3) Release accelerator pedal for 2 sec.
4) Repeat Step 2) – 3) 3 times.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K12M
(Page 1A-138).
2 TP sensor power supply circuit check Go to Step 4. Go to Step 3.
1) With ignition “OFF”, disconnect electric throttle body
assembly connector.
2) Check for proper terminal connection to electric throttle
body assembly connector.
3) If connection is OK, set ignition “ON”.
4) Check that voltage between “B1” and “B4” is approx. 5 V.

Is check result OK?

3 TP sensor ground circuit check Check “B4” circuit. Check “B1” circuit.
1) Check that voltage between “B1” and ground is approx. If defective circuit is If defective circuit is
5 V. found, repair or replace found, repair or replace
“B4” circuit. “B1” circuit.
Is check result OK?
If circuit is OK, replace If circuit is OK, replace
ECM and recheck DTC. ECM and recheck DTC.
(Page 1C-22) (Page 1C-22)
4 TP sensor (main) signal circuit check Go to Step 5. Repair or replace
1) With ignition “OFF”, disconnect “C02” and “E02” defective wire harness.
connectors from ECM.
2) Check for proper terminal connection to “C02” and “E02”
connectors.
3) If connections are OK, check the following points.
• Resistance of “B2” circuit: less than 1 Ω
• Resistance between “B2” circuit and ground: infinity
• Resistance between “B2” circuit terminal and other
terminal at electric throttle body assembly connector:
infinity
• Voltage of “B2” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

5 TP sensor check Replace ECM and Replace electric throttle
1) Check TP sensor referring to “TP Sensor Performance recheck DTC. (Page body assembly. (Page
Check” under “Electric Throttle Body Assembly On- 1C-22) 1D-84)
Vehicle Inspection”: K12M in Section 1C (Page 1C-23).

Is check result OK?

 Engine General Information and Diagnosis: K12M 1A-187

DTC P0130
AENJCA0A1124022
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0130: O2 Sensor Circuit (Bank 1 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 0.4 V even • HO2S-1 heater and/or its circuit
if HO2S-2 signal voltage is higher than 0.6 V for 25 sec.
• HO2S-2 heater and/or its circuit
• HO2S-1 signal voltage is between 0.6 V and 1.25 V even
• ECM
if HO2S-2 signal voltage is lower than 0.1 V for 25 sec.
(3 D/C detection logic)

Circuit Diagram

3
5V
+B 1 4 A3
RED C02-6
A2
GRN C02-7
A4
BLU PPL C02-49
A1 LT GRN C02-55
5V
2 4 B3
YEL C02-8
B2
BRN C02-19
B4
BLU RED C02-52
B1 BEG C02-56

[A] C02 E02

[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

IGSB0A112013-01

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

DTC Confirmation Procedure

! WARNING
If you do not select a suitable route and take proper precautions when performing a road test, an
accident can occur.
• Select a level road with no traffic to minimize the risk of accident.
• Perform the test extremely carefully.
• Perform the road test with 2 persons, a driver and a tester.
1A-188 Engine General Information and Diagnosis: K12M

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

1) Warm up engine to normal operating temperature.

2) Drive vehicle at 60 to 80 km/h (37 to 50 mile/h) constantly for 10 min. or more.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K12M
(Page 1A-138).
2 DTC check Go to troubleshooting Go to Step 3.
1) Check DTC. for applicable DTC.

Is there DTC(s) detected other than P0130?

3 HO2S-1 heater, HO2S-1 circuit and HO2S-1 heater circuit Go to Step 4. Repair or replace
check defective parts.
1) Check the following points.
• HO2S-1 heater: (Page 1C-29)
• HO2S-1 circuit: Step 3 under “DTC P0131 / P0132”:
K12M (Page 1A-189)
• HO2S-1 heater circuit: Step 2 – 3 under “DTC P0030 /
P0031 / P0032”: K12M (Page 1A-175)

Is check result OK?

4 HO2S-2 heater, HO2S-2 circuit and HO2S-2 heater circuit Go to Step 5. Repair or replace
check defective parts.
1) Check the following points.
• HO2S-2 heater: (Page 1C-29)
• HO2S-2 circuit: Step 3 under “DTC P0137 / P0138 /
P0140”: K12M (Page 1A-195)
• HO2S-2 heater circuit: Step 2 – 3 under “DTC P0036 /
P0037 / P0038”: K12M (Page 1A-177)

Is check result OK?

5 DTC recheck Go to Step 6. End.
1) Replace HO2S-1. (Page 1C-29)
2) Clear DTC. (Page 1A-141)
3) Set ignition “OFF”.
4) Perform “DTC Confirmation Procedure” and check DTC.

Is DTC P0130 still detected?

 Engine General Information and Diagnosis: K12M 1A-189

Step Action Yes No

6 DTC recheck Replace ECM and End.
1) Replace HO2S-2. (Page 1C-29) recheck DTC. (Page
1C-22)
2) Clear DTC. (Page 1A-141)
3) Set ignition “OFF”.
4) Perform “DTC Confirmation Procedure” and check DTC.

Is DTC P0130 still detected?

DTC P0131 / P0132

AENJCA0A1124023
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0131: O2 Sensor Circuit Low Voltage (Bank 1 Sensor 1) • HO2S-1 and/or its circuit
Output voltage of HO2S-1 circuit is lower than 0.06 V and output • ECM
voltage of HO2S-2 circuit is higher than 0.6 V for 25 sec.
(3 D/C detection logic)
P0132: O2 Sensor Circuit High Voltage (Bank 1 Sensor 1)
Output voltage of HO2S-1 circuit is higher than 1.25 V for 25 sec.
(3 D/C detection logic)

Circuit Diagram

3
5V
+B 1 4 A3
RED C02-6
A2
GRN C02-7
A4
BLU PPL C02-49
A1 LT GRN C02-55
5V
2 4 B3
YEL C02-8
B2
BRN C02-19
B4
BLU RED C02-52
B1 BEG C02-56

[A] C02 E02

[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

IGSB0A112013-01

[A]: ECM connector (View: [a]) B1: HO2S-2 heater power supply circuit 2. HO2S-2
A1: HO2S-1 heater power supply circuit B2: HO2S-2 signal circuit 3. ECM
A2: HO2S-1 signal circuit B3: HO2S-2 ground circuit 4. Shield wire
A3: HO2S-1 ground circuit B4: HO2S-2 heater drive circuit
A4: HO2S-1 heater drive circuit 1. HO2S-1
1A-190 Engine General Information and Diagnosis: K12M

DTC Confirmation Procedure

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

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

1) Warm up engine to normal operating temperature.

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

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K12M
(Page 1A-138).
2 DTC check Go to troubleshooting Go to Step 3.
for applicable DTC.
Is there any DTC(s) other than P0131 and P0132?
3 HO2S-1 signal and ground circuit check Go to Step 4. Repair or replace
1) With ignition “OFF”, disconnect “C02” and “E02” defective wire harness.
connectors of ECM and HO2S-1 connector.
2) Check for proper terminal connection to “C02” and “E02”
connectors and HO2S-1 connector.
3) If connections are OK, check the following points.
• Resistance of “A2” and “A3” circuits: less than 1 Ω
• Resistance between each of “A2” and “A3” circuits
and ground: infinity
• Resistance between “A2” circuit terminal and other
terminal at HO2S-1 connector: infinity
• Resistance between “A3” circuit terminal and other
terminal at HO2S-1 connector: infinity
• Voltage of “A2” and “A3” circuits: approx. 0 V (When
ignition is “ON”)

Is check result OK?

 Engine General Information and Diagnosis: K12M 1A-191

Step Action Yes No

4 DTC recheck Replace ECM and End.
1) Replace HO2S-1. (Page 1C-29) recheck DTC. (Page
1C-22)
2) Clear DTC. (Page 1A-141)
3) Set ignition “OFF”.
4) Perform “DTC Confirmation Procedure” and check DTC.

Is DTC P0131 and/or P0132 still detected?

DTC P0133
AENJCA0A1124024
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0133: O2 Sensor Circuit Slow Response (Bank 1 Sensor 1) • HO2S-1 and/or its circuit
Cycle duration from rich to lean and lean to rich of HO2S-1 is • HO2S-1 heater
longer than specified time.
• Air intake system
(3 D/C detection logic)
• Exhaust system
• Fuel system
• ECM

Circuit Diagram

3
5V
+B 1 4 A3
RED C02-6
A2
GRN C02-7
A4
BLU PPL C02-49
A1 LT GRN C02-55
5V
2 4 B3
YEL C02-8
B2
BRN C02-19
B4
BLU RED C02-52
B1 BEG C02-56

[A] C02 E02

[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

IGSB0A112013-01

[A]: ECM connector (View: [a]) B1: HO2S-2 heater power supply circuit 2. HO2S-2
A1: HO2S-1 heater power supply circuit B2: HO2S-2 signal circuit 3. ECM
A2: HO2S-1 signal circuit B3: HO2S-2 ground circuit 4. Shield wire
A3: HO2S-1 ground circuit B4: HO2S-2 heater drive circuit
A4: HO2S-1 heater drive circuit 1. HO2S-1
1A-192 Engine General Information and Diagnosis: K12M

DTC Confirmation Procedure

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

NOTE
• Limit the driving permissible in road conditions and regulations.
• Check that the following condition is met in this “DTC Confirmation Procedure”.
– A/F feedback (closed loop) control is activated.
• Check that the following DTCs are not detected in this “DTC Confirmation Procedure”.
– HO2S-1 heater (P0030, P0031 and P0032)
– HO2S-1 (P0130, P0131, P0132 and P0134)
– HO2S-2 (P0137 and P0140)
– Fuel trim system (P0171 and P0172)
– Cylinder misfire detected (P0300)
– CKP sensor (P0335)
– CMP sensor (P0340)
– EVAP canister purge valve (P0443, P0458 and P0459)
– System voltage (P0560, P0562 and P0563)

1) Warm up engine to normal operating temperature.

2) With engine speed at 1,200 to 3,500 rpm, drive vehicle at 50 to 80 km/h (31 to 50 mile/h) for 5 min.
3) Check whether O2 sensor readiness / monitoring test has completed or not using scan tool. If O2 sensor
readiness / monitoring test has not completed, check vehicle conditions (environmental) and repeat Step 2) – 3).

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K12M
(Page 1A-138).
2 DTC check Go to troubleshooting Go to Step 3.
for applicable DTC.
Is there any DTC(s) other than P0133?
3 Exhaust system and air intake system check Go to Step 4. Repair or replace
1) Check exhaust system and air intake system for defective part.
clogging or leakage.

Is check result OK?

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

Is check result OK?

5 HO2S-1 signal and ground circuit check Go to Step 6. Repair or replace
1) Check “A2” and “A3” circuits according to Step 3 under defective wire harness.
“DTC P0131 / P0132”: K12M (Page 1A-189).

Is check result OK?

 Engine General Information and Diagnosis: K12M 1A-193

Step Action Yes No

6 HO2S-1 heater check Go to Step 7. Replace HO2S-1.
1) Check HO2S-1 heater. (Page 1C-29) (Page 1C-29)

Is check result OK?

7 DTC recheck Replace ECM and End.
1) Replace HO2S-1. (Page 1C-29) recheck DTC. (Page
1C-22)
2) Clear DTC. (Page 1A-141)
3) Set ignition “OFF”.
4) Perform “DTC Confirmation Procedure” and check DTC.

Is DTC P0133 still detected?

DTC P0134
AENJCA0A1124025
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0134: O2 Sensor Circuit No Activity Detected (Bank • HO2S-1 and/ or its circuit
1 Sensor 1) • HO2S-1 heater
Output voltage of HO2S-1 circuit stays between 0.4 and
• Air intake system
0.6 V for 24 sec.
(3 D/C detection logic) • Exhaust system
• ECM

Circuit Diagram

3
5V
+B 1 4 A3
RED C02-6
A2
GRN C02-7
A4
BLU PPL C02-49
A1 LT GRN C02-55
5V
2 4 B3
YEL C02-8
B2
BRN C02-19
B4
BLU RED C02-52
B1 BEG C02-56

[A] C02 E02

[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

IGSB0A112013-01

[A]: ECM connector (View: [a]) B1: HO2S-2 heater power supply circuit 2. HO2S-2
A1: HO2S-1 heater power supply circuit B2: HO2S-2 signal circuit 3. ECM
A2: HO2S-1 signal circuit B3: HO2S-2 ground circuit 4. Shield wire
A3: HO2S-1 ground circuit B4: HO2S-2 heater drive circuit
A4: HO2S-1 heater drive circuit 1. HO2S-1
1A-194 Engine General Information and Diagnosis: K12M

DTC Confirmation Procedure

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

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

1) Warm up engine to normal operating temperature.

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

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K12M
(Page 1A-138).
2 DTC check Go to troubleshooting Go to Step 3.
for applicable DTC.
Is there any DTC(s) other than P0134?
3 Exhaust system and air intake system check Go to Step 4. Repair or replace
1) Check exhaust system and air intake system for defective part.
clogging or leakage.

Is check result OK?

4 HO2S-1 signal and ground circuit check Go to Step 5. Repair or replace
1) Check “A2” and “A3” circuits according to Step 3 under defective wire harness.
“DTC P0131 / P0132”: K12M (Page 1A-189).

Is check result OK?

5 HO2S-1 heater recheck Go to Step 6. Replace HO2S-1.
1) Check HO2S-1 heater. (Page 1C-29) (Page 1C-29)
2) Clear DTC. (Page 1A-141)
3) Set ignition “OFF”.
4) Perform “DTC Confirmation Procedure” and check DTC.

Is check result OK?

6 DTC recheck Replace ECM and End.
1) Replace HO2S-1. (Page 1C-29) recheck DTC. (Page
1C-22)
2) Clear DTC. (Page 1A-141)
3) Set ignition “OFF”.
4) Perform “DTC Confirmation Procedure” and check DTC.

Is DTC P0134 still detected?

 Engine General Information and Diagnosis: K12M 1A-195

DTC P0137 / P0138 / P0140

DTC Detecting Condition and Trouble Area
DTC detecting condition
P0137: O2 Sensor Circuit Low Voltage (Bank 1 Sensor 2)
Output voltage of HO2S-2 circuit is lower than 0.06 V for 25 sec. after warming up. •
(3 D/C detection logic)
P0138: O2 Sensor Circuit High Voltage (Bank 1 Sensor 2)
Output voltage of HO2S-2 signal circuit is higher than 1.25 V for 25 sec.
(3 D/C detection logic)
P0140: O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 2)
Output voltage of HO2S-2 circuit stays between 0.4 and 0.6 V for 24 sec.
(3 D/C detection logic)
AENJCA0A1124026
Trouble area
• HO2S-2 and/or its circuit
HO2S-2 heater and/or its circuit
• Exhaust system
• Air intake system
• Fuel system
• ECM

Circuit Diagram

3
5V
+B 1 4 A3
RED C02-6
A2
GRN C02-7
A4
BLU PPL C02-49
A1 LT GRN C02-55
5V
2 4 B3
YEL C02-8
B2
BRN C02-19
B4
BLU RED C02-52
B1 BEG C02-56

[A] C02 E02

[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

IGSB0A112013-01

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

DTC Confirmation Procedure

! WARNING
If you do not select a suitable route and take proper precautions when performing a road test, an
accident can occur.
• Select a level road with no traffic to minimize the risk of accident.
• Perform the test extremely carefully.
• Perform the road test with 2 persons, a driver and a tester.
1A-196 Engine General Information and Diagnosis: K12M

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

1) Warm up engine to normal operating temperature.

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

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K12M
(Page 1A-138).
2 DTC check Go to troubleshooting Go to Step 3.
for applicable DTC.
Is there any DTC(s) other than P0137, P0138 and P0140?
3 HO2S-2 signal circuit and ground circuit check Go to Step 4. Repair or replace
1) With ignition “OFF”, disconnect “C02” and “E02” defective wire harness.
connectors of ECM and HO2S-2 connector.
2) Check for proper terminal connection to “C02” and “E02”
connectors and HO2S-2 connector.
3) If connections are OK, check the following points.
• Resistance of “B2” and “B3” circuits: less than 1 Ω
• Resistance between each of “B2” and “B3” circuits
and ground: infinity
• Resistance between “B2” circuit terminal and other
terminal at HO2S-2 connector: infinity
• Resistance between “B3” circuit terminal and other
terminal at HO2S-2 connector: infinity
• Voltage of “B2” and “B3” circuits: approx. 0 V (When
ignition is “ON”)

Is check result OK?

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

Is check result OK?

5 HO2S-2 heater circuit check Go to Step 6. Repair or replace
1) Check HO2S-2 heater circuits according to Step 2 – 3 defective part.
under “DTC P0036 / P0037 / P0038”: K12M (Page 1A-
177).

Is check result OK?

6 Fuel injector and its circuit check Go to Step 7. Faulty injector(s) or its
1) Check fuel injector circuit. (Page 1G-7) circuit.
2) Check fuel injectors. (Page 1G-24)

Is check result OK?

 Engine General Information and Diagnosis: K12M 1A-197

Step Action Yes No

7 DTC recheck Replace ECM and End.
1) Replace HO2S-2. (Page 1C-29) recheck DTC. (Page
1C-22)
2) Clear DTC. (Page 1A-141)
3) Set ignition “OFF”.
4) Perform “DTC Confirmation Procedure” and check DTC.

Is DTC P0137, P0138 or P0140 still detected?

DTC P0171 / P0172

AENJCA0A1124027
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0171: System Too Lean (Bank 1) • Fuel system
Fuel trim correction is higher than specified value for • Air intake system
specified time under specified vehicle condition.
• Exhaust system
(3 D/C detection logic)
P0172: System Too Rich (Bank 1) • HO2S-1 and/or its circuit
Fuel trim correction is lower than specified value for • Emission control system
specified time under specified vehicle condition. • ECM
(3 D/C detection logic)

Circuit Diagram

3
5V
+B 1 4 A3
RED C02-6
A2
GRN C02-7
A4
BLU PPL C02-49
A1 LT GRN C02-55
5V
2 4 B3
YEL C02-8
B2
BRN C02-19
B4
BLU RED C02-52
B1 BEG C02-56

[A] C02 E02

[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

IGSB0A112013-01

[A]: ECM connector (View: [a]) B1: HO2S-2 heater power supply circuit 2. HO2S-2
A1: HO2S-1 heater power supply circuit B2: HO2S-2 signal circuit 3. ECM
A2: HO2S-1 signal circuit B3: HO2S-2 ground circuit 4. Shield wire
A3: HO2S-1 ground circuit B4: HO2S-2 heater drive circuit
A4: HO2S-1 heater drive circuit 1. HO2S-1
1A-198 Engine General Information and Diagnosis: K12M

DTC Confirmation Procedure

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

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

1) Warm up engine to normal operating temperature.

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

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K12M
(Page 1A-138).
2 DTC check Go to troubleshooting Go to Step 3.
for applicable DTC.
Is there any DTC(s) other than P0171 and P0172?
3 Fuel system and emission control system check Go to Step 4. Repair or replace
1) Check the following points related to fuel and emission defective parts.
control systems.
• Fuel pressure: (Page 1G-12)
• Fuel injector circuit: (Page 1G-7)
• Fuel injector: (Page 1G-24)
• MAP sensor: (Page 1C-27)
• EVAP canister purge valve: (Page 1B-11)
• PCV valve: (Page 1B-13)

Is check result OK?

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

Is check result OK?

5 HO2S-1 signal and ground circuit check Go to Step 6. Repair or replace
1) Check “A2” and “A3” circuits according to Step 3 under defective wire harness.
“DTC P0131 / P0132”: K12M (Page 1A-189).

Is check result OK?

 Engine General Information and Diagnosis: K12M 1A-199

Step Action Yes No

6 DTC recheck Replace ECM and End.
1) Replace HO2S-1. (Page 1C-29) recheck DTC. (Page
1C-22)
2) Clear DTC. (Page 1A-141)
3) Set ignition “OFF”.
4) Perform “DTC Confirmation Procedure” and check DTC.

Is DTC P0171 or P0172 still detected?

DTC P0201 / P0202 / P0203 / P0204 / P0261 / P0262 / P0264 / P0265 / P0267 / P0268 / P0270 / P0271
AENJCA0A1124028
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0201: Injector Circuit / Open – Cylinder 1 • Fuel injector and/or its circuit
Fuel injector No.1 and/or its circuit is open with engine running. • ECM
(3 D/C detection logic)
P0202: Injector Circuit / Open – Cylinder 2
Fuel injector No.2 and/or its circuit is open with engine running.
(3 D/C detection logic)
P0203: Injector Circuit / Open – Cylinder 3
Fuel injector No.3 and/or its circuit is open with engine running.
(3 D/C detection logic)
P0204: Injector Circuit / Open – Cylinder 4
Fuel injector No.4 and/or its circuit is open with engine running.
(3 D/C detection logic)
P0261: Cylinder 1 Injector Circuit Low
Fuel injector No.1 drive circuit is shorted to ground with engine running.
(3 D/C detection logic)
P0262: Cylinder 1 Injector Circuit High
Fuel injector No.1 drive circuit is shorted to power supply with engine running.
(3 D/C detection logic)
P0264: Cylinder 2 Injector Circuit Low
Fuel injector No.2 drive circuit is shorted to ground with engine running.
(3 D/C detection logic)
P0265: Cylinder 2 Injector Circuit High
Fuel injector No.2 drive circuit is shorted to power supply with engine running.
(3 D/C detection logic)
P0267: Cylinder 3 Injector Circuit Low
Fuel injector No.3 drive circuit is shorted to ground with engine running.
(3 D/C detection logic)
P0268: Cylinder 3 Injector Circuit High
Fuel injector No.3 drive circuit is shorted to power supply with engine running.
(3 D/C detection logic)
P0270: Cylinder 4 Injector Circuit Low
Fuel injector No.4 drive circuit is shorted to ground with engine running.
(3 D/C detection logic)
P0271: Cylinder 4 Injector Circuit High
Fuel injector No.4 drive circuit is shorted to power supply with engine running.
(3 D/C detection logic)
1A-200 Engine General Information and Diagnosis: K12M

Circuit Diagram

5 +B

A2 A1 BLU
1
C02-31 PNK

B2 B1
2
C02-11 WHT

C2 C1
3
C02-10 RED

D2 D1
4
C02-12 GRN

[A] C02 E02

[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

IJCA0A112014-01

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

DTC Confirmation Procedure

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

1) Run engine at idle speed for 1 min.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K12M
(Page 1A-138).
2 Fuel injector power supply circuit check Go to Step 3. Repair or replace
1) When ignition “OFF”, disconnect connector from fuel defective wire harness.
injector related to DTC.
2) Check for proper terminal connection to fuel injector
connector.
3) If connection is OK, set ignition “ON”.
4) Check that voltage between “A1”, “B1”, “C1” or “D1” and
ground is battery voltage.

Is check result OK?

 Engine General Information and Diagnosis: K12M 1A-201

Step Action Yes No

3 Fuel injector drive circuit check Go to Step 4. Repair or replace
1) With ignition “OFF”, disconnect “C02” and “E02” defective wire harness.
connectors from ECM.
2) Check for proper terminal connections to “C02” and
“E02” connectors.
3) If connections are OK, check the following points.
• Resistance of “A2”, “B2”, “C2” or “D2” circuit: less than
1Ω
• Resistance between each of “A2”, “B2”, “C2” and “D2”
circuit and ground: infinity
• Resistance between “A1” circuit terminal and “A2”
circuit terminal at fuel injector connector: infinity
• Resistance between “B1” circuit terminal and “B2”
circuit terminal at fuel injector connector: infinity
• Resistance between “C1” circuit terminal and “C2”
circuit terminal at fuel injector connector: infinity
• Resistance between “D1” circuit terminal and “D2”
circuit terminal at fuel injector connector: infinity
• Voltage of “A2”, “B2”, “C2” or “D2” circuit: approx. 0 V
(When ignition is “ON”)

Is check result OK?

4 Fuel injector check Replace ECM and Replace fuel injector
1) Check fuel injector related to DTC. (Page 1G-24) recheck DTC. (Page related to DTC. (Page
1C-22) 1G-22)
Is check result OK?
1A-202 Engine General Information and Diagnosis: K12M

DTC P0222 / P0223

AENJCA0A1124029
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0222: Throttle / Pedal Position Sensor / Switch “B” Circuit Low • TP sensor (sub) and/or its circuit
Output voltage of TP sensor (sub) signal circuit is lower than 0.2 V. • ECM
(1 D/C detection logic)
P0223: Throttle / Pedal Position Sensor / Switch “B” Circuit High
Output voltage of TP sensor (sub) signal circuit is higher than 4.8 V.
(1 D/C detection logic)

Circuit Diagram

5
12V
A1 1
C02-51 LT GRN
4
C02-54 BRN M
5V A2 B1
C02-13 RED
B2 2
C02-26 GRN
B3 3
C02-16 WHT
B4
C02-15 BLK
C02-17 BLK 6

[A] C02 E02

[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

IJCA0A112013-01

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

DTC Confirmation Procedure

P0222

NOTE
Check that the following DTC is not detected in this “DTC Confirmation Procedure”.
• TP sensor (P0223)

1) Set ignition “ON” for 10 sec.

2) Keep accelerator pedal at fully depressed position for 2 sec.
3) Release accelerator pedal for 2 sec.
4) Repeat Step 2) – 3) 3 times.
 Engine General Information and Diagnosis: K12M 1A-203

P0223
1) Set ignition “ON” for 10 sec.
2) Keep accelerator pedal at fully depressed position for 2 sec.
3) Release accelerator pedal for 2 sec.
4) Repeat Step 2) – 3) 3 times.

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”: K12M
(Page 1A-138).
2 TP sensor power supply circuit check Go to Step 4. Go to Step 3.
1) With ignition “OFF”, disconnect electric throttle body
assembly connector.
2) Check for proper terminal connection to electric throttle
body assembly connector.
3) If connection is OK, set ignition “ON”.
4) Check that voltage between “B1” and “B4” is approx. 5 V.

Is check result OK?

3 TP sensor ground circuit check Check “B4” circuit. Check “B1” circuit.
1) Check that voltage between “B1” and ground is approx. If defective circuit is If defective circuit is
5 V. found, repair or replace found, repair or replace
“B4” circuit. “B1” circuit.
Is check result OK?
If circuit is OK, replace If circuit is OK, replace
ECM and recheck DTC. ECM and recheck DTC.
(Page 1C-22) (Page 1C-22)
4 TP sensor (sub) signal circuit check Go to Step 5. Repair or replace
1) With ignition “OFF”, disconnect “C02” and “E02” defective wire harness.
connectors from ECM.
2) Check for proper terminal connection to “C02” and “E02”
connectors.
3) If connections are OK, check the following points.
• Resistance of “B3” circuit: less than 1 Ω
• Resistance between “B3” circuit and ground: infinity
• Resistance between “B3” circuit terminal and other
terminal at electric throttle body assembly connector:
infinity
• Voltage of “B3” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

5 TP sensor check Replace ECM and Replace electric throttle
1) Check TP sensor referring to “TP Sensor Performance recheck DTC. (Page body assembly. (Page
Check” under “Electric Throttle Body Assembly On- 1C-22) 1D-84)
Vehicle Inspection”: K12M in Section 1C (Page 1C-23).

Is check result OK?

1A-204 Engine General Information and Diagnosis: K12M

DTC P0300 / P0301 / P0302 / P0303 / P0304

AENJCA0A1124030
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0300: Random / Multiple Cylinder Misfire Detected • Exhaust system
Any of the following conditions is met. • Air intake system
• Misfire, which causes catalyst to overheat during 200 • Ignition system
engine revolutions, is detected at 2 or more cylinders.
• Fuel system
(MIL blinks as long as misfire lasts.)
• Engine compression
• Misfire, which affects exhaust emission adversely during
1,000 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 • ECM
engine revolutions, is detected at specific cylinder.
(MIL blinks as long as misfire lasts.)
• Misfire, which affects exhaust emission adversely during
1,000 engine revolutions, is detected at specific cylinder.
(3 D/C detection logic)

DTC Confirmation Procedure

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

NOTE
• Limit the driving permissible in road conditions and regulations.
• Check that the following conditions are met in this “DTC Confirmation Procedure”.
– IAT ≥ –10 °C (14 °F)
– ECT > –10 °C (14 °F)
– Engine speed < 4,500 rpm

1) Warm up engine to normal operating temperature.

2) With engine speed at 4,500 rpm or less, drive vehicle at 50 to 80 km/h (31 to 50 mile/h) constantly for 5 min. or
more.
 Engine General Information and Diagnosis: K12M 1A-205

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”: K12M
(Page 1A-138).
2 Fuel level check Add fuel and recheck Go to Step 3.
1) Check fuel level by fuel level meter. DTC.

Does it indicate “E” level (empty)?

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

Is check result OK?

5 Ignition system check Go to Step 6. Repair or replace
1) Check ignition system. (Page 1H-13) 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: (Page 1G-12)
• Fuel injector circuit: (Page 1G-7)
• Fuel injector: (Page 1G-24)

Is check result OK?

7 Engine mechanical system check Check ECM power Repair or replace
1) Check the following points which can be cause of rough supply and ground defective parts.
idling or poor performance. circuits. (Page 1A-
267)
• Engine compression: (Page 1D-77)
• Valve clearance: (Page 1D-79) If circuit is OK, replace
ECM and recheck DTC.
• Valve timing: (Page 1D-111) (Page 1C-22)
Is check result OK?
1A-206 Engine General Information and Diagnosis: K12M

DTC P0327 / P0328

AENJCA0A1124031
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0327: Knock Sensor 1 Circuit Low (Bank 1 or Single Sensor) • Knock sensor and/or its circuit
Output voltage of knock sensor signal circuit is lower than specified • ECM
value for specified time with engine running.
(3 D/C detection logic)
P0328: Knock Sensor 1 Circuit High (Bank 1 or Single Sensor)
Output voltage of knock sensor signal circuit is higher than specified
value for specified time with engine running.
(3 D/C detection logic)

Circuit Diagram

2
A1
1
WHT C02-25
BLU C02-37
B1

[A] C02 E02

[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

IGSB0A112024-01

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

DTC Confirmation Procedure

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

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

1) Warm up engine to normal operating temperature.

2) Drive vehicle at 2,400 rpm or more. (Keep throttle valve opening constant in this step.)
 Engine General Information and Diagnosis: K12M 1A-207

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”: K12M
(Page 1A-138).
2 Knock sensor signal circuit check Go to Step 3. Repair or replace
1) With ignition “OFF”, disconnect “C02” and “E02” defective wire harness.
connectors of ECM and knock sensor connector.
2) Check for proper terminal connection to “C02” and “E02”
connectors and knock sensor connector.
3) If connections are OK, check the following points.
• Resistance of “A1” and “B1” circuits: less than 1 Ω
• Resistance between each of “A1” and “B1” circuits
and ground: infinity
• Resistance between “A1” circuit terminal and “B1”
circuit terminal at knock sensor connector: infinity
• Voltage of “A1” and “B1” circuits: approx. 0 V (When
ignition is “ON”)

Is check result OK?

3 Knock sensor check Go to Step 4. Replace knock sensor.
1) Check knock sensor. (Page 1C-32) (Page 1C-32)

Is check result OK?

4 Troubleshooting of other DTC(s) at the same time Go to troubleshooting Replace ECM and
for applicable DTC. recheck DTC. (Page
Is other DTC(s) detected together? 1C-22)
1A-208 Engine General Information and Diagnosis: K12M

DTC P0335 / P0336

AENJCA0A1124032
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0335: Crankshaft Position Sensor “A” Circuit • CKP sensor and/or its circuit
CKP sensor signal is not inputted while CMP sensor signal is being inputted. • Sensor plate
(3 D/C detection logic)
• ECM
P0336: Crankshaft Position Sensor “A” Circuit Range / Performance
Any of the following conditions is met.
• Signal detecting time is longer than specification.
• Number of teeth between gaps is more than specification.
• Time between adjacent two teeth is longer than specification.
(3 D/C detection logic)

Circuit Diagram

+B 3
A1 BLU
A2 5V
1
PPL C02-30

A3

B1
B2 5V
2
PNK C02-39
GRY
B3

[A] C02 E02

[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

IJCA0A112015-01

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

DTC Confirmation Procedure

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

1) Run engine at idle speed for 5 min.

 Engine General Information and Diagnosis: K12M 1A-209

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”: K12M
(Page 1A-138).
2 CKP sensor power supply circuit check Go to Step 4. Go to Step 3.
1) With ignition “OFF”, disconnect CKP sensor connector.
2) Check for proper terminal connection to CKP sensor
connector.
3) If connection is OK, set ignition “ON”.
4) Check that voltage between “B1” and “B3” is battery
voltage.

Is check result OK?

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

Is check result OK?

4 CKP sensor signal circuit check Go to Step 5. Repair or replace
1) With ignition “OFF”, disconnect “C02” and “E02” defective wire harness.
connectors from ECM.
2) Check for proper terminal connection to “C02” and “E02”
connectors.
3) If connections are OK, check the following points.
• Resistance of “B2” circuit: less than 1 Ω
• Resistance between “B2” circuit and ground: infinity
• Resistance between “B2” circuit terminal and other
terminal at CKP sensor connector: infinity
• Voltage of “B2” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

5 CKP sensor and sensor plate check Replace ECM and Repair or replace
1) Check CKP sensor and sensor plate. recheck DTC. (Page defective parts.
1C-22)
• CKP sensor: (Page 1C-31)
• Sensor plate: (Page 1D-147)

Is check result OK?

1A-210 Engine General Information and Diagnosis: K12M

DTC P0340
AENJCA0A1124033
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0340: Camshaft Position Sensor “A” Circuit (Bank 1 or Single Sensor) • CMP sensor and/or its circuit
Any of the following conditions is met. • Signal rotor
• CMP sensor signal is not inputted while CKP sensor signal is being inputted. • ECM
• CMP sensor signal pattern is not equal to the expected pattern.
(3 D/C detection logic)

Circuit Diagram

+B 3
A1 BLU
A2 5V
1
PPL C02-30

A3

B1
B2 5V
2
PNK C02-39
GRY
B3

[A] C02 E02

[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

IJCA0A112015-01

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

DTC Confirmation Procedure

1) Run engine at idle speed for 10 min.
 Engine General Information and Diagnosis: K12M 1A-211

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”: K12M
(Page 1A-138).
2 CMP sensor power supply circuit check Go to Step 4. Go to Step 3.
1) With ignition “OFF”, disconnect CMP sensor connector.
2) Check for proper terminal connection to CMP sensor
connector.
3) If connection is OK, set ignition “ON”.
4) Check that voltage between “A1” and “A3” is battery
voltage.

Is check result OK?

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

Is check result OK?

4 CMP sensor signal circuit check Go to Step 5. Repair or replace
1) With ignition “OFF”, disconnect “C02” and “E02” defective wire harness.
connectors from ECM.
2) Check for proper terminal connection to “C02” and “E02”
connectors.
3) If connections are OK, check the following points.
• Resistance of “A2” circuit: less than 1 Ω
• Resistance between “A2” circuit and ground: infinity
• Resistance between “A2” circuit terminal and other
terminal at CMP sensor connector: infinity
• Voltage of “A2” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

5 CMP sensor and signal rotor check Replace ECM and Repair or replace
1) Check CMP sensor and signal rotor. recheck DTC. (Page defective parts.
1C-22)
• CMP sensor: (Page 1C-30)
• Signal rotor: (Page 1D-95)

Is check result OK?

1A-212 Engine General Information and Diagnosis: K12M

DTC P0351 / P0352 / P0353 / P0354 / P2300 / P2301 / P2303 / P2304 / P2306 / P2307 / P2309 / P2310
AENJCA0A1124034
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0351: Ignition Coil “A” Primary / Secondary Circuit • Ignition coil assembly and/
Ignition coil assembly No.1 and/or its circuit is open with engine running. or its circuit
(3 D/C detection logic) • ECM
P0352: Ignition Coil “B” Primary / Secondary Circuit
Ignition coil assembly No.2 and/or its circuit is open with engine running.
(3 D/C detection logic)
P0353: Ignition Coil “C” Primary / Secondary Circuit
Ignition coil assembly No.3 and/or its circuit is open with engine running.
(3 D/C detection logic)
P0354: Ignition Coil “D” Primary / Secondary Circuit
Ignition coil assembly No.4 and/or its circuit is open with engine running.
(3 D/C detection logic)
P2300: Ignition Coil “A” Primary Control Circuit Low
Ignition coil assembly No.1 drive circuit is shorted to ground with engine running.
(3 D/C detection logic)
P2301: Ignition Coil “A” Primary Control Circuit High
Ignition coil assembly No.1 drive circuit is shorted to power supply with engine running.
(3 D/C detection logic)
P2303: Ignition Coil “B” Primary Control Circuit Low
Ignition coil assembly No.2 drive circuit is shorted to ground with engine running.
(3 D/C detection logic)
P2304: Ignition Coil “B” Primary Control Circuit High
Ignition coil assembly No.2 drive circuit is shorted to power supply with engine running.
(3 D/C detection logic)
P2306: Ignition Coil “C” Primary Control Circuit Low
Ignition coil assembly No.3 drive circuit is shorted to ground with engine running.
(3 D/C detection logic)
P2307: Ignition Coil “C” Primary Control Circuit High
Ignition coil assembly No.3 drive circuit is shorted to power supply with engine running.
(3 D/C detection logic)
P2309: Ignition Coil “D” Primary Control Circuit Low
Ignition coil assembly No.4 drive circuit is shorted to ground with engine running.
(3 D/C detection logic)
P2310: Ignition Coil “D” Primary Control Circuit High
Ignition coil assembly No.4 drive circuit is shorted to power supply with engine running.
(3 D/C detection logic)
 Engine General Information and Diagnosis: K12M 1A-213

Circuit Diagram

IG1

5 A1 WHT
1
5V
A2
C02-44 YEL
A3 B1
BLK
2
5V
B2
C02-33 GRN
B3 C1
BLK 3
5V
C2
C02-34 PNK
C3 D1
BLK 4
5V
D2
C02-35 BEG
D3
BLK

[A] C02 E02

[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

IJCA0A112016-01

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

DTC Confirmation Procedure

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

1) Run engine at idle speed for 1 min.

1A-214 Engine General Information and Diagnosis: K12M

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”: K12M
(Page 1A-138).
2 Ignition coil assembly power supply circuit check Go to Step 4. Go to Step 3.
1) With ignition “OFF”, disconnect connector from ignition
coil assembly related to DTC.
2) Check for proper terminal connection to ignition coil
assembly connector.
3) If connection is OK, set ignition “ON”.
4) Check that voltage between “A1” and “A3”, “B1” and
“B3”, “C1” and “C3” or “D1” and “D3” is battery voltage.

Is check result OK?

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

Is check result OK?

4 Ignition coil assembly drive circuit check Go to Step 5. Repair or replace
1) With ignition “OFF”, disconnect “C02” and “E02” defective wire harness.
connectors from ECM.
2) Check for proper terminal connections to “C02” and
“E02” connectors.
3) If connections are OK, check the following points.
• Resistance of “A2”, “B2”, “C2” or “D2” circuit: less than
1Ω
• Resistance between each of “A2”, “B2”, “C2” or “D2”
circuit and ground: infinity
• Resistance between “A2” circuit terminal and other
terminal at ignition coil connector: infinity
• Resistance between “B2” circuit terminal and other
terminal at ignition coil connector: infinity
• Resistance between “C2” circuit terminal and other
terminal at ignition coil connector: infinity
• Resistance between “D2” circuit terminal and other
terminal at ignition coil connector: infinity
• Voltage of “A2”, “B2”, “C2” or “D2” circuit: approx. 0 V
(When ignition is “ON”)

Is check result OK?

5 DTC recheck Replace ECM and End.
1) Replace ignition coil assembly related to DTC with recheck DTC. (Page
normal ignition coil assembly. (Page 1H-17) 1C-22)
2) Clear DTC. (Page 1A-141)
3) Set ignition “OFF”.
4) Perform “DTC Confirmation Procedure” and check DTC.

Is the same DTC still detected?

 Engine General Information and Diagnosis: K12M 1A-215

DTC P0420
AENJCA0A1124035
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0420: Catalyst System Efficiency below Threshold • Exhaust system
(Bank 1) • HO2S-1 and/or its circuit
Average amplitude of HO2S-2 signal is more than specified
• HO2S-2 and/or its circuit
valve for 60 sec. under specified vehicle condition.
(3 D/C detection logic) • TWC
• ECM

Circuit Diagram

4
5V

RED C02-6
GRN C02-7
1

5V
3

YEL C02-8
BRN C02-19

[A] C02 E02

[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

IGSB0A112027-01

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

1. HO2S-1 3. HO2S-2

DTC Confirmation Procedure

! WARNING
If you do not select a suitable route and take proper precautions when performing a road test, an
accident can occur.
• Select a level road with no traffic to minimize the risk of accident.
• Perform the test extremely carefully.
• Perform the road test with 2 persons, a driver and a tester.
1A-216 Engine General Information and Diagnosis: K12M

NOTE
• Limit the driving permissible in road condition is regulations.
• Check that the following condition is met in this “DTC Confirmation Procedure”.
– A/F feedback (closed loop) control is activated.
• Check that the following DTCs are not detected in this “DTC Confirmation Procedure”.
– HO2S-1 heater (P0030, P0031 and P0032)
– HO2S-2 heater (P0036, P0037 and P0038)
– TP sensor (P0122, P0123, P0222 and P0223)
– HO2S-1 (P0130, P0131, P0132, P0133 and P0134)
– HO2S-2 (P0137, P0138, P0140 and P2271)
– Fuel trim system (P0171 and P0172)
– Cylinder misfire detected (P0300)
– EVAP canister purge valve (P0443, P0458 and P0459)

1) Warm up engine to normal operating temperature.

2) With engine speed at 1,500 to 3,500 rpm, drive vehicle at 50 to 80 km/h (31 to 50 mile/h) constantly for 5 min. or
more at 5th gear (M/T model) or D range (auto gear shift model). (Keep throttle valve opening constant in this
step.)
3) Check whether catalyst readiness / monitoring test has completed or not using scan tool. If catalyst readiness /
monitoring test has not completed, check vehicle conditions (environmental) and repeat Step 2) – 3).

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K12M
(Page 1A-138).
2 DTC check Go to troubleshooting Go to Step 3.
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 HO2S-2 signal and ground circuits according to defective wire harness.
Step 3 under “DTC P0137 / P0138 / P0140”: K12M
(Page 1A-195).

Is check result OK?

5 HO2S-1 circuit check Go to Step 6. Repair or replace
1) Check HO2S-1 signal and ground circuits according to defective wire harness.
Step 3 under “DTC P0131 / P0132”: K12M (Page 1A-
189).

Is check result OK?

6 DTC recheck Go to Step 7. End.
1) Replace exhaust manifold (incorporating TWC). (Page
1K-9)
2) Clear DTC. (Page 1A-141)
3) Set ignition “OFF”.
4) Perform “DTC Confirmation Procedure” and check DTC.

Is DTC P0420 still detected?

 Engine General Information and Diagnosis: K12M 1A-217

Step Action Yes No

7 DTC recheck Go to Step 8. End.
1) Replace HO2S-2. (Page 1C-29)
2) Clear DTC. (Page 1A-141)
3) Set ignition “OFF”.
4) Perform “DTC Confirmation Procedure” and check DTC.

Is DTC P0420 still detected?

8 DTC recheck Replace ECM and End.
1) Replace HO2S-1. (Page 1C-29) recheck DTC. (Page
1C-22)
2) Clear DTC. (Page 1A-141)
3) Set ignition “OFF”.
4) Perform “DTC Confirmation Procedure” and check DTC.

Is DTC P0420 still detected?

DTC P0443 / P0458 / P0459

AENJCA0A1124036
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0443: Evaporative Emission System Purge Control Valve Circuit • EVAP canister purge valve
EVAP canister purge valve drive circuit is open with engine running. and/or its circuit
(3 D/C detection logic) • ECM
P0458: Evaporative Emission System Purge Control Valve Circuit Low
EVAP canister purge valve drive circuit is shorted to ground with engine running.
(3 D/C detection logic)
P0459: Evaporative Emission System Purge Control Valve Circuit High
EVAP canister purge valve drive circuit is shorted to power supply with engine running.
(3 D/C detection logic)

Circuit Diagram

1 A1
C02-41 GRY 3
B1

[A] C02 E02

[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

IJCA0A112017-01

[A]: ECM connector (View: [a]) B1: EVAP canister purge valve drive circuit 2. ECM
A1: EVAP canister purge valve power supply circuit 1. EVAP canister purge valve 3. To main relay
1A-218 Engine General Information and Diagnosis: K12M

DTC Confirmation Procedure

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

1) Run engine at idle speed for 10 min.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K12M
(Page 1A-138).
2 EVAP canister purge valve power supply circuit check Go to Step 3. Repair or replace
1) With ignition “OFF”, disconnect EVAP canister purge defective wire harness.
valve connector.
2) Check for proper terminal connection to EVAP canister
purge valve connector.
3) If connection is OK, set ignition “ON”.
4) Check that voltage between “A1” and ground is battery
voltage.

Is check result OK?

3 EVAP canister purge valve drive circuit check Go to Step 4. Repair or replace
1) With ignition “OFF”, disconnect “C02” and “E02” defective wire harness.
connectors of ECM.
2) Check for proper terminal connection to “C02” and “E02”
connectors.
3) If connections are OK, check the following points.
• Resistance of “B1” circuit: less than 1 Ω
• Resistance between “B1” circuit and ground: infinity
• Resistance between “A1” circuit terminal and “B1”
circuit terminal at EVAP canister purge valve
connector: infinity
• Voltage of “B1” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

4 EVAP canister purge valve check Replace ECM and Replace EVAP canister
1) Check EVAP canister purge valve for resistance. recheck DTC. (Page purge valve.
(Page 1B-11) 1C-22)

Is check result OK?

 Engine General Information and Diagnosis: K12M 1A-219

DTC P0480 / P0692

AENJCA0A1124037
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0480: Fan 1 Control Circuit • Radiator cooling fan relay No.1 and/or
Radiator cooling fan relay No.1 drive circuit is shorted to ground or open. its circuit
(3 D/C detection logic but MIL does not light up) • ECM
P0692: Fan 1 Control Circuit High
Radiator cooling fan relay No.1 drive circuit is shorted to power supply.
(3 D/C detection logic but MIL does not light up)

Circuit Diagram

6
7 BLU B1
1
A1
5 LT GRN E02-2
8 GRY
C1 BLU B2
GRN
2 A3 3 GRN E02-27
A2 L+
H+ L-
RED 4 BLK

C2 H-
LT BLU

C3

[A] C02 E02

[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

IJCA0A112018-01

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

DTC Confirmation Procedure

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

1) Connect SUZUKI scan tool to DLC.

2) Display “ECT” of “Data List” mode on SUZUKI scan tool.
3) Keep engine at idle speed until engine coolant temperature reaches 97 °C (206.6 °F) or more.
4) Stop engine.
5) Repeat Step 2) – 4) 2 times.
1A-220 Engine General Information and Diagnosis: K12M

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”: K12M
(Page 1A-138).
2 Radiator cooling fan relay No.1 power supply circuit Go to Step 3. Repair or replace
(coil side) check defective wire harness.
1) With ignition “OFF”, remove radiator cooling fan relay
No.1.
2) Check for proper terminal connection to radiator cooling
fan relay No.1 connector.
3) If connection is OK, set ignition “ON”.
4) Check that voltage between “A1” and ground is battery
voltage.

Is check result OK?

3 Radiator cooling fan relay No.1 check Go to Step 4. Replace radiator cooling
1) Check radiator cooling fan relay No.1. (Page 1F-31) fan relay No.1.

Is check result OK?

4 Radiator cooling fan relay No.1 drive circuit check Replace ECM and Repair or replace
1) With ignition “OFF”, disconnect “C02” and “E02” recheck DTC. (Page defective wire harness.
connectors from ECM. 1C-22)
2) Check for proper terminal connection to “C02” and “E02”
connectors.
3) If connections are OK, check the following points.
• Resistance of “B1” circuit: less than 1 Ω
• Resistance between “B1” circuit and ground: infinity
• Resistance between “B1” circuit terminal and other
terminal at radiator cooling fan relay No.1 connector:
infinity
• Voltage of “B1” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

 Engine General Information and Diagnosis: K12M 1A-221

DTC P0481 / P0694

AENJCA0A1124038
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0481: Fan 2 Control Circuit • Radiator cooling fan relay No.2 (coil side) and/or its
Radiator cooling fan relay No.2 and/or No.3 drive circuit is circuit
shorted to ground or open. • Radiator cooling fan relay No.3 (coil side) and/or its
(3 D/C detection logic but MIL does not light up) circuit
P0694: Fan 2 Control Circuit High
• ECM
Radiator cooling fan relay No.2 and/or No.3 drive circuit is
shorted to power supply.
(3 D/C detection logic but MIL does not light up)

Circuit Diagram

6
7 BLU B1
1
A1
5 LT GRN E02-2
8 GRY
C1 BLU B2
GRN
2 A3 3 GRN E02-27
A2 L+
H+ L-
RED 4 BLK

C2 H-
LT BLU

C3

[A] C02 E02

[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

IJCA0A112018-01

[A]: ECM connector (View: [a]) C1: Radiator cooling fan relay No.1 power 4. Radiator cooling fan motor
supply circuit (switch side)
A1: Radiator cooling fan relay No.1 power supply circuit C2: Radiator cooling fan relay No.2 power 5. “RDTR” fuse
(coil side) supply circuit (switch side)
A2: Radiator cooling fan relay No.2 power supply circuit C3: Radiator cooling fan relay No.3 power 6. ECM
(coil side) supply circuit (switch side)
A3: Radiator cooling fan relay No.3 power supply circuit 1. Radiator cooling fan relay No.1 7. To main relay
(coil side)
B1: Radiator cooling fan relay No.1 drive circuit 2. Radiator cooling fan relay No.2 8. To main fuse box
B2: Radiator cooling fan relay No.2 and No.3 drive circuit 3. Radiator cooling fan relay No.3
1A-222 Engine General Information and Diagnosis: K12M

DTC Confirmation Procedure

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

1) Connect SUZUKI scan tool to DLC.

2) Display “ECT” of “Data List” mode on SUZUKI scan tool.
3) Race engine so that engine coolant temperature reaches 102 °C (215.6 °F) or more.
4) Stop engine.
5) Repeat Step 2) – 4) 2 times.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K12M
(Page 1A-138).
2 Radiator cooling fan relay No.2 and No.3 power supply Go to Step 3. Repair or replace
circuit (coil side) check defective wire harness.
1) With ignition “OFF”, remove radiator cooling fan relays
No.2 and No.3.
2) Check for proper terminal connection to radiator cooling
fan relay No.2 and No.3 connectors.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between each of “A2” and “A3”
circuits and ground is battery voltage.

Is check result OK?

3 Radiator cooling fan relay No.2 and No.3 check Go to Step 4. Replace radiator cooling
1) Check radiator cooling fan relays No.2 and No.3. fan relays No.2 and/or
(Page 1F-31) No.3.

Is check result OK?

4 Radiator cooling fan relay No.2 and No.3 drive circuit Replace ECM and Repair or replace
check recheck DTC. (Page defective wire harness.
1) With ignition “OFF”, disconnect “C02” and “E02” 1C-22)
connectors from ECM.
2) Check for proper terminal connection to “C02” and “E02”
connectors.
3) If connections are OK, check the following points.
• Resistance of “B2” circuit: less than 1 Ω
• Resistance between “B2” circuit and ground: infinity
• Resistance between “B2” circuit terminal and other
terminal at drive circuit connector of radiator cooling
fan relay No.2 and No.3: infinity
• Voltage of “B2” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

 Engine General Information and Diagnosis: K12M 1A-223

DTC P0500
AENJCA0A1124039
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0500: Vehicle Speed Sensor “A” • CAN communication line
Vehicle speed is slower than 4 km/h (2 mile/h) for 5 sec. at • Wheel speed sensor
fuel cut condition.
• ABS control module
(3 D/C detection logic)
• ECM

Circuit Diagram

1
6

2
7 RED E02-28
WHT E02-29 7
3

[A] C02 E02

[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

IGSB0A112030-01

[A]: ECM connector (View: [a]) 3. Left-front wheel speed sensor 6. Right-rear wheel speed sensor
1. ECM 4. Right-front wheel speed sensor 7. CAN driver
2. ABS / ESP® control module 5. Left-rear wheel speed sensor
1A-224 Engine General Information and Diagnosis: K12M

DTC Confirmation Procedure

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

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

1) Warm up engine to normal operating temperature.

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

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K12M
(Page 1A-138).
2 DTC check Go to troubleshooting Go to Step 3.
for CAN-DTC. (Page
Is there any CAN-DTC detected? 10H-7)
3 DTC check Go to troubleshooting Replace ECM and
1) Check DTC in ABS control module. for applicable DTC. recheck DTC. (Page
1C-22)
Is any DTC(s) detected?
 Engine General Information and Diagnosis: K12M 1A-225

DTC P0504
AENJCA0A1124040
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0504: Brake Switch “A”/“B” Correlation • Brake light switch and/or its circuit
Brake light switch signal does not correlate with brake switch signal. • ECM
(1 D/C detection logic)

Circuit Diagram

+BB 1
2
4
BLU BRN YEL E02-18
3
A1 A2

[A] C02 E02

[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

IJCA0A112019-01

[A]: ECM connector (View: [a]) 1. ECM 4. “STOP” fuse

A1: Brake light switch power supply circuit 2. Brake light switch
A2: Brake light switch signal circuit 3. Brake light

DTC Confirmation Procedure

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

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K12M
(Page 1A-138).
2 Brake light switch power supply circuit check Go to Step 3. Repair or replace
1) With ignition “OFF”, disconnect brake light switch defective wire harness.
connector.
2) Check for proper terminal connection to brake light
switch connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between “A1” circuit and ground is
battery voltage.

Is check result OK?

1A-226 Engine General Information and Diagnosis: K12M

Step Action Yes No

3 Brake light switch signal circuit check Go to Step 4. Repair or replace
1) With ignition “OFF”, disconnect “C02” and “E02” defective wire harness.
connectors from ECM.
2) Check for proper terminal connection to “C02” and “E02”
connectors.
3) If connections are OK, check the following points.
• Resistance of “A2” circuit: less than 1 Ω
• Resistance between “A2” circuit and ground: infinity
• Resistance between “A1” circuit terminal and “A2”
circuit terminal at brake light switch connector: infinity
• Voltage of “A2” circuit: approx. 0 V (when ignition is
“ON”)

Is check result OK?

4 Brake light switch check Replace ECM and Replace brake light
1) Check brake light switch. (Page 4A-12) recheck DTC. (Page switch. (Page 4A-12)
1C-22)
Is check result OK?

DTC P0530
AENJCA0A1124041
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0530: A/C Refrigerant Pressure Sensor “A” Circuit • A/C refrigerant pressure sensor and/or its circuit
Any of the following conditions is met. • ECM
• Output voltage of A/C refrigerant pressure sensor
signal circuit is lower than 0.15 V.
• Output voltage of A/C refrigerant pressure sensor
signal circuit is higher than 4.93 V.
(3 D/C detection logic but MIL does not light up)

Circuit Diagram

2
A1 5V
LT GRN E02-14
1 A2 5V

BEG E02-33

A3
BLK E02-9

[A] C02 E02

[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

IJCA0A112020-01

[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
 Engine General Information and Diagnosis: K12M 1A-227

DTC Confirmation Procedure

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

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K12M
(Page 1A-138).
2 A/C refrigerant pressure sensor power supply circuit Go to Step 4. Go to Step 3.
check
1) With ignition “OFF”, disconnect A/C refrigerant pressure
sensor connector.
2) Check for proper terminal connection to A/C refrigerant
pressure sensor connector.
3) If connection is OK, set ignition “ON”.
4) Check that voltage between “A1” and “A3” is approx. 5 V.

Is check result OK?

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 or replace found, repair or replace
“A3” circuit. “A1” circuit.
Is check result OK?
If circuit is OK, replace If circuit is OK, replace
ECM and recheck DTC. ECM and recheck DTC.
(Page 1C-22) (Page 1C-22)
4 A/C refrigerant pressure sensor signal circuit check Go to Step 5. Repair or replace
1) With ignition “OFF”, disconnect “C02” and “E02” defective wire harness.
connectors from ECM.
2) Check for proper terminal connection to “C02” and “E02”
connectors.
3) If connections are OK, check the following points.
• Resistance of “A2” circuit: less than 1 Ω
• Resistance between “A2” circuit and ground: infinity
• Resistance between “A2” circuit terminal and other
terminal at A/C refrigerant pressure sensor connector:
infinity
• Voltage of “A2” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

5 A/C refrigerant pressure sensor check Replace ECM and Replace A/C refrigerant
1) Check A/C refrigerant pressure sensor. (Page 7B-47) recheck DTC. (Page pressure sensor.
1C-22) (Page 7B-48)
Is check result OK?
1A-228 Engine General Information and Diagnosis: K12M

DTC P0560 / P0562 / P0563

AENJCA0A1124042
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0560: System Voltage • ECM power supply circuit and/or ground circuit
Main power supply voltage is lower than 2.54 V for 10 sec. • Charging system
(3 D/C detection logic)
• ECM
P0562: System Voltage Low
Main power supply circuit voltage is lower than 9.8 V for 10 sec.
(3 D/C detection logic)
P0563: System Voltage High
Main power supply circuit voltage is higher than 18.0 V for 10 sec.
(3 D/C detection logic)

Circuit Diagram

1
A1
2 5V 12V
GRN E02-20 7
3 PNK E02-16 C02-51 LT GRN
GRY E02-19 8
C02-54 BRN M
A2 D1
5V
BLU E02-6 5V
4 C02-13 RED
GRY E02-3 9
YEL E02-5 C02-26 GRN
10
C02-16 WHT
C02-15 BLK
12V
C02-17 BLK
E1 11 F1
5V
E02-49 PNK 12
E02-55 BLU
E2
3.3V F2
E02-56 BLU E3
B1 5V 14
5 15
LT GRN E02-14 5V

BEG E02-33
BLK E02-9 16
13
E02-1 WHT
C1 5V
6 G1
LT BLU C02-14
H1 17
BRN C02-27 C02-50 BLK
H2
GRY C02-4 C02-53 BLK 18

[A] C02 E02

[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

IJCA0A112021-01

[A]: ECM connector (View: [a]) G1: Ignition ON signal circuit 9. TP sensor (main)
A1: APP sensor (main) power supply circuit H1: ECM ground circuit 1 10. TP sensor (sub)
A2: APP sensor (sub) power supply circuit H2: ECM ground circuit 2 11. Main relay
B1: A/C refrigerant pressure sensor power supply circuit 1. ECM 12. “FI” fuse
C1: MAP sensor power supply circuit 2. APP sensor 13. “IG” fuse
D1: TP sensor power supply circuit 3. APP sensor (main) 14. IG11 relay
E1: Main relay drive circuit 4. APP sensor (sub) 15. “IGN” fuse
E2: Main power supply circuit 2 5. A/C refrigerant pressure sensor 16. Ignition switch
E3: Main power supply circuit 1 6. MAP sensor 17. Main fuse box
F1: Main relay power supply circuit (coil side) 7. Electric throttle body assembly 18. Battery
F2: Main relay power supply circuit (switch side) 8. Throttle actuator
 Engine General Information and Diagnosis: K12M 1A-229

DTC Confirmation Procedure

P0560 / P0562
1) Set ignition “ON” for 1 min.

P0563

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

NOTE
Limit the driving permissible in road conditions and regulations.

1) Drive vehicle at 5 km/h (3 mile/h) or more for 1 min.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K12M
(Page 1A-138).
2 ECM power supply and ground circuit check Go to Step 3. Repair ECM power
1) Check ECM power supply and ground circuits. (Page supply and/or ground
1A-267) circuit.

Is check result OK?

3 Charging system check Replace ECM and Repair or replace
1) Check that charging system is working properly. (Page recheck DTC. (Page defective parts.
1J-23) 1C-22)

Is check result OK?

1A-230 Engine General Information and Diagnosis: K12M

DTC P0602
AENJCA0A1124043
DTC Detecting Condition and Trouble Area

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

DTC detecting condition Trouble area

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

DTC Confirmation Procedure

1) Set ignition “ON” for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 DTC recheck Go to Step 2. Check for intermittent
1) Clear DTC. (Page 1A-141) trouble. (Page 00-13)
2) Set ignition “OFF”.
3) Perform “DTC Confirmation Procedure” and check DTC.

Is DTC P0602 still detected?

2 ECM reprogramming check Execute reprogramming Go to Step 3.
of ECM correctly again.
Was reprogramming of ECM executed?
3 ECM power and ground circuit check Replace ECM and Repair or replace
1) Check ECM power and ground circuit. (Page 1A-267) recheck DTC. (Page defective wire harness.
1C-22)
Is check result OK?

DTC P0606
AENJCA0A1124044
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0606: Control Module Processor • ECM power supply circuit and/or ground circuit
ECM internal processor failure. • ECM
(3 D/C detection logic)

System Description
Internal control module is installed in ECM.

DTC Confirmation Procedure

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

1) Run engine at idle speed for 1 min.

 Engine General Information and Diagnosis: K12M 1A-231

DTC Troubleshooting
Step Action Yes No
1 DTC recheck Go to Step 2. Check for intermittent
1) Clear DTC. (Page 1A-141) trouble. (Page 00-13)
2) Set ignition “OFF”.
3) Perform “DTC Confirmation Procedure” and check DTC.

Is DTC P0606 still detected?

2 ECM power and ground circuit check Replace ECM and Repair or replace
1) Check ECM power supply and ground circuits. (Page recheck DTC. (Page defective wire harness.
1A-267) 1C-22)

Is check result OK?

DTC P0607
AENJCA0A1124045
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0607: Control Module Performance • ECM power supply circuit and/or ground circuit
Internal failure in ECM is detected. • ECM
(1 D/C detection logic or 3 D/C detection logic but MIL
does not light up)

DTC Confirmation Procedure

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

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

2) If possible, run engine at 1,200 rpm or more for 30 sec. and at 3,000 rpm for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 DTC recheck Go to Step 2. Check for intermittent
1) Clear DTC. (Page 1A-141) trouble. (Page 00-13)
2) Set ignition “OFF”.
3) Perform “DTC Confirmation Procedure” and check DTC.

Is DTC P0607 still detected?

2 ECM power supply and ground circuit check Replace ECM and Repair or replace
1) Check ECM power supply circuit and ECM ground recheck DTC. (Page defective wire harness.
circuit. (Page 1A-267) 1C-22)

Is check result OK?

1A-232 Engine General Information and Diagnosis: K12M

DTC P0645 / P0646 / P0647

AENJCA0A1124046
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0645: A/C Clutch Relay Control Circuit • A/C compressor relay and/or its circuit
A/C compressor relay drive circuit is open. • ECM
(3 D/C detection logic but MIL does not light up)
P0646: A/C Clutch Relay Control Circuit Low
A/C compressor relay drive circuit is shorted to ground.
(3 D/C detection logic but MIL does not light up)
P0647: A/C Clutch Relay Control Circuit High
A/C compressor relay drive circuit is shorted to power supply.
(3 D/C detection logic but MIL does not light up)

Circuit Diagram

B1 1 A1
E02-41 GRY BLU 5

2 4
GRY BLU 6

[A] C02 E02

[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

IJCA0A112022-01

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

DTC Confirmation Procedure

NOTE
• Check that the following conditions are met in this “DTC Confirmation Procedure”.
– Battery voltage > 8.5 V
– Evaporator temperature > 3 °C (37 °F)
• Check that the following DTCs are not detected in this “DTC Confirmation Procedure”.
– ECT sensor (P0116, P0117 and P0118)
– A/C refrigerant pressure sensor (P0530)

1) Run engine at idle speed for 10 sec.

2) Set A/C switch ON for 10 sec.
3) Set A/C switch OFF.
 Engine General Information and Diagnosis: K12M 1A-233

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”: K12M
(Page 1A-138).
2 A/C compressor relay power supply circuit (coil side) Go to Step 3. Repair or replace
check defective wire harness.
1) With ignition “OFF”, remove A/C compressor relay.
2) Check for proper terminal connection to A/C compressor
relay connector.
3) If connection is OK, set ignition “ON”.
4) Check that voltage between “A1” and ground is battery
voltage.

Is check result OK?

3 A/C compressor relay check Go to Step 4. Replace A/C
1) Check A/C compressor relay. (Page 7B-50) compressor relay.

Is check result OK?

4 A/C compressor relay drive circuit check Replace ECM and Repair or replace
1) With ignition “OFF”, disconnect “C02” and “E02” recheck DTC. (Page defective wire harness.
connectors from ECM. 1C-22)
2) Check for proper terminal connection to “C02” and “E02”
connectors.
3) If connections are OK, check the following points.
• Resistance of “B1” circuit: less than 1 Ω
• Resistance between “B1” circuit and ground: infinity
• Resistance between “B1” circuit terminal and other
terminal at A/C compressor relay connector: infinity
• Voltage of “B1” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

1A-234 Engine General Information and Diagnosis: K12M

DTC P1520 / P1521

AENJCA0A1124068
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P1520: ECM Starter protection circuit on error • Starting motor control relay and/or its circuit
Starting motor control relay drive circuit is shorted to ground. • ECM
(1 D/C detection logic but MIL does not light up)
P1521: ECM Starter protection circuit off error
Starting motor control relay drive circuit is shorted to power supply.
(1 D/C detection logic but MIL does not light up)

Circuit Diagram

7
[A] B2
E02-38 GRN B1
2 1

[B]
3 4

E02-43 LT BLU
5

6
A1

[C] C02 E02

[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

IJCA0A112028-01

[A]: M/T model B2: Starting motor control relay drive circuit 5. “ST SIG” fuse
[B]: Auto gear shift model 1. Ignition switch 6. Starting motor
[C]: ECM connector (View: [a]) 2. Starting motor control relay 7. ECM
A1: Starting motor control relay signal circuit 3. TCM
B1: Starting motor control relay power supply circuit (coil side) 4. “ST” fuse

DTC Confirmation Procedure

1) Start engine and leave ignition “ON” for 5 sec. or more.
 Engine General Information and Diagnosis: K12M 1A-235

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”: K12M
(Page 1A-138).
2 Starting motor control relay power supply circuit (coil Go to Step 3. Repair or replace
side) check defective wire harness.
1) With ignition “OFF”, remove starting motor control relay.
2) Check for proper terminal connection to starting motor
control relay connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between “B1” and ground is battery
voltage.

Is check result OK?

3 Starting motor control relay check Go to Step 4. Replace starting motor
1) Check starting motor control relay. (Page 1I-5) control relay.

Is check result OK?

4 Starting motor control relay drive circuit check Replace ECM and Repair or replace
1) When ignition is “OFF”, disconnect “C02” and “E02” recheck DTC. (Page defective wire harness.
connectors of ECM. 1C-22)
2) Check for proper terminal connection to “C02” and “E02”
connectors.
3) If connections are OK, check the following points.
• Resistance of “B2” circuit: less than 1 Ω
• Resistance between “B2” circuit and ground: infinity
• Resistance between “B2” circuit terminal and other
terminal at starting motor control relay connector:
infinity
• Voltage of “B2” circuit: 0 to 1 V (When ignition is “ON”)

Is check result OK?

1A-236 Engine General Information and Diagnosis: K12M

DTC P1693
AENJCA0A1124067
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P1693: Equipment Information Mismatched • Combination meter
ECM detects incorrect vehicle variant data from ABS • ABS control module
control module and combination meter.
• ECM
(1 D/C detection logic but MIL does not light up)

DTC Confirmation Procedure

1) Set ignition “ON”.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K12M
(Page 1A-138).
2 DTC check for combination meter Go to Step 3. Go to troubleshooting
1) Check DTC in combination meter. for applicable DTC.

Is check result OK?

3 DTC check for ABS control module Go to Step 4. Go to troubleshooting
1) Check DTC in ABS control module. (Page 4E-13) for applicable DTC.

Is check result OK?

4 Combination meter specification check Go to Step 5. Replace combination
1) Perform “Warning Light Check” in Section 4E (Page 4E- meter and recheck
12). DTC. (Page 9C-25)

Is check result OK?

5 ABS control module specification check Replace ECM and Replace ABS control
1) Check that ABS control module with the correct part recheck DTC. (Page module and recheck
number is installed. 1C-22) DTC. (Page 4E-32)

Is check result OK?

 Engine General Information and Diagnosis: K12M 1A-237

DTC P2100
AENJCA0A1124047
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P2100: Throttle Actuator “A” Control Motor Circuit / Open • Throttle actuator and/or its circuit
Throttle actuator and/or its circuit malfunction (open, short to • ECM
power supply or short to ground) is detected.
(1 D/C detection logic)

Circuit Diagram

5
12V
A1 1
C02-51 LT GRN
4
C02-54 BRN M
5V A2 B1
C02-13 RED
B2 2
C02-26 GRN
B3 3
C02-16 WHT
B4
C02-15 BLK
C02-17 BLK 6

[A] C02 E02

[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

IJCA0A112013-01

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

DTC Confirmation Procedure

1) Set ignition “ON”.
2) Keep accelerator pedal at fully depressed position for 2 sec.
3) Release accelerator pedal for 2 sec.
1A-238 Engine General Information and Diagnosis: K12M

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”: K12M
(Page 1A-138).
2 Throttle actuator drive circuit check Go to Step 3. Repair or replace
1) With ignition “OFF”, disconnect “C02” and “E02” defective wire harness.
connectors of ECM and electric throttle body assembly
connector.
2) Check for proper terminal connection to “C02” and “E02”
connectors and electric throttle body assembly
connector.
3) If connections are OK, check the following points.
• Resistance of “A1” and “A2” circuits: less than 1 Ω
• Resistance between each of “A1” and “A2” circuits
and ground: infinity
• Resistance between “A1” circuit terminal and other
terminal at electric throttle body assembly connector:
infinity
• Resistance between “A2” circuit terminal and other
terminal at electric throttle body assembly connector:
infinity
• Voltage of “A1” and “A2” circuits: approx. 0 V (When
ignition is “ON”)

Is check result OK?

3 Electric throttle body assembly check Replace ECM and Replace electric throttle
1) Check electric throttle body assembly for performance. recheck DTC. (Page body assembly. (Page
(Page 1C-23) 1C-22) 1D-84)

Is check result OK?

 Engine General Information and Diagnosis: K12M 1A-239

DTC P2101 / P2119

AENJCA0A1124048
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P2101: Throttle Actuator “A” Control Motor Circuit Range / Performance • Throttle actuator and/or its circuit
Any of the following conditions is met. • Electric throttle body assembly
• Difference between measured throttle valve position and targeted throttle • ECM
valve position is more than specified value.
• Duty ratio of throttle actuator signal is out of specified range for specified time.
(1 D/C detection logic)
P2119: Throttle Actuator Control Throttle Body Range / Performance
Any of the following conditions is met.
• Time taken by throttle valve to return from partially open position to
mechanical default position is more than specified time during return spring
check process after setting ignition “OFF”.
• Measured default throttle position is out of specified range.
(1 D/C detection logic, monitoring once per D/C)

Circuit Diagram

5
12V
A1 1
C02-51 LT GRN
4
C02-54 BRN M
5V A2 B1
C02-13 RED
B2 2
C02-26 GRN
B3 3
C02-16 WHT
B4
C02-15 BLK
C02-17 BLK 6

[A] C02 E02

[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

IJCA0A112013-01

[A]: ECM connector (View: [a]) B3: TP sensor (sub) signal circuit 4. Throttle actuator
A1: Throttle actuator control circuit (close) B4: TP sensor ground circuit 5. ECM
A2: Throttle actuator control circuit (open) 1. Electric throttle body assembly 6. Shield wire
B1: TP sensor power supply circuit 2. TP sensor (main)
B2: TP sensor (main) signal circuit 3. TP sensor (sub)
1A-240 Engine General Information and Diagnosis: K12M

DTC Confirmation Procedure

NOTE
Check that the following conditions are met in this “DTC Confirmation Procedure”.
• Battery voltage > 10 V
• ECT > 5 °C (41 °F)
• IAT > 5 °C (41 °F)

1) Set ignition “ON” for 1 min.

2) Set ignition “OFF” for 1 min.
3) Repeat Step 1) – 2) 3 times.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K12M
(Page 1A-138).
2 DTC recheck Go to Step 3. End.
1) Clear DTC.
2) Perform electric throttle control system calibration.
(Page 1C-25)
3) Recheck DTC.

Is DTC P2101 / P2119 still detected?

3 Throttle actuator drive circuit check Go to Step 4. Repair or replace
1) Check “A1” and “A2” circuits according to Step 2 under defective wire harness.
“DTC P2100”: K12M (Page 1A-237).

Is check result OK?

4 Electric throttle body assembly check Replace ECM and Replace electric throttle
1) Check electric throttle body assembly for performance. recheck DTC. (Page body assembly. (Page
(Page 1C-23) 1C-22) 1D-84)

Is check result OK?

 Engine General Information and Diagnosis: K12M 1A-241

DTC P2122 / P2123

AENJCA0A1124049
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P2122: Throttle / Pedal Position Sensor / Switch “D” Circuit Low • APP sensor (main) and/or its circuit
Output voltage of APP sensor (main) signal circuit is lower than 0.4 V. • ECM
(1 D/C detection logic)
P2123: Throttle / Pedal Position Sensor / Switch “D” Circuit High
Output voltage of APP sensor (main) signal circuit is higher than 4.8 V.
(1 D/C detection logic)

Circuit Diagram

4
1
A1 5V
GRN E02-20
A2
2 PNK E02-16
A3
GRY E02-19
B1 5V
BLU E02-6
B2
3 GRY E02-3
B3
YEL E02-5

[A] C02 E02

[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

IJCA0A112023-01

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

DTC Confirmation Procedure

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

1) Set ignition “ON” for 10 sec.

1A-242 Engine General Information and Diagnosis: K12M

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”: K12M
(Page 1A-138).
2 Accelerator pedal assembly (incorporating APP sensor) Go to Step 3. Reinstall accelerator
mounting check pedal assembly
1) Check that accelerator pedal assembly (incorporating (incorporating APP
APP sensor) has been mounted to vehicle body properly sensor) properly.
(no pinched floor carpet, etc.). (Page 1C-26)

Is check result OK?

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

Is check result OK?

4 APP sensor (main) ground circuit check 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 or replace found, repair or replace
“A3” circuit. “A1” circuit.
Is check result OK?
If circuit is OK, replace If circuit is OK, replace
ECM and recheck DTC. ECM and recheck DTC.
(Page 1C-22) (Page 1C-22)
5 APP sensor (main) signal circuit check Go to Step 6. Repair or replace
1) With ignition “OFF”, disconnect “C02” and “E02” defective wire harness.
connectors from ECM.
2) Check for proper terminal connection to “C02” and “E02”
connectors.
3) If connections are OK, check the following points.
• Resistance of “A2” circuit: less than 1 Ω
• Resistance between “A2” circuit and ground: infinity
• Resistance between “A2” circuit terminal and other
terminal at APP sensor connector: infinity
• Voltage of “A2” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

6 APP sensor check Replace ECM and Replace accelerator
1) Check APP sensor. (Page 1C-25) recheck DTC. (Page pedal assembly
1C-22) (incorporating APP
Is check result OK? sensor). (Page 1C-
26)
 Engine General Information and Diagnosis: K12M 1A-243

DTC P2127 / P2128

AENJCA0A1124050
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P2127: Throttle / Pedal Position Sensor / Switch “E” Circuit Low • APP sensor (sub) and/or its circuit
Output voltage of APP sensor (sub) signal circuit is lower than 0.2 V. • ECM
(1 D/C detection logic)
P2128: Throttle / Pedal Position Sensor / Switch “E” Circuit High
Output voltage of APP sensor (sub) signal circuit is higher than 2.4 V.
(1 D/C detection logic)

Circuit Diagram

4
1
A1 5V
GRN E02-20
A2
2 PNK E02-16
A3
GRY E02-19
B1 5V
BLU E02-6
B2
3 GRY E02-3
B3
YEL E02-5

[A] C02 E02

[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

IJCA0A112023-01

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

DTC Confirmation Procedure

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

1) Set ignition “ON” for 10 sec.

1A-244 Engine General Information and Diagnosis: K12M

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”: K12M
(Page 1A-138).
2 Accelerator pedal assembly (incorporating APP sensor) Go to Step 3. Reinstall accelerator
mounting check pedal assembly
1) Check that accelerator pedal assembly (incorporating (incorporating APP
APP sensor) has been mounted to vehicle body properly sensor) properly.
(no pinched floor carpet, etc.). (Page 1C-26)

Is check result OK?

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

Is check result OK?

4 APP sensor (sub) ground circuit check Check “B3” circuit. Check “B1” circuit.
1) Check that voltage between “B1” and ground is approx. If defective circuit is If defective circuit is
5 V. found, repair or replace found, repair or replace
“B3” circuit. “B1” circuit.
Is check result OK?
If circuit is OK, replace If circuit is OK, replace
ECM and recheck DTC. ECM and recheck DTC.
(Page 1C-22) (Page 1C-22)
5 APP sensor (sub) signal circuit check Go to Step 6. Repair or replace
1) With ignition “OFF”, disconnect “C02” and “E02” defective wire harness.
connectors from ECM.
2) Check for proper terminal connection to “C02” and “E02”
connectors.
3) If connections are OK, check the following points.
• Resistance of “B2” circuit: less than 1 Ω
• Resistance between “B2” circuit and ground: infinity
• Resistance between “B2” circuit terminal and other
terminal at APP sensor connector: infinity
• Voltage of “B2” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

6 APP sensor check Replace ECM and Replace accelerator
1) Check APP sensor. (Page 1C-25) recheck DTC. (Page pedal assembly
1C-22) (incorporating APP
Is check result OK? sensor). (Page 1C-
26)
 Engine General Information and Diagnosis: K12M 1A-245

DTC P2135
AENJCA0A1124051
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P2135: Throttle / Pedal Position Sensor / Switch “A” / “B” • TP sensor and/or its circuit
Voltage Correlation • Electric throttle body assembly
Difference between TP sensor (main) signal voltage and TP
• ECM
sensor (sub) signal voltage is higher than specified value.
(1 D/C detection logic)

Circuit Diagram

5
12V
A1 1
C02-51 LT GRN
4
C02-54 BRN M
5V A2 B1
C02-13 RED
B2 2
C02-26 GRN
B3 3
C02-16 WHT
B4
C02-15 BLK
C02-17 BLK 6

[A] C02 E02

[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

IJCA0A112013-01

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

DTC Confirmation Procedure

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

1) Start engine.
2) Depress accelerator pedal fully, and release it.
1A-246 Engine General Information and Diagnosis: K12M

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”: K12M
(Page 1A-138).
2 Wire harness check Go to Step 3. Repair or replace
1) Check the following points. defective wire harness.
• “B1”, “B2” and “B4” circuits: Refer to Step 2 – 4 under
“DTC P0122 / P0123”: K12M (Page 1A-185).
• “B3” circuit: Refer to Step 4 under “DTC P0222 /
P0223”: K12M (Page 1A-202).

Is check result OK?

3 TP sensor check Replace ECM and Replace electric throttle
1) Check TP sensor referring to “TP Sensor Performance recheck DTC. (Page body assembly. (Page
Check” under “Electric Throttle Body Assembly On- 1C-22) 1D-84)
Vehicle Inspection”: K12M in Section 1C (Page 1C-23).

Is check result OK?

DTC P2138
AENJCA0A1124052
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P2138: Throttle / Pedal Position Sensor / Switch “D” / • APP sensor and/or its circuit
“E” Voltage Correlation • ECM
Difference between half of APP (main) sensor signal and
APP (sub) sensor signal is more than specified value.
(1 D/C detection logic)

Circuit Diagram

4
1
A1 5V
GRN E02-20
A2
2 PNK E02-16
A3
GRY E02-19
B1 5V
BLU E02-6
B2
3 GRY E02-3
B3
YEL E02-5

[A] C02 E02

[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

IJCA0A112023-01

[A]: ECM connector (View: [a]) B1: APP sensor (sub) power supply circuit 2. APP sensor (main)
A1: APP sensor (main) power supply circuit B2: APP sensor (sub) signal circuit 3. APP sensor (sub)
A2: APP sensor (main) signal circuit B3: APP sensor (sub) ground circuit 4. ECM
A3: APP sensor (main) ground circuit 1. APP sensor
 Engine General Information and Diagnosis: K12M 1A-247

DTC Confirmation Procedure

NOTE
• Check that the following condition is met in this “DTC Confirmation Procedure”.
– System voltage > 8.5 V
• Check that the following DTCs are not detected in this “DTC Confirmation Procedure”.
– APP sensor (P2122, P2123, P2127 and P2128)

1) Set ignition “ON”.

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

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K12M
(Page 1A-138).
2 Wire harness check Go to Step 3. Repair or replace
1) Check the following points. defective wire harness.
• “A1”, “A2” and “A3” circuits: Refer to Step 3 – 5 under
“DTC P2122 / P2123”: K12M (Page 1A-241).
• “B1”, “B2” and “B3” circuits: Refer to Step 3 – 5 under
“DTC P2127 / P2128”: K12M (Page 1A-243).

Is check result OK?

3 APP sensor check Replace ECM and Replace accelerator
1) Check APP sensor. (Page 1C-25) recheck DTC. (Page pedal assembly
1C-22) (incorporating APP
Is check result OK? sensor). (Page 1C-
26)
1A-248 Engine General Information and Diagnosis: K12M

DTC P2176
AENJCA0A1124053
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P2176: Throttle Actuator Control System – Idle Position Not Learned • TP sensor and/or its circuit
Any of the following conditions is met. • Electric throttle body assembly
• TP sensor (main) or TP sensor (sub) signal voltage at default position is • ECM
out of specified range for specified time.
• Electric throttle control system calibration is not completed.
(1 D/C detection logic, monitoring once per D/C)

Circuit Diagram

5
12V
A1 1
C02-51 LT GRN
4
C02-54 BRN M
5V A2 B1
C02-13 RED
B2 2
C02-26 GRN
B3 3
C02-16 WHT
B4
C02-15 BLK
C02-17 BLK 6

[A] C02 E02

[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

IJCA0A112013-01

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

DTC Confirmation Procedure

NOTE
Check that the following conditions are met in this “DTC Confirmation Procedure”.
• Battery voltage > 10 V
• ECT > 5 °C (41 °F)
• IAT > 5 °C (41 °F)

1) Set ignition “ON” for 10 sec.

2) Keep accelerator pedal at fully depressed position for 2 sec.
3) Keep accelerator pedal or released position for 2 sec.
4) Repeat Step 2) – 3) 3 times.
 Engine General Information and Diagnosis: K12M 1A-249

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”: K12M
(Page 1A-138).
2 Electric throttle control system calibration Go to Step 3. End.
1) Perform electric throttle control system calibration.
(Page 1C-25)
2) Clear DTC. (Page 1A-141)
3) Set ignition “OFF”.
4) Perform “DTC Confirmation Procedure” and check DTC.

Is DTC P2176 still detected?

3 Wire harness check Go to Step 4. Repair or replace
1) Check the following points. defective wire harness.
• “B1”, “B2” and “B4” circuits: Refer to Step 2 – 4 under
“DTC P0122 / P0123”: K12M (Page 1A-185).
• “B3” circuit: Refer to Step 4 under “DTC P0222 /
P0223”: K12M (Page 1A-202).

Is check result OK?

4 TP sensor check Replace ECM and Replace electric throttle
1) Check TP sensor referring to “TP Sensor Performance recheck DTC. (Page body assembly. (Page
Check” under “Electric Throttle Body Assembly On- 1C-22) 1D-84)
Vehicle Inspection”: K12M in Section 1C (Page 1C-23).

Is check result OK?

DTC P2226 / P2227

AENJCA0A1124054
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P2226: Barometric Pressure Sensor “A” Circuit Barometric pressure sensor in ECM
Barometric pressure sensor and/or its circuit malfunction (open, short to
power supply or short to ground) is detected.
(3 D/C detection logic)
P2227: Barometric Pressure Sensor “A” Circuit Range / Performance
This DTC is detected if any one of the following conditions is met.
• BARO sensor signal is out of specified range.
• Difference between actual and expected ambient pressure is more than
the specified value and the fluctuation of ambient pressure is more than
the specified value.
(3 D/C detection logic)

DTC Confirmation Procedure

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

P2227
1) Run engine at idle speed for 1 min.
1A-250 Engine General Information and Diagnosis: K12M

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”: K12M
(Page 1A-138).
2 ECM power supply and ground circuit check Replace ECM and Repair ECM power
1) Check ECM power supply and ground circuits. (Page recheck DTC. (Page supply and ground
1A-267) 1C-22) circuits.

Is check result OK?

DTC P2271
AENJCA0A1124069
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P2271: O2 Sensor Signal Biased / Stuck Rich (Bank1 Sensor2) • HO2S-2 and/or its circuit
Output voltage of HO2S-2 signal circuit is higher than 0.3 V for • Exhaust system
specified time after warming up even when vehicle is in fuel cut
• Air intake system
driving condition.
(3 D/C detection logic) • Fuel system
• Engine compression
• Ignition system
• Emission control system
• ECM

Circuit Diagram

3
5V
+B 1 4 A3
RED C02-6
A2
GRN C02-7
A4
BLU PPL C02-49
A1 LT GRN C02-55
5V
2 4 B3
YEL C02-8
B2
BRN C02-19
B4
BLU RED C02-52
B1 BEG C02-56

[A] C02 E02

[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

IGSB0A112013-01

[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
 Engine General Information and Diagnosis: K12M 1A-251

DTC Confirmation Procedure

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

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

1) Warm up engine to normal operating temperature.

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

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”: K12M
(Page 1A-138).
2 DTC check Go to troubleshooting Go to Step 3.
1) Check DTC. (Page 1A-140) for applicable DTC.

Is there any DTC(s) other than P2271?

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

Is check result OK?

4 HO2S-2 signal and ground circuit check Go to Step 5. Repair or replace
1) Check “B2” and “B3” circuits according to Step 3 under defective parts.
“DTC P0137 / P0138 / P0140”: K12M (Page 1A-195).

Is check result OK?

5 Engine mechanical system check Go to Step 6. Repair or replace
1) Check the following points related to engine mechanical defective parts.
system.
• Engine compression: (Page 1D-77)
• Spark plug: (Page 1H-16)

Is check result OK?

1A-252 Engine General Information and Diagnosis: K12M

Step Action Yes No

6 Fuel system and emission control system check Go to Step 7. Repair or replace
1) Check the following points related to fuel and emission defective parts.
control systems.
• Fuel pressure: (Page 1G-12)
• Fuel injector circuit: (Page 1G-7)
• Fuel injector: (Page 1G-24)
• MAP sensor: (Page 1C-27)
• EVAP canister purge valve: (Page 1B-11)
• PCV valve: (Page 1B-13)

Is check result OK?

7 DTC recheck Replace ECM and End.
1) Replace HO2S-2. (Page 1C-29) recheck DTC. (Page
1C-22)
2) Clear DTC. (Page 1A-141)
3) Set ignition “OFF”.
4) Perform “DTC Confirmation Procedure” and check DTC.
(Page 1A-140)

Is DTC P2271 still detected?

DTC U0073 Refer to “Troubleshooting for Lost Communication” in

AENJCA0A1124056 Section 10H (Page 10H-9).
Refer to “Troubleshooting for Communication Bus Off” in
Section 10H (Page 10H-15).
DTC U0140
AENJCA0A1124060
DTC U0101 Refer to “Troubleshooting for Lost Communication” in
AENJCA0A1124057 Section 10H (Page 10H-9).
Refer to “Troubleshooting for Lost Communication” in
Section 10H (Page 10H-9).
DTC U0155
AENJCA0A1124061
DTC U0121 Refer to “Troubleshooting for Lost Communication” in
AENJCA0A1124058 Section 10H (Page 10H-9).

DTC U2001
AENJCA0A1124062
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
U2001: LIN Lost Communication With Generator • Generator LIN communication circuit
Received data from generator via LIN is faulty. • Regulator (stator assembly)
(1 D/C detection logic but MIL does not light up)
• ECM
 Engine General Information and Diagnosis: K12M 1A-253

Circuit Diagram

1 3

A1

2 BLU C02-1 4

[A] C02 E02

[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

IJCA0A112024-01

[A]: ECM connector (View: [a]) 1. Generator 3. ECM

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

DTC Confirmation Procedure

1) Set ignition “ON”.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K12M
(Page 1A-138).
2 Generator LIN communication circuit check Go to Step 3. Repair or replace
1) With ignition “OFF”, disconnect “C02” and “E02” defective wire harness.
connectors of ECM and generator connector.
2) Check for proper terminal connection to “C02” and “E02”
connectors and generator connector.
3) If connections are OK, check the following points.
• Resistance of “A1” circuit: less than 1 Ω
• Resistance between “A1” circuit and ground: infinity
• Resistance between “A1” circuit terminal and other
terminal at ECM connector: infinity
• Voltage of “A1” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

3 DTC recheck Replace ECM and End.
1) Replace stator assembly. (Page 1J-30) recheck DTC. (Page
1C-22)
2) Clear DTC. (Page 1A-141)
3) Set ignition “OFF”.
4) Perform “DTC Confirmation Procedure” and check DTC.

Is DTC U2001 still detected?

1A-254 Engine General Information and Diagnosis: K12M

DTC U2021
AENJCA0A1124063
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
U2021: LIN Invalid Data from ECM to Generator • ECM power supply circuit and/or ground circuit
Transmitted data from ECM to generator via LIN is faulty. • ECM
(1 D/C detection logic but MIL does not light up)

DTC Confirmation Procedure

1) Set ignition “ON”.

DTC Troubleshooting
Step Action Yes No
1 DTC recheck Go to Step 2. Check for intermittent
1) Clear DTC. (Page 1A-141) trouble. (Page 00-13)
2) Set ignition “OFF”.
3) Perform “DTC Confirmation Procedure” and check DTC.

Is DTC U2021 still detected?

2 ECM power supply and ground circuit check Replace ECM and Repair ECM power
1) Check ECM power supply and ground circuits. (Page recheck DTC. (Page supply and ground
1A-267) 1C-22) circuits.

Is check result OK?

Inspection of ECM and Its Circuits

AENJCA0A1124064
Voltage Check

NOTE
• As each terminal voltage is affected by battery voltage, check that battery voltage is 12 V or more
when ignition is “ON”.
• Voltage with asterisk (*) cannot be measured with voltmeter because it is pulse signal. Use
oscilloscope for its check.
• Before performing this inspection, read “Precautions for ECM Circuit Inspection” under
“Precautions for Engine (K12M)” in Section 1 (Page 1-2).

[A] C02 E02

[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

IGSB0A112007-01

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

“C02” connector
Terminal No. Wire color Circuit Normal voltage Condition
Generator LIN Refer to reference waveform.
C02-1* BLU
communication circuit “Generator LIN communication signal”: K12M (Page 1A-266)
CAN (low) Refer to reference waveform.
C02-2* WHT
communication circuit “CAN communication signal”: K12M (Page 1A-266)
CAN (high) Refer to reference waveform.
C02-3* RED
communication circuit “CAN communication signal”: K12M (Page 1A-266)
 Engine General Information and Diagnosis: K12M 1A-255

Terminal No. Wire color Circuit Normal voltage Condition

MAP sensor and ECT
C02-4 GRY Below 0.3 V Ignition: “ON”
sensor ground circuit
C02-5 BEG IAT sensor ground circuit Below 0.3 V Ignition: “ON”
C02-6 RED HO2S-1 ground circuit Below 0.3 V Ignition: “ON”
Refer to reference waveform.
C02-7* GRN HO2S-1 signal circuit
“HO2S-1 signal”: K12M (Page 1A-263)
C02-8 YEL HO2S-2 ground circuit Below 0.3 V Ignition: “ON”
C02-9 — — — —
10 to 14 V Ignition: “ON”
Refer to reference waveform.
Fuel injector No.3 drive
C02-10* RED • “Fuel injector signal”: K12M (Page 1A-260)
circuit
• “Fuel injector No.3 signal and ignition coil No.3 signal”: K12M
(Page 1A-262)
10 to 14 V Ignition: “ON”
Refer to reference waveform.
Fuel injector No.2 drive
C02-11* WHT • “Fuel injector signal”: K12M (Page 1A-260)
circuit
• “Fuel injector No.2 signal and ignition coil No.2 signal”: K12M
(Page 1A-261)
10 to 14 V Ignition: “ON”
Refer to reference waveform.
Fuel injector No.4 drive
C02-12* GRN • “Fuel injector signal”: K12M (Page 1A-260)
circuit
• “Fuel injector No.4 signal and ignition coil No.4 signal”: K12M
(Page 1A-262)
TP sensor power supply
C02-13 RED 4.5 to 5.5 V Ignition: “ON”
circuit
MAP sensor power
C02-14 LT BLU 4.5 to 5.5 V Ignition: “ON”
supply circuit
C02-15 BLK TP sensor ground circuit Below 0.3 V Ignition: “ON”
Ignition: “ON”
4.0 to 4.2 V
TP sensor (sub) signal Accelerator pedal: Released
C02-16 WHT
circuit Ignition: “ON”
0.5 to 0.7 V
Accelerator pedal: Fully depressed
TP sensor shield ground
C02-17 BLK Below 0.3 V Ignition: “ON”
circuit
C02-18 — — — —
Refer to reference waveform.
C02-19* BRN HO2S-2 signal circuit
“HO2S-2 signal”: K12M (Page 1A-263)
Ignition: “ON”
3.2 to 3.6 V
ECT: 0 °C (32 °F)
Ignition: “ON”
C02-20 BLU ECT sensor signal circuit 1.0 to 1.4 V
ECT: 50 °C (122 °F)
Ignition: “ON”
0.2 to 0.5 V
ECT: 100 °C (212 °F)
C02-21 — — — —
Ignition: “ON”
3.2 to 3.6 V
IAT: 0 °C (32 °F)
Ignition: “ON”
C02-22 YEL IAT sensor signal circuit 1.3 to 1.7 V
IAT: 40 °C (104 °F)
Ignition: “ON”
0.4 to 0.8 V
IAT: 80 °C (176 °F)
C02-23 — — — —
C02-24 — — — —
1 to 2 V Engine: Idle speed
Knock sensor signal
C02-25* WHT Refer to reference waveform.
circuit 1
“Knock sensor signal”: K12M (Page 1A-265)
1A-256 Engine General Information and Diagnosis: K12M

Terminal No. Wire color Circuit Normal voltage Condition

MAP sensor and ECT
C02-4 GRY Below 0.3 V Ignition: “ON”
sensor ground circuit
C02-5 BEG IAT sensor ground circuit Below 0.3 V Ignition: “ON”
C02-6 RED HO2S-1 ground circuit Below 0.3 V Ignition: “ON”
Refer to reference waveform.
C02-7* GRN HO2S-1 signal circuit
“HO2S-1 signal”: K12M (Page 1A-263)
C02-8 YEL HO2S-2 ground circuit Below 0.3 V Ignition: “ON”
C02-9 — — — —
10 to 14 V Ignition: “ON”
Refer to reference waveform.
Fuel injector No.3 drive
C02-10* RED • “Fuel injector signal”: K12M (Page 1A-260)
circuit
• “Fuel injector No.3 signal and ignition coil No.3 signal”: K12M
(Page 1A-262)
10 to 14 V Ignition: “ON”
Refer to reference waveform.
Fuel injector No.2 drive
C02-11* WHT • “Fuel injector signal”: K12M (Page 1A-260)
circuit
• “Fuel injector No.2 signal and ignition coil No.2 signal”: K12M
(Page 1A-261)
10 to 14 V Ignition: “ON”
Refer to reference waveform.
Fuel injector No.4 drive
C02-12* GRN • “Fuel injector signal”: K12M (Page 1A-260)
circuit
• “Fuel injector No.4 signal and ignition coil No.4 signal”: K12M
(Page 1A-262)
TP sensor power supply
C02-13 RED 4.5 to 5.5 V Ignition: “ON”
circuit
MAP sensor power
C02-14 LT BLU 4.5 to 5.5 V Ignition: “ON”
supply circuit
C02-15 BLK TP sensor ground circuit Below 0.3 V Ignition: “ON”
Ignition: “ON”
4.0 to 4.2 V
TP sensor (sub) signal Accelerator pedal: Released
C02-16 WHT
circuit Ignition: “ON”
0.5 to 0.7 V
Accelerator pedal: Fully depressed
TP sensor shield ground
C02-17 BLK Below 0.3 V Ignition: “ON”
circuit
C02-18 — — — —
Refer to reference waveform.
C02-19* BRN HO2S-2 signal circuit
“HO2S-2 signal”: K12M (Page 1A-263)
Ignition: “ON”
3.2 to 3.6 V
ECT: 0 °C (32 °F)
Ignition: “ON”
C02-20 BLU ECT sensor signal circuit 1.0 to 1.4 V
ECT: 50 °C (122 °F)
Ignition: “ON”
0.2 to 0.5 V
ECT: 100 °C (212 °F)
C02-21 — — — —
Ignition: “ON”
3.2 to 3.6 V
IAT: 0 °C (32 °F)
Ignition: “ON”
C02-22 YEL IAT sensor signal circuit 1.3 to 1.7 V
IAT: 40 °C (104 °F)
Ignition: “ON”
0.4 to 0.8 V
IAT: 80 °C (176 °F)
C02-23 — — — —
C02-24 — — — —
1 to 2 V Engine: Idle speed
Knock sensor signal
C02-25* WHT Refer to reference waveform.
circuit 1
“Knock sensor signal”: K12M (Page 1A-265)
 Engine General Information and Diagnosis: K12M 1A-257

Terminal No. Wire color Circuit Normal voltage Condition

Ignition: “ON”
0.8 to 1.0 V
TP sensor (main) signal Accelerator pedal: Released
C02-26 GRN
circuit Ignition: “ON”
4.3 to 4.5 V
Accelerator pedal: Fully depressed
4.0 to 4.2 V Ignition: “ON”
Engine: Idle speed after warming up
BRN MAP sensor signal 1.5 to 1.8 V Barometric pressure: 100 kPa, 760
C02-27*
circuit mmHg
Refer to reference waveform.
“MAP sensor signal”: K12M (Page 1A-265)
C02-28 — — — —
C02-29 — — — —
Approx. 0 V or 4 to 5 V Ignition: “ON”
CMP sensor signal Refer to reference waveform.
C02-30* PPL
circuit “CMP sensor signal and CKP sensor signal”: K12M (Page 1A-
265)
10 to 14 V Ignition: “ON”
Refer to reference waveform.
Fuel injector No.1 drive
C02-31* PNK • “Fuel injector signal”: K12M (Page 1A-260)
circuit
• “Fuel injector No.1 signal and ignition coil No.1 signal”: K12M
(Page 1A-261)
C02-32 — — — —
Approx. 0 V Ignition: “ON”
Refer to reference waveform.
Ignition coil No.2 drive
C02-33* GRN • “Ignition coil signal”: K12M (Page 1A-263)
circuit
• “Fuel injector No.2 signal and ignition coil No.2 signal”: K12M
(Page 1A-261)
Approx. 0 V Ignition: “ON”
Refer to reference waveform.
Ignition coil No.3 drive
C02-34* PNK • “Ignition coil signal”: K12M (Page 1A-263)
circuit
• “Fuel injector No.3 signal and ignition coil No.3 signal”: K12M
(Page 1A-262)
Approx. 0 V Ignition: “ON”
Refer to reference waveform.
Ignition coil No.4 drive
C02-35* BEG • “Ignition coil signal”: K12M (Page 1A-263)
circuit
• “Fuel injector No.4 signal and ignition coil No.4 signal”: K12M
(Page 1A-262)
C02-36 — — — —
1 to 2 V Engine: Idle speed
Knock sensor signal
C02-37* BLU Refer to reference waveform.
circuit 2
“Knock sensor signal”: K12M (Page 1A-265)
C02-38 — — — —
Approx. 0 V or 4 to 5 V Ignition: “ON”
Refer to reference waveform.
C02-39* PNK CKP sensor signal circuit
“CMP sensor signal and CKP sensor signal”: K12M (Page 1A-
265)
C02-40 — — — —
10 to 14 V Ignition: “ON”
EVAP canister purge
C02-41* GRY Refer to reference waveform.
valve drive circuit
“EVAP canister purge valve signal”: K12M (Page 1A-264)
10 to 14 V Ignition: “ON”
C02-42* GRN OCV drive circuit Refer to reference waveform.
“OCV signal”: K12M (Page 1A-265)
C02-43 — — — —
1A-258 Engine General Information and Diagnosis: K12M

Terminal No. Wire color Circuit Normal voltage Condition

Approx. 0 V Ignition: “ON”
Refer to reference waveform.
Ignition coil No.1 drive
C02-44* YEL • “Ignition coil signal”: K12M (Page 1A-263)
circuit
• “Fuel injector No.1 signal and ignition coil No.1 signal”: K12M
(Page 1A-261)
C02-45 — — — —
C02-46 — — — —
C02-47 — — — —
C02-48 — — — —
10 to 14 V Ignition: “ON”
HO2S-1 heater drive Refer to reference waveform.
C02-49* PPL
circuit “HO2S-1 heater signal and HO2S-2 heater signal”: K12M
(Page 1A-263)
C02-50 BLK ECM ground circuit 1 Below 0.3 V Ignition: “ON”
Throttle actuator drive Refer to reference waveform.
C02-51* LT GRN
circuit (close) “Throttle actuator signal”: K12M (Page 1A-264)
10 to 14 V Ignition: “ON”
HO2S-2 heater drive Refer to reference waveform.
C02-52* RED
circuit “HO2S-1 heater signal and HO2S-2 heater signal”: K12M
(Page 1A-263)
C02-53 BLK ECM ground circuit 2 Below 0.3 V Ignition: “ON”
Throttle actuator drive Refer to reference waveform.
C02-54* BRN
circuit (open) “Throttle actuator signal”: K12M (Page 1A-264)
HO2S-1 shield ground
C02-55 LT GRN Below 0.3 V Ignition: “ON”
circuit
HO2S-2 shield ground
C02-56 BEG Below 0.3 V Ignition: “ON”
circuit

“E02” connector
Terminal No. Wire color Circuit Normal voltage Condition
Approx. 0 V Ignition: “OFF” or “ACC”
E02-1 WHT Ignition ON signal circuit
10 to 14 V Ignition: “ON”
Ignition: “ON”
10 to 14 V ECT < 95 °C (203 °F)
Radiator cooling fan A/C switch: OFF
E02-2 LT GRN
relay No.1 drive circuit Ignition: “ON”
Approx. 0 V 97 °C (206.6 °F) < ECT
A/C switch: OFF
Ignition: “ON”
0.37 to 0.38 V
APP sensor (sub) signal Accelerator pedal: Released
E02-3 GRY
circuit Ignition: “ON”
2.15 to 2.25 V
Accelerator pedal: Fully depressed
E02-4 — — — —
APP sensor (sub)
E02-5 YEL Below 0.3 V Ignition: “ON”
ground circuit
APP sensor (sub) power
E02-6 BLU 4.5 to 5.5 V Ignition: “ON”
supply circuit
E02-7 — — — —
E02-8 — — — —
A/C refrigerant pressure
E02-9 BLK Below 0.3 V Ignition: “ON”
sensor ground circuit
E02-10 — — — —
E02-11 — — — —
E02-12 — — — —
E02-13 — — — —
A/C refrigerant pressure
E02-14 LT GRN 4.5 to 5.5 V Ignition: “ON”
sensor supply circuit
E02-15 — — — —
 Engine General Information and Diagnosis: K12M 1A-259

Terminal No. Wire color Circuit Normal voltage Condition

Ignition: “ON”
0.70 to 0.80 V
APP sensor (main) Accelerator pedal: Released
E02-16 PNK
signal circuit Ignition: “ON”
4.35 to 4.45 V
Accelerator pedal: Fully depressed
E02-17 — — — —
Ignition: “ON”
Approx. 0 V
Brake light switch signal Brake pedal: Released
E02-18 YEL
circuit Ignition: “ON”
10 to 14 V
Brake pedal: Fully depressed
APP sensor (main)
E02-19 GRY Below 0.3 V Ignition: “ON”
ground circuit
APP sensor (main)
E02-20 GRN 4.5 to 5.5 V Ignition: “ON”
power supply circuit
Ignition: “ON”
Approx. 0 V Blower speed switch: 2nd or higher
speed position
Blower motor signal
E02-21 YEL Ignition: “ON”
circuit 5 to 7 V
Blower speed switch: 1st position
Ignition: “ON”
10 to 14 V
Blower speed switch: OFF
E02-22 — — — —
E02-23 — — — —
Fuel pump relay drive Refer to reference waveform.
E02-24 YEL
circuit “Fuel pump relay signal”: K12M (Page 1A-266)
E02-25 — — — —
E02-26 — — — —
Ignition: “ON”
10 to 14 V ECT < 100 °C (212 °F)
Radiator cooling fan
A/C switch: OFF
E02-27 GRN relay No.2 and No.3
Ignition: “ON”
drive circuit
Approx. 0 V 102 °C (215.6 °F) < ECT
A/C switch: OFF
CAN (high) Refer to reference waveform.
E02-28* RED
communication circuit “CAN communication signal”: K12M (Page 1A-266)
CAN (low) Refer to reference waveform.
E02-29* WHT
communication circuit “CAN communication signal”: K12M (Page 1A-266)
E02-30 — — — —
E02-31 — — — —
E02-32 — — — —
Engine: Running
0.9 to 1.3 V
A/C refrigerant pressure A/C compressor: Not operating
E02-33 BEG
sensor signal circuit Engine: Running
1.6 to 2.6 V
A/C compressor: Operating
E02-34 — — — —
E02-35 — — — —
E02-36 — — — —
E02-37 — — — —
Staring motor control Approx. 0 V Staring motor: Operating
E02-38 GRN relay drive circuit (M/T Refer to reference waveform.
model) “Starting motor control relay signal”: K12M (Page 1A-266)
E02-39 — — — —
E02-40 — — — —
A/C compressor relay 10 to 14 V A/C compressor: Not operating
E02-41 GRY
drive circuit Approx. 0 V A/C compressor: Operating
Ignition: “ON”
10 to 14 V
CPP No.2 switch signal Clutch pedal: Released
E02-42 GRN
circuit (M/T model) Ignition: “ON”
Approx. 0 V
Clutch pedal: Fully depressed
1A-260 Engine General Information and Diagnosis: K12M

Terminal No. Wire color Circuit Normal voltage Condition

Starting motor control Approx. 0 V Ignition: “ON”
E02-43 LT BLU
relay signal circuit 6 to 12 V Ignition: “START”
E02-44 — — — —
E02-45 — — — —
E02-46 — — — —
E02-47 — — — —
E02-48 — — — —
Approx. 0 V Ignition: “ON”
Main relay drive circuit
E02-49 PNK Ignition: 25 sec.
10 to 14 V
after ignition “OFF”
E02-50 — — — —
E02-51 — — — —
E02-52 — — — —
E02-53 — — — —
E02-54 — — — —
Main power supply
E02-55 BLU 10 to 14 V Ignition: “ON”
circuit 2
Main power supply
E02-56 BLU 10 to 14 V Ignition: “ON”
circuit 1

Reference Waveform

NOTE
• Display includes the following types of
data:

I7V20A111014-02

1. Fuel injector signal

ICP70A110009-01

[A]: Waveform of channel 1 [C]: VOLT/DIV of each channel

[B]: Ground level of each channel [D]: TIME/DIV

• Waveform varies depending on

measurement condition and vehicle spec.

Fuel injector signal

Channel Probe Terminal No.
C02-31 (No.1)
C02-11 (No.2)
+
1 C02-10 (No.3)
C02-12 (No.4)
– C02-50

Measurement condition
• Engine: Idle speed after warming up
 Engine General Information and Diagnosis: K12M 1A-261

Fuel injector No.1 signal and ignition coil No.1 signal Fuel injector No.2 signal and ignition coil No.2 signal

Fuel injector No.1 signal (1) Fuel injector No.2 signal (1)
Channel Probe Terminal No. Channel Probe Terminal No.
+ C02-31 + C02-11
1 1
– C02-50 – C02-50

Ignition coil No.1 signal (2) Ignition coil No.2 signal (2)
Channel Probe Terminal No. Channel Probe Terminal No.
+ C02-44 + C02-33
2 2
– C02-50 – C02-50

CMP sensor signal (3) CMP sensor signal (3)

Channel Probe Terminal No. Channel Probe Terminal No.
+ C02-30 + C02-30
3 3
– C02-50 – C02-50

CKP sensor signal (4) CKP sensor signal (4)

Channel Probe Terminal No. Channel Probe Terminal No.
+ C02-39 + C02-39
4 4
– C02-50 – C02-50

Measurement condition Measurement condition

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

IFRA0A111032-01 IFRA0A111033-01

5. Camshaft 360° angle 6. Crankshaft 720° angle 5. Camshaft 360° angle 6. Crankshaft 720° angle
1A-262 Engine General Information and Diagnosis: K12M

Fuel injector No.3 signal and ignition coil No.3 signal Fuel injector No.4 signal and ignition coil No.4 signal

Fuel injector No.3 signal (1) Fuel injector No.4 signal (1)
Channel Probe Terminal No. Channel Probe Terminal No.
+ C02-10 + C02-12
1 1
– C02-50 – C02-50

Ignition coil No.3 signal (2) Ignition coil No.4 signal (2)
Channel Probe Terminal No. Channel Probe Terminal No.
+ C02-34 + C02-35
2 2
– C02-50 – C02-50

CMP sensor signal (3) CMP sensor signal (3)

Channel Probe Terminal No. Channel Probe Terminal No.
+ C02-30 + C02-30
3 3
– C02-50 – C02-50

CKP sensor signal (4) CKP sensor signal (4)

Channel Probe Terminal No. Channel Probe Terminal No.
+ C02-39 + C02-39
4 4
– C02-50 – C02-50

Measurement condition Measurement condition

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

IFRA0A111035-01
IJCA0A112025-01
5. Camshaft 360° angle 6. Crankshaft 720° angle
5. Camshaft 360° angle 6. Crankshaft 720° angle
 Engine General Information and Diagnosis: K12M 1A-263

HO2S-1 heater signal and HO2S-2 heater signal Ignition coil signal
Channel Probe Terminal No.
HO2S-1 heater signal (1) C02-44 (No.1)
Channel Probe Terminal No. C02-33 (No.2)
+ C02-49 +
1 1 C02-34 (No.3)
– C02-50 C02-35 (No.4)
– C02-50
HO2S-2 heater signal (2)
Channel Probe Terminal No. Measurement condition
+ C02-52 • Engine: Idle speed after warming up
2
– C02-50

Measurement condition
• Engine: Idle speed after warming up

IBP60B110043-01

1. Ignition coil signal

HO2S-1 signal
Channel Probe Terminal No.
IFAE0A110043-01
+ C02-7
1
HO2S-2 signal – C02-50
Channel Probe Terminal No. Measurement condition
+ C02-19
1 • Engine: Idle speed after warming up
– C02-50

Measurement condition
• Engine: Racing after warming up

IFAE0A110048-01

IFRA0A111046-01

1. Engine: Racing 2. Engine: Idle speed

1A-264 Engine General Information and Diagnosis: K12M

EVAP canister purge valve signal Measurement condition

Channel Probe Terminal No. • Ignition: More than 10 sec. after ignition “ON”
+ C02-41 • Accelerator pedal: Idle position
1
– C02-50

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

IDAA0A111030-01

Measurement condition
• Ignition: “ON”
• Accelerator pedal: Fully depressed position
IFAE0A110038-01

Throttle actuator signal

Throttle actuator signal (Open) (1)

Channel Probe Terminal No.
+ C02-54
1
– C02-50

Throttle actuator signal (Close) (2)

Channel Probe Terminal No.
+ C02-51
2 I8C50B111049-01
– C02-50

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

IDAA0A111029-01
 Engine General Information and Diagnosis: K12M 1A-265

CMP sensor signal and CKP sensor signal MAP sensor signal

CMP sensor signal (1) MAP sensor signal (1)

Channel Probe Terminal No. Channel Probe Terminal No.
+ C02-30 + C02-27
1 1
– C02-50 – C02-50

CKP sensor signal (2) TP sensor (main) signal circuit (2)

Channel Probe Terminal No. Channel Probe Terminal No.
+ C02-39 + C02-26
3 2
– C02-50 – C02-50

Measurement condition Measurement condition

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

IFAE0A110044-01 IFRA0A111039-01

3. Engine: Idle speed 4. Engine: Racing

Knock sensor signal
Channel Probe Terminal No. OCV signal
C02-25 Channel Probe Terminal No.
+
1 C02-37 + C02-42
– C02-50 1
– C02-50

Measurement condition Measurement condition

• Engine: Running at 4,000 rpm after warming up • Engine: Racing after warming up
• Accelerator pedal: Fully depressed position

IJCA0A112026-01

IDAA0A111031-01

1. OCV signal
1A-266 Engine General Information and Diagnosis: K12M

Fuel pump relay signal CAN communication signal

Channel Probe Terminal No.
+ E02-24 CAN (High) communication signal (1)
1 Channel Probe Terminal No.
– C02-50
C02-3
+
Measurement condition 1 E02-28
• Ignition: “OFF” → “ON” → “START” – C02-50

CAN (Low) communication signal (2)

Channel Probe Terminal No.
C02-2
+
2 E02-29
– C02-50

Measurement condition
• Ignition: “ON”

IAW101110042-01

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

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

Starting motor control relay signal

Ignition ON signal (1)

Channel Probe Terminal No.
+ E02-1
1
– C02-50 I8C50B111041-01

Starting motor control relay signal (2) Generator LIN communication signal
Channel Probe Terminal No. Channel Probe Terminal No.
+ E02-38 + C02-1
2 1
– C02-50 – C02-50

Fuel pump relay signal (3) Measurement condition

Channel Probe Terminal No. • Engine: Idle speed after warming up
+ E02-24
3
– C02-50

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

ICV00P111021-02

1. Generator LIN communication signal

IJCA0A111033-01

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

5. Ignition: “ON” 7. Starting motor: Operation prohibited
 Engine General Information and Diagnosis: K12M 1A-267

ECM Power Supply and Ground Circuit Check

AENJCA0A1124065
Circuit Diagram

1
A1
2 5V 12V
GRN E02-20 7
3 PNK E02-16 C02-51 LT GRN
GRY E02-19 8
C02-54 BRN M
A2 D1
5V
BLU E02-6 5V
4 C02-13 RED
GRY E02-3 9
YEL E02-5 C02-26 GRN
10
C02-16 WHT
C02-15 BLK
12V
C02-17 BLK
E1 11 F1
5V
E02-49 PNK 12
E02-55 BLU
E2
3.3V F2
E02-56 BLU E3
B1 5V 14
5 15
LT GRN E02-14 5V

BEG E02-33
BLK E02-9 16
13
E02-1 WHT
C1 5V
6 G1
LT BLU C02-14
H1 17
BRN C02-27 C02-50 BLK
H2
GRY C02-4 C02-53 BLK 18

[A] C02 E02

[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

IJCA0A112021-01

[A]: ECM connector (View: [a]) G1: Ignition ON signal circuit 9. TP sensor (main)
A1: APP sensor (main) power supply circuit H1: ECM ground circuit 1 10. TP sensor (sub)
A2: APP sensor (sub) power supply circuit H2: ECM ground circuit 2 11. Main relay
B1: A/C refrigerant pressure sensor power supply circuit 1. ECM 12. “FI” fuse
C1: MAP sensor power supply circuit 2. APP sensor 13. “IG” fuse
D1: TP sensor power supply circuit 3. APP sensor (main) 14. IG11 relay
E1: Main relay drive circuit 4. APP sensor (sub) 15. “IGN” fuse
E2: Main power supply circuit 2 5. A/C refrigerant pressure sensor 16. Ignition switch
E3: Main power supply circuit 1 6. MAP sensor 17. Main fuse box
F1: Main relay power supply circuit (coil side) 7. Electric throttle body assembly 18. Battery
F2: Main relay power supply circuit (switch side) 8. Throttle actuator
1A-268 Engine General Information and Diagnosis: K12M

Circuit Description
When ignition is set to “ON”, the main relay turns on (contacts close) and the main power is supplied to ECM. ECM
then supplies 5 V power to the following sensors: MAP sensor, A/C refrigerant pressure sensor, APP sensor and TP
sensor.

Troubleshooting

NOTE
• Before troubleshooting, read “Precautions for ECM Circuit Inspection” under “Precautions for
Engine (K12M)” in Section 1 (Page 1-2).
• Before performing, check that related fuses of ECM power circuit have not blown out.
If any fuse has blown out, replace the fuse and check circuits connected to the blown fuse for short
circuit to ground.

Step Action Yes No

1 Battery check Go to Step 2. Check battery and
1) Check that battery voltage is 12 V or more. generator referring to
“Battery Inspection”:
Is check result OK? K12M in Section 1J
(Page 1J-22) and
“Generator Test”: K12M
in Section 1J (Page 1J-
23).
2 Main relay power supply check Go to Step 3. • “FI” fuse blown:
1) With ignition “OFF”, remove main relay (1) from – Replace “FI” fuse
individual circuit fuse box No.1. and check “F1”
and “F2” circuits
again. If check
result is not OK,
repair or replace
defective wire
1 harness.
• “FI” fuse not blown:
– Repair or replace
defective wire
harness.

IJCA0A112027-01

2) Check for proper terminal connection to main relay

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

Is check result OK?

3 Main relay check Go to Step 4. Replace main relay.
1) Check main relay. (Page 1C-32)

Is check result OK?

 Engine General Information and Diagnosis: K12M 1A-269

Step Action Yes No

4 Ignition mode circuit check Go to Step 5. Check that “IG” fuse has
1) With ignition “OFF”, install main relay to individual circuit not blown.
fuse box No.1. If check result is OK,
2) Disconnect “C02” and “E02” connectors from ECM. repair or replace
defective wire harness.
3) Check for proper terminal connection to “C02” and “E02”
connectors.
4) If connections are OK, set ignition “ON”.
5) Check that voltage between “G1” and ground is battery
voltage.

Is check result OK?

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

Is check result OK?

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

Is check result OK?

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

Is check result OK?

8 Sensor power supply circuit check ECM power supply and Check wiring harness
1) With ignition “OFF”, connect “C02” and “E02” connectors ground circuits are in for open, short circuit to
to ECM. good condition. battery and short circuit
to ground. If wiring
2) Disconnect connectors from APP sensor, electric throttle
harness is in good
body assembly, MAP sensor 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. (Page
4) If connections are OK, set ignition “ON”. 1C-22)
5) Check that voltage between each of the following circuits
and ground is approx. 5 V.
• A1
• A2
• B1
• C1
• D1

Is check result OK?

1A-270 Engine General Information and Diagnosis: K12M

Fuel Cut Operation Inspection

AENJCA0A1124066 1 2
1) For M/T model, place gear shift lever in neutral
position and apply parking brake.
For auto gear shift model, place shift selector in N
range and apply parking brake.
2) Warm up engine to normal operating temperature.
3) While listening to sound of fuel injector (2) using
sound scope (1) or the like, increase engine speed
to higher than 3,000 rpm.

IFRA0A111042-01

4) Check that fuel injector operation sound stops when

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

Repair Instructions
Idle Speed Inspection 1) With ignition “OFF”, connect SUZUKI scan tool to
AENJCA0A1126001 DLC (1).
Before idle speed check, check the following items.
• Lead wires and hoses of electronic fuel injection and Special tool
engine and emission control systems are connected (A): SUZUKI scan tool (Suzuki SDT-II)
securely.
• Valve clearance is checked according to maintenance
schedule.
• Ignition timing is within specification.
• All electrical systems (wipers, heater, lights, A/C, etc.)
are off. 1

• Air cleaner is properly installed and is in good

condition.
• There is no air abnormally drawn in from air intake
system.
• There is no obstruction in PCV valve or its hose.
• There is no DTC in ECM.
• The following items are turned off as checked using
“Data List” mode on scan tool.
– A/C Comp Relay
– A/C Switch (A)
– Brake Switch IJCA0A181004-01

– Electric Load 2) Warm up engine to normal operating temperature.

– Blower Fan 3) If check result is not as specified, check engine idle
After checking all items, check idle speed as follows. speed referring to “Improper engine idling or engine
fails to idle” under “Engine Symptom Diagnosis”:
NOTE K12M (Page 1A-160).
Before starting engine, place gear shift lever
Engine idle speed
in neutral position (M/T model), or shift
A/C OFF: 600 to 750 rpm
selector in N range (auto gear shift model),
A/C ON: 700 to 900 rpm
apply parking brake and block drive wheels.
 Engine General Information and Diagnosis: K12M 1A-271

Special Tools and Equipment

Special Tool
AENJCA0A1128001
SUZUKI scan tool (Suzuki
SDT-II)
—
(Page 1A-140) /
(Page 1A-141) /
(Page 1A-270)
1A-272 Engine General Information and Diagnosis: Bi-Fuel CNG

Bi-Fuel CNG
General Description
Engine Diagnosis General Description • CNG control module, ECM and DLC are connected
AENJCA0A1131002 through CAN line.
The engine and emission control systems in this vehicle
Some CNG control module information can be
are controlled by ECM / CNG control module. ECM /
checked via DLC (4) by SUZUKI scan tool (3).
CNG control module has an OBD system which detects
a malfunction in this system and abnormality of those
parts that influence the engine exhaust emission. When
diagnosing engine troubles, be sure to have full
understanding of the outline of “OBD System 2 1

Description”: Bi-Fuel CNG (Page 1A-272) and each item

in “Precautions for Diagnosing Trouble” under
“Precautions for Engine (Bi-Fuel CNG)” in Section 1
(Page 1-4) and execute diagnosis according to “Engine
and Emission Control System Check”: Bi-Fuel CNG
(Page 1A-291).
There is a close relationship between the emission
system, engine mechanical, engine cooling system,
ignition system, exhaust system, etc. in their structure
and operation. In case of an engine trouble, even when
the MIL and/or CNG warning light doesn’t turn on,
diagnosis should be performed according to “Engine and 4
Emission Control System Check”: Bi-Fuel CNG (Page
1A-291).

OBD System Description

AENJCA0A1131003
ECM
Refer to “OBD System Description”: K10B (Page 1A-1).

CNG Control Module

General description
CNG control module in this vehicle has the following
functions.
• When ignition is “ON” with the engine stopped, CNG
warning light (1) turns on for 2 sec. in order to check
the CNG warning light 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 and/or
MIL (2) in the combination meter and stores the DTC
in its memory.
(If it detects normal condition for continuously three
driving cycles after detecting a malfunction, it turns
OFF CNG warning light although DTC stored in its
memory remains as a history DTC.)
• For some malfunctions, CNG control module adopts
the 3 D/C detecting logic to prevent erroneous
detection. With this logic, CNG warning light is turned
on when the malfunction is detected in 3 consecutive
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, refer to description on “Freeze frame
data”: Bi-Fuel CNG (Page 1A-273).
3
IJCA0A113001-01
Warm-up cycle
Warm-up cycle means that the coolant temperature has
risen by at least 22 °C (40 °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
The malfunction detected in the first driving cycle is
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
module causes the CNG warning light to light up when it
detects third time the same malfunction in the next two
driving cycles.
 Engine General Information and Diagnosis: Bi-Fuel CNG 1A-273

Pending DTC
Pending DTC means a DTC detected and stored
temporarily at the first driving cycle of the 3 driving cycle
detection logic.

Freeze frame data

CNG control module stores the engine and driving
conditions (in the form of data as shown) at the moment
of the detection of a malfunction in its memory. This data
is called “Freeze frame data”.
It is possible to know engine and driving conditions (e.g.,
whether the fuel was petrol or CNG, whether the engine
was warm or not, whether the vehicle was running or
stopped, whether air / fuel mixture was lean or rich)
when a malfunction was detected by checking the freeze
frame data. Also, CNG control module has a function to
store each freeze frame data for three different
malfunctions in the order of their detection. Utilizing this
function, it is possible to know the order of detection of
these malfunctions. This is helpful when rechecking or
diagnosing a trouble.

NOTE
Absolute TP indicates the ratio of the output
voltage to the power supply voltage of related
sensor.
When power supply voltage is 5.0 V and
output voltage is 4.0 V, freeze frame data is
displayed as follows.
• The sensor that the output voltage
increases according to the opening angle,
it displays 80%.
• The sensor that the output voltage
decreases according to the opening angle,
it displays 20%.
However, for systems where the output is
inversely proportional to the input voltage, it
displays 100% minus the above-mentioned
formula.

Freeze frame data (for example)

IJCA0A113002-02
1A-274 Engine General Information and Diagnosis: Bi-Fuel CNG

Priority of freeze frame data

CNG control module has 4 freeze frames from 0 to 3 where freeze frame data can be stored.
Frame 0 is a special frame limited for freeze frame data with MIL turned ON.
Frames 1 to 3 are assigned to store DTCs in detected order whether MIL turn on or not.
CNG control module stores 3 kinds of freeze frame data at a maximum, that is, DTCs are stored in detected order and
a DTC that turns on MIL is stored in frame 0 as well.
If more than 3 DTCs are detected, frames 1 to 3 are occupied with 1st to 3rd DTCs. Therefore, it is not possible to
access to the 4th DTC. On condition that all frames are occupied, if a new DTC with MIL is detected, the last DTC
without MIL stored in frame is overwritten by the new DTC with MIL. “DTC detection order” 6th row in the following
table shows the overwritten result.
In this situation, when a malfunction stored in frame 0 to 3 is resolved, the next DTC becomes accessible.

Frame 0 Frame 1 Frame 2 Frame 3

Freeze frame 1st freeze frame 2nd freeze frame 3rd freeze frame
data data data data
1 No DTC
2 P2408 P2408 data
DTC 3 P0007 P2408 data P0007 data
detection
order 4 P0182 P0182 data P2408 data P0007 data P0182 data
5 P2665 P0182 data P2408 data P0007 data P0182 data
6 P0193 P0182 data P2408 data P0182 data P0193 data
IJCA0A113020-02
—: No freeze frame data

Freeze frame data clearance

The freeze frame data is cleared at the same time as clearance of DTC.

DLC Description
AENJCA0A1131004 2 3
NOTE
16 15 14 13 12 11 10 9
SUZUKI scan tool can communicate with
CNG control module as well as ECM. 8 7 6 5 4 3 2 1

6 5
DLC (1) is in compliance with SAE J1962 in the shape of 4
1
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 (7) or CAN
communication OBD generic scan tool to communicate
with ECM and other control modules.
1

7
IJCA0A111002-01

2. B + (Continuous battery power)

4. ECM ground (Signal ground)
5. Ground (Chassis ground)
 Engine General Information and Diagnosis: Bi-Fuel CNG 1A-275
Engine and Emission Control System
Description
AENJCA0A1131006
The engine and emission control system is divided into 4
major sub-systems: air intake system, fuel delivery
system, electronic control system and emission control
system.
The air intake system includes air cleaner, throttle body,
and intake manifold.
The fuel delivery system includes fuel pump / CNG
cylinder valve, petrol fuel delivery pipe / CNG fuel
delivery pipe, petrol fuel pressure regulator / CNG
cylinder pressure regulator, petrol fuel injectors / CNG
fuel injectors, etc.
The electronic control system includes ECM / CNG
control module, various sensors and controlled devices.
The emission control system includes EVAP and PCV
systems.
When hoses are disconnected and system components
are removed for service, be sure to reinstall components
properly and route and connect hoses correctly after
service.
Bi-Fuel CNG System Description
AENJCA0A1131007
Bi-fuel CNG system consists of two kinds of fuel system
(petrol and CNG).
CNG system, which consists of CNG fuel supply system
and CNG fuel injection system, is added to conventional
petrol system. Vehicle runs using either petrol or CNG.
For detail about fuel system, refer to “Fuel System
Description”: Bi-Fuel CNG in Section 1G (Page 1G-35).
Bi-fuel CNG system is equipped with fuel select switch
and operating mode can be selected from three modes
by fuel select switch as follows.
When ignition is “ON”, operating mode is “Petrol MODE”
or “AUTO MODE”.
Petrol MODE
During “Petrol MODE”, engine runs on petrol only.
Operating mode can be switched between “Petrol
MODE” and “AUTO MODE” at every push of fuel select
switch when ignition is “ON” with engine stopped, or
when engine is running.
AUTO MODE
During “AUTO MODE”, engine starts in petrol system
and then the system automatically switches to CNG
system, depending on the condition of engine warming
up.
Operating mode can be switched between “AUTO
MODE” and “Petrol MODE” at every push of fuel select
switch when ignition is “ON” with engine stopped, or
when engine is running.
Forced CNG MODE
During “Forced CNG MODE”, engine runs on CNG only.
“Forced CNG MODE” can be selected by pushing and
holding fuel select switch for more than eight seconds
when ignition is “ON” with engine stopped.
If ignition is “OFF” and then is “ON” again under “Forced
CNG MODE”, operating mode is switched to “AUTO
MODE”.
Petrol / CNG Indicator
Petrol / CNG indicator is on combination meter. Petrol /
CNG indicator lights up or blinks depending on selected
operating mode.
[A]: 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”.
[B]: AUTO MODE
In this mode engine starts in petrol mode and then
automatically changes to CNG after reaching
programmed warming up condition. With ignition “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.
[C]: 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”.
[A]
[B]
[C]
IJCA0A113003-01
1A-276 Engine General Information and Diagnosis: Bi-Fuel CNG

Bi-Fuel CNG System Construction

AENJCA0A1131008

2
4
B1
A1
C1
A2
7 25 10 24
3
5 A3
B2
1
C2

8 11
6 20
B3 19
C3

9 12
13
18

21
27 23
28
14 22
15
16

26 17

IJCA0A113021-01

A1: Fuel injector No.1 drive signal from ECM
A2: Fuel injector No.2 drive signal from ECM
A3: Fuel injector No.3 drive signal from ECM
B1: Fuel injector No.1 drive signal
B2: Fuel injector No.2 drive signal
B3: Fuel injector No.3 drive signal
C1: CNG fuel injector No.1 drive signal
C2: CNG fuel injector No.2 drive signal
C3: CNG fuel injector No.3 drive signal
1. ECM
2. CNG control module
3. CPU
4. Fuel control relay No.1
5. Fuel control relay No.2 18. Fuel select switch
6. Fuel control relay No.3 19. Fuel tank
7. Fuel injector No.1 20. CNG cylinder
8. Fuel injector No.2 21. CNG cylinder valve
9. Fuel injector No.3 22. Shut off valve of CNG cylinder valve
10. CNG fuel injector No.1 23. Manual valve
11. CNG fuel injector No.2 24. CNG fuel delivery pipe
12. CNG fuel injector No.3 25. Fuel delivery pipe
13. CNG pressure-and-temperature sensor 26. CNG receptacle
14. CNG cylinder pressure regulator 27. CNG fuel filter
15. CNG cylinder pressure sensor 28. CNG valve control relay
16. Shut off valve of CNG cylinder pressure regulator
17. Fuel filler lid switch

Air Intake System Description Fuel injection control

AENJCA0A1131010 ECM and CNG control module judge the fuel system
Refer to “Air Intake System Description”: K10B (Page
depending on the signal from fuel select switch.
1A-5).
Therefore, CNG control module switches three built-in
fuel control relays and controls petrol fuel injector or
Electric Throttle Control System Description CNG fuel injector.
AENJCA0A1131013
Refer to “Electric Throttle Control System Description”:
K10B (Page 1A-5). CNG shut off valve power supply control
CNG control module drives CNG valve control relay for
power supply to shut off valve of CNG cylinder valve and
Electronic Control System Description shut off valve of CNG cylinder pressure regulator.
AENJCA0A1131011
ECM
Refer to “Electronic Control System Description”: K10B CNG shut off valve control
(Page 1A-7). During “Forced CNG MODE” or CNG control in “AUTO
MODE”, CNG control module opens shut off valve of
CNG Control Module CNG cylinder valve and shut off valve of CNG cylinder
CNG control module controls the fuel system as follows, pressure regulator to supply CNG fuel, and closes them
based on the signals from ECM and sensors related to when “Petrol MODE” or petrol control in “AUTO MODE”
CNG system. is operating.
 Engine General Information and Diagnosis: Bi-Fuel CNG 1A-277

Fuel cut control CNG shortage control

When fuel filler lid is open, CNG control module prohibits
fuel injection at engine cranking or idling. CNG warning
light blinks under this control.
Indicator control
• CNG control module calculates remaining CNG in
CNG cylinder based on CNG cylinder pressure sensor
signal, and then indicates the remaining CNG by CNG
pressure indicator on combination meter.
• CNG control module identifies fuel system based on
signal from fuel select switch, and ECM, and then
indicates selected fuel system by petrol / CNG
indicator on combination meter.
• CNG warning light lights up or blinks, when CNG
control module detects malfunction related to bi-fuel
CNG system.
When remaining CNG is less than specified amount,
CNG control module stops CNG usage and fuel system
switches to “Petrol MODE”. Thus customer can
continuously run vehicle automatically with petrol even
as CNG shortage. CNG warning light blinks under this
control. (Only under this control, blinking of CNG
warning light can be stopped by pushing fuel select
switch.)
Fail-safe control
If CNG system cannot maintain the control, “Petrol
MODE” is only selected. CNG warning light blinks under
this control.

Engine and Emission Control Input / Output Table

AENJCA0A1131012
ECM
Function Output Input
• Ignition “ON” signal
• Ignition “ST” signal
• ECT sensor
• CKP sensor
• CMP sensor
• TP sensor
• APP sensor
Injection control CNG control module • MAP sensor
• IAT sensor
• HO2S-1
• HO2S-2
• Battery voltage
• Brake light switch
• ABS control module (wheel speed signal)
• CNG control module
CNG control module • Ignition “ON” signal
Immobilizer control
Ignition coil assembly • BCM
• Ignition “ON” signal
• Ignition “ST” signal
• ECT sensor
• CKP sensor
• CMP sensor
• TP sensor
Ignition control Ignition coil with igniter • APP sensor
• MAP sensor
• IAT sensor
• Knock sensor
• Battery voltage
• ABS control module (wheel speed signal)
• CNG control module
1A-278 Engine General Information and Diagnosis: Bi-Fuel CNG

Function Output Input

• Ignition “ON” signal
• Ignition “ST” signal
• ECT sensor
• CKP sensor
• APP sensor
• TP sensor
Idle speed control Throttle actuator • MAP sensor
• IAT sensor
• EVAP canister purge valve
• Generator (field coil monitor signal)
• Battery voltage
• ABS control module (wheel speed signal)
• CNG control module
• Ignition “ON” signal
• CKP sensor
• TP sensor
• APP sensor
Throttle valve control Throttle actuator
• IAT sensor
• A/C refrigerant pressure sensor
• BCM (electric load signal and A/C OFF/ON request
signal)
• Ignition “ON” signal
• Ignition “ST” signal
• ECT sensor
HO2S-1
HO2S heater control • CKP sensor
HO2S-2
• TP sensor
• IAT sensor
• Battery voltage
• Ignition “ON” signal
• ECT sensor
• CKP sensor
• TP sensor
EVAP purge control EVAP canister purge valve • IAT sensor
• HO2S-1
• HO2S-2
• ABS control module (wheel speed signal)
• BCM (A/C OFF/ON request signal)
• Ignition “ON” signal
• Ignition “ST” signal
• ECT sensor
• CKP sensor
• A/C refrigerant pressure sensor
A/C compressor control A/C compressor relay
• TP sensor
• APP sensor
• ABS control module (wheel speed signal)
• BCM (evaporator temperature signal and A/C ON request
signal)
 Engine General Information and Diagnosis: Bi-Fuel CNG 1A-279

Function Output Input

• Ignition “ON” signal
• ECT sensor
• CKP sensor
Radiator cooling fan control Radiator cooling fan relay • A/C refrigerant pressure sensor
• A/C switch
• ABS control module (wheel speed signal)
• BCM (A/C OFF/ON request signal)
• Ignition “ON” signal
Fuel pump control Fuel pump relay
• CKP sensor
Starting motor control relay Starting motor control
• Ignition “ST” signal
control relay
Main relay control Main relay • Ignition “ON” signal
1A-280 Engine General Information and Diagnosis: Bi-Fuel CNG

CNG Control Module

Function Output Input
• Ignition “ON” signal
• 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 “ON” signal
• Fuel select switch
Fuel injection control Fuel injector
• Fuel filler lid switch
• ECM
• Ignition “ON” signal
• ECT sensor
• MAP sensor
CNG injection control CNG fuel injector • CNG pressure-and-temperature sensor
• Fuel select switch
• Fuel filler lid switch
• ECM
Fuel injector • Ignition “ON” signal
Fuel cut control
CNG fuel injector • Fuel filler lid switch
Shut off valve of CNG • Ignition “ON” signal
cylinder pressure • Fuel select switch
CNG shut off valve control
regulator
• CNG valve control relay
CNG cylinder valve

Schematic and Routing Diagram

Engine and Emission Control System Flow Diagram
AENJCA0A1132001
 CAN communication line Air Vapor
Exhaust gas Fuel (Petrol)
Fuel (CNG)

MAP sensor Exhaust manifold

Engine (Threeway catalyst)
Intake manifold
Air cleaner Electric throttle HO2S-1 HO2S-2
outlet hose body assembly CMP CKP Knock Ignition coil
Throttle TP CNG fuel sensor sensor sensor assembly
IAT sensor Fuel injector
actuator sensor injector
EVAP EVAP
canister canister
purge
ECT sensor valve Fuel EVAP Fuel
valve pump CNG fuel delivery pipe
CNG pressure-and- CNG cylinder pressure regulator
Fuel tank temperature sensor
CNG cylinder pressure sensor
Shut off valve

ECM
Shut off valve
CNG cylinder valve

CNG Cylinder
A/C compressor
relay
CNG valve Fuel select Fuel filler
· ABS control module A/C refrigerant control relay switch lid switch
Radiator cooling
· P/S control module pressure sensor fan relay
· BCM
· SDM
· Combination meter APP sensor
Generator CNG control module

Brake light switch

Main relay

Starting motor Ignition switch

CPP No.2 switch

IJCA0A113004-02
Engine General Information and Diagnosis: Bi-Fuel CNG 1A-281
1A-282 Engine General Information and Diagnosis: Bi-Fuel CNG

Engine Control System Circuit Diagram

AENJCA0A1132002
 Engine General Information and Diagnosis: Bi-Fuel CNG 1A-283

ECM

1
2 27 +B
GRN E01-31 C01-70 LT GRN
3 28
PNK E01-32 C01-75 BRN
GRY E01-33 C01-56 RED
29
BLU E01-40 C01-54 GRN
30
4 GRY E01-41 C01-55 WHT
YEL E01-42 C01-45 BLK
+B C01-44 GRY 61
31
C01-77 YEL
5 C01-78 BRN 58 32
PPL C01-58
C01-79 GRN 33

6
PNK C01-60
GRY 34
C01-40 RED
7 61
+B RED C01-53
GRN C01-37 35
BLU PPL C01-71 E01-38 YEL
BLK PNK +BB
LT GRN C01-32
36
8 61 37
BRN C01-52 E01-22 LT GRN 39
YEL C01-51 BLK BLU
BLU RED C01-76 38
BEG C01-42
40
9 E01-12 GRY
41 42
YEL C01-34 GRY BLU
BEG C01-38
10
WHT C01-33
BLU C01-43

43
11 LT BLU C01-57
C01-17 YEL
BEG C01-35 44
GRY C01-39 C01-18 GRN
12
BLU C01-36 45
13 LT GRN E01-37 C01-19 PNK

BEG E01-54
BLK E01-43

25 C01-31 BLU 46

+BB 47
E01-10 PNK
14 48
18 E01-56 BLU
GRN E01-20
E01-55 BLU

15
IG1

16 E01-19 WHT
YEL E01-23
17
49

IG2
WHT C01-21 50
59 IG1 51
RED C01-22
+BB ST 53
20 52 54
WHT E01-18
19 26
RED E01-9 55

E01-11 GRN 59
56
YEL E01-48
21 22 60
23 57
24 E01-24 LT BLU
C01-61 BLK
C01-66 BLK
: 62 : 63 : 12V : 5V
IJCA0A113005-03
1A-284 Engine General Information and Diagnosis: Bi-Fuel CNG

1. ECM 22. Blower speed switch 43. Ignition coil assembly No.1
2. APP sensor 23. A/C switch 44. Ignition coil assembly No.2
3. APP sensor (main) 24. To BCM 45. Ignition coil assembly No.3
4. APP sensor (sub) 25. LIN driver 46. Generator
5. CMP sensor 26. CAN driver 47. Main relay
6. CKP sensor 27. Electric throttle body assembly 48. “FI” fuse
7. HO2S-1 28. Throttle actuator 49. “IG COIL” fuse
8. HO2S-2 29. TP sensor (main) 50. Ignition switch
9. IAT sensor 30. TP sensor (sub) 51. “IGN” fuse
10. Knock sensor 31. Fuel injector No.1 52. “ST SIG” fuse (in fuse box)
11. MAP sensor 32. Fuel injector No.2 53. “IGN2” fuse
12. ECT sensor 33. Fuel injector No.3 54. “ST” fuse
13. A/C refrigerant pressure sensor 34. EVAP canister purge valve 55. Starting motor control relay
14. CPP No.2 switch 35. Fuel pump relay 56. Starting motor
15. Brake light switch 36. Fuel pump 57. “ST SIG” fuse (in relay box)
16. Brake light 37. Radiator cooling fan relay 58. CNG Control module
17. To other control modules 38. Radiator cooling fan 59. Main fuse box
18. “STOP” fuse 39. “RDTR” fuse 60. Battery
19. DLC 40. A/C compressor relay 61. Shield wire
20. To other control modules and sensor connected by CAN 41. A/C compressor 62. Engine ground
21. To blower motor 42. “CPRSR” fuse 63. Body ground

Terminal Arrangement of ECM Connector

NOTE
For circuit name and terminal voltage, refer to “Inspection of ECM and Its Circuits”: Bi-Fuel CNG (Page
1A-347).

[A] C01 E01

10 9 8 7 6 5 4 3 2 1
65 64 63 62 61 20 19 18 17 16 15 14 13 12 11
70 69 68 67 66 30 29 28 27 26 25 24 23 22 21
75 74 73 72 71 40 39 38 37 36 35 34 33 32 31
80 79 78 77 76 50 49 48 47 46 45 44 43 42 41
60 59 58 57 56 55 54 53 52 51
[a]
9 8 7 6 5 4 3 2 1
57 56 55 18 17 16 15 14 13 12 11 10
60 59 58 27 26 25 24 23 22 21 20 19
63 62 61 36 35 34 33 32 31 30 29 28
66 65 64 45 44 43 42 41 40 39 38 37
54 53 52 51 50 49 48 47 46

IJCA0A111006-02

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

 Engine General Information and Diagnosis: Bi-Fuel CNG 1A-285

CNG Control Module

+B

BLU
1
5 8
C12-6 RNK
9
C12-1 WHT
YEL C12-8

6
C12-14 WHT
10
C12-10 GRY
BRN C12-16

2 7
C12-5 RED
11
C12-18 BLU
GRN C12-7

RED C12-25 12V 5V

19
WHT C12-33
E23-1 RED

20
E23-10 RED

3 IG1
LT GRN E23-5 12
GRY E23-14 E23-21 WHT
RED E23-13 13
LT BLU E23-24 E23-30 GRN
BLK +BB
4 E23-31 LT BLU
BLU E23-6
WHT
RED E23-15

YEL E23-23 14 15
E23-22 LT GRN BLK

16
E23-4 BLU
17
E23-34 BLU

BLK C12-9
BLK C12-17 18
E23-26 BLU
BLK C12-26

: 21 : 22 : 5V : 12V
IJCA0A113006-01

1. CNG control module 9. CNG fuel injector No.1 17. Shut off valve of CNG cylinder valve
2. ECM 10. CNG fuel injector No.2 18. Shut off valve of CNG cylinder pressure regulator
3. CNG pressure-and-temperature sensor 11. CNG fuel injector No.3 19. CAN driver
4. CNG cylinder pressure sensor 12. “CNG IG1” fuse 20. CPU
5. Fuel injector No.1 13. Fuel filler lid switch 21. Engine ground
6. Fuel injector No.2 14. Fuel select switch 22. Body ground
7. Fuel injector No.3 15. “CNG VLV” fuse
8. “CNG” fuse 16. CNG valve control relay
1A-286 Engine General Information and Diagnosis: Bi-Fuel CNG

Terminal Arrangement of CNG Control Module Connector

NOTE
For circuit name and terminal voltage, refer to “Inspection of CNG Control Module and Its Circuit”: Bi-
Fuel CNG (Page 1A-358).

[A]

E23 C12
9 8 7 6 5 4 3 2 1 9 8 7 65 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

IJCA0A113018-01

[A]: CNG control module connector (View: [a])

 Engine General Information and Diagnosis: Bi-Fuel CNG 1A-287

Component Location
Electronic Control System Component Location
AENJCA0A1133001
Engine Compartment

[a] [b]

[1]

[2]

[3]

[d]

[c] [e]

[h]

[g]
[f]

IJCA0A113007-01

Information sensors Control devices Others

1. A/C refrigerant pressure sensor
2. CNG cylinder pressure sensor
[a]: Generator [1]: ECM
[b]: Shut off valve of CNG cylinder pressure regulator [2]: Individual circuit fuse box No.1
[c]: A/C compressor relay [3]: CNG control module
[d]: CNG valve control relay
[e]: Radiator cooling fan relay
[f]: Fuel pump relay
[g]: Main relay
[h]: Starting motor control relay
1A-288 Engine General Information and Diagnosis: Bi-Fuel CNG

Exterior

[a]

[1]

IJCA0A113008-01

Information sensors Control devices Others

1. Fuel filler lid switch [a]: Shutoff valve of CNG cylinder valve [1]: CNG cylinder
 Engine General Information and Diagnosis: Bi-Fuel CNG 1A-289

Interior (Around Instrument Panel)

[1]

[a] [b]

[1]

[2]
2

IJCA0A113009-01

Information sensors Control devices Others

1. APP sensor [a]: MIL [1]: Combination meter
2. CPP No.2 switch [b]: CNG warning light [2]: DLC
3. Brake light switch
4. Fuel select switch
1A-290 Engine General Information and Diagnosis: Bi-Fuel CNG

Engine Assembly

[a]
[b]
[f]
7
[c] [g]
[h]

6
1

[i]

2, [d] 8

[k]
[e]

9
4
3

10
[m]

5
IJCA0A113010-01

Information sensors Control devices

1. IAT sensor [a]: Ignition coil assembly No.1
2. TP sensor [b]: Ignition coil assembly No.2
3. ECT sensor [c]: Ignition coil assembly No.3
4. HO2S-1 [d]: Electric throttle body assembly
5. HO2S-2 [e]: EVAP canister purge valve
6. CNG pressure-and-temperature sensor [f]: Fuel injector No.3
7. CMP sensor [g]: Fuel injector No.2
8. MAP sensor [h]: Fuel injector No.1
9. Knock sensor [i]: CNG fuel injector No.3
10. CKP sensor [k]: CNG fuel injector No.2
[m]: CNG fuel injector No.1
 Engine General Information and Diagnosis: Bi-Fuel CNG 1A-291

Diagnostic Information and Procedures

Engine and Emission Control System Check
AENJCA0A1134001
Refer to the following items for the details of each step.
Step Action Yes No
1 Customer complaint analysis Go to Step 2. Perform customer
1) Perform customer complaint analysis. (Page 1A-292) complaint analysis.

Was customer complaint analysis performed?

2 DTC / freeze frame data check, record and clearance Print DTC and freeze Go to Step 4.
1) Check for DTC (current and pending DTC) and freeze frame data or write them
frame data in ECM and/or CNG control module. (Page down and clear them by
1A-293) referring to “DTC
Clearance”: Bi-Fuel
Is there any DTC(s)? CNG (Page 1A-294),
and go to Step 3.
3 Visual inspection Repair or replace faulty Go to Step 5.
1) Perform visual inspection. (Page 1A-293) 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 1A-293) part, and go to Step 11.

Is there any faulty condition?

5 Trouble symptom confirmation Go to Step 6. Go to Step 7.
1) Confirm trouble symptom. (Page 1A-293)

Is trouble symptom identified?

6 Rechecking and recording DTC / freeze frame data Go to Step 9. Go to Step 8.
1) Recheck for DTC (current and pending DTC) and freeze
frame data in ECM and/or CNG control module. (Page
1A-293)

Is there any DTC(s)?

7 Rechecking and recording DTC / freeze frame data Go to Step 9. Go to Step 10.
1) Recheck for DTC (current and pending DTC) and freeze
frame data in ECM and/or CNG control module. (Page
1A-293)

Is there any DTC(s)?

8 Engine basic inspection and engine symptom diagnosis Check and repair faulty Go to Step 10.
1) Perform engine basic inspection and engine symptom part(s), and go to Step
diagnosis. (Page 1A-293) 11.

Is there any faulty condition?

9 Troubleshooting for DTC Go to Step 11. Check and repair faulty
1) Perform troubleshooting for applicable DTC. (Page part(s), and go to Step
1A-293) 11.

Are check and repair complete?

10 Intermittent problem check Repair or replace faulty Go to Step 11.
1) Check for intermittent problems. (Page 1A-293) part(s), and go to Step
11.
Is there any faulty condition?
11 Final confirmation test Go to Step 6. End.
1) Perform final confirmation test. (Page 1A-293)

Is there any problem symptom, DTC or abnormal condition?

1A-292 Engine General Information and Diagnosis: Bi-Fuel CNG

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

Customer questionnaire form (Example)

I7V20A111010-01
 Engine General Information and Diagnosis: Bi-Fuel CNG 1A-293
Step 2: DTC / Freeze Frame Data Check, Record and
Clearance
First, check DTC (current and pending DTC). (Page
1A-293)
If DTC is indicated, print it and freeze frame data or write
them down and then clear them. (Page 1A-294)
Step 3 and 4: Visual Inspection
As a preliminary step, be sure to perform visual check of
the items that support proper function of engine. (Page
1A-306)
Step 5: Trouble Symptom Confirmation
In case that there is no DTC at Step 2:
Based on information obtained in “Step 1: Customer
Complaint Analysis”: Bi-Fuel CNG (Page 1A-292) and
“Step 2: DTC / Freeze Frame Data Check, Record and
Clearance”: Bi-Fuel CNG (Page 1A-293), confirm trouble
symptoms.
In case that there is any DTC at Step 2:
Recheck DTC according to “DTC Confirmation
Procedure” described in each DTC troubleshooting.
Step 6 and 7: Rechecking and Recording DTC /
Freeze Frame Data
Refer to “DTC Check”: Bi-Fuel CNG (Page 1A-293) for
checking procedure.
Step 8: Engine Basic Inspection and Engine
Symptom Diagnosis
1) Perform basic engine inspection. (Page 1A-308)
2) In case there is no faulty part found in inspection
procedure of “Engine basic inspection”, perform
“Engine Symptom Diagnosis”: Bi-Fuel CNG (Page
1A-310) based on symptom found in vehicle
checking in the following steps.
• Customer complaint analysis
• Trouble symptom confirmation
Step 9: Troubleshooting for DTC
Perform applicable DTC troubleshooting and repair or
replace faulty parts.
Step 10: Intermittent Problem Check
In case that there is no DTC at Step 2:
Check for intermittent problem. Refer to “Intermittent
Connection and Poor Contact Inspection” in Section 00
(Page 00-13).
In case that there is any DTC at Step 2:
Check parts related to detected DTC (e.g. wire harness,
connector, etc.).
Step 11: Final Confirmation Test
Confirm that the problem symptom has gone and engine
is free from any abnormal conditions. If what has been
repaired is related to DTC, clear DTC once, perform
DTC confirmation procedure and confirm that no DTC is
indicated.
MIL Check
AENJCA0A1134002
Refer to “MIL Check”: K10B (Page 1A-22).
CNG Warning Light Check
AENJCA0A1134003
1) Set ignition “ON” (with engine 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 “ON” and Engine
Stopped”: Bi-Fuel CNG (Page 1A-320) 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
(Page 1A-320) for troubleshooting.
1
IJCA0A113011-01
DTC Check
AENJCA0A1134004
ECM
Refer to “DTC Check”: K10B (Page 1A-22).
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
stores the trouble information (DTC, freeze
frame data, etc.) in its memory.
1) Set ignition “OFF”.
2) Connect SUZUKI scan tool to DLC (1).
Special tool
(A): SUZUKI scan tool (Suzuki SDT-II)
3) Set ignition “ON”.
1A-294 Engine General Information and Diagnosis: Bi-Fuel CNG
4) Read DTC, pending DTC and freeze frame data
according to instructions displayed on SUZUKI scan
tool and print them or write them down. Refer to
Operator's Manual of SUZUKI scan tool for further
details.
NOTE
If communication between SUZUKI scan tool
and CNG control module is not possible,
perform the following checks:
• Check communication condition between
PC and VCI (2) using SUZUKI scan tool
function.
• Check DLC power circuit and ground
circuit.
• Check DLC cable. If necessary, check DLC
cable by substituting a known-good DLC
cable.
• Check CAN communication system.
(“Control Module Communication Bus Off”
is detected in any control module.) (Page
10H-15)
• Check CNG control module power circuit
and ground circuit. (Page 1A-363)
1 1
2 2
(A)
IJCA0A111011-01
5) After completing the check, set ignition “OFF” and
disconnect SUZUKI scan tool from DLC.
DTC Clearance
AENJCA0A1134005
ECM
Refer to “DTC Clearance”: K10B (Page 1A-23).
CNG Control Module
1) Set ignition “OFF”.
2) Connect SUZUKI scan tool to DLC (1).
Special tool
(A): SUZUKI scan tool (Suzuki SDT-II)
3) Set ignition “ON”.
4) Clear DTC and pending DTC according to
instructions displayed on SUZUKI scan tool and print
them or write them down. Refer to Operator's
Manual of SUZUKI scan tool for further details.
NOTE
If communication between SUZUKI scan tool
and CNG control module is not possible,
perform the following checks:
• Check communication condition between
PC and VCI (2) using SUZUKI scan tool
function.
• Check DLC power circuit and ground
circuit.
• Check DLC cable. If necessary, check DLC
cable by substituting a known-good DLC
cable.
• Check CAN communication system.
(“Control Module Communication Bus Off”
is detected in any control module.) (Page
10H-15)
• Check CNG control module power circuit
and ground circuit. (Page 1A-363)
(A)
IJCA0A111011-01
5) After completing DTC clearance, set ignition “OFF”
and disconnect SUZUKI scan tool from DLC.
 Engine General Information and Diagnosis: Bi-Fuel CNG 1A-295

NOTE
DTC and freeze frame data stored in CNG
control module memory are also cleared in
the following cases. Be careful not to clear
them before recording them.
• When the same malfunction (DTC) is not
detected again for 40 engine warm-up
cycles (refer to Warm-Up Cycle of “OBD
System Description”: Bi-Fuel CNG (Page
1A-272).

DTC Table
AENJCA0A1134006
ECM
Other than DTC in the table below, refer to “DTC Table”: K10B (Page 1A-24).
DTC
DTC DTC name DTC detecting condition detection MIL
logic
Lost Communication With
U0108 (Page Receiving error of ECM from CNG control module
Alternative Fuel Control 1 D/C Lights up
1A-320) for specified time continuously.
Module

CNG Control Module

DTC CNG
DTC DTC name DTC detecting condition detection warning MIL
logic light
Measured signal of shut off valve of
CNG cylinder pressure regulator is
P0005 (Page Fuel Shutoff Valve “A”
high voltage for 5 sec. even if its 1 D/C Blinks Off
1A-321) Control Circuit/Open
command signal is low voltage and
CNG valve control relay is ON.
Measured signal of shut off valve of
CNG cylinder pressure regulator is low
P0007 (Page Fuel Shutoff Valve “A”
voltage for 5 sec. even if its command 1 D/C Blinks Off
1A-321) Control Circuit High
signal is high voltage and CNG valve
control relay is ON.
Voltage of CNG temperature sensor
P0182 (Page Fuel Temperature Sensor
signal circuit is lower than 0.1 V for 5 3 D/C Lights up Lights up
1A-324) “A” Circuit Low
sec.
Voltage of CNG temperature sensor
P0183 (Page Fuel Temperature Sensor
signal circuit is higher than 4.9 V for 5 3 D/C Lights up Lights up
1A-324) “A” Circuit High
sec.
P0192 (Page Fuel Rail Pressure Sensor Voltage of CNG pressure sensor signal
3 D/C Lights up Lights up
1A-326) “A” Circuit Low circuit is lower than 0.1 V for 5 sec.
P0193 (Page Fuel Rail Pressure Sensor Voltage of CNG pressure sensor signal
3 D/C Lights up Lights up
1A-326) “A” Circuit High circuit is higher than 4.9 V for 5 sec.
Measured voltage of CNG fuel injector
P0201 (Page Injector Circuit/Open -
No.1 is high voltage for 5 sec. even if 3 D/C Lights up Lights up
1A-328) Cylinder 1
its command signal is low voltage.
Measured voltage of CNG fuel injector
P0202 (Page Injector Circuit/Open -
No.2 is high voltage for 5 sec. even if 3 D/C Lights up Lights up
1A-328) Cylinder 2
its command signal is low voltage.
Measured voltage of CNG fuel injector
P0203 (Page Injector Circuit/Open -
No.3 is high voltage for 5 sec. even if 3 D/C Lights up Lights up
1A-328) Cylinder 3
its command signal is low voltage.
P0601 (Page Internal Control Module CNG control module internal failure
3 D/C Lights up Lights up
1A-331) Memory Check Sum Error related to check sum error.
1A-296 Engine General Information and Diagnosis: Bi-Fuel CNG

DTC CNG
DTC DTC name DTC detecting condition detection warning MIL
logic light
Any of the following conditions is met.
• Measured voltage of CNG valve
control relay is lower than specified
voltage for 3 sec. even if its
P0607 (Page Control Module
command signal is output. 1 D/C Blinks Off
1A-332) Performance
• Measured voltage of CNG valve
control relay is higher than specified
voltage for 3 sec. even if its
command signal is not output.
Any of the following conditions is met.
• Measured signal of either of fuel
control relays is “Petrol” side for 5
sec. with engine running on CNG.
P0612 (Page Fuel Injector Control • Measured signal of either of fuel 3 D/C Lights up Lights up
1A-334) Module Relay Control control relays is “CNG” side for 5
sec. with engine running on petrol.
• Petrol fuel injector is disconnected
or shorted to ground with engine
running on CNG.
P062F (Page Internal Control Module CNG control module internal failure
1 D/C Lights up Lights up
1A-337) EEPROM Error (EEPROM error)
Voltage of CNG cylinder pressure
P1432 (Page Remaining Fuel Sensor
sensor signal circuit is lower than 0.1 V 1 D/C Lights up Off
1A-338) Low Voltage
for 5 sec.
Voltage of CNG cylinder pressure
P1433 (Page Remaining Fuel Sensor
sensor signal circuit is higher than 4.9 1 D/C Lights up Off
1A-338) High Voltage
V for 5 sec.
Any of the following conditions is met.
• The state of changing over “Petrol”
to “CNG” is detected continuously
P1601 (Page
Monitor Circuit Fault for 5 sec. 3 D/C Blinks Lights up
1A-340)
• The state of changing over “CNG” to
“Petrol” is detected continuously for
5 sec.
Any of the following conditions is met.
• Both fuel filler lid switch No.1 and
P2408 (Page Fuel Cap Sensor/Switch No.2 ON signals are input for 5 sec.
3 D/C Lights up Off
1A-341) Circuit • Both fuel filler lid switch No.1 and
No.2 OFF signals are input for 5
sec.
Measured signal of shut off valve of
CNG cylinder is high voltage for 5 sec.
P2665 (Page Fuel Shutoff Valve “B”
even if its command signal is low 1 D/C Blinks Off
1A-343) Control Circuit/Open
voltage and CNG valve control relay is
ON.
Measured signal of shut off valve of
CNG cylinder is low voltage for 5 sec.
P2667 (Page Fuel Shutoff Valve “B”
even if its command signal is high 1 D/C Blinks Off
1A-343) Control Circuit High
voltage and CNG valve control relay is
ON.
P2668 (Page Fuel Mode Indicator Lamp Fuel select switch ON signal is input
1 D/C Lights up Off
1A-346) Control Circuit continuously for more than 120 sec.
CNG control module fails to transmit
U0073 (Page Control Module
and receive the data via CAN for 1 D/C Blinks Off
1A-347) Communication Bus Off
specified time continuously.
 Engine General Information and Diagnosis: Bi-Fuel CNG 1A-297

DTC CNG
DTC DTC name DTC detecting condition detection warning MIL
logic light
Receiving error of the data from ECM
U0100 (Page Lost Communication with
via CAN for specified time 1 D/C Blinks Lights up
1A-347) ECM
continuously.

Fail-Safe Table
AENJCA0A1134007
ECM
Other than DTC in the table below, refer to “Fail-Safe Table”: K10B (Page 1A-27).
DTC DTC name Fail-safe operation
U0108 (Page Lost Communication With Alternative
—
1A-320) Fuel Control Module

CNG Control Module

When any of the following DTCs is detected, CNG control module enters fail-safe mode as long as malfunction
continues to exist but that mode is canceled when CNG control module detects normal condition or ignition is “OFF”.

NOTE
When CNG control is stopped by fail-safe control, CNG warning light blinks.

DTC DTC name Fail-safe operation

P0005 (Page Fuel Shutoff Valve “A” Control Circuit/ • CNG control module closes shut off valve of CNG
1A-321) Open cylinder.
P0007 (Page Fuel Shutoff Valve “A” Control Circuit • CNG control module stops CNG control and then shifts
1A-321) High to “Petrol MODE”.
P0182 (Page
Fuel Temperature Sensor “A” Circuit Low
1A-324) CNG control module controls engine assuming that CNG
P0183 (Page temperature is 50 °C (122 °F).
Fuel Temperature Sensor “A” Circuit High
1A-324)
P0192 (Page Fuel Rail Pressure Sensor “A” Circuit
CNG control module controls engine assuming that CNG
1A-326) Low
fuel pressure is MAP (Manifold Absolute Pressure) + 190
P0193 (Page Fuel Rail Pressure Sensor “A” Circuit
KPa.
1A-326) High
P0201 (Page
Injector Circuit/Open - Cylinder 1 —
1A-328)
P0202 (Page
Injector Circuit/Open - Cylinder 2 —
1A-328)
P0203 (Page
Injector Circuit/Open - Cylinder 3 —
1A-328)
P0601 (Page Internal Control Module Memory Check
—
1A-331) Sum Error
P0607 (Page CNG control module stops CNG control and then shifts to
Control Module Performance
1A-332) “Petrol MODE”.
P0612 (Page Fuel Injector Control Module Relay
—
1A-334) Control
P062F (Page
Internal Control Module EEPROM Error —
1A-337)
P1432 (Page
Remaining Fuel Sensor Low Voltage
1A-338) CNG control module stops CNG residual quantity
P1433 (Page indication.
Remaining Fuel Sensor High Voltage
1A-338)
P1601 (Page CNG control module stops CNG control and then shifts to
Monitor Circuit Fault
1A-340) “Petrol MODE”.
P2408 (Page
Fuel Cap Sensor/Switch Circuit CNG control module stops “Fuel cut control”.
1A-341)
1A-298 Engine General Information and Diagnosis: Bi-Fuel CNG

DTC DTC name Fail-safe operation

P2665 (Page Fuel Shutoff Valve “B” Control Circuit/ • CNG control module closes shut off valve of CNG
1A-343) Open cylinder pressure regulator.
P2667 (Page Fuel Shutoff Valve “B” Control Circuit • CNG control module stops CNG control and then shifts
1A-343) High to “Petrol MODE”.
P2668 (Page
Fuel Mode Indicator Lamp Control Circuit —
1A-346)
U0073 (Page
Control Module Communication Bus Off
1A-347) CNG control module stops CNG control and then shifts to
U0100 (Page “Petrol MODE”.
Lost Communication with ECM
1A-347)

Scan Tool Data (ECM)

AENJCA0A1134008
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-8)

NOTE
• With the generic scan tool, only data 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, P/S and all the other switches.

Normal condition /
Scan tool data Vehicle condition
Reference value
–5 °C (23 °F) +
CNG/LPG Temperature environmental temperature
Engine: Idle speed after warming up
(Page 1A-301) to 40 °C (104 °F) +
environmental temperature
CNG/LPG Pressure (Page
Engine: Idle speed after warming up Approx. 200 to 265 KPa
1A-301)
Open loop (OL) control before satisfaction of closed
loop control conditions (ECT >10 °C, HO2S-1, IAT, TP OL
sensor / system = OK)
Open loop (OL) control due to driving conditions
OL-Drive
(Power enrichment, etc.)
Fuel System B1 (Page 1A-
* Open loop (OL) control due to fuel system failure OL-Fault
301)
Closed loop (CL) control using HO2S-1 as feedback
CL
sensors for fuel control
Closed loop (CL) control due to fuel system failure CL-Fault
Fuel select mode: Forced CNG MODE —
When engine stops with ignition “ON” —
Open loop (OL) control before satisfaction of closed
loop control conditions (ECT >10 °C, HO2S-1, IAT, TP OL
sensor / system = OK)
Open loop (OL) control due to driving conditions
OL-Drive
(Power enrichment, etc.)
Fuel System B2 (Page 1A-
* Open loop (OL) control due to fuel system failure OL-Fault
301)
Closed loop (CL) control using HO2S-1 as feedback
CL
sensors for fuel control
Closed loop (CL) control due to fuel system failure CL-Fault
Fuel select mode: Petrol MODE —
When engine stops with ignition “ON” —
 Engine General Information and Diagnosis: Bi-Fuel CNG 1A-299

Normal condition /
Scan tool data Vehicle condition
Reference value
Short Term Fuel Trim
* Engine: Idle speed after warming up Approx. –20 to 20%
(Page 1A-301)
Long Term Fuel Trim (Page
* Engine: Idle speed after warming up Approx. –20 to 20%
1A-301)
Total Fuel Trim (Page 1A-
Engine: Idle speed after warming up Approx. –30 to 30%
302)
Inj Pulse Width (Page 1A-
Engine: Idle speed with no load after warming up Approx. 1.6 to 4.0 msec
302)
Ignition Advance (Page
* Engine: Idle speed with no load after warming up 1 to 15° BTDC
1A-302)
Calculated Load (Page 1A-
* Engine: Idle speed with no load after warming up Approx. 20 to 40%
302)
Engine: Idle speed after warming up
Engine Speed (Page 1A- Radiator cooling fan: Stopped
* 650 to 750 rpm
302) All electrical equipment: OFF
Gear shift lever: Neutral position
Engine: Idle speed after warming up
Radiator cooling fan: Stopped
Desired Idle (Page 1A-302) 700 rpm
All electrical equipment: OFF
Gear shift lever: Neutral position
Vehicle Speed (Page 1A- Almost the same as
* Vehicle running
302) speedometer reading
* MAP (Page 1A-302) Engine: Idle speed after warming up Approx. 20 to 55 kPa
Approx. 80 to 105 °C (176
* ECT (Page 1A-302) Engine: Idle speed after warming up
– 221 °F)
Ambient air temperature –
Intake Air Temperature 5 °C (41 °F) to ambient air
* Engine: Idle speed after warming up
(Page 1A-302) temperature +40 °C (104
°F)
Barometric Pres (Page 1A- Barometric pressure is
* —
302) displayed.
EVAP Canist Prg Duty
* Engine: Idle speed after warming up 0%
(Page 1A-302)
Engine: Idle speed with no load after warming up Approx. 5 to 25%
IAC Throttle Opening Engine: Idle speed after warming up
(Page 1A-302) A/C switch: ON Approx. 20 to 50%
Blower speed selector: Max
Ignition: “ON”
0.8 to 1.0 V
TP Sensor 1 Volt (Page Accelerator pedal: Released
1A-302) Ignition: “ON”
4.3 to 4.5 V
Accelerator pedal: Fully depressed
Ignition: “ON”
4.0 to 4.2 V
TP Sensor 2 Volt (Page Accelerator pedal: Released
1A-302) Ignition: “ON”
0.5 to 0.7 V
Accelerator pedal: Fully depressed
Ignition: “ON”
0.7 to 0.8 V
APP Sensor 1 Voltage Accelerator pedal: Released
(Page 1A-302) Ignition: “ON”
4.35 to 4.45 V
Accelerator pedal: Fully depressed
Ignition: “ON”
0.37 to 0.38 V
APP Sensor 2 Voltage Accelerator pedal: Released
(Page 1A-302) Ignition: “ON”
2.15 to 2.25 V
Accelerator pedal: Fully depressed
Ignition: “ON”
0 to 2%
Accelerator Position (Page Accelerator pedal: Released
1A-302) Ignition: “ON”
90 to 100%
Accelerator pedal: Fully depressed
1A-300 Engine General Information and Diagnosis: Bi-Fuel CNG

Normal condition /
Scan tool data Vehicle condition
Reference value
Ignition: “ON”
0 to 10%
Throttle Position (Page 1A- Accelerator pedal: Released
302) Ignition: “ON”
90 to 100%
Accelerator pedal: Fully depressed
Ignition: “ON”
0 to 10%
Target Throttle Posi (Page Accelerator pedal: Released
*
1A-302) Ignition: “ON”
90 to 100%
Accelerator pedal: Fully depressed
* O2S B1 S1 (Page 1A-302) Engine: Idle speed for 2 min. after warming up Approx. 0 to 1.0 V
* O2S B1 S2 (Page 1A-302) Engine: 2,000 rpm for 3 min. or more after warming up Approx. 0 to 1.0 V
Battery Voltage (Page 1A-
* Engine: Idle speed Approx. 13 to 15 V
302)
Fuel Tank Level (Page 1A-
* Ignition: “ON” 0 to 100%
303)
Engine: Idle speed
A/C Pressure (Page 1A- A/C compressor: Operating
1,180 to 1,520 kPa
303) Blower speed selector: MAX position
Ambient temperature: 30 °C (86 °F)
Generator Field Duty
Engine: Idle speed after warming up Approx. 20 to 100%
(Page 1A-303)
Type of Fuel (Page 1A- Engine: Running on petrol Petrol
303) Engine: Running on CNG CNG
• Engine: Idle speed with no load after warming up
0 msec
Inj Pulse Width (CNG/LPG) • Fuel select mode: Petrol MODE
(Page 1A-303) • Engine: Idle speed with no load after warming up
Approx. 3.5 – 5.5 msec
• Fuel select mode: Forced CNG MODE
Fuel select mode: AUTO MODE Auto
Fuel Select Mode (Page
Fuel select mode: Petrol MODE Petrol
1A-303)
Fuel select mode: Forced CNG MODE Gas
Generator Reg Volt (Com)
Engine: Idle speed after warming up Approx. 10.7 V to 16.0 V
(Page 1A-303)
Radiator Fan (Page 1A- Radiator cooling fan: OFF OFF
303) Radiator cooling fan: ON ON
Engine: Running
A/C Comp Relay (Page A/C compressor: Operating ON
1A-303) Blower speed selector: ON
Other than above condition OFF
• Engine: Running
ON
Fuel Pump (Page 1A-303) • Fuel select mode: Petrol MODE
Other than above condition OFF
Starter Switch (Page 1A- Ignition: “ST” (engine cranking) ON
303) Other than above condition OFF
A/C switch: ON
ON
A/C Switch (Page 1A-303) Blower speed selector: ON
Other than above condition OFF
2nd or higher speed position ON
Blower Fan (Page 1A-303)
Other than above condition OFF
Brake Switch (Page 1A- Brake pedal: Depressed ON
303) Brake pedal: Released OFF
Electric Load (Page 1A- Headlight switch: ON ON
303) Headlight switch: OFF OFF
Clutch Switch (Page 1A- Clutch pedal: More than halfway depressed Declutch
303) Clutch pedal: Released Clutched
Engine: Idle speed after warming up OFF
Fuel Cut (Page 1A-303) Accelerator pedal: Released
ON
Engine: 2,000 rpm or more after warming up
 Engine General Information and Diagnosis: Bi-Fuel CNG 1A-301
Scan tool data
Ignition: “ON”
Closed Throttle Pos (Page Accelerator pedal: Released
1A-303) Ignition: “ON”
Accelerator pedal: Fully depressed
O2S B1 S1 Act (Page 1A-
Engine: Idle speed after warming up
303)
O2S B1 S2 Act (Page 1A-
Engine: Idle speed after warming up
303)
Starter Count Information
Ignition: “ON”
(Overrun) (Page 1A-303)
Starter Count Information
(Overcranking) (Page 1A- Ignition: “ON”
303)
Starter Count Information
Ignition: “ON”
(Inching) (Page 1A-303)
Starter Count Information
(Starter Relay Slow Ignition: “ON”
Response) (Page 1A-303)
Scan Tool Data Definitions
CNG/LPG Temperature (°C, °F)
CNG temperature sensor signal inputted into CNG
control module is calculated to physical value and is sent
to ECM via CAN.
CNG/LPG Pressure (kPa)
CNG temperature sensor signal inputted into CNG
control module is calculated to physical value and is sent
to ECM via CAN.
Fuel System B1 (Petrol fuel system status)
This parameter indicates the state of A/F feedback
control by ECM when the vehicle runs using petrol.
NOTE
• Open loop
Fuel injection time (volume) in the various
engines states is determined beforehand.
Information from HO2S-1 is not reflected to
CNG fuel injection control.
• Closed loop
Information from HO2S-1 is reflected to
fuel injection control. When ECM judges
that actual air-fuel ratio is higher than
stoichiometric air-fuel ratio, ECM controls
to increase the volume of fuel. On the
contrary, when the actual air-fuel ratio is
lower than stoichiometric air-fuel ratio,
ECM controls to decrease the volume of
fuel.
Fuel System B2 (CNG fuel system status)
This parameter indicates the state of A/F feedback
control by ECM when the vehicle runs using CNG.
Normal condition /
Vehicle condition
Reference value
ON
OFF
Active
Active
Starting motor overrun
counter
Starting motor
overcranking counter
Starting motor inching
counter
Starting motor control relay
slow response counter
NOTE
• Open loop
CNG fuel injection time (volume) in the
various engines states is determined
beforehand. Information from HO2S-1 is
not reflected to CNG fuel injection control.
• Closed loop
Information from HO2S-1 is reflected to
CNG fuel injection control. When ECM
judges that actual air-fuel ratio is higher
than stoichiometric air-fuel ratio, CNG
control module controls to increase the
volume of CNG fuel. On the contrary, when
the actual air-fuel ratio is lower than
stoichiometric air-fuel ratio, CNG control
module controls to decrease the volume of
CNG fuel.
Short Term Fuel Trim (%)
This parameter indicates short term fuel trim value (short
term air/fuel mixture correction factor) and changes the
value corresponding to driving conditions. 0 (zero)
indicates no correction, a value greater than 0 indicates
enrichment correction, and a value less than 0 indicates
enleanment correction.
Long Term Fuel Trim (%)
This parameter indicates a median value of short term
trim learned in A/F feedback control (closed loop). This
median value is used by ECM to correct fuel injection
volume appropriately in open loop control avoiding
interference caused by individual difference and aging. 0
(zero) indicates no correction, a value greater than 0
indicates enrichment correction, and a value less than 0
indicates enleanment correction.
1A-302 Engine General Information and Diagnosis: Bi-Fuel CNG
Total Fuel Trim (%)
This parameter indicates the comprehensive fuel trim
computed based on short term and long term fuel trim.
Inj Pulse Width (Fuel injection pulse width, msec.)
This parameter indicates the injector drive pulse width
(open time) during the injector valve stays open
commanded by ECM.
Ignition Advance (Ignition timing advance for No.1
cylinder, ° BTDC)
This parameter indicates the ignition timing of No.1
cylinder commanded by ECM.
Calculated Load (Calculated load value, %)
This parameter indicates the engine load calculated by
ECM based on input signals of various sensors as a
percentage.
Engine Speed (rpm)
The engine revolution speed is calculated based on the
input signal of CKP sensor.
Desired Idle (Desired idle speed, rpm)
This parameter indicates target engine idle speed
requested by ECM.
NOTE
When performing “Fixed Spark” in “Active
Test”, actual engine idle speed may not
follow target engine idle speed.
Vehicle Speed (km/h, mph)
This parameter indicates the vehicle speed based on
wheel speed sensors sent from ABS control module via
CAN communication.
MAP (Manifold absolute pressure, kPa, mmHg, inHg,
psi, inH2O)
This parameter indicates the calculated MAP based on
input voltage of MAP sensor.
ECT (Engine coolant temperature, °C, °F)
This parameter indicates the calculated ECT based on
input voltage of ECT sensor.
Intake Air Temperature. (°C, °F)
This parameter indicates the calculated IAT based on
input voltage of IAT sensor.
Barometric Pres (Barometric pressure, kPa, mmHg,
inHg, psi, inH2O)
This parameter represents barometric air pressure
measurement and is used for altitude correction of the
fuel injection rate.
EVAP Canist Prg Duty (EVAP canister purge flow
duty, %)
This parameter indicates valve ON (valve open) time
rate within a certain set cycle of EVAP canister purge
valve.
IAC Throttle Opening (Idle air throttle valve opening,
%)
This parameter indicates opening% of throttle valve on
the assumption that the maximum opening of idle air
control is100%.
TP Sensor 1 Volt (TP sensor (main) output voltage,
V)
This parameter indicates the input voltage of TP sensor
(main) installed in throttle body.
TP Sensor 2 Volt (TP sensor (sub) output voltage, V)
This parameter indicates the input voltage of TP sensor
(sub) installed in throttle body.
APP Sensor 1 Voltage (APP sensor (main) output
voltage, V)
This parameter indicates the input voltage of APP
sensor (main) installed in accelerator pedal.
APP Sensor 2 Voltage (APP sensor (sub) output
voltage, V)
This parameter indicates the input voltage of APP
sensor (sub) installed in accelerator pedal.
Accelerator Position (Absolute accelerator pedal
position, %)
This parameter indicates the depressing amount of
accelerator pedal that ECM calculated based on the
input signals of APP sensor (main and sub) in
percentage.
Throttle Position (Absolute throttle position, %)
This parameter indicates the calculated throttle valve
opening in percentage based on input signal from TP
sensor.
Target Throttle Posi (Target throttle valve position,
%)
This parameter indicates the target throttle position
requested by ECM.
O2S B1 S1 (HO2S-1, V)
This parameter indicates output voltage of HO2S-1
installed on exhaust manifold (pre-TWC).
O2S B1 S2 (HO2S-2, V)
This parameter indicates output voltage of HO2S-2
installed on exhaust manifold (post-TWC). It is used to
detect catalyst deterioration.
Battery Voltage (V)
This parameter indicates battery positive voltage
inputted from main relay to ECM.
 Engine General Information and Diagnosis: Bi-Fuel CNG 1A-303
Fuel Tank Level
This parameter indicates the information of fuel level
inputted via combination meter. The fuel level data is
provided as a percentage from 0 to 100%.
A/C Pressure (A/C refrigerant absolute pressure,
kPa, mmHg, inHg, psi, inH2O)
This parameter indicates A/C refrigerant pressure
calculated by ECM based on A/C refrigerant pressure
sensor voltage.
Generator Field Duty (%)
This parameter indicates operation rate (generation
condition) of generator using operation duty of generator
field coil.
Type of Fuel (Petrol / CNG)
This parameter indicates type of fuel injected now.
Inj Pulse Width (CNG/LPG) (Injection pulse width
(CNG), msec.)
This parameter indicates time of CNG injector drive
(valve opening) pulse outputted from CNG control
module.
Fuel Select Mode (Auto / Petrol / Gas)
This parameter indicates the information of fuel select
switch inputted into ECM via CNG control module.
Generator Reg Voltage (Com) (Generator regulated
voltage (Com) (V))
This parameter indicates commanded generator
regulated voltage.
Radiator Fan (Radiator cooling fan control relay, ON/
OFF)
This parameter indicates the state that ECM operates
radiator cooling fan relay.
A/C Comp Relay (A/C compressor relay, ON/OFF)
This parameter indicates the state that ECM operates A/
C compressor relay.
Fuel Pump (ON/OFF)
This parameter indicates the state that ECM operates
fuel pump relay.
Starter Switch (Starter switch, ON/OFF)
This parameter indicates state of starting motor control
relay output.
A/C Switch (ON/OFF)
This parameter indicates the state that ECM operates A/
C by request from BCM.
Blower Fan (ON/OFF)
This parameter indicates the signal state of the blower
fan motor inputted into ECM.
Brake Switch (ON/OFF)
This parameter indicates operating state of the brake
switch.
Electric Load (ON/OFF)
This parameter indicates the state of electric load signal
inputted into ECM.
Clutch Switch (Declutch / Clutched)
This parameter indicates operating state of CPP No.2
switch.
Fuel Cut (ON/OFF)
This parameter indicates the operating state of fuel cut.
Closed Throttle Pos (Closed throttle position, ON/
OFF)
This parameter monitors idle state for engine control.
O2S B1 S1 Act (HO2S-1, Active / Inactive)
This parameter indicates the activation condition of
HO2S-1.
O2S B1 S2 Act (HO2S-2, Active / Inactive)
This parameter indicates the activation condition of
HO2S-2.
Starter Count Information (Overrun) (times)
This parameter indicates the starter count information
(overrun).
Starter Count Information (Overcranking) (times)
This parameter indicates the starter count information
(overcranking).
Starter Count Information (Inching) (times)
This parameter indicates the starter count information
(Inching).
Starter Count Information (Starter Relay Slow
Response) (times)
This parameter indicates the starter count information
(starter relay slow response).
1A-304 Engine General Information and Diagnosis: Bi-Fuel CNG

Scan Tool Data (CNG Control Module)

AENJCA0A1134009
As the data values are standard values estimated on the basis of values obtained from the normally operating vehicles
by using a scan tool, use them as reference values. Even when the vehicle is in good condition, there may be cases
where the checked value does not fall within each specified data range. Therefore, judgment as abnormal should not
be made depending on these data alone.

NOTE
When checking the data with the engine running at idle or racing, be sure to place gear shift lever in
“Neutral” and apply the parking brake fully.

Normal condition /
Scan tool data Vehicle condition
Reference value
• Engine: Idle speed with no load after warming up
Approx. 1.5 – 4.5 msec
Inj Pulse Width #1 (Page • Fuel select mode: Petrol MODE
1A-305) • Engine: Idle speed with no load after warming up
Approx. 1.5 – 2.5 msec
• Fuel select mode: Forced CNG MODE
• Engine: Idle speed with no load after warming up
Approx. 1.5 – 4.5 msec
Inj Pulse Width #2 (Page • Fuel select mode: Petrol MODE
1A-305) • Engine: Idle speed with no load after warming up
Approx. 1.5 – 2.5 msec
• Fuel select mode: Forced CNG MODE
• Engine: Idle speed with no load after warming up
Approx. 1.5 – 4.5 msec
Inj Pulse Width #3 (Page • Fuel select mode: Petrol MODE
1A-305) • Engine: Idle speed with no load after warming up
Approx. 1.5 – 2.5 msec
• Fuel select mode: Forced CNG MODE
• Engine: Idle speed with no load after warming up
0 msec
Gas Inj Pulse Width #1 • Fuel select mode: Petrol MODE
(Page 1A-305) • Engine: Idle speed with no load after warming up
Approx. 3.5 – 5.5 msec
• Fuel select mode: Forced CNG MODE
• Engine: Idle speed with no load after warming up
0 msec
Gas Inj Pulse Width #2 • Fuel select mode: Petrol MODE
(Page 1A-305) • Engine: Idle speed with no load after warming up
Approx. 3.5 – 5.5 msec
• Fuel select mode: Forced CNG MODE
• Engine: Idle speed with no load after warming up
0 msec
Gas Inj Pulse Width #3 • Fuel select mode: Petrol MODE
(Page 1A-305) • Engine: Idle speed with no load after warming up
Approx. 3.5 – 5.5 msec
• Fuel select mode: Forced CNG MODE
Calculated Load (Page
Engine: Idle speed with no load after warming up Approx. 20 to 40%
1A-305)
Engine: Idle speed after warming up
Engine Speed (Page 1A-
All electrical parts: OFF Approx. 650 to 750 rpm
305)
Shift lever: Neutral position
Vehicle Speed (Page 1A-
Vehicle running Vehicle speed is displayed.
306)
MAP (Page 1A-306) Engine: Idle speed with no load after warming up Approx. 20 – 45 KPa
Approx. 80 – 100 °C (176 –
ECT (Page 1A-306) Engine: Idle speed after warming up
212 °F)
–5 °C (23 °F) +
Intake Air Temperature environmental temperature
Engine: Idle speed after warming up
(Page 1A-306) to 40 °C (104 °F) +
environmental temperature
• Engine: Stopped
Approx. 0%
Throttle Position (Page • Accelerator pedal: Released
1A-306) • Engine: Stopped
90 – 100%
• Accelerator pedal: Fully depressed
CNG/LPG Lack Counter
Ignition: “ON” CNG fuel shortage counter
(Page 1A-306)
 Engine General Information and Diagnosis: Bi-Fuel CNG 1A-305

Normal condition /
Scan tool data Vehicle condition
Reference value
Fuel select mode: AUTO MODE Auto
Fuel Select Mode (Page
Fuel select mode: Petrol MODE Petrol
1A-306)
Fuel select mode: Forced CNG MODE Gas
Fuel Running Status Engine: Running on petrol Petrol
(Page 1A-306) Engine: Running on CNG Gas
–5 °C (23 °F) +
CNG/LPG Temperature environmental temperature
Engine: Idle speed after warming up
(Page 1A-306) to 40 °C (104 °F) +
environmental temperature
CNG/LPG Pressure
Engine: Idle speed after warming up Approx. 200 to 265 KPa
(Page 1A-306)
CNG/LPG Inj Pressure
Engine: Idle speed after warming up Approx. 160 to 225 KPa
(Page 1A-306)
CNG Cylinder Pressure CNG fuel pressure in CNG
—
(Page 1A-306) cylinder is displayed.
Battery Voltage (Page
Engine: Idle speed Approx. 12 to 15 V
1A-306)
Ignition Switch (Page 1A-
Ignition: “ON” ON
306)
Fuel Select Switch (Page Fuel select switch: Pushed ON
1A-306) Fuel select switch: Not pushed OFF
Fuel Filler Lid SW 1 Fuel filler lid: Close ON
(Page 1A-306) Fuel filler lid: Open OFF
Fuel Filler Lid SW 2 Fuel filler lid: Close OFF
(Page 1A-306) Fuel filler lid: Open ON
Shut Off V Tank (Page Fuel select mode: Petrol MODE OFF
1A-306) Fuel select mode: Forced CNG MODE ON
Shut Off V Reg (Page Fuel select mode: Petrol MODE OFF
1A-306) Fuel select mode: Forced CNG MODE ON
• Engine: Stopped
Power Supply Relay OFF
(Page 1A-306) • Fuel select mode: Petrol MODE
Engine: Running ON

Scan Tool Data Definitions
Inj Pulse Width #1 (Fuel injection pulse width No.1,
msec.)
This parameter indicates the fuel injector No.1 drive
pulse width (time) commanded by ECM.
Gas Inj Pulse Width #2 (CNG injection pulse width
No.2, msec.)
This parameter indicates time of CNG fuel injector drive
(valve opening) pulse which is output from CNG control
module.

Inj Pulse Width #2 (Fuel injection pulse width No.2,
msec.)
This parameter indicates the fuel injector No.1 drive
pulse width (time) commanded by ECM.
Inj Pulse Width #3 (Fuel injection pulse width No.3,
msec.)
This parameter indicates the fuel injector No.1 drive
pulse width (time) commanded by ECM.
Gas Inj Pulse Width #1 (CNG injection pulse width
No.1, msec.)
This parameter indicates time of CNG fuel injector drive
(valve opening) pulse which is output from CNG control
module.
Gas Inj Pulse Width #3 (CNG injection pulse width
No.3, msec.)
This parameter indicates time of CNG fuel injector drive
(valve opening) pulse which is output from CNG control
module.
Calculated Load (Calculated load value, %)
This parameter indicates the percentage of engine load
calculated based on input signal to ECM from various
engine sensors.
Engine Speed (rpm)
This parameter indicates the calculated engine speed
based on reference pulses from the crankshaft position
sensor.
1A-306 Engine General Information and Diagnosis: Bi-Fuel CNG
Vehicle Speed (km/h, MPH)
This parameter indicates the vehicle speed based on
wheel speed sensors sent from ABS control module via
CAN communication.
MAP (Manifold absolute pressure, kPa, in.Hg, inH2O,
mmHg, psi)
This parameter indicates the calculated manifold
pressure based on MAP sensor signal.
ECT (Engine coolant temperature, °C, °F)
This parameter indicates the calculated engine coolant
temperature based on ECT sensor signal.
Intake Air Temperature (°C, °F)
This parameter indicates the calculated intake air
temperature based on IAT sensor signal.
Throttle Position (Absolute throttle position, %)
This parameter indicates the calculated opening
percentage of throttle valve based on signal voltage of
throttle position sensor.
CNG/LPG Lack Counter (Times)
This parameter indicates frequency of fuel shortage
which is output from CNG control module.
Fuel Select Mode (Auto / Petrol / Gas)
This parameter indicates the state of fuel select mode.
Fuel Running Status (Petrol / Gas)
This parameter indicates the state of fuel.
CNG/LPG Temperature (°C, °F)
This parameter indicates the calculated CNG
temperature based on CNG temperature sensor signal.
CNG/LPG Pressure (kPa)
This parameter indicates the calculated CNG pressure in
CNG fuel delivery pipe based on CNG pressure sensor
signal.
Visual Inspection
Visually check the following parts and systems.
Inspection Item
Level
Engine oil
Leakage
Level
Engine coolant
Leakage
Level
Fuel (Petrol)
Leakage
CNG/LPG Inj Pressure (CNG/LPG injection pressure
(kPa))
This parameter indicates the calculated CNG fuel
injector pressure based on CNG pressure sensor signal
and MAP sensor signal.
CNG Cylinder Pressure (kPa)
This parameter indicates the calculated CNG pressure in
CNG cylinder based on CNG cylinder pressure sensor
signal.
Battery Voltage (V)
This parameter indicates battery voltage inputted from
main relay to ECM.
Ignition Switch (ON / OFF)
This parameter indicates the state of ignition switch.
Fuel Select Switch (ON / OFF)
This parameter indicates the state of fuel select switch.
Fuel Filler Lid SW 1 (Fuel filler lid switch 1 (ON /
OFF))
This parameter indicates the state of fuel filler lid switch
(normal close side).
Fuel Filler Lid SW 2 (Fuel filler lid switch 2, ON /
OFF))
This parameter indicates the state of fuel filler lid switch
(normal open side).
Shut Off V Tank (Shut off valve tank, ON / OFF)
This parameter indicates the state of shut off valve of
CNG cylinder valve.
Shut Off V Reg (Shut off valve regulator, ON / OFF)
This parameter indicates the state of shut off valve of
CNG cylinder pressure regulator.
Power Supply Relay (CNG valve control relay) (ON /
OFF)
This parameter indicates the state of CNG valve control
relay.
AENJCA0A1134010
Referring section
“Engine Oil and Filter Change” in Section 0B
(Page 0B-5)
—
“Coolant Level Check”: K10B and Bi-Fuel CNG in
Section 1F (Page 1F-8)
“Engine Cooling System Inspection”: K10B and
Bi-Fuel CNG in Section 1F (Page 1F-8)
—
“Fuel Leakage Check Procedure”: Petrol in
Section 1G (Page 1G-20)
 Engine General Information and Diagnosis: Bi-Fuel CNG 1A-307

Inspection Item Referring section

Level —
Fuel (CNG) “Fuel Leakage Check Procedure”: Bi-Fuel CNG in
Leakage
Section 1G (Page 1G-56)
Manual valve Opened —
Dirt “Air Cleaner Filter Inspection and Cleaning”: K10B
Air cleaner filter
Clogging and Bi-Fuel CNG in Section 1D (Page 1D-6)
Fluid level “Battery Inspection”: K10B and Bi-Fuel CNG in
Battery
Corrosion of terminal Section 1J (Page 1J-4)
Tension “Water Pump / Generator Drive Belt Tension
Water pump belt Inspection and Adjustment”: K10B and Bi-Fuel
Damage
CNG in Section 1J (Page 1J-7)
“Electric Throttle Body Assembly Removal and
Installation Installation”: K10B and Bi-Fuel CNG in Section
1D (Page 1D-8)
Dirt “Electric Throttle Body Cleaning”: K10B and Bi-
Throttle
Clogging Fuel CNG in Section 1D (Page 1D-8)
“Electric Throttle Body On-Vehicle Inspection”:
Operation K10B and Bi-Fuel CNG in Section 1D (Page 1D-
7)
Disconnection —
Looseness —
Vacuum hoses of air intake system
Deterioration —
Bend —
Connectors of electric wire Disconnection —
harness Pinch —
Fuel filler lid Closed —
Fuses Burning —
Installation —
Parts
Deformation —
Bolt Looseness —

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

Inspection Item Referring section
MIL Operation “MIL Check”: Bi-Fuel CNG (Page 1A-293)
“CNG Warning Light Check”: Bi-Fuel CNG (Page
CNG warning light Operation
1A-293)
“Generator Symptom Diagnosis”: K10B and Bi-
Charging light Operation
Fuel CNG in Section 1J (Page 1J-4)
“Oil Pressure Switch On-Vehicle Inspection”:
Engine oil pressure light Operation
K10B and Bi-Fuel CNG in Section 1E (Page 1E-5)
Engine coolant temperature “ECT Sensor Inspection”: K10B and Bi-Fuel CNG
Operation
warning light in Section 1C (Page 1C-11)
“Fuel Level Sensor Inspection”: Petrol in Section
Fuel level sensor Operation
1G (Page 1G-32)
“Fuel Select Switch Inspection (Bi-Fuel CNG)”:
Fuel select switch Operation K10B and Bi-Fuel CNG in Section 1C (Page 1C-
18)
“Exhaust System Check”: K10B and Bi-Fuel CNG
Exhaust system Leakage of exhaust gas, noise
in Section 1K (Page 1K-1)
Abnormal air being inhaled at air intake system —
Other parts that can be checked visually —
1A-308 Engine General Information and Diagnosis: Bi-Fuel CNG

Engine Basic Inspection

AENJCA0A1134011
This check is very important for troubleshooting when ECM / CNG control module has detected no DTC and no
abnormality has been found in “Visual Inspection”: Bi-Fuel CNG (Page 1A-306).
Follow the flow carefully.
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: Bi-Fuel
CNG (Page 1A-291).
2 Check battery voltage Go to Step 3. Charge or replace
battery.
Is it 12 V or more?
3 Can engine be cranked? Go to Step 4. Go to “Cranking System
Symptom Diagnosis” in
Section 1I (Page 1I-3).
4 Check fuel select system Go to Step 5. Go to “Engine Symptom
1) Check each “Petrol MODE”, “AUTO MODE” and “Forced Diagnosis”: Bi-Fuel
CNG MODE” can be selected. (Page 1A-275) CNG (Page 1A-310).

Is check result OK?

5 Check engine starting system Go to Step 7. Go to Step 6.
1) Crank engine with “Petrol MODE” and “Forced CNG
MODE” respectively.

Does engine start on both petrol and CNG?

6 Does engine start on petrol or CNG? Engine starts on only Go to Step 10.
petrol: Go to Step 12.
Engine starts on only
CNG: Go to Step 15.
7 Check “AUTO MODE” operation Go to Step 8. Go to “Engine Symptom
1) Select “AUTO MODE”. Diagnosis”: Bi-Fuel
CNG (Page 1A-310).
2) Start engine.
3) Check that fuel mode switches from petrol to CNG
automatically.

Is check result OK?

8 Check idle speed Go to Step 9. Go to “Engine Symptom
1) Check engine idle speed, when engine running on each Diagnosis”: Bi-Fuel
of petrol and CNG. (Page 1A-365) CNG (Page 1A-310).

Is check result OK?

9 Check ignition system Go to “Engine Symptom Repair or replace
1) Check ignition system. (Page 1H-4) Diagnosis”: Bi-Fuel defective parts.
CNG (Page 1A-310).
Is check result OK?
10 Check fuel filler lid Go to Step 11. Fuel filler lid switch
1) Check that fuel filler lid is closed. malfunction.
2) Check fuel filler lid switch. (Page 1C-17)

Are they in good condition?

11 Check immobilizer system for operation Check for petrol system: Immobilizer control
1) Check immobilizer control system. (Page 10C-4) Go to Step 12. system malfunction.
Check for CNG system:
Is check result OK? Go to Step 15.
12 Check petrol fuel supply Go to Step 13. Repair or replace
1) Check petrol fuel supply. (Page 1G-29) defective parts.

Is check result OK?

 Engine General Information and Diagnosis: Bi-Fuel CNG 1A-309

Step Action Yes No

13 Check ignition system Go to Step 14. Repair or replace
1) Check ignition system. (Page 1H-4) defective parts.

Is check result OK?

14 Check petrol fuel injector circuit Go to “Engine Symptom Repair or replace
1) Check petrol fuel injector circuit referring to “Fuel Injector Diagnosis”: Bi-Fuel defective parts.
Circuit Check”: Petrol in Section 1G (Page 1G-7). CNG (Page 1A-310).

Is check result OK?

15 Check CNG fuel supply Go to Step 16. Refill CNG fuel.
1) Check that manual valve is opened.
2) Check to make sure that remaining CNG fuel is enough.
(Page 9C-1)

Are they in good condition?

16 Check shut off valve for operation Go to Step 17. Repair or replace
1) Check shut off valve operation. defective parts.
• Shut off valve of CNG cylinder pressure regulator:
(Page 1G-69)
• Shut off valve of CNG cylinder valve: (Page 1G-73)

Are they in good condition?

17 Check ignition system Go to Step 18. Repair or replace
1) Check ignition system. (Page 1H-4) defective parts.

Is check result OK?

18 Check CNG fuel injector circuit Go to “Engine Symptom Repair or replace
1) Check CNG fuel injector circuit referring to “Fuel Injector Diagnosis”: Bi-Fuel defective parts.
Circuit Check”: Bi-Fuel CNG in Section 1G (Page 1G- CNG (Page 1A-310)
41).

Is check result OK?

1A-310 Engine General Information and Diagnosis: Bi-Fuel CNG
Engine Symptom Diagnosis
Perform troubleshooting referring to the following when ECM has detected no DTC and no abnormality has been
found in “Visual Inspection”: Bi-Fuel CNG (Page 1A-306) and “Engine Basic Inspection”: Bi-Fuel CNG (Page 1A-308).
Condition Possible cause
Hard starting (Engine can Faulty spark plug
be cranked)
Faulty ignition coil assembly
Dirty or clogged petrol and/or CNG fuel “Fuel Pressure Check”: Bi-Fuel CNG in
hose or pipe
Malfunctioning fuel pump
Faulty petrol fuel injector(s) (Petrol “Fuel Injector Circuit Check”: Bi-Fuel CNG in
MODE or AUTO MODE)
Faulty CNG fuel injector(s) (Forced
CNG MODE)
Air drawn in through intake manifold
gasket or throttle body gasket
Faulty electric throttle body assembly “Electric Throttle Body Assembly On-Vehicle
Faulty APP sensor
Faulty ECT sensor or MAP sensor
Faulty ECM
Faulty CNG control module
Low compression
Poor spark plug tightening or faulty
gasket
Compression leak from valve seat
Sticky valve stem
Weak or damaged valve springs
Compression leak at cylinder head
gasket
Sticky or damaged piston ring
Worn piston, piston ring or cylinder
Malfunctioning PCV valve
AENJCA0A1134012
Correction / Reference Item
“Spark Plug Inspection”: K10B and Bi-Fuel
CNG in Section 1H (Page 1H-7)
“Ignition Coil Assembly Inspection”: K10B and
Bi-Fuel CNG in Section 1H (Page 1H-7)
Section 1G (Page 1G-46)
“Fuel Pump and Its Circuit Check”: Petrol in
Section 1G (Page 1G-10)
Section 1G (Page 1G-41)
“Fuel Injector Circuit Check”: Bi-Fuel CNG in
Section 1G (Page 1G-41)
Check air intake system.
Inspection”: K10B and Bi-Fuel CNG in Section
1C (Page 1C-5)
“APP Sensor On-Vehicle Inspection”: K10B
and Bi-Fuel CNG in Section 1C (Page 1C-7)
“ECT Sensor Inspection”: K10B and Bi-Fuel
CNG in Section 1C (Page 1C-11) or “MAP
Sensor Inspection”: K10B and Bi-Fuel CNG in
Section 1C (Page 1C-9)
“Inspection of ECM and Its Circuits”: Bi-Fuel
CNG (Page 1A-347)
“Inspection of CNG Control Module and Its
Circuit”: Bi-Fuel CNG (Page 1A-358)
“Compression Check”: K10B and Bi-Fuel CNG
in Section 1D (Page 1D-1)
“Spark Plug Removal and Installation”: K10B
and Bi-Fuel CNG in Section 1H (Page 1H-7)
“Valve and Valve Guide Inspection”: K10B and
Bi-Fuel CNG in Section 1D (Page 1D-45)
“Valve and Valve Guide Inspection”: K10B and
Bi-Fuel CNG in Section 1D (Page 1D-45)
“Valve Spring Inspection”: K10B and Bi-Fuel
CNG in Section 1D (Page 1D-48)
“Cylinder Head Inspection”: K10B and Bi-Fuel
CNG in Section 1D (Page 1D-47)
“Cylinder, Piston and Piston Ring Inspection”:
K10B and Bi-Fuel CNG in Section 1D (Page
1D-53)
“Cylinder, Piston and Piston Ring Inspection”:
K10B and Bi-Fuel CNG in Section 1D (Page
1D-53)
“PCV Valve Inspection”: K10B and Bi-Fuel
CNG in Section 1B (Page 1B-7)
 Engine General Information and Diagnosis: Bi-Fuel CNG 1A-311

Condition Possible cause Correction / Reference Item

Low oil pressure Improper oil viscosity
Malfunctioning oil pressure switch
Clogged oil strainer
Functional deterioration of oil pump
Worn oil pump relief valve
Excessive clearance in various sliding
parts
Engine noise – Valve Improper valve clearance
noise
Worn valve stem and guide
NOTE
Before checking Weak or broken valve spring
mechanical noise, make
sure that: Warped or bent valve
• Specified spark plug is
used.
• Specified fuel is used.
“Engine Oil and Filter Change” in Section 0B
(Page 0B-5)
“Oil Pressure Switch On-Vehicle Inspection”:
K10B and Bi-Fuel CNG in Section 1E (Page
1E-5)
Check oil strainer for clog.
“Oil Pump Inspection”: K10B and Bi-Fuel CNG
in Section 1E (Page 1E-13)
“Oil Pump Inspection”: K10B and Bi-Fuel CNG
in Section 1E (Page 1E-13)
—
“Camshaft and Tappet Inspection”: K10B and
Bi-Fuel CNG in Section 1D (Page 1D-19)
“Valve and Valve Guide Inspection”: K10B and
Bi-Fuel CNG in Section 1D (Page 1D-45)
“Valve Spring Inspection”: K10B and Bi-Fuel
CNG in Section 1D (Page 1D-48)
“Valve and Valve Guide Inspection”: K10B and
Bi-Fuel CNG in Section 1D (Page 1D-45)

Engine noise – Piston, Worn piston, piston ring and cylinder “Cylinder, Piston and Piston Ring Inspection”:
piston ring and cylinder bore K10B and Bi-Fuel CNG in Section 1D (Page
noise 1D-53)

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

Engine noise – Worn piston, piston ring and cylinder “Cylinder, Piston and Piston Ring Inspection”:
Connecting rod noise bore K10B and Bi-Fuel CNG in Section 1D (Page
1D-53)
NOTE Worn connecting rod bearing “Crankshaft Pin and Connecting Rod Bearing
Before checking Inspection”: K10B and Bi-Fuel CNG in Section
mechanical noise, make 1D (Page 1D-56)
sure that: Worn crank pin “Crankshaft Pin and Connecting Rod Bearing
• Specified spark plug is Inspection”: K10B and Bi-Fuel CNG in Section
used. 1D (Page 1D-56)
Loose connecting rod bolts “Piston, Piston Ring and Connecting Rod
• Specified fuel is used.
Removal and Installation”: K10B and Bi-Fuel
CNG in Section 1D (Page 1D-50)
Low oil pressure Condition “Low oil pressure”
1A-312 Engine General Information and Diagnosis: Bi-Fuel CNG
Condition Possible cause
Engine noise – Low oil pressure
Crankshaft noise Worn main bearing
NOTE Worn crankshaft journal
Before checking
mechanical noise, make Loose bearing cap bolts
sure that:
• Specified spark plug is
used. Excessive crankshaft thrust play
• Specified fuel is used.
Engine overheating Inoperative thermostat
Poor water pump performance
Clogged or leaky radiator
Improper engine oil grade
Clogged oil filter or oil strainer
Poor oil pump performance
Faulty radiator cooling fan control
system
Dragging brakes
Slipping clutch
Blown cylinder head gasket
Air mixed in cooling system
Correction / Reference Item
Condition “Low oil pressure”
“Main Bearing Inspection”: K10B and Bi-Fuel
CNG in Section 1D (Page 1D-63)
“Crankshaft Inspection”: K10B and Bi-Fuel
CNG in Section 1D (Page 1D-63)
“Main Bearing, Crankshaft and Cylinder Block
Removal and Installation”: K10B and Bi-Fuel
CNG in Section 1D (Page 1D-60)
“Crankshaft Inspection”: K10B and Bi-Fuel
CNG in Section 1D (Page 1D-63)
“Thermostat Inspection”: K10B and Bi-Fuel
CNG in Section 1F (Page 1F-11)
“Water Pump Inspection”: K10B and Bi-Fuel
CNG in Section 1F (Page 1F-16)
“Radiator On-Vehicle Inspection and
Cleaning”: K10B and Bi-Fuel CNG in Section
1F (Page 1F-15)
“Engine Oil and Filter Change” in Section 0B
(Page 0B-5)
“Oil Pressure Check”: K10B and Bi-Fuel CNG
in Section 1E (Page 1E-3)
“Oil Pressure Check”: K10B and Bi-Fuel CNG
in Section 1E (Page 1E-3)
“Radiator Cooling Fan System Check”: K10B
and Bi-Fuel CNG in Section 1F (Page 1F-5)
Condition “Dragging brakes” in “Brake
Symptom Diagnosis” in Section 4A (Page 4A-
2)
Condition “Slipping clutch” in “Clutch System
Symptom Diagnosis” in Section 5C (Page 5C-
1)
“Cylinder Head Inspection”: K10B and Bi-Fuel
CNG in Section 1D (Page 1D-47)
“Cooling System Refilling”: K10B and Bi-Fuel
CNG in Section 1F (Page 1F-9)
 Engine General Information and Diagnosis: Bi-Fuel CNG 1A-313

Condition Possible cause Correction / Reference Item

Poor fuel mileage Faulty spark plug (improper gap, heavy “Spark Plug Inspection”: K10B and Bi-Fuel
deposits and burned electrodes, etc.) CNG in Section 1H (Page 1H-7)
High idle speed Condition “Improper engine idling or engine
fails to idle”
Poor performance of ECT sensor or “ECT Sensor Inspection”: K10B and Bi-Fuel
MAP sensor CNG in Section 1C (Page 1C-11) or “MAP
Sensor Inspection”: K10B and Bi-Fuel CNG in
Section 1C (Page 1C-9)
Faulty electric throttle body assembly “Electric Throttle Body Assembly On-Vehicle
Inspection”: K10B and Bi-Fuel CNG in Section
1C (Page 1C-5)
Faulty APP sensor “APP Sensor On-Vehicle Inspection”: K10B
and Bi-Fuel CNG in Section 1C (Page 1C-7)
Faulty petrol fuel injector(s) and/or CNG “Fuel Injector Circuit Check”: Bi-Fuel CNG in
fuel injector(s) Section 1G (Page 1G-41)
Faulty ECM “Inspection of ECM and Its Circuits”: Bi-Fuel
CNG (Page 1A-347)
Faulty CNG control module “Inspection of CNG Control Module and Its
Circuit”: Bi-Fuel CNG (Page 1A-358)
Low compression “Compression Check”: K10B and Bi-Fuel CNG
in Section 1D (Page 1D-1)
Poor valve seating “Valve and Valve Guide Inspection”: K10B and
Bi-Fuel CNG in Section 1D (Page 1D-45)
Dragging brakes Condition “Dragging brakes” in “Brake
Symptom Diagnosis” in Section 4A (Page 4A-
2)
Slipping clutch Condition “Slipping clutch” in “Clutch System
Symptom Diagnosis” in Section 5C (Page 5C-
1)
Thermostat out of order “Thermostat Inspection”: K10B and Bi-Fuel
CNG in Section 1F (Page 1F-11)
Improper tire pressure “Tire Description” in Section 2D (Page 2D-1)
Fuel pressure out of specification “Fuel Pressure Basic Check”: Bi-Fuel CNG in
Section 1G (Page 1G-47)
Excessive engine oil Blown cylinder head gasket “Cylinder Head Inspection”: K10B and Bi-Fuel
consumption – Oil CNG in Section 1D (Page 1D-47)
leakage Leaky crankshaft pulley oil seal “Camshaft and Tappet Inspection”: K10B and
Bi-Fuel CNG in Section 1D (Page 1D-19)
Leaky crankshaft rear oil seal “Main Bearing, Crankshaft and Cylinder Block
Removal and Installation”: K10B and Bi-Fuel
CNG in Section 1D (Page 1D-60)
Leaky cylinder head cover gasket “Cylinder Head Cover Components”: K10B
and Bi-Fuel CNG in Section 1D (Page 1D-10)
Excessive engine oil Sticky piston ring “Cylinder, Piston and Piston Ring Inspection”:
consumption – Oil K10B and Bi-Fuel CNG in Section 1D (Page
entering combustion 1D-53)
chamber Worn piston and cylinder “Cylinder, Piston and Piston Ring Inspection”:
K10B and Bi-Fuel CNG in Section 1D (Page
1D-53)
Worn piston ring groove and ring “Cylinder, Piston and Piston Ring Inspection”:
K10B and Bi-Fuel CNG in Section 1D (Page
1D-53)
Improper location of piston ring gap “Piston, Piston Ring and Connecting Rod
Disassembly and Reassembly”: K10B and Bi-
Fuel CNG in Section 1D (Page 1D-52)
Worn or damaged valve stem seal “Valve and Valve Guide Inspection”: K10B and
Bi-Fuel CNG in Section 1D (Page 1D-45)
Worn valve stem and guide “Valve and Valve Guide Inspection”: K10B and
Bi-Fuel CNG in Section 1D (Page 1D-45)
1A-314 Engine General Information and Diagnosis: Bi-Fuel CNG

Condition Possible cause Correction / Reference Item

Engine hesitates – Spark plug faulty or plug gap out of
Momentary lack of adjustment
response as accelerator Petrol and/or CNG fuel pressure out of
is depressed. Can occur specification
at all vehicle speeds. Poor performance of ECT sensor or
Usually most severe when MAP sensor
first trying to move
vehicle, such as from a
stop sign Faulty electric throttle body assembly
Faulty APP sensor
Faulty petrol fuel injector(s) and/or CNG “Fuel Injector Circuit Check”: Bi-Fuel CNG in
fuel injector(s)
Faulty ECM
Faulty CNG control module
Engine overheating
Low compression
Surge – Engine power Faulty spark plug (excess carbon
variation under steady deposits, improper gap, burned
throttle or cruise. Vehicle electrodes, etc.)
speed changes up and Variable petrol and/or CNG fuel
down with no change in pressure
accelerator pedal Kinky or damaged petrol and/or CNG
fuel lines
Faulty fuel pump (clogged fuel suction “Fuel Pump Inspection”: Bi-Fuel CNG in
filter)
Poor performance of MAP sensor
Faulty petrol fuel injector(s) and/or CNG “Fuel Injector Circuit Check”: Bi-Fuel CNG in
fuel injector(s)
Faulty ECM
Faulty CNG control module
Faulty electric throttle body assembly
Faulty APP sensor
“Spark Plug Inspection”: K10B and Bi-Fuel
CNG in Section 1H (Page 1H-7)
“Fuel Pressure Basic Check”: Bi-Fuel CNG in
Section 1G (Page 1G-47)
“ECT Sensor Inspection”: K10B and Bi-Fuel
CNG in Section 1C (Page 1C-11) or “MAP
Sensor Inspection”: K10B and Bi-Fuel CNG in
Section 1C (Page 1C-9)
“Electric Throttle Body Assembly On-Vehicle
Inspection”: K10B and Bi-Fuel CNG in Section
1C (Page 1C-5)
“APP Sensor On-Vehicle Inspection”: K10B
and Bi-Fuel CNG in Section 1C (Page 1C-7)
Section 1G (Page 1G-41)
“Inspection of ECM and Its Circuits”: Bi-Fuel
CNG (Page 1A-347)
“Inspection of CNG Control Module and Its
Circuit”: Bi-Fuel CNG (Page 1A-358)
Condition “Engine overheating”
“Compression Check”: K10B and Bi-Fuel CNG
in Section 1D (Page 1D-1)
“Spark Plug Inspection”: K10B and Bi-Fuel
CNG in Section 1H (Page 1H-7)
“Fuel Pressure Check”: Bi-Fuel CNG in
Section 1G (Page 1G-46)
“Fuel Line On-Vehicle Inspection”: Bi-Fuel
CNG in Section 1G (Page 1G-58)
Section 1G (Page 1G-73)
“MAP Sensor Inspection”: K10B and Bi-Fuel
CNG in Section 1C (Page 1C-9)
Section 1G (Page 1G-41)
“Inspection of ECM and Its Circuits”: Bi-Fuel
CNG (Page 1A-347)
“Inspection of CNG Control Module and Its
Circuit”: Bi-Fuel CNG (Page 1A-358)
“Electric Throttle Body Assembly On-Vehicle
Inspection”: K10B and Bi-Fuel CNG in Section
1C (Page 1C-5)
“APP Sensor On-Vehicle Inspection”: K10B
and Bi-Fuel CNG in Section 1C (Page 1C-7)
 Engine General Information and Diagnosis: Bi-Fuel CNG 1A-315

Condition Possible cause Correction / Reference Item

Excessive detonation – Faulty spark plug “Spark Plug Inspection”: K10B and Bi-Fuel
Engine continuously CNG in Section 1H (Page 1H-7)
generates sharp, metallic Engine overheating Condition “Engine overheating”
knocking sound that Clogged petrol fuel filter or petrol fuel“Fuel Pressure Check”: Bi-Fuel CNG in
changes with throttle lines Section 1G (Page 1G-46)
opening. Clogged CNG fuel filter or CNG fuel “Fuel Pressure Check”: Bi-Fuel CNG in
lines Section 1G (Page 1G-46)
Air drawn in through intake manifold or Check air intake system.
throttle body gasket
Poor performance of knock sensor, ECT “Knock Sensor On-Vehicle Inspection”: K10B
sensor or MAP sensor and Bi-Fuel CNG in Section 1C (Page 1C-14),
“ECT Sensor Inspection”: K10B and Bi-Fuel
CNG in Section 1C (Page 1C-11) or “MAP
Sensor Inspection”: K10B and Bi-Fuel CNG in
Section 1C (Page 1C-9)
Faulty petrol fuel injector(s) and/or CNG “Fuel Injector Circuit Check”: Bi-Fuel CNG in
fuel injector(s) Section 1G (Page 1G-41)
Faulty ECM “Inspection of ECM and Its Circuits”: Bi-Fuel
CNG (Page 1A-347)
Faulty CNG control module “Inspection of CNG Control Module and Its
Circuit”: Bi-Fuel CNG (Page 1A-358)
Excessive combustion chamber “Cylinder Head Inspection”: K10B and Bi-Fuel
deposits CNG in Section 1D (Page 1D-47) and
“Cylinder, Piston and Piston Ring Inspection”:
K10B and Bi-Fuel CNG in Section 1D (Page
1D-53)
Petrol fuel pressure out of specification “Fuel Pressure Check”: Bi-Fuel CNG in
– Dirty petrol fuel filter Section 1G (Page 1G-46)
– Dirty or clogged petrol fuel hose or
pipe
– Faulty petrol fuel pressure regulator
– Faulty fuel pump
CNG fuel pressure out of specification “Fuel Pressure Check”: Bi-Fuel CNG in
– Dirty CNG fuel filter Section 1G (Page 1G-46)
– Dirty or clogged CNG fuel hose or pipe
– Faulty CNG cylinder pressure
regulator
1A-316 Engine General Information and Diagnosis: Bi-Fuel CNG

Condition Possible cause Correction / Reference Item

Engine has no power Faulty spark plug “Spark Plug Inspection”: K10B and Bi-Fuel
CNG in Section 1H (Page 1H-7)
Faulty ignition coil assembly “Ignition Coil Assembly Inspection”: K10B and
Bi-Fuel CNG in Section 1H (Page 1H-7)
Faulty knock sensor “Knock Sensor On-Vehicle Inspection”: K10B
and Bi-Fuel CNG in Section 1C (Page 1C-14)
Clogged petrol and/or CNG fuel hose or “Fuel Pressure Check”: Bi-Fuel CNG in
pipe Section 1G (Page 1G-46)
Malfunctioning fuel pump “Fuel Pump and Its Circuit Check”: Bi-Fuel
CNG in Section 1G (Page 1G-46)
Air drawn in through intake manifold Check air intake system.
gasket or throttle body gasket
Engine overheating Condition “Engine overheating”
Poor performance of ECT sensor or “ECT Sensor Inspection”: K10B and Bi-Fuel
MAP sensor CNG in Section 1C (Page 1C-11) or “MAP
Sensor Inspection”: K10B and Bi-Fuel CNG in
Section 1C (Page 1C-9)
Faulty electric throttle body assembly “Electric Throttle Body Assembly On-Vehicle
Inspection”: K10B and Bi-Fuel CNG in Section
1C (Page 1C-5)
Faulty APP sensor “APP Sensor On-Vehicle Inspection”: K10B
and Bi-Fuel CNG in Section 1C (Page 1C-7)
Faulty petrol fuel injector(s) and/or CNG “Fuel Injector Circuit Check”: Bi-Fuel CNG in
fuel injector(s) Section 1G (Page 1G-41)
Faulty ECM “Inspection of ECM and Its Circuits”: Bi-Fuel
CNG (Page 1A-347)
Faulty CNG control module “Inspection of CNG Control Module and Its
Circuit”: Bi-Fuel CNG (Page 1A-358)
Dragging brakes Condition “Dragging brakes” in “Brake
Symptom Diagnosis” in Section 4A (Page 4A-
2)
Slipping clutch Condition “Slipping clutch” in “Clutch System
Symptom Diagnosis” in Section 5C (Page 5C-
1)
Low compression “Compression Check”: K10B and Bi-Fuel CNG
in Section 1D (Page 1D-1)
 Engine General Information and Diagnosis: Bi-Fuel CNG 1A-317

Condition Possible cause Correction / Reference Item

Improper engine idling or Faulty spark plug “Spark Plug Inspection”: K10B and Bi-Fuel
engine fails to idle CNG in Section 1H (Page 1H-7)
Faulty ignition coil assembly “Ignition Coil Assembly Inspection”: K10B and
Bi-Fuel CNG in Section 1H (Page 1H-7)
Petrol and/or CNG fuel pressure out of “Fuel Pressure Check”: Bi-Fuel CNG in
specification Section 1G (Page 1G-46)
Leaky manifold, throttle body, or cylinder Check air intake system.
head gasket
Faulty evaporative emission control “EVAP Canister Purge System Inspection”:
system K10B and Bi-Fuel CNG in Section 1B (Page
1B-1)
Faulty petrol fuel injector(s) and/or CNG “Fuel Injector Circuit Check”: Bi-Fuel CNG in
fuel injector(s) Section 1G (Page 1G-41)
Poor performance of ECT sensor or “ECT Sensor Inspection”: K10B and Bi-Fuel
MAP sensor CNG in Section 1C (Page 1C-11) or “MAP
Sensor Inspection”: K10B and Bi-Fuel CNG in
Section 1C (Page 1C-9)
Faulty electric throttle body assembly “Electric Throttle Body Assembly On-Vehicle
Inspection”: K10B and Bi-Fuel CNG in Section
1C (Page 1C-5)
Faulty APP sensor “APP Sensor On-Vehicle Inspection”: K10B
and Bi-Fuel CNG in Section 1C (Page 1C-7)
Faulty ECM “Inspection of ECM and Its Circuits”: Bi-Fuel
CNG (Page 1A-347)
Faulty CNG control module “Inspection of CNG Control Module and Its
Circuit”: Bi-Fuel CNG (Page 1A-358)
Loose connection or disconnection of Check connection or disconnection of vacuum
vacuum hoses hoses.
Malfunctioning PCV valve “PCV Valve Inspection”: K10B and Bi-Fuel
CNG in Section 1B (Page 1B-7)
Engine overheating Condition “Engine overheating”
Low compression “Compression Check”: K10B and Bi-Fuel CNG
in Section 1D (Page 1D-1)
Faulty generator and/or its circuit “Generator Test”: K10B and Bi-Fuel CNG in
Section 1J (Page 1J-5)
1A-318 Engine General Information and Diagnosis: Bi-Fuel CNG

Condition Possible cause Correction / Reference Item

Excessive hydrocarbon Faulty spark plug “Spark Plug Inspection”: K10B and Bi-Fuel
(HC) or carbon monoxide CNG in Section 1H (Page 1H-7)
(CO) emission Faulty ignition coil assembly “Ignition Coil Assembly Inspection”: K10B and
Bi-Fuel CNG in Section 1H (Page 1H-7)
Low compression “Compression Check”: K10B and Bi-Fuel CNG
in Section 1D (Page 1D-1)
Lead contamination of three way Check for absence of filler neck restrictor.
catalytic converter
Faulty evaporative emission control “EVAP Canister Purge System Inspection”:
system K10B and Bi-Fuel CNG in Section 1B (Page
1B-1)
Petrol and/or CNG fuel pressure out of “Fuel Pressure Basic Check”: Bi-Fuel CNG in
specification Section 1G (Page 1G-47)
Faulty electric throttle body assembly “Electric Throttle Body Assembly On-Vehicle
Inspection”: K10B and Bi-Fuel CNG in Section
1C (Page 1C-5)
Faulty APP sensor “APP Sensor On-Vehicle Inspection”: K10B
and Bi-Fuel CNG in Section 1C (Page 1C-7)
Faulty petrol fuel injector(s) and/or CNG “Fuel Injector Circuit Check”: Bi-Fuel CNG in
fuel injector(s) Section 1G (Page 1G-41)
Faulty ECM “Inspection of ECM and Its Circuits”: Bi-Fuel
CNG (Page 1A-347)
Faulty CNG control module “Inspection of CNG Control Module and Its
Circuit”: Bi-Fuel CNG (Page 1A-358)
Engine not at normal operating —
temperature
Clogged air cleaner “Air Cleaner Filter Inspection and Cleaning”:
K10B and Bi-Fuel CNG in Section 1D (Page
1D-6)
Vacuum leak “Engine Vacuum Check”: K10B and Bi-Fuel
CNG in Section 1D (Page 1D-2)
Excessive nitrogen Improper ignition timing “Ignition Timing Inspection”: K10B and Bi-Fuel
oxides (NOx) emission CNG in Section 1H (Page 1H-8)
Lead contamination of three-way Check for absence of filler neck restrictor.
catalytic converter
Petrol and/or CNG fuel pressure out of “Fuel Pressure Basic Check”: Bi-Fuel CNG in
specification Section 1G (Page 1G-47)
Faulty electric throttle body assembly “Electric Throttle Body Assembly On-Vehicle
Inspection”: K10B and Bi-Fuel CNG in Section
1C (Page 1C-5)
Faulty APP sensor “APP Sensor On-Vehicle Inspection”: K10B
and Bi-Fuel CNG in Section 1C (Page 1C-7)
Faulty petrol fuel injector(s) and/or CNG “Fuel Injector Circuit Check”: Bi-Fuel CNG in
fuel injector(s) Section 1G (Page 1G-41)
Faulty ECM “Inspection of ECM and Its Circuits”: Bi-Fuel
CNG (Page 1A-347)
Faulty CNG control module “Inspection of CNG Control Module and Its
Circuit”: Bi-Fuel CNG (Page 1A-358)
 Engine General Information and Diagnosis: Bi-Fuel CNG 1A-319

Condition Possible cause Correction / Reference Item

Unusable CNG (“AUTO Faulty shut off valve of CNG cylinder “CNG Cylinder with Valve On-Vehicle
MODE” or “Forced CNG valve Inspection”: Bi-Fuel CNG in Section 1G (Page
MODE” can not be 1G-73)
selected) Faulty shut off valve of CNG cylinder “CNG Pressure Regulator Inspection”: Bi-Fuel
pressure regulator CNG in Section 1G (Page 1G-69)
Faulty fuel select switch “Fuel Select Switch Inspection (Bi-Fuel CNG)”:
K10B and Bi-Fuel CNG in Section 1C (Page
1C-18)
Faulty CNG valve control relay Check CNG valve control relay
Faulty ECM “Inspection of ECM and Its Circuits”: Bi-Fuel
CNG (Page 1A-347)
Faulty CNG control module “Inspection of CNG Control Module and Its
Circuit”: Bi-Fuel CNG (Page 1A-358)
Unusable CNG (Fuel can Faulty IAT sensor “IAT Sensor Inspection”: K10B and Bi-Fuel
not change over to CNG CNG in Section 1C (Page 1C-15)
in “AUTO MODE”) Faulty ECT sensor “ECT Sensor Inspection”: K10B and Bi-Fuel
CNG in Section 1C (Page 1C-11)
Faulty electric throttle body assembly “Electric Throttle Body Assembly On-Vehicle
Inspection”: K10B and Bi-Fuel CNG in Section
1C (Page 1C-5)
Faulty HO2S “HO2S On-Vehicle Inspection”: K10B and Bi-
Fuel CNG in Section 1C (Page 1C-11)
Faulty ECM “Inspection of ECM and Its Circuits”: Bi-Fuel
CNG (Page 1A-347)
Faulty CNG control module “Inspection of CNG Control Module and Its
Circuit”: Bi-Fuel CNG (Page 1A-358)
1A-320 Engine General Information and Diagnosis: Bi-Fuel CNG

MIL Does Not Come ON with Ignition “ON” and Engine Stopped (but Engine Can Be Started)
AENJCA0A1134013
Refer to “MIL Does Not Come ON with Ignition “ON” and Engine Stopped (but Engine Can Be Started)”: K10B (Page
1A-45).

MIL Remains ON after Engine Starts

AENJCA0A1134014
Refer to “MIL Remains ON after Engine Starts”: K10B (Page 1A-45).

CNG Warning Light Does Not Come ON with Ignition “ON” and Engine Stopped
AENJCA0A1134015
Troubleshooting
Step Action Yes No
1 DTC check Go to troubleshooting Go to Step 2.
1) Check DTC related to CAN communication. for applicable DTC.

Is there any CAN-DTC(s) detected?

2 DTC check Go to troubleshooting Replace CNG control
1) Check combination meter for DTC. for applicable DTC. module and recheck.
(Page 1C-4)
Is there any DTC(s) detected?

CNG Warning Light Remains ON after Engine Starts

AENJCA0A1134016
Troubleshooting
Step Action Yes No
1 DTC check Go to troubleshooting Replace combination
1) Start engine and recheck DTC of CNG control module for applicable DTC. meter and recheck. If
while engine running. CNG warning light still
remains ON, replace
Is there any DTC(s)? CNG control module
and recheck. (Page
1C-4)

DTC U0108
AENJCA0A1134047
Refer to “Troubleshooting for Lost Communication” in Section 10H (Page 10H-9).
 Engine General Information and Diagnosis: Bi-Fuel CNG 1A-321

DTC P0005 / P0007

AENJCA0A1134055
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0005: Fuel Shutoff Valve “A” Control Circuit/Open • Shut off valve of CNG cylinder pressure regulator
Measured signal of shut off valve of CNG cylinder pressure and/or its circuit
regulator is high voltage for 5 sec. even if its command • CNG valve control relay and/or its circuit
signal is low voltage and CNG valve control relay is ON.
• CNG control module
(1 D/C detection logic)
P0007: Fuel Shutoff Valve “A” Control Circuit High
Measured signal of shut off valve of CNG cylinder pressure
regulator is low voltage for 5 sec. even if its command signal
is high voltage and CNG valve control relay is ON.
(1 D/C detection logic)

Circuit Diagram

+B
1
BLU
12V 5V
5
E23-1 RED

E23-10 RED
IG1 +BB

7
E23-21 WHT
WHT
12V B1 C1
4
E23-4 BLU BLK 6
B2 2 A2
E23-34 BLU
BLK C12-9
BLK C12-17 A1
B3 A3
BLK C12-26 3
E23-26 BLU

[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

IJCA0A113012-02

[A]: CNG control module connector (View: [a]) 1. CNG control module
A1: CNG valve control relay power supply circuit (switch side) 2. Shut off valve of CNG cylinder valve
A2: Shut off valve of CNG cylinder valve power supply circuit 3. Shut off valve of CNG cylinder pressure regulator
A3: Shut off valve of CNG cylinder pressure regulator power supply circuit 4. CNG valve control relay
B1: CNG valve control relay drive circuit 5. “CNG” fuse
B2: Shut off valve of CNG cylinder valve drive circuit 6. “CNG VLV” fuse
B3: Shut off valve of CNG cylinder pressure regulator drive circuit 7. “CNG IG1” fuse
C1: CNG valve control relay ground circuit (coil side)
1A-322 Engine General Information and Diagnosis: Bi-Fuel CNG

DTC Confirmation Procedure

NOTE
Check that the following condition is met in this “DTC Confirmation Procedure”.
• DTC P0607 is not detected.

1) Set ignition “ON”.

2) Operate fuel select switch and select “Forced CNG MODE”.
3) Leave it for 10 sec.
4) Select “Petrol MODE”.
5) Start engine and run it for 1 min.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: Bi-Fuel
CNG (Page 1A-291).
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) When ignition is “OFF”, remove CNG valve control relay.
2) Check for proper terminal connections to CNG valve
control relay connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between “A1” and ground is battery
voltage.

Is check result OK?

4 “CNG VLV” fuse check Repair or replace Check that CNG valve
1) When ignition is “OFF”. defective wire harness. control relay power
supply circuit (switch
2) Check “CNG VLV” fuse for blowout.
side) is shorted to
Is check result OK? 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-51) control relay.

Is check result OK?

 Engine General Information and Diagnosis: Bi-Fuel CNG 1A-323

Step Action Yes No

6 Shut off valve power supply circuit check Go to Step 8. Repair or replace
1) When ignition is “OFF”, disconnect connectors from shut defective wire harness.
off valve of CNG cylinder pressure regulator and shut off
valve of CNG cylinder valve.
2) Check for proper terminal connection to shut off valve of
CNG cylinder pressure regulator and shut off valve of
CNG cylinder valve connectors.
3) If connections are OK, check the following points.
• Resistance of “A2” and “A3” circuits: less than 1 Ω
• Resistance between each of “A2” and “A3” circuits
and ground: infinity
• Resistance between “A2” circuit terminal and other
terminal at CNG valve control relay connector: infinity
• Resistance between “A3” circuit terminal and other
terminal at CNG valve control relay connector: infinity
• Voltage of “A2” and “A3” circuits: 0 to 1 V (When
ignition is “ON”)

Is check result OK?

7 Shut off valve of CNG cylinder pressure regulator power Go to Step 8. Repair or replace
supply circuit check defective wire harness.
1) When ignition is “OFF”, disconnect connector from shut
off valve of CNG cylinder pressure regulator.
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, check the following points.
• Resistance of “A3” circuit: less than 1 Ω
• Resistance between “A3” circuit and ground: infinity
• Resistance between “A3” circuit terminal and “B3”
circuit terminal at shut off valve of CNG cylinder
pressure regulator connector: infinity
• Voltage of “A3” circuit: 0 to 1 V (When ignition is “ON”)

Is check result OK?

8 Shut off valve of CNG cylinder pressure regulator drive Go to Step 9. Repair or replace
circuit check defective wire harness.
1) When ignition is “OFF”, disconnect “C12” and “E23”
connectors from CNG control module.
2) Check for proper terminal connection to “C12” and “E23”
connectors.
3) If connections are OK, check the following points.
• Resistance of “B3” circuit: less than 1 Ω
• Resistance between “B3” circuit and ground: infinity
• Resistance between “B3” circuit terminal and “A3”
circuit terminal at shut off valve of CNG cylinder
pressure regulator connector: infinity
• Voltage of “B3” circuit: 0 to 1 V (When ignition is “ON”)

Is check result OK?

1A-324 Engine General Information and Diagnosis: Bi-Fuel CNG

Step Action Yes No

9 Shut off valve of CNG cylinder pressure regulator check Replace CNG control Replace CNG cylinder
1) Check shut off valve of CNG cylinder pressure regulator. module and recheck pressure regulator.
(Page 1G-69) DTC. (Page 1C-4) (Page 1G-67)

Is check result OK?

DTC P0182 / P0183

AENJCA0A1134056
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0182: Fuel Temperature Sensor “A” Circuit Low • CNG pressure-and-temperature
Voltage of CNG temperature sensor signal circuit is lower than 0.1 V for 5 sec. sensor and/or its circuit
(3 D/C detection logic) • CNG control module
P0183: Fuel Temperature Sensor “A” Circuit High
Voltage of CNG temperature sensor signal circuit is higher than 4.9 V for 5 sec.
(3 D/C detection logic)

Circuit Diagram

2 5V
A1
LT GRN E23-5 12V
GRY E23-14
B1 5V
B2
RED E23-13
LT BLU E23-24
C1

[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

IJCA0A113013-02

[A]: CNG control module connector (View: [a]) B2: CNG temperature sensor signal circuit 2. CNG pressure-and-temperature sensor
A1: CNG pressure sensor power supply circuit C1: CNG pressure-and-temperature sensor ground circuit
B1: CNG pressure sensor signal circuit 1. CNG control module

DTC Confirmation Procedure

1) Set ignition “ON” and leave it for 10 sec.
 Engine General Information and Diagnosis: Bi-Fuel CNG 1A-325

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”: Bi-Fuel
CNG (Page 1A-291).
2 CNG temperature sensor signal circuit and ground Go to Step 3. Repair or replace
circuit check defective wire harness.
1) When ignition is “OFF”, disconnect “C12” and “E23”
connectors of CNG control module and CNG pressure-
and-temperature sensor.
2) Check for proper terminal connection to “C12” and “E23”
connectors and CNG pressure-and-temperature sensor
connector.
3) If connections are OK, check the following points.
• Resistance of “B2” and “C1” circuits: less than 1 Ω
• Resistance between each of “B2” and “C1” circuits
and ground: infinity
• Resistance between “B2” circuit terminal and other
terminal at CNG pressure-and-temperature sensor
connector: infinity
• Resistance between “C1” circuit terminal and other
terminal at CNG pressure-and-temperature sensor
connector: infinity
• Voltage of “B3” and “C1” circuits: 0 to 1 V (When
ignition is “ON”)

Is check result OK?

3 CNG pressure-and-temperature sensor check Replace CNG control Replace CNG pressure-
1) Check CNG pressure-and-temperature sensor. (Page module and recheck and-temperature
1C-16) DTC. (Page 1C-4) sensor. (Page 1C-16)

Is check result OK?

1A-326 Engine General Information and Diagnosis: Bi-Fuel CNG

DTC P0192 / P0193

AENJCA0A1134057
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0192: Fuel Rail Pressure Sensor “A” Circuit Low • CNG pressure-and-temperature
Voltage of CNG pressure sensor signal circuit is lower than 0.1 V for 5 sec. sensor and/or its circuit
(3 D/C detection logic) • CNG control module
P0193: Fuel Rail Pressure Sensor “A” Circuit High
Voltage of CNG pressure sensor signal circuit is higher than 4.9 V for 5 sec.
(3 D/C detection logic)

Circuit Diagram

2 5V
A1
LT GRN E23-5 12V
GRY E23-14
B1 5V
B2
RED E23-13
LT BLU E23-24
C1

[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

IJCA0A113013-02

[A]: CNG control module connector (View: [a]) B2: CNG temperature sensor signal circuit 2. CNG pressure-and-temperature sensor
A1: CNG pressure sensor power supply circuit C1: CNG pressure-and-temperature sensor ground circuit
B1: CNG pressure sensor signal circuit 1. CNG control module

DTC Confirmation Procedure

1) Set ignition “ON” and leave it for 10 sec.
 Engine General Information and Diagnosis: Bi-Fuel CNG 1A-327

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”: Bi-Fuel
CNG (Page 1A-291).
2 CNG pressure sensor power supply circuit check Go to Step 4. Go to Step 3.
1) When ignition is “OFF”, disconnect connector from CNG
pressure-and-temperature sensor.
2) Check for proper terminal connection to CNG pressure-
and-temperature sensor connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between “A1” and “C1” is approx. 5
V.

Is check result OK?

3 CNG pressure sensor ground circuit check Check “C1” 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 or replace found, repair or replace
“C1” circuit. “A1” circuit.
Is check result OK?
If circuit is OK, replace If circuit is OK, replace
CNG control module CNG control module
and recheck DTC. and recheck DTC.
(Page 1C-4) (Page 1C-4)
4 CNG pressure sensor signal circuit check Go to Step 5. Repair or replace
1) When ignition is “OFF”, disconnect “C12” and “E23” defective wire harness.
connectors from CNG control module.
2) Check for proper terminal connection to “C12” and “E23”
connectors.
3) If connections are OK, check the following points.
• Resistance of “B1” circuit: less than 1 Ω
• Resistance between of “B1” circuit and ground: infinity
• Resistance between “B1” circuit terminal and other
terminal at CNG pressure-and-temperature sensor
connector: infinity
• Voltage of “B1” circuit: 0 to 1 V (When ignition is “ON”)

Is check result OK?

5 CNG pressure-and-temperature sensor check Replace CNG control Replace CNG pressure-
1) Check CNG pressure-and-temperature sensor. (Page module and recheck and-temperature
1C-16) DTC. (Page 1C-4) sensor. (Page 1C-16)

Is check result OK?

1A-328 Engine General Information and Diagnosis: Bi-Fuel CNG

DTC P0201 / P0202 / P0203

AENJCA0A1134058
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0201: Injector Circuit/Open - Cylinder 1 • CNG fuel injector and/or its circuit
Measured voltage of CNG fuel injector No.1 is high voltage • CNG control module
for 5 sec. even if its command signal is low voltage.
(3 D/C detection logic)
P0202: Injector Circuit/Open - Cylinder 2
Measured voltage of CNG fuel injector No.2 is high voltage
for 5 sec. even if its command signal is low voltage.
(3 D/C detection logic)
P0203: Injector Circuit/Open - Cylinder 3
Measured voltage of CNG fuel injector No.3 is high voltage
for 5 sec. even if its command signal is low voltage.
(3 D/C detection logic)
 Engine General Information and Diagnosis: Bi-Fuel CNG 1A-329

Circuit Diagram

+B

BLU
2
C1 A1
1 5 4
C12-6 PNK
E1 11
D1 8 B1
C12-1 WHT
C01-77 YEL C12-8

12V
C2 A2
6
C12-14 WHT
E2
12 D2 9 B2
C12-10 GRY
C01-78 BRN C12-16 3

12V
C3 A3
7
C12-5 RED
E3 10
13 D3 B3
C12-18 BLU
C01-79 GRN C12-7

12V

12V 5V

C01-22 RED C12-25 E23-1

14 14 RED
C01-21 WHT C12-33
E23-10 RED

[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

10 9 8 7 6 5 4 3 2 1
65 64 63 62 61 20 19 18 17 16 15 14 13 12 11
70 69 68 67 66 30 29 28 27 26 25 24 23 22 21
75 74 73 72 71 40 39 38 37 36 35 34 33 32 31
80 79 78 77 76 50 49 48 47 46 45 44 43 42 41
60 59 58 57 56 55 54 53 52 51
9 8 7 6 5 4 3 2 1
57 56 55 18 17 16 15 14 13 12 11 10
60 59 58 27 26 25 24 23 22 21 20 19
63 62 61 36 35 34 33 32 31 30 29 28
66 65 64 45 44 43 42 41 40 39 38 37
54 53 52 51 50 49 48 47 46

IJCA0A113014-04

[A]: CNG control module connector (View: [a]) D1: CNG fuel injector No.1 drive circuit 6. Fuel injector No.2
[B]: ECM connector (View: [a]) D2: CNG fuel injector No.2 drive circuit 7. Fuel injector No.3
A1: Fuel injector No.1 power supply circuit D3: CNG fuel injector No.3 drive circuit 8. CNG fuel injector No.1
A2: Fuel injector No.2 power supply circuit E1: Fuel injector No.1 drive signal from ECM circuit 9. CNG fuel injector No.2
A3: Fuel injector No.3 power supply circuit E2: Fuel injector No.2 drive signal from ECM circuit 10. CNG fuel injector No.3
B1: CNG fuel injector No.1 power supply circuit E3: Fuel injector No.3 drive signal from ECM circuit 11. Fuel control relay No.1
B2: CNG fuel injector No.2 power supply circuit 1. ECM 12. Fuel control relay No.2
B3: CNG fuel injector No.3 power supply circuit 2. CNG control module 13. Fuel control relay No.3
C1: Fuel injector No.1 drive circuit 3. CPU 14. CAN driver
C2: Fuel injector No.2 drive circuit 4. “CNG” fuse
C3: Fuel injector No.3 drive circuit 5. Fuel injector No.1

DTC Confirmation Procedure

1) Set ignition “ON” and leave it for 10 sec.
1A-330 Engine General Information and Diagnosis: Bi-Fuel CNG

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”: Bi-Fuel
CNG (Page 1A-291).
2 CNG fuel injector power supply circuit check Go to Step 3. Repair or replace
1) When ignition is “OFF”, disconnect connector(s) from defective wire harness.
CNG fuel injector related to DTC(s).
2) Check for proper terminal connection to CNG fuel
injector connector(s).
3) If connections are OK, set ignition “ON”.
4) Check that voltage between “B1”, “B2” or “B3” and
ground is battery voltage.

Is check result OK?

3 CNG fuel injector drive circuit check Go to Step 4. Repair or replace
1) When ignition is “OFF”, disconnect “C12” and “E23” defective wire harness.
connectors from CNG control module.
2) Check for proper terminal connection to “C12” and “E23”
connectors.
3) If connections are OK, check the following points.
• Resistance of “D1”, “D2” or “D3” circuit: less than 1 Ω.
• Resistance between “D1”, “D2” and “D3” circuit and
ground: infinity
• Resistance between “D1” circuit terminal and other
terminal at CNG fuel injector connector: infinity
• Resistance between “D2” circuit terminal and other
terminal at CNG fuel injector connector: infinity
• Resistance between “D3” circuit terminal and other
terminal at CNG fuel injector connector: infinity
• Voltage of “D1”, “D2” or “D3” circuit: 0 to 1 V (When
ignition is “ON”)

Is check result OK?

4 CNG fuel injector check Replace CNG control Replace CNG fuel
1) Check CNG fuel injector(s) related to DTC(s). (Page module and recheck injector(s) related to
1G-66) DTC. (Page 1C-4) DTC(s). (Page 1G-65)

Is check result OK?

 Engine General Information and Diagnosis: Bi-Fuel CNG 1A-331

DTC P0601
AENJCA0A1134059
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0601: Internal Control Module Memory Check Sum Error • CNG control module power supply circuit and/
CNG control module internal failure related to check sum error. or ground circuit
(3 D/C detection logic) • CNG control module

DTC Confirmation Procedure

1) Set ignition “ON”.
2) Start engine if possible.

DTC Troubleshooting
Step Action Yes No
1 DTC recheck Go to Step 2. Check for intermittent
1) Clear DTC. (Page 1A-294) trouble. (Page 00-13)
2) Set ignition “OFF”.
3) Perform DTC confirmation procedure and check DTC.

Is DTC P0601 still detected?

2 CNG control module power supply circuit and ground Replace CNG control Repair or replace
circuit check module and recheck defective wire harness.
1) Check CNG control module power supply circuit and DTC. (Page 1C-4)
CNG control module ground circuit are in good
condition. (Page 1A-363)

Are they in good condition?

1A-332 Engine General Information and Diagnosis: Bi-Fuel CNG

DTC P0607
AENJCA0A1134060
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0607: Control Module Performance • CNG valve control relay (coil side) and/or
Any of the following conditions is met. its circuit
• Measured voltage of CNG valve control relay is lower than specified • CNG control module
voltage for 3 sec. even if its command signal is output.
• Measured voltage of CNG valve control relay is higher than specified
voltage for 3 sec. even if its command signal is not output.
(1 D/C detection logic)

Circuit Diagram

+B
1
BLU
12V 5V
5
E23-1 RED

E23-10 RED
IG1 +BB

7
E23-21 WHT
WHT
12V B1 C1
4
E23-4 BLU BLK 6
B2 2 A2
E23-34 BLU
BLK C12-9
BLK C12-17 A1
B3 A3
BLK C12-26 3
E23-26 BLU

[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

IJCA0A113012-02

[A]: CNG control module connector (View: [a]) 1. CNG control module
A1: CNG valve control relay power supply circuit (switch side) 2. Shut off valve of CNG cylinder valve
A2: Shut off valve of CNG cylinder valve power supply circuit 3. Shut off valve of CNG cylinder pressure regulator
A3: Shut off valve of CNG cylinder pressure regulator power supply circuit 4. CNG valve control relay
B1: CNG valve control relay drive circuit 5. “CNG” fuse
B2: Shut off valve of CNG cylinder valve drive circuit 6. “CNG VLV” fuse
B3: Shut off valve of CNG cylinder pressure regulator drive circuit 7. “CNG IG1” fuse
C1: CNG valve control relay ground circuit (coil side)

DTC Confirmation Procedure

1) Set ignition “ON” and leave it for 10 sec.
2) Start engine and run it for 1 min.
 Engine General Information and Diagnosis: Bi-Fuel CNG 1A-333

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”: Bi-Fuel
CNG (Page 1A-291).
2 CNG valve control relay ground circuit check Go to Step 3. Repair or replace
1) When ignition is “OFF”, remove CNG valve control relay. defective wire harness.
2) Check for proper terminal connection to CNG valve
control relay connector.
3) If connections are OK, check that resistance between
“C1” and ground is less than 1 Ω.

Is check result OK?

3 CNG valve control relay drive circuit check Go to Step 4. Repair or replace
1) When ignition is “OFF”, disconnect “C12” and “E23” defective wire harness.
connectors from CNG control module.
2) Check for proper terminal connection to “C12” and “E23”
connectors.
3) If connections are OK, check the following points.
• Resistance of “B1” circuit: less than 1 Ω
• Resistance between “B1” circuit and ground: infinity
• Resistance between “B1” circuit terminal and other
terminal at CNG valve control relay connector: infinity
• Voltage of “B1” circuit: 0 to 1 V (When ignition is “ON”)

Is check result OK?

4 CNG valve control relay check Replace CNG control Replace CNG valve
1) Check CNG valve control relay. (Page 10B-51) module and recheck control relay.
DTC. (Page 1C-4)
Is check result OK?
1A-334 Engine General Information and Diagnosis: Bi-Fuel CNG

DTC P0612
AENJCA0A1134061
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0612: Fuel Injector Control Module Relay Control • Fuel injector drive circuit between ECM and CNG
Any of the following conditions is met. control module
• Measured signal of either of fuel control relays is • CNG control module
“Petrol” side for 5 sec. with engine running on CNG. • ECM
• Measured signal of either of fuel control relays is “CNG” • Fuel injector and/or circuit
side for 5 sec. with engine running on petrol.
• Petrol fuel injector is disconnected or shorted to ground
with engine running on CNG.
(3 D/C detection logic)
 Engine General Information and Diagnosis: Bi-Fuel CNG 1A-335

Circuit Diagram

+B

BLU
2
C1 A1
1 5 4
C12-6 PNK
E1 11
D1 8 B1
C12-1 WHT
C01-77 YEL C12-8

12V
C2 A2
6
C12-14 WHT
E2
12 D2 9 B2
C12-10 GRY
C01-78 BRN C12-16 3

12V
C3 A3
7
C12-5 RED
E3 10
13 D3 B3
C12-18 BLU
C01-79 GRN C12-7

12V

12V 5V

C01-22 RED C12-25 E23-1

14 14 RED
C01-21 WHT C12-33
E23-10 RED

[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

10 9 8 7 6 5 4 3 2 1
65 64 63 62 61 20 19 18 17 16 15 14 13 12 11
70 69 68 67 66 30 29 28 27 26 25 24 23 22 21
75 74 73 72 71 40 39 38 37 36 35 34 33 32 31
80 79 78 77 76 50 49 48 47 46 45 44 43 42 41
60 59 58 57 56 55 54 53 52 51
9 8 7 6 5 4 3 2 1
57 56 55 18 17 16 15 14 13 12 11 10
60 59 58 27 26 25 24 23 22 21 20 19
63 62 61 36 35 34 33 32 31 30 29 28
66 65 64 45 44 43 42 41 40 39 38 37
54 53 52 51 50 49 48 47 46

IJCA0A113014-04

[A]: CNG control module connector (View: [a]) D1: CNG fuel injector No.1 drive circuit 6. Fuel injector No.2
[B]: ECM connector (View: [a]) D2: CNG fuel injector No.2 drive circuit 7. Fuel injector No.3
A1: Fuel injector No.1 power supply circuit D3: CNG fuel injector No.3 drive circuit 8. CNG fuel injector No.1
A2: Fuel injector No.2 power supply circuit E1: Fuel injector No.1 drive signal from ECM circuit 9. CNG fuel injector No.2
A3: Fuel injector No.3 power supply circuit E2: Fuel injector No.2 drive signal from ECM circuit 10. CNG fuel injector No.3
B1: CNG fuel injector No.1 power supply circuit E3: Fuel injector No.3 drive signal from ECM circuit 11. Fuel control relay No.1
B2: CNG fuel injector No.2 power supply circuit 1. ECM 12. Fuel control relay No.2
B3: CNG fuel injector No.3 power supply circuit 2. CNG control module 13. Fuel control relay No.3
C1: Fuel injector No.1 drive circuit 3. CPU 14. CAN driver
C2: Fuel injector No.2 drive circuit 4. “CNG” fuse
C3: Fuel injector No.3 drive circuit 5. Fuel injector No.1
1A-336 Engine General Information and Diagnosis: Bi-Fuel CNG

DTC Confirmation Procedure

1) Set ignition “ON”.
2) Operate fuel select switch and select “Forced CNG MODE”.
3) Run engine at idle speed for 10 sec.
4) Select “Petrol MODE”.
5) 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”: Bi-Fuel
CNG (Page 1A-291).
2 Fuel injector power supply circuit check Go to Step 3. Repair or replace
1) When ignition is “OFF”, disconnect connector(s) from defective wire harness.
fuel injector related to DTC(s).
2) Check for proper terminal connection to fuel injector
connector(s).
3) If connections are OK, set ignition “ON”.
4) Check that voltage between “A1”, “A2” or “A3” and
ground is battery voltage.

Is check result OK?

3 Fuel injector drive circuit check Go to Step 4. Repair or replace
1) When ignition is “OFF”, disconnect “C12” and “E23” defective wire harness.
connectors from CNG control module.
2) Check for proper terminal connection to “C12” and “E23”
connectors.
3) If connections are OK, check the following points.
• Resistance of “C1”, “C2” or “C3” circuit: less than 1Ω
• Resistance between “C1”, “C2” and “C3” circuit and
ground: infinity
• Resistance between “C1” circuit terminal and other
terminal at fuel injector connector: infinity
• Resistance between “C2” circuit terminal and other
terminal at fuel injector connector: infinity
• Resistance between “C3” circuit terminal and other
terminal at fuel injector connector: infinity
• Voltage of “C1”, “C2” or “C3” circuit: 0 to 1 V (When
ignition is “ON”)

Is check result OK?

4 Fuel injector check Go to Step 5. Replace fuel injector(s)
1) Check fuel injector(s) related to DTC(s). (Page 1G-24) related to DTC(s).
(Page 1G-22)
Is check result OK?
 Engine General Information and Diagnosis: Bi-Fuel CNG 1A-337

Step Action Yes No

5 Fuel injector drive signal from ECM circuit check Go to Step 6. Repair or replace
1) When ignition is “OFF”, disconnect “C01” and “E01” defective wire harness.
connectors from ECM.
2) Check for proper terminal connection to “C01” and “E01”
connectors.
3) If connections are OK, check the following points.
• Resistance of “E1”, “E2” or “E3” circuit: less than 1 Ω
• Resistance between “E1”, “E2” and “E3” circuit and
ground: infinity
• Resistance between “E1” circuit terminal and other
terminal at CNG control module connector: infinity
• Resistance between “E2” circuit terminal and other
terminal at CNG control module connector: infinity
• Resistance between “E3” circuit terminal and other
terminal at CNG control module connector: infinity
• Voltage of “E1”, “E2” or “E3” circuit: 0 to 1 V (When
ignition is “ON”)

Is DTC P0612 still detected?

6 DTC check Replace ECM and End.
1) Replace CNG control module. (Page 1C-4) recheck DTC. (Page
1C-3)
2) Clear DTC. (Page 1A-294)
3) Set ignition “OFF”.
4) Perform DTC confirmation procedure and check DTC.

Is DTC P0612 still detected?

DTC P062F
AENJCA0A1134062
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P062F: Internal Control Module EEPROM Error • CNG control module power supply circuit and/or ground
CNG control module internal failure (EEPROM error) circuit
(1 D/C detection logic) • CNG control module

DTC Confirmation Procedure

1) Set ignition “ON”.
2) Start engine if possible.

DTC Troubleshooting
Step Action Yes No
1 DTC recheck Go to Step 2. Check for intermittent
1) Clear DTC. (Page 1A-294) trouble. (Page 00-13)
2) Set ignition “OFF”.
3) Perform DTC confirmation procedure and check DTC.

Is DTC P062F still detected?

2 CNG control module power supply circuit and ground Replace CNG control Repair or replace
circuit check module and recheck defective wire harness.
1) Check CNG control module power supply circuit and DTC. (Page 1C-4)
CNG control module ground circuit are in good
condition. (Page 1A-363)

Are they in good condition?

1A-338 Engine General Information and Diagnosis: Bi-Fuel CNG

DTC P1432 / P1433

AENJCA0A1134063
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P1432: Remaining Fuel Sensor Low Voltage • CNG cylinder pressure sensor and/or its circuit
Voltage of CNG cylinder pressure sensor signal circuit is • CNG control module
lower than 0.1 V for 5 sec.
(1 D/C detection logic)
P1433: Remaining Fuel Sensor High Voltage
Voltage of CNG cylinder pressure sensor signal circuit is
higher than 4.9 V for 5 sec.
(1 D/C detection logic)

Circuit Diagram

2 A1 5V
BLU E23-6
RED E23-15
B1
YEL E23-23
C1

[A]

E23 C12
9 8 7 6 5 4 3 2 1 9 8 7 65 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

IJCA0A113015-02

[A]: CNG control module connector (View: [a]) B1: CNG cylinder pressure sensor signal circuit 1. CNG control module
A1: CNG cylinder pressure sensor power supply circuit C1: CNG cylinder pressure sensor ground circuit 2. CNG cylinder pressure sensor

DTC Confirmation Procedure

1) Set ignition “ON” and leave it for 10 sec.
 Engine General Information and Diagnosis: Bi-Fuel CNG 1A-339

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”: Bi-Fuel
CNG (Page 1A-291).
2 CNG cylinder pressure sensor power supply circuit Go to Step 4. Go to Step 3.
check
1) When ignition is “OFF”, disconnect connector from CNG
cylinder pressure sensor.
2) Check for proper terminal connection to CNG cylinder
pressure sensor connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between “A1” and “C1” is approx. 5
V.

Is check result OK?

3 CNG cylinder pressure sensor ground circuit check Check “C1” 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 or replace found, repair or replace
“C1” circuit. “A1” circuit.
Is check result OK?
If circuit is OK, replace If circuit is OK, replace
CNG control module CNG control module
and recheck DTC. and recheck DTC.
(Page 1C-4) (Page 1C-4)
4 CNG cylinder pressure sensor signal circuit check Go to Step 5. Repair or replace
1) When ignition is “OFF”, disconnect “C12” and “E23” defective wire harness.
connectors from CNG control module.
2) Check for proper terminal connection to “C12” and “E23”
connectors.
3) If connections are OK, check the following points.
• Resistance of “B1” circuit: less than 1 Ω
• Resistance between of “B1” circuit and ground: infinity
• Resistance between “B1” circuit terminal and other
terminal at CNG cylinder pressure sensor connector:
infinity
• Voltage of “B1” circuit: 0 to 1 V (When ignition is “ON”)

Is check result OK?

5 CNG cylinder pressure sensor check Replace CNG control Replace CNG cylinder
1) Check CNG cylinder pressure sensor. (Page 1G-69) module and recheck pressure regulator.
DTC. (Page 1C-4) (Page 1G-67)
Is check result OK?
1A-340 Engine General Information and Diagnosis: Bi-Fuel CNG

DTC P1601
AENJCA0A1134064
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P1601: Monitor Circuit Fault • CAN communication line
Any of the following conditions is met. • CNG control module
• The state of changing over “Petrol” to “CNG” is detected continuously for 5 sec. • ECM
• The state of changing over “CNG” to “Petrol” is detected continuously for 5 sec.
(3 D/C detection logic)

DTC Confirmation Procedure

1) Set ignition “ON”.
2) Operate fuel select switch and select “Forced CNG MODE”.
3) Leave it for 10 sec.
4) Select “Petrol MODE” 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”: Bi-Fuel
CNG (Page 1A-291).
2 DTC check Go to troubleshooting Go to Step 3.
1) Check DTC related to CAN communication. for applicable DTC.

Is there CAN-DTC(s) detected?

3 DTC recheck Replace ECM and End.
1) Replace CNG control module. (Page 1C-4) recheck DTC. (Page
1C-3)
2) Clear DTC. (Page 1A-294)
3) Set ignition “OFF”.
4) Perform DTC confirmation procedure and check DTC.

Is DTC P1601 still detected?

 Engine General Information and Diagnosis: Bi-Fuel CNG 1A-341

DTC P2408
AENJCA0A1134065
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P2408: Fuel Cap Sensor/Switch Circuit • Fuel filler lid switch and/or its circuit
Any of the following conditions is met. • CNG control module
• Both fuel filler lid switch No.1 and No.2 ON signals are input for 5 sec.
• Both fuel filler lid switch No.1 and No.2 OFF signals are input for 5 sec.
(3 D/C detection logic)

Circuit Diagram

A1 2
12V B1
E23-30 GRN
12V BLK
E23-31 LT BLU
A2

[A]

E23 C12
9 8 7 6 5 4 3 2 1 9 8 7 65 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

IJCA0A113016-02

[A]: CNG control module connector (View: [a]) A2: Fuel filler lid switch No.1 signal circuit 1. CNG control module
A1: Fuel filler lid switch No.2 signal circuit B1: Fuel filler lid switch ground circuit 2. Fuel filler lid switch

DTC Confirmation Procedure

1) Set ignition “ON” with fuel filler lid closed.
2) Leave it for 10 sec.
3) Open fuel filler lid and leave it 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”: Bi-Fuel
CNG (Page 1A-291).
2 Fuel filler lid switch ground circuit check Go to Step 3. Repair or replace
1) When ignition is “OFF”, disconnect connector from fuel defective wire harness.
filler lid switch.
2) Check for proper terminal connection to fuel filler lid
switch connector.
3) If connections are OK, check that resistance between
“B1” and ground is less than 1 Ω.

Is check result OK?

1A-342 Engine General Information and Diagnosis: Bi-Fuel CNG

Step Action Yes No

3 Fuel filler lid switch signal circuit check Go to Step 4. Repair or replace
1) Disconnect “C12” and “E23” connectors from CNG defective wire harness.
control module.
2) Check for proper terminal connections to “C12” and
“E23” connectors.
3) If connections are OK, check the following points.
• Resistance of “A1” and “A2” circuits: less than 1 Ω
• Resistance between each of “A1” and “A2” circuits
and ground: infinity
• Resistance between “A1” circuit terminal and other
terminal at fuel filler lid switch connector: infinity
• Resistance between “A2” circuit terminal and other
terminal at fuel filler lid switch connector: infinity
• Voltage of “A1” and “A2” circuits: 0 to 1 V (When
ignition is “ON”)

Is check result OK?

4 Fuel filler lid switch Check Replace CNG control Replace fuel filler lid
1) Check fuel filler lid switch. (Page 1C-17) module and recheck switch. (Page 1C-18)
DTC. (Page 1C-4)
Is check result OK?
 Engine General Information and Diagnosis: Bi-Fuel CNG 1A-343

DTC P2665 / P2667

AENJCA0A1134066
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P2665: Fuel Shutoff Valve “B” Control Circuit/Open • Shut off valve of CNG cylinder
Measured signal of shut off valve of CNG cylinder is high voltage for 5 sec. valve and/or its circuit
even if its command signal is low voltage and CNG valve control relay is ON. • CNG valve control relay and/or its
(1 D/C detection logic) circuit
P2667: Fuel Shutoff Valve “B” Control Circuit High
• CNG control module
Measured signal of shut off valve of CNG cylinder is low voltage for 5 sec. even
if its command signal is high voltage and CNG valve control relay is ON.
(1 D/C detection logic)

Circuit Diagram

+B
1
BLU
12V 5V
5
E23-1 RED

E23-10 RED
IG1 +BB

7
E23-21 WHT
WHT
12V B1 C1
4
E23-4 BLU BLK 6
B2 2 A2
E23-34 BLU
BLK C12-9
BLK C12-17 A1
B3 A3
BLK C12-26 3
E23-26 BLU

[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

IJCA0A113012-02

[A]: CNG control module connector (View: [a]) 1. CNG control module
A1: CNG valve control relay power supply circuit (switch side) 2. Shut off valve of CNG cylinder valve
A2: Shut off valve of CNG cylinder valve power supply circuit 3. Shut off valve of CNG cylinder pressure regulator
A3: Shut off valve of CNG cylinder pressure regulator power supply circuit 4. CNG valve control relay
B1: CNG valve control relay drive circuit 5. “CNG” fuse
B2: Shut off valve of CNG cylinder valve drive circuit 6. “CNG VLV” fuse
B3: Shut off valve of CNG cylinder pressure regulator drive circuit 7. “CNG IG1” fuse
C1: CNG valve control relay ground circuit (coil side)
1A-344 Engine General Information and Diagnosis: Bi-Fuel CNG

DTC Confirmation Procedure

NOTE
Check that the following condition is met in this “DTC Confirmation Procedure”.
• DTC P0607 is not detected.

1) Set ignition “ON”.

2) Operate fuel select switch and select “Forced CNG MODE”.
3) Leave it for 10 sec.
4) Select “Petrol MODE”.
5) Start engine and run it for 1 min.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: Bi-Fuel
CNG (Page 1A-291).
2 DTC check Go to Step 3. Go to Step 5.

Is there DTC P0005 and/or P0007?

3 CNG valve control relay and its circuit check Go to Step 4. Repair or replace
1) Check CNG valve control relay and its circuit according defective part.
to Step 3 – 5 under “DTC P0005 / P0007”: Bi-Fuel CNG
(Page 1A-321).

Is check result OK?

4 Shut off valve power supply circuit check Go to Step 6. Repair or replace
1) When ignition is “OFF”, disconnect connectors from shut defective wire harness.
off valve of CNG cylinder pressure regulator and shut off
valve of CNG cylinder valve.
2) Check for proper terminal connection to shut off valve of
CNG cylinder pressure regulator and shut off valve of
CNG cylinder valve connectors.
3) If connections are OK, check the following points.
• Resistance of “A2” and “A3” circuits: less than 1 Ω
• Resistance between each of “A2” and “A3” circuits
and ground: infinity
• Resistance between “A2” circuit terminal and other
terminal at CNG valve control relay connector: infinity
• Resistance between “A3” circuit terminal and other
terminal at CNG valve control relay connector: infinity
• Voltage of “A2” and “A3” circuits: 0 to 1 V (When
ignition is “ON”)

Is check result OK?

 Engine General Information and Diagnosis: Bi-Fuel CNG 1A-345

Step Action Yes No

5 Shut off valve of CNG cylinder valve power supply Go to Step 6. Repair or replace
circuit check defective wire harness.
1) When ignition is “OFF”, disconnect connectors from shut
off valve of CNG cylinder valve.
2) Remove CNG valve control relay.
3) Check for proper terminal connection to CNG valve
control relay and shut off valve of CNG cylinder valve
connectors.
4) If connections are OK, check the following points.
• Resistance of “A2” circuit: less than 1 Ω
• Resistance between “A2” circuit and ground: infinity
• Resistance between “A2” circuit terminal and “B2”
circuit terminal at shut off valve of CNG cylinder valve
connector: infinity
• Voltage of “A2” circuit: 0 to 1 V (When ignition is “ON”)

Is check result OK?

6 Shut off valve of CNG cylinder valve drive circuit check Go to Step 7. Repair or replace
1) When ignition is “OFF”, disconnect “C12” and “E23” defective wire harness.
connectors from CNG control module.
2) Check for proper terminal connection to “C12” and “E23”
connectors.
3) If connections are OK, check the following points.
• Resistance of “B2” circuit: less than 1 Ω
• Resistance between “B2” circuit and ground: infinity
• Resistance between “B2” circuit terminal and “A2”
circuit terminal at shut off valve of CNG cylinder valve
connector: infinity
• Voltage of “B2” circuit: 0 to 1 V (When ignition is “ON”)

Is check result OK?

7 Shut off valve of CNG cylinder valve check Replace CNG control Replace CNG cylinder.
1) Check shut off valve of CNG cylinder valve. (Page 1G- module and recheck (Page 1G-74)
73) DTC. (Page 1C-4)

Is check result OK?

1A-346 Engine General Information and Diagnosis: Bi-Fuel CNG

DTC P2668
AENJCA0A1134067
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P2668: Fuel Mode Indicator Lamp Control Circuit • Fuel select switch and/or its circuit
Fuel select switch ON signal is input continuously for more than 120 sec. • CNG control module
(1 D/C detection logic)

Circuit Diagram

2
12V A1 B1
E23-22 LT GRN BLK

[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

IJCA0A113019-01

[A]: CNG control module connector (View: [a]) B1: Fuel select switch ground circuit 2. Fuel select switch
A1: Fuel select switch signal circuit 1. CNG control module

DTC Confirmation Procedure

1) Set ignition “ON” and leave it for 3 min.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: Bi-Fuel
CNG (Page 1A-291).
2 Fuel select switch ground circuit check Go to Step 3. Repair or replace
1) When ignition is “OFF”, disconnect connector from fuel defective wire harness.
select switch.
2) Check for proper terminal connection to fuel select
switch connector.
3) If connections are OK, check that resistance between
“B1” and ground is less than 1 Ω.

Is check result OK?

 Engine General Information and Diagnosis: Bi-Fuel CNG 1A-347

Step Action Yes No

3 Fuel select switch signal circuit check Go to Step 4. Repair or replace
1) Disconnect “C12” and “E23” connectors from CNG defective wire harness.
control module.
2) Check for proper terminal connection to “C12” and “E23”
connectors.
3) If connections are OK, check the following points.
• Resistance of “A1” circuit: less than 1 Ω
• Resistance between “A1” circuit and ground: infinity
• Resistance between “A1” circuit terminal and “B1”
circuit terminal at fuel select switch connector: infinity
• Voltage of “A1” circuit: 0 to 1 V (When ignition is “ON”)

Is check result OK?

4 Fuel select switch check Replace CNG control Replace fuel select
1) Check fuel select switch. (Page 1C-18) module and recheck switch. (Page 1C-18)
DTC. (Page 1C-4)
Is check result OK?

DTC U0073
AENJCA0A1134073
Refer to “Troubleshooting for Communication Bus Off” in Section 10H (Page 10H-15).

DTC U0100
AENJCA0A1134068
Refer to “Troubleshooting for Lost Communication” in Section 10H (Page 10H-9).

Inspection of ECM and Its Circuits

AENJCA0A1134069
Voltage Check

NOTE
• As each terminal voltage is affected by battery voltage, confirm that it is 12 V or more when ignition
is “ON”.
• Voltage of terminals 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 (Bi-Fuel CNG)” in Section 1 (Page 1-4).

[A] C01 E01

10 9 8 7 6 5 4 3 2 1
65 64 63 62 61 20 19 18 17 16 15 14 13 12 11
70 69 68 67 66 30 29 28 27 26 25 24 23 22 21
75 74 73 72 71 40 39 38 37 36 35 34 33 32 31
80 79 78 77 76 50 49 48 47 46 45 44 43 42 41
60 59 58 57 56 55 54 53 52 51
[a]
9 8 7 6 5 4 3 2 1
57 56 55 18 17 16 15 14 13 12 11 10
60 59 58 27 26 25 24 23 22 21 20 19
63 62 61 36 35 34 33 32 31 30 29 28
66 65 64 45 44 43 42 41 40 39 38 37
54 53 52 51 50 49 48 47 46

IJCA0A111006-02

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

1A-348 Engine General Information and Diagnosis: Bi-Fuel CNG

“C01” connector
Terminal No. Wire color Circuit Normal voltage Condition
C01-1 — — — —
C01-2 — — — —
C01-3 — — — —
C01-4 — — — —
C01-5 — — — —
C01-6 — — — —
C01-7 — — — —
C01-8 — — — —
C01-9 — — — —
C01-10 — — — —
C01-11 — — — —
C01-12 — — — —
C01-13 — — — —
C01-14 — — — —
C01-15 — — — —
C01-16 — — — —
Refer to reference waveform.
• “Ignition coil signal”: Bi-Fuel CNG (Page 1A-354)
C01-17* YEL Ignition coil No.1 drive circuit
• “Fuel injector No.1 signal and ignition coil No.1 signal”:
Bi-Fuel CNG (Page 1A-353)
Refer to reference waveform.
• “Ignition coil signal”: Bi-Fuel CNG (Page 1A-354)
C01-18* GRN Ignition coil No.2 drive circuit
• “Fuel injector No.2 signal and ignition coil No.2 signal”:
Bi-Fuel CNG (Page 1A-353)
Refer to reference waveform.
• “Ignition coil signal”: Bi-Fuel CNG (Page 1A-354)
C01-19* PNK Ignition coil No.3 drive circuit
• “Fuel injector No.3 signal and ignition coil No.3 signal”:
Bi-Fuel CNG (Page 1A-354)
C01-20 — — — —
CAN (low) communication Refer to reference waveform.
C01-21* WHT
circuit “CAN communication signal”: Bi-Fuel CNG (Page 1A-357)
CAN (high) communication Refer to reference waveform.
C01-22* RED
circuit “CAN communication signal”: Bi-Fuel CNG (Page 1A-357)
C01-23 — — — —
C01-24 — — — —
C01-25 — — — —
C01-26 — — — —
C01-27 — — — —
C01-28 — — — —
C01-29 — — — —
C01-30 — — — —
Refer to reference waveform.
Generator LIN
C01-31* BLU “Generator LIN communication signal”: Bi-Fuel CNG (Page
communication circuit
1A-356)
HO2S-1 shield ground
C01-32 LT GRN Below 0.3 V Ignition: “ON”
circuit
1 to 2 V Engine: Idle speed
C01-33* WHT Knock sensor signal circuit Refer to reference waveform.
“Knock sensor signal”: Bi-Fuel CNG (Page 1A-356)
Ignition: “ON”
3.2 to 3.6 V
IAT: 0 °C (32 °F)
Ignition: “ON”
C01-34 YEL IAT sensor signal circuit 1.3 to 1.7 V
IAT: 40 °C (104 °F)
Ignition: “ON”
0.4 to 0.8 V
IAT: 80 °C (176 °F)
 Engine General Information and Diagnosis: Bi-Fuel CNG 1A-349

Terminal No. Wire color Circuit Normal voltage Condition

4.0 to 4.2 V Ignition: “ON”
Engine: Idle speed after warming up
1.5 to 1.8 V
C01-35 BRN MAP sensor signal circuit Barometric pressure: 100 kPa, 760 mmHg
Refer to reference waveform.
“MAP sensor signal”: Bi-Fuel CNG (Page 1A-355)
Ignition: “ON”
3.2 to 3.6 V
ECT: 0 °C (32 °F)
Ignition: “ON”
C01-36 BLU ECT sensor signal circuit 1.0 to 1.4 V
ECT: 50 °C (122 °F)
Ignition: “ON”
0.2 to 0.5 V
ECT: 100 °C (212 °F)
C01-37 GRN HO2S-1 ground circuit Below 0.3 V Ignition: “ON”
C01-38 BEG IAT sensor ground circuit Below 0.3 V Ignition: “ON”
ECT sensor and MAP
C01-39 GRY Below 0.3 V Ignition: “ON”
sensor ground circuit
10 to 14 V Ignition: “ON”
EVAP canister purge valve Refer to reference waveform.
C01-40* RED
drive circuit “EVAP canister purge valve signal”: Bi-Fuel CNG (Page 1A-
355)
C01-41 — — — —
HO2S-2 shield ground
C01-42 BEG Below 0.3 V Ignition: “ON”
circuit
C01-43 BLU Knock sensor ground circuit Below 0.3 V Ignition: “ON”
TP sensor shield ground
C01-44 GRY Below 0.3 V Ignition: “ON”
circuit
C01-45 BLK TP sensor ground circuit Below 0.3 V Ignition: “ON”
C01-46 — — — —
C01-47 — — — —
C01-48 — — — —
C01-49 — — — —
C01-50 — — — —
C01-51 YEL HO2S-2 ground circuit Below 0.3 V Ignition: “ON”
Refer to reference waveform.
C01-52* BRN HO2S-2 signal circuit
“HO2S-2 signal”: Bi-Fuel CNG (Page 1A-354)
Refer to reference waveform.
C01-53* RED HO2S-1 signal circuit
“HO2S-1 signal”: Bi-Fuel CNG (Page 1A-354)
Ignition: “ON”
0.8 to 1.0 V
TP sensor (main) signal Accelerator pedal: Released
C01-54 GRN
circuit Ignition: “ON”
4.3 to 4.5 V
Accelerator pedal: Fully depressed
Ignition: “ON”
4.0 to 4.2 V
TP sensor (sub) signal Accelerator pedal: Released
C01-55 WHT
circuit Ignition: “ON”
0.5 to 0.7 V
Accelerator pedal: Fully depressed
TP sensor power supply
C01-56 RED 4.5 to 5.5 V Ignition: “ON”
circuit
MAP sensor power supply
C01-57 LT BLU 4.5 to 5.5 V Ignition: “ON”
circuit
Approx. 0 V or 4
Ignition: “ON”
to 5 V
C01-58* PPL CMP sensor signal circuit Refer to reference waveform.
“CKP sensor signal and CMP sensor signal”: Bi-Fuel CNG
(Page 1A-356)
C01-59 — — — —
Approx. 0 V or 4
Ignition: “ON”
to 5 V
C01-60* PNK CKP sensor signal circuit Refer to reference waveform.
“CKP sensor signal and CMP sensor signal”: Bi-Fuel CNG
(Page 1A-356)
1A-350 Engine General Information and Diagnosis: Bi-Fuel CNG

Terminal No. Wire color Circuit Normal voltage Condition

C01-61 BLK ECM ground circuit 1 Below 0.3 V Ignition: “ON”
C01-62 — — — —
C01-63 — — — —
C01-64 — — — —
C01-65 — — — —
C01-66 BLK ECM ground circuit 2 Below 0.3 V Ignition: “ON”
C01-67 — — — —
C01-68 — — — —
C01-69 — — — —
Throttle actuator control Refer to reference waveform.
C01-70* LT GRN
circuit (close) “Throttle actuator signal”: Bi-Fuel CNG (Page 1A-355)
Refer to reference waveform.
C01-71* PPL HO2S-1 heater drive circuit “HO2S-1 and HO2S-2 heater signal”: Bi-Fuel CNG (Page
1A-356)
C01-72 — — — —
C01-73 — — — —
C01-74 — — — —
Throttle actuator control Refer to reference waveform.
C01-75* BRN
circuit (open) “Throttle actuator signal”: Bi-Fuel CNG (Page 1A-355)
Refer to reference waveform.
C01-76* RED HO2S-2 heater drive circuit “HO2S-1 and HO2S-2 heater signal”: Bi-Fuel CNG (Page
1A-356)
10 to 14 V Ignition: “ON”
Refer to reference waveform.
Fuel injector No.1 drive
C01-77* YEL • “Fuel injector signal”: Bi-Fuel CNG (Page 1A-352)
circuit
• “Fuel injector No.1 signal and ignition coil No.1 signal”:
Bi-Fuel CNG (Page 1A-353)
10 to 14 V Ignition: “ON”
Refer to reference waveform.
Fuel injector No.2 drive
C01-78* BRN • “Fuel injector signal”: Bi-Fuel CNG (Page 1A-352)
circuit
• “Fuel injector No.2 signal and ignition coil No.2 signal”:
Bi-Fuel CNG (Page 1A-353)
10 to 14 V Ignition: “ON”
Refer to reference waveform.
Fuel injector No.3 drive
C01-79* GRN • “Fuel injector signal”: Bi-Fuel CNG (Page 1A-352)
circuit
• “Fuel injector No.3 signal and ignition coil No.3 signal”:
Bi-Fuel CNG (Page 1A-354)
C01-80 — — — —

“E01” connector
Terminal No. Wire color Circuit Normal voltage Condition
E01-1 — — — —
E01-2 — — — —
E01-3 — — — —
E01-4 — — — —
E01-5 — — — —
E01-6 — — — —
E01-7 — — — —
E01-8 — — — —
CAN (high) communication Refer to reference waveform.
E01-9* RED
circuit “CAN communication signal”: Bi-Fuel CNG (Page 1A-357)
0 to 1 V Ignition: “ON”
E01-10 PNK Main relay drive circuit
10 to 14 V Ignition: 3 sec. after ignition “OFF”
Approx. 0 V Starting motor: Operating
Starting motor control relay Refer to reference waveform.
E01-11 GRN
drive circuit “Starting motor control relay signal”: Bi-Fuel CNG (Page 1A-
357)
 Engine General Information and Diagnosis: Bi-Fuel CNG 1A-351

Terminal No. Wire color Circuit Normal voltage Condition

A/C compressor relay drive 10 to 14 V A/C compressor: Not operating
E01-12 GRY
circuit 0 to 1 V A/C compressor: Operating
E01-13 — — — —
E01-14 — — — —
E01-15 — — — —
E01-16 — — — —
E01-17 — — — —
CAN (low) communication Refer to reference waveform.
E01-18* WHT
circuit “CAN communication signal”: Bi-Fuel CNG (Page 1A-357)
Approx. 0 V Ignition: “OFF”, “ACC”
E01-19 WHT Ignition signal circuit
10 to 14 V Ignition: “ON”
Ignition: “ON”
0 to 1 V
CPP No.2 switch signal Clutch pedal: Halfway depressed
E01-20 GRN
circuit Ignition: “ON”
10 to 14 V
Clutch pedal: Released
E01-21 — — — —
Engine: Idle speed
10 to 14 V ECT < 95 °C (203 °F)
Radiator cooling fan relay A/C switch: OFF
E01-22 LT GRN
drive circuit Engine: Idle speed
0 to 1 V ECT > 97 °C (207 °F)
A/C switch: OFF
Brake light switch signal 0 to 1 V Brake pedal: Released
E01-23 YEL
circuit 10 to 14 V Brake pedal: Fully depressed
Starting motor control relay 0 to 1 V Ignition: “ON”
E01-24 LT BLU
signal circuit 6 to 12 V Ignition: “START”
E01-25 — — — —
E01-26 — — — —
E01-27 — — — —
E01-28 — — — —
E01-29 — — — —
E01-30 — — — —
APP sensor (main) power
E01-31 GRN 4.5 to 5.5 V Ignition: “ON”
supply circuit
Ignition: “ON”
0.70 to 0.80 V
APP sensor (main) signal Accelerator pedal: Released
E01-32 PNK
circuit Ignition: “ON”
4.35 to 4.45 V
Accelerator pedal: Fully depressed
APP sensor (main) ground
E01-33 GRY Below 0.3 V Ignition: “ON”
circuit
E01-34 — — — —
E01-35 — — — —
E01-36 — — — —
A/C refrigerant pressure
E01-37 LT GRN 4.5 to 5.5 V Ignition: “ON”
sensor power supply circuit
Refer to reference waveform.
E01-38 YEL Fuel pump relay drive circuit
“Fuel pump relay signal”: Bi-Fuel CNG (Page 1A-357)
E01-39 — — — —
APP sensor (sub) power
E01-40 BLU 4.5 to 5.5 V Ignition: “ON”
supply circuit
Ignition: “ON”
0.37 to 0.38 V
APP sensor (sub) signal Accelerator pedal: Released
E01-41 GRY
circuit Ignition: “ON”
2.15 to 2.25 V
Accelerator pedal: Fully depressed
APP sensor (sub) ground
E01-42 YEL Below 0.3 V Ignition: “ON”
circuit
A/C refrigerant pressure
E01-43 BLK Below 0.3 V Ignition: “ON”
sensor ground circuit
E01-44 — — — —
1A-352 Engine General Information and Diagnosis: Bi-Fuel CNG

Terminal No. Wire color Circuit Normal voltage Condition

E01-45 — — — —
E01-46 — — — —
E01-47 — — — —
Ignition: “ON”
Approx. 0 V
Blower speed switch: 2nd or more
Ignition: “ON”
E01-48 YEL Blower motor signal circuit 5 to 7 V
Blower speed switch: 1st position
Ignition: “ON”
10 to 14 V
Blower speed switch: “OFF”
E01-49 — — — —
E01-50 — — — —
E01-51 — — — —
E01-52 — — — —
E01-53 — — — —
Engine: Running
0.9 to 1.3 V
A/C refrigerant pressure A/C compressor: Not operating
E01-54 BEG
sensor signal circuit Engine: Running
1.3 to 2.2 V
A/C compressor: Operating
E01-55 BLU Main power supply circuit 1 10 to 14 V Ignition: “ON”
E01-56 BLU Main power supply circuit 2 10 to 14 V Ignition: “ON”
E01-57 — — — —
E01-58 — — — —
E01-59 — — — —
E01-60 — — — —
E01-61 — — — —
E01-62 — — — —
E01-63 — — — —
E01-64 — — — —
E01-65 — — — —
E01-66 — — — —

Reference Waveform • Waveform varies depending on

measurement condition and vehicle spec.
NOTE
• How to read waveforms is shown below. Fuel injector signal
Channel Probe Terminal No.
C01-77 (No.1)
+ C01-78 (No.2)
1
C01-79 (No.3)
– C01-61

Measurement condition
• Engine: Idle speed after warming up

IBP80A111034-01

[A]: Waveform of channel 1 [C]: VOLT/DIV of each channel

[B]: Ground level of each channel [D]: TIME/DIV
I7V20A111014-02

1. Fuel injector signal

 Engine General Information and Diagnosis: Bi-Fuel CNG 1A-353

Fuel injector No.1 signal and ignition coil No.1 signal Fuel injector No.2 signal and ignition coil No.2 signal

Fuel injector No.1 signal (1) Fuel injector No.2 signal (1)
Channel Probe Terminal No. Channel Probe Terminal No.
+ C01-77 + C01-78
1 1
– C01-61 – C01-61

Ignition coil No.1 signal (2) Ignition coil No.2 signal (2)
Channel Probe Terminal No. Channel Probe Terminal No.
+ C01-17 + C01-18
2 2
– C01-61 – C01-61

CMP sensor signal (3) CMP sensor signal (3)

Channel Probe Terminal No. Channel Probe Terminal No.
+ C01-58 + C01-58
3 3
– C01-61 – C01-61

CKP sensor signal (4) CKP sensor signal (4)

Channel Probe Terminal No. Channel Probe Terminal No.
+ C01-60 + C01-60
4 4
– C01-61 – C01-61

Measurement condition Measurement condition

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

I7V10A111011-05 I7V10A111015-01

5. Camshaft 360° angle 6. Crankshaft 720° angle 5. Camshaft 360° angle 6. Crankshaft 720° angle
1A-354 Engine General Information and Diagnosis: Bi-Fuel CNG

Fuel injector No.3 signal and ignition coil No.3 signal HO2S-2 signal
Channel Probe Terminal No.
Fuel injector No.3 signal (1) + C01-52
Channel Probe Terminal No. 1
– C01-61
+ C01-79
1
– C01-61 Measurement condition
• Engine: Racing after warming up
Ignition coil No.3 signal (2)
Channel Probe Terminal No.
+ C01-19
2
– C01-61

CMP sensor signal (3)

Channel Probe Terminal No.
+ C01-58
3
– C01-61

CKP sensor signal (4)

Channel Probe Terminal No.
IJCA0A111031-01
+ C01-60
4
– C01-61 1. Engine: Racing 2. Engine: Idle speed

Measurement condition Ignition coil signal

• Engine: Idle speed after warming up Channel Probe Terminal No.
C01-17 (No.1)
+ C01-18 (No.2)
1
C01-19 (No.3)
– C01-61

Measurement condition
• Engine: Idle speed after warming up

I7V10A111016-01

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

HO2S-1 signal
Channel Probe Terminal No.
+ C01-53
1 I8T401112041-01
– C01-61

Measurement condition
• Engine: Idle speed after warm up

IJCA0A111032-01
 Engine General Information and Diagnosis: Bi-Fuel CNG 1A-355

MAP sensor signal Throttle actuator signal

Channel Probe Terminal No.
+ C01-35 Throttle actuator signal (Open) (1)
1 Channel Probe Terminal No.
– C01-61
+ C01-70
1
Measurement condition – C01-61
• Engine: Racing after warming up
Throttle actuator signal (Close) (2)
Channel Probe Terminal No.
+ C01-75
2
– C01-61

Measurement condition
• Engine: Idle speed after warming up

IBV10A111022-01

1. Engine: Racing 2. Engine: Idle speed

EVAP canister purge valve signal

Channel Probe Terminal No.
+ C01-40
1
– C01-61 IJCA0A111028-01

Measurement condition Measurement condition

• EVAP canister purge valve: 10% open • Engine: Racing after warming up (Momentarily at
(using “Active Test” of SUZUKI scan tool) accelerator pedal depressed)

I7V20A111065-02
IJCA0A111029-01
1. EVAP canister purge valve signal
1A-356 Engine General Information and Diagnosis: Bi-Fuel CNG

CKP sensor signal and CMP sensor signal Knock sensor signal
Channel Probe Terminal No.
CMP sensor signal (1) + C01-33
Channel Probe Terminal No. 1
– C01-61
+ C01-58
1
– C01-61 Measurement condition
• Engine: Running at 3,000 rpm after warming up
CKP sensor signal (2)
Channel Probe Terminal No.
+ C01-60
2
– C01-61

Measurement condition
• Engine: Idle speed after warming up

IJCA0A111030-01

Generator LIN communication signal

Channel Probe Terminal No.
+ C01-31
1
– C01-61
I8C50B111039-01
Measurement condition
HO2S-1 and HO2S-2 heater signal • Engine: Idle speed after warming up

HO2S-1 heater signal (1)

Channel Probe Terminal No.
+ C01-71
1
– C01-61

HO2S-1 heater signal (2)

Channel Probe Terminal No.
+ C01-76
2
– C01-61

Measurement condition ICV00P111021-02

• Engine: Idle speed after warming up 1. Generator LIN communication signal

IDLA0A110032-01
 Engine General Information and Diagnosis: Bi-Fuel CNG 1A-357

Fuel pump relay signal Starting motor control relay signal

Channel Probe Terminal No.
+ E01-35 Ignition ON signal (1)
1 Channel Probe Terminal No.
– C01-61
+ E01-19
1
Measurement condition – C01-61
• Ignition: “OFF” → “ON” → “START”
Starting motor control relay signal (2)
Channel Probe Terminal No.
+ E01-11
2
– C01-61

Fuel pump relay signal (3)

Channel Probe Terminal No.
+ E01-38
3
– C01-61

Measurement condition
IAW101110042-01 • Ignition: “OFF” → “ON” → “START”
1. Fuel pump relay signal 3. Ignition: “ON”
2. Ignition: “OFF” 4. Ignition: “START”

CAN communication signal

CAN communication signal (High) (1)

Channel Probe Terminal No.
C01-22
+
1 E01-9
– C01-61

CAN communication signal (Low) (2)

IJCA0A111033-01
Channel Probe Terminal No.
C01-21 4. Ignition: “OFF” 6. Ignition: “START”
+ 5. Ignition: “ON” 7. Starting motor: Operating prohibited
2 E01-18
– C01-61

Measurement condition
• Ignition: “ON”

I8C50B111041-01
1A-358 Engine General Information and Diagnosis: Bi-Fuel CNG

Inspection of CNG Control Module and Its Circuit

AENJCA0A1134070
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”.
• 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, read “Precautions for CNG Control Module Circuit Inspection” under
“Precautions for Engine (Bi-Fuel CNG)” in Section 1 (Page 1-4).

[A]

E23 C12
9 8 7 6 5 4 3 2 1 9 8 7 65 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

IJCA0A113018-01

[A]: CNG control module connector (View: [a])

“C12” connector
Terminal No. Wire color Circuit Normal voltage Condition
10 to 14 V Ignition: “ON”
Refer to reference waveform.
CNG fuel injector No.1 drive
C12-1* WHT • “CNG fuel injector signal”: Bi-Fuel CNG (Page 1A-361)
circuit
• “Fuel injector signal and CNG fuel injector signal”: Bi-
Fuel CNG (Page 1A-362)
C12-2 — — — —
C12-3 — — — —
C12-4 — — — —
10 to 14 V Ignition: “ON”
Refer to reference waveform.
Fuel injector No.3 drive
C12-5* RED • “Fuel injector signal”: Bi-Fuel CNG (Page 1A-361)
circuit
• “Fuel injector signal and CNG fuel injector signal”: Bi-
Fuel CNG (Page 1A-362)
10 to 14 V Ignition: “ON”
Refer to reference waveform.
Fuel injector No.1 drive
C12-6* PNK • “Fuel injector signal”: Bi-Fuel CNG (Page 1A-361)
circuit
• “Fuel injector signal and CNG fuel injector signal”: Bi-
Fuel CNG (Page 1A-362)
10 to 14 V Ignition: “ON”
Fuel injector No.3 drive Refer to reference waveform.
C12-7* GRN
signal from ECM circuit “Fuel injector signal and CNG fuel injector signal”: Bi-Fuel
CNG (Page 1A-362)
10 to 14 V Ignition: “ON”
Fuel injector No.1 drive Refer to reference waveform.
C12-8* YEL
signal from ECM circuit “Fuel injector signal and CNG fuel injector signal”: Bi-Fuel
CNG (Page 1A-362)
CNG control module ground
C12-9 BLK Below 0.3 V Ignition: “ON”
circuit 1
 Engine General Information and Diagnosis: Bi-Fuel CNG 1A-359

Terminal No. Wire color Circuit Normal voltage Condition

10 to 14 V Ignition: “ON”
Refer to reference waveform.
CNG fuel injector No.2 drive
C12-10* GRY • “CNG fuel injector signal”: Bi-Fuel CNG (Page 1A-361)
circuit
• “Fuel injector signal and CNG fuel injector signal”: Bi-
Fuel CNG (Page 1A-362)
C12-11 — — — —
C12-12 — — — —
C12-13 — — — —
10 to 14 V Ignition: “ON”
Refer to reference waveform.
Fuel injector No.2 drive
C12-14* WHT • “Fuel injector signal”: Bi-Fuel CNG (Page 1A-361)
circuit
• “Fuel injector signal and CNG fuel injector signal”: Bi-
Fuel CNG (Page 1A-362)
C12-15 — — — —
10 to 14 V Ignition: “ON”
Fuel injector No.2 drive Refer to reference waveform.
C12-16* BRN
signal from ECM circuit “Fuel injector signal and CNG fuel injector signal”: Bi-Fuel
CNG (Page 1A-362)
CNG control module ground
C12-17 BLK Below 0.3 V Ignition: “ON”
circuit 2
10 to 14 V Ignition: “ON”
Refer to reference waveform.
CNG fuel injector No.3 drive
C12-18* BLU • “CNG fuel injector signal”: Bi-Fuel CNG (Page 1A-361)
circuit
• “Fuel injector signal and CNG fuel injector signal”: Bi-
Fuel CNG (Page 1A-362)
C12-19 — — — —
C12-20 — — — —
C12-21 — — — —
C12-22 — — — —
C12-23 — — — —
C12-24 — — — —
CAN (high) communication Refer to reference waveform.
C12-25* RED
circuit “CAN communication signal”: Bi-Fuel CNG (Page 1A-362)
CNG control module ground
C12-26 BLK Below 0.3 V Ignition: “ON”
circuit 3
C12-27 — — — —
C12-28 — — — —
C12-29 — — — —
C12-30 — — — —
C12-31 — — — —
C12-32 — — — —
CAN (low) communication Refer to reference waveform.
C12-33* WHT
circuit “CAN communication signal”: Bi-Fuel CNG (Page 1A-362)
C12-34 — — — —

“E23” connector
Terminal No. Wire color Circuit Normal voltage Condition
10 to 14 V Ignition: “ON”
E23-1 RED Main power supply circuit 1
0 to 1 V Ignition: “OFF”
E23-2 — — — —
E23-3 — — — —
CNG valve control relay 0 to 1 V Ignition: “OFF”
E23-4 BLU
drive circuit 10 to 14 V Engine: Running
CNG pressure-and- 4.5 to 5.5 V Ignition: “ON”
E23-5 LT GRN temperature sensor power
0 to 1 V Ignition: “OFF”
supply circuit
1A-360 Engine General Information and Diagnosis: Bi-Fuel CNG

Terminal No. Wire color Circuit Normal voltage Condition

CNG cylinder pressure 4.5 to 5.5 V Ignition: “ON”
E23-6 BLU
sensor power supply circuit 0 to 1 V Ignition: “OFF”
E23-7 — — — —
E23-8 — — — —
E23-9 — — — —
10 to 14 V Ignition: “ON”
E23-10 RED Main power supply circuit 2
0 to 1 V Ignition: “OFF”
E23-11 — — — —
E23-12 — — — —
Ignition: “ON”
3.21 to 3.93 V
CNG temperature: 20 °C (68 °F)
CNG temperature sensor Ignition: “ON”
E23-13 RED 2.43 to 2.97 V
signal circuit CNG temperature: 40 °C (104 °F)
Ignition: “ON”
1.67 to 2.05 V
CNG temperature: 60 °C (140 °F)
Ignition: “ON”
0.78 to 0.96 V
CNG pressure: 100 KPa
CNG pressure sensor signal Ignition: “ON”
E23-14 GRY 1.43 to 1.75 V
circuit CNG pressure: 200 KPa
Ignition: “ON”
2.08 to 2.55 V
CNG pressure: 300 KPa
Ignition: “ON”
0.73 to 0.89 V
CNG cylinder pressure: 2 MPa
CNG cylinder pressure Ignition: “ON”
E23-15 RED 1.15 to 1.41 V
sensor signal circuit CNG cylinder pressure: 5 MPa
Ignition: “ON”
1.86 to 2.27 V
CNG cylinder pressure: 10 MPa
E23-16 — — — —
E23-17 — — — —
E23-18 — — — —
E23-19 — — — —
E23-20 — — — —
10 to 14 V Ignition: “ON”
E23-21 WHT Ignition ON signal circuit
0 to 1 V Ignition: “OFF”
Ignition: “ON”
0 to 1 V
Fuel select switch signal Fuel select switch: Pushed
E23-22 LT GRN
circuit Ignition: “ON”
8 to 13 V
Fuel select switch: Released
CNG cylinder pressure
E23-23 YEL Below 0.3 V Ignition: “ON”
sensor ground circuit
CNG pressure-and-
E23-24 LT BLU temperature sensor ground Below 0.3 V Ignition: “ON”
circuit
E23-25 — — — —
0 to 1 V Ignition: “ON”
Shut off valve of CNG Engine: Running
10 to 14 V
E23-26 BLU cylinder pressure regulator Fuel select mode: Petrol MODE
drive circuit Engine: Running
0 to 1 V
Fuel select mode: Forced CNG MODE
E23-27 — — — —
E23-28 — — — —
E23-29 — — — —
0 to 1 V Ignition: “OFF”
Ignition: “ON”
Fuel filler lid switch No.2 0 to 1 V
E23-30 GRN Fuel filler lid: Open
signal circuit
Ignition: “ON”
8 to 13 V
Fuel filler lid: Close
 Engine General Information and Diagnosis: Bi-Fuel CNG 1A-361

Terminal No. Wire color Circuit Normal voltage Condition

0 to 1 V Ignition: “OFF”
Ignition: “ON”
Fuel filler lid switch No.1 8 to 13 V
E23-31 LT BLU Fuel filler lid: Open
signal circuit
Ignition: “ON”
0 to 1 V
Fuel filler lid: Close
E23-32 — — — —
E23-33 — — — —
0 to 1 V Ignition: “ON”
Engine: Running
Shut off valve of CNG 10 to 14 V
E23-34 BLU Fuel select mode: Petrol MODE
cylinder valve drive circuit
Engine: Running
0 to 1 V
Fuel select mode: Forced CNG MODE

Reference Waveform Fuel injector signal

NOTE Fuel injector drive signal (1)
• Waveform analysis is as follows. Channel Probe Terminal No.
C12-6 (No.1)
+ C12-14 (No.2)
1
C12-5 (No.3)
– C12-9

Measurement condition
• Engine: Idle speed after warming up
• Fuel select mode: Petrol MODE

I8T401111066-01

[A]: Waveform of channel 1 [C]: VOLT/DIV of each channel

[B]: Ground level of each channel [D]: TIME/DIV

• Waveform varies depending on

measurement condition and vehicle spec. I7V20A111014-02

CNG fuel injector signal

Fuel injector drive signal from ECM (1)

Channel Probe Terminal No.
C12-8 (No.1)
+ C12-16 (No.2)
1
C12-7 (No.3)
– C12-9

CNG fuel injector drive signal (2)

Channel Probe Terminal No.
C12-1 (No.1)
+ C12-10 (No.2)
2
C12-18 (No.3)
– C12-9
1A-362 Engine General Information and Diagnosis: Bi-Fuel CNG

Measurement condition • Engine: Idle speed after warming up

• Engine: Idle speed after warming up • Fuel select mode: Petrol MODE
• Fuel select mode: Forced CNG MODE

I9R90A112019-01

I9R90A112018-01
CAN communication signal
Fuel injector signal and CNG fuel injector signal
CAN communication signal (High) (1)
Fuel injector drive 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)
– C12-9 Channel Probe Terminal No.
+ C12-33
2
CNG fuel injector drive signal (2) – C12-9
Channel Probe Terminal No.
C12-1 (No.1) Measurement condition
+ C12-10 (No.2) • Ignition: “ON”
2
C12-18 (No.3)
– C12-9

Fuel injector drive signal (3)

Channel Probe Terminal No.
C12-6 (No.1)
+ C12-14 (No.2)
3
C12-5 (No.3)
– C12-9

Measurement condition
• Engine: Idle speed after warming up
• Fuel select mode: Forced CNG MODE I7RW01110028-01

I9R90A112021-01

ECM Power and Ground Circuit Check

AENJCA0A1134071
Refer to “ECM Power Supply and Ground Circuit Check”: K10B (Page 1A-113).
 Engine General Information and Diagnosis: Bi-Fuel CNG 1A-363

CNG Control Module Power and Ground Circuit Check

AENJCA0A1134072
Circuit Diagram

C1
2 5V
LT GRN E23-5 12V
GRY E23-14
5V
RED E23-13
LT BLU E23-24
D1
3 5V
BLU E23-6
RED E23-15 A1

YEL E23-23
E23-21 WHT

B1 5V 12V
E1
C12-9 BLK
RED E23-1 E2
C12-17 BLK
5 E3
RED E23-10 C12-26 BLK
4 B2
E01-19 WHT
7
8 6
10
E01-10 PNK
9
E01-56 BLU
E01-55 BLU
11
C01-61 BLK
C01-66 BLK 12

[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
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

10 9 8 7 6 5 4 3 2 1 9 8 7 6 5 4 3 2 1
65 64 63 62 61 20 19 18 17 16 15 14 13 12 11 57 56 55 18 17 16 15 14 13 12 11 10
70 69 68 67 66 30 29 28 27 26 25 24 23 22 21 60 59 58 27 26 25 24 23 22 21 20 19
75 74 73 72 71 40 39 38 37 36 35 34 33 32 31 63 62 61 36 35 34 33 32 31 30 29 28
80 79 78 77 76 50 49 48 47 46 45 44 43 42 41 66 65 64 45 44 43 42 41 40 39 38 37
60 59 58 57 56 55 54 53 52 51 54 53 52 51 50 49 48 47 46

IJCA0A113017-03

[A]: CNG control module connector (View: [a]) E2: CNG control module ground circuit 2 7. Ignition switch
[B]: ECM connector (View: [a]) E3: CNG control module ground circuit 3 8. “IG COIL” fuse
A1: Ignition ON signal circuit 1. CNG control module 9. “FI” fuse
B1: Main power supply circuit 1 2. CNG pressure-and-temperature sensor 10. Main relay
B2: Main power supply circuit 2 3. CNG cylinder pressure sensor 11. Main fuse box
C1: CNG pressure sensor power supply circuit 4. “CNG” fuse 12. Battery
D1: CNG cylinder pressure sensor power supply circuit 5. ECM
E1: CNG control module ground circuit 1 6. “IGN” fuse
1A-364 Engine General Information and Diagnosis: Bi-Fuel CNG

Circuit Description
When ignition is set to “ON”, the main relay turns ON (the contact point closes) and the main power is supplied to ECM
and CNG control module. And then CNG control module supplies 5 V power to each sensor (CNG pressure-and-
temperature sensor and CNG cylinder pressure sensor).

Troubleshooting

NOTE
• Before troubleshooting, read “Precautions for CNG Control Module Circuit Inspection” under
“Precautions for Engine (Bi-Fuel CNG)” in Section 1 (Page 1-4).
• Before performing, check that related fuses of CNG control module 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? K10B and Bi-Fuel CNG
in Section 1J (Page 1J-
4) and “Generator Test”:
K10B and Bi-Fuel CNG
in Section 1J (Page 1J-
5).
2 Main relay and its circuit check Go to Step 3. Repair or replace
1) Check main relay and its circuit referring to “ECM Power defective wire harness
and Ground Circuit Check”: Bi-Fuel CNG (Page 1A-362). and/or main relay.

Is check result OK?

3 Ignition mode circuit check Go to Step 4. Check that “IG COIL”
1) When ignition is “OFF”, disconnect “C12” and “E23” fuse has or “IGN” fuse
connectors from CNG control module. not blown. If check
result is OK, repair or
2) Check for proper terminal connection to “C12” and “E23”
replace defective wire
connectors.
harness.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between “A1” and ground is battery
voltage.

Is check result OK?

4 Main power supply circuit check Go to Step 5. Check that “CNG” fuse
1) Check that voltage between each of “B1” and “B2” circuit has not blown. If check
and ground is battery voltage. result is OK, repair or
replace defective wire
Is check result OK? harness.
5 CNG control module ground circuit check Go to Step 6. Repair or replace
1) Set ignition “OFF”. defective wire harness.
2) Check that resistance between each of “E1”, “E2” and
“E3” circuit and ground is less than 1 Ω.

Is check result OK?

 Engine General Information and Diagnosis: Bi-Fuel CNG 1A-365

Step Action Yes No

6 Sensor power supply circuit check CNG control module Check wiring harness
1) When ignition is “OFF”, connect “C12” and “E23” power supply and for open, short circuit to
connectors from CNG control module. ground circuit is in good battery and short circuit
condition. to ground. If wiring
2) Disconnect connectors from CNG pressure-and-
harness is in good
temperature sensor and CNG cylinder pressure sensor.
condition, replace CNG
3) Check for proper terminal connection to each sensor control module and
connector. recheck CNG control
4) If connections are OK, set ignition “ON”. module power supply
5) Check that voltage between each of the following circuits and ground circuits.
and ground is approx. 5 V. (Page 1C-4)
• C1
• D1

Is check result OK?

Repair Instructions
Idle Speed Inspection
AENJCA0A1136001
Before idle speed check, check the following points.
• Lead wires and hoses of electronic fuel injection and
engine and emission control systems are connected
securely.
• Valve lash is checked according to maintenance 1

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
condition.
• There is no air abnormally drawn in from air intake
system.
• There is no obstruction in PCV valve or its hoses.
• There is no DTCs in ECM and CNG control module.
(A)
• The following items are turned OFF as checked using IJCA0A181004-01
“Data List” mode of scan tool.
2) Warm up engine to normal operating temperature.
– A/C Comp Relay
3) Check engine idle speed using “Data List” mode on
– A/C Switch scan tool.
– Blower Fan 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-
After checking all items, check idle speed as follows. Fuel CNG (Page 1A-310).

NOTE Engine idle speed

Petrol mode:
Before starting engine, place gear shift lever • A/C OFF: 650 to 750 rpm
in “Neutral”, apply parking brake and block • A/C ON: 800 to 900 rpm
drive wheels. CNG mode:
• A/C OFF: 650 to 750 rpm
1) With ignition “OFF”, connect SUZUKI scan tool to • A/C ON: 800 to 900 rpm
DLC (1).
Special tool
(A): SUZUKI scan tool (Suzuki SDT-II)
1A-366 Engine General Information and Diagnosis: Bi-Fuel CNG

Special Tools and Equipment

Special Tool
AENJCA0A1138001
SUZUKI scan tool (Suzuki
SDT-II)
—
(Page 1A-293) /
(Page 1A-294) /
(Page 1A-365)
 Aux. Emission Control Devices: K10B and Bi-Fuel CNG 1B-1

Aux. Emission Control Devices

Engine

K10B and Bi-Fuel CNG

Diagnostic Information and Procedures
EVAP Canister Purge System Inspection NOTE
AENJCA0A1214001
EVAP canister purge valve is operated using
! WARNING
scan tool as follows.
If you suck at the nipple on the EVAP canister • EVAP canister purge valve is OFF: 0%
purge valve, you will inhale harmful fuel • EVAP canister purge valve is ON: 100%
vapor that may be present inside the EVAP
canister purge valve.
Never suck the nipple on the EVAP canister
purge valve.

NOTICE
If excessive negative pressure is applied, the
1
EVAP canister purge valve may be damaged.
Do not exceed negative pressure of –66 kPa
(–0.67 kgf/cm2, –9.57 psi, –0.66 bar).

1) Prepare to operate EVAP canister purge valve as

follows.
• Using SUZUKI scan tool:
a. Connect SUZUKI scan tool to DLC (1) with
ignition “OFF”.
b. With ignition “ON”, clear DTC and select
“Active Test” mode on SUZUKI scan tool.
(A)
Special tool
IJCA0A181004-01
(A): SUZUKI scan tool (Suzuki SDT-II)
1B-2 Aux. Emission Control Devices: K10B and Bi-Fuel CNG

• Without using SUZUKI scan tool:
a. Connect service wire (2) between EVAP
canister purge valve and EVAP canister purge
valve connector with ignition “OFF”.
b. Set ignition “ON”.
7) If faulty condition is found, check the following items.
• Wire harness and connections
• EVAP canister purge valve: (Page 1B-4)
• Vacuum hose: (Page 1B-6)

NOTE [A]

EVAP canister purge valve (1) is operated

using service wire as follows. 1 (A)

• EVAP canister purge valve is OFF:

[a]: Unground “RED” harness side
terminal of EVAP canister purge valve.
2
• EVAP canister purge valve is ON:
[b]: Ground “RED” harness side terminal
of EVAP canister purge valve.
[B]

[a] 1 (A)

[b]

IJCA0A121001-01

1
I8C50B120002-01

2) Set ignition “OFF”.

3) Disconnect vacuum hose (2) from intake manifold
and purge hose from EVAP canister purge valve (1).
4) Install special tool to vacuum hose.
Special tool
(A): 09917M47011
5) Set ignition “ON”.
6) Check EVAP canister purge valve operation as
follows.
a) Check that negative pressure of –60 kPa (–0.6
kgf/cm2, –8.7 psi, –0.6 bar) can be applied when
EVAP canister purge valve is turned off [A].
b) Check that no negative pressure can be applied
when EVAP canister purge valve is turned on [B].
 Aux. Emission Control Devices: K10B and Bi-Fuel CNG 1B-3

Repair Instructions
EVAP System Components
AENJCA0A1216001

K10B

(b)
3

2 (b)

(a)
1

IJCA0A121002-02

1. EVAP canister purge valve 3. EVAP canister bracket : 9.0 Nm (0.92 kgf-m, 7.0 lbf-ft)
2. EVAP canister : 7.0 Nm (0.71 kgf-m, 5.5 lbf-ft)
1B-4 Aux. Emission Control Devices: K10B and Bi-Fuel CNG

Bi-fuel CNG

(a)

IJCA0A121003-03

1. EVAP canister purge valve 2. EVAP canister : 7.0 Nm (0.71 kgf-m, 5.5 lbf-ft)

EVAP Canister Purge Valve Inspection If faulty condition is found, replace purge valve.
AENJCA0A1216002
EVAP canister purge valve resistance
! WARNING
22 – 26 Ω at 20 °C (68 °F)
If you suck at the nipple on the EVAP canister
purge valve, you will inhale harmful fuel
vapor that may be present inside the EVAP
canister purge valve.
Never suck the nipple on the EVAP canister
purge valve.

NOTICE
If excessive negative pressure is applied, the 1
I8T401122005-01
EVAP canister purge valve may be damaged.
Do not exceed a negative pressure of –66 kPa
(–0.67 kgf/cm2, –9.57 psi, –0.66 bar).

1) With ignition “OFF”, disconnect connector and hoses

from EVAP canister purge valve (1).
2) Remove purge valve from engine harness bracket.
3) Check resistance between two terminals of purge
valve.
 Aux. Emission Control Devices: K10B and Bi-Fuel CNG 1B-5

4) Check purge valve operation as follows. EVAP Canister Removal and Installation (Bi-
If faulty condition is found, replace purge valve. Fuel CNG)
AENJCA0A1216007
a) Install special tool and vacuum hose (2) to purge
Removal
valve (1).
1) Hoist vehicle.
Special tool 2) Disconnect purge pipe (1) from pipe (2). (Page
(A): 09917M47011 1G-54)
b) When connecting 12 V battery to purge valve
terminals, check that negative pressure (–60
kPa, –0.6 kgf/cm2, –8.7 psi, –0.6 bar) cannot be
applied to purge valve. 2
c) When not connecting 12 V battery to purge valve
terminals, check that negative pressure (–60
kPa, –0.6 kgf/cm2, –8.7 psi, –0.6 bar) can be
applied to purge valve.

[A]
1

2 IJCA0A121004-01

3) Detach EVAP canister (1) from fuel tank in arrow

1 (A)
direction (“1” – “2”) and move it downward.
4) Disconnect air suction pipe (2) and fuel EVAP hose
(3) and remove EVAP canister.
5) Disconnect purge pipe (4) from EVAP canister.
[B]
3

2 4

(A)
2
1
“2” “1”

IDAA0A121003-01 1

[A]: Purge valve ON [B]: Purge valve OFF

IJCA0A121005-02

Installation
Reverse removal procedure noting the following points.
• Install clamps to specified position on fuel EVAP hose.
(Page 1G-54)
• Connect quick joint securely. (Page 1G-54)

EVAP Canister Inspection

AENJCA0A1216003
! WARNING
If you suck at the nozzle on the EVAP
canister by mistake, you will inhale harmful
fuel vapor that may be present inside the
canister.
Never suck at any of the nozzles on the EVAP
canister.
1B-6 Aux. Emission Control Devices: K10B and Bi-Fuel CNG

1) For bi-fuel CNG, remove EVAP canister. (Page 1B- K10B

5)
1 5
3
2) For K10B, disconnect hoses from EVAP canister.
(A)
3) Check outside of EVAP canister visually.
4) Check that there is no restriction of flow through
purge port (1) and air port (2) when air is blown (4) 4
into tank port (3).
K10B
1 3

3 2
IGJA0A121005-01

Bi-fuel CNG
(A)
4 5 3

2
2

IGJA0A121004-01
1

Bi-fuel CNG

4
2

1 IFRA0A121006-01

If faulty condition is found, replace EVAP canister.

EVAP Connection Hose Inspection

AENJCA0A1216004
Check hoses for connection, leakage, clogging and
deterioration.
Replace hose if defective.

PCV Hose Inspection

IFRA0A121005-01 AENJCA0A1216005
5) Check EVAP canister for air leakage according to Check hoses for connection, leakage, clogging and
the following procedure. deterioration.
Replace hose if defective.
a) Plug purge port (1) and air port (2) using rubber
plug (3).
b) Install hose (4) and special tool to tank port (5).
Special tool
(A): 09917M47011
c) Using special tool, apply specified negative
pressure to EVAP canister for one minute.
EVAP canister holding negative pressure
–20.0 kPa (–0.20 kgf/cm2, –2.90 psi, –0.20 bar)
 Aux. Emission Control Devices: K10B and Bi-Fuel CNG 1B-7

PCV Valve Inspection 3) Check fuel cut valve for operation as follows.
AENJCA0A1216006
a) Connect fuel EVAP hose (1) to vacuum port (2)
1) Disconnect PCV valve from cylinder head cover and of special tool.
install plug to head cover hole.
2) Run engine at idle speed. Special tool
(A): 09917M47011
3) Place finger over end of PCV valve (1) to check for
negative pressure. b) Check that air can be sucked when negative
If no vacuum is felt, check valve for clogging. pressure is applied to fuel cut valve.
Replace PCV valve if defective. c) Disconnect hose from special tool.
d) Connect hose to pressure port (3) of special tool.
1
e) Check that air flows into tank when pressure is
applied to fuel cut valve.

I7V20A121009-01

4) Stop engine and remove PCV valve (1).

Install clean hose to valve and check that there is air
flow when blowing air into hose from “a” to “b” and
1
that there is no air flow when blowing air into hose
from “b” to “a” as shown in figure.
If faulty condition is found, replace PCV valve.
[B]
1
(A) (A)
b

2 3
1 a

[A]

I7V10A121002-01 IJCA0A121007-01

[A]: Air flow to vacuum port [B]: Air flow from pressure port
Fuel Cut Valve Inspection
AENJCA0A1216008
4) If faulty condition is found, replace fuel tank.
1) For K10B, Disconnect fuel EVAP hose (1).
• K10B: (Page 1G-26)
• Bi-fuel CNG: (Page 1G-71)

IJCA0A121006-01

2) For bi-fuel CNG, Remove EVAP canister. (Page

1B-5)
1B-8 Aux. Emission Control Devices: K10B and Bi-Fuel CNG

Specifications
Tightening Torque Specifications
AENJCA0A1217001
Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“EVAP System Components”: K10B and Bi-Fuel CNG (Page 1B-3)
“Fasteners Information” in Section 0A (Page 0A-6)

Special Tools and Equipment

Special Tool
AENJCA0A1218001
09917M47011 SUZUKI scan tool (Suzuki
SDT-II)
Vacuum pump gauge —
(Page 1B-2) / (Page 1B-1)
(Page 1B-5) /
(Page 1B-6) /
(Page 1B-7)
 Aux. Emission Control Devices: K12M 1B-9

K12M
Diagnostic Information and Procedures
EVAP Canister Purge System Inspection
AENJCA0A1224001
! WARNING
If you suck at the nipple on the EVAP canister
purge valve, you will inhale harmful fuel
vapor that may be present inside the EVAP
canister purge valve.
Never suck the nipple on the EVAP canister
purge valve.
NOTICE
If excessive negative pressure is applied, the
EVAP canister purge valve may be damaged.
Do not exceed negative pressure of –66 kPa
(–0.67 kgf/cm2, –9.57 psi, –0.66 bar).
• Without using SUZUKI scan tool:
a. Connect service wire (2) between EVAP
canister purge valve and EVAP canister purge
valve connector with ignition “OFF”.
b. Set ignition “ON”.
NOTE
EVAP canister purge valve (1) is operated
using service wire as follows.
• EVAP canister purge valve is OFF:
[a]: Unground “GRY” harness side
terminal of EVAP canister purge valve.
• EVAP canister purge valve is ON:
[b]: Ground “GRY” harness side terminal
of EVAP canister purge valve.

1) Prepare to operate EVAP canister purge valve as

follows.
[a]
• Using SUZUKI scan tool:
a. Connect SUZUKI scan tool to DLC (1) with [b]
ignition “OFF”.
b. With ignition “ON”, clear DTC and select
“Active Test” mode on SUZUKI scan tool.
2
Special tool
(A): SUZUKI scan tool (Suzuki SDT-II)

NOTE
1
EVAP canister purge valve is operated using I8C50B120002-01
scan tool as follows.
• EVAP canister purge valve is OFF: 0%
• EVAP canister purge valve is ON: 100%

(A)
IJCA0A181004-01
1B-10 Aux. Emission Control Devices: K12M

2) Set ignition “OFF”.

3) Disconnect vacuum hose (2) from intake manifold
and purge hose from EVAP canister purge valve (1).
4) Install special tool to vacuum hose.
Special tool
(A): 09917M47011
5) Set ignition “ON”.
6) Check EVAP canister purge valve operation as
follows.
a) Check that negative pressure of –60 kPa (–0.61
kgf/cm2, –8.70 psi, –0.60 bar) can be applied
when EVAP canister purge valve is turned off [A].
b) Check that no negative pressure can be applied
when EVAP canister purge valve is turned on [B].
7) If faulty condition is found, check the following items.
• Wire harness and connections
• EVAP canister purge valve: (Page 1B-11)
• Vacuum hose: (Page 1B-12)

[A]

1
(A)

[B]

1
(A)

IJCA0A122001-01
 Aux. Emission Control Devices: K12M 1B-11

Repair Instructions
EVAP System Components
AENJCA0A1226001

(b)

2 (b)

(a)
1

IJCA0A122002-02

1. EVAP canister purge valve 3. EVAP canister bracket : 9.0 Nm (0.92 kgf-m, 7.0 lbf-ft)
2. EVAP canister : 7.0 Nm (0.71 kgf-m, 5.5 lbf-ft)

EVAP Canister Purge Valve Inspection 1) With ignition “OFF”, disconnect connector and hoses
AENJCA0A1226002 from EVAP canister purge valve (1).
! WARNING 2) Remove purge valve from engine harness bracket.
If you suck at the nipple on the EVAP canister 3) Check resistance between two terminals of purge
purge valve, you will inhale harmful fuel valve.
vapor that may be present inside the EVAP If faulty condition is found, replace purge valve.
canister purge valve.
EVAP canister purge valve resistance
Never suck at any of the nipples on the EVAP
22 – 26 Ω at 20 °C (68 °F)
canister purge valve.

NOTICE
If excessive negative pressure is applied, the
EVAP canister purge valve may be damaged.
Do not exceed negative pressure of –66 kPa
(–0.67 kgf/cm2, –9.57 psi, –0.66 bar).

1
I8T401122005-01
1B-12 Aux. Emission Control Devices: K12M

4) Check purge valve operation as follows.

If faulty condition is found, replace purge valve. 1 3

a) Install special tool and vacuum hose (2) to purge

valve (1). 4

Special tool
(A): 09917M47011
b) When connecting 12 V battery to purge valve
terminals, check that negative pressure (–60
kPa, –0.61 kgf/cm2, –8.70 psi, –0.60 bar) cannot
be applied to purge valve.
c) When not connecting 12 V battery to purge valve
terminals, check that negative pressure (–60
kPa, –0.61 kgf/cm2, –8.70 psi, –0.60 bar) can be 2
applied to purge valve.

[A] IGJA0A121004-01

4) Check EVAP canister for air leakage according to

the following procedure.
a) Plug purge port (1) and air port (2) using rubber
2 plug (3).
(A)
b) Install hose (4) and special tool to tank port (5).
1
Special tool
(A): 09917M47011
c) Using special tool, apply specified negative
pressure to EVAP canister for one minute.
[B]
EVAP canister holding negative pressure
–20.0 kPa (–0.20 kgf/cm2, –2.90 psi, –0.20 bar)

2
1 5
3
(A)
(A)
1

4
IDAA0A121003-01

[A]: Purge valve ON [B]: Purge valve OFF

EVAP Canister Inspection

AENJCA0A1226004
! WARNING
If you suck at the nozzle on the EVAP 3 2
IGJA0A121005-01
canister, you will inhale harmful fuel vapor
that may be present inside the canister. If faulty condition is found, replace EVAP canister.
Never suck at any of the nozzles on the EVAP
canister. EVAP Connection Hose Inspection
AENJCA0A1226005
Check hoses for connection, leakage, clogging and
1) Disconnect hoses from EVAP canister.
deterioration.
2) Check outside of EVAP canister visually. Replace hose if defective.
3) Check that there is no restriction of flow through
purge port (1) and air port (2) when air is blown (4) PCV Hose Inspection
into tank port (3). AENJCA0A1226006
Check hoses for connection, leakage, clogging and
deterioration.
Replace hose if defective.
 Aux. Emission Control Devices: K12M 1B-13

PCV Valve Inspection a) Connect fuel EVAP hose (1) to vacuum port (2)
AENJCA0A1226007 of special tool.
1) Disconnect PCV valve from cylinder head cover and
install plug to head cover hole. Special tool
(A): 09917M47011
2) Run engine at idle speed.
3) Place finger over end of PCV valve (1) to check for b) Check that air can be sucked when negative
negative pressure. pressure is applied to fuel cut valve.
If no negative pressure is felt, check valve for c) Disconnect hose from special tool.
clogging. Replace PCV valve if defective. d) Connect hose to pressure port (3) of special tool.
e) Check that air flows into tank when pressure is
1
applied to fuel cut valve.

I7V20A121009-01

4) Stop engine and remove PCV valve (1).

1
Install clean hose to valve and check that there is air
flow when blowing air into hose from “a” to “b” and
that there is no air flow when blowing air into hose
from “b” to “a” as shown in figure.
If faulty condition is found, replace PCV valve. [B]
1
(A) (A)

b 2 3

1 a
[A]

IJCA0A122003-02

I7V10A121002-01 [A]: Air flow to vacuum port [B]: Air flow from pressure port

Fuel Cut Valve Inspection 3) If faulty condition is found, replace fuel tank. (Page
AENJCA0A1226008 1G-26)
1) Disconnect fuel EVAP hose (1).

IJCA0A122004-01

2) Check fuel cut valve for operation as follows.

1B-14 Aux. Emission Control Devices: K12M

Specifications
Tightening Torque Specifications
AENJCA0A1227001
Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“EVAP System Components”: K12M (Page 1B-11)
“Fasteners Information” in Section 0A (Page 0A-6)

Special Tools and Equipment

Special Tool
AENJCA0A1228001
09917M47011 SUZUKI scan tool (Suzuki
SDT-II)
Vacuum pump gauge —
(Page 1B-10) / (Page 1B-9)
(Page 1B-12) /
(Page 1B-12) /
(Page 1B-13)
 Engine Electrical Devices: K10B and Bi-Fuel CNG 1C-1

Engine Electrical Devices

Engine

K10B and Bi-Fuel CNG

General Description
Engine Electrical Devices Description
AENJCA0A1311001
Various sensors for the engine control in this model are outlined as follows.
Sensor Construction
• The sensor is mounted on electric throttle body.
• A non-contact type sensor with Hall IC generates dual voltage signals in
TP sensor (main / sub) response to throttle valve opening and these signals, main and sub, are
inputted to ECM. Based on the signals, ECM calculates opening degree of the
throttle valve.
• The sensor is mounted on accelerator pedal.
• A non-contact type sensor applying electromagnetic induction detects
APP sensor (main / sub) depressing degree of accelerator pedal.
• Dual voltage signals, main and sub, are inputted to ECM. Based on the signals,
ECM controls throttle valve opening activating throttle actuator.
• The sensor is mounted on cylinder block near the crank pulley at intake
manifold side.
• Magnetic variation induced by a sensor plate installed on crankshaft is
CKP sensor converted to voltage signal in the sensor and the signal is inputted to ECM.
Using the signal, ECM calculates engine speed.
• Based on CMP signal and CKP signal, ECM reads each piston position in
cylinder and controls fuel injection and ignition timing.
• The sensor is mounted on the end of cylinder head at intake manifold side.
• Magnetic variation induced by a signal rotor press-fitted on camshaft end is
CMP sensor converted to voltage signal in the sensor and the signal is inputted to ECM.
• Based on CMP signal and CKP signal, ECM reads each piston position in
cylinder and controls fuel injection and ignition timing.
• The sensor is mounted on intake manifold.
• A pressure responsive silicon membrane incorporated in diaphragm generates
MAP sensor voltage signal corresponding to intake pressure (absolute pressure) and the
signal is inputted to ECM. Based on the signal, ECM calculates manifold
absolute pressure.
• The sensor is mounted on air cleaner outlet hose.
IAT sensor • A thermistor incorporated in the sensor generates voltage signal corresponding
to intake air temperature and the signal is inputted to ECM. Using the signal,
ECM calculates intake air temperature.
• The sensor is mounted on thermostat case.
• A thermistor incorporated in the sensor changes electrical resistance
ECT sensor corresponding to temperature and the resistance converted to voltage is
inputted to ECM. Based on the voltage signal, ECM calculates coolant
temperature.
• The sensor is mounted on cylinder block.
Knock sensor • A piezoelectric ceramic element incorporated in the sensor generates
electromotive force in proportion to degree of shock and the generated voltage
signal is inputted to ECM. Using the signal, ECM detects piston knocking.
1C-2 Engine Electrical Devices: K10B and Bi-Fuel CNG

Sensor Construction
• HO2S-1 is mounted on exhaust manifold.
• The sensor is composed of a platinum coated zirconia element which
generates electromotive force sensing difference of oxygen concentration.
Voltage signal corresponding to variation of oxygen concentration in exhaust
HO2S-1 gas before flowing into catalyst is inputted to ECM.
• Judging from signals of HO2S-1 and HO2S-2, ECM controls A/F (air fuel ratio)
to maintain purification rate of exhaust gas in high level for stabile emissions. A
heater is incorporated in oxygen sensor for quick startup and maintenance of
activation.
• HO2S-2 is mounted on exhaust manifold.
• The sensor is composed of a platinum coated zirconia element which
generates electromotive force sensing difference of oxygen concentration.
Voltage signal corresponding to variation of oxygen concentration in exhaust
HO2S-2 gas after flowing out of catalyst is inputted to ECM.
• Judging from signals of HO2S-1 and HO2S-2, ECM controls A/F (air fuel ratio)
to maintain purification rate of exhaust gas in high level for stabile emissions. A
heater is incorporated in oxygen sensor for quick startup and maintenance of
activation.
• The sensor is mounted on high pressure piping in A/C system.
• A pressure transductor (semiconductor chip) is incorporated in the sensor and
A/C refrigerant pressure sensor variation of refrigerant pressure is converted to voltage signal and then the
signal is inputted to ECM. Using the signal, ECM calculates refrigerant
pressure.

Engine Electrical Devices Description (Bi-Fuel CNG)

Various sensors for the bi-fuel CNG control in this model are outlined as follows.
Component
CNG cylinder pressure sensor
Shut off valve of CNG cylinder
pressure regulator
CNG pressure-and-temperature CNG pressure-and-temperature sensor detects CNG fuel pressure and CNG
sensor
Shut off valve of CNG cylinder
valve
Fuel filler lid switch
Fuel select switch
AENJCA0A1311002
Construction
CNG cylinder pressure sensor, which is installed in CNG cylinder pressure
regulator, detects CNG fuel pressure in CNG cylinder. This signal is recognized as
remaining CNG.
Shut off valve is installed in CNG cylinder pressure regulator, and opens and
closes solenoid valve based on signals from CNG control module to supply or to
shut off CNG fuel to CNG fuel delivery pipe. For detail, refer to “CNG Pressure
Regulator Description”: Bi-Fuel CNG in Section 1G (Page 1G-37).
temperature in CNG fuel delivery pipe.
Shut off valve is installed in CNG cylinder valve, and opens and closes solenoid
valve based on signals from CNG control module to supply or to shut off CNG to
CNG fuel lines. For detail, refer to “Shut-Off Valve” under “CNG Cylinder Valve
Description”: Bi-Fuel CNG in Section 1G (Page 1G-36).
Fuel filler lid switch detects open or close state of fuel filler lid.
Fuel select switch, which is installed on instrument panel, outputs on or off signal
to CNG control module to select operating mode among three modes. Selected
operating mode and remaining CNG are indicated on combination meter. For
detail, refer to “Petrol / CNG Indicator” under “Bi-Fuel CNG System Description”:
Bi-Fuel CNG in Section 1A (Page 1A-275).

Component Location
Electronic Control System Component Location
AENJCA0A1313004
• K10B: Refer to “Electronic Control System Component Location”: K10B in Section 1A (Page 1A-17).
• Bi-Fuel CNG: Refer to “Electronic Control System Component Location”: Bi-Fuel CNG in Section 1A (Page 1A-
287).
 Engine Electrical Devices: K10B and Bi-Fuel CNG 1C-3

Repair Instructions
ECM Removal and Installation 4) Remove ECM bracket (1), if necessary.
AENJCA0A1316001
NOTICE 1
The ECM is a precision unit and can be easily
damaged.
Handle the ECM carefully and do not expose
it to large shock.

NOTE
After ECM is replaced with new one, perform
“Procedure after ECM Replacement”: K10B
and Bi-Fuel CNG (Page 1C-4).

Removal
1) Disconnect negative (–) cable at battery. IJCA0A131002-01

2) Disconnect connectors from ECM as follows:

Installation
a) Push lock claw (1) in arrow direction.
Reverse removal procedure noting the following points.
b) Turn lock lever (2) in arrow direction until it stops.
• Tighten ECM bracket bolts according to the following
Then, disconnect connector from ECM.
procedure, if removed.
2 1 2 a. Tighten ECM bracket bolt (1) temporarily.
b. Tighten ECM bracket bolts (1) and (2) in
numerical order (“1” – “2”).

2, “1”

IGW00P130032-01

3) Remove ECM (1) from ECM bracket.

1, “2”

IJCA0A131003-01

• Connect connectors to ECM as follows:

a. Check that lock lever (2) of ECM connectors (1) is
in unlocked position.

1 2
IJCA0A131001-01

IGW00P130033-01
1C-4 Engine Electrical Devices: K10B and Bi-Fuel CNG

b. Insert ECM connectors (2) to ECM (3) until they CNG Control Module Removal and Installation
stop with lock lever (1) in unlocked position. (Bi-Fuel CNG)
AENJCA0A1316027
2 1 3 NOTICE
The CNG control module is a precision unit
and can be easily damaged.
Handle the CNG control module carefully and
do not expose it to large shock.

Removal
IGW00P130034-01 1) Disconnect negative (–) cable at battery.
c. Pull lock lever (1) down to lock ECM connectors 2) Disconnect connectors from CNG control module.
(2) securely.
3) Remove CNG control module (1) from CNG control
1 1 2
module bracket.

1
IGW00P130035-01

Procedure after ECM Replacement

AENJCA0A1316002
NOTE
When ECM and BCM are replaced with new
ones at the same time, perform “Immobilizer
Key Registration” instead of “ECM IJCA0A131004-01
Registration” using SUZUKI scan tool and 4) Remove CNG control module bracket (1), if
security device. necessary.
Refer to Operator’s Manual of SUZUKI scan
tool for the immobilizer registration. 1

After ECM is replaced with new one, perform the

following procedure:
1) Perform “Immobilizer key Registration” mode of
SUZUKI scan tool.
Refer to “SUZUKI Immobilizer Control System
Operator’s Manual”.
2) Perform electric throttle control system calibration.
(Page 1C-7)

IJCA0A131005-01
 Engine Electrical Devices: K10B and Bi-Fuel CNG 1C-5

Installation NOTICE
Reverse removal procedure noting the following points. Failure to take proper precautions when
• Tighten CNG control module bracket nut (1) to handling the electric throttle body assembly
specified torque, if removed. may lead to malfunction of the electric
Tightening torque throttle body assembly or damage to its
CNG control module bracket nut (a): 8.8 N·m ( components.
0.90 kgf-m, 6.5 lbf-ft) • Do not disassemble the electric throttle
body assembly.
• Tighten CNG control module nuts (2) to specified
torque. • Do not drop or otherwise expose the
electric throttle body assembly to large
Tightening torque shock. Any electric throttle body assembly
CNG control module nut (b): 5.5 N·m (0.56 kgf-m, that has received large shock should be
4.0 lbf-ft) replaced.
• Keep the throttle body housing and/or
2, (b)
throttle valve free of dust, metallic particles
or other foreign materials.
• Do not apply undue forces to the throttle
valve when checking operation of the
throttle valve or performance of the TP
sensor; otherwise the plastic gears in the
throttle valve actuator will be damaged.

1, (a)
Throttle Valve Visual Check
IJCA0A131006-01
Electric Throttle Body Assembly On-Vehicle
Inspection
AENJCA0A1316003
! CAUTION
If you touch the throttle valve with your finger
when the ignition is “ON” and the accelerator
pedal is depressed, your finger may be
Throttle Valve Operation Check
pinched in the gap between the throttle valve
and throttle body housing when the
accelerator pedal is released.
Never touch the throttle valve with your
finger when the ignition is “ON” and the
accelerator pedal is depressed.
NOTE
After replacing or cleaning electric throttle
body assembly, calibration of throttle valve
position is required. (Page 1C-7)
1) Set ignition “OFF”.
2) Remove air cleaner outlet hose. (Page 1D-6)
3) Check that there is no foreign material caught
between throttle valve and throttle body housing. If
foreign materials are present, remove electric throttle
body assembly and clean its inside thoroughly.
(Page 1D-8)
1) Set ignition “OFF”.
2) Remove air cleaner outlet hose. (Page 1D-6)
3) Check throttle valve operation as follows.
If faulty condition is found, replace electric throttle
body assembly. (Page 1D-8)
a) Check that throttle valve (1) moves smoothly to
both fully closed position and fully open position
when pressed manually.

IFKA0P130007-01
1C-6 Engine Electrical Devices: K10B and Bi-Fuel CNG

b) Check throttle valve returns to default position Throttle Motor Check

when finger pressure on throttle valve is
released at both fully closed position and fully
open position.
Throttle valve default position
“a”: A slight opening from fully closed
position (1)
1 0.3 to 100 Ω at 20 °C (68 °F)
1) Set ignition “OFF”.
2) Disconnect connector from electric throttle body
assembly.
3) Measure resistance between terminal “5” and
terminal “6” of electric throttle body assembly.
If faulty condition is found, replace electric throttle
body assembly. (Page 1D-8)
Throttle motor resistance

6 5 4 32 1

“a”

I7V20A131002-04
IFKA0P130008-01
Electric Throttle Body System Operation Check
1) Check that engine idle speed is specified value. TP Sensor Performance Check
• K10B: (Page 1A-116) 1) Set ignition “OFF”.
• Bi-fuel CNG: (Page 1A-365) 2) Disconnect connector from electric throttle body
assembly.
2) Check that engine speed increases smoothly in
response to depressing of accelerator pedal, and 3) Check output voltage of TP sensor main and sub
engine speed decreases to specified idle speed signals as follows.
when accelerator pedal is released. If faulty condition is found, replace electric throttle
body assembly. (Page 1D-8)
3) Stop engine and with ignition is “ON”.
a) Arrange 3 new 1.5 V batteries (1) in series, and
4) Select “Target Throttle Posi” and “Throttle Position”
check that total voltage is 4.5 to 5.0 V.
in “Data List” mode on SUZUKI scan tool. And check
the following points. Refer to “Scan Tool Data”: K10B b) Connect voltmeter (2) and batteries to TP sensor
in Section 1A (Page 1A-30) or “Scan Tool Data (CNG as shown in figure.
Control Module)”: Bi-Fuel CNG in Section 1A (Page
[A]
1A-304).
• “Throttle Position” value when accelerator pedal is 6 5 4 32 1
released.
• “Throttle Position” value when accelerator pedal is
fully depressed. 2

• “Throttle Position” follows “Target Throttle Posi”

when accelerator pedal is opened fully from fully
closed position. 1
5) If faulty condition is found in Step 1) – 4), check the
following points.
[B]
• Wire harness and connections
• APP sensor: (Page 1C-7) 6 5 4 32 1

• TP sensor: (Page 1C-6)

• Throttle motor: (Page 1C-6)
2
6) If check result is OK in Step 5), replace ECM.
(Page 1C-3)

1
IFKA0P130009-01

[A]: TP sensor (main) [B]: TP sensor (sub)

 Engine Electrical Devices: K10B and Bi-Fuel CNG 1C-7

c) Check that voltage varies depending on throttle Calibration procedure [B]:

opening angle as shown in the following graph a) Clear DTC.
while throttle valve is opened and closed
• K10B: (Page 1A-23)
manually.
• Bi-fuel CNG: (Page 1A-294)
[c] b) Set ignition “OFF”.
4.4 - 4.6 4.4 - 4.7
4.3 - 4.5 c) Set ignition “ON” and leave it for 5 sec. or more.
4.0 - 4.2 [a]
d) Start engine.
[b]
e) Turn off A/C and all electrical loads.
0.8 - 1.0
f) Warm up engine at idle speed to normal
0.5 - 0.7
0.4 - 0.6 0.3 - 0.6 operating temperature.
[e] [d]

[f] APP Sensor On-Vehicle Inspection

[g] AENJCA0A1316005
IDLA0A130003-02 Using SUZUKI Scan Tool
[a]: TP sensor (main) voltage 1) Check that accelerator pedal assembly has been
[b]: TP sensor (sub) voltage mounted to vehicle body properly (no pinched floor
[c]: Voltage (V) carpet, etc.).
[d]: Throttle valve opening If mounting is improper, reinstall accelerator pedal
[e]:
Position where throttle valve is a slight opening from fully closed assembly. (Page 1C-8)
position (default position)
[f]: Angle obtained when accelerator pedal is depressed fully 2) Connect SUZUKI scan tool to DLC with ignition
[g]: Angle obtained when throttle valve is fully opened manually “OFF”.
3) Display “Data List” mode.
Electric Throttle Control System Calibration 4) Check that voltage varies depending on accelerator
AENJCA0A1316004
position as shown in the following graph.
1) It is necessary to perform calibration when carrying If faulty condition is found, check the following items.
out any of the “Job details” listed below. The
calibration procedure differ depending on the job • Wire harness and connections
being carried out. Select the proper calibration • APP sensor
procedure from the table below, and then perform
[c]
calibration.
4.350 - 4.450
Job details Procedure
• ECM replacement
[A] [a]
• Clearance of DTC(s) related to ECM
• Electric throttle body assembly 2.150 - 2.250
replacement
[B]
• Accelerator pedal assembly
[b]
(incorporating APP sensor) replacement 0.700 - 0.800
0.370 - 0.380
2) Perform selected calibration procedure as follows. [d] [e]
Calibration procedure [A]: IJCA0A131007-01

a) Set ignition “ON” and leave it for 5 sec. or more. [a]: APP sensor (main) voltage
[b]: APP sensor (sub) voltage
b) Start engine.
[c]: Voltage (V)
c) Turn off A/C and all electrical loads. [d]: Idle position of accelerator pedal
d) Warm up engine at idle speed to normal [e]: Fully depressed position of accelerator pedal
operating temperature
1C-8 Engine Electrical Devices: K10B and Bi-Fuel CNG

Without Using SUZUKI Scan Tool Accelerator Pedal Assembly (Incorporating

1) Check APP sensor output voltage as follows. APP Sensor) Removal and Installation
AENJCA0A1316006
If faulty condition is found, replace accelerator pedal
assembly. (Page 1C-8) NOTICE
a) Arrange 3 new 1.5 V batteries (1) in series, and Failure to take proper precautions when
check that total voltage is 4.5 – 5.0 V. handling the APP sensor assembly may lead
b) Connect voltmeter (2) and batteries to APP to malfunction of the APP sensor.
sensor as shown in figure. • Do not drop or otherwise expose the APP
sensor assembly to large shock. Any APP
[A]
sensor assembly that has received large
6 5 4 3 21 shock must be replaced.
• Keep the sensor section of the APP sensor
assembly away from water.
2
NOTE
After replacing accelerator pedal assembly,
calibrate throttle valve positions. (Page 1C-
1 7)

[B] Removal
6 5 4 3 21
1) Disconnect negative (–) cable at battery.
2) Disconnect connector from accelerator pedal
assembly.
2
3) Remove accelerator pedal cover (1).
4) Remove accelerator pedal assembly (2).

1
IE3J0P130009-01

[A]: APP sensor (main) [B]: APP sensor (sub)

2
c) Check that voltage varies depending on
accelerator pedal stroke as shown in the
following graph. 1

[c]
4.350 - 4.450

[a] IJCA0A131008-01

5) Remove accelerator pedal bracket (1), if necessary.

2.150 - 2.250

[b]
0.700 - 0.800
0.370 - 0.380

[d] [e]
IJCA0A131007-01

[a]: APP sensor (main) voltage

[b]: APP sensor (sub) voltage
[c]: Voltage (V)
1
[d]: Idle position of accelerator pedal
[e]: Fully depressed position of accelerator pedal

IJCA0A131009-01
 Engine Electrical Devices: K10B and Bi-Fuel CNG 1C-9

Installation Installation
Reverse removal procedure noting the following points. Reverse removal procedure noting the following points.
• Tighten brake booster nut (1) to specified torque. • Check that O-ring is free from damage.
(Page 4A-9) • Tighten MAP sensor bolt (1) to specified torque.
• Tighten accelerator pedal bracket nuts (2) and
Tightening torque
accelerator pedal assembly nuts (3) to specified
MAP sensor bolt (a): 4.0 N·m (0.41 kgf-m, 3.0 lbf-
torque.
ft)
Tightening torque
Accelerator pedal bracket nut (a): 13 N·m (1.3
kgf-m, 9.5 lbf-ft)
1, (a)
Accelerator pedal assembly nut (b): 13 N·m (1.3
kgf-m, 9.5 lbf-ft)

2, (a)

3, (b)
3, (b)
IJCA0A131012-01

MAP Sensor Inspection

AENJCA0A1316009
2, (a) NOTICE
IJCA0A131010-01 If excessive negative pressure is applied, the
MAP sensor may be damaged.
MAP Sensor Removal and Installation Do not exceed a negative pressure of –70 kPa
AENJCA0A1316008 (–0.7 kgf/cm2, –10.2 psi, –0.7 bar).
Removal
1) Disconnect negative (–) cable at battery. 1) Remove MAP sensor. (Page 1C-9)
2) Remove air cleaner assembly. (Page 1D-6) 2) Check MAP sensor output voltage as follows. If
3) Disconnect connector of MAP sensor. faulty condition is found, replace MAP sensor.
(Page 1C-9)
4) Remove MAP sensor from intake manifold (1).
a) Arrange 3 new 1.5 V batteries (1) in series, and
check that total voltage is 4.5 to 5.0 V.
1
b) Connect voltmeter (2), special tool and batteries
to MAP sensor (3) as shown in figure.
Special tool
(A): 09917M47011

3
3 2 1

(A)

4
IJCA0A131011-01

1
IDLA0A130007-01

4. Adapter included in special tool.

1C-10 Engine Electrical Devices: K10B and Bi-Fuel CNG

c) Check that voltage drops gradually when ECT Sensor Removal and Installation
negative pressure is gradually applied with AENJCA0A1316011

special tool. Removal

1) Disconnect negative (–) cable at battery.
NOTICE 2) Drain coolant. (Page 1F-9)
Environmental condition affects output 3) Disconnect connector from ECT sensor.
voltage largely.
4) Remove ECT sensor (1).
The sensor voltage below is reference value
when measuring under the following
conditions.
• Power supply voltage: 5 V
• Ambient temperature: 20 °C (68 °F)
• Atmospheric pressure: 101.3 kPa (1.01 kgf/
cm2, 14.7 psi, 1.01 bar)

MAP sensor reference voltage

Atmospheric pressure: Approx. 4.1 V
Negative pressure of –30 kPa (–0.3 kgf/cm2, –
4.35 psi, –0.3 bar): Approx. 2.9 V 1

Negative pressure of –60 kPa (–0.6 kgf/cm2, –

8.70 psi, –0.6 bar): Approx. 1.7 V IJCA0A131013-01

ECT Sensor On-Vehicle Inspection Installation

AENJCA0A1316010
Reverse removal procedure noting the following points.
NOTE
• Check O-ring for damage and replace ECT sensor.
Before performing this inspection, read
“Precautions for ECM Circuit Inspection” • Tighten ECT sensor (1) to specified torque.
under “Precautions for Engine”. Tightening torque
• K10B: (Page 1-1) ECT sensor (a): 12 N·m (1.2 kgf-m, 9.0 lbf-ft)
• Bi-fuel CNG: (Page 1-4)

Check that ECT sensor signal is outputted properly.

Refer to “Inspection of ECM and Its Circuits”: K10B in
Section 1A (Page 1A-103) or “Inspection of ECM and Its
Circuits”: Bi-Fuel CNG in Section 1A (Page 1A-347).
If faulty condition is found, check the following points.
• Wire harness and connections
• ECT sensor: (Page 1C-11)

1, (a)

IJCA0A131014-01

• Refill cooling system. (Page 1F-9)

• Check cooling system for leakage. (Page 1F-8)
 Engine Electrical Devices: K10B and Bi-Fuel CNG 1C-11

ECT Sensor Inspection HO2S On-Vehicle Inspection

AENJCA0A1316012 AENJCA0A1316013
HO2S Heater
NOTE
1) Disconnect HO2S-1 or HO2S-2 connector with
Do not measure resistance with terminal of ignition “OFF”.
the ECT sensor soaked in water. As for the
2) Using ohmmeter, measure heater resistance of
measurement in the soaked state, an
HO2S-1 or HO2S-2 connector (sensor side).
accurate measurement cannot be done.
If faulty condition is found, replace HO2S-1 or
Check resistance between terminal “1” and terminal “2” HO2S-2. (Page 1C-11)
varies depending on coolant temperature as shown in NOTE
the following graph.
If faulty condition is found, replace ECT sensor (1). Temperature of sensor affects resistance
(Page 1C-10) largely. Check that sensor heater is at
specified temperature.
2
HO2S-1 heater resistance
3
Between terminal “3” and “4”: 5.0 to 6.4 Ω at 20
°C (68 °F)

1
2 1
IBV10A131003-01

1. HO2S-1 connector (viewed from terminal side)

4

HO2S-2 heater resistance

IAW101130017-01
Between terminals “1” and “2”: 5.0 to 6.4 Ω at 20
2. Ohmmeter 4. Heater °C (68 °F)
3. Temperature gauge

[a]

(5.74)
I7V20A131012-01

1. HO2S-2 connector (viewed from terminal side)

HO2S Removal and Installation

2.29 - 2.62 AENJCA0A1316014

(1.16)
(0.59)
Removal
0.31 - 0.33
! CAUTION
20 40 60 80 [b]

I9P60A131005-04
Touching exhaust system components when
they are still hot may cause burns.
[a]: Resistance [b]: Temperature
Check that the exhaust system has cooled
down before removing the HO2S.

1) Disconnect negative (–) cable at battery.

2) Disconnect connector of HO2S-1 or HO2S-2 and
release its wire harness from clamps.
3) Remove HO2S-1 (1) or HO2S-2 (2) from exhaust
manifold.
1C-12 Engine Electrical Devices: K10B and Bi-Fuel CNG

Installation • CMP sensor: (Page 1C-12)

Reverse removal procedure noting the following points.
• Tighten HO2S-1 (1) or HO2S-2 (2) to specified torque. CMP Sensor Removal and Installation
AENJCA0A1316016
Tightening torque
HO2S-1 (a): 45 N·m (4.6 kgf-m, 33.5 lbf-ft) Removal
HO2S-2 (b): 45 N·m (4.6 kgf-m, 33.5 lbf-ft) 1) Disconnect negative (–) cable at battery.
2) Disconnect connector from CMP sensor.
3) Remove CMP sensor (1) from cylinder head.

1, (a)
2, (b)
IJCA0A131015-01

• After installation, check exhaust leakage from sensor

with engine running.
IJCA0A131017-01

CMP Sensor On-Vehicle Inspection Installation

AENJCA0A1316015
Reverse removal procedure noting the following point.
1) With ignition “OFF”, disconnect CMP sensor
connector. • Apply engine oil to O-ring of sensor.
2) Connect service wires (1) between CMP sensor and
CMP sensor connector as shown in figure. CMP Sensor Inspection
AENJCA0A1316017
3) With ignition “ON”, check that output voltage varies 1) Remove CMP sensor. (Page 1C-12)
depending on position of signal rotor as follows.
2) Check the following points.
1 • O-ring (1) is free from damage.
• End face of sensor and signal rotor teeth are free
[A]
from any metal particles and damage.

1
3 2 1

[B]
IJCA0A131018-01

IJCA0A131016-01

[A]: Approx. 5 V
CMP sensor is facing to projection of signal rotor.
[B]: Approx. 0 V
CMP sensor is not facing to projection of signal rotor.

4) If faulty condition is found, check the following

points.
• Wire harness and connection.
 Engine Electrical Devices: K10B and Bi-Fuel CNG 1C-13

3) Check CMP sensor as follows. Installation

If faulty condition is found, replace CMP sensor.
(Page 1C-12)
a) Connect battery (1) and ohmmeter (3) to CMP
sensor as shown in figure.
b) Check that CMP sensor resistance varies as
specified below by passing ferromagnetic
material (iron) (2) in front of CMP sensor.
NOTE
Keep approximately 1 mm (0.03 in) gap “a”
between ferromagnetic material (iron) and
end face of CMP sensor.
Reverse removal procedure noting the following point.
• Apply engine oil to O-ring of sensor.
CKP Sensor Inspection
AENJCA0A1316019
1) Remove CKP sensor. (Page 1C-13)
2) Check the following points.
• O-ring (1) is free from damage.
• End face of sensor and sensor plate teeth are free
from any metal particles and damage.
1

CMP sensor resistance

Resistance alternates between 220 Ω or
smaller (ON) and infinity (OFF)
I7N301132020-01

“a” 3) Check CKP sensor as follows.

3 2 1
If faulty condition is found, replace CKP sensor.
3
(Page 1C-13)
a) Connect battery (1) and ohmmeter (3) to CKP
sensor as shown in figure.
b) Check that CKP sensor resistance varies as
2 specified below by passing ferromagnetic
1
material (iron) (2).
IJCA0A131019-01
NOTE
CKP Sensor Removal and Installation Keep approximately 1 mm (0.03 in) gap “a”
AENJCA0A1316018 between ferromagnetic material (iron) and
NOTICE end face of CKP sensor.
The CKP sensor bolt is pre-coated with
adhesive. If the bolt is reused, it may work CKP sensor resistance
loose. Resistance alternates between 220 Ω or
Replace the CKP sensor bolt with a new one. smaller (ON) and infinity (OFF)

Removal “a”
3 2 1
1) Disconnect negative (–) cable at battery.
2) Remove generator. (Page 1J-10) 3
3) Disconnect connector from CKP sensor.
4) Remove CKP sensor (1) from cylinder block.

2
1

IBV10A131008-01
1

IJCA0A131020-01
1C-14 Engine Electrical Devices: K10B and Bi-Fuel CNG

Knock Sensor On-Vehicle Inspection Installation

AENJCA0A1316020 Reverse removal procedure noting the following point.
1) Remove intake manifold. (Page 1D-9)
• Tighten knock sensor bolt (1) to specified torque.
2) Disconnect connector from knock sensor.
Tightening torque
3) Connect oscilloscope (1) to knock sensor connector
Knock sensor bolt (a): 23 N·m (2.3 kgf-m, 17.0 lbf-
(2) as shown in figure.
ft)
4) Check that oscilloscope displays waveform like a
one shown below when cylinder block is given a
shock by plastic hammer.
If faulty condition is found, replace knock sensor.
(Page 1C-14)
1, (a)

2 1

“a”
1
IBV10A131009-01

IJCA0A131021-01

“a”: 0 – 20°

Engine and Emission Control System Relay

Inspection
AENJCA0A1316022
Refer to “Control Relay Inspection” in Section 10B (Page
10B-51).

IAT Sensor On-Vehicle Inspection

AENJCA0A1316023

I9P60A131019-02
Knock Sensor Removal and Installation
AENJCA0A1316021
Removal
1) Disconnect negative (–) cable at battery.
2) Remove intake manifold. (Page 1D-9)
3) Disconnect connector from knock sensor.
4) Remove knock sensor (1) from cylinder block.
1
NOTE
Before performing this inspection, read
“Precautions for ECM Circuit Inspection”
under “Precautions for Engine”.
• K10B: (Page 1-1)
• Bi-fuel CNG: (Page 1-4)
Check that IAT sensor signal is outputted properly.
Refer to “Inspection of ECM and Its Circuits”: K10B in
Section 1A (Page 1A-103) or “Inspection of ECM and Its
Circuits”: Bi-Fuel CNG in Section 1A (Page 1A-347).
If faulty condition is found, check the following points.
• Wire harness and connections
• IAT sensor: (Page 1C-15)

IAT Sensor Removal and Installation

AENJCA0A1316024

NOTICE
The IAT sensor is a precision component and
can be easily damaged.
Handle the IAT sensor carefully and do not
expose it to large shock.
IJCA0A131022-01
 Engine Electrical Devices: K10B and Bi-Fuel CNG 1C-15

Removal IAT Sensor Inspection

AENJCA0A1316025
1) Disconnect negative (–) cable at battery.
1) Remove IAT sensor. (Page 1C-14)
2) Disconnect IAT sensor connector.
2) Check that resistance between sensor terminals
3) Remove IAT sensor (1) from air cleaner outlet hose varies depending on temperature while blowing hot
(2). air to temperature sensing part (1) of IAT sensor (2)
using hot air drier (3).
2 If faulty condition is found, replace IAT sensor.
(Page 1C-14)

1
4

2 1

1
3

IJCA0A131023-01
IBV10A131012-01

Installation
[a]
Reverse removal procedure noting the following point.
• Install IAT sensor (1) as shown in figure.

2.21 - 2.69

“a” (0.322)
0 20 40 60 80 [b]

IBV10A131013-01

[a]: Resistance 4. Temperature gauge

[b]: Temperature

IJCA0A131024-01

“a”: 90 °
1C-16 Engine Electrical Devices: K10B and Bi-Fuel CNG

CNG Pressure-and-Temperature Sensor CNG Pressure-and-Temperature Sensor

Removal and Installation (Bi-Fuel CNG)
AENJCA0A1316030
Removal
1) Relieve CNG fuel pressure in CNG fuel feed line.
(Page 1G-55)
2) Disconnect negative (–) cable at battery.
3) Remove air cleaner assembly. (Page 1D-6)
4) Disconnect connector from CNG pressure-and-
temperature sensor.
5) Remove CNG pressure-and-temperature sensor (1).
1
Inspection (Bi-Fuel CNG)
AENJCA0A1316031
CNG Pressure Sensor
1) Check CNG pressure-and-temperature sensor
output voltage as follows. If faulty condition is found,
replace CNG pressure-and-temperature sensor.
a) Arrange 3 new 1.5 V batteries (1) in series, and
check that total voltage is 4.5 to 5.0 V.
b) Connect voltmeter (2), special tool and batteries
to CNG pressure-and-temperature sensor (3) as
shown in figure.
Special tool
(A): 09917M47011

[A]

IJCA0A131025-01

Installation [A]
Reverse removal procedure noting the following points. (A)
4
• Check O-ring for cracks, deformation or damage. 2
• Apply petrol gasoline to O-ring.
• Tighten CNG pressure-and-temperature sensor bolts
(1) to specified torque.
Tightening torque
CNG pressure-and-temperature sensor bolt (a): 1
10 N·m (1.0 kgf-m, 7.5 lbf-ft) IJCA0A131027-01

4. Adapter included in special tool.

1, (a) c) Check that voltage drops gradually when positive

pressure is gradually applied with special tool.

NOTICE
Environmental condition affects output
voltage largely.
The sensor voltage below is reference value
when measuring under the following
conditions.
• Power supply voltage: 5 V
• Ambient temperature: 20 °C (68 °F)
IJCA0A131026-01
• Atmospheric pressure: 101.3 kPa (1.01 kgf/
• Check for CNG fuel leakage. (Page 1G-56) cm2, 14.7 psi, 1.01 bar)
 Engine Electrical Devices: K10B and Bi-Fuel CNG 1C-17

CNG pressure-and-temperature sensor Fuel Filler Lid Switch Removal and Installation
reference voltage (Bi-Fuel CNG)
Atmospheric pressure: Approx. 0.9 V AENJCA0A1316032

Positive pressure of 70 kPa (0.7 kgf/cm2, 10.1 Removal

psi, 0.7 bar): Approx. 1.4 V 1) Disconnect negative (–) cable at battery.
Positive pressure of 50 kPa (0.5 kgf/cm2, 7.25 2) Open fuel filler lid.
psi, 0.5 bar): Approx. 1.2 V 3) Remove left side quarter upper trim. (Page 9H-25)
CNG Temperature Sensor 4) Disconnect connector of fuel filler lid switch.
Check that resistance between sensor terminals varies 5) Remove fuel filler lid switch (1) while releasing locks
depending on while blowing hot air to temperature (2) in arrow direction.
sensing part (2) of CNG pressure-and-temperature
sensor (3) using hot air drier (4).
If faulty condition is found, replace CNG pressure-and- 1
temperature sensor.

1
3

"1"
"2"
5
1 2

4
2

IJCA0A131028-01
[A]
Installation
Reverse removal procedure.

Fuel Filler Lid Switch Inspection (Bi-Fuel CNG)

AENJCA0A1316033
Check fuel filler lid switch for continuity between
2.24 - 2.75 terminals at each switch condition. If check result is not
as specified, replace fuel filler lid switch.
1.05 - 1.29 “1” “3”
“2”
0.535 - 0.655

0 20 40 60 80 [B]
32 68 104 140 176 F
I9R90A130009-02

[A]: Resistance 1. O-ring

[B]: Temperature 5. Temperature gauge

[A] “1” “2” “3”

[B]
[C]
[D]
I9R90A130011-02

[A]: Terminal [C]: Switch shaft is free

[B]: Switch condition [D]: Switch shaft is pushed
1C-18 Engine Electrical Devices: K10B and Bi-Fuel CNG

Fuel Select Switch Removal and Installation (Bi- NOTE

Fuel CNG) When measuring resistance between
AENJCA0A1316034
Removal terminals “2” and “3”, set circuit tester in
diode mode, because there is a diode
1) Disconnect negative (–) cable at battery.
between these terminals.
2) Remove fuel select switch (1) from instrument main
lower panel while holding claws (2) pressed in arrow
directions.

4 3 2 1

1 1 3

4 2
IJCA0A131030-01

Fuel select switch continuity

2
[A]
IJCA0A131029-01
[B] 2 3
3) Disconnect fuel select switch connector.
Released
Installation
Reverse removal procedure.
Pushed
Fuel Select Switch Inspection (Bi-Fuel CNG)
AENJCA0A1316035 IJCA0A131031-01
Check continuity between terminals at each switch
[A]: Terminal [B]: Switch position
position. If check result is not as specified, replace fuel
select switch.

Specifications
Tightening Torque Specifications
AENJCA0A1317001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
CNG control module bracket nut 8.8 0.90 6.5 (Page 1C-5)
CNG control module nut 5.5 0.56 4.0 (Page 1C-5)
Accelerator pedal bracket nut 13 1.3 9.5 (Page 1C-9)
Accelerator pedal assembly nut 13 1.3 9.5 (Page 1C-9)
MAP sensor bolt 4.0 0.41 3.0 (Page 1C-9)
ECT sensor 12 1.2 9.0 (Page 1C-10)
HO2S-1 45 4.6 33.5 (Page 1C-12)
HO2S-2 45 4.6 33.5 (Page 1C-12)
Knock sensor bolt 23 2.3 17.0 (Page 1C-14)
CNG pressure-and-temperature sensor bolt 10 1.0 7.5 (Page 1C-16)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Fasteners Information” in Section 0A (Page 0A-6)
 Engine Electrical Devices: K10B and Bi-Fuel CNG 1C-19

Special Tools and Equipment

Special Tool
AENJCA0A1318001
09917M47011
Vacuum pump gauge
(Page 1C-9) /
(Page 1C-16)
1C-20 Engine Electrical Devices: K12M

K12M
General Description
Engine Electrical Devices Description
AENJCA0A1321001
Various sensors for the engine control in this model are outlined as follows.
Sensor Description
• The sensor is mounted on electric throttle body.
• A non-contact type sensor with Hall IC generates dual voltage signals in
TP sensor (main / sub) response to throttle valve opening and these signals, main and sub, are
inputted to ECM. Based on the signals, ECM calculates opening degree of the
throttle valve.
• The sensor is mounted on accelerator pedal.
• A non-contact type sensor applying electromagnetic induction detects
APP sensor (main / sub) depressing degree of accelerator pedal.
• Dual voltage signals, main and sub, are inputted to ECM. Based on the signals,
ECM controls throttle valve opening activating throttle actuator.
• The sensor is mounted on cylinder block near the crank pulley at intake
manifold side.
• Magnetic variation induced by a sensor plate installed on crankshaft is
CKP sensor converted to voltage signal in the sensor and the signal is inputted to ECM.
Using the signal, ECM calculates engine speed.
• Based on CMP signal and CKP signal, ECM reads each piston position in
cylinder and controls fuel injection and ignition timing.
• The sensor is mounted on the end of cylinder head at intake manifold side.
• Magnetic variation induced by a signal rotor press-fitted on camshaft end is
converted to voltage signal in the sensor and the signal is inputted to ECM.
CMP sensor
• Based on CMP signal and CKP signal, ECM reads each piston position in
cylinder and controls fuel injection and ignition timing. Further, detecting open/
close timing of intake valves, ECM controls VVT operation.
• The sensor is mounted on intake manifold.
• A pressure responsive silicon membrane incorporated in diaphragm generates
MAP sensor voltage signal corresponding to intake pressure (absolute pressure) and the
signal is inputted to ECM. Based on the signal, ECM calculates manifold
absolute pressure.
• The sensor is mounted on air cleaner outlet hose.
IAT sensor • A thermistor incorporated in the sensor generates voltage signal corresponding
to intake air temperature and the signal is inputted to ECM. Using the signal,
ECM calculates intake air temperature.
• The sensor is mounted on thermostat case.
• A thermistor incorporated in the sensor changes electrical resistance
ECT sensor corresponding to temperature and the resistance converted to voltage is
inputted to ECM. Based on the voltage signal, ECM calculates coolant
temperature.
• The sensor is mounted on cylinder block.
Knock sensor • A piezoelectric ceramic element incorporated in the sensor generates
electromotive force in proportion to degree of shock and the generated voltage
signal is inputted to ECM. Using the signal, ECM detects piston knocking.
 Engine Electrical Devices: K12M 1C-21

Sensor Description
• HO2S-1 is mounted on exhaust manifold.
• The sensor is composed of a platinum coated zirconia element which
generates electromotive force sensing difference of oxygen concentration.
Voltage signal corresponding to variation of oxygen concentration in exhaust
HO2S-1 gas before flowing into catalyst is inputted to ECM.
• Judging from signals of HO2S-1 and HO2S-2, ECM controls A/F (air fuel ratio)
to maintain purification rate of exhaust gas in high level for stabile emissions. A
heater is incorporated in oxygen sensor for quick startup and maintenance of
activation.
• HO2S-2 is mounted on exhaust manifold.
• The sensor is composed of a platinum coated zirconia element which
generates electromotive force sensing difference of oxygen concentration.
Voltage signal corresponding to variation of oxygen concentration in exhaust
HO2S-2 gas after flowing out of catalyst is inputted to ECM.
• Judging from signals of HO2S-1 and HO2S-2, ECM controls A/F (air fuel ratio)
to maintain purification rate of exhaust gas in high level for stabile emissions. A
heater is incorporated in oxygen sensor for quick startup and maintenance of
activation.
• The sensor is mounted on high pressure piping in A/C system.
• A pressure transductor (semiconductor chip) is incorporated in the sensor and
A/C refrigerant pressure sensor variation of refrigerant pressure is converted to voltage signal and then the
signal is inputted to ECM. Using the signal, ECM calculates refrigerant
pressure.
Barometric pressure sensor The sensor is incorporated in ECM and detects atmospheric pressure.

Component Location
Electronic Control System Component Location
AENJCA0A1323003
Refer to “Electronic Control System Component Location”: K12M in Section 1A (Page 1A-135).
1C-22 Engine Electrical Devices: K12M

Repair Instructions
ECM Removal and Installation Installation
AENJCA0A1326001 Reverse removal procedure noting the following points.
NOTICE
• Tighten ECM bracket bolts according to the following
The ECM is a precision unit and can be easily procedure, if removed.
damaged.
a. Tighten ECM bracket bolt (1) temporarily.
Handle the ECM carefully and do not expose
it to large shock. b. Tighten ECM bracket bolts (1) and (2) in
numerical order (“1” – “2”).
NOTE
After ECM is replaced with new one, perform
“Procedure after ECM Replacement”: K12M
(Page 1C-23).

Removal 2, “1”

1) Disconnect negative (–) cable at battery.

2) Turn lock lever (1) in arrow direction until it stops.
Then, disconnect connectors from ECM. 1, “2”

1 1

IJCA0A132003-01

• Tighten ECM nuts (1) to specified torque.

Tightening torque
IBK80P130001-01
ECM nut (a): 8.8 N·m (0.90 kgf-m, 6.5 lbf-ft)
3) Remove ECM (1) from ECM bracket.

1 1, (a)

IJCA0A132004-01
IJCA0A132001-01
• Connect connectors to ECM as follows:
4) Remove ECM bracket (1), if necessary.
a. Check that lock lever (1) of ECM connectors is in
unlocked position.
1
1

IBK80P130005-01

IJCA0A132002-01

b. Insert ECM connectors to ECM until they stop with
lock lever in unlocked position.
IBK80P130006-01
c. Pull lock lever (1) down to lock ECM connectors
securely.
1 1
IBK80P130007-01
Procedure after ECM Replacement
AENJCA0A1326002
NOTE
When ECM and BCM are replaced with new
ones at the same time, perform “Immobilizer
Key Registration” instead of “ECM
Registration” using SUZUKI scan tool and
security device.
Refer to Operator’s Manual of SUZUKI scan
tool for the immobilizer registration.
After ECM is replaced with new one, perform the
following procedure:
1) Perform “Immobilizer key Registration” mode of
SUZUKI scan tool.
Refer to “SUZUKI Immobilizer Control System
Operator’s Manual”.
2) Perform electric throttle control system calibration.
(Page 1C-25)
Electric Throttle Body Assembly On-Vehicle
Inspection
AENJCA0A1326003
! CAUTION
If you touch the throttle valve with your finger
when the ignition is “ON” and the accelerator
pedal is depressed, your finger may be
pinched in the gap between the throttle valve
and throttle body housing when the
accelerator pedal is released.
Never touch the throttle valve with your
finger when the ignition is “ON” and the
accelerator pedal is depressed.
Engine Electrical Devices: K12M 1C-23
NOTICE
Failure to take proper precautions when
handling the electric throttle body assembly
may lead to malfunction of the electric
throttle body assembly or damage to its
components.
• Do not disassemble the electric throttle
body assembly.
• Do not drop or otherwise expose the
electric throttle body assembly to large
shock. Any electric throttle body assembly
that has received large shock should be
replaced.
• Keep the throttle body housing and/or
throttle valve free of dust, metallic particles
or other foreign materials.
• Do not apply undue forces to the throttle
valve when checking operation of the
throttle valve or performance of the TP
sensor; otherwise the plastic gears in the
throttle valve actuator will be damaged.
NOTE
After replacing or cleaning electric throttle
body assembly, calibration of throttle valve
position is required. (Page 1C-25)
Throttle Valve Visual Check
1) Set ignition “OFF”.
2) Remove air cleaner outlet hose. (Page 1D-82)
3) Check that there is no foreign material caught
between throttle valve and throttle body housing. If
foreign materials are present, remove electric throttle
body assembly and clean its inside thoroughly.
(Page 1D-84)
Throttle Valve Operation Check
1) Set ignition “OFF”.
2) Remove air cleaner outlet hose. (Page 1D-82)
3) Check throttle valve operation as follows.
If faulty condition is found, replace electric throttle
body assembly. (Page 1D-84)
a) Check that throttle valve (1) moves smoothly to
both fully closed position and fully open position
when pressed manually.
1
IFKA0P130007-01
1C-24 Engine Electrical Devices: K12M

b) Check throttle valve returns to default position Throttle Motor Check

when finger pressure on throttle valve is
released at both fully closed position and fully
open position.
Throttle valve default position
“a”: A slight opening from fully closed
position (1)
1 0.3 to 100 Ω at 20 °C (68 °F)
1) Set ignition “OFF”.
2) Disconnect connector from electric throttle body
assembly.
3) Measure resistance between terminal “5” and
terminal “6” of electric throttle body assembly.
If faulty condition is found, replace electric throttle
body assembly. (Page 1D-84)
Throttle motor resistance

6 5 4 32 1

“a”

I7V20A131002-04
IFKA0P130008-01
Electric Throttle Body System Operation Check
1) Check that engine idle speed is specified value. TP Sensor Performance Check
(Page 1A-270) 1) Set ignition “OFF”.
2) Check that engine speed increases smoothly in 2) Disconnect connector from electric throttle body
response to depressing of accelerator pedal, and assembly.
engine speed decreases to specified idle speed 3) Check output voltage of TP sensor main and sub
when accelerator pedal is released. signals as follows.
3) Stop engine and with ignition is “ON”. If faulty condition is found, replace electric throttle
4) Select “Target Throttle Posi” and “Throttle Position” body assembly. (Page 1D-84)
in “Data List” mode on SUZUKI scan tool. And check a) Arrange 3 new 1.5 V batteries (1) in series, and
the following points. (Page 1A-153) check that total voltage is 4.5 to 5.0 V.
• “Throttle Position” value when accelerator pedal is b) Connect voltmeter (2) and batteries to TP sensor
released. as shown in figure.
• “Throttle Position” value when accelerator pedal is
[A]
fully depressed.
• “Throttle Position” follows “Target Throttle Posi” 6 5 4 32 1
when accelerator pedal is opened fully from fully
closed position.
5) If faulty condition is found in Step 1) – 4), check the 2

following points.
• Wire harness and connections
• APP sensor: (Page 1C-25) 1
• TP sensor: (Page 1C-24)
• Throttle motor: (Page 1C-24) [B]
6) If check result is OK in Step 5), replace ECM.
6 5 4 32 1
(Page 1C-22)

1
IFKA0P130009-01

[A]: TP sensor (main) [B]: TP sensor (sub)

 Engine Electrical Devices: K12M 1C-25

c) Check that voltage varies depending on throttle ECM Learning Procedure of Engine Torque
opening angle as shown in the following graph AENJCA0A1326005

while throttle valve is opened and closed 1) Check that the following conditions are satisfied
manually. when performing this procedure.
• DTC is not detected.
[c]
4.4 - 4.6 4.4 - 4.7 • Vehicle: Stop
4.3 - 4.5
4.0 - 4.2 [a] • Engine: Stationary
• 6 °C (43 °F) < ECT < 100 °C (212 °F)
[b] • IAT > 6 °C (43 °F)
0.8 - 1.0 0.5 - 0.7 • Accelerator pedal position: Idle position
0.4 - 0.6 0.3 - 0.6
[d] • Battery voltage > 10 V
[e]
[f] 2) Start engine.
[g] 3) Warm up engine at idle speed to normal operating
IDLA0A130003-02 temperature.
[a]: TP sensor (main) voltage
[b]: TP sensor (sub) voltage APP Sensor On-Vehicle Inspection
[c]: Voltage (V) AENJCA0A1326006
[d]: Throttle valve opening Using SUZUKI Scan Tool
[e]: Position where throttle valve is a slight opening from fully closed 1) Check that accelerator pedal assembly has been
position (default position)
[f]: Angle obtained when accelerator pedal is depressed fully
mounted to vehicle body properly (no pinched floor
[g]: Angle obtained when throttle valve is fully opened manually
carpet, etc.).
If mounting is improper, reinstall accelerator pedal
assembly. (Page 1C-26)
Electric Throttle Control System Calibration
AENJCA0A1326004 2) Connect SUZUKI scan tool to DLC with ignition
1) After performing any one of the following services, it “OFF”.
is necessary to calibrate electric throttle control 3) Display “Data List” mode.
system.
4) Check that voltage varies depending on accelerator
• Replacement of ECM position as shown in the following graph.
• Clearance of DTC related to ECM If faulty condition is found, check the following items.
• Removal and installation of electric throttle body • Wire harness and connections
assembly (cleaning or replacement) • APP sensor
2) Check that the following conditions are satisfied
when performing this calibration procedure. [c]
4.350 - 4.450
• DTC is not detected.
• Vehicle: Stop
[a]
• Engine: Stationary
• 6 °C (43 °F) < ECT < 100 °C (212 °F) 2.150 - 2.250

• IAT > 6 °C (43 °F)

• Accelerator pedal position: Idle position [b]
0.700 - 0.800
• Battery voltage > 10 V 0.370 - 0.380

3) Perform this calibration procedure as follows. [d] [e]

IJCA0A131007-01
a) Clear DTC. (Page 1A-141)
[a]: APP sensor (main) voltage
NOTE [b]: APP sensor (sub) voltage
[c]: Voltage (V)
Perform “DTC clear” although DTC is not
[d]: Idle position of accelerator pedal
detected. [e]: Fully depressed position of accelerator pedal

b) Set ignition “ON” and leave it for 40 sec. or more.

c) Set ignition “OFF” and leave it for 10 sec. or
more.
4) Perform “ECM Learning Procedure of Engine
Torque”: K12M (Page 1C-25).
1C-26 Engine Electrical Devices: K12M

Without Using SUZUKI Scan Tool Accelerator Pedal Assembly (Incorporating

1) Check APP sensor output voltage as follows. APP Sensor) Removal and Installation
AENJCA0A1326007
If faulty condition is found, replace accelerator pedal
assembly. (Page 1C-26) NOTICE
a) Arrange 3 new 1.5 V batteries (1) in series, and Failure to take proper precautions when
check that total voltage is 4.5 – 5.0 V. handling the APP sensor assembly may lead
b) Connect voltmeter (2) and batteries to APP to malfunction of the APP sensor.
sensor as shown in figure. • Do not drop or otherwise expose the APP
sensor assembly to large shock. Any APP
[A]
sensor assembly that has received large
6 5 4 3 21 shock must be replaced.
• Keep the sensor section of the APP sensor
assembly away from water.
2
Removal
1) Disconnect negative (–) cable at battery.
2) Disconnect connector from accelerator pedal
1 assembly.
3) Remove accelerator pedal cover (1).
[B]
4) Remove accelerator pedal assembly (2).
6 5 4 3 21

1
IE3J0P130009-01 1

[A]: APP sensor (main) [B]: APP sensor (sub)

c) Check that voltage varies depending on

accelerator pedal stroke as shown in the
IJCA0A131008-01
following graph.
5) Remove accelerator pedal bracket (1), if necessary.
[c]
4.350 - 4.450

[a]

2.150 - 2.250

[b]
0.700 - 0.800
0.370 - 0.380 1

[d] [e]
IJCA0A131007-01

[a]: APP sensor (main) voltage

[b]: APP sensor (sub) voltage
IJCA0A131009-01
[c]: Voltage (V)
[d]: Idle position of accelerator pedal
[e]: Fully depressed position of accelerator pedal
 Engine Electrical Devices: K12M 1C-27

Installation MAP Sensor Inspection

Reverse removal procedure noting the following points. AENJCA0A1326010
NOTICE
• Tighten brake booster nut (1) to specified torque.
(Page 4A-9) If excessive negative pressure is applied, the
MAP sensor may be damaged.
• Tighten accelerator pedal bracket nuts (2) and
Do not exceed negative pressure of –70 kPa
accelerator pedal assembly nuts (3) to specified
(–0.7 kgf/cm2, –10.2 psi, –0.7 bar).
torque.
Tightening torque 1) Remove MAP sensor. (Page 1C-27)
Accelerator pedal bracket nut (a): 13 N·m (1.3 2) Check MAP sensor output voltage as follows. If
kgf-m, 9.5 lbf-ft) faulty condition is found, replace MAP sensor.
Accelerator pedal assembly nut (b): 13 N·m (1.3 (Page 1C-27)
kgf-m, 9.5 lbf-ft) a) Arrange 3 new 1.5 V batteries (1) in series, and
check that total voltage is 4.5 to 5.0 V.
2, (a)
b) Connect voltmeter (2), special tool and batteries
to MAP sensor (3) as shown in figure.
Special tool
1 (A): 09917M47011
3, (b) 3
3, (b)
3 2 1

(A)

2, (a)
4

IJCA0A131010-01
2

MAP Sensor Removal and Installation

AENJCA0A1326009
Removal
1) Disconnect negative (–) cable at battery.
2) Remove electric throttle body assembly. (Page
1
1D-84)
IDLA0A130007-01
3) Disconnect connector of MAP sensor.
4. Adapter included in special tool.
4) Remove MAP sensor (1) from intake manifold (2).
c) Check that voltage drops gradually when
negative pressure is gradually applied with
special tool.

NOTICE
1
Environmental condition affects output
voltage largely.
The sensor voltage below is reference value
when measuring under the following
2 conditions.
• Power supply voltage: 5 V
• Ambient temperature: 20 °C (68 °F)
• Atmospheric pressure: 101.3 kPa (1.01 kgf/
IJCA0A132006-01
cm2, 14.7 psi, 1.01 bar)
Installation
MAP sensor reference voltage
Reverse removal procedure noting the following point.
Atmospheric pressure: Approx. 4.1 V
• Check that O-ring is free from damage. Negative pressure of –30 kPa (–0.3 kgf/cm2, –
4.35 psi, –0.3 bar): Approx. 2.9 V
Negative pressure of –60 kPa (–0.6 kgf/cm2, –
8.70 psi, –0.6 bar): Approx. 1.7 V
1C-28 Engine Electrical Devices: K12M

ECT Sensor On-Vehicle Inspection • Check cooling system for leakage. (Page 1F-26)
AENJCA0A1326011
NOTE
ECT Sensor Inspection
Before performing this inspection, read AENJCA0A1326013
“Precautions for ECM Circuit Inspection”
NOTE
under “Precautions for Engine (K12M)” in
Section 1 (Page 1-2). Do not measure resistance with terminal of
the ECT sensor soaked in water. As for the
Check that ECT sensor signal is outputted properly. measurement in the soaked state, an
(Page 1A-254) accurate measurement cannot be done.
If faulty condition is found, check the following points.
• Wire harness and connections Check resistance between terminal “1” and terminal “2”
varies depending on coolant temperature as shown in
• ECT sensor: (Page 1C-28) the following graph.
If faulty condition is found, replace ECT sensor (1).
ECT Sensor Removal and Installation (Page 1C-28)
AENJCA0A1326012
Removal
2
1) Disconnect negative (–) cable at battery.
2) Drain coolant. (Page 1F-27) 3

3) Disconnect connector from ECT sensor.

4) Remove ECT sensor (1).

1
2 1

IAW101130017-01

1 2. Ohmmeter 4. Heater
3. Temperature gauge

[a]
IJCA0A132007-01

(5.74)
Installation
Reverse removal procedure noting the following points.
• Check O-ring for damage and replace ECT sensor.
• Tighten ECT sensor (1) to specified torque.
2.29 - 2.62
Tightening torque
(1.16)
ECT sensor (a): 12 N·m (1.2 kgf-m, 9.0 lbf-ft)
(0.59)
0.31 - 0.33
20 40 60 80 [b]

I9P60A131005-04

[a]: Resistance [b]: Temperature

1, (a)

IJCA0A132008-01

• Refill cooling system. (Page 1F-27)

 Engine Electrical Devices: K12M 1C-29

HO2S On-Vehicle Inspection HO2S Removal and Installation

AENJCA0A1326014 AENJCA0A1326015
HO2S Heater
1) Disconnect HO2S-1 or HO2S-2 connector with Removal
ignition “OFF”.
! CAUTION
2) Using ohmmeter, measure heater resistance of
HO2S-1 or HO2S-2 connector (sensor side). Touching exhaust system components when
If faulty condition is found, replace HO2S-1 or they are still hot may cause burns.
HO2S-2. (Page 1C-29) Check that the exhaust system has cooled
down before removing the HO2S.
NOTE
Temperature of sensor affects resistance 1) Disconnect negative (–) cable at battery.
largely. Check that sensor heater is at 2) Disconnect connector of HO2S-1 or HO2S-2 and
specified temperature. release its wire harness from clamps.
3) Remove HO2S-1 (1) or HO2S-2 (2) from exhaust
HO2S-1 heater resistance manifold.
Between terminal “3” and “4”: 5.0 to 6.4 Ω at 20
°C (68 °F) Installation
Reverse removal procedure noting the following points.
1
• Tighten HO2S-1 (1) or HO2S-2 (2) to specified torque.
Tightening torque
HO2S-1 (a): 45 N·m (4.6 kgf-m, 33.5 lbf-ft)
HO2S-2 (b): 45 N·m (4.6 kgf-m, 33.5 lbf-ft)
IBV10A131003-01

1. HO2S-1 connector (viewed from terminal side)

HO2S-2 heater resistance

Between terminals “1” and “2”: 5.0 to 6.4 Ω at 20
°C (68 °F)

I7V20A131012-01 “a”
1, (a)
1. HO2S-2 connector (viewed from terminal side)

2, (b)
IJCA0A132009-01

“a”: 40 to 120 mm (1.6 to 4.7 in.) 3. Clamp

• After installation, check exhaust leakage from sensor

with engine running.
1C-30 Engine Electrical Devices: K12M

CMP Sensor On-Vehicle Inspection CMP Sensor Removal and Installation

AENJCA0A1326016 AENJCA0A1326017
1) With ignition “OFF”, disconnect CMP sensor NOTICE
connector. Reinstallation of CMP sensor may cause oil
2) Connect service wires (1) between CMP sensor and leakage.
CMP sensor connector as shown in figure. Once CMP sensor is removed, replace it with
3) With ignition “ON”, check that output voltage varies new one.
depending on position of signal rotor as follows.
Removal
1 1) Disconnect negative (–) cable at battery.
3 2 1 2) Remove electric throttle body assembly. (Page
1D-84)
[A] 3) Disconnect connector from CMP sensor.
4) Remove CMP sensor (1) from cylinder head.

1
[B]

IJCA0A132010-01

IFAE0A130018-01
Installation
[A]: Approx. 0 V Reverse removal procedure noting the following point.
CMP sensor is facing to projection of signal rotor.
[B]: Approx. 5 V • Apply engine oil to O-ring of sensor.
CMP sensor is not facing to projection of signal rotor.

4) If faulty condition is found, replace CMP sensor.

 Engine Electrical Devices: K12M 1C-31

CKP Sensor Removal and Installation CKP Sensor Inspection

AENJCA0A1326018 AENJCA0A1326019
NOTICE 1) Remove CKP sensor. (Page 1C-31)
The CKP sensor bolt is pre-coated with 2) Check the following points.
adhesive. If the bolt is reused, it may work • O-ring (1) is free from damage.
loose.
Replace the CKP sensor bolt with a new one. • End face of sensor and sensor plate teeth are free
from any metal particles and damage.
Removal
1
1) Disconnect negative (–) cable at battery.
2) Remove generator. (Page 1J-28)
3) Disconnect connector from CKP sensor.
4) Remove CKP sensor (1) from cylinder block.
I7N301132020-01

3) Check CKP sensor as follows.

If faulty condition is found, replace CKP sensor.
(Page 1C-31)
a) Connect battery (1) and ohmmeter (3) to CKP
1 sensor as shown in figure.
b) Check that CKP sensor resistance varies as
specified below by passing ferromagnetic
material (iron) (2).

NOTE
Keep approximately 1 mm (0.03 in) gap “a”
between ferromagnetic material (iron) and
IJCA0A132011-01 end face of CKP sensor.

Installation CKP sensor resistance

Reverse removal procedure noting the following point. Resistance alternates between 220 Ω or
• Apply engine oil to O-ring of sensor. smaller (ON) and infinity (OFF)

“a”
3 2 1

2
1

IBV10A131008-01
1C-32 Engine Electrical Devices: K12M

Knock Sensor On-Vehicle Inspection Installation

AENJCA0A1326020 Reverse removal procedure noting the following point.
1) Remove intake manifold. (Page 1D-85)
• Tighten knock sensor bolt (1) to specified torque.
2) Disconnect connector from knock sensor.
Tightening torque
3) Connect oscilloscope (1) to knock sensor connector
Knock sensor bolt (a): 23 N·m (2.3 kgf-m, 17.0 lbf-
(2) as shown in figure.
ft)
4) Check that oscilloscope displays waveform like a
one shown below when cylinder block is given a
shock by plastic hammer.
1, (a)
If faulty condition is found, replace knock sensor.
(Page 1C-32)

2 1

“a”

1
IFRA0B132015-01

IGRA0A133001-01

“a”: 0 – 20°

Engine and Emission Control System Relay

Inspection
AENJCA0A1326022
Refer to “Control Relay Inspection” in Section 10B (Page
10B-51).

IAT Sensor On-Vehicle Inspection

AENJCA0A1326023
NOTE
I9P60A131019-02
Before performing this inspection, read
“Precautions for ECM Circuit Inspection”
Knock Sensor Removal and Installation under “Precautions for Engine (K12M)” in
AENJCA0A1326021
Removal Section 1 (Page 1-2).
1) Disconnect negative (–) cable at battery. Check that IAT sensor signal is outputted properly.
2) Remove intake manifold. (Page 1D-85) (Page 1A-254)
3) Disconnect connector from knock sensor. If faulty condition is found, check the following points.
4) Remove knock sensor (1) from cylinder block. • Wire harness and connections
• IAT sensor: (Page 1C-33)

IAT Sensor Removal and Installation

AENJCA0A1326024
1

NOTICE
The IAT sensor is a precision component and
can be easily damaged.
Handle the IAT sensor carefully and do not
expose it to large shock.

IFRA0A131020-01
 Engine Electrical Devices: K12M 1C-33

Removal IAT Sensor Inspection

AENJCA0A1326025
1) Disconnect negative (–) cable at battery.
1) Remove IAT sensor. (Page 1C-32)
2) Disconnect IAT sensor connector.
2) Check that resistance between sensor terminals
3) Remove IAT sensor (1) from air cleaner outlet hose varies depending on temperature while blowing hot
(2). air to temperature sensing part (1) of IAT sensor (2)
using hot air drier (3).
2 If faulty condition is found, replace IAT sensor.
(Page 1C-32)

4
1
2 1

1
3

IJCA0A132012-01
IBV10A131012-01

Installation
[a]
Reverse removal procedure noting the following point.
• Install IAT sensor (1) as shown in figure.

2.21 - 2.69

“a”
(0.322)
0 20 40 60 80 [b]

IBV10A131013-01

[a]: Resistance 4. Temperature gauge

[b]: Temperature

IJCA0A132013-01

“a”: 90°
1C-34 Engine Electrical Devices: K12M

OCV Inspection • Connect battery to OCV connector (1) as shown in

AENJCA0A1326026 figure, and check operating sound caused by
1) Remove OCV. (Page 1D-108) movement of spool valve (2).
2) Check OCV as follows. If check result is not as specified, replace OCV.
• Check resistance between terminals of OCV (Page 1D-108)
connector (1).
If measured resistance is out of specified range,
replace OCV. (Page 1D-108)
OCV resistance
6.7 to 7.7 Ω at 20 °C (68 °F)

I9T401132007-02

I9T401132006-02

Specifications
Tightening Torque Specifications
AENJCA0A1327001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
ECM nut 8.8 0.90 6.5 (Page 1C-22)
Accelerator pedal bracket nut 13 1.3 9.5 (Page 1C-27)
Accelerator pedal assembly nut 13 1.3 9.5 (Page 1C-27)
ECT sensor 12 1.2 9.0 (Page 1C-28)
HO2S-1 45 4.6 33.5 (Page 1C-29)
HO2S-2 45 4.6 33.5 (Page 1C-29)
Knock sensor bolt 23 2.3 17.0 (Page 1C-32)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Fasteners Information” in Section 0A (Page 0A-6)

Special Tools and Equipment

Special Tool
AENJCA0A1328001
09917M47011
Vacuum pump gauge
(Page 1C-27)
 Engine Mechanical: K10B and Bi-Fuel CNG 1D-1

Engine Mechanical
Engine

K10B and Bi-Fuel CNG

General Description
Engine Construction Description
AENJCA0A1411001
The engine is water-cooled, in-line 3-cylinder, 4-stroke-cycle unit with a DOHC valve mechanism arranged in a “V”
type configuration and has 12 valves (4 valves / one cylinder). The camshafts mounted over the cylinder head are
driven by a crankshaft with a timing chain.

Diagnostic Information and Procedures

Compression Check 8) For bi-fuel CNG, it is necessary to select “Petrol
AENJCA0A1414001 MODE” by pushing selector switch.
1) Warm up engine to normal operating temperature.
9) Depress clutch pedal (M/T model) (1) and
2) Stop engine after warming up. accelerator pedal (2) all the way to make throttle fully
3) For M/T model, place gear shift control lever in open.
“Neutral” and apply parking brake.
For auto gear shift model, place shift selector in “N”
and apply parking brake.
4) Remove air cleaner assembly. (Page 1D-6)
5) Remove all ignition coil assemblies and all spark
plugs. (Page 1H-7)
6) Disconnect all fuel injector connectors.
7) Install special tools into spark plug hole.
Special tool
(A): 09915M64512
(B): 09915M64530 IGJA0A141031-02
(C): 09915M64550

(A)

(C)

(B)

IDLA0A140001-01
1D-2 Engine Mechanical: K10B and Bi-Fuel CNG

10) Crank engine with fully charged battery, and read the 4) Connect SUZUKI scan tool to DLC (1) with ignition
highest pressure on special tool. “OFF”.

NOTE Special tool

(A): SUZUKI scan tool (Suzuki SDT-II)
• For measuring compression pressure,
crank engine at least 200 rpm with fully
charged battery.
• Check installation condition of special tool
if measured compression pressure is
lower than the limit.
1
• If the measured compression pressure of
particular cylinder is lower than the limit,
add a bit of engine oil into the cylinder
through the spark plug hole, and then
repeat the compression check.
– If the compression pressure increases
after adding engine oil, the following
may be the cause:
– Pressure leakage due to worn piston
rings or worn cylinder
– If the compression pressure does not
increase, one of the following may be (A)
the cause: IJCA0A181004-01

– Incorrect valve timing 5) Run engine at specified idle speed.

– Pressure leakage from the valve or
valve seats
– Pressure leakage from the cylinder
head gasket
Compression pressure
• Standard: 1,800 kPa (18.4 kgf/cm2, 261 psi, 18
bar)
• Limit: 1,550 kPa (15.8 kgf/cm2, 225 psi, 15.5
bar)
• Max difference between any two cylinders: 100
kPa (1.02 kgf/cm2, 14.5 psi, 1 bar)
11) Carry out Step 7) – 10) on each cylinder to obtain 3
readings.
12) Install spark plugs and ignition coil assemblies.
(Page 1H-7)
13) Connect fuel injector connectors.
14) Install air cleaner assembly. (Page 1D-6)
Engine Vacuum Check
AENJCA0A1414002
The engine vacuum that develops in the intake line is a
good indicator of the condition of the engine.
Using SUZUKI Scan Tool
1) Warm up engine to normal operating temperature.
2) For M/T model, place gear shift control lever in
“Neutral” and apply parking brake.
For auto gear shift model, place shift selector in “N”
and apply parking brake.
3) Stop engine.
• Petrol: (Page 1A-116)
• Bi-fuel CNG: (Page 1A-365)
6) Select “MAP” under “Data List” mode on scan tool.
Check manifold absolute pressure displayed on scan
tool.
Manifold absolute pressure should be within
specification.
Manifold absolute pressure specification (at sea
level)
50 kPa or less (0.51 kgf-cm2, 7.25 psi, 0.50 bar) at
specified idle speed
Not Using SUZUKI Scan Tool
1) Warm up engine to normal operating temperature.
2) For M/T model, place gear shift control lever in
“Neutral” and apply parking brake.
For auto gear shift model, place shift selector in “N”
and apply parking brake.
3) Stop engine.
4) Remove air cleaner assembly. (Page 1D-6)
5) Remove PCV hose (1) from PCV valve (2).
6) Connect special tool to PCV hose.
Special tool
(A): 09915M67311
 Engine Mechanical: K10B and Bi-Fuel CNG 1D-3

7) Close PCV valve using tape (3) or the like. 5) Check valve clearance with feeler gauge (4) as
follows.
(A)
a) Check valve clearance at valves “1” and “4”.
b) Turn camshafts 60° clockwise with wrench.
c) Check that cam lobes are perpendicular to
tappet faces at valves to be checked (in this
case, “3” and “6”), if not, adjust cam lobe position
2 by turning crankshaft.
Check valve clearance.
1
3
d) In the same manner as in Step b) – c), check
valve clearance at valves “2” and “5”.
If valve clearance is not as specified, record valve
clearance and adjust it to specification. (Page 1D-
4)
IJCA0A141001-01

8) Install air cleaner assembly. (Page 1D-6) Valve clearance specification

9) Run engine at specified idle speed. When cold (ECT: 15 – 25 °C (59 – 77 °F)):
• Intake: 0.14 – 0.23 mm (0.0056 – 0.0090 in.)
• Petrol: (Page 1A-116) • Exhaust: 0.30 – 0.40 mm (0.0119 – 0.0157 in.)
• Bi-fuel CNG: (Page 1A-365)
10) Read vacuum gauge. Negative pressure should be
within specification. 1
Negative pressure specification (at sea level)
–50 kPa or less (–0.51 kgf/cm2, –7.25 psi, –0.50
bar)
11) Remove air cleaner assembly. (Page 1D-6)
12) Disconnect special tool from PCV valve.
13) Pull off tape from PCV valve.
14) Connect PCV hose to PCV valve.
2
15) Install air cleaner assembly. (Page 1D-6)

Valve Clearance Inspection and Adjustment

AENJCA0A1414003
NOTICE “a”
If engine oil contacts to compressor drive
belt and water pump / generator drive belt,
problems such as belt squeal could occur. 4
Do not allow engine oil to contact
compressor drive belt and water pump / 3
IFRA0A141006-01
generator drive belt. If engine oil contacts
“a”: 90°
them, wash it off with water.

Inspection
“1” “2” “3”
1) Remove cylinder head cover. (Page 1D-11)
2) Hoist vehicle.
3) Remove right side splash cover.
4) Using wrench, turn crankshaft pulley (1) clockwise
until cam lobes (2) become perpendicular to tappet
faces (3) at valves “1” and “4” as shown in figure.

“4” “5” “6”

I8C50A140006-01
1D-4 Engine Mechanical: K10B and Bi-Fuel CNG

Adjustment c) Select new tappet closest to calculated value

1) Remove tappet to be replaced. (Page 1D-14) from available size of spare part.
2) Select proper size of tappet. Available tappets No.
a) Using a micrometer, measure the thickness of Thickness Thickness
Tappet No. Tappet No.
the removed tappet (1). mm (in.) mm (in.)
b) Calculate the thickness of new tappet by the 3.88 (0.1528) 388 3.48 (0.1370) 348
following formula. 3.86 (0.1520) 386 3.46 (0.1362) 346
3.84 (0.1512) 384 3.44 (0.1354) 344
NOTE 3.82 (0.1504) 382 3.42 (0.1346) 342
If the number in the second decimal place is 3.80 (0.1496) 380 3.40 (0.1339) 340
odd, use (A – 0.01) tappet. 3.78 (0.1488) 378 3.38 (0.1331) 338
3.76 (0.1480) 376 3.36 (0.1323) 336
Intake side: 3.74 (0.1472) 374 3.34 (0.1315) 334
A = B + C – 0.19 mm (0.0075 in.) 3.72 (0.1465) 372 3.32 (0.1307) 332
Exhaust side: 3.70 (0.1457) 370 3.30 (0.1299) 330
A = B + C – 0.35 mm (0.0138 in.) 3.68 (0.1449) 368 3.28 (0.1291) 328
• A: Thickness “a” of new tappet 3.66 (0.1441) 366 3.26 (0.1283) 326
3.64 (0.1433) 364 3.24 (0.1276) 324
• B: Thickness “a” of removed tappet 3.62 (0.1425) 362 3.22 (0.1268) 322
• C: Measured valve clearance 3.60 (0.1417) 360 3.20 (0.1260) 320
3.58 (0.1409) 358 3.18 (0.1252) 318
"a" 3.56 (0.1402) 356 3.16 (0.1244) 316
1
3.54 (0.1394) 354 3.14 (0.1236) 314
3.52 (0.1386) 352 3.12 (0.1228) 312
3.50 (0.1378) 350 3.10 (0.1220) 310

3) Install tappets and camshafts. (Page 1D-14)

1
4) Recheck valve clearance.

I7V20A141015-01
 Engine Mechanical: K10B and Bi-Fuel CNG 1D-5

Repair Instructions
Air Cleaner Components
AENJCA0A1416001

(a)

2
6 4

7
6
5
(a)

9
11

10
IJCA0A141002-01

1. Air cleaner assembly 5. IAT sensor 9. Breather hose

2. Air cleaner suction pipe
3. Air cleaner suction hose
4. Air cleaner outlet hose
: For installation, refer to “IAT Sensor
Removal and Installation”: K10B and Bi-
Fuel CNG in Section 1C (Page 1C-14).
6. Air cleaner grommet 10. To cylinder head cover
7. Air cleaner bracket 11. To electric throttle body assembly
8. Breather hose pipe : 1.3 Nm (0.13 kgf-m, 1.0 lbf-ft)

Air Cleaner Filter Removal and Installation Installation

AENJCA0A1416002
1) Install air cleaner filter to air cleaner housing.
Removal 2) Fit tabs (2) of the cover with hooks of the housing.
1) Unhook air cleaner housing clamps (1). And join air cleaner cover (1) with air cleaner
housing (3).
2) Pull up air cleaner cover (2).
3) Hook air cleaner housing clamps (4).

2 2

1
1

IJCA0A141003-02

3) Remove air cleaner filter from air cleaner housing. 4

4

IJCA0A141004-01
1D-6 Engine Mechanical: K10B and Bi-Fuel CNG

Air Cleaner Filter Inspection and Cleaning 5) Remove air cleaner outlet hose (1) as follows, if
AENJCA0A1416003 necessary.
Inspection • Disconnect IAT sensor connector (2).
Check air cleaner filter for dirt. Replace excessively dirty • Remove breather hose (3).
filter. • Remove air cleaner outlet hose.

Cleaning
Blow off dust by compressed air from air outlet side of
filter. 1

I5RS0B140007-01 IJCA0A141007-01

Air Cleaner Assembly Removal and Installation Installation

AENJCA0A1416004 Reverse removal procedure noting the following points.
Removal NOTE
1) Disconnect air cleaner outlet hose (1) and air cleaner Check that air cleaner grommets are fitted to
suction hose (2). intake manifold.
2) Unhook air cleaner housing clamps (3). If the grommets are disconnected, fit them to
3) Remove air cleaner cover (4). intake manifold before installing air cleaner
assembly.
1
4 • Tighten air cleaner outlet hose clamp to specified
torque. (Page 1D-5)
2 • Install air cleaner assembly pressing it until two
grommets fit completely into intake manifold and
cylinder head cover respectively.
• Tighten air cleaner bolt securely.
3
3

IJCA0A141005-02

4) Remove air cleaner housing (1).

IJCA0A141006-01
 Engine Mechanical: K10B and Bi-Fuel CNG 1D-7

Electric Throttle Body and Intake Manifold Components

AENJCA0A1416005

9 2

10

8
2
11 7

(a)
5 11

11

IJCA0A141008-01

1. Intake manifold
2. Intake manifold gasket
3. Electric throttle body assembly
: Do not disassemble.
4. Electric throttle body gasket
5. MAP sensor
6. PCV hose 11. To CNG fuel injector (Bi-fuel CNG)
7. To PCV valve : 4.0 Nm (0.41 kgf-m, 3.0 lbf-ft)
8. To brake booster : Do not reuse.
9. To EVAP canister purge valve
10. To CNG pressure regulator (Bi-fuel CNG)

Electric Throttle Body On-Vehicle Inspection

AENJCA0A1416006
Check electric throttle body assembly. (Page 1C-5)
1D-8 Engine Mechanical: K10B and Bi-Fuel CNG

Electric Throttle Body Assembly Removal and Installation

Installation 1) Clean mating surfaces and install new throttle body
AENJCA0A1416007
gasket (1) to intake manifold.
NOTICE
The electric throttle body will lose its original
performance if it is disassembled.
Do not disassemble the electric throttle body.
If any faulty condition is found, replace the
electric throttle body with a new one.

NOTE
After removing electric throttle body 1

assembly, calibration of throttle valve

position is required. (Page 1C-7)
IJCA0A141010-01
Removal
1) Disconnect negative (–) cable at battery. 2) Install electric throttle body assembly (2) to intake
manifold.
2) Remove air cleaner assembly and air cleaner outlet
hose. (Page 1D-6) 3) Connect electric throttle body connector (1) to
electric throttle body assembly.
3) Disconnect electric throttle body connector (1) from
electric throttle body assembly (2).

IJCA0A141009-01

4) Install air cleaner outlet hose and air cleaner

IJCA0A141009-01
assembly. (Page 1D-6)
4) Remove electric throttle body assembly from intake
manifold. 5) Connect negative (–) cable at battery.
5) Remove electric throttle body gasket.
Electric Throttle Body Cleaning
AENJCA0A1416008
Clean electric throttle body assembly referring to
“Throttle Valve Visual Check” under “Electric Throttle
Body Assembly On-Vehicle Inspection”: K10B and Bi-
Fuel CNG in Section 1C (Page 1C-5).
 Engine Mechanical: K10B and Bi-Fuel CNG 1D-9

Intake Manifold Removal and Installation 6) Disconnect MAP sensor connector (1).
AENJCA0A1416009

NOTE
When servicing petrol fuel devices in bi-fuel
CNG model, follow the procedure in the 1
petrol model.

Removal
1) Relieve fuel pressure from fuel system concerned.
• Petrol: (Page 1G-19)
• CNG: (Page 1G-55)
2) Remove air cleaner assembly and air cleaner outlet
hose. (Page 1D-6)
3) Remove electric throttle body assembly. (Page IJCA0A141012-01

1D-8) 7) Disconnect engine harness clamps and heater hose

clamp from intake manifold.
4) Remove fuel injectors from the engine concerned.
8) Remove intake manifold (1) and its gasket from
• Petrol: (Page 1G-22)
cylinder head.
• CNG: (Page 1G-65)
5) Disconnect the following hoses.
• Brake booster hose (1)
• PCV hose (2)
• EVAP canister purge valve hose (3)
• CNG vacuum hose (Bi-fuel CNG) (4)

2 1 1

4 IJCA0A141013-01

9) Remove MAP sensor if necessary. (Page 1C-9)

Installation
Reverse removal procedure noting the following points.
• Use new gaskets.
3
IJCA0A141011-01
• Check that all removed parts are back in place.
• Check fuel system concerned for leakage.
– Petrol: (Page 1G-20)
– CNG: (Page 1G-56)
1D-10 Engine Mechanical: K10B and Bi-Fuel CNG

Cylinder Head Cover Components

AENJCA0A1416010

7
4 3 (a)

2 1217G

IJCA0A141014-01

1. Cylinder head cover 4. PCV valve 7. To air cleaner outlet hose

2. Cylinder head cover gasket 5. Oil filler cap : 5.0 Nm → 8.0 Nm → 11 Nm (0.51 kgf-m → 0.82
: Apply sealant 99000-31260 referring to kgf-m → 1.1 kgf-m, 4.0 lbf-ft → 6.0 lbf-ft → 8.5 lbf-ft)
“Cylinder Head Cover Removal and Installation”:
K10B and Bi-Fuel CNG (Page 1D-11).
3. Cylinder head cover bolt 6. PCV valve grommet : Do not reuse.
: For tightening order, refer to “Cylinder Head
Cover Removal and Installation”: K10B and Bi-
Fuel CNG (Page 1D-11).
 Engine Mechanical: K10B and Bi-Fuel CNG 1D-11

Cylinder Head Cover Removal and Installation 7) Disconnect the following connectors.
AENJCA0A1416011
• Magnet clutch lead wire (1)
Removal • Oil pressure switch lead wire (2)
1) Disconnect negative (–) cable at battery. • Fuel injectors (3)
2) Remove air cleaner assembly. (Page 1D-5) • Electric throttle body (4)
3) Remove ignition coil assemblies. (Page 1H-7) • CMP sensor (5)
4) Remove engine harness bolts (1). • ECT sensor (6)
5) Remove air cleaner bracket (2). • EVAP canister purge valve (7)
6) Remove HO2S bracket (3).
3

5 4

7
2 6

1
2
1

IJCA0A141016-01

8) Disconnect harness clamps from cylinder head

cover and cylinder block pulley side.
9) Remove oil level gauge (1).
10) Disconnect breather hose (2).
11) Disconnect PCV valve hose (3).

1
3 2
3
IJCA0A141015-01 1

IJCA0A141017-01
1D-12 Engine Mechanical: K10B and Bi-Fuel CNG

12) Loosen cylinder head cover bolts in numerical order 4) Apply sealant “A” to the mating surface as shown.
(“1” – “5”) evenly and gradually.
“A”: Sealant 99000–31250 (SUZUKI Bond
No.1207F)

“4” “A” 2
“2”

“1”
1

“A”
“5” I8C50A140025-01
“3”
IJCA0A141018-01 1. Timing chain cover 2. Cylinder head
13) While pulling up engine harness, remove cylinder
head cover with cylinder head cover gasket. And 5) Install PCV valve (1) to cylinder head cover, if
separate the gasket. removed.
14) Remove PCV valve (1), if necessary.

IJCA0A141019-01

IJCA0A141019-01 6) Install cylinder head cover to cylinder head.

Installation NOTE
1) Remove oil, old sealant and dust from sealing When installing cylinder head cover, use care
surfaces on cylinder head and cover. so that cylinder head cover gasket will not
get out of place or fall off.
2) Install new cylinder head cover gasket (1) to cylinder
head cover (2).
3) Apply engine oil to inside surface of plug pipe seals
(3).

1
2

3 3 3

IJCA0A141020-01
 Engine Mechanical: K10B and Bi-Fuel CNG 1D-13

7) Tighten cylinder head cover bolts according to the
following procedure.
a) Tighten cylinder head cover bolts to 5.0 Nm
(0.51 kgf-m, 4.0 lbf-ft) in numerical order (“1” –
“5”) evenly and gradually.
b) In the same manner as in Step a), tighten them
to 8.0 Nm (0.82 kgf-m, 6.0 lbf-ft).
c) In the same manner as in Step a), tighten them
to 11 Nm (1.1 kgf-m, 8.5 lbf-ft).
Tightening torque
Cylinder head cover bolt* (a): 5.0 Nm → 8.0
Nm → 11 Nm (0.51 kgf-m → 0.82 kgf-m → 1.1
kgf-m, 4.0 lbf-ft → 6.0 lbf-ft → 8.5 lbf-ft)
11) Connect all other disconnected electric wire clamps
and connectors to original positions.
12) Install HO2S bracket (1).
13) Install air cleaner bracket (2).
14) Install engine harness (3).
15) Tighten engine harness bracket bolt (4) to specified
torque.
Tightening torque
Engine harness bracket bolt (a): 11 N·m (1.1 kgf-
m, 8.5 lbf-ft)
3

“2”, (a)
“4”, (a)

“5”, (a)

3
“1”, (a)
“3”, (a)
IJCA0A141021-01

8) Connect PCV valve hose (3) to PCV valve.

9) Connect breather hose (2) to cylinder head cover.
10) Install oil level gauge (1). 1

2
3
1

4, (a)

IJCA0A141022-01

16) Install ignition coil assemblies. (Page 1H-7)

IJCA0A141017-01
17) Install air cleaner assembly. (Page 1D-5)
18) Connect negative (–) cable at battery.
1D-14 Engine Mechanical: K10B and Bi-Fuel CNG

Camshaft and Tappet Components

AENJCA0A1416012

3 4 (b) 3 4 (b)

OIL
1
7
7

OIL
2
(a)
OIL

OIL
6
I8C50B140015-01

1. Intake camshaft 4. Camshaft housing bolt 7. Dowel pin

: Apply engine oil to sliding surface.
2. Exhaust camshaft
: Apply engine oil to sliding surface.
3. Camshaft housing
: For tightening order, refer to“Camshaft
and Tappet Removal and Installation”:
K10B and Bi-Fuel CNG (Page 1D-14).
5. Exhaust camshaft timing sprocket : 60 Nm (6.1 kgf-m, 44.5 lbf-ft)
6. Tappet : 5.0 Nm → 8.0 Nm → 11 Nm (0.51 kgf-m → 0.82
: Apply engine oil to sliding surface. kgf-m → 1.1 kgf-m, 4.0 lbf-ft → 6.0 lbf-ft → 8.5 lbf-ft)

Camshaft and Tappet Removal and Installation NOTE

AENJCA0A1416013
When the lines are aligned with cylinder head
NOTICE surface as shown, each sprocket timing mark
If engine oil contacts to compressor drive at the chain cover side points the top.
belt and water pump / generator drive belt,
problems such as belt squeal could occur.
1 1
Do not allow engine oil to contact
compressor drive belt and water pump /
generator drive belt. If engine oil contacts
them, wash it off with water.

Removal
1) Hoist vehicle.
2) Remove right side splash cover.
2
3) Remove cylinder head cover. (Page 1D-11) 2
I7V20A141006-01
4) Turn crankshaft clockwise and position piston No.1 b) Check that notch (1) on crankshaft pulley is
to TDC as follows. aligned with “0” line (2) (TDC) on timing chain
a) Align both intake and exhaust camshaft timing cover.
sprocket marks (1) with surface of cylinder head
(2) respectively. 2

IJHB0D140002-01
 Engine Mechanical: K10B and Bi-Fuel CNG 1D-15

5) Remove timing chain cover plug (1) and gasket (2).
b) Tighten fixing bolt (2) by hand and push timing
chain tensioner (1) at upper part of the pivot.
c) Turn crankshaft 20° (3) counterclockwise and
tighten the bolt by hand again.
d) Turn crankshaft 20° clockwise and tighten the
bolt more by hand.

1 2
I7V20A141008-01 2

6) Release tension of timing chain by fixing timing chain 1

tensioner as follows.

NOTICE
Tightening fixing bolt with wrench may
damage timing chain tensioner.
Tighten the bolt only by hand.

NOTE 2
If this step to slacken timing chain is omitted,
reinstallation of the exhaust camshaft timing I7V20A141010-01
sprocket will become difficult.

a) Prepare an M8 bolt of the following dimensions. 3

• Thread pitch: 1.25 mm (0.049 in.)

• Length “a”: 35 mm (1.4 in.) or longer

“a”

I7V20A141009-02

IJHB0D140003-01
1D-16 Engine Mechanical: K10B and Bi-Fuel CNG

7) Put matchmarks (2) on timing chain links aligned 10) Remove intake camshaft and exhaust camshaft.
with timing marks (1) on intake sprocket (3) and
exhaust sprocket (4). NOTE
Because a guide to prevent coming off of
NOTE timing chain from crankshaft timing sprocket
If colored chain links are aligned with timing is provided at the lower part of oil pump,
marks on intake sprocket and exhaust timing chain will not be disengaged from
sprocket respectively with success, it is not crankshaft timing sprocket even when
necessary to put matchmarks. camshafts are removed.
In this case, use the colored chain links as
matchmarks for installation.
“2” “13” “12 ” “17” “16” “9” “8”

“5”
2 2

“3”
1
1

4 3

“4”

“1” “10” “11” “14” “15” “6” “7”

I8C50A140029-01

11) Remove tappet, if necessary.

Installation
IJCA0A141023-01
1) Apply engine oil to contact surface of each tappet
8) With hexagonal section of exhaust camshaft held (hatched area), and install tappet (1) to cylinder
stationary with spanner or adjustable wrench, head.
remove sprocket bolt and then remove camshaft
timing sprocket (1).

NOTE 1
Do not turn camshaft after removing exhaust
camshaft timing sprocket.

1
I7V20A141016-01

2) Apply engine oil to sliding part of camshaft, and set

camshaft to cylinder head.
a) Align matchmark (1) on intake camshaft sprocket
with colored mark (2) on timing chain.
b) Install exhaust camshaft and position dowel pin
(3) of exhaust camshaft upward.

IDLA0A140020-01 2
9) Loosen camshaft housing bolts in numerical order 1
(“1” – “17”) evenly and gradually. 3

I7V20A141017-01

3) After checking installation of dowel pins for camshaft
housings, set camshaft housings (1) to specified
places indicated by character (2), number (3) and
arrow mark (4) on each camshaft housing.
NOTE
Shapes and functions of No.1 camshaft
housing are different from No.2 – 4 camshaft
housings. And, their positioning is restricted
by their shape.
1
2 3
2. I: Intake camshaft housing
E: Exhaust camshaft housing
3. Position from timing chain side
4. Point arrow to timing chain side
4) Tighten camshaft housing bolts according to the
following procedure.
a) Tighten camshaft housing bolts to 5.0 Nm (0.51
kgf-m, 4.0 lbf-ft) in numerical order (“1” – “17”)
evenly and gradually.
b) In the same manner as in Step a), tighten them
to 8.0 Nm (0.82 kgf-m, 6.0 lbf-ft).
c) In the same manner as in Step b), tighten them
to 11 Nm (1.1 kgf-m, 8.5 lbf-ft).
Tightening torque
Camshaft housing bolt* (a): 5.0 Nm → 8.0
Nm → 11 Nm (0.51 kgf-m → 0.82 kgf-m → 1.1
kgf-m, 4.0 lbf-ft → 6.0 lbf-ft → 8.5 lbf-ft)
“16” “6” “5” “1”,(a) “2”
“13”
“15”
“14”
“17” “8” “7” “4” “3”
Engine Mechanical: K10B and Bi-Fuel CNG 1D-17
5) Install exhaust camshaft timing sprocket to camshaft
as follows.
a) Fit timing chain by aligning its matchmark
marked before removal (or colored link) (1) on
timing chain with timing mark (2) on exhaust
camshaft timing sprocket.
b) With timing chain engaged, install exhaust
camshaft timing sprocket to exhaust camshaft.
NOTE
Slight turning the exhaust camshaft by a
wrench will facilitate fitting the sprocket.
1
2
I8C50A140081-01
IDLA0A140053-01
6) Tighten exhaust camshaft timing sprocket bolt to
specified torque using special tool as follows.
NOTICE
If the exhaust camshaft timing sprocket bolt
is tightened using the special tool (offset
adapter) until the torque wrench reads the
specified torque below, the bolt will be
tightened too much.
Follow the steps below to tighten the bolt
using the special tool appropriately.
a) Measure length (L) of torque wrench.
b) Calculate reading value (M) of the torque wrench
“9” “10” using the following formula.
NOTE
If offset adapter other than the special tool is
used, measure the center distance
corresponding to “a” and apply the
dimension to the formula.
“12” “11”
I8C50A140030-01
1D-18 Engine Mechanical: K10B and Bi-Fuel CNG

Formula for torque wrench reading value 8) Remove fixing bolt from timing chain cover.
when using special tool 9) Install timing chain cover plug (1) with new gasket
M = T x L / (L + “a”) (2), and tighten timing chain cover plug to specified
• M: Torque wrench reading value when using torque.
special tool
Tightening torque
• T: Specified torque Timing chain cover plug (a): 25 N·m (2.5 kgf-m,
• L: Torque wrench length 18.5 lbf-ft)
• “a”: Dimension of special tool (50 mm (1.97
in.))
Special tool
(A): 09945M25710
c) Tighten exhaust camshaft timing sprocket bolt
(1) until torque wrench reads the value obtained
in the above Step b).
Tightening torque
Exhaust camshaft timing sprocket bolt (a):
60 N·m (6.1 kgf-m, 44.5 lbf-ft) 1,(a) 2
I7V20A141023-01

10) Check that camshaft and timing chain are installed

(A)
properly as follows.
a) Check that intake and exhaust camshaft timing
sprocket marks (1) are aligned with top face of
cylinder head (2).

1 1

1,(a)
“a”
IDLA0A140021-01
2 2
7) Check that matchmarks marked before removal (or I7V20A141006-01
colored links) (2) are aligned with timing marks (1) b) Check that notch (1) is aligned with “0” line (2)
on intake and exhaust camshaft timing sprockets. (TDC) on timing chain cover.
2 2
2

1
1

IJCA0A141024-01

IJHB0D140002-01
 Engine Mechanical: K10B and Bi-Fuel CNG 1D-19

c) Turn crankshaft clockwise 720° and check again Cam Wear

that matchmarks are aligned. Using a micrometer, measure cam height “a”. If
measured height is below its limit, replace camshaft.
NOTE
Cam height “a” of camshaft
If crankshaft is turned only 360°, the timing
sprocket marks (1) will not align with top face Cam height Standard Limit
of cylinder head (2). 44.520 – 44.680 mm 44.420 mm
Intake cam
(1.7528 – 1.7590 in.) (1.7488 in.)
1 45.388 – 45.548 mm 45.288 mm
1 Exhaust cam
(1.7870 – 1.7932 in.) (1.7830 in.)

“a”

2 2
I7V20A141006-01

11) Check valve clearance. (Page 1D-3)

12) Install cylinder head cover. (Page 1D-11) I8C50A140031-01

13) Run engine and check for oil leakage. Camshaft Runout
14) Install right side splash cover. Set camshaft between two “V” blocks and measure its
runout using a dial gauge.
Camshaft and Tappet Inspection If measured runout exceeds limit, replace camshaft.
AENJCA0A1416014
Camshaft runout
Signal Rotor Limit: 0.015 mm (0.00059 in.)
Check signal rotor (1) for crack and damage. If any
defect is found, replace camshaft.

I8C50A140032-01

Camshaft Journal Wear

IJCA0A141025-01 Check camshaft journals and camshaft housings for
pitting, scratches, wear or damage.
If any defect is found, replace camshaft and/or cylinder
head with camshaft housings as assembly.

I9T401142013-01
1D-20 Engine Mechanical: K10B and Bi-Fuel CNG

Check clearance using gauging plastic according to the

following procedure. [A]

1) Clean camshaft housings and camshaft journals.

2) Remove all tappets.
3) Install camshafts to cylinder head.
4) Place a piece of gauging plastic to full width of
camshaft journal parallel to camshaft.
5) Install camshaft housings referring to Step 3) – 4) in
“Installation” under “Camshaft and Tappet Removal [B]
and Installation”: K10B and Bi-Fuel CNG (Page 1D-
14).

NOTE
When installing camshaft housings for
measuring the journal clearance, use
removed camshaft housing bolts.

6) Remove camshaft housing, and using scale (2) on

gauging plastic envelope, measure gauging plastic I8C50A140033-01

(1) width at the widest point. 7) Install intake and exhaust camshafts without tappet,
Camshaft journal clearance and then measure intake and exhaust camshaft
Standard: 0.045 – 0.087 mm (0.0018 – 0.0034 in.) housing thrust clearance using a dial gauge.
Limit: 0.10 mm (0.0039 in.) If measured clearance exceeds limit, replace
camshaft and/or cylinder head with camshaft
housings as assembly.
Camshaft housing thrust clearance
Standard: 0.10 – 0.35 mm (0.0040 – 0.0137 in.)
Limit: 0.50 mm (0.020 in.)

I2RH0B140083-01

If measured camshaft journal clearance exceeds

limit, measure camshaft journal diameter and
camshaft journal housing bore diameter. Replace
camshaft or cylinder head assembly whichever the
difference from specification is greater. I7V20A141074-01

Camshaft journal diameter [A]

Item Standard
Intake and Exhaust side 26.934 – 26.955 mm
No.1 housing (1.0604 – 1.0612 in.)
22.934 – 22.955 mm
Others
(0.9030 – 0.9037 in.)

Camshaft journal housing bore diameter [B]

Item Standard
Intake and Exhaust side 27.000 – 27.021 mm
No.1 housing (1.0630 – 1.0638 in.)
23.000 – 23.021 mm
Others
(0.9056 – 0.9063 in.)

Wear of Tappet
Check tappet for pitting, scratches or damage.
If any defect is found, replace tappet.
I7V20A141075-01
Measure cylinder head bore and tappet outside diameter
to determine cylinder head-to-tappet clearance. If
clearance exceeds limit, replace tappet or cylinder head.
Cylinder head to tappet clearance
Standard: 0.025 – 0.062 mm (0.0010 – 0.0024 in.)
Limit: 0.10 mm (0.0039 in.)
Tappet outside diameter [A]
Standard: 27.959 – 27.975 mm (1.1008 – 1.1013 in.)
Cylinder head tappet bore [B]
Standard: 28.000 – 28.021 mm (1.1024 – 1.1031 in.)
I2RH0B140086-01
Intake Camshaft Timing Sprocket
Check intake camshaft timing sprocket for wear and
damage.
If any defect is found, replace intake camshaft.
Exhaust Camshaft Timing Sprocket
Check exhaust camshaft timing sprocket for wear and
damage.
If any defect is found, replace exhaust camshaft timing
sprocket.
Engine Mechanical: K10B and Bi-Fuel CNG 1D-21
Crankshaft Front Oil Seal Replacement
AENJCA0A1416044
1) Hoist vehicle and remove right side splash cover.
2) Remove compressor drive belt. (Page 7B-51)
3) Remove water pump / generator drive belt. (Page
1J-8)
4) Remove crankshaft pulley referring to Step 3) – 4) in
“Removal” under “Timing Chain Cover Removal and
Installation”: K10B and Bi-Fuel CNG (Page 1D-31).
5) Using a flat-bladed screwdriver or the like wrapped
with protective tape, remove crankshaft front oil seal
(1) slowly.
NOTICE
• If tip of screwdriver scratches timing chain
cover, it may cause oil leakage.
Carefully remove oil seal not to damage
timing chain cover.
• If crankshaft edge is dented, it may disturb
smooth installation of crankshaft pulley.
Carefully remove oil seal not to damage
crankshaft edge.
IJHA0A140022-01
6) Using special tool and hammer, install new
crankshaft front oil seal (1) into timing chain cover.
Special tool
(A): 09913M70123
Depth
“a”: 1.15 – 1.35 mm (0.0453 – 0.0531 in.)
“a”
1
(A)
IJHA0A140023-01
7) Install crankshaft pulley referring to Step 15) – 17) in
“Installation” under “Timing Chain Cover Removal
and Installation”: K10B and Bi-Fuel CNG (Page 1D-
31).
1D-22 Engine Mechanical: K10B and Bi-Fuel CNG

8) Install water pump / generator drive belt. (Page 1J-

8)
9) Install compressor drive belt. (Page 7B-51)
10) Install right side splash cover.

Crankshaft Rear Oil Seal Replacement

AENJCA0A1416045
1) Drain engine oil. (Page 1E-4)
2) Dismount transaxle assembly.
• M/T model: (Page 5B-14)
• Auto gear shift model: (Page 5D-117)
3) Remove clutch cover and clutch disc.
• M/T model: (Page 5C-9)
• Auto gear shift model: (Page 5D-145)
4) Remove flywheel. (Page 1D-33)
5) Remove oil pan. (Page 1E-8)
6) Remove oil seal housing and rear oil seal referring to
Step 4) – 5) “Removal” under “Main Bearing,
Crankshaft and Cylinder Block Removal and
Installation”: K10B and Bi-Fuel CNG (Page 1D-60).
7) Install new rear oil seal and oil seal housing referring
to Step 13) – 19) “Installation” under “Main Bearing,
Crankshaft and Cylinder Block Removal and
Installation”: K10B and Bi-Fuel CNG (Page 1D-60).
8) Install oil pan. (Page 1E-8)
9) Install flywheel. (Page 1D-33)
10) Install clutch cover and clutch disc.
• M/T model: (Page 5C-9)
• Auto gear shift model: (Page 5D-145)
11) Remount transaxle assembly.
• M/T model: (Page 5B-14)
• Auto gear shift model: (Page 5D-117)
12) Refill engine with engine oil. (Page 1E-4)
 Engine Mechanical: K10B and Bi-Fuel CNG 1D-23

Engine Mounting Components

AENJCA0A1416015

(e) (e)

(e)
(e)

(c)

(e)
(e)

4 (e)
3 (a) 1

(e)
(e)

3 (a)

(d)

(b)

(a)
IJCA0A141027-01

1. Engine right mounting
2. Engine right mounting bracket
3. Engine right mounting bracket bolt
: For tightening order, refer to “Engine
Assembly Removal and Installation”:
K10B and Bi-Fuel CNG (Page 1D-24).
4. Engine left mounting
5. Engine rear torque rod
: For M/T model, face blue mark downward.
: For auto gear shift model, face yellow mark upward.
6. Engine rear torque rod bracket
: 93 Nm (9.5 kgf-m, 68.5 lbf-ft)
: 85 Nm (8.7 kgf-m, 63.0 lbf-ft)
: 65 Nm (6.6 kgf-m, 48.0 lbf-ft)
: 60 Nm (6.1 kgf-m, 44.5 lbf-ft)
: 55 Nm (5.6 kgf-m, 40.5 lbf-ft)
: Do not reuse.
1D-24 Engine Mechanical: K10B and Bi-Fuel CNG

Engine Assembly Removal and Installation 10) Disconnect the following connectors and cables
AENJCA0A1416016 including the related clamps.
NOTE
• Connectors (1) in main fuse box
When servicing petrol fuel devices in bi-fuel
• Connector (2) in individual circuit fuse box No1
CNG model, follow the procedure in the
petrol model. • Battery ground cables (3)
• CNG control module connector (Bi-fuel CNG) (4)
Removal
1) Relieve fuel pressure from fuel system concerned. 2

• Petrol: (Page 1G-19)

• CNG: (Page 1G-55)
2) For bi-fuel CNG, relieve CNG fuel pressure in CNG
fuel feed line. (Page 1G-55)
3) Disconnect steering lower shaft from pinion shaft.
(Page 6B-12)
4) Remove battery and battery tray. (Page 1J-6)
5) Disconnect ECM connectors. (Page 1C-3)
3 3
6) Drain the following oils, if necessary.
1
• Engine oil: (Page 1E-4) IJCA0A141026-02

• Manual transaxle oil (M/T model): (Page 5B-8)

4
• Auto gear shift transaxle oil (auto gear shift
model): (Page 5D-99)
7) Drain coolant. (Page 1F-9)
8) Remove air cleaner assembly and air cleaner outlet
hose. (Page 1D-6)
9) Remove right and left side splash covers.

IJCA0A141028-01

11) For auto gear shift model, disconnect junction

connector (1) in numerical order (“1” – “2”) as shown
in figure.

“2”
“1”

IJCA0A141029-01
 Engine Mechanical: K10B and Bi-Fuel CNG 1D-25

12) Disconnect the following hoses. 14) With A/C hoses connected, detach A/C compressor
• Brake booster hose (1) from cylinder block. (Page 7B-52)
• Radiator inlet hose (2) NOTICE
• Radiator outlet hose (3) When A/C compressor is detached, the A/C
• Fuel hose (4) hoses could be damaged receiving weight of
• Canister purge hose (5) the compressor.
• Heater inlet hose (6) Suspend the removed A/C compressor to the
vehicle body while the compressor is
• Heater outlet hose (7) detached.
1
15) For M/T model, disconnect the following cables from
6
transaxle.
4 7 • Clutch cable: (Page 5C-5)
• Gear shift and gear select control cables: (Page
5B-11)
16) Remove exhaust pipe and muffler. (Page 1K-5)
17) Remove stabilizer bar joints from stabilizer bar at
5 each of right and left sides. (Page 2B-14)
18) Disconnect tie-rod end from steering knuckle at each
2
of right and left sides. (Page 6B-15)
19) Disconnect suspension arm joint from steering
IJCA0A141030-01
knuckle at each of right and left sides. (Page 2B-
10)
20) Disconnect right and left drive shaft joints from
steering knuckle. (Page 3A-3)
21) Support front suspension frame (1), transaxle case
(2) and oil pan (3) using jack.
22) Remove front suspension frame bolts (4).

2
3
3

IJCA0A141031-01

13) For bi-fuel CNG, disconnect the following hoses.

• CNG vacuum hose (1)
• CNG water inlet hose (2)
4 4
• CNG water outlet hose (3)
• CNG fuel hose (4) 1

IJCA0A141033-01
4 23) Remove engine right mounting bolt (1) and nuts (2).

1
3

IJCA0A141032-01
1D-26 Engine Mechanical: K10B and Bi-Fuel CNG

28) Install a shackle (1) or the like to timing chain cover,

and then lift engine with transaxle and suspension
frame as a set using the shackle or the like and hook
(2) of transaxle, if necessary.

1
2

IJCA0A141034-01

24) Remove engine left mounting bolt (1) and nuts (2).

IJCA0A141037-01

[A] [B]

2
1

2
2
IJCA0A141038-01

IJCA0A141035-01 [A]: M/T model [B]: Auto gear shift model

25) Before removing engine, check that all hoses,

electric wires and cables are disconnected from
engine.
26) Lower engine assembly with transaxle, front
suspension frame, drive shafts, steering gear case
all together.
29) Remove front drive shaft assembly, if necessary.
(Page 3A-3)
30) Remove engine right mounting bracket (1), if
necessary.

NOTICE
The A/C compressor may be damaged if it
hits against or interferes with other parts.
Suspend the removed A/C compressor in a
place where no damage will be caused during
installation of the engine assembly.

27) Remove engine harness bolt (1), if necessary.

1

IJCA0A141039-01

IJCA0A141036-01
 Engine Mechanical: K10B and Bi-Fuel CNG 1D-27

31) Check that a shackle (1) or the like is installed as Installation

shown in figure. Install engine hook (11851- 77EA0) 1) Install the following components to engine assembly,
(2) on stud bolts of exhaust manifold with nuts if removed.
(08316-1010A) (3), and then using these hooks lift
• Flywheel: (Page 1D-33)
engine assembly.
• Clutch cover and disc
– M/T model: (Page 5C-9)
– Auto gear shift model: (Page 5D-145)
• Transaxle
– M/T model: (Page 5B-14)
1 – Auto gear shift model: (Page 5D-117)
• Engine harness
2) Set engine harness ground cable to its original
position and tighten engine harness ground bolt (1)
to specified torque, if removed.
Tightening torque
IJCA0A141037-01 Engine harness ground bolt (a): 11 N·m (1.1 kgf-
m, 8.5 lbf-ft)

“a” “a”
3

1, (a)

IJCA0A141041-01

“a”: 22.5°
IJCA0A141040-01

32) Remove front suspension frame, if necessary. 3) Install engine right mounting, if removed.
(Page 2B-15)
33) Remove the following components from engine
assembly, if necessary.
• Engine harness
• Transaxle
– M/T model: (Page 5B-14)
– Auto gear shift model: (Page 5D-117)
• Clutch cover and disc
– M/T model: (Page 5C-9)
– Auto gear shift model: (Page 5D-145)
• Flywheel: (Page 1D-33)
1D-28 Engine Mechanical: K10B and Bi-Fuel CNG

4) Tighten engine right mounting bolts in numerical 9) Tighten engine left mounting nuts (1) and bolt (2) to
order as follows. specified torque.
a) Temporarily tighten engine right mounting bolts Tightening torque
(1). Engine left mounting nut (a): 55 N·m (5.6 kgf-m,
b) Tighten engine right mounting bolts (2) to 40.5 lbf-ft)
specified torque. Engine left mounting bolt (b): 55 N·m (5.6 kgf-
c) Tighten engine right mounting bolts to specified m, 40.5 lbf-ft)
torque.
Tightening torque
Engine right mounting bolt (a): 93 N·m (9.5
kgf-m, 68.5 lbf-ft)

1, (a) 1, (a) 1, (a)

2, (b)

IJCA0A141043-01

10) Tighten engine right mounting nuts (1) and bolt (2) to
specified torque.

2, (a) 2, (a) Tightening torque

IJCA0A141042-01 Engine right mounting nut (a): 65 N·m (6.6 kgf-
5) Install front suspension frame, if removed. (Page m, 48.0 lbf-ft)
2B-15) Engine right mounting bolt (b): 65 N·m (6.6 kgf-
6) Tighten engine harness bolt (1) securely, if removed. m, 48.0 lbf-ft)

2, (b)
1, (a)

IJCA0A141044-01
IJCA0A141036-01

7) Install front drive shaft assembly, if removed.
(Page 3A-3)
8) Lift up engine assembly with transaxle, front
suspension frame, drive shafts and steering gear
case all together.
NOTICE
The A/C compressor may be damaged if it
hits against or interferes with other parts.
Suspend the removed A/C compressor in a
place where no damage will be caused during
installation of the engine assembly.
11) Tighten front suspension frame bolts to specified
torque. (Page 2B-14)
12) Remove jack.
13) Connect right and left drive shaft joints to steering
knuckle. (Page 3A-3)
14) Connect suspension arm joint to steering knuckle at
each of right and left sides. (Page 2B-10)
15) Connect tie-rod end to steering knuckle at each of
right and left sides. (Page 6B-15)
16) Install stabilizer bar joints to stabilizer bar at each of
right and left sides. (Page 2B-14)
17) Install exhaust pipe and muffler. (Page 1K-5)
 Engine Mechanical: K10B and Bi-Fuel CNG 1D-29

18) For M/T model, connect the following cables to

transaxle.
• Gear shift and gear select control cables: (Page
5B-11)
• Clutch cable: (Page 5C-5)
19) Install A/C compressor to cylinder block. (Page
7B-52)
20) Install all other removed electric wires, connectors
and hoses to original positions.
21) Tighten ground terminal bolt (1) to specified torque.
Tightening torque
Ground terminal bolt (a): 25 N·m (2.5 kgf-m, 18.5
lbf-ft)

1, (a)

IJCA0A141045-01

22) Install air cleaner assembly and air cleaner outlet

hose. (Page 1D-6)
23) Check that all removed parts are back in their
places. Reinstall any necessary parts which have not
been reinstalled.
24) Refill engine and transaxle with oil if drained.
• Engine oil: (Page 1E-4)
• Manual transaxle oil (M/T model): (Page 5B-8)
• Auto gear shift transaxle oil (auto gear shift
model): (Page 5D-99)
25) Connect ECM connectors. (Page 1C-3)
26) Install battery tray and battery. (Page 1J-6)
27) Connect steering lower shaft to pinion shaft. (Page
6B-12)
28) Refill cooling system with coolant. (Page 1F-9)
29) Check front wheel alignment. (Page 2B-2)
30) Check for leakage of fuel, coolant, oil and exhaust
gas.
• Fuel leakage:
– Petrol: (Page 1G-20)
– CNG: (Page 1G-56)
• Coolant leakage: (Page 1F-8)
31) Install right and left side splash covers.
1D-30 Engine Mechanical: K10B and Bi-Fuel CNG

Timing Chain Cover Components

AENJCA0A1416017

OIL
8
9 (b)

10

4 1217G
6 (b)

OIL
8
OIL

3
OIL

2
5

1 (a)
7 (b)

IJCA0A141046-01

1. Crankshaft pulley bolt 6. Timing chain cover bolt No.1 : 19 Nm → +75° (1.9 kgf-m → +75°,
: For tightening order, refer to “Timing 14.0 lbf-ft → +75°)
Chain Cover Removal and Installation”:
K10B and Bi-Fuel CNG (Page 1D-31).
2. Crankshaft pulley 7. Timing chain cover bolt No.2 : 25 Nm (2.5 kgf-m, 18.5 lbf-ft)
: Apply engine oil referring to “Timing Chain : For tightening order, refer to “Timing
Cover Removal and Installation”: K10B and Chain Cover Removal and Installation”:
Bi-Fuel CNG (Page 1D-31). K10B and Bi-Fuel CNG (Page 1D-31).
3. Crankshaft front oil seal 8. O-ring : Do not reuse.
: Apply engine oil to oil seal lip. : Apply engine oil.
4. Timing chain cover 9. Timing chain cover plug
: Apply 99000-31260.
: For details, refer to Step 8) of “Installation”
under “Timing Chain Cover Removal and
Installation”: K10B and Bi-Fuel CNG (Page
1D-31).
5. Dowel pin 10. Timing chain cover plug gasket
 Engine Mechanical: K10B and Bi-Fuel CNG 1D-31

Timing Chain Cover Removal and Installation 10) Remove O-rings (1) from timing chain cover.
AENJCA0A1416018

Removal
1) Remove engine assembly from vehicle. (Page 1D-
24)
2) Remove belt tensioner arm. (Page 1J-9) 1
3) Remove crankshaft pulley bolt (1).
To lock crankshaft pulley (2), use special tool as
shown in figure. 1

Special tool
(A): 09917M68222

IJCA0A141047-01

11) Remove oil pump from timing chain cover, if

necessary. (Page 1E-12)

2 Installation
(A)
1) Remove oil, sealant and dust.
2) Install oil pump to timing chain cover, if removed.
(Page 1E-12)
3) Install new crankshaft front oil seal referring to Step
6) under “Crankshaft Front Oil Seal Replacement”:
K10B and Bi-Fuel CNG (Page 1D-21).
1
IFRA0A141052-01 4) Apply engine oil to new O-rings (1) and install O-
4) Remove crankshaft pulley (1). rings to oil pump and timing chain cover.
If it is hard to remove, use special tools.
Special tool
(A): 09926M58010
(B): 09913M66710
1

IJCA0A141047-01

5) Check that dowel pins are installed to cylinder block.

(A) 6) Clean mating surface of timing chain cover, cylinder
(B) block and cylinder head.
7) Clean mating portions (1) of cylinder block and
cylinder head with cleaning solvent particularly.

1
IJHA0A140040-01

5) Remove cylinder head cover. (Page 1D-11)

6) Remove oil pan. (Page 1E-8)
7) Remove water pump pulley. (Page 1F-16)
8) Remove timing chain cover.
9) Remove crankshaft front oil seal referring to Step 5)
under “Crankshaft Front Oil Seal Replacement”:
K10B and Bi-Fuel CNG (Page 1D-21).
1D-32 Engine Mechanical: K10B and Bi-Fuel CNG

8) Apply sealant “A” to mating surface of timing chain 10) Tighten timing chain cover bolts No.1 and No.2 in
cover as shown in figure. numerical order (“1” – “15”) evenly and gradually to
specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G) Tightening torque
Timing chain cover bolt No.1* (a): 25 N·m (2.5
Sealant bead size for timing chain cover
kgf-m, 18.5 lbf-ft)
Width “a”: 3 mm (0.12 in.)
Timing chain cover bolt No.2* (b): 25 N·m (2.5
Height “b”: 2 mm (0.08 in.)
kgf-m, 18.5 lbf-ft)
“A”
“1”, (a)
“10”, (b) “8”, (b)

“6”, (a)
1 “3”, (b)
“A” 1 “4”, (b)
“A”

“2”, (b)
“a” “5”, (b)
“A” “b”
“9”, (b) “7”, (b)
IJCA0A141048-01
“11”, (b)
9) Install timing chain cover noting the following points. “12”, (b)

• Apply engine oil to oil seal lip. “13”, (b)

• Align straight lines (1) of oil pump inner rotor with “15”, (b) “14”, (b)
straight lines (2) of crankshaft sprocket. IJCA0A141049-01

• Install timing chain cover within 2 minutes after
applying sealant.
• Check O-ring and gasket for proper fit.
• Use care so that oil seal lip is not damaged and oil
seal spring is not coming off.
11) Wipe off excessive sealant squeezed out from timing
chain cover at the top end and lower end.
12) Install water pump pulley. (Page 1F-16)
13) Install cylinder head cover. (Page 1D-11)
14) Install oil pan. (Page 1E-8)
15) Clean crankshaft pulley and apply engine oil to
sealing surface (1).

2 1
IFRA0A141057-01

IHSB0A141003-01
 Engine Mechanical: K10B and Bi-Fuel CNG 1D-33

16) Insert crankshaft pulley (1) aligning key groove (2) a) Tighten crankshaft pulley bolt to 19 Nm (1.9 kgf-
with key (3) on crankshaft. m, 14.0 lbf-ft).
b) Retighten the bolt 75°.
NOTICE
Turning over of oil seal lip or coming off of Tightening torque
the inside spring will cause oil leakage. Crankshaft pulley bolt* (a): 19 Nm → +75°
While inserting crankshaft pulley, pay (1.9 kgf-m → +75°, 14.0 lbf-ft → +75°)
attention not to damage oil seal lip nor
disengage the inside spring.

1
(A)
2 3

1 2, (a)
IFRA0A141059-01

IJHA0A140041-01 18) Install belt tensioner arm. (Page 1J-9)

17) Hold crankshaft pulley (1) with special tool and 19) Install engine assembly to vehicle. (Page 1D-24)
tighten new crankshaft pulley bolt (2) according to
the following procedure. Timing Chain Cover Inspection
AENJCA0A1416019
NOTICE
The crankshaft pulley bolt is pre-coated with Oil Seal
friction stabilizer. If the bolt is reused, it may Check oil seal lip for fault or other damage. Replace it if
work loose. necessary.
Never reuse the crankshaft pulley bolt.
Flywheel Removal and Installation
AENJCA0A1416020
NOTE
Removal
For accurate angle tightening of the bolt, use 1) For M/T model, remove clutch cover and clutch disc.
tightening angle gauge available in the (Page 5C-9)
market.
2) For auto gear shift model, remove clutch cover and
clutch disc. (Page 5D-145)
3) Install special tool in ring gear teeth to lock flywheel
as shown in figure.
Special tool
(A): 09924M17811

IJHA0A140061-01

Special tool
(A): 09917M68222

I8C50A140045-01

4) Remove flywheel from crankshaft.

1D-34 Engine Mechanical: K10B and Bi-Fuel CNG

5) Remove input shaft bearing (1) from flywheel, if d. Tighten flywheel bolts to specified torque.
necessary, using special tool as shown in figure.
Tightening torque
Special tool Flywheel bolt (a): 83 N·m (8.5 kgf-m, 61.5 lbf-
(A): 09921M20210 ft)
(B): 09930M30104

(B)

(A)

1
I8C50A140046-01

IHL10A141086-01

Flywheel Inspection
Installation AENJCA0A1416021
Reverse removal procedure noting the following points.
Visual Inspection
• Press-fit input shaft bearing (1) using special tool and
hydraulic press (2). • If ring gear is damaged, cracked or worn, replace
flywheel.
Special tool
• If the surface contacting clutch disc is damaged or
(A): 09913M75821 excessively worn, replace flywheel.
Depth • If input shaft bearing is damaged or does not rotate
“a”: 0 – 0.5 mm (0 – 0.01 in.) smoothly, replace input shaft bearing.

1 2 Flywheel Face Runout

“a” Check flywheel face runout with a dial gauge. If runout
exceeds its limit, replace flywheel.
(A)
Flywheel face runout
Limit: 0.2 mm (0.0079 in.)

IGSB0A141019-01

• Install flywheel as follows.

a. Install flywheel to crankshaft.
b. Install new flywheel bolts temporarily.

NOTICE
The flywheel bolts are pre-coated with
adhesive. If these bolts are reused, they may
work loose. IBP70A140027-01
Replace the flywheel bolts with new ones
whenever they are removed.

c. Install special tool to lock flywheel as shown in

figure.
Special tool
(A): 09924M17811
 Engine Mechanical: K10B and Bi-Fuel CNG 1D-35

Timing Chain and Chain Tensioner Components

AENJCA0A1416022

OIL
2

OIL
4

(a)

5 (b)

OIL
3

(b)

(b)
IGSB0A143035-01

1. Crankshaft timing sprocket 4. Timing chain tensioner : 11 Nm (1.1 kgf-m, 8.5 lbf-ft)
: Apply engine oil to sliding surface.
2. Timing chain 5. Timing chain tensioner adjuster
: Apply engine oil. : For installation, refer to “Timing Chain and
Chain Tensioner Removal and Installation”:
K10B and Bi-Fuel CNG (Page 1D-36).
3. Timing chain guide : 25 Nm (2.5 kgf-m, 18.5 lbf-ft)
: Apply engine oil to sliding surface.
1D-36 Engine Mechanical: K10B and Bi-Fuel CNG

Timing Chain and Chain Tensioner Removal NOTE

and Installation If it is necessary to rotate the camshaft with
AENJCA0A1416023
the timing chain removed, rotate the
Removal camshaft after turning crankshaft
counterclockwise 30 – 90° as shown in figure.
NOTICE
After the timing chain has been removed,
independently turning the camshaft or
“a”
crankshaft beyond the allowable angle
ranges shown in figure will cause “b”
interference between piston and valve or
between the valves themselves, which will
cause damage to these parts and/or related 1
parts. I7V20A141058-01

Avoid turning each of the camshaft or “a”: 30° 1. Crankshaft timing sprocket key
crankshaft alone beyond the angle ranges “b”: 90°
shown in figure.

1 1 1) Remove timing chain cover. (Page 1D-31)

2) By turning crankshaft, align camshafts and
crankshaft at specific position as follows.
a) Align both intake and exhaust camshaft timing
sprocket marks (1) with matchmarks (2) of
2 cylinder head respectively.
“b” “b” “b” “b”
b) Position crankshaft timing sprocket key (3) with
matchmark (4) on cylinder block.
3) Remove timing chain tensioner adjuster (5).
4) Remove timing chain tensioner (6).
4 5) Remove timing chain guide (7).
“a” “a” 6) Remove timing chain (8) and crankshaft timing
sprocket (9) and crankshaft timing sprocket key.

1 1
3
I7V20A141057-02

“a”: 90° 2. Matchmark on cylinder head

“b”: 15° 3. Crankshaft timing sprocket key
1. Matchmark on camshaft 4. Matchmark on cylinder block 2
6

3
9
IJCA0A141050-01
 Engine Mechanical: K10B and Bi-Fuel CNG 1D-37

Installation
1 1
1) Position crankshaft timing sprocket key (1) within a
30 – 90° range (2) counterclockwise from 2
2
matchmark (3) on cylinder block.
2) Align timing marks (4) on intake and exhaust
camshaft timing sprockets with matchmarks (5) on
cylinder head.

4 4

3 4

2
3
IJCA0A141052-01

7) Apply engine oil to sliding surface of timing chain

guide (1).
8) Install timing chain guide and tighten guide bolts to
1
IJCA0A141051-01
specified torque.
3) Set timing chain while aligning two colored marks (1) Tightening torque
of timing chain with timing marks (2) on camshaft Timing chain guide bolt (a): 11 N·m (1.1 kgf-m,
timing sprockets. 8.5 lbf-ft)
4) Set crankshaft timing sprocket key and align it with 9) Apply engine oil to sliding surface of timing chain
matchmark on cylinder block by turning crankshaft. tensioner (2).
5) Install crankshaft timing sprocket. 10) Install timing chain tensioner and tighten tensioner
6) Install timing chain while aligning colored mark (3) of bolt to specified torque.
timing chain with groove (4) of crankshaft timing
sprocket. Tightening torque
Timing chain tensioner bolt (b): 25 N·m (2.5 kgf-
m, 18.5 lbf-ft)

(b) (a)

2 (a)

I7V20A141062-03

11) Check that all colored marks (1) of timing chain are
aligned with timing marks (2) on camshaft timing
sprocket, and groove (3) of crankshaft timing
sprocket.
1D-38 Engine Mechanical: K10B and Bi-Fuel CNG

1 1 1

2
2

3,(a)

2
IELA0A142071-02

13) Apply engine oil to timing chain, and then turn

crankshaft clockwise 720°, and check that the
following conditions are satisfied:
• Timing marks (1) on intake and exhaust camshaft
timing sprockets are aligned with matchmarks (2)
on cylinder head.
3 • Crankshaft timing sprocket key (3) is aligned with
matchmark (4) on cylinder block.
1
IJCA0A141053-01 1 1

12) Install timing chain tensioner adjuster (1) as follows.

a) Release lock cam moving link plate (2) in arrow
direction and push in plunger (3) fully.
b) Insert a retainer (1.0 – 1.2 mm (0.040 – 0.047 in.) 2
diameter wire or the like) to hole (4) and hold
plunger in place.

1
3

2
4

3
IJCA0A141054-01

14) Install timing chain cover. (Page 1D-31)

4
IJAA0A142003-01

c) Install timing chain tensioner adjuster (1) with the

retainer (2) inserted.
Tighten timing chain tensioner adjuster bolts (3)
to specified torque, and then remove the
retainer.
Tightening torque
Timing chain tensioner adjuster bolt (a): 11
N·m (1.1 kgf-m, 8.5 lbf-ft)
 Engine Mechanical: K10B and Bi-Fuel CNG 1D-39

Timing Chain and Chain Tensioner Inspection

AENJCA0A1416024

Timing Chain Guide

Check sliding surface of timing chain guide (1) for wear
or damage.
I2RH01140077-01
If abnormality is found, replace timing chain guide.
Timing Chain Tensioner Adjuster
Check that teeth (1) is free from damage.
If abnormality is found, replace timing chain tensioner
adjuster.

I7V20A141066-01

1
Timing Chain Tensioner
Check sliding surface of timing chain tensioner (1) for
wear or damage. IELA0A142075-02
If abnormality is found, replace timing chain tensioner.

I7V20A141067-01

Crankshaft Timing Sprocket

Check sprocket teeth for wear or damage.
If abnormality is found, replace crankshaft timing
sprocket.

I2RH0B140070-01

Timing Chain
Check timing chain for wear or damage.
If abnormality is found, replace timing chain.
1D-40 Engine Mechanical: K10B and Bi-Fuel CNG

Valve and Cylinder Head Components

AENJCA0A1416025

OIL
9

OIL
14 (b) (a)

13 (c)

1 10

3 1
5
8
2
OIL

4
3

OIL
4
OIL

6 11
OIL

12

12

IDLA0A140047-01

1. Valve cotter 7. Exhaust valve 13. Venturi plug

: Apply engine oil to sliding surface.
2. Valve spring retainer 8. Valve guide
3. Valve spring 9. Cylinder head bolt (M10)
: Apply engine oil to bolt thread.
: For tightening order, refer to “Valve
and Cylinder Head Removal and
Installation”: K10B and Bi-Fuel CNG
(Page 1D-41).
4. Valve stem seal 10. Cylinder head
: Apply engine oil to valve stem seal lip.
5. Valve spring seat 11. Cylinder head gasket
6. Intake valve 12. Dowel pin
: Apply engine oil to sliding surface.
14. Cylinder head bolt (M8)
: For tightening order, refer to “Valve
and Cylinder Head Removal and
Installation”: K10B and Bi-Fuel CNG
(Page 1D-41).
: 20 Nm → 40 Nm → +60° → +60° (2.0
kgf-m → 4.1 kgf-m → +60° → +60°,
15.0 lbf-ft → 29.5 lbf-ft → +60° → +60°)
: 25 Nm (2.5 kgf-m, 18.5 lbf-ft)
: 3.5 Nm (0.36 kgf-m, 2.5 lbf-ft)
: Do not reuse.
 Engine Mechanical: K10B and Bi-Fuel CNG 1D-41

Valve and Cylinder Head Removal and Installation

Installation 1) Clean mating surfaces of cylinder head and cylinder
AENJCA0A1416026
block. Remove oil, old gasket and dust from mating
surfaces.
Removal
2) Install dowel pins (1) to cylinder block.
1) Remove timing chain. (Page 1D-36)
3) Install new cylinder head gasket (2) to cylinder block.
2) Remove intake manifold. (Page 1D-9)
3) Remove exhaust manifold. (Page 1K-3) 2
4) Remove water inlet pipe. (Page 1F-10)
5) Remove spark plugs. (Page 1H-7) 1
6) Remove intake and exhaust camshafts. (Page 1D-
14)
7) Remove cylinder head bolt (M8) (1).
8) Loosen cylinder head bolts (M10) in numerical order
(“1” – “8”) as shown in figure using a 12-point socket
wrench and remove them.
I8C50A140049-01

“6” “8” “2” 4) Install cylinder head to cylinder block according to

the following procedure.
“4”
NOTE
• Before installing the cylinder head to the
cylinder block, turn crankshaft
counterclockwise and position the
“1” crankshaft timing sprocket key (1) within
an angle of 30° – 90° from TDC as shown in
1 “7” “5” “3” figure and keep the valves from coming in
I8C50A140048-01
contact with the piston.
9) Check all around cylinder head for any other parts
required to be removed or disconnected and remove
or disconnect them if any.
10) Remove cylinder head (1) from cylinder block. “a”

11) Remove dowel pins (2) from cylinder block, if “b”

necessary.
12) Remove cylinder head gasket (3) from cylinder
block. 1
I7V20A141058-01

“a”: 30° “b”: 90°

• For accurate angle tightening of the bolt,

use tightening angle gauge available in the
1
market.
2

IJCA0A141055-01

13) Remove the following components from cylinder

head, if necessary.
• CMP sensor: (Page 1C-12)
• Thermostat case with thermostat: (Page 1F-7)
IJHA0A140061-01

a) Apply engine oil to thread for 4.0 mm (0.16 in.)

from lower end of new cylinder head bolts (M10).
1D-42 Engine Mechanical: K10B and Bi-Fuel CNG

b) Tighten cylinder head bolts (M10) to 20 Nm (2.0

kgf-m, 15.0 lbf-ft) in numerical order (“1” – “8”) as 1
shown using a 12-point socket wrench.
c) In the same manner as in Step b), tighten them
to 40 Nm (4.1 kgf-m, 29.5 lbf-ft).
d) Retighten all cylinder head bolts (M10) 60° in
numerical order as shown in figure.
e) Repeat Step d).
f) Tighten cylinder head bolt (M8) (1) to specified
torque.
Tightening torque I9R90A140030-01
Cylinder head bolt (M10)* (a): 20 Nm → 40 3) Place disassembled parts except valve stem seal
Nm → +60° → +60° (2.0 kgf-m → 4.1 kgf-m → and valve guide in order so that they can be installed
+60° → +60°, 15.0 lbf-ft → 29.5 lbf-ft → +60° → in their original positions.
+60°)
4) Using special tools (A) and (B), compress valve
Cylinder head bolt (M8)* (b): 25 N·m (2.5 kgf-
spring and then remove valve cotters (1) also using
m, 18.5 lbf-ft)
special tool (C).

“3”, (a) “1”, (a) “7”, (a)

Special tool
(A): 09916M14510
(B): 09916M14522
“5”, (a)
(C): 09916M84511

(B)

“8”, (a)

1, (b) “2”, (a) “4”, (a) “6”, (a)

I8C50A140050-01

5) Install thermostat case with thermostat, if removed.

(Page 1F-7)
6) Install CMP sensor, if removed. (Page 1C-12)
7) Install tappet and intake and exhaust camshafts.
(Page 1D-14) (A)
8) Install spark plugs. (Page 1H-7) I8C50A140051-01

9) Install water inlet pipe. (Page 1F-10)

10) Install exhaust manifold. (Page 1K-3)
11) Install intake manifold. (Page 1D-9)
12) Install timing chain. (Page 1D-36)

Cylinder Head Disassembly and Reassembly

AENJCA0A1416027

Disassembly
1) Remove tappets from cylinder head.
2) Remove venturi plug (1).

I9T401142010-01

5) Release special tools, and remove spring retainer

and valve spring.
6) Remove valve from combustion chamber side.
7) Remove valve stem seal (1) and valve spring seat
(2).
 Engine Mechanical: K10B and Bi-Fuel CNG 1D-43

2) Using special tools, install new valve guide to

cylinder head as follows.
Special tool
(A): 09916M57330
(B): 09916M56011
a) Uniformly heat cylinder head to a temperature of
80 to 100 °C (176 to 212 °F) so that it will not be
distorted, and drive new valve guide into its hole
with special tools.
b) Install new valve guide until special tool (B)
I2RH0B140094-01 contacts cylinder head.
8) Using special tool (A), remove valve guide from After installation, check that valve guide
combustion chamber side to valve spring side. protrudes from cylinder head by specified
dimension “a”.
Special tool
(A): 09916M44310 Valve guide protrusion (In and Ex)
“a”: 11.1 – 11.5 mm (0.438 – 0.452 in.)

I2RH0B140095-01

I8C50A140052-01
Reassembly
3) Ream valve guide bore with special tools.
NOTICE After reaming, clean bore.
The engine could be damaged if shavings Special tool
remain inside the valve guide hole after (A): 09916M34542
reaming it. (B): 09916M34570
Thoroughly remove shavings from the
reamed hole.

1) Before installing valve guide into cylinder head, ream

guide hole with special tool to remove burrs and
make the hole truly round.
Special tool
(A): 09916M34542
(B): 09916M37320

I2RH0B140096-01

4) Install valve spring seat to cylinder head.

I2RH0B140096-01
1D-44 Engine Mechanical: K10B and Bi-Fuel CNG

5) After applying engine oil to new valve stem seal (1)
and spindle of special tool (A), fit valve stem seal to
spindle, and then install valve stem seal to valve
guide by pushing special tool by hand. After
installation, check that valve stem seal is properly
fixed to valve guide.
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 get down past the
seal.
Push the special tool only by hand to force
the valve stem seal into position.
Special tool
(A): 09916M57330
(B): 09917M98221
9) Using special tools, compress valve spring and fit
two valve cotters (1) into groove in valve stem.
NOTICE
• Damaging the wall surface of the tappet
fitting hole could result in engine
problems.
Prevent the special tool from touching the
tappet sliding surface in the cylinder head.
• Insufficient seating of valve cotters
between retainer and valve stem neck may
cause coming off of the cotters after
engine start.
Check seating position of the cotters
carefully when fitting them. Tapping of
stem end with plastic hammer after fitting
cotters will help confirmation of their
seating.

NOTE
Applying small amount of grease to valve
cotters may facilitate the fitting.

Special tool
(A): 09916M14510
(B): 09916M14522
(C): 09916M84511

I8C50A140053-01

6) Apply engine oil to valve stem seal, valve guide bore

and valve stem.
7) Install valve to valve guide.
8) Install valve spring and valve spring retainer.
Each valve spring has top end (large-pitch end (1))
and bottom end (small-pitch end (2)). Position spring
in place with its bottom end (small-pitch end) facing
the bottom (valve spring seat side).
I2RH0B140101-01

[a] 3 10) Install venturi plug (1) and tighten venturi plug to
1 specified torque.
Tightening torque
Venturi plug (a): 3.5 N·m (0.36 kgf-m, 2.5 lbf-ft)

2 1, (a)
[b]
I8C50A140054-01

[a]: Valve spring retainer side 3. Paint mark

[b]: Valve spring seat side

I7V20A141078-01

11) Install tappets to cylinder head.

 Engine Mechanical: K10B and Bi-Fuel CNG 1D-45

Valve and Valve Guide Inspection

AENJCA0A1416028

Valve Guide
Valve stem-to-guide clearance
Using a micrometer and bore gauge, take diameter readings on valve stems and guides to check valve stem-to-valve
guide clearance.
Take reading at more than one place along the length of each valve stem and valve guide.
If clearance exceeds limit, replace valve and valve guide.
Valve stem and valve guide specification
Item Standard Limit
In 4.965 – 4.980 mm (0.1955 – 0.1960 in.) —
Valve stem outside diameter [A]
Ex 4.940 – 4.955 mm (0.1945 – 0.1950 in.) —
Valve guide inside diameter [B] In & Ex 5.000 – 5.012 mm (0.1969 – 0.1973 in.) —
Valve stem-to-valve guide In 0.020 – 0.047 mm (0.0008 – 0.0018 in.) 0.070 mm (0.0028 in.)
clearance Ex 0.045 – 0.072 mm (0.0018 – 0.0028 in.) 0.090 mm (0.0035 in.)

I4RS0B140016-01

Valve stem end deflection Valve

If bore gauge is not available, check end deflection of Visual inspection
valve stem with a dial gauge instead. • Remove all carbon deposits from all valves (1).
Move valve stem end in directions (1) and (2) to
• Check each valve for wear, burn or distortion at its
measure end deflection.
face and stem.
If deflection exceeds its limit, replace valve and valve
Replace it if necessary.
guide.
• Measure valve protrusion “a”.
Valve stem end deflection limit If measured length is out of standard value, replace
In: 0.14 mm (0.0055 in.) valve.
Ex: 0.18 mm (0.0071 in.)
Valve protrusion “a”
Standard
IN: 34.7 – 35.3 mm (1.367 – 1.389 in.)
EX: 34.6 – 35.2 mm (1.363 – 1.385 in.)

I8V101140017-01
1D-46 Engine Mechanical: K10B and Bi-Fuel CNG

1
“a”

I2RH0B140103-01

Valve seat repair

3 If a valve seat does not contact its valve uniformly or
shows width of seating contact out of specified range,
I9T401142024-01
repair it by cutting (if necessary) and regrinding and then
2. Valve guide 3. Valve seat finish it by lapping.
1) Intake valve seat:
Valve head radial runout Use valve seat cutters (1) to make three cuts as
Check each valve for radial runout with a dial gauge and shown in figure. Three cutters must be used: the 1st
“V” block. To check runout, rotate valve slowly. If runout for making 30° angle, the 2nd for making 70° angle,
exceeds its limit, replace valve. and 3rd for making 45° angle. The 3rd cut (45°) must
Valve head radial runout be made to produce desired seat width.
Standard Limit Seat width for intake valve seat
In 0 – 0.05 mm (0 – 0.0019 in.) 0.08 mm (0.0031 in.) “a”: 1.0 – 1.4 mm (0.0394 – 0.0551 in.)
Ex 0 – 0.03 mm (0 – 0.0011 in.) 0.08 mm (0.0031 in.)
2) Exhaust valve seat:
Use valve seat cutters to make two cuts as illustrated
in the figure. Two cutters must be used: the 1st for
making 15° angle, and the 2nd for making 45° angle.
The 2nd cut must be made to produce desired seat
width.
Seat width for exhaust valve seat
“b”: 1.0 – 1.4 mm (0.0394 – 0.0551 in.)

I2RH01140136-01

Seating contact width 1

Create contact pattern on each valve in the usual
manner, i.e., by giving uniform coat of marking
compound to valve seat and by rotating and tapping seat
with valve head. Valve lapper (tool used in valve lapping)
IDLA0A140048-01
must be used.
Pattern produced on seating surface of valve must be a
[A] [B]
continuous ring without any break, and the width of
pattern must be within specified range.
“a”
Standard seating width “a” revealed by contact 4 “b”
pattern on valve face 3 3
IN & EX: 1.0 –1.4 mm (0.0394 – 0.0551) 2
1
I8C50A140056-01

[A]: Intake 2. 30°

[B]: Exhaust 3. 45°
1. 15° 4. 70°
 Engine Mechanical: K10B and Bi-Fuel CNG 1D-47

3) Valve lapping: NOTE

Lap valve on seat in two steps, first with coarse size
lapping compound applied to face and the second
with fine-size compound, each time using valve
lapper according to usual lapping method.
Venturi Plug Inspection
Check that venturi plug passage is not clogged.
If venturi plug passage is clogged, clean or replace
venturi plug.
Distorted mating surface of cylinder head
and cylinder head gasket causes combustion
gas and/or coolant leakage, overheating and
reduced power output.
Distortion of mating surface of cylinder head and
cylinder head gasket
Limit: 0.03 mm (0.0012 in.)

I7V20A141083-03

Cylinder Head Inspection

AENJCA0A1416029
2
Combustion Chamber
I9T401142027-01
• Remove all carbon deposits from all combustion
chambers.

NOTICE
Metal surfaces can be scuffed or nicked
when removing carbon deposits with sharp-
edged tool.
Do not use any sharp-edged tool to scrape
off carbon deposits from engine parts.

I8C50A140057-01

Manifold Seating Surface Flatness

Using straightedge (1) and feeler gauge (2), check
flatness of manifold seating surface.
If measured value exceeds its limit, correct seating
surface or replace cylinder head.
Distortion of seating face of intake manifold and
exhaust manifold on cylinder head
I2RH0B140105-01
Limit: 0.05 mm (0.0020 in.)
• Check cylinder head for crack on intake and exhaust
1
ports, combustion chambers and head surface. 2

Cylinder Head Flatness

Using straightedge (1) and feeler gauge (2), check
flatness of gasket surface at a total of 6 positions.
If any measured value exceeds its limit, correct gasket
surface with a surface plate and abrasive paper #400
(waterproof silicon carbide abrasive paper) by placing
abrasive paper on surface plate and rubbing gasket
surface against paper to grind high spots.
I8C50A140059-01
If it is impossible to correct cylinder head distortion,
replace cylinder head.
1D-48 Engine Mechanical: K10B and Bi-Fuel CNG

Spring Squareness
[A] Use a square and surface plate to check each spring for
squareness in terms of clearance between end of valve
spring and square. If clearance exceeds limit, replace
valve springs.
Valve spring squareness “a”
[B] Limit: 1.9 mm (0.075 in.)

“a”

I8C50A140060-01

[A]: Intake side [B]: Exhaust side

Valve Spring Inspection

AENJCA0A1416030

I8T401142134-01
Valve Spring Free Length and Preload
• Check each valve spring for breakage or weakening.
• Measure valve spring free length and preload.
If measured value is less than limit, replace valve
spring.

NOTE
Weakened valve springs can cause chatter,
not to mention possibility of reducing power
output due to gas leakage caused by
decreased seating pressure.

Valve spring free length “a”

Standard: 42.87 mm (1.688 in.)
Valve spring preload when compressed to 28.9 mm
(1.138 in.)
Standard: 104 – 120 N (10.6 – 12.2 kgf, 23.4 – 27.0 lbf)
Limit: 94 N (9.6 kgf, 21.1 lbf)

“a”
I9T401142034-01

I9T401142035-01
 Engine Mechanical: K10B and Bi-Fuel CNG 1D-49

Piston, Piston Ring and Connecting Rod Components

AENJCA0A1416031

OIL
1

OIL
2

OIL
3

OIL
4

OIL
8

OIL
5

11
11
OIL

OIL
10 (a)
6

IHL10A141032-03

1. 1st ring 8. Piston pin

: For assembly, refer to “Piston, Piston Ring and Connecting : Apply engine oil to sliding surface.
Rod Removal and Installation”: K10B and Bi-Fuel CNG (Page
1D-50).
: Apply engine oil to sliding surface.
2. 2nd ring 9. Piston pin circlip
: For assembly, refer to “Piston, Piston Ring and Connecting
Rod Removal and Installation”: K10B and Bi-Fuel CNG (Page
1D-50).
: Apply engine oil to sliding surface.
3. Oil ring 10. Connecting rod bolt
: For assembly, refer to “Piston, Piston Ring and Connecting : Check connecting rod bolt for deformation to reuse. (Page 1D-
Rod Removal and Installation”: K10B and Bi-Fuel CNG (Page 55)
1D-50). : Apply engine oil to bolt thread and seat.
: Apply engine oil to sliding surface. : For tightening order, refer to “Piston, Piston Ring and Connecting
Rod Removal and Installation”: K10B and Bi-Fuel CNG (Page 1D-
50).
4. Piston 11. Dowel pin
: For assembly, refer to “Piston, Piston Ring and Connecting
Rod Removal and Installation”: K10B and Bi-Fuel CNG (Page
1D-50).
: Apply engine oil to sliding surface.
5. Connecting rod : 15 Nm → +65° (1.5 kgf-m → +65°, 11.0 lbf-ft → +65°)
: Do not apply engine oil to mating surface between connecting
rod bearing and connecting rod.
: Apply engine oil to sliding surface.
6. Connecting rod bearing cap : Do not reuse.
: To install connecting rod cap, direct arrow on it to crank pulley.
: Do not apply engine oil to mating surface between connecting
rod bearing and connecting rod cap.
7. Connecting rod bearing
: For applying engine oil, refer to “Piston, Piston Ring and
Connecting Rod Removal and Installation”: K10B and Bi-Fuel
CNG (Page 1D-50).
1D-50 Engine Mechanical: K10B and Bi-Fuel CNG

Piston, Piston Ring and Connecting Rod
Removal and Installation
AENJCA0A1416032
NOTICE
If any of the parts listed below is reinstalled
into a position different from the original
position, engine problems could occur.
If these parts are to be reused, keep them in
numerical order so that they can be
reinstalled in their original positions.
• Connecting rods
• Connecting rod bearings
• Connecting rod bearing caps
• Pistons
Removal
1) Remove engine assembly from vehicle. (Page 1D-
24)
2) Remove cylinder head. (Page 1D-41)
3) Mark cylinder numbers on all pistons, connecting
rods and connecting rod bearing caps using silver
pencil or quick drying paint.
4) Remove connecting rod bearing caps.
5) Remove carbon deposits from top of cylinder bore
before removing piston from cylinder.
6) Push piston and connecting rod assembly out from
the top of cylinder bore.
7) Remove connecting rod bearings from connecting
rod and connecting rod bearing cap, if necessary.
Installation
NOTICE
The engine will seize up if it is operated when
the parts listed below are not properly
lubricated.
Lubricate all the friction surfaces of these
parts with engine oil before installing them.
• Crankshaft pins
• Connecting rod bearings
• Pistons
• Piston rings
• Cylinder walls
2) Install connecting rod bearing to connecting rod
bearing cap and connecting rod as follows.
a) Check mating surfaces of bearing backside and
corresponding connecting rod are clean and dry.
b) Fit tab (1) of connecting rod bearing to each
groove (2) of connecting rod and bearing cap.
c) Press bearing end (3) until it becomes flush with
connecting rod and other half with connecting
rod bearing cap mating surface.
NOTICE
If oil is present between the bearing backside
and connecting rod surface, the bearing
could heat up to very high temperature,
resulting in seizure.
Thoroughly wipe off any trace of oil that is
present between the bearing backside and
connecting rod surface.
1 3
2
I7V20A141088-01
3) Apply engine oil to pistons, piston rings, cylinder
walls, connecting rod bearings and crankshaft pins.
4) Position crankshaft pin corresponding to piston and
connecting rod assembly to be installed to the
bottom dead center.
5) Install piston and connecting rod assembly into
cylinder bore as follows.
a) Point front mark (1) on piston head to crankshaft
pulley side (2) and carefully insert piston and
connecting rod assembly.
1
2

1) Check that dowel pins (1) are installed to connecting

rod bearing cap. IDLA0A140055-01

1
IELA0A142163-02

b) Compress piston rings with special tool.
c) Holding special tool firmly against cylinder block,
tap piston head with a hammer handle.
d) If oil ring catches cylinder edge, do not push
piston by force. Draw out piston a little and
repeat Step b) – c).
e) After piston rings enter cylinder bore, continue
pushing piston and connecting rod assembly
until big end bearing meets crankshaft pin.
NOTICE
• With oil ring got stuck in the cylinder edge,
forced pushing the piston will break the oil
ring rail and spoil the engine performance
if the ring is installed as it is.
If breakage of oil ring is noted, replace the
piston ring as a set.
• While inserting piston and connecting rod
assembly into cylinder bore, connecting
rod big end may hit crankshaft pin and
damage the pin surface.
Carefully insert piston and connecting rod
assembly not to hit crankshaft pin with the
big end.
Special tool
(A): 09916M77310
(A)
IDLA0A140050-01
6) Install connecting rod bearing cap as follows.
7) Install cylinder head. (Page 1D-41)
8) Install engine assembly. (Page 1D-24)
Engine Mechanical: K10B and Bi-Fuel CNG 1D-51
NOTICE
Using connecting rod bolts that are deformed
exceeding the service limit could lead to
engine problems.
Before installing connecting rod bearing cap,
check that connecting rod bolts are not
deformed exceeding the service limit
referring to “Connecting rod bolt
deformation” under “Piston Pin and
Connecting Rod Inspection”: K10B and Bi-
Fuel CNG (Page 1D-55).
NOTE
For accurate angle tightening of the bolt, use
tightening angle gauge available in the
market.
IJHA0A140061-01
a) Point front mark (protrusion) (2) on connecting
rod bearing cap (1) to crankshaft pulley side.
b) Apply engine oil to thread and seat of connecting
rod bolt.
c) Tighten all connecting rod bolts (3) evenly and
gradually to 15 Nm (1.5 kgf-m, 11.0 lbf-ft).
d) Retighten them 65°.
e) In the same manner as in Step c) – d), tighten
connecting rod bolts of other cylinders.
f) Apply engine oil to all of connecting rod big ends.
Tightening torque
Connecting rod bolt* (a): 15 Nm → +65° (1.5
kgf-m → +65°, 11.0 lbf-ft → +65°)
3, (a)
2
1
3, (a)
IAP70P140031-01
1D-52 Engine Mechanical: K10B and Bi-Fuel CNG

Piston, Piston Ring and Connecting Rod Reassembly

Disassembly and Reassembly
AENJCA0A1416033 NOTICE

NOTICE The engine will seize up if it is operated when

If any of the parts listed below is reinstalled
into a position different from the original
position, engine problems could occur.
If these parts are to be reused, keep them in
numerical order so that they can be
reinstalled in their original positions.
• Pistons
• Piston pins
• Piston rings
• Connecting rods
1) Remove carbon deposits from piston head and ring
• Connecting rod bearings
2) Install piston pin, piston (1) and connecting rod (2) as
Disassembly
1) Using piston ring expander, remove 1st and 2nd
rings and oil ring from piston.
2) Remove piston pin from connecting rod as follows.
a) Remove piston pin circlips (1), as shown.
the parts listed below are not properly
lubricated.
Lubricate all the friction surfaces of these
parts with engine oil before installing them.
• Pistons
• Piston pins
• Piston rings
• Connecting rods
• Connecting rod bearings
grooves using a suitable tool.
follows.
a) Apply engine oil to piston pin and piston pin
holes in piston and connecting rod.
b) Fit connecting rod positioning oil hole (5) on
connecting rod and front mark (4) piston as
shown in figure.
c) Insert piston pin into piston and connecting rod.
d) Install new piston pin circlips (3) so that each
opening comes within the range indicated by
arrow (6) as shown in figure.

6 4
“a”

6
3 “a”

I2RH0B140113-01

b) Remove piston pin. 2 3

1
5

IHL10A141034-01

“a”: 45°

I2RH0B140114-01
 Engine Mechanical: K10B and Bi-Fuel CNG 1D-53

3) Install piston rings to piston noting the following
points.
• As shown in figure, 1st and 2nd rings have top
mark (1) respectively. When installing them, face
each top mark upward.
• 1st ring (2) differs from 2nd ring (3) in thickness
and shape of surface contacting cylinder wall.
• When installing oil ring (4), install spacer first and
then two rails.
1 Limit: 73.050 mm (2.8760 in.)
1
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.
• Cylinder bore diameter exceeds limit.
• Difference of measurements at two positions exceeds
taper limit.
• Difference between thrust and axial measurements
exceeds out-of-round limit.
Cylinder bore diameter
Standard: 73.000 – 73.014 mm (2.8741 – 2.8745 in.)
Cylinder taper and out-of-round
Limit: 0.010 mm (0.0004 in.)

I8C50A140063-01

4) After installing three rings (1st, 2nd and oil rings),

distribute their end gaps as shown in figure.
I7V20A141095-01

“e” “f”

“c”

IFAE0A140127-01
“d”
“b”
“a”: 45° 3. 1st ring end gap
“a”
1. Front mark 4. 2nd ring end gap and oil ring
spacer gap I9P60A141081-01
2. Oil ring upper rail gap 5. Oil ring lower rail gap “e”: 50 mm (1.97 in.) “f”: 100 mm (3.94 in.)

Cylinder, Piston and Piston Ring Inspection Piston

AENJCA0A1416034
Visual inspection
Cylinder Check piston for faults, crack or other damages.
Damaged or faulty piston should be replaced.
Visual inspection
Check cylinder walls for scratches, roughness or ridges
which indicate excessive wear.
If cylinder bore is very rough, deeply scratched or ridged,
replace cylinder block, piston rings and/or pistons.
1D-54 Engine Mechanical: K10B and Bi-Fuel CNG

Piston diameter Ring groove clearance

Piston diameter should be measured at specified 1) Before checking, piston grooves must be clean, dry
position “a” 9.00 mm (0.354 in.) from piston skirt end in and free from carbon deposits.
the direction perpendicular to piston pin.
2) Fit new piston ring (1) into piston groove, and
If measured diameter is less than its limit, replace piston.
measure clearance between ring and ring land using
Piston diameter specification feeler gauge (2). If clearance is out of limit, replace
Standard size (used piston): 72.978 – 72.990 mm piston.
(2.8732 – 2.8736 in.)
Ring groove clearance
Standard size (new piston with coating): 72.984 –
73.016 mm (2.8734 – 2.8746 in.) Item Standard Limit
0.03 – 0.07 mm 0.12 mm
1st ring
(0.0012 – 0.0027 in.) (0.0047 in.)
0.02 – 0.06 mm 0.10mm
2nd ring
(0.0008 – 0.0023 in.) (0.0039 in.)
0.04 – 0.12 mm
Oil ring —
(0.0016 – 0.0047 in.)
“a”

IDLA0A140057-01

“a”: 9.00 mm (0.354 in.)

1
Piston clearance
Measure cylinder bore diameter and piston diameter to
find their difference which is piston clearance. Piston
clearance should be within specification. If it is not as 2
specified, replace cylinder block, piston rings and/or
pistons.

NOTE
Cylinder bore diameters used here are IDLA0A140058-01

measured in thrust direction at two positions.

Piston clearance
Standard (used piston): 0.010 to 0.036 mm (0.00040
to 0.00141 in.)
Standard (new piston with coating): –0.016 to 0.030
mm (–0.00063 to 0.00118 in.)
Limit: 0.139 mm (0.00547 in.)

I7V20A141095-01

“a”

IDLA0A140057-01

“a”: 9.00 mm (0.354 in.)

 Engine Mechanical: K10B and Bi-Fuel CNG 1D-55

Piston Ring Piston pin clearance in connecting rod small-end

Piston ring end gap Standard: 0.003 – 0.018 mm (0.0002 – 0.00071 in.)
To measure end gap, insert piston ring (1) into cylinder Limit: 0.018 mm (0.00071 in.)
bore and then measure the gap using feeler gauge (2). Piston pin clearance in piston
If measured gap exceeds limit, replace piston ring. Standard: 0.006 – 0.016 mm (0.00024 – 0.00062 in.)
NOTE Limit: 0.016 mm (0.00063 in.)
Remove carbon deposit from top of cylinder
bore before inserting piston ring.

Piston ring end gap

Item Standard Limit
0.15 – 0.28 mm 0.7 mm
1st ring
(0.0060 – 0.0110 in.) (0.0276 in.)
0.28 – 0.41 mm 1.0 mm
2nd ring
(0.0111 – 0.0161 in.) (0.0394 in.)
0.2 – 0.5 mm 1.2 mm
Oil ring
(0.0079 – 0.0196 in.) (0.0472 in.)

"a" I4RS0A140023-01

1 Connecting Rod
I7V20A141096-02
Big-end side clearance
“a”: 50 mm (1.97 in.) Check big-end of connecting rod for side clearance with
rod fitted and connected to its crankshaft pin in a normal
Piston Pin and Connecting Rod Inspection manner. If measured clearance exceeds its limit, replace
AENJCA0A1416035 connecting rod.
Piston Pin Big-end side clearance
Visual inspection Standard: 0.10 – 0.30 mm (0.0040 – 0.0118 in.)
Check piston pin, connecting rod small-end bore and Limit: 0.55 mm (0.0217 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 bore or piston pin
hole in piston is badly worn or damaged, replace piston
pin, connecting rod and/or piston.

Piston pin clearance

Check piston pin clearance in connecting rod small-end
and piston. Replace connecting rod, piston pin and/or
piston, if small-end is badly worn or damaged or if
measured clearance exceeds limit.
I8T401142102-01

Piston pin outside diameter

17.995 – 18.000 mm (0.70847 – 0.70866 in.)
Small-end bore
18.003 – 18.013 mm (0.70878 – 0.70917 in.)
Diameter of piston pin hole in piston
18.006 – 18.011 mm (0.70890 – 0.70909 in.)
1D-56 Engine Mechanical: K10B and Bi-Fuel CNG

Connecting rod alignment Crankshaft Pin and Connecting Rod Bearing

Mount connecting rod on aligner to check it for bow and Inspection
twist. If measured value exceeds the limit, replace AENJCA0A1416036

connecting rod.
Crankshaft Pin Diameter
Connecting rod alignment Check crankshaft pin for uneven wear or damage.
Limit on bow: 0.05 mm (0.0020 in.) Measure crankshaft pin for out-of-round or its taper with
Limit on twist: 0.10 mm (0.0039 in.) a micrometer. If crankshaft pin is damaged or out-of
round or taper is out of limit, replace crankshaft or
regrind crankshaft pin to undersize and use undersize
bearing.

NOTE
When regrinding crank pin to undersize, use
undersize connecting rod bearing.

Crankshaft pin diameter

I4RH01140053-01 Connecting rod bearing
Crankshaft pin diameter
size
Connecting rod bolt deformation 37.982 – 38.000 mm
Measure each thread diameter of connecting rod bolt (1) Standard
(1.4954 – 1.4960 in.)
at “c” on 12 mm (0.47 in.) from bolt mounting surface 0.25 mm (0.0098 in.) 37.732 – 37.750 mm
and “d” on 32 mm (1.26 in.) from bolt mounting surface undersize (1.4856 – 1.4862 in.)
using a micrometer (3).
Calculate difference in diameters (“c” – “d”). If it exceeds Crankshaft pin taper ([a] –[b]) and out-of-round ([1] –
limit, replace connecting rod bolt. [2])
Connecting rod bolt measurement points Limit: 0.01 mm (0.0004 in.)
“a”: 12 mm (0.47 in.)
“b”: 32 mm (1.26 in.)
Connecting rod bolt diameter difference
Limit (“c” – “d”): 0.05 mm (0.002 in.)

1 “c” “d”

“a”
[1] [a] [b]
“b”

3 [2]

2
I8C50A140066-01

I9P60A141082-01

2. Thread

Connecting Rod Bearing General Information
• Service connecting rod bearings are available in
standard size and 0.25 mm (0.0098 in.) undersize
bearing, and standard size bearing has 5 kinds of
bearings differing in tolerance.
• For identification of undersize bearing, it is painted red
at the position as shown in figure. Undersize bearing
thickness is 1.605 – 1.615 mm (0.0632 – 0.0635 in.)
at its center.
1
IHL10A141037-01
1. Painting
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.
Connecting Rod Bearing Clearance
NOTICE
Using connecting rod bolts that are deformed
exceeding the service limit could lead to
engine problems.
After checking connecting rod bearing
clearance, check that connecting rod bolts
are not deformed exceeding the service limit
referring to “Connecting rod bolt
deformation” under “Piston Pin and
Connecting Rod Inspection”: K10B and Bi-
Fuel CNG (Page 1D-55).
1) Clean connecting rod bearings and crankshaft pin.
2) Place a piece of gauging plastic (1) to full width of
crankshaft pin as contacted by bearing (parallel to
crankshaft), avoiding oil hole.
1
I7V20A141100-01
Engine Mechanical: K10B and Bi-Fuel CNG 1D-57
3) Without applying engine oil, install connecting rod
bearings and its cap referring to Step 1) – 6)
“Installation” under “Piston, Piston Ring and
Connecting Rod Removal and Installation”: K10B
and Bi-Fuel CNG (Page 1D-50).
4) After three minutes, remove cap and measure
gauging plastic (1) width (clearance) at the widest
point using a scale (2) on gauging plastic envelope.
If clearance exceeds its limit, select a new standard
size connecting rod bearing. (Page 1D-57) After
selecting new connecting rod bearing, recheck
clearance.
Connecting rod bearing clearance
Standard: 0.031 – 0.049 mm (0.0013 – 0.0019 in.)
Limit: 0.065 mm (0.0026 in.)
2
1
I7V20A141101-01
5) If clearance cannot be brought to its limit even by a
new standard size bearing, use next thicker bearing
and recheck clearance or regrind crankshaft pin to
undersize and use 0.25 mm (0.0098 in.) undersize
bearing.
Selection of Connecting Rod Bearing
Standard size
If engine is under the following conditions, select a new
standard bearing as follows, and install it.
• Bearing is defective.
• Bearing clearance is out of specification.
• Crankshaft or connecting rod is replaced.
1) Check stamped numbers on connecting rod and its
cap as shown. Three kinds of numbers (“1”, “2” and
“3”) represent the following connecting rod big-end
inside diameters. For example, stamped number “1”
indicates that corresponding connecting rod big-end
inside diameter is 41.0000 – 41.0060 mm (1.61418 –
1.61440 in.).
1D-58 Engine Mechanical: K10B and Bi-Fuel CNG

Connecting rod big-end inside diameter 3) There are five kinds of standard bearing thickness
Stamped and they are painted in the following colors. Each
Connecting rod big-end inside diameter color indicates the following thickness at the center
number
41.0000 – 41.0060 mm (1.61418 – 1.61440 of bearing.
1
in.) Standard size connecting rod bearing thickness
41.0061 – 41.0120 mm (1.61442 – 1.61464
2 Color
in.) Bearing thickness
painted
41.0121 – 41.0180 mm (1.61465 – 1.61488
3 Blue 1.4981 – 1.5010 mm (0.05899 – 0.05909 in.)
in.)
Yellow 1.4951 – 1.4980 mm (0.05887 – 0.05897 in.)
Nothing 1.4921 – 1.4950 mm (0.05875 – 0.05885 in.)
Black 1.4891 – 1.4920 mm (0.05863 – 0.05874 in.)
Green 1.4860 – 1.4890 mm (0.05851 – 0.05862 in.)

I8T401142106-02

1. Connecting rod big-end inside diameter number

1
2. Weight indication mark
IHL10A141037-01

1. Painting
2) Check crankshaft pin diameter. On crank web No.6,
three alphabets are stamped as shown in figure.
4) From number stamped on connecting rod and its cap
Three kinds of alphabet (“A”, “B” and “C”) represent
and alphabets stamped on crank web No.6,
the following crankshaft pin diameter respectively.
determine new standard bearing to be installed to
For example, stamped “A” indicates that
connecting rod big-end inside, referring to the
corresponding crankshaft pin diameter is 37.9940 –
following table. For example, if number stamped on
38.0000 mm (1.49583 – 1.49606 in.).
connecting rod and its cap is “1” and alphabet
Crankshaft pin outer diameter stamped on crank web No.6 is “B”, install a new
Stamped standard bearing painted in “Black” to its connecting
Crankshaft pin diameter rod big-end inside.
alphabet
37.9940 – 38.0000 mm (1.49583 – 1.49606 Connecting rod bearing cross-reference
A
in.) selection table (standard size)
37.9880 – 37.9939 mm (1.49560 – 1.49582
B Stamped number for
in.)
connecting rod big-end inside
37.9820 – 37.9879 mm (1.49536 – 1.49558
C diameter
in.)
1 2 3
Stamped alphabet A Green Black Colorless
for crankshaft pin B Black Colorless Yellow
diameter C Colorless Yellow Blue

5) Check bearing clearance with newly selected

standard bearing referring to “Connecting Rod
Bearing Clearance”: K10B and Bi-Fuel CNG (Page
1D-57). If clearance still exceeds its limit, use next
thicker bearing and recheck clearance.

1 2 3
I8C50A140067-02

1. Crankshaft pin No.1 3. Crankshaft pin No.3

2. Crankshaft pin No.2
 Engine Mechanical: K10B and Bi-Fuel CNG 1D-59

Main Bearing, Crankshaft and Cylinder Block Components

AENJCA0A1416037

(c)
2

OIL
3

(b)

14

14
4
7

12

OIL
13
5 1217G
(b)
OIL

6 (a)

OIL
9
OIL

10
OIL

8
15
11
(b)
IJCA0A141056-01

1. CKP sensor 11. Sensor plate

2. Knock sensor 12. Crankshaft timing sprocket key
3. Cylinder block 13. Crankshaft rear oil seal
: Do not apply engine oil to main bearing seating face. : Apply engine oil to oil seal lip.
: Apply engine oil to sliding surface.
4. Timing chain oil jet 14. Dowel pin
5. Oil seal housing 15. Spring pin
: Apply sealant 99000-31260 referring to “Main Bearing, Crankshaft and
Cylinder Block Removal and Installation”: K10B and Bi-Fuel CNG (Page
1D-60).
6. Main bearing cap bolt : 20 Nm → 40 Nm → +60° (2.0 kgf-m → 4.1 kgf-m →
: Apply engine oil to bolt thread and seat. +60°, 15.0 lbf-ft → 29.5 lbf-ft → +60°)
: For tightening order, refer to “Main Bearing, Crankshaft and Cylinder
Block Removal and Installation”: K10B and Bi-Fuel CNG (Page 1D-60).
7. Main bearing cap : 11 Nm (1.1 kgf-m, 8.5 lbf-ft)
8. Crankshaft : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
: Apply engine oil to sliding surface.
9. Thrust bearing : Do not reuse.
: Install thrust bearing with oil grooves facing out.
: Apply engine oil to sliding surface.
10. Main bearing
: For applying engine oil, refer to “Main Bearing, Crankshaft and
Cylinder Block Removal and Installation”: K10B and Bi-Fuel CNG (Page
1D-60).
1D-60 Engine Mechanical: K10B and Bi-Fuel CNG

Main Bearing, Crankshaft and Cylinder Block Installation

Removal and Installation
AENJCA0A1416038 NOTICE

Removal • The engine will seize up if it is operated

when the parts listed below are not
1) Remove engine assembly. (Page 1D-24) properly lubricated.
2) Remove flywheel. (Page 1D-33) Lubricate all the friction surfaces of these
3) Remove pistons and connecting rods. (Page 1D- parts with engine oil before installing them.
50) – Crankshaft journals
4) Remove oil seal housing (1). – Main bearings (sliding surface)
– Thrust bearings
• Using main bearing cap bolts that are
deformed exceeding the service limit could
lead to engine problems.
When main bearing cap bolts are reused,
check that main bearing cap bolts are not
deformed exceeding the service limit
referring to “Main Bearing Cap Bolt” under
“Main Bearing Inspection”: K10B and Bi-
Fuel CNG (Page 1D-63).
1
1) Install oil pressure switch, if removed. (Page 1E-6)
2) Install knock sensor, if removed. (Page 1C-14)
I7V20A141105-01
3) Install water pump, if removed. (Page 1F-16)
5) Remove crankshaft rear oil seal from oil seal
housing. 4) Install generator, if removed. (Page 1J-10)
6) Remove CKP sensor. (Page 1C-13) 5) Install sensor plate (1) as follows, if removed.
7) Remove main bearing cap bolts in numerical order a) Attach spring pin (2) to crankshaft (3).
(“1” – “8”) evenly and gradually as shown in figure. b) Install sensor plate to crankshaft, fitting spring
8) Remove main bearing caps. pin into hole (4) and facing inside edge (5)
outward as shown in figure.
“5” “7” c) Tighten sensor plate screws to specified torque.
Tightening torque
“3” “1” Sensor plate screw (a): 11 N·m (1.1 kgf-m,
8.5 lbf-ft)

6 3

“4” “2”
5 1

“6” “8” (a)

I8C50B140028-01

9) Remove crankshaft from cylinder block. 1

2
10) Remove sensor plate and spring pin from crankshaft,
if necessary. (a) 2

11) Remove generator, if necessary. (Page 1J-10) 4 3

12) Remove water pump, if necessary. (Page 1F-16)

“a”
13) Remove knock sensor, if necessary. (Page 1C-14) IGSB0A143040-01
14) Remove oil pressure switch, if necessary. (Page “a”: 3.1 – 4.9 mm (0.13 – 0.19 in.) 6. Crankshaft side
1E-6)
 Engine Mechanical: K10B and Bi-Fuel CNG 1D-61

6) Install main bearings to cylinder block and main 9) Apply engine oil to sliding surface of main bearings
bearing caps as follows. and crankshaft.
10) Install crankshaft to cylinder block.
NOTE
11) Install main bearing caps according to the following
• Install main bearing halves with oil groove procedure.
to cylinder block.
• Install other main bearing halves to main NOTICE
bearing caps. Using main bearing cap bolts that are
deformed exceeding the service limit could
a) Check mating surfaces (5) of bearing backside lead to engine problems.
and corresponding cylinder block and main Before installing main bearing cap, check
bearing cap are clean and dry. that main bearing cap bolts are not deformed
b) Fit the tab (1) on each bearing into groove (2) in exceeding the service limit referring to “Main
cylinder block and main bearing cap. Bearing Cap Bolt” under “Main Bearing
c) Press bearing end (3) until it fully seats in Inspection”: K10B and Bi-Fuel CNG (Page
cylinder block and main bearing cap. 1D-63).
d) Apply engine oil to sliding surface (4) of main
NOTE
bearing halves at cylinder block side.
For accurate angle tightening of the bolt, use
NOTICE tightening angle gauge available in the
If oil is present between the bearing backside market.
and cylinder block or main bearing cap
surface, the bearing could heat up to very
high temperature, resulting in seizure.
Thoroughly wipe off any trace of oil that is
present between the bearing backside and
cylinder block or main bearing cap surface.

1 3
4
IJHA0A140061-01

2
a) Point arrow mark on cap to crankshaft pulley
5 side.
I8T401142036-01
b) Apply engine oil to bolt thread and seat of main
7) Apply engine oil to thrust bearings (1) and install
bearing cap bolt.
them to cylinder block journal No.3, with oil grooves
(2) facing outward. c) Tighten main bearing cap bolts to 20 Nm (2.0
kgf-m, 15.0 lbf-ft) in numerical order (“1” – “8”) as
8) Check that dowel pins (3) are installed to intake side
shown using a 12-point socket wrench.
main bearing cap bolt holes.
d) In the same manner as in Step c), tighten them
to 40 Nm (4.1 kgf-m, 29.5 lbf-ft).

1 3

I7V20A141108-01
1D-62 Engine Mechanical: K10B and Bi-Fuel CNG

e) Retighten all main bearing cap bolts 60° in Height “b”: 2 mm (0.08 in.)
numerical order as shown in figure.
“a”
Tightening torque
“A” “b”
Main bearing cap bolt* (a): 20 Nm → 40 Nm
→ +60° (2.0 kgf-m → 4.1 kgf-m → +60°, 15.0
lbf-ft → 29.5 lbf-ft → +60°) “A”

“4”, (a) “2”, (a) 1

“6”, (a) “8”, (a) 2 2

IFRA0A141083-01

19) Install oil seal housing (1) according to the following

“5”, (a) “7”, (a) procedure.
a) Apply engine oil to oil seal lip.
“3”, (a) “1”, (a)
b) Within 2 minutes after applying sealant, install oil
IJCA0A141057-01 seal housing applying special tool to crankshaft.
12) Check that crankshaft rotates smoothly when turning
NOTICE
it by hand.
13) Clean sealing surface between oil seal housing and • Turning over of oil seal lip or coming off of
cylinder block. the inside spring will cause oil leakage.
14) Check smoothness of crankshaft flange and apply While installing oil seal housing, pay
engine oil to the sealing surface. attention not to turn over oil seal lip nor
disengage the inside spring.
15) Install new crankshaft rear oil seal (1) to oil seal
housing (2) using special tool. • The oil seal housing bolts are pre-coated
with adhesive. If the bolts are reused, they
Special tool may work loose.
(A): 09911M16300 Replace the oil seal housing bolts with new
Crankshaft rear oil seal installing position ones whenever they are removed.
(depth)
c) Tighten new oil seal housing bolts (2) to
“a”: 1.5 – 2.5 mm (0.060 – 0.098 in.)
specified torque.
(A) Special tool
(A): 09911M97720
Tightening torque
Oil seal housing bolt (a): 11 N·m (1.1 kgf-m,
(A) 1
8.5 lbf-ft)
“a”

(A)
2
3

2 1

I7V20A141110-01 1
16) Install dowel pins (2) to engine rear crankshaft oil
seal housing (1) as shown in figure.
(A)
17) Clean mating surfaces of cylinder block and oil seal
housing. 2,(a)

18) Apply sealant to mating surface of oil seal housing. I7V20A141112-01

3. Crankshaft side
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
20) Install pistons and connecting rods. (Page 1D-50)
Sealant amount for rear oil seal crankshaft 21) Install CKP sensor. (Page 1C-13)
housing
22) Install flywheel. (Page 1D-33)
Width: “a”: 3 mm (0.12 in.)
23) Install engine assembly. (Page 1D-24)
 Engine Mechanical: K10B and Bi-Fuel CNG 1D-63

Crankshaft Inspection Crankshaft journal outside diameter

AENJCA0A1416039 Standard: 45.000 – 45.018 mm (1.7717 – 1.7723 in.)
Crankshaft Runout Crankshaft out-of-roundness ([1] – [2]) and taper ([a]
Using dial gauge, measure runout at center journal. – [b])
Rotate crankshaft slowly. If runout exceeds its limit, Limit: 0.01 mm (0.0004 in.)
replace crankshaft.
[a] [b]
Crankshaft runout
Limit: 0.02 mm (0.0008 in.)

[1]

[2]

I8C50A140073-02

I8C50A140075-01
Crankshaft Thrust Play
1) Assemble crankshaft, main bearings, thrust bearings Main Bearing Inspection
and main bearing caps. (Page 1D-60) AENJCA0A1416040

2) Using dial gauge (1), measure crankshaft thrust play
(2) as shown in figure.
If measured thrust play exceeds limit, replace thrust
bearing with new one (standard size or oversize) to
obtain standard thrust play.
Recheck crankshaft thrust play.
Crankshaft thrust play
Standard: 0.11 – 0.31 mm (0.0044 – 0.0122 in.)
Limit: 0.35 mm (0.0138 in.)
General Information
• Service main bearings are available in standard size
and 0.25 mm (0.0098 in.) undersize, and each of them
has 5 kinds of bearings differing in tolerance.
• Upper bearing half (1) has oil groove (2) as shown in
figure. Install the one half to cylinder block (3).
• Lower bearing half does not have an oil groove.
3 2

1 2 2

I8C50A140074-01 1

Thrust bearing thickness

1
Standard size: 2.470 – 2.520 mm (0.9725 – 0.9921 IDLA0A140052-01
in.)
Oversize (0.125 mm (0.00492 in.)): 2.533 – 2.583 Visual Inspection
mm (0.0998 – 0.1016 in.) Check bearings for pitting, scratches, wear or damage.
If any defect is found, replace both upper and lower
Out-of-Roundness and Taper (Uneven Wear) of halves. Never replace either half without replacing the
Journal other half.
An unevenly worn crankshaft journal shows up as a
difference in diameter at a cross section or along its
length (or both). This difference, if any, is determined by
taking micrometer readings. If any one of journals is
badly damaged or uneven wear exceeds its limit, regrind
or replace crankshaft.
1D-64 Engine Mechanical: K10B and Bi-Fuel CNG

Main Bearing Clearance • More than standard:

Replace bearing with one size thicker or regrind
NOTE
crankshaft journal to undersize and use 0.25 mm
Do not rotate crankshaft while gauging (0.0098 in.) undersize bearing.
plastic is fitted.
• Less than standard:
Check clearance using gauging plastic according to the Replace bearing with one size thinner or regrind
following procedure. crankshaft journal to undersize and use 0.25 mm
(0.0098 in.) undersize bearing.
1) Remove main bearing caps.
2) Clean bearings and crankshaft journals. Selection of Main Bearing
3) Place a piece of gauging plastic (1) to full width of Standard size bearing
bearing (parallel to crankshaft) on journal, avoiding If engine is under one of the following conditions, select
oil hole. new standard bearing as follows, and install it.
• Bearing is defective.
1 • Bearing clearance is out of specification.
• Crankshaft or cylinder block is replaced.
1) Check journal diameter. As shown in figure, crank
web No.5 has stamped numbers. Six kinds of
numbers (“1” through “6”) represent the following
journal diameters. Stamped numbers on crank web
No.5 represent diameters of journal indicated with an
arrow in figure respectively. For example stamped
number “1” indicates that corresponding journal
I7V20A141118-01
diameter is 45.0150 – 45.0180 mm (1.77225 –
4) Without applying engine oil, install main bearing cap
1.77236 in.).
referring to Step 11) – 12) in “Installation” under
“Main Bearing, Crankshaft and Cylinder Block Crankshaft journal diameter
Removal and Installation”: K10B and Bi-Fuel CNG Stamped number Journal diameter
(Page 1D-60). 45.0150 – 45.0180 mm
1
5) After three minutes, remove main bearing cap and (1.77225 – 1.77236 in.)
using scale (2) on gauging plastic envelope (1), 45.0120 – 45.0149 mm
2
measure gauging plastic width at the widest point. (1.77213 – 1.77224 in.)
45.0090 – 45.0119 mm
Main bearing clearance 3
(1.77201 – 1.77212 in.)
Standard: 0.016 – 0.034 mm (0.00063 – 0.00133 45.0060 – 45.0089 mm
in.) 4
(1.77189 – 1.77200 in.)
Limit: 0.050 mm (0.00197 in.) 45.0030 – 45.0059 mm
5
(1.77178 – 1.77188 in.)
1 45.0000 – 45.0029 mm
6
2 (1.77166 – 1.77176 in.)

5
I7V20A141119-01

If measured clearance is less than standard or more

than service limit, replace main bearings with new ones
referring to “Selection of Main Bearing”: K10B and Bi-
Fuel CNG (Page 1D-64) and recheck main bearing
clearance.
If measured clearance with new bearings is out of 1 2 3 4
I8C50A140076-01
standard, select other bearings according to the
following procedure and recheck main bearing 1. Crankshaft journal No.1 4. Crankshaft journal No.4

clearance. 2. Crankshaft journal No.2 5. Crankshaft pulley side

3. Crankshaft journal No.3
 Engine Mechanical: K10B and Bi-Fuel CNG 1D-65

2) Check bearing cap bore diameter without bearing. 3) There are five kinds of standard bearing thickness
On mating surface of cylinder block, four alphabets and they are painted in the following colors.
or numbers are stamped as shown in figure. Six Each color indicates the following thickness at the
kinds of alphabets (“A” through “F”) or numbers (“1” center of bearing.
through “6”) represent the following journal inside
Standard size crankshaft main bearing thickness
diameters. Stamped alphabets or numbers on
cylinder block represent bearing cap bore diameter Painted color Bearing thickness
marked with an arrow in figure respectively. For 1.990 – 1.993 mm
Pink
example, stamped “A” or “1” indicates that (0.07835 – 0.07846 in.)
corresponding bearing cap bore diameter is 49.0000 1.993 – 1.996 mm
Purple
– 49.0030 mm (1.92914 – 1.92925 in.). (0.07847 – 0.07858 in.)
1.996 – 1.999 mm
Crankshaft bearing cap bore Brown
(0.07859 – 0.07870 in.)
Stamped alphabet Bearing cap bore diameter 1.999 – 2.002 mm
Green
(number) (without bearing) (0.07871 – 0.07881 in.)
49.0000 – 49.0030 mm 2.002 – 2.005 mm
A or 1 Black
(1.92914 – 1.92925 in.) (0.07882 – 0.07893 in.)
49.0031 – 49.0060 mm
B or 2
(1.92926 – 1.92937 in.)
49.0061 – 49.0090 mm
C or 3
(1.92938 – 1.92948 in.)
49.0091 – 49.0120 mm
D or 4
(1.92950 – 1.92960 in.)
49.0121 – 49.0150 mm
E or 5
(1.92962 – 1.92972 in.)
49.0151 – 49.0180 mm
F or 6
(1.92973 – 1.92984 in.)
1
IFAE0A140144-01

1. Paint
1 2 3 4

I8C50A140077-01

1. Cylinder block journal No.1 4. Cylinder block journal No.4

2. Cylinder block journal No.2 5. Crankshaft pulley side
3. Cylinder block journal No.3
1D-66 Engine Mechanical: K10B and Bi-Fuel CNG

4) From number stamped on crank web No.5 and alphabet or number stamped on cylinder block, determine new
standard bearing to be installed to journal, referring to the following table. For example, if number stamped on
crank web No.5 is “1” and alphabet stamped on cylinder block is “B”, install a new standard bearing painted in
“Pink” to its journal.
Main bearing cross – reference selection table (standard size)
Stamped number on crank web No.5
1 2 3 4 5 6
Upper Pink Pink Pink Purple Purple Brown
A or 1
Lower Pink Pink Purple Purple Brown Brown
Upper Pink Pink Purple Purple Brown Brown
B or 2
Lower Pink Purple Purple Brown Brown Green
Alphabet or
Upper Pink Purple Purple Brown Brown Green
number C or 3
Lower Purple Purple Brown Brown Green Green
stamped on
Upper Purple Purple Brown Brown Green Green
cylinder D or 4
Lower Purple Brown Brown Green Green Black
block
Upper Purple Brown Brown Green Green Black
E or 5
Lower Brown Brown Green Green Black Black
Upper Brown Brown Green Green Black Black
F or 6
Lower Brown Green Green Black Black Black

5) Using scale (2) and gauging plastic (1), check bearing clearance with newly selected standard bearing. If
clearance still exceeds its limit, use next thicker bearing and recheck clearance, referring to “Main Bearing
Clearance”: K10B and Bi-Fuel CNG (Page 1D-64).

1
2

I7V20A141119-01

Undersize bearing (0.25 mm (0.0098 in.))

• There are five kinds of undersize bearing thickness and they are painted in the following colors. Each color
indicates the following thickness at the center of bearing.
Undersize crankshaft main bearing thickness
Painted color Bearing thickness
Red & Pink 2.115 – 2.118 mm (0.08327 – 0.08338 in.)
Red & Purple 2.118 – 2.121 mm (0.08339 – 0.08350 in.)
Red & Brown 2.121 – 2.124 mm (0.08351 – 0.08362 in.)
Red & Green 2.124 – 2.127 mm (0.08363 – 0.08374 in.)
Red & Black 2.127 – 2.130 mm (0.08375 – 0.08385 in.)
 Engine Mechanical: K10B and Bi-Fuel CNG 1D-67

1
IFAE0A140145-01

1. Paint

• If necessary, regrind crankshaft journal and select undersize bearing to use with crankshaft as follows.
a. Regrind journal to the following finished diameter.
Finished crankshaft journal diameter
44.750 – 44.768 mm (1.76182 – 1.76251 in.)
b. Using micrometer, measure reground journal diameter. Measurement should be taken in two directions
perpendicular to each other to check for out-of-roundness.
c. Using journal diameter measured above and alphabets or numbers stamped on cylinder block, select an
undersize bearing referring to the following table. Check bearing clearance with newly selected undersize
bearing.

I2RH0B140144-01

Main bearing cross – reference table (undersize)

Measured journal diameter
44.7650 – 44.7620 – 44.7590 – 44.7560 – 44.7530 – 44.7500 –
44.7680 mm 44.7649 mm 44.7619 mm 44.7589 mm 44.7559 mm 44.7529 mm
(1.76241 – (1.76229 – (1.76217 – (1.76205 – (1.76193 – (1.76182 –
1.76251 in.) 1.76239 in.) 1.76227 in.) 1.76216 in.) 1.76204 in.) 1.76192 in.)
Upper Red & Pink Red & Pink Red & Pink Red & Purple Red & Purple Red & Brown
A or 1
Lower Red & Pink Red & Pink Red & Purple Red & Purple Red & Brown Red & Brown
Stamped Upper Red & Pink Red & Pink Red & Purple Red & Purple Red & Brown Red & Brown
B or 2
alphabet Lower Red & Pink Red & Purple Red & Purple Red & Brown Red & Brown Red & Green
or Upper Red & Pink Red & Purple Red & Purple Red & Brown Red & Brown Red & Green
C or 3
number Lower Red & Purple Red & Purple Red & Brown Red & Brown Red & Green Red & Green
stamped Upper Red & Purple Red & Purple Red & Brown Red & Brown Red & Green Red & Green
D or 4
on Lower Red & Purple Red & Brown Red & Brown Red & Green Red & Green Red & Black
cylinder Upper Red & Purple Red & Brown Red & Brown Red & Green Red & Green Red & Black
E or 5
block Lower Red & Brown Red & Brown Red & Green Red & Green Red & Black Red & Black
Upper Red & Brown Red & Brown Red & Green Red & Green Red & Black Red & Black
F or 6
Lower Red & Brown Red & Green Red & Green Red & Black Red & Black Red & Black
1D-68 Engine Mechanical: K10B and Bi-Fuel CNG

Main Bearing Cap Bolt Cylinder Block Inspection

Measure each thread diameter at specified points on AENJCA0A1416043

main bearing cap bolts (1) using a micrometer (3).

Calculate difference in diameters (“c” – “d”). Distortion of Gasket Surface
If it exceeds limit, replace main bearing cap bolt with new Using straightedge and feeler gauge, check gasket
one. surface for distortion. If distortion exceeds its limit, repair
it.
Main bearing cap bolt diameter measurement points If repair is not possible, replace cylinder block.
“a”: 40 mm (1.6 in.)
“b”: 64 mm (2.5 in.) Cylinder block distortion
Limit: 0.03 mm (0.0012 in.)
Main bearing cap bolt diameter difference
Limit (“c” – “d”): 0.2 mm (0.0079 in.)

1
“c” “d”

“a”

“b”
I9P60A141079-01

I7V20A141125-01
3

I9T401142032-01

2. Thread

Sensor Plate Inspection

AENJCA0A1416041
Check sensor plate for crack or damage.
If any defect is found, replace sensor plate. I8C50A140079-01

I7V20A141122-01
 Engine Mechanical: K10B and Bi-Fuel CNG 1D-69

Specifications
Tightening Torque Specifications
AENJCA0A1417001
NOTE
For fastener(s) with * (asterisk) below, refer to the specified procedure in “Repair Instructions”.

Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Cylinder head cover bolt* 5.0 Nm → 8.0 Nm → 11 Nm (0.51 kgf-m (Page 1D-13)
→ 0.82 kgf-m → 1.1 kgf-m, 4.0 lbf-ft → 6.0
lbf-ft → 8.5 lbf-ft)
Engine harness bracket bolt 11 1.1 8.5 (Page 1D-13)
Camshaft housing bolt* 5.0 Nm → 8.0 Nm → 11 Nm (0.51 kgf-m (Page 1D-17)
→ 0.82 kgf-m → 1.1 kgf-m, 4.0 lbf-ft → 6.0
lbf-ft → 8.5 lbf-ft)
Exhaust camshaft timing sprocket bolt 60 6.1 44.5 (Page 1D-18)
Timing chain cover plug 25 2.5 18.5 (Page 1D-18)
Engine harness ground bolt 11 1.1 8.5 (Page 1D-27)
Engine right mounting bolt 93 9.5 68.5 (Page 1D-28)
Engine left mounting nut 55 5.6 40.5 (Page 1D-28)
Engine left mounting bolt 55 5.6 40.5 (Page 1D-28)
Engine right mounting nut 65 6.6 48.0 (Page 1D-28)
Engine right mounting bolt 65 6.6 48.0 (Page 1D-28)
Ground terminal bolt 25 2.5 18.5 (Page 1D-29)
Timing chain cover bolt No.1* 25 2.5 18.5 (Page 1D-32)
Timing chain cover bolt No.2* 25 2.5 18.5 (Page 1D-32)
Crankshaft pulley bolt* (Page 1D-33)19 Nm
→ +75° (1.9 kgf-m →
+75°, 14.0 lbf-ft →
+75°)
Flywheel bolt 83 8.5 61.5 (Page 1D-34)
Timing chain guide bolt 11 1.1 8.5 (Page 1D-37)
Timing chain tensioner bolt 25 2.5 18.5 (Page 1D-37)
Timing chain tensioner adjuster bolt 11 1.1 8.5 (Page 1D-38)
Cylinder head bolt (M10)* 20 Nm → 40 Nm → +60° → +60° (2.0 kgf- (Page 1D-42)
m → 4.1 kgf-m → +60° → +60°, 15.0 lbf-ft
→ 29.5 lbf-ft → +60° → +60°)
Cylinder head bolt (M8)* 25 2.5 18.5 (Page 1D-42)
Venturi plug 3.5 0.36 2.5 (Page 1D-44)
Connecting rod bolt* 15 Nm → +65° (1.5 kgf-m → +65°, 11.0 lbf- (Page 1D-51)
ft → +65°)
Sensor plate screw 11 1.1 8.5 (Page 1D-60)
Main bearing cap bolt* 20 Nm → 40 Nm → +60° (2.0 kgf-m → 4.1 (Page 1D-62)
kgf-m → +60°, 15.0 lbf-ft → 29.5 lbf-ft →
+60°)
Oil seal housing bolt 11 1.1 8.5 (Page 1D-62)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Air Cleaner Components”: K10B and Bi-Fuel CNG (Page 1D-5)
“Electric Throttle Body and Intake Manifold Components”: K10B and Bi-Fuel CNG (Page 1D-7)
“Cylinder Head Cover Components”: K10B and Bi-Fuel CNG (Page 1D-10)
“Camshaft and Tappet Components”: K10B and Bi-Fuel CNG (Page 1D-14)
“Engine Mounting Components”: K10B and Bi-Fuel CNG (Page 1D-23)
“Timing Chain Cover Components”: K10B and Bi-Fuel CNG (Page 1D-30)
“Timing Chain and Chain Tensioner Components”: K10B and Bi-Fuel CNG (Page 1D-35)
“Valve and Cylinder Head Components”: K10B and Bi-Fuel CNG (Page 1D-40)
“Piston, Piston Ring and Connecting Rod Components”: K10B and Bi-Fuel CNG (Page 1D-49)
“Main Bearing, Crankshaft and Cylinder Block Components”: K10B and Bi-Fuel CNG (Page 1D-59)
1D-70 Engine Mechanical: K10B and Bi-Fuel CNG

“Fasteners Information” in Section 0A (Page 0A-6)

Special Tools and Equipment

Recommended Service Material
AENJCA0A1418001
Material SUZUKI recommended product or Specification Note
Sealant SUZUKI Bond No.1207F P/No.: 99000–31250 (Page 1D-12)
SUZUKI Bond No.1217G P/No.: 99000–31260 (Page 1D-32) / (Page
1D-62)

NOTE
Required service material(s) is also described in:
“Cylinder Head Cover Components”: K10B and Bi-Fuel CNG (Page 1D-10)
“Camshaft and Tappet Components”: K10B and Bi-Fuel CNG (Page 1D-14)
“Timing Chain Cover Components”: K10B and Bi-Fuel CNG (Page 1D-30)
“Timing Chain and Chain Tensioner Components”: K10B and Bi-Fuel CNG (Page 1D-35)
“Valve and Cylinder Head Components”: K10B and Bi-Fuel CNG (Page 1D-40)
“Piston, Piston Ring and Connecting Rod Components”: K10B and Bi-Fuel CNG (Page 1D-49)
“Main Bearing, Crankshaft and Cylinder Block Components”: K10B and Bi-Fuel CNG (Page 1D-59)

Special Tool
AENJCA0A1418002
09911M16300 09911M97720
Oil seal installer Oil seal installer
(Page 1D-62) (Page 1D-62)

09913M66710 09913M70123
Bearing puller Bearing installer
(Page 1D-31) (Page 1D-21)

09913M75821 09915M64512
Bearing installer attachment Compression gauge
(Page 1D-34) (Page 1D-1)

09915M64530 09915M64550
Compression gauge hose Compression gauge
attachment (B)
(Page 1D-1) (Page 1D-1)
 Engine Mechanical: K10B and Bi-Fuel CNG 1D-71

09915M67311 09916M14510
Vacuum gauge Valve lifter
(Page 1D-2) (Page 1D-42) /
(Page 1D-44)

09916M14522 09916M34542
Valve spring compressor Reamer handle
attachment
(Page 1D-42) / (Page 1D-43) /
(Page 1D-44) (Page 1D-43)

09916M34570 09916M37320
Valve guide reamer (5 mm) Valve guide outer reamer
(10.5 mm)
(Page 1D-43) (Page 1D-43)

09916M44310 09916M56011
Valve guide remover (5 mm) Valve guide installer
attachment (protrusion: 11.5
mm)
(Page 1D-43) (Page 1D-43)

09916M57330 09916M77310
Valve guide installer handle Piston ring compressor (50 -
125 mm)
(Page 1D-43) / (Page 1D-51)
(Page 1D-44)

09916M84511 09917M68222
Forceps Crankshaft pulley holder
(Page 1D-42) / (Page 1D-31) /
(Page 1D-44) (Page 1D-33)

09917M98221 09921M20210
Valve guide stem Bearing remover (12 mm)
attachment
(Page 1D-44) (Page 1D-34)

09924M17811 09926M58010
Flywheel holder Bearing remover attachment
(Page 1D-33) / (Page 1D-31)
(Page 1D-34)
1D-72 Engine Mechanical: K10B and Bi-Fuel CNG

09930M30104 09945M25710
Sliding shaft Torque wrench adaptor
(Page 1D-34) (Page 1D-18)

SUZUKI scan tool (Suzuki

SDT-II)
—
(Page 1D-2)
 Engine Mechanical: K12M 1D-73

K12M
General Description
Engine Construction Description
AENJCA0A1421001
The engine is a water-cooled, in-line 4-cylinder, 4-stroke-cycle gasoline unit with a DOHC valve mechanism arranged
in a “V” type valve configuration and has 16 valves. The intake camshaft is equipped with a VVT actuator and the
actuator improves engine performance changing intake valve timing continuously. The cylinder block is equipped with
a water jacket spacer and the spacer controls the coolant flow for effective cylinder head cooling.
1D-74 Engine Mechanical: K12M

VVT System Description

AENJCA0A1421002
System Description
The VVT system continuously varies the intake valve timing in response to the engine operating condition and
optimizes it.
The optimized intake valve timing produces such an air intake with high efficiency that both the higher power
generation and lower fuel consumption can be attained in the whole engine speed range from low to high. In the area
of the average engine load, low emission of nitrogen oxides (NOx) and high fuel efficiency can also be attained by
making the valve opening overlap between the intake and exhaust valves longer.
The intake valve timing is varied by the VVT actuator (1) which varies the rotational phase between the intake
camshaft (3) and sprocket. The rotor (2) in the VVT actuator is actuated by switching or adjusting the hydraulic
pressure applied to the chambers for the timing advancing (7) and/or retarding (6). To switch or adjust the hydraulic
pressure appropriately, ECM operates the OCV (12) according to the engine speed, intake air value, throttle opening,
engine coolant temperature and camshaft position (angle).

1
7 2 6

8 9
12

11

10
Most advanced timing 50° (variable angle)

Intake valve
Valve lift

Exhaust valve

Most retarded timing

Crank angle

Overlap of valves
IJCA0A142001-01

4. Oil passage to chamber for timing retarding 8. Oil filter 10. Oil pan
5. Oil passage to chamber for timing advancing 9. Oil pump 11. Control signal from ECM
 Engine Mechanical: K12M 1D-75

Operation Description Timing advancing

OCV
The OCV switches and adjusts the hydraulic pressure
applied to the VVT actuator by moving the valve spool
(1) according to the duty cycle pulses from ECM.
Through this control, the valve timing is varied
continuously. ECM outputs duty signal of about 240 Hz
to the OCV.
When the duty ratio of the signal from the ECM to the
intake OCV is high, the valve spool (4) of the OCV
moves to the left. By this valve spool movement, the
pressurized oil (1) is led into the timing advancing
chamber and the oil in the timing retarding chamber is
drained. As a result, the rotor (3) turns in the timing
advancing direction.

1 3

I5RW0C140034-01

VVT actuator
4 1 2
The VVT actuator has chambers for timing advancing (2) IBP60B140088-01
and retarding (3) which are separated by the rotor (5).
2. Drain
The rotor turns according to change in balance between
the hydraulic pressures applied to both chambers. The
Timing holding
sprocket (1) is installed on the housing (4) and the rotor
When ECM keeps the duty ratio of the signal sent to the
is secured on the camshaft by bolts. Therefore, the
OCV constant, the valve spool of the OCV is held in the
rotation of the rotor changes the phase between the
same position. Because this condition creates no oil
sprocket and camshaft.
pressure change in both chambers, the rotor is fixed at a
5
target position.
3
1

2
4

6 I5RW0C140036-01
IJCA0A142002-01

6. Seal Timing retarding

When the duty ratio of the signal from the ECM to the
intake OCV is low, the valve spool of the OCV moves to
the right. By this valve spool movement, the pressurized
oil is led into the timing retarding chamber and the oil in
the timing advancing chamber is drained. As a result, the
rotor turns in the timing retarding direction.

I5RW0C140037-01
1D-76 Engine Mechanical: K12M

VVT Operation
Driving condition Valve timing Target of control Effect
To shorten the valve opening overlap
Engine running at idle Stabilization of the engine
Most retarded to prevent the exhaust gas counterflow
speed rotation at idle speed.
to intake manifold.
To lengthen the valve opening overlap Improvement of the fuel
Average engine load To the advanced to enhance the internal exhaust gas efficiency.
range side recirculation and reduce the pumping Lowering of the exhaust
loss. emission.
To shorten the valve opening overlap
Light engine load
To the retarded side to prevent the exhaust gas counterflow Keeping of the engine stability.
range
to intake manifold.
Low or average
To advance the closing timing of the Improvement of generating the
engine speed range To the advanced
intake valve to improve the volumetric engine torque at low and
with heavy engine side
efficiency. average engine speed.
load
High engine speed To retard the closing timing of the
Improvement of generating the
range with heavy To the retarded side intake valve to improve the volumetric
engine power.
engine load efficiency.
To shorten the valve opening overlap
to prevent the exhaust gas counterflow
Stabilization of engine speed at
to intake manifold and reduce the fuel
Low engine coolant fast idle.
Most retarded increasing.
temperature Improvement of the fuel
To slow the fast idle speed of the
efficiency.
engine as a result of stabilizing the
engine idling.
To shorten the valve opening overlap
At engine starting and Improvement of engine start
Most retarded to prevent the exhaust gas counterflow
stopping ability.
to intake manifold.
 Engine Mechanical: K12M 1D-77

Diagnostic Information and Procedures

Compression Check 9) Crank engine with fully charged battery, and read the
AENJCA0A1424001 highest pressure on special tool.
1) Warm up engine to normal operating temperature.
2) Stop engine after warming up. NOTE
3) For M/T model, place gear shift lever in “Neutral” and • For measuring compression pressure,
apply parking brake. crank engine at least 200 rpm with fully
For auto gear shift model, place shift selector in N charged battery.
range and apply parking brake. • Check installation condition of special tool
4) Remove all ignition coil assemblies and all spark if measured compression pressure is
plugs. (Page 1H-17) lower than the limit.
5) Remove air cleaner assembly. (Page 1D-82) • If the measured compression pressure of
6) Disconnect all fuel injector connectors. particular cylinder is lower than the limit,
add a bit of engine oil into the cylinder
7) Install special tools into spark plug hole.
through the spark plug hole, and then
Special tool repeat the compression check.
(A): 09915M64512 – If the compression pressure increases
(B): 09915M64530 after adding engine oil, the following
(C): 09915M64550 may be the cause:
– Pressure leakage due to worn piston
(A) rings or worn cylinder
– If the compression pressure does not
(B)
increase, one of the following may be
the cause:
– Incorrect valve timing
– Pressure leakage from the valve or
valve seats
– Pressure leakage from the cylinder
(C)
head gasket
IFRA0A141002-01
Compression pressure
8) Depress clutch pedal (1) (M/T model) and
Standard: 1,400 kPa (14.3 kgf/cm2, 203 psi, 14
accelerator pedal (2) all the way.
bar)
Limit: 1,150 kPa (11.8 kgf/cm2, 167 psi, 11.5 bar)
Max. difference between any two cylinders: 100
kPa (1.0 kgf/cm2, 14.5 psi, 1 bar)
10) Carry out Step 7) – 9) on each cylinder to obtain 4
readings.
11) Install spark plugs and ignition coil assemblies.
(Page 1H-17)
12) Connect fuel injector connectors.
13) Install air cleaner assembly. (Page 1D-82)

IGJA0A141031-02
1D-78 Engine Mechanical: K12M

Engine Vacuum Check 5) Remove PCV hose (1) from PCV valve (2).
AENJCA0A1424002
Using SUZUKI Scan Tool
1) Warm up engine to normal operating temperature.
2) For M/T model, place gear shift lever in “Neutral” and
apply parking brake. 1
For auto gear shift model, place select lever in N 2
range and apply parking brake.
3) Stop engine and turn off all electric switches.
4) When ignition is “OFF”, connect SUZUKI scan tool to
DLC (1).
Special tool
(A): SUZUKI scan tool (Suzuki SDT-II)
IFRA0A141004-01

6) Connect special tool to PCV hose (1).

Special tool
(A): 09915M67311
7) Close PCV valve (2) using tape (3) or the like.
1
8) Install air cleaner assembly. (Page 1D-82)

(A)

3
(A)
2
IJCA0A181004-01

5) Run engine at specified idle speed.

6) Select “MAP” under “Data List” mode on scan tool.
Manifold absolute pressure should be within
specification.
Manifold absolute pressure specification (at sea
level)
50 kPa (0.50 kgf/cm2, 7.25 psi, 0.5 bar) or less at
specified idle speed
Not Using SUZUKI Scan Tool
1) Warm up engine to normal operating temperature.
2) For M/T model, place gear shift lever in “Neutral” and
apply parking brake.
For auto gear shift model, place shift selector in N
range and apply parking brake.
3) Stop engine and turn off all electric switches.
4) Remove air cleaner assembly. (Page 1D-82)
IFRA0A141005-01
9) Run engine at specified idle speed. (Page 1A-270)
10) Read vacuum gauge. Negative pressure should be
within specification.
Negative pressure specification (at sea level)
–73 to –59 kPa (–0.74 to –0.61 kgf/cm2, –10.58 to
–8.56 psi, –0.73 to –0.59 bar) at specified idle
speed
11) Remove air cleaner assembly. (Page 1D-82)
12) Disconnect special tool from PCV hose.
13) Pull off tape from PCV valve.
14) Install PCV hose to PCV valve.
15) Install air cleaner assembly. (Page 1D-82)
 Engine Mechanical: K12M 1D-79

Valve Clearance Inspection and Adjustment If valve clearance is not as specified, record valve
AENJCA0A1424003 clearance and adjust it to specification. (Page 1D-80)
NOTICE
Valve clearance specification
If engine oil contacts to compressor drive
When cold (ECT: 15 – 25 °C (59 – 77 °F)):
belt and water pump / generator drive belt,
• Intake: 0.14 – 0.23 mm (0.0056 – 0.0090 in.)
problems such as belt squeal could occur.
• Exhaust: 0.30 – 0.40 mm (0.0119 – 0.0157 in.)
Do not allow engine oil to contact
compressor drive belt and water pump /
generator drive belt. If engine oil contacts
1
them, wash it off with water.

Inspection
1) Remove cylinder head cover. (Page 1D-86)
2) Hoist vehicle and remove right side splash cover.
3) Using wrench, turn crankshaft pulley (1) clockwise
until cam lobes (2) become perpendicular to tappet
faces (3) at valves “1” and “7” as shown in figure.
2
4) Check valve clearance with feeler gauge (4) as
follows.
a) Check valve clearance at valves “1” and “7”.
b) Turn camshafts by 90° (by turning crankshaft
with wrench). “a”

c) Check that cam lobes are perpendicular to

tappet faces at valves to be checked (in this
4
case, “3” and “8”). If not, adjust cam lob position
by turning crankshaft. Check valve clearances.
3
d) In the same manner as in Step b) – c), check IFRA0A141006-01

valve clearances at valves “4” and “6”. “a”: 90°

e) In the same manner as in Step b) – c) again,
check valve clearances at valves “2” and “5”.

IBP60B140003-02
1D-80 Engine Mechanical: K12M

Adjustment c) Select new tappet closest to calculated value

1) Remove tappet to be replaced. (Page 1D-89) from available size of spare part.
2) Select proper size of tappet as follows to adjust valve Available tappets No.
clearance to specified valve. Thickness Thickness
Tappet No. Tappet No.
a) Using a micrometer, measure the thickness of mm (in.) mm (in.)
the removed tappet (1). 3.88 (0.1528) 388 3.48 (0.1370) 348
b) Calculate the thickness of new tappet by the 3.86 (0.1520) 386 3.46 (0.1362) 346
following formula. 3.84 (0.1512) 384 3.44 (0.1354) 344
3.82 (0.1504) 382 3.42 (0.1346) 342
NOTE 3.80 (0.1496) 380 3.40 (0.1339) 340
If the number in the second decimal place is 3.78 (0.1488) 378 3.38 (0.1331) 338
odd, use (A – 0.01) tappet. 3.76 (0.1480) 376 3.36 (0.1323) 336
3.74 (0.1472) 374 3.34 (0.1315) 334
Intake: 3.72 (0.1465) 372 3.32 (0.1307) 332
A = B + C – 0.19 mm (0.0075 in.) 3.70 (0.1457) 370 3.30 (0.1299) 330
Exhaust: 3.68 (0.1449) 368 3.28 (0.1291) 328
A = B + C – 0.35 mm (0.0138 in.) 3.66 (0.1441) 366 3.26 (0.1283) 326
• A: Thickness “a” of new tappet 3.64 (0.1433) 364 3.24 (0.1276) 324
3.62 (0.1425) 362 3.22 (0.1268) 322
• B: Thickness “a” of removed tappet 3.60 (0.1417) 360 3.20 (0.1260) 320
• C: Measured valve clearance 3.58 (0.1409) 358 3.18 (0.1252) 318
3.56 (0.1402) 356 3.16 (0.1244) 316
"a" 3.54 (0.1394) 354 3.14 (0.1236) 314
1
3.52 (0.1386) 352 3.12 (0.1228) 312
3.50 (0.1378) 350 3.10 (0.1220) 310

3) Install camshafts and tappets. (Page 1D-89)

1
4) Recheck valve clearance.

I7V20A141015-01

Air Cleaner Components
2
1. Air cleaner assembly
2. Air cleaner suction hose
3. Air cleaner suction pipe
4. Air cleaner outlet hose
Engine Mechanical: K12M 1D-81
Repair Instructions
AENJCA0A1426001
(a)
4
(a)
6
5
9
7
IJCA0A142003-01
5. Breather hose pipe 9. To electric throttle body assembly
6. IAT sensor : 1.5 Nm (0.15 kgf-m, 1.5 lbf-ft)
: For installation, refer to “IAT Sensor Removal
and Installation”: K12M in Section 1C (Page 1C-
32).
7. Breather hose
8. To cylinder head cover
1D-82 Engine Mechanical: K12M

Air Cleaner Filter Removal and Installation Air Cleaner Filter Inspection and Cleaning
AENJCA0A1426002 AENJCA0A1426003

Removal Inspection
1) Unhook air cleaner case clamps (1). Check air cleaner filter for dirt. Replace excessively dirty
filter.
2) Open air cleaner cap (2), and then remove air
cleaner filter.
Cleaning
Blow off dust by compressed air from air outlet side of
2 filter.

1
I5RS0B140007-01

IFRA0A141009-01
Air Cleaner Assembly Removal and Installation
AENJCA0A1426004
Installation
1) Install air cleaner filter to air cleaner case. Removal
2) Fit tabs (1) of the cap with the case hooks, and join 1) Remove air cleaner bolt (1).
air cleaner cap (2) with air cleaner case (3). 2) Disconnect air cleaner suction hose (2) from air
cleaner assembly (3).
1 3) Loosen air cleaner outlet hose clamp (4) and remove
air cleaner assembly.

3
4

1
2

3
IJCA0A142005-01

IJCA0A142004-01

3) Hook air cleaner case clamps.

 Engine Mechanical: K12M 1D-83

4) Remove air cleaner suction hose (1) and air cleaner Installation
suction pipe (2), if necessary. Reverse removal procedure noting the following points.

NOTE
Check that air cleaner grommets are fitted to
intake manifold.
If the grommets are disconnected, fit them to
intake manifold before installing air cleaner
assembly.

• Tighten air cleaner outlet hose clamps to specified

torque. (Page 1D-81)
• Insert protrusions (1) of air cleaner assembly (2) into
grommets (3) on intake manifold.
1

IJCA0A142006-01

5) Loosen air cleaner outlet hose clamp (1) and 3

disconnected breather hose (2), and then remove air
cleaner outlet hose (3), if necessary.

1
2

IFRA0A141015-01

IJCA0A142007-01
1D-84 Engine Mechanical: K12M

Throttle Body and Intake Manifold Components

AENJCA0A1426005

10

2
2
2

11

IJCA0A142008-02

1. Intake manifold 5. PCV hose 9. To PCV valve

2. Intake manifold gasket 6. Vacuum pipe intake hose 10. To brake booster
3. Electric throttle body assembly 7. MAP sensor 11. To EVAP canister purge valve
: Do not disassemble.
4. Electric throttle body gasket 8. EVAP canister purge valve hose : Do not reuse.

Throttle Body On-Vehicle Inspection NOTE

AENJCA0A1426006
Check electric throttle body assembly. (Page 1C-23) After removing electric throttle body
assembly, calibration of throttle valve
position is required. (Page 1C-25)
Electric Throttle Body Assembly Removal and
Installation Removal
AENJCA0A1426007
1) Disconnect negative (–) cable at battery.
NOTICE
2) Remove air cleaner assembly and air cleaner outlet
The electric throttle body will lose its original hose. (Page 1D-82)
performance if it is disassembled.
Do not disassemble the electric throttle body.
If any faulty condition is found, replace the
electric throttle body with a new one.
 Engine Mechanical: K12M 1D-85

3) Disconnect electric throttle body connector (1) from
electric throttle body assembly (2).
4) Remove electric throttle body assembly from intake
manifold.
2 1
Throttle Body Cleaning
AENJCA0A1426008
Clean electric throttle body assembly referring to
“Throttle Valve Visual Check” under “Electric Throttle
Body Assembly On-Vehicle Inspection”: K12M in Section
1C (Page 1C-23).

Intake Manifold Removal and Installation

AENJCA0A1426009

Removal
1) Relieve fuel pressure. (Page 1G-19)
2) Remove air cleaner assembly. (Page 1D-82)
3) Remove electric throttle body assembly. (Page
1D-84)
4) Disconnect MAP sensor connector. (Page 1C-27)
5) Disconnect the following hoses from intake manifold.
IJCA0A142009-01
• Vacuum pipe intake hose (1)
5) Remove electric throttle body gasket.
• EVAP canister purge valve hose (2)
Installation • PCV hose (3)
1) Clean mating surfaces and install new electric • Fuel feed hose (4)
throttle body gasket (1) to intake manifold. 6) Disconnect engine harness clamps and heater hose
clamp from intake manifold.
7) Remove intake manifold (5) and its gaskets.
1

1 2
4

3
IJCA0A142010-01

2) Install electric throttle body assembly (1) to intake

manifold. IJCA0A142041-01

3) Connect electric throttle body connector (2) to 8) Remove MAP sensor, if necessary. (Page 1C-27)
electric throttle body assembly.
Installation
1 Reverse removal procedure noting the following points.
2
• Use new gaskets.
• Check that all removed parts are back in place.
• Check for fuel leakage. (Page 1G-20)

IJCA0A142011-01

4) Install air cleaner assembly with air cleaner outlet

hose. (Page 1D-82)
5) Connect negative (–) cable at battery.
1D-86 Engine Mechanical: K12M

Cylinder Head Cover Components

AENJCA0A1426010

7
5

1
3 (a)

2 1207F

IJCA0A142012-01

1. Cylinder head cover 4. PCV valve 7. To air cleaner outlet hose

2. Cylinder head cover gasket 5. Oil filler cap : 3.0 Nm → 5.0 Nm → 7.5 Nm (0.31
: Apply sealant 99000-31250 referring to “Cylinder kgf-m → 0.51 kgf-m → 0.76 kgf-m, 2.5
Head Cover Removal and Installation”: K12M (Page lbf-ft → 4.0 lbf-ft → 5.5 lbf-ft)
1D-86).
3. Cylinder head cover bolt 6. PCV valve seal : Do not reuse.
: For tightening order, refer to “Cylinder Head Cover
Removal and Installation”: K12M (Page 1D-86).

Cylinder Head Cover Removal and Installation

AENJCA0A1426011

Removal
1) Remove air cleaner assembly. (Page 1D-82)
2) Remove ignition coil assemblies. (Page 1H-17)
3) Disconnect engine harness clamps and remove
engine harness protector (1).
1

IJCA0A142013-01
 Engine Mechanical: K12M 1D-87

4) Remove HO2S bracket (1). Installation

5) Remove oil level gauge (2). 1) Install PCV valve (1), if removed.
6) Disconnect PCV hose (3) from PCV valve.
7) Disconnect breather hose (4) from cylinder head
cover.

3 4

1
IJCA0A142014-01

2) Remove oil, old sealant and dust from sealing

2 surfaces on cylinder head and cover.
1
3) Install new gasket (2) to cylinder head cover (1).
4) Apply engine oil to inside surface of plug pipe seals
(3).

3 3 1
IFRA0A141024-01

8) Loosen cylinder head cover mounting bolts in

numerical order (“1” – “14”) evenly and gradually.

“3” “7” “10” “13” “12” “5”

2
“1” “2” IFRA0A141026-01

5) Apply sealant “A” to the mating surface as shown.

“A”: Sealant 99000–31250 (SUZUKI Bond
No.1207F)

“A”
“4” “6” “11” “14” “9” “8”
IFRA0A141025-01

9) Remove cylinder head cover with gasket.

10) Remove PCV valve (1), if necessary.

“A”
IFRA0A141027-01
1
IJCA0A142014-01 6) 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.
1D-88 Engine Mechanical: K12M

7) Tighten cylinder head cover bolts according to the 12) Install ignition coil assemblies. (Page 1H-17)
following procedure: 13) Connect engine harness clamps and install engine
a) Tighten cylinder head cover bolts to 3.0 Nm harness protector (1).
(0.31 kgf-m, 2.5 lbf-ft) in numerical order (“1” –
“14”) evenly and gradually.
b) Retighten them to 5.0 Nm (0.51 kgf-m, 4.0 lbf-ft)
in the same manner as in Step a).
c) Retighten them to 7.5 Nm (0.76 kgf-m, 5.5 lbf-ft)
in the same manner as in Step a).
Tightening torque
Cylinder head cover bolt* (a): 3.0 Nm → 5.0 1
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)

“12”, (a) “8”, (a) “5”, (a) “2”, (a) “3”, (a) “10”, (a) IJCA0A142013-01

14) Install air cleaner assembly. (Page 1D-82)

“14”, (a) “13”, (a)

“11”, (a) “9”, (a) “4”, (a) “1”, (a) “6”, (a) “7”, (a)
IFRA0A141028-01

8) Connect PCV hose (3) to PCV valve.

9) Connect breather hose (4) to cylinder head cover.
10) Install oil level gauge (2).
11) Install HO2S bracket (1).

3 4

IFRA0A141024-01
 Engine Mechanical: K12M 1D-89

Camshaft and Tappet Components

AENJCA0A1426012

OIL
3

OIL
7

OIL
8
5

1
6 (b)
5

9 9 5 9

9
OIL

OIL
(a) 9 4

9 5

OIL
8
9

(a) 2
IFRA0A141029-01

1. VVT actuator 5. Camshaft housing 9. Dowel pin

: Do not disassemble.
2. Exhaust camshaft timing sprocket
3. Intake camshaft
: Apply engine oil to sliding surface.
4. Exhaust camshaft
: Apply engine oil to sliding surface.
6. Camshaft housing bolt : 60 Nm (6.1 kgf-m, 44.5 lbf-ft)
: For tightening order, refer to “Camshaft and
Tappet Removal and Installation”: K12M (Page
1D-89).
7. Camshaft bearing : 5.0 Nm → 8.0 Nm → 11 Nm (0.51
: For applying engine oil, refer to “Camshaft and kgf-m → 0.82 kgf-m → 1.1 kgf-m,
Tappet Removal and Installation”: K12M (Page 4.0 lbf-ft → 6.0 lbf-ft → 8.5 lbf-ft)
1D-89).
8. Tappet
: Apply engine oil to sliding surface.

Camshaft and Tappet Removal and Installation a) Align marks (lines) (1) on VVT actuator
AENJCA0A1426013 (sprocket) and exhaust camshaft timing sprocket
with surface of cylinder head (2).
Removal
NOTE
NOTICE
When the lines are aligned with cylinder head
If engine oil contacts to compressor drive
surface as shown, each sprocket mark at the
belt and water pump / generator drive belt,
chain cover side points the top.
problems such as belt squeal could occur.
Do not allow engine oil to contact
compressor drive belt and water pump / 1 1
generator drive belt. If engine oil contacts
them, wash it off with water.

1) Hoist vehicle and remove right side splash cover.

2) Remove cylinder head cover. (Page 1D-86)
3) Turn crankshaft clockwise and position piston No.1
to TDC as follows.
2 2
I7V20A141006-01
1D-90 Engine Mechanical: K12M

b) Align notch (1) on crankshaft pulley with “0” (2) b) Tighten fixing bolt (2) by hand and push timing
indication on timing chain cover. chain tensioner at upper part of the pivot.
c) Turn crankshaft 20° (3) counterclockwise and
2 tighten the bolt by hand again.
d) Turn crankshaft 20° clockwise and tighten the
bolt more by hand.

1 1

IJCA0A142016-01

4) Remove timing chain cover plug (1) and gasket (2).

I7V20A141010-01

1 2
I7V20A141008-01

5) Release tension of timing chain by fixing timing chain

tensioner (1) as follows.

NOTICE
Tightening fixing bolt with wrench may
damage timing chain tensioner.
Tighten the bolt only by hand.

NOTE
IJCA0A142017-01
If this step to slacken timing chain is omitted,
reinstallation of the exhaust camshaft timing
sprocket will become difficult.

a) Prepare an M8 bolt of the following dimensions.

• Thread pitch: 1.25 mm (0.049 in.)
• Length “a”: 35 mm (1.4 in.) or longer

“a”

I7V20A141009-02
 Engine Mechanical: K12M 1D-91

6) Put matchmarks (2) on timing chain links aligned 9) Remove exhaust camshaft and intake camshaft.
with each sprocket mark (1).
NOTE
NOTE Because a guide to prevent coming off of
If colored chain links are aligned with timing timing chain from crankshaft timing sprocket
marks on intake sprocket and exhaust is provided at the lower part of oil pump,
sprocket respectively with success, it is not timing chain will not be disengaged from
necessary to put matchmarks. crankshaft timing sprocket even when
In this case, use the colored chain links as camshafts are removed.
matchmarks for installation.
10) Remove tappets, if necessary.
11) Remove VVT actuator from intake camshaft as
2 2 follows, if necessary.
a) Hold hexagonal section of camshaft using vice.
1
1 b) Remove VVT actuator bolt and remove VVT
actuator (1).

1
IJCA0A142018-01

7) With hexagonal section of exhaust camshaft held

stationary using spanner or adjustable wrench,
remove sprocket bolt and remove exhaust camshaft
timing sprocket (1).

NOTE
Do not turn camshaft after removing exhaust I9P60A141035-01
camshaft timing sprocket.
Installation
1) Install VVT actuator (1) to camshaft as follows, if
1
removed.
a) Hold hexagonal section of camshaft using vice.
b) Install VVT actuator and tighten VVT actuator
bolt to specified torque.
Tightening torque
VVT actuator bolt (a): 60 N·m (6.1 kgf-m, 44.5
lbf-ft)

I7V20A141013-01 (a)

8) Loosen camshaft housing bolts in numerical order

(“1” – “21”) evenly and gradually.

“2” “12” “13” “20” “21” “16” “17” “8” “9”

1

“5”

“3”

“4”

I9P60A141076-01
“1” “10” “11” “18” “19” “14” “15” “6” “7”

IFRA0A141033-01
1D-92 Engine Mechanical: K12M

2) Apply engine oil to contact surfaces of each tappet 7) Install camshaft housings (1) to proper places
(hatched area), if removed, and install tappets (1) to distinguished by letter (2), number (3) and arrow
cylinder head. direction (4) on each camshaft housing.

NOTE
Shapes and functions of No.1 and No.2
1
camshaft housings are different from No.3 –
5 camshaft housings. And, their positioning
is restricted by their shape.

1
2 3
I7V20A141016-01

3) Install camshaft bearings as follows.

a) Check mating surfaces of bearing backside and
4
corresponding cylinder head and camshaft
housing are clean and dry.
I8T401142038-01
b) Fit tab (1) of camshaft bearing half to groove (2)
of cylinder head and other half to camshaft 2. I: For intake camshaft
E: For exhaust camshaft
housing. 3. Position from timing chain side
c) Press bearing end (3) until it becomes flush with 4. Point arrow to timing chain side
cylinder head and other half with camshaft
housing mating surface. 8) Tighten camshaft housing bolts according to the
following procedure.
a) Tighten camshaft housing bolts to 5.0 Nm (0.51
kgf-m, 4.0 lbf-ft) in numerical order (“1” – “21”)
1 3 evenly and gradually.
b) In the same manner as in Step a), tighten them
to 8.0 Nm (0.82 kgf-m, 6.0 lbf-ft).
2
c) In the same manner as in Step b), tighten them
I7V20A141088-01
to 11 Nm (1.1 kgf-m, 8.5 lbf-ft).
4) Apply engine oil to bearing portions of cylinder head. Tightening torque
5) Set camshafts to cylinder head as follows. Camshaft housing bolt* (a): 5.0 Nm → 8.0
Nm → 11 Nm (0.51 kgf-m → 0.82 kgf-m → 1.1
a) Align matchmark (1) on VVT actuator with
kgf-m, 4.0 lbf-ft → 6.0 lbf-ft → 8.5 lbf-ft)
matchmark marked before removal (or colored
link) (2) on timing chain. “10”, (a) “2”, (a) “6”, (a) “14”, (a)
b) Put exhaust camshaft so that pin (3) is located “20”, (a) “9”, (a) “1”, (a) “5”, (a) “13”, (a)
as shown in figure.

2 “17”, (a)
1 “a”
“19”, (a)
3

“18”, (a)

“21”, (a) “11”, (a) “3”, (a) “7”, (a) “15”, (a)
“12”, (a) “4”, (a) “8”, (a) “16”, (a)
IFRA0A141035-01

IFRA0A141034-01

“a”: Approx. 11° from vertical line

c) Apply engine oil to sliding surfaces of camshafts.

6) Check that all dowel pins are fitted to cylinder head.
 Engine Mechanical: K12M 1D-93

9) Install exhaust camshaft timing sprocket to camshaft a) Measure length (L) of torque wrench (1).
as follows. b) Calculate reading value (M) of the torque wrench
a) Engage timing chain with exhaust camshaft using the following formula.
timing sprocket aligning its matchmark marked
before removal (or colored link) (2) with timing NOTE
mark (3) on the sprocket. If offset adapter other than the special tool is
b) With timing chain engaged, install exhaust used, measure the center distance
camshaft timing sprocket to exhaust camshaft corresponding to “a” and apply the
and tighten exhaust camshaft timing sprocket dimension to the formula.
bolt (1) temporarily.
Special tool
NOTE (A): 09911M05120
Slight turning the exhaust camshaft by a Formula for torque wrench reading value
wrench will facilitate fitting the sprocket. when using special tool
M = T x L ÷ (L + “a”)
M: Torque wrench reading value when using
2 special tool
3
T: Specified torque
L: Torque wrench length
“a”: Dimension of special tool (18 mm (0.71
in.))

1 (A) 1

L
IJHA0A140020-01
“a”
10) Tighten exhaust camshaft timing sprocket bolt to IBP70A140024-01

specified torque using special tool as follows. c) Tighten exhaust camshaft timing sprocket bolt
(1) until torque wrench reads the value obtained
NOTICE in the above Step b).
If the exhaust camshaft timing sprocket bolt
Tightening torque
is tightened using the special tool (offset
Exhaust camshaft timing sprocket bolt (a):
adapter) until the torque wrench reads the
60 N·m (6.1 kgf-m, 44.5 lbf-ft)
specified torque below, the bolt will be
tightened to a torque more than the specified
torque.
Follow the steps below to tighten the bolt to
specified torque using the special tool.

1, (a)

IFRA0A141036-01
1D-94 Engine Mechanical: K12M

11) Check that timing marks (1) on VVT actuator and b) Check that notch (1) on crankshaft pulley is
exhaust camshaft timing sprocket are aligned with aligned with “0” line (2) (TDC) on timing chain
matchmarks (2) marked before removal (or colored cover.
links) respectively.
2
2 2

1
1

IJCA0A142018-01

12) Remove fixing bolt from timing chain cover.

13) Install timing chain cover plug (1) with new gasket (2)
and tighten it to specified torque.
Tightening torque
Timing chain cover plug (a): 25 N·m (2.5 kgf-m,
18.5 lbf-ft)
IJCA0A142016-01
c) Turn crankshaft clockwise 720° and check again
that matchmarks are aligned.
NOTE
If crankshaft is turned only 360°, the timing
marks (lines) (1) on VVT actuator and exhaust
camshaft timing sprocket will not meet top
face of cylinder head (2) as shown in figure.

1 1

1,(a) 2
I7V20A141023-01
2 2
14) Check that timing chain is installed properly as
I7V20A141006-01
follows.
a) Check that VVT actuator and exhaust camshaft 15) Check valve clearance. (Page 1D-79)
timing sprocket marks (lines) (1) are aligned with
16) Install cylinder head cover. (Page 1D-86)
top face of cylinder head (2). If not, align exhaust
camshaft timing sprocket with timing chain again 17) Run engine and check for oil leakage.
repeating the installation from step 9). 18) Install right side splash cover.

NOTE
Check of exact alignment is necessary.

1 1

2 2
I7V20A141006-01
 Engine Mechanical: K12M 1D-95

VVT Actuator, Camshaft and Tappet Inspection Camshaft Runout

AENJCA0A1426014 Set camshaft between two “V” blocks and measure its
runout using a dial gauge.
VVT Actuator If measured runout exceeds limit, replace camshaft.
Fit VVT actuator to camshaft and hold hexagonal section
of camshaft using spanner or adjustable wrench. Camshaft runout
Check if VVT actuator (1) is not turned by hand. Limit: 0.015 mm (0.00059 in.)
If moved, replace VVT actuator.

I2RH0B140081-01

Camshaft Journal Wear

Check camshaft journals and camshaft housings for
pitting, scratches, wear or damage.
IAP70B140015-01
If any defect is found, replace camshaft or cylinder head
with housing. Replace cylinder head and housings as a
Signal Rotor set.
Check signal rotor (1) for crack and damage. If any
defect is found, replace camshaft.

I2RH0B140082-01

Check clearance using gauging plastic according to the

following procedure.
1) Clean housings and camshaft journals.
IFRA0A141084-01
2) Remove all tappets.
Cam Wear 3) Install camshafts to cylinder head.
Using a micrometer, measure cam height “a”. If 4) Place a piece of gauging plastic to full width of
measured height is below its limit, replace camshaft. camshaft journal parallel to camshaft.
Cam height “a” of camshaft 5) Without applying engine oil, install camshaft
Cam height Standard Limit housings referring to Step 1) – 8) in “installation”
45.421 – 45.581 mm 45.321 mm under “Camshaft and Tappet Removal and
Intake cam Installation”: K12M (Page 1D-89).
(1.7883 – 1.7945 in.) (1.7843 in.)
42.901 – 43.061 mm 42.801 mm
Exhaust cam
(1.6891 – 1.6953 in.) (1.6851 in.)

I2RH0B140080-01
1D-96 Engine Mechanical: K12M

6) Remove housings, and using scale (2) on gauging Camshaft bearing thickness
plastic envelope, measure gauging plastic (1) width 1.513 – 1.519 mm (0.0596 – 0.0598 in.)
at the widest point.
Camshaft journal clearance
Standard Limit
Intake side 0.031 – 0.087 mm 0.10 mm
No.1 housing (0.0013 – 0.0034 in.) (0.0039 in.)
Exhaust side 0.045 – 0.087 mm 0.10 mm
No.1 housing (0.0018 – 0.0034 in.) (0.0039 in.)
0.045 – 0.087 mm 0.10 mm
Others
(0.0018 – 0.0034 in.) (0.0039 in.)

I2RH0B140083-01
I2RH0B140084-01
If measured camshaft journal clearance exceeds
limit, measure camshaft journal diameter and 7) Install intake and exhaust camshafts without tappet,
camshaft journal housing bore diameter. Replace and then measure intake and exhaust camshaft
camshaft or cylinder head assembly whichever the housing thrust clearance using a dial gauge.
difference from specification is greater. If measured clearance exceeds limit, replace
camshaft and/or cylinder head with camshaft
Camshaft journal diameter [A] housings as assembly.
Item Standard
Camshaft housing thrust clearance
29.440 – 29.455 mm
Intake side No.1 housing Standard: 0.10 – 0.35 mm (0.0040 – 0.0137 in.)
(1.1591 – 1.1596 in.)
Limit: 0.50 mm (0.019 in.)
Exhaust side No.1 26.934 – 26.955 mm
housing (1.0604 – 1.0612 in.)
22.934 – 22.955 mm
Others
(0.9030 – 0.9037 in.)

Camshaft journal housing bore diameter [B]

Item Standard
32.500 – 32.515 mm
Intake side No.1 housing
(1.2796 – 1.2801 in.)
Exhaust side No.1 27.000 – 27.021 mm
housing (1.0630 – 1.0638 in.)
23.000 – 23.021 mm
Others I7V20A141074-01
(0.9056 – 0.9063 in.)

Wear of Tappet
Check tappet for pitting, scratches or damage.
If any defect is found, replace tappet.
I7V20A141075-01
Measure cylinder head bore and tappet outside diameter
to determine cylinder head-to-tappet clearance. If
clearance exceeds limit, replace tappet or cylinder head.
Cylinder head to tappet clearance
Standard: 0.025 – 0.062 mm (0.00099 – 0.00244 in.)
Limit: 0.10 mm (0.0039 in.)
Tappet outside diameter [A]
Standard: 27.959 – 27.975 mm (1.1008 – 1.1013 in.)
Cylinder head tappet bore [B]
Standard: 28.000 – 28.021 mm (1.1024 – 1.1031 in.)
I2RH0B140086-01
Crankshaft Front Oil Seal Replacement
AENJCA0A1426046
1) Hoist vehicle and remove right side splash cover.
2) Remove compressor drive belt. (Page 7B-51)
3) Remove water pump / generator drive belt. (Page
1J-26)
4) Remove crankshaft pulley referring to Step 4) – 5) in
“Removal” under “Timing Chain Cover Removal and
Installation”: K12M (Page 1D-105).
10) Install right side splash cover.
Engine Mechanical: K12M 1D-97
5) Using a flat-bladed screwdriver or the like wrapped
with protective tape, remove crankshaft front oil seal
(1) slowly.
NOTICE
• If tip of screwdriver scratches timing chain
cover, it may cause oil leakage.
Carefully remove oil seal not to damage
timing chain cover.
• If crankshaft edge is dented, it may disturb
smooth installation of crankshaft pulley.
Carefully remove oil seal not to damage
crankshaft edge.
1
IJCA0A142019-01
6) Using special tool and hammer, install new
crankshaft front oil seal (1) into timing chain cover.
Special tool
(A): 09913M70123
Depth
“a”: 1.15 – 1.35 mm (0.0453 – 0.0531 in.)
1 “a”
(A)
IJCA0A142020-01
7) Install crankshaft pulley referring to Step 19) – 21) in
“Installation” under “Timing Chain Cover Removal
and Installation”: K12M (Page 1D-105).
8) Install water pump / generator drive belt. (Page 1J-
26)
9) Install compressor drive belt. (Page 7B-51)
1D-98 Engine Mechanical: K12M

Crankshaft Rear Oil Seal Replacement

AENJCA0A1426047
1) Drain engine oil. (Page 1E-19)
2) Dismount transaxle assembly.
• M/T model: (Page 5B-54)
• Auto gear shift model: (Page 5D-117)
3) Remove clutch cover and clutch disc.
• M/T model: (Page 5C-9)
• Auto gear shift model: (Page 5D-145)
4) Remove flywheel. (Page 1D-108)
5) Remove oil pan. (Page 1E-23)
6) Remove oil seal housing and crankshaft rear oil seal
referring to Step 6) – 7) in “Removal” under “Main
Bearing, Crankshaft and Cylinder Block Removal
and Installation”: K12M (Page 1D-136).
7) Check smoothness of crankshaft flange and apply
engine oil to the sealing surface.
8) Install new crankshaft rear oil seal and oil seal
housing referring to Step 12) – 17) in “Installation”
under “Main Bearing, Crankshaft and Cylinder Block
Removal and Installation”: K12M (Page 1D-136).
9) Install oil pan. (Page 1E-23)
10) Install flywheel. (Page 1D-108)
11) Install clutch cover and clutch disc.
• M/T model: (Page 5C-9)
• Auto gear shift model: (Page 5D-145)
12) Remount transaxle assembly.
• M/T model: (Page 5B-54)
• Auto gear shift model: (Page 5D-117)
13) Refill engine with engine oil. (Page 1E-19)
 Engine Mechanical: K12M 1D-99

Engine Mounting Components

AENJCA0A1426015

(b) (b)

(a)
(b)
2
(b)

1 (b)

(b)

(b)

(c)

(d)

(e)
IJCA0A142021-01

1. Engine right mounting : 65 Nm (6.6 kgf-m, 48.0 lbf-ft) : 93 Nm (9.5 kgf-m, 68.5 lbf-ft)
2. Engine left mounting : 55 Nm (5.6 kgf-m, 40.5 lbf-ft) : Do not reuse.
3. Engine rear torque rod bracket : 60 Nm (6.1 kgf-m, 44.5 lbf-ft)
4. Engine rear torque rod : 85 Nm (8.7 kgf-m, 63.0 lbf-ft)
1D-100 Engine Mechanical: K12M

Engine Assembly Removal and Installation

AENJCA0A1426016
1
Removal
1) Relieve fuel pressure. (Page 1G-19) “2”
“1”
2) Disconnect steering lower shaft from pinion shaft.
(Page 6B-12)
3) Remove battery and battery tray. (Page 1J-24)
4) Disconnect ECM connectors. (Page 1C-22)
5) Hoist vehicle and remove splash covers.
6) Drain the following oils, if necessary.
• Engine oil: (Page 1E-19)
• Manual transaxle oil (M/T model): (Page 5B-49)
• Auto gear shift transaxle oil (auto gear shift
model): (Page 5D-99)
7) Drain coolant. (Page 1F-27)
8) Remove air cleaner assembly. (Page 1D-82) IJCA0A142024-01

9) Disconnect the following connectors and cable 11) For M/T model, disconnect the following cables.
including the related clamps. • Gear shift and select control cables: (Page 5B-
• Connectors (1) in main fuse box 52)
• Connector (2) in individual circuit fuse box No.1 • Clutch cable: (Page 5C-5)
• Battery ground cable (3) 12) Disconnect the following hoses.
• Vacuum pipe intake hose (1)
2
• Heater inlet hose (2)
• Heater outlet hose (3)
• Fuel feed hose (4)
• EVAP canister purge hose (5)
• Radiator inlet hose (6)
• Radiator outlet hose (7)

4
2 1 3 5

1 3

IJCA0A142022-02

10) For auto gear shift model, disconnect junction IJCA0A142025-01

connector (1) in numerical order (“1” – “2”) as shown
in figure.

7 6

IJCA0A142026-01
 Engine Mechanical: K12M 1D-101

13) With hoses connected, detach A/C compressor from 21) Remove engine left mounting bolts (1) and nut (2).
cylinder block. (Page 7B-52)

NOTICE
When A/C compressor is detached, the A/C
hoses could be damaged receiving weight of
the compressor.
Suspend the removed A/C compressor to the
vehicle body while the compressor is 1

detached. 2

14) Disconnect tie-rod end from steering knuckle at each

of right and left sides. (Page 6B-15)
15) Disconnect suspension arm joint from steering
knuckle at each of right and left sides. (Page 2B-
IJCA0A142029-01
10)
22) Before removing engine, check that all hoses,
16) Disconnect right and left drive shaft joints from
electric wires and cables are disconnected from
steering knuckle. (Page 3A-3)
engine.
17) Remove exhaust pipe and muffler. (Page 1K-10)
23) Lower engine assembly with transaxle, front
18) Support front suspension frame (1), transaxle case suspension frame, drive shafts, steering gear case
(2) and oil pan (3) using jack. all together.
19) Remove front suspension frame bolts (4).
NOTICE
The A/C compressor may be damaged if it
hits against or interferes with other parts.
2
Suspend the removed A/C compressor in a
3 place where no damage will be caused during
1 removal of the engine assembly.

24) Install a shackle (1) or the like to timing chain cover,

and then lift engine with transaxle and suspension
frame as a set using the shackle or the like and hook
4 (2) of transaxle, if necessary.

IJCA0A142027-01
1

20) Remove engine right mounting bolt (1) and nuts (2).

IFRA0A141045-01

[A] [B]
2

2 2
IJCA0A142028-01
IJCA0A142030-01

[A]: M/T model [B]: Auto gear shift model

1D-102 Engine Mechanical: K12M

25) Remove front suspension frame, if necessary. Installation

(Page 2B-15) 1) Install the following components to engine, if
26) Remove front drive shaft assemblies, if necessary. removed.
(Page 3A-3) • Flywheel: (Page 1D-108)
27) If necessary, install special tool (engine hook) onto • Clutch disc and cover
stud bolts of exhaust manifold with nuts (08316-
– M/T model: (Page 5C-9)
1010A) (2), and then lift engine using a shackle (1)
or the like as shown in figure. – Auto gear shift model: (Page 5D-145)
• Transaxle
Special tool
(A): 09910M66820 – M/T model: (Page 5B-54)
– Auto gear shift model: (Page 5D-117)
• Engine harness
2) Set engine harness ground cable to its original
position and tighten engine harness ground bolt (1)
1 to specified torque, if removed.
Tightening torque
Engine harness ground bolt (a): 11 N·m (1.1 kgf-
m, 8.5 lbf-ft)

“a” “a”
IFRA0A141045-01

(A)

1, (a)

IJCA0A142031-01

2 “a”: 22.5 °

IFRA0A141047-01
3) Install front drive shaft assemblies, if removed.
28) Remove the following components from engine (Page 3A-3)
assembly, if necessary.
4) Install front suspension frame, if removed. (Page
• Engine harness 2B-15)
• Transaxle 5) Lift up engine assembly with transaxle, front
– M/T model: (Page 5B-54) suspension frame, drive shafts and steering gear
– Auto gear shift model: (Page 5D-117) case all together.
• Clutch cover and disc NOTICE
– M/T model: (Page 5C-9) The A/C compressor may be damaged if it
– Auto gear shift model: (Page 5D-145) hits against or interferes with other parts.
• Flywheel: (Page 1D-108) Suspend the removed A/C compressor in a
place where no damage will be caused during
installation of the engine assembly.
 Engine Mechanical: K12M 1D-103

6) Tighten engine left mounting nut (1) and bolts (2) to 15) Install A/C compressor to cylinder block. (Page
specified torque. 7B-52)
Tightening torque 16) Check that removed parts are back in place.
Engine left mounting nut (a): 55 N·m (5.6 kgf-m, Reinstall any necessary parts which have not been
40.5 lbf-ft) reinstalled.
Engine left mounting bolt (b): 55 N·m (5.6 kgf- 17) Refill engine and transaxle with oil, if drained.
m, 40.5 lbf-ft) • Engine oil: (Page 1E-19)
• Manual transaxle oil (M/T model): (Page 5B-49)
• Auto gear shift transaxle oil (auto gear shift
model): (Page 5D-99)
18) Install air cleaner assembly. (Page 1D-82)
19) Refill cooling system with coolant. (Page 1F-27)
20) Install battery and bracket. (Page 1J-24)
2, (b)
21) Connect steering lower shaft to pinion shaft. (Page
1, (a)
6B-12)
22) Check for leakage of fuel, coolant, oil and exhaust
gas.
• Fuel leakage: (Page 1G-20)
• Coolant leakage: (Page 1F-26)
IJCA0A142032-01

7) Tighten engine right mounting nuts (1) and bolt (2) to 23) Install splash covers.
specified torque.
Tightening torque
Engine right mounting nut (a): 65 N·m (6.6 kgf-
m, 48.0 lbf-ft)
Engine right mounting bolt (b): 65 N·m (6.6 kgf-
m, 48.0 lbf-ft)

1, (a)

2, (b)

IJCA0A142033-01

8) Tighten front suspension frame bolts to specified

torque. (Page 2B-14)
9) Remove jack.
10) Install exhaust pipe and muffler. (Page 1K-10)
11) Connect right and left drive shaft joints to steering
knuckle. (Page 3A-3)
12) Connect suspension arm joint to steering knuckle at
each of right and left sides. (Page 2B-10)
13) Connect tie-rod end to steering knuckle at each of
right and left sides. (Page 6B-15)
14) Install all other removed electric wires, connectors
and hoses to original positions.
1D-104 Engine Mechanical: K12M

Timing Chain Cover Components

AENJCA0A1426017

OIL
5

6
(c)

8 (b)

OIL
4

12
9 (b)

OIL
13
1 1217G

12
OIL

10 (b)

11 (a)
IJCA0A142034-03

1. Timing chain cover 7. Timing chain cover plug gasket 13. O-ring
: Apply sealant 99000-31260. : Apply engine oil.
: For details, refer to “Timing Chain Cover
Removal and Installation”: K12M (Page 1D-
105).
2. Crankshaft pulley 8. Timing chain cover plug : 19 Nm → +75° (1.9 kgf-m → +75°,
14.0 lbf-ft → +75°)
3. Crankshaft front oil seal 9. Timing chain cover bolt No.1 : 25 Nm (2.5 kgf-m, 18.5 lbf-ft)
: Apply engine oil to oil seal lip. : For tightening order, refer to “Timing Chain
Cover Removal and Installation”: K12M
(Page 1D-105).
4. OCV 10. Timing chain cover bolt No.2 : 11 Nm (1.1 kgf-m, 8.5 lbf-ft)
: Apply engine oil to O-ring. : For tightening order, refer to “Timing Chain
Cover Removal and Installation”: K12M
(Page 1D-105).
5. Gasket 11. Crankshaft pulley bolt : Do not reuse.
: Apply engine oil.
6. Filter 12. Dowel pin
 Engine Mechanical: K12M 1D-105

Timing Chain Cover Removal and Installation 11) Remove O-ring (1) and gasket (2).
AENJCA0A1426018
12) Remove filters (3) from timing chain cover, if
Removal necessary.
1) Remove engine assembly from vehicle. (Page 1D- 3
2
100)
2) Remove water pump / generator drive belt. (Page
1J-26)
3) Remove belt tensioner arm. (Page 1J-27)
4) Remove crankshaft pulley bolt (1).
To lock crankshaft pulley (2), use special tool as
shown in figure.
Special tool
(A): 09917M68222
1

IFRA0A141054-01
2
(A) 13) Remove OCV from timing chain cover. (Page 1D-
108)
14) Remove oil pump from timing chain cover. (Page
1E-26)

Installation
1) Remove oil, old sealant and dust.
1
IFRA0A141052-01 2) Install oil pump to timing chain cover. (Page 1E-
5) Remove crankshaft pulley (1). 26)
If it is hard to remove, use special tools. 3) Install new crankshaft front oil seal referring to Step
Special tool 6) under “Crankshaft Front Oil Seal Replacement”:
(A): 09926M58010 K12M (Page 1D-97).
(B): 09913M66710 4) Install OCV to timing chain cover. (Page 1D-108)
5) Check cleanliness of filters (3) and install it to timing
chain cover, if removed.
6) Apply engine oil to new gasket (2) and install it to
timing chain cover.
7) Apply engine oil to new O-ring (1) and install it to oil
pump.

3
2

(A)
(B)

1
IJHA0A140040-01

6) Remove cylinder head cover. (Page 1D-86)

7) Remove oil pan. (Page 1E-23) 1
8) Remove water pump pulley. (Page 1F-33)
9) Remove timing chain cover.
10) Remove crankshaft front oil seal referring to Step 5)
IFRA0A141054-01
under “Crankshaft Front Oil Seal Replacement”:
8) Check that dowel pins are installed to cylinder block.
K12M (Page 1D-97), if necessary.
1D-106 Engine Mechanical: K12M

9) Clean mating surface of timing chain cover, cylinder 13) Tighten timing chain cover bolts No.1 and No.2 in
block and cylinder head. numerical order (“1” – “15”) evenly and gradually to
10) Clean mating portions (1) of cylinder block and specified torque.
cylinder head with cleaning solvent particularly. Tightening torque
11) Apply sealant “A” to mating surface of cylinder, Timing chain cover bolt No.1* (a): 25 N·m (2.5
cylinder head and timing chain cover as shown in kgf-m, 18.5 lbf-ft)
figure. Timing chain cover bolt No.2* (b): 25 N·m (2.5
kgf-m, 18.5 lbf-ft)
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G) “1”, (a)
“10”, (b) “8”, (b)
Sealant bead size for timing chain cover
Width “a”: 3 mm (0.12 in.) “6”, (a)
Height “b”: 2 mm (0.08 in.)
“4”, (b) “3”, (b)

“2”, (b)
“5”, (b)
“9”, (b)

“11”, (b) “7”, (b)

1, “A” 1, “A”
“12”, (b)
“A” “A” “13”, (b)

“15”, (b)
“14”, (b)
IFRA0A141058-01

“a” 14) Wipe off excessive sealant squeezed out from timing
“A” “b” chain cover at the lower end.
IJCA0A142035-01 15) Install water pump pulley. (Page 1F-33)
12) Install timing chain cover noting the following points. 16) Install cylinder head cover. (Page 1D-86)
• Apply engine oil to oil seal lip. 17) Install oil pan. (Page 1E-23)
• Align straight lines (1) of oil pump inner rotor with 18) Clean crankshaft pulley and apply engine oil to
straight lines (2) of crankshaft sprocket. sealing surface (1).
• Install timing chain cover within 2 minutes after
applying sealant.
• Check O-ring and gasket for proper fit.
• Use care so that oil seal lip is not damaged and oil
seal spring is not coming off.

IJHB0A141009-01

2 1
IFRA0A141057-01
 Engine Mechanical: K12M 1D-107

19) Insert crankshaft pulley (1) aligning key groove (2) a) Tighten crankshaft pulley bolt to 19 Nm (1.9 kgf-
with key (3) on crankshaft. m, 14.0 lbf-ft).
b) Retighten the bolt 75°.
NOTICE
Turning over of oil seal lip or coming off of Tightening torque
the inside spring will cause oil leakage. Crankshaft pulley bolt* (a): 19 Nm → +75°
While inserting crankshaft pulley, pay (1.9 kgf-m → +75°, 14.0 lbf-ft → +75°)
attention not to damage oil seal lip nor
disengage the inside spring.

1
(A)

2 3
1

2, (a)
IFRA0A141059-01

21) Install belt tensioner arm. (Page 1J-27)

22) Install water pump / generator drive belt. (Page 1J-
26)
IJCA0A142036-01
23) Install engine assembly to vehicle. (Page 1D-100)
20) Hold crankshaft pulley (1) with special tool and
tighten new crankshaft pulley bolt (2) according to
the following procedure.
Timing Chain Cover Inspection
AENJCA0A1426019

NOTICE
Oil Seal
The crankshaft pulley bolt is pre-coated with Check oil seal lip for fault or other damage. Replace it if
friction stabilizer. If the bolt is reused, it may necessary.
work loose.
Never reuse the crankshaft pulley bolt. Timing Chain Cover
Check oil passages for VVT actuator and filters (1).
NOTE Clean oil passages and filters if clogging or foreign
For accurate angle tightening of the bolt, use material exists.
tightening angle gauge available in the
market.

IFRA0A141060-01

IJHA0A140061-01

Special tool
(A): 09917M68222
1D-108 Engine Mechanical: K12M

OCV Removal and Installation Flywheel Removal and Installation

AENJCA0A1426020 AENJCA0A1426021
Removal
Removal 1) Remove clutch cover and clutch disc.
1) Disconnect OCV connector from OCV. • M/T model: (Page 5C-9)
2) Remove OCV (1). • Auto gear shift model: (Page 5D-145)
2) Install special tool to ring gear teeth to lock flywheel
as shown in figure.
Special tool
(A): 09924M17811

IJCA0A142037-01

Installation
Reverse removal procedure noting the following points.
• Apply engine oil to O-ring and carefully insert OCV to I8C50A140045-01
timing chain cover. 3) Remove flywheel from crankshaft.
• Tighten OCV bolt (1) to specified toque. 4) Remove input shaft bearing (1) from flywheel, if
Tightening torque necessary, using special tool as shown in figure.
OCV bolt (a): 11 N·m (1.1 kgf-m, 8.5 lbf-ft) Special tool
(A): 09921M20210
(B): 09930M30104

(B)
1, (a)

(A)

1
IJCA0A142038-01

IHL10A141086-01
 Engine Mechanical: K12M 1D-109

Installation Flywheel Inspection

Reverse removal procedure noting the following points. AENJCA0A1426022
Refer to “Clutch Cover and Clutch Disc Removal and
• Press-fit new input shaft bearing (1) using special tool Installation” in Section 5C (Page 5C-9).
and hydraulic press (2), if removed. Refer to “Clutch Cover and Clutch Disc Removal and
Special tool Installation” in Section 5D (Page 5D-145).
(A): 09913M75821
Visual Inspection
Depth
“a”: 0 – 0.5 mm (0 – 0.019 in.) • If ring gear is damaged, cracked or worn, replace
flywheel.
• If the surface contacting clutch disc is damaged or
1 2
“a” excessively worn, replace flywheel.
• If input shaft bearing is damaged or does not rotate
(A) smoothly, replace input shaft bearing.

Flywheel Face Runout

Check flywheel face runout with a dial gauge.
1
If runout exceeds its limit, replace flywheel.
Flywheel face runout
Limit: 0.2 mm (0.0078 in.)

IGSB0A141019-01

• Install flywheel as follows.

a. Install flywheel to crankshaft.
b. Install new flywheel bolts temporarily.

NOTICE
The flywheel bolts are pre-coated with
adhesive. If these bolts are reused, they may
work loose.
Replace the flywheel bolts with new ones
whenever they are removed.

c. Install special tool to lock flywheel as shown in

figure. IBP70A140027-01

Special tool
(A): 09924M17811
d. Tighten flywheel bolts to specified torque.
Tightening torque
Flywheel bolt (a): 83 N·m (8.5 kgf-m, 61.5 lbf-
ft)

I8C50A140046-01
1D-110 Engine Mechanical: K12M

Timing Chain and Chain Tensioner Components

AENJCA0A1426023

OIL
2

OIL
4

(a)

5 (b)

OIL
3

(b)

(b)
IGSB0A143035-01

1. Crankshaft timing sprocket 4. Timing chain tensioner : 11 Nm (1.1 kgf-m, 8.5 lbf-ft)
: Apply engine oil to sliding surface.
2. Timing chain 5. Timing chain tensioner adjuster
: Apply engine oil. : For installation, refer to “Timing Chain and Chain
Tensioner Removal and Installation”: K12M (Page
1D-111).
3. Timing chain guide : 25 Nm (2.5 kgf-m, 18.5 lbf-ft)
: Apply engine oil to sliding surface.
 Engine Mechanical: K12M 1D-111

Timing Chain and Chain Tensioner Removal NOTE

and Installation If it is necessary to rotate the camshaft with
AENJCA0A1426024
the timing chain removed, rotate the
Removal camshaft after turning crankshaft
counterclockwise 30 – 90° as shown in figure.
NOTICE
After the timing chain has been removed,
independently turning the camshaft or
crankshaft beyond the allowable angle “a”
ranges shown in figure will cause
interference between pistons and valves or “b”
between the valves themselves, which will
cause damage to these parts and/or related
parts. 1
I7V20A141058-01
Avoid turning each of the camshaft or
crankshaft alone beyond the angle ranges “a”: 30° 1. Camshaft sprocket key
shown in figure. “b”: 90°

1 1) Remove timing chain cover. (Page 1D-105)

2) By turning crankshaft, align camshafts and
“b”
crankshaft at specific position as follows.
“b” a) Align timing mark (1) on VVT actuator with
surface of cylinder head (2).
b) Align timing mark (3) on exhaust camshaft timing
“b” “b”
2 sprocket with matchmark (4) on cylinder head.
c) Check crankshaft sprocket key (5) is aligned with
3
matchmark (6) on cylinder block.
3) Remove timing chain tensioner adjuster (7).
5 4) Remove timing chain tensioner (8).
5) Remove timing chain guide (9).
6) Remove timing chain (10), crankshaft timing
4 sprocket (11) and crankshaft sprocket key.
“a” “a”

2
1 10

IAP70B140027-01

“a”: 90° 3. Matchmark on cylinder head

“b”: 15° 4. Crankshaft sprocket key
1. Timing mark on VVT actuator 5. Matchmark on cylinder block
2. Timing mark on exhaust 8
camshaft timing sprocket 4

7 5

11
IGSB0A143036-01
1D-112 Engine Mechanical: K12M

Installation 7) With timing chain engaged, install crankshaft timing

1) Position crankshaft sprocket key (1) within a 30° – sprocket to crankshaft aligning the keyway with
90° range (2) counterclockwise from matchmark (3) crankshaft key.
on cylinder block.
1 1
2) Align timing mark (4) on VVT actuator with surface of
cylinder head (5).
3) Align timing mark (6) on exhaust camshaft timing 2
2
sprocket with matchmark (7) on cylinder head.

NOTE
Camshaft may rotate a little pushed by valve
springs and does not remain in the aligned
position. Hold the camshaft in the position
using a wrench carefully.

4 5

4
6

3
7
IFRA0A141066-01

8) Apply engine oil to sliding surface of timing chain

guide (1) and timing chain tensioner (2).
3 9) Tighten timing chain guide bolts (3) to specified
2
torque.
1 Tightening torque
Timing chain guide bolt (a): 11 N·m (1.1 kgf-m,
8.5 lbf-ft)
10) Tighten timing chain tensioner bolt (4) to specified
torque.
IFRA0A141065-01 Tightening torque
4) Set timing chain while aligning two colored marks (1) Timing chain tensioner bolt (b): 25 N·m (2.5 kgf-
of timing chain with timing marks (2) on VVT actuator m, 18.5 lbf-ft)
and exhaust camshaft timing sprocket.
5) Set crankshaft sprocket key and align it with
matchmark on cylinder block by turning crankshaft.
6) Engage timing chain with crankshaft timing sprocket 4, (b) 3, (a)
aligning its colored link (3) with groove (4) of the
sprocket.
1

2 3, (a)

IFRA0A141067-01
 Engine Mechanical: K12M 1D-113

11) Check that all colored links (1) of timing chain are c) Install timing chain tensioner adjuster (1) with the
aligned with timing marks (2) on VVT actuator and retainer (2) inserted.
exhaust camshaft timing sprocket, and groove (3) of Tighten timing chain tensioner adjuster bolts (3)
timing sprocket. to specified torque and remove the retainer.

1 1
Tightening torque
Timing chain tensioner adjuster bolt (a): 11
N·m (1.1 kgf-m, 8.5 lbf-ft)

2 2
1

3,(a)

2
IELA0A142071-02

13) Apply engine oil to timing chain, and then turn

3
1
IFRA0A141068-01
12) Install timing chain tensioner adjuster (1) as follows.
a) Release lock cam moving link plate (2) in arrow
direction and push in plunger (3) fully.
b) Insert a retainer (1.0 – 1.2 mm (0.039 – 0.047 in.)
diameter wire or the like) to hole (4) and hold
plunger in place.
crankshaft clockwise 720°, and check that the
following conditions are satisfied:
• Timing mark (1) on VVT actuator is aligned with
surface of cylinder head (2).
• Timing mark (3) on exhaust camshaft timing
sprocket is aligned with matchmark (4) on cylinder
head.
• Crankshaft sprocket key (5) is aligned with
matchmark (6) on cylinder block.
2
1
3

1
3

4
IJAA0A142003-01

IGSB0A143037-01

14) Install timing chain cover and crankshaft pulley.

(Page 1D-105)
1D-114 Engine Mechanical: K12M

Timing Chain and Chain Tensioner Inspection Crankshaft Timing Sprocket

AENJCA0A1426025 Check teeth of sprocket for wear or damage.
If abnormality is found, replace crankshaft timing
Timing Chain Guide
sprocket.
Check sliding surface of timing chain guide (1) for wear
or damage.
If abnormality is found, replace timing chain guide.

1
I2RH0B140070-01

Timing Chain
I7V20A141066-01
Check timing chain for wear or damage.
Timing Chain Tensioner If abnormality is found, replace timing chain.
Check sliding surface of timing chain tensioner (1) for
wear or damage.
If abnormality is found, replace timing chain tensioner.

I2RH01140077-01

Timing Chain Tensioner Adjuster

Check that teeth (1) is free from damage.
If abnormality is found, replace timing chain tensioner
adjuster.

I7V20A141067-01
1

IELA0A142075-02
 Engine Mechanical: K12M 1D-115

Valve and Cylinder Head Components

AENJCA0A1426026

OIL
9 (a)

OIL
8

10

1
1

3
2

3 2 13 (b)

5
OIL

4 12 11
OIL

4
OIL

6
OIL

7
12

IJCA0A142039-02

1. Valve cotter 9. Cylinder head bolt

: Check cylinder head bolt for deformation to reusing. (Page 1D-124)
: Apply engine oil to bolt thread.
: For tightening order, refer to “Valve and Cylinder Head Removal and Installation”: K12M
(Page 1D-116).
2. Valve spring retainer 10. Cylinder head
3. Valve spring 11. Cylinder head gasket
: For installation, refer to “Valve and
Cylinder Head Disassembly and
Reassembly”: K12M (Page 1D-117).
4. Valve stem seal 12. Dowel pin
: Apply engine oil to valve stem seal lip.
5. Valve spring seat 13. Venturi plug
6. Intake valve : 20 Nm → 40 Nm → +60° → +60° (2.0 kgf-m → 4.1 kgf-m → +60° → +60°, 15.0 lbf-ft → 29.5
: Apply engine oil to sliding surface. lbf-ft → +60° → +60°)
7. Exhaust valve : 3.5 Nm (0.36 kgf-m, 2.5 lbf-ft)
: Apply engine oil to sliding surface.
8. Valve guide : Do not reuse.
: Apply engine oil to sliding surface.
1D-116 Engine Mechanical: K12M

Valve and Cylinder Head Removal and 16) Remove the following components from cylinder
Installation head, if necessary.
AENJCA0A1426027
• Fuel injector: (Page 1G-22)
Removal • CMP sensor: (Page 1C-30)
1) Remove engine assembly from vehicle. (Page 1D- • Thermostat case: (Page 1F-25)
100) • EVAP canister purge valve: (Page 1B-11)
2) Remove intake manifold. (Page 1D-85)
Installation
3) Remove exhaust manifold. (Page 1K-9)
1) Clean mating surfaces of cylinder head and cylinder
4) Remove water inlet pipe. (Page 1F-28)
block. Remove oil, old gasket and dust from mating
5) Remove oil pan. (Page 1E-23) surfaces.
6) Remove cylinder head cover. (Page 1D-86) 2) Install dowel pins (1) to cylinder block, if removed.
7) Remove timing chain cover. (Page 1D-105) 3) Set new cylinder head gasket (2) to cylinder block.
8) Remove timing chain. (Page 1D-111)
9) Remove spark plugs. (Page 1H-17)
2
1
10) Remove intake camshaft, exhaust camshaft,
camshaft bearings and tappets. (Page 1D-89).
11) Remove cylinder head bolts in numerical order (“1” –
1
“10”) evenly and gradually.

“5” “10” “8” “2”

1

“3”

IFRA0A141071-01

4) Install cylinder head to cylinder block according to

the following procedure.
“1”
NOTE

“7” “9” “6” “4” • Before installing the cylinder head to the
I9P60A141002-01 cylinder block, turn crankshaft
12) Check all around cylinder head for any other parts counterclockwise and position the
required to be removed or disconnected and remove crankshaft sprocket key (1) within an angle
or disconnect them if any. of 30° – 90° from TDC as shown in figure
13) Remove cylinder head (1) from cylinder block. and keep the valves from coming in
contact with the piston.
14) Remove dowel pins (2) from cylinder block, if
necessary.
15) Remove cylinder head gasket (3) from cylinder
block. “a”

“b”

1
I7V20A141058-01

“a”: 30° “b”: 90°

1

2
3

2
IFRA0A141070-01
 Engine Mechanical: K12M 1D-117

• If cylinder head bolt is reused, check bolt
for deformation. (Page 1D-124)
• For accurate angle tightening of the bolt,
use tightening angle gauge available in the
market.
14) Install oil pan. (Page 1E-23)
15) Install cooling water pipe. (Page 1F-25)
16) Install exhaust manifold. (Page 1K-9)
17) Install intake manifold. (Page 1D-85)
18) Install engine assembly to vehicle. (Page 1D-100)

Valve and Cylinder Head Disassembly and

Reassembly
AENJCA0A1426028

Disassembly
1) Remove venturi plug (1).

IJHA0A140061-01

a) Apply engine oil to thread for 4 mm (0.16 in.)

from lower end of cylinder head bolts.
b) Tighten cylinder head bolts to 20 Nm (2.0 kgf-m,
15.0 lbf-ft) in numerical order (“1” – “10”) as
shown.
c) In the same manner as in Step b), tighten them
to 40 Nm (4.1 kgf-m, 29.5 lbf-ft).
1
d) Retighten all cylinder head bolts 60° in numerical
order as shown in figure. I9P60A141070-01

e) Retighten all cylinder head bolts 60° again in 2) Place disassembled parts except valve stem seal
numerical order as shown in figure. and valve guide in order so that they can be installed
in their original positions.
Tightening torque
Cylinder head bolt* (a): 20 Nm → 40 Nm →
+60° → +60° (2.0 kgf-m → 4.1 kgf-m → +60° →
+60°, 15.0 lbf-ft → 29.5 lbf-ft → +60° → +60°)

“8”,(a) “6”,(a) “1”,(a) “3”,(a) “9”,(a)

“10”,(a) “4”,(a) “2”,(a) “5”,(a) “7”,(a)

I9P60A141005-02

5) Install EVAP canister purge valve, if removed.

(Page 1B-11)
6) Install thermostat case, if removed. (Page 1F-25)
7) Install CMP sensor, if removed. (Page 1C-30)
8) Install fuel injector, if removed. (Page 1G-22)
9) Install camshafts and tappets. (Page 1D-89)
10) Install spark plugs. (Page 1H-17)
11) Install timing chain. (Page 1D-111)
12) Install timing chain cover. (Page 1D-105)
13) Install cylinder head cover. (Page 1D-86)
1D-118 Engine Mechanical: K12M

3) Using special tools (A) and (B), compress valve 7) Using special tool (A), remove valve guide from
spring and then remove valve cotters (1) also using combustion chamber side to valve spring side.
special tool (C).
Special tool
Special tool (A): 09916M44310
(A): 09916M14510
(B): 09916M14522
(C): 09916M84511

I2RH0B140095-01

Reassembly

NOTICE
The engine could be damaged if shavings
remain inside the valve guide hole after
reaming it.
Thoroughly remove shavings from the
reamed hole.

1) Before installing valve guide into cylinder head, ream

guide hole with special tool to remove burrs and
make the hole truly round.
Special tool
I2RH0B140093-01
(A): 09916M34542
(B): 09916M37320
4) Release special tools, and remove spring retainer
and valve spring.
5) Remove valve to combustion chamber side.
6) Remove valve stem seal (1) and valve spring seat
(2).

I2RH0B140096-01

I2RH0B140094-01
 Engine Mechanical: K12M 1D-119

2) Using special tools, install new valve guide to
cylinder head as follows.
Special tool
(A): 09916M58210
(B): 09916M56011
a) Uniformly heat cylinder head to a temperature of
80 to 100 °C (176 to 212 °F) so that it will not be
distorted, and drive new valve guide into its hole
with special tools.
b) Install new valve guide until special tool (B)
contacts cylinder head.
After installation, check that valve guide
protrudes from cylinder head by specified
dimension “a”.
5) After applying engine oil to valve stem seal (1) and
spindle of special tool (B), fit valve stem seal to
spindle, and then install valve stem seal to valve
guide by pushing special tool by hand.
After installation, check that valve stem seal is
properly fixed to valve guide.
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 get down past the
seal.
Push the special tool only by hand to force
the valve stem seal into position.

Valve guide protrusion (In and Ex) Special tool

“a”: 11.0 – 11.5 mm (0.434 – 0.452 in.) (A): 09917M98221
(B): 09916M57330

I2RH0B140097-01

3) Ream valve guide bore with special tools.

After reaming, clean bore.
I2RH0B140098-01
Special tool
(A): 09916M34542 6) Apply engine oil to valve stem seal lip and valve
(B): 09916M34570 stem.
7) Install valve to valve guide.
8) Install valve spring and spring retainer.
Each valve spring has top end (large-pitch end (1))
and bottom end (small-pitch end (2)). Position spring
in place with its bottom end (small-pitch end) facing
the bottom (valve spring seat side).

[a] 3

I2RH0B140096-01
2
4) Install valve spring seat to cylinder head.
[b]
IDAA0A141035-01

[a]: Valve spring retainer side 3. Paint mark

[b]: Valve spring seat side
1D-120 Engine Mechanical: K12M

9) Use special tools to compress valve spring and fit

two valve cotters (1) into groove in valve stem.

NOTICE
Insufficient seating of valve cotters between
retainer and valve stem neck may cause
coming off of the cotters after engine start.
Check seating position of the cotters
carefully when fitting them. Tapping of stem
end with plastic hammer after fitting cotters
will help confirmation of their seating.

NOTE
Applying small amount of grease to valve
cotters may facilitate the fitting.

Special tool
(A): 09916M14510
(B): 09916M14522
(C): 09916M84511

I2RH0B140101-01

10) Install venturi plug (1) and tighten venturi plug to

specified torque.
Tightening torque
Venturi plug (a): 3.5 N·m (0.36 kgf-m, 2.5 lbf-ft)

1, (a)

I9P60A141003-01
 Engine Mechanical: K12M 1D-121

Valve and Valve Guide Inspection

AENJCA0A1426029

Valve Guide
Valve stem-to-valve guide clearance
Using a micrometer and bore gauge, take diameter readings on valve stems and valve guides to check valve stem-to-
valve guide clearance.
Take reading at more than one place along the length of each valve stem and valve guide.
If clearance exceeds limit, replace valve and valve guide.
Valve stem and valve guide specification
Item Standard Limit
In 4.965 – 4.980 mm (0.1955 – 0.1960 in.) —
Valve stem outside diameter [A]
Ex 4.940 – 4.955 mm (0.1945 – 0.1950 in.) —
Valve guide inside diameter [B] In & Ex 5.000 – 5.012 mm (0.1969 – 0.1973 in.) —
Valve stem-to-valve guide In 0.020 – 0.047 mm (0.0008 – 0.0018 in.) 0.070 mm (0.0027 in.)
clearance Ex 0.045 – 0.072 mm (0.0018 – 0.0028 in.) 0.090 mm (0.0035 in.)

I4RS0B140016-01

Valve stem end deflection • Measure valve protrusion “a”.

If bore gauge is not available, check end deflection of If measured length is out of standard value, replace
valve stem with a dial gauge instead. valve.
Move valve stem end in directions (1) and (2) to
Valve protrusion “a” standard
measure end deflection.
IN: 34.6 – 35.4 mm (1.363 – 1.393 in.)
If deflection exceeds its limit, replace valve and valve
EX: 34.5 – 35.3 mm (1.359 – 1.389 in.)
guide.
Valve stem end deflection limit
In: 0.14 mm (0.0055 in.)
Ex: 0.18 mm (0.0070 in.) 1
“a”

IYSQ01141096-01
3

Valve
I9T401142024-01
Visual inspection
2. Valve guide 3. Valve seat
• Remove all carbon deposits from valve (1).
• Check each valve for wear, burn or distortion at its
face and valve stem and, if necessary, replace it.
1D-122 Engine Mechanical: K12M

Valve head radial runout Valve seat repair

Check each valve for radial runout with a dial gauge and If a valve seat does not contact its valve uniformly or
“V” block. To check runout, rotate valve slowly. If runout shows width of seating contact out of specified range,
exceeds its limit, replace valve. repair it by cutting, if necessary, and regrinding and then
finish it by lapping.
Valve head radial runout
1) Intake valve seat:
Standard Limit
Use valve seat cutters (1) to make three cuts as
0 – 0.05 mm 0.08 mm
Intake valve shown in figure. Three cutters must be used: the 1st
(0 – 0.0019 in.) (0.0031 in.)
for making 30° angle, the 2nd for making 70° angle,
0 – 0.03 mm 0.08 mm
Exhaust valve and 3rd for making 45° angle. The 3rd cut (45°) must
(0 – 0.0011 in.) (0.0031 in.)
be made to produce desired seat width.
Seat width for intake valve seat
“a”: 1.0 – 1.4 mm (0.0394 – 0.0551 in.)
2) Exhaust valve seat:
Use valve seat cutters (1) to make two cuts as
shown in figure. Two cutters must be used: the 1st
for making 15° angle, and the 2nd for making 45°
angle. The second cut must be made to produce
desired seat width.
Seat width for exhaust valve seat
I2RH01140136-01 “b”: 1.0 – 1.4 mm (0.0394 – 0.0551 in.)

Seating contact width

Create contact pattern on each valve in the usual
manner, i.e., by giving uniform coat of marking
compound to valve seat and by rotating and tapping seat
with valve head. Valve lapper (tool used in valve lapping)
must be used. 1

Pattern produced on seating face of valve must be a

continuous ring without any break, and the width of
pattern must be within specified range.
Standard seating width “a” revealed by contact
[A] [B]
pattern on valve face
Intake and Exhaust: 1.0 – 1.4 mm (0.0394 – 0.0551
in.) “a” “b”
“f”
“e” “e”
“d”
“c”
I9P60A141078-01

[A]: Intake “d”: 30°

[B]: Exhaust “e”: 45°
“c”: 15° “f”: 70°

3) Valve lapping:
Lap valve on seat in two steps, first with coarse size
lapping compound applied to face and the second
with fine-size compound, each time using valve
lapper according to usual lapping method.
I2RH0B140103-01
 Engine Mechanical: K12M 1D-123

Venturi Plug Inspection Distortion of mating surface of cylinder head and

AENJCA0A1426030 cylinder head gasket
Check that venturi plug is not clogged.
Limit: 0.03 mm (0.00118 in.)
If clogged, clean or replace venturi plug.

I7V20A141083-03

Cylinder Head Inspection

AENJCA0A1426031
• Remove all carbon deposits from combustion
chambers.

NOTICE
Metal surfaces can be scuffed or nicked
when removing carbon deposits with sharp-
edged tool.
Do not use any sharp-edged tool to scrape
off carbon deposits from engine parts.

I2RH0B140106-01

Distortion of seating faces intake manifold and

exhaust manifold on cylinder head
Limit: 0.05 mm (0.00196 in.)

[A]

I2RH0B140105-01

• Check cylinder head for crack on intake and exhaust [B]

ports, combustion chambers and head surface.

Cylinder Head Flatness

Use a straightedge and feeler gauge to check flatness of
gasket surface at a total of 6 positions.
IFRA0A141072-01
If any measured value exceeds its limit, correct gasket
surface with a surface plate and abrasive paper #400 [A]: Intake side [B]: Exhaust side
(waterproof silicon carbide abrasive paper) by placing
abrasive paper on surface plate and rubbing gasket
surface against paper to grind high spots.
If it is impossible to correct cylinder head distortion,
replace cylinder head.

NOTE
Distorted mating surface of cylinder head
and cylinder head gasket causes combustion
gas and/or coolant leakage, overheating and
reduced power output.
1D-124 Engine Mechanical: K12M

Cylinder Head Bolt Inspection NOTE

AENJCA0A1426032
NOTE Weakened valve spring can cause chatter,
not to mention possibility of reducing power
If cylinder head bolt is reused, check thread
output due to gas leakage caused by
diameter of cylinder head bolt (1) for
decreased seating pressure.
deformation as follows and replace it with
new one if thread diameter difference Valve spring free length “a”
exceeds limit. Standard: 42.87 mm (1.688 in.)
Measure each thread diameter of cylinder head bolt “c” Valve spring preload when compressed to 28.9
at “a” and “d” at “b” using micrometer (3). mm (1.138 in.)
Then calculate difference in diameters (“c” – “d”). Standard: 104 – 120 N (10.7 – 12.2 kgf, 23.4 – 26.9
If it exceeds limit, replace cylinder head bolt with new lbf)
one. Limit: 94 N (9.6 kgf, 21.1 lbf)
Cylinder head bolt diameter measurement points
“a”: 70 mm (2.76 in.)
“b”: 105 mm (4.13 in.)
Cylinder head bolt diameter difference (deformation)
Limit (“c” – “d”): 0.2 mm (0.0078 in.)

1
“c” “d” “a”
I9T401142034-01

“a”

“b”
I9P60A141079-01

2
I9T401142035-01

Spring Squareness
Use a square and surface plate to check each spring for
I9T401142032-01 squareness in terms of clearance between end of valve
2. Thread
spring and square. If clearance exceeds limit, replace
valve springs.
Valve Spring Inspection Valve spring squareness “a”
AENJCA0A1426033 Limit: 1.9 mm (0.074 in.)
Valve Spring Free Length and Preload “a”
• Check each valve spring for breakage or weakening.
• Measure valve spring free length and preload.
If measured value is less than limit, replace valve
spring.

IFRA0A141073-01
 Engine Mechanical: K12M 1D-125

Piston, Piston Ring and Connecting Rod Components

AENJCA0A1426034

OIL
1

OIL
2

OIL
3

OIL
4

OIL
5
9

OIL
8
11 9
OIL

6
OIL

10 (a)
IFRA0A141074-01

1. 1st ring 8. Piston pin

: For assembly, refer to “Piston, Piston Ring and Connecting Rod : Apply engine oil to sliding surface.
Disassembly and Reassembly”: K12M (Page 1D-128).
: Apply engine oil to sliding surface.
2. 2nd ring 9. Piston pin circlip
: For assembly, refer to “Piston, Piston Ring and Connecting Rod
Disassembly and Reassembly”: K12M (Page 1D-128).
: Apply engine oil to sliding surface.
3. Oil ring 10. Connecting rod bolt
: For assembly, refer to “Piston, Piston Ring and Connecting Rod : Check connecting rod bolt for deformation to reuse. (Page
Disassembly and Reassembly”: K12M (Page 1D-128). 1D-131)
: Apply engine oil to sliding surface. : Apply engine oil to bolt thread and seat.
: For tightening order, refer to “Piston, Piston Ring and
Connecting Rod Removal and Installation”: K12M (Page 1D-
126).
4. Piston 11. Dowel pin
: For assembly, refer to “Piston, Piston Ring and Connecting Rod
Removal and Installation”: K12M (Page 1D-126).
: Apply engine oil to sliding surface.
5. Connecting rod : 15 Nm → +65° (1.5 kgf-m → +65°, 11.0 lbf-ft → +65°)
: Do not apply engine oil to mating surface between connecting rod
bearing and connecting rod.
: Apply engine oil to sliding surface.
6. Connecting rod bearing cap : Do not reuse.
: To install connecting rod cap, direct arrow on it to crank pulley.
: Do not apply engine oil to mating surface between connecting rod
bearing and connecting rod cap.
7. Connecting rod bearing
: For applying engine oil, refer to “Piston, Piston Ring and
Connecting Rod Removal and Installation”: K12M (Page 1D-126).
1D-126 Engine Mechanical: K12M
Piston, Piston Ring and Connecting Rod
Removal and Installation
AENJCA0A1426035
NOTICE
If any of the parts listed below is reinstalled
into a position different from the original
position, engine problems could occur.
If these parts are to be reused, keep them in
numerical order so that they can be
reinstalled in their original positions.
• Connecting rods
• Connecting rod bearing caps
• Connecting rod bearings
• Pistons
Removal
1) Remove engine assembly from vehicle. (Page 1D-
100)
2) Remove cylinder head. (Page 1D-116)
3) Mark cylinder numbers on all pistons, connecting
rods and connecting rod caps using silver pencil or
quick drying paint.
4) Remove connecting rod bearing caps.
5) Remove carbon deposits from top of cylinder bore
before removing piston from cylinder.
6) Push piston and connecting rod assembly out from
the top of cylinder bore.
7) Remove connecting rod bearings from connecting
rod and connecting rod bearing cap, if necessary.
Installation
NOTICE
The engine will seize up if it is operated when
the parts listed below are not properly
lubricated.
Lubricate all the friction surfaces of these
parts with engine oil before installing them.
• Crankshaft pins
• Connecting rod bearings
• Pistons
• Piston rings
• Cylinder walls
1) Check that dowel pins (1) are installed to connecting
rod bearing cap.
1
IELA0A142163-02
2) Install connecting rod bearing to connecting rod
bearing cap and connecting rod as follows.
a) Check mating surfaces of bearing backside and
corresponding connecting rod are clean and dry.
b) Fit tab (1) of connecting rod bearing to groove (2)
of connecting rod and bearing cap.
c) Press bearing end (3) until it becomes flush with
connecting rod or connecting rod bearing cap
mating surface.
NOTICE
If oil is present between the bearing backside
and connecting rod surface, the bearing
could heat up to very high temperature,
resulting in seizure.
Thoroughly wipe off any trace of oil that is
present between the bearing backside and
connecting rod surface.
1 3
2
I7V20A141088-01
3) Apply engine oil to pistons, piston rings, cylinder
walls, connecting rod bearings and crankshaft pins.
4) Position crankshaft pin corresponding to piston and
connecting rod assembly to be installed to the
bottom dead center.
 Engine Mechanical: K12M 1D-127

5) Install piston and connecting rod assembly into 6) Install connecting rod bearing cap as follows.
cylinder bore as follows.
NOTICE
a) Point front mark (1) on piston head to crankshaft
pulley side (2) and carefully insert piston and Using connecting rod bolts that are deformed
connecting rod assembly. exceeding the service limit could lead to
engine problems.
2 Before installing connecting rod bearing cap,
check that connecting rod bolts are not
deformed exceeding the service limit
1 referring to “Connecting rod bolt
deformation” under “Piston Pin and
Connecting Rod Inspection”: K12M (Page 1D-
131).

IHL10A141033-01 NOTE
b) Compress piston rings with special tool.
For accurate angle tightening of the bolt, use
c) Holding special tool firmly against cylinder block, tightening angle gauge available in the
tap piston head with a hammer handle. market.
d) If oil ring catches cylinder edge, do not push
piston by force. Draw out piston a little and
repeat Step b) – c).
e) After piston rings enter cylinder bore, continue
pushing piston and connecting rod assembly
until big-end bearing meets crankshaft pin.

NOTICE
• With oil ring got stuck in the cylinder edge,
forced pushing the piston will break the oil
ring rail and spoil the engine performance
if the ring is installed as it is.
IJHA0A140061-01
If breakage of oil ring is noted, replace the
piston ring as a set.
• While inserting piston and connecting rod
assembly into cylinder bore, connecting
rod big-end may hit crankshaft pin and
damage the pin surface.
Carefully insert piston and connecting rod
assembly not to hit crankshaft pin with the
big-end.

Special tool
(A): 09916M77310

(A)

I8T401142095-01
1D-128 Engine Mechanical: K12M

a) Point front mark (protrusion) (2) on connecting Disassembly

rod bearing cap (1) to crankshaft pulley side. 1) Using a piston ring expander, remove 1st ring, 2nd
b) Apply engine oil to thread and seat of connecting ring and oil ring from piston.
rod bolt (3). 2) Remove piston pin from piston and connecting rod
c) Tighten a pair of connecting rod bolts evenly and as follows.
gradually to 15 Nm (1.5 kgf-m, 11.0 lbf-ft). a) Remove piston pin circlips (1), as shown.
d) Retighten them 65°.
e) In the same manner as in Step c) – d), tighten
connecting rod bolts of other cylinders.
f) Apply engine oil to all of connecting rod big ends.
Tightening torque
Connecting rod bolt* (a): 15 Nm → +65° (1.5
kgf-m → +65°, 11.0 lbf-ft → +65°)

3, (a)
2
1

I2RH0B140113-01

b) Remove piston pin.

3, (a)
IAP70P140031-01

7) Install cylinder head. (Page 1D-116)

8) Install engine assembly. (Page 1D-100)

Piston, Piston Ring and Connecting Rod

Disassembly and Reassembly
AENJCA0A1426036

NOTICE I2RH0B140114-01

If any of the parts listed below is reinstalled Reassembly

into a position different from the original
position, engine problems could occur. NOTICE
If these parts are to be reused, keep them in The engine will seize up if it is operated when
numerical order so that they can be the parts listed below are not properly
reinstalled in their original positions. lubricated.
• Pistons Lubricate all the friction surfaces of these
• Piston pins parts with engine oil before installing them.
• Piston rings • Pistons
• Connecting rods • Piston pins
• Connecting rod bearings • Piston rings
• Connecting rods
• Connecting rod bearings

1) Remove carbon deposits from piston head and ring

grooves using a suitable tool.
2) Install piston pin to piston (1) and connecting rod (2)
as follows.
a) Apply engine oil to piston pin, piston pin hole in
piston and connecting rod.
b) Fit connecting rod positioning oil hole (5) on
connecting rod and front mark (4) on piston as
shown in figure.
c) Insert piston pin into piston and connecting rod.
 Engine Mechanical: K12M 1D-129

d) Install new piston pin circlips (3) so that each Cylinder, Piston and Piston Ring Inspection
opening comes within the range indicated by AENJCA0A1426037

arrow (6) as shown in figure.

Cylinder
Visual inspection
6 4
Check cylinder walls for scratches, roughness or ridges
“a”
which indicate excessive wear.
If cylinder bore is very rough, deeply scratched or ridged,
6
3 “a” replace cylinder block, piston rings and/or pistons.

Cylinder bore diameter, taper and out-of-round

2 3 Using a cylinder gauge, measure cylinder bore in thrust
1
5
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
IFRA0A141076-01 cylinder block.
“a”: 45° • Cylinder bore diameter exceeds limit.
• Difference of measurements at two positions exceeds
3) Install piston rings to piston noting the following taper limit.
points.
• Difference between thrust and axial measurements
• As shown in figure, 1st and 2nd rings have top exceeds out-of-round limit.
mark (1) respectively. When installing them, face
each top mark upward. Cylinder bore diameter
Standard: 73.000 – 73.014 mm (2.8741 – 2.8745 in.)
• 1st ring (2) differs from 2nd ring (3) in thickness
Limit: 73.056 mm (2.8762 in.)
and shape of surface contacting cylinder wall.
• When installing oil ring (4), install spacer first and Cylinder taper and out-of-round
then two rails. Limit: 0.010 mm (0.00039 in.)

I7V20A141095-01
3

4
“e” “f”

I8C50A140063-01 “c”
4) After installing three rings (1st, 2nd and oil rings),
distribute their end gaps as shown in figure.
“d”
“b”
“a”
I9P60A141081-01

“e”: 50 mm (1.97 in.) “f”: 100 mm (3.94 in.)

Piston
Visual inspection
IFAE0A140127-01 Check piston for faults, crack or other damages.
“a”: 45° 3. 1st ring end gap
Damaged or faulty piston should be replaced.
1. Front mark 4. 2nd ring end gap and oil ring
spacer gap
2. Oil ring upper rail gap 5. Oil ring lower rail gap
1D-130 Engine Mechanical: K12M

Piston diameter Ring groove clearance

As shown in figure, piston diameter should be measured 1) Before checking, piston grooves must be clean, dry
at specified position “a” 9.0 mm (0.354 in.) from piston and free from carbon deposits.
skirt end in the direction perpendicular to piston pin.
2) Fit new piston ring (1) into piston groove, and
If measured diameter is less than its limit, replace piston.
measure clearance between ring and ring land using
Piston diameter specification feeler gauge (2). If clearance is out of limit, replace
Standard size (used piston): 72.978 – 72.990 mm piston.
(2.8732 – 2.8736 in.)
Ring groove clearance
Standard size (new piston with coating): 72.984 –
73.016 mm (2.8734 – 2.8746 in.) Standard Limit
0.03 – 0.07 mm
1st ring 0.12 mm (0.0047 in.)
(0.0012 – 0.0027 in.)
0.02 – 0.06 mm
2nd ring 0.10 mm (0.0039 in.)
(0.0008 – 0.0023 in.)
0.04 – 0.12 mm
Oil ring —
(0.0016 – 0.0047 in.)
“a”

IFRA0A141077-01

“a”: 9.0 mm (0.354 in.)

1
Piston clearance
Measure cylinder bore diameter and piston diameter to
find their difference which is piston clearance. Piston
clearance should be within specification. If it is not as 2
specified, replace cylinder block, piston rings and/or
pistons.

NOTE
Cylinder bore diameters used here are IFRA0A141078-01

measured in thrust direction at two positions.

Piston clearance
Standard (used piston): 0.010 to 0.036 mm (0.00040
to 0.00141 in.)
Standard (new piston with coating): –0.016 to 0.030
mm (–0.00062 to 0.00118 in.)
Limit: 0.072 mm (0.0028 in.)

I7V20A141095-01

“a”

IFRA0A141077-01

“a”: 9.0 mm (0.354 in.)

 Engine Mechanical: K12M 1D-131

Piston Ring Piston pin outside diameter

Piston ring end gap 17.995 – 18.000 mm (0.7085 – 0.7086 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 – 18.014 mm (0.7089 – 0.7092 in.)
If measured gap exceeds limit, replace piston ring.

NOTE
Remove carbon deposit from top of cylinder
bore before inserting piston ring.

Piston ring end gap

Item Standard Limit
0.15 – 0.28 mm
Top ring 0.7 mm (0.0275 in.)
(0.0060 – 0.0110 in.)
0.28 – 0.41 mm
2nd ring 1.0 mm (0.0393 in.)
(0.0111 – 0.0161 in.)
0.10 – 0.40 mm
Oil ring 1.2 mm (0.0472 in.)
(0.0040 – 0.0157 in.)

I4RS0A140023-01

"a"
Connecting Rod
Big-end side clearance
1 Check big-end of connecting rod for side clearance, with
I7V20A141096-02
rod fitted and connected to its crankshaft pin in a normal
“a”. 50 mm (1.97 in.) manner. If measured clearance exceeds its limit, replace
connecting rod.
Piston Pin and Connecting Rod Inspection Big-end side clearance
AENJCA0A1426038
Standard: 0.10 – 0.30 mm (0.0040 – 0.0118 in.)
Piston Pin Limit: 0.55 mm (0.0216 in.)
Visual inspection
Check piston pin, connecting rod small-end bore and
piston pin hole in piston for wear or damage, paying
particular attention to condition of small-end bore
bushing. If piston pin, connecting rod small end bore or
piston pin hole in piston is badly worn or damaged,
replace piston pin, connecting rod and/or piston.

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
IEL70B140192-01
exceeds limit.
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.)
Piston pin clearance in piston
Standard: 0.006 – 0.019 mm (0.00024 – 0.00074 in.)
Limit: 0.019 mm (0.00074 in.)
Small-end bore
18.003 – 18.013 mm (0.7088 – 0.7091 in.)
1D-132 Engine Mechanical: K12M

Connecting rod alignment Crankshaft Pin and Connecting Rod Bearing

Mount connecting rod on aligner to check it for bow and Inspection
twist. If measured value exceeds the limit, replace AENJCA0A1426039

connecting rod.
Crankshaft Pin Diameter
Connecting rod alignment Check crankshaft pin for uneven wear or damage.
Limit on bow: 0.05 mm (0.0019 in.) Measure crankshaft pin for out-of-round or its taper with
Limit on twist: 0.10 mm (0.0039 in.) a micrometer. If crankshaft pin is damaged or out-of
round or taper is out of limit, replace crankshaft or
regrind crankshaft pin to undersize and use undersize
bearing.

NOTE
When regrinding crank pin to undersize, use
undersize connecting rod bearing.

Crankshaft pin diameter

I4RH01140053-01 Connecting rod bearing
Crankshaft pin diameter
size
Connecting rod bolt deformation 37.982 – 38.000 mm
Measure each thread diameter of connecting rod bolt (1) Standard
(1.4954 – 1.4960 in.)
at “c” on 12 mm (0.47 in.) from bolt mounting surface 0.25 mm (0.0098 in.) 37.732 – 37.750 mm
and “d” on 32 mm (1.26 in.) from bolt mounting surface undersize (1.4856 – 1.4862 in.)
using a micrometer (3).
Calculate difference in diameters (“c” – “d”). If it exceeds Crankshaft pin taper ([a] – [b]) and out-of-roundness
limit, replace connecting rod bolt. ([1] – [2])
Connecting rod bolt measurement points Limit: 0.01 mm (0.0004 in.)
“a”: 12 mm (0.47 in.)
“b”: 32 mm (1.26 in.)
Connecting rod bolt diameter difference
Limit (“c” – “d”): 0.05 mm (0.0019 in.)

1 “c” “d”

“a” [1] [a] [b]

“b”

[2]

I8T401142103-01
2

I9P60A141082-01

2. Thread

Connecting Rod Bearing General Information
• Service connecting rod bearings are available in
standard size and 0.25 mm (0.0098 in.) undersize
bearing, and standard size bearing has five kinds of
bearings differing in tolerance.
• For identification of undersize bearing, it is painted red
at the position as shown in figure, undersize bearing
thickness is 1.605 – 1.615 mm (0.0632 – 0.0635 in.)
at its center.
1
IFAE0A140128-01
1. Painting
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.
Connecting Rod Bearing Clearance
NOTICE
Using connecting rod bolts that are deformed
exceeding the service limit could lead to
engine problems.
After checking connecting rod bearing
clearance, check that connecting rod bolts
are not deformed exceeding the service limit
referring to “Connecting rod bolt
deformation” under “Piston Pin and
Connecting Rod Inspection”: K12M (Page 1D-
131).
1) Clean connecting rod bearings and crankshaft pin.
2) Place a piece of gauging plastic (1) to full width of
crankshaft pin as contacted by bearing (parallel to
crankshaft), avoiding oil hole.
1 diameter is 41.0000 – 41.0060 mm (1.61418 –
I7V20A141100-01
Engine Mechanical: K12M 1D-133
3) Without applying engine oil, install connecting rod
bearings and its cap referring to Step 1) – 6)
“Installation” under “Piston, Piston Ring and
Connecting Rod Removal and Installation”: K12M
(Page 1D-126).
4) After three minutes, remove cap and measure
gauging plastic (1) width (clearance) at the widest
point using a scale (2) on gauging plastic envelope.
If clearance exceeds its limit, select a new standard
size connecting rod bearing. (Page 1D-133)
After selecting new connecting rod bearing, recheck
clearance.
Connecting rod bearing clearance
Standard: 0.031 – 0.049 mm (0.0013 – 0.0019 in.)
Limit: 0.065 mm (0.0025 in.)
2
1
I7V20A141101-01
5) If clearance cannot be brought to its limit even by a
new standard size bearing, use next thicker bearing
and recheck clearance or regrind crankshaft pin to
undersize and use 0.25 mm (0.0098 in.) undersize
bearing.
Selection of Connecting Rod Bearing
If engine is under the following conditions, select a new
standard bearing as follows, and install it.
• Bearing is defective.
• Bearing clearance is out of specification.
• Crankshaft or connecting rod is replaced.
1) Check stamped numbers on connecting rod and its
cap as shown.
Three kinds of numbers (“1”, “2” and “3”) represent
the following connecting rod big-end inside
diameters.
For example, stamped number “1” indicates that
corresponding connecting rod big-end inside
1.61440 in.).
1D-134 Engine Mechanical: K12M

Connecting rod big-end inside diameter 3) There are five kinds of standard bearing thickness
Stamped and they are painted in the following colors.
Connecting rod big-end inside diameter Each color indicates the following thickness at the
number
41.0000 – 41.0060 mm center of bearing.
1
(1.61418 – 1.61440 in.) Standard size connecting rod bearing thickness
41.0061 – 41.0120 mm
2 Color
(1.61442 – 1.61464 in.) Bearing thickness
painted
41.0121 – 41.0180 mm
3 Blue 1.498 – 1.501 mm (0.05898 – 0.05909 in.)
(1.61465 – 1.61488 in.)
Yellow 1.495 – 1.498 mm (0.05886 – 0.05897 in.)
Nothing 1.492 – 1.495 mm (0.05875 – 0.05885 in.)
Black 1.489 – 1.492 mm (0.05863 – 0.05874 in.)
Green 1.486 – 1.489 mm (0.05851 – 0.05862 in.)

I8T401142106-02

1. Connecting rod big-end inside diameter number

2. Weight indication mark 1
IFAE0A140128-01

1. Painting
2) Check crankshaft pin diameter. On crank web No.5,
four alphabets are stamped as shown in figure.
Three kinds of alphabet (“A”, “B” and “C”) represent 4) From number stamped on connecting rod and its cap
the following crankshaft pin diameter respectively. and alphabets stamped on crank web No.5,
For example, stamped “A” indicates that determine new standard bearing to be installed to
corresponding crankshaft pin diameter is 37.9940 – connecting rod big-end inside, referring to the
38.0000 mm (1.49583 – 1.49606 in.). following table.
For example, if number stamped on connecting rod
Crankshaft pin outer diameter and its cap is “1” and alphabet stamped on crank
Stamped alphabet Crankshaft pin diameter web No.5 is “B”, install a new standard bearing
37.9940 – 38.0000 mm painted in “Black” to its connecting rod big-end
A
(1.49583 – 1.49606 in.) inside.
37.9880 – 37.9939 mm
B Connecting rod bearing cross-reference
(1.49560 – 1.49582 in.)
selection table (standard size)
37.9820 – 37.9879 mm
C Stamped number for
(1.49536 – 1.49558 in.)
connecting rod big end
inside diameter
1 2 3
Stamped alphabet A Green Black Nothing
for crankshaft pin B Black Nothing Yellow
diameter C Nothing Yellow Blue

5) Check bearing clearance with newly selected

standard bearing referring to “Connecting Rod
Bearing Clearance”: K12M (Page 1D-133).
If clearance still exceeds its limit, use next thicker
bearing and recheck clearance.
1 2 3 4
I9P60A141010-01

1. Crankshaft pin No.1 3. Crankshaft pin No.3

2. Crankshaft pin No.2 4. Crankshaft pin No.4
 Engine Mechanical: K12M 1D-135

Main Bearing, Crankshaft and Cylinder Block Components

AENJCA0A1426040

3
(c)

OIL
5

19 (a)
17
OIL

13 18

(e)
4 1322 (d)
OIL

12

9
7

9 16 1217G
15
OIL
OIL

(e) 14

9
OIL

12

10
OIL

11 (b)
IJCA0A142040-01

1. CKP sensor 10. Main bearing cap 19. Flywheel bolt

2. Knock sensor 11. Main bearing cap bolt : 83 Nm (8.5 kgf-m, 61.5 lbf-ft)
: For removal and installation, refer : Apply engine oil to bolt thread and seat.
to “Knock Sensor Removal and : For tightening order, refer to “Main
Installation”: K12M in Section 1C Bearing, Crankshaft and Cylinder Block
(Page 1C-32). Removal and Installation”: K12M (Page
1D-136).
3. Water jacket spacer 12. Main bearing : 20 Nm → 40 Nm → +60° (2.0 kgf-m
: For applying engine oil, refer to “Main → 4.1 kgf-m → +60°, 15.0 lbf-ft →
Bearing, Crankshaft and Cylinder Block 29.5 lbf-ft → +60°)
Removal and Installation”: K12M (Page
1D-136).
4. Oil pressure switch 13. Thrust bearing : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
: Apply sealant 99000-32150 to : Install thrust bearing with oil grooves
thread. facing out.
: Apply engine oil to sliding surface.
5. Cylinder block 14. Crankshaft : 13 Nm (1.3 kgf-m, 9.5 lbf-ft)
: Do not apply engine oil to main : Apply engine oil to sliding surface.
bearing seating face.
: Apply engine oil to sliding surface.
6. Sensor plate 15. Crankshaft rear oil seal : 11 Nm (1.1 kgf-m, 8.5 lbf-ft)
: Apply engine oil to seal lip.
1D-136 Engine Mechanical: K12M

7. Crankshaft timing sprocket key 16. Oil seal housing : Do not reuse.
: Apply sealant 99000-31260 referring to
“Main Bearing, Crankshaft and Cylinder
Block Removal and Installation”: K12M
(Page 1D-136).
8. Spring pin 17. Flywheel
9. Dowel pin 18. Input shaft bearing

Main Bearing, Crankshaft and Cylinder Block 7) Remove crankshaft rear oil seal from oil seal
Removal and Installation housing.
AENJCA0A1426041
8) Remove main bearing cap bolts in numerical order
(“1” – “10”) evenly and gradually.
Removal
9) Remove main bearing caps.
1) Remove engine assembly from vehicle. (Page 1D-
100) “7” “9” “5”
2) Remove flywheel. (Page 1D-108)
3) Remove pistons and connecting rods. (Page 1D- “3” “1”
126)
4) Remove water jacket spacer (1).

1 “4” “2”

“8” “10” “6”

I9P60A141012-01

10) Remove crankshaft from cylinder block.

11) Remove sensor plate and spring pin from crankshaft,
if necessary.
12) Remove generator, if necessary. (Page 1J-28)
13) Remove water pump, if necessary. (Page 1F-33)
14) Remove knock sensor, if necessary. (Page 1C-32)
15) Remove oil pressure switch, if necessary. (Page
1E-20)
IFRA0A141080-01

5) Remove CKP sensor. (Page 1C-31)

6) Remove oil seal housing (1).

I7V20A141105-01
 Engine Mechanical: K12M 1D-137

Installation b) Install sensor plate to crankshaft, spring pin into

hole (4) and facing inside edge (5) outward as
NOTICE shown in figure.
• The engine will seize up if it is operated c) Tighten sensor plate screws to specified torque.
when the parts listed below are not
Tightening torque
properly lubricated.
Sensor plate screw (a): 11 N·m (1.1 kgf-m,
Lubricate all the friction surfaces of these
8.5 lbf-ft)
parts with engine oil before installing them.
– Crankshaft journals
6 3
– Main bearings (sliding surface)
– Thrust bearings
5 1
• Using main bearing cap bolts that are
deformed exceeding the service limit could (a)
lead to engine problems.
When main bearing cap bolts are reused,
1
check that main bearing cap bolts are not 2
deformed exceeding the service limit (a) 2
referring to “Main Bearing Cap Bolt” under
4 3
“Main Bearing Inspection”: K12M (Page
1D-141).
“a”
IGSB0A143040-01
NOTE
“a”: 3.1 – 4.9 mm (0.12 – 0.19 in.) 6. Crankshaft side
Properly use main bearings checking their
width and oil hole.
6) Install main bearings to cylinder block and main
“a” “a”
bearing caps as follows.

1 2
NOTICE
If oil is present between the bearing backside
and cylinder block or main bearing cap
surface, the bearing could heat up to very
high temperature, resulting in seizure.
Thoroughly wipe off any trace of oil that is
present between the bearing backside and
cylinder block or main bearing cap surface.

NOTE
3 4
• Install main bearing halves (1) with oil
groove (2) to cylinder block.

“b” “b”
IJHA0A140051-02

“a”: Width (wider than “b”)

“b”: Width (narrower than “a”)
2
1. Main bearing No.1 upper half with oil groove and 2 holes 2
2. Main bearing No.1 lower half
3. Main bearing No.2 – 5 upper halves with oil groove and 1 hole
2
4. Main bearing No.2 – 5 lower halves

1) Install oil pressure switch, if removed. (Page 1E- 1

20)
2) Install knock sensor, if removed. (Page 1C-32) 1

3) Install water pump, if removed. (Page 1F-33) IFRA0A141081-01

4) Install generator, if removed. (Page 1J-28) • Install other main bearing halves without
5) Install sensor plate (1) as follows, if removed. oil groove to main bearing caps.
a) Insert spring pin (2) to crankshaft (3).
1D-138 Engine Mechanical: K12M

a) Check mating surfaces (5) of bearing backside
and corresponding cylinder block and main
bearing cap are clean and dry.
b) Fit the tab (1) on each bearing into groove (2) in
cylinder block and main bearing cap.
c) Press bearing end (3) until it fully seats in
cylinder block and main bearing cap.
d) Apply engine oil to sliding surface (4) of main
bearing halves at cylinder block side.
10) Install main bearing caps according to the following
procedure.
NOTICE
Using main bearing cap bolts that are
deformed exceeding the service limit could
lead to engine problems.
Before installing main bearing cap, check
that main bearing cap bolts are not deformed
exceeding the service limit referring to “Main
Bearing Cap Bolt” under “Main Bearing
Inspection”: K12M (Page 1D-141).

1 3 NOTE
4
For accurate angle tightening of the bolt, use
2
tightening angle gauge available in the
market.
5
I8T401142036-01

7) Check that dowel pins (3) are installed to intake side

of each journal securely.
8) Apply engine oil to thrust bearings (1) and install
them to cylinder block between No.2 and No.3
cylinders with oil grooves (2) facing outward.

2
IJHA0A140061-01

1 3

I7V20A141108-01

9) Check cleanliness of crankshaft journal and place

crankshaft on cylinder block and then apply engine
oil to crankshaft journal.
 Engine Mechanical: K12M 1D-139

a) Point arrow mark on cap to crankshaft pulley 14) Check that dowel pins (2) are installed to oil seal
side and set main bearing caps to cylinder block. housing (1) as shown in figure.
b) Apply engine oil to bolt thread and seat of main 15) Clean mating surfaces of cylinder block and oil seal
bearing cap bolts. housing.
c) Tighten main bearing cap bolts to 20 Nm (2.0 16) Apply sealant to mating surface of oil seal housing.
kgf-m, 15.0 lbf-ft) in numerical order (“1” – “10”)
“A”: Sealant 99000–31260 (SUZUKI Bond
as shown.
No.1217G)
d) In the same manner as in Step c), tighten them
to 40 Nm (4.1 kgf-m, 29.5 lbf-ft). Sealant bead size for rear oil seal housing
Width: “a”: 3 mm (0.12 in.)
e) Retighten all main bearing cap bolts 60° in
Height “b”: 2 mm (0.08 in.)
numerical order as shown in figure.
Tightening torque “a”
Main bearing cap bolt* (a): 20 Nm → 40 Nm “A” “b”
→ +60° (2.0 kgf-m → 4.1 kgf-m → +60°, 15.0
lbf-ft → 29.5 lbf-ft → +60°)
“A”
“4”, (a) “2”, (a) “6”, (a)
1

“8”, (a) “10”, (a)

2 2

IFRA0A141083-01

“7”, (a) “9”, (a)

17) Install oil seal housing (1) according to the following
procedure.
a) Apply engine oil to oil seal lip.
“3”, (a) “1”, (a) “5”, (a) b) Within 2 minutes after applying sealant, install oil
IFRA0A141082-01
seal housing using special tool to cylinder block.
11) Check that crankshaft rotates smoothly when turning
it by hand. NOTICE
12) Clean sealing surface between oil seal housing and Turning over of oil seal lip or coming off of
cylinder block. the inside spring will cause oil leakage.
13) Install new crankshaft rear oil seal (1) to oil seal While installing oil seal housing, pay
housing (2) using special tool. attention not to turn over oil seal lip nor
disengage the inside spring.
Special tool
(A): 09911M16300
Crankshaft rear oil seal installing position
(depth)
“a”: 1.5 – 2.5 mm (0.059 – 0.098 in.)

(A)

(A) 1
“a”

2 1

I7V20A141110-01
1D-140 Engine Mechanical: K12M

c) Tighten new oil seal housing bolts (2) to Crankshaft Inspection

specified torque. AENJCA0A1426042

NOTICE Crankshaft Runout

Using a dial gauge, measure runout at center journal.
The rear oil seal housing bolts are pre-coated
Rotate crankshaft slowly. If runout exceeds its limit,
with adhesive. If these bolts are reused, they
replace crankshaft.
may work loose.
Replace the rear oil seal housing bolts with Crankshaft runout
new ones whenever they are removed. Limit: 0.02 mm (0.00078 in.)

Special tool
(A): 09911M97720
Tightening torque
Oil seal housing bolt (a): 11 N·m (1.1 kgf-m,
8.5 lbf-ft)

(A)

I7V20A141113-01
1
Crankshaft Thrust Play
(A)
1) Assemble crankshaft, main bearings, thrust bearings
and main bearing caps. (Page 1D-136)
2,(a) 2) Using dial gauge (1), measure crankshaft thrust play
I7V20A141112-01 (2) as shown in figure.
3. Crankshaft side If measured thrust play exceeds limit, replace thrust
bearing with new one (standard size or oversize) to
18) Install CKP sensor. (Page 1C-31) obtain standard thrust play.
Recheck crankshaft thrust play.
19) Install pistons and connecting rods. (Page 1D-126)
20) Install flywheel. (Page 1D-108) Crankshaft thrust play
Standard: 0.11 – 0.31 mm (0.0044 – 0.0122 in.)
21) Install water jacket spacer (1).
Limit: 0.35 mm (0.0138 in.)
1

1 2

I8C50A140074-01

Thrust bearing thickness

Standard size: 2.470 – 2.520 mm (0.0973 – 0.0992
IFRA0A141080-01
in.)
22) Install cylinder head. (Page 1D-116)
Oversize (0.125 mm, 0.00492 in.): 2.533 – 2.583
23) Install camshafts and tappets. (Page 1D-89) mm (0.0998 – 0.1016 in.)
24) Install timing chain. (Page 1D-111)
25) Install timing chain cover. (Page 1D-105)
26) Install cylinder head cover. (Page 1D-86)
27) Install oil pan. (Page 1E-23)
28) Install engine assembly to vehicle. (Page 1D-100)
 Engine Mechanical: K12M 1D-141

Out-of-Roundness and Taper (Uneven Wear) of Main Bearing Inspection

Journal AENJCA0A1426043

An unevenly worn crankshaft journal shows up as a NOTE

difference in diameter at a cross section or along its
length (or both). This difference, if any, is determined by Properly use main bearings checking their
taking micrometer readings. If any one of journals is width and oil hole.
badly damaged or uneven wear exceeds its limit, regrind
“a” “a”
or replace crankshaft.
Crankshaft journal outside diameter
Standard: 45.000 – 45.018 mm (1.7717 – 1.7723 in.)
1 2
Limit: 44.99 mm (1.7712 in.)
Crankshaft out-of-roundness ([1] – [2]) and taper ([a]
– [b])
Limit: 0.01 mm (0.00039 in.)

[a] [b]

3 4

“b” “b”
IJHA0A140051-02
[1]
“a”: Width (wider than “b”)
“b”: Width (narrower than “a”)
1. Main bearing No.1 upper half with oil groove and 2 holes
[2] 2. Main bearing No.1 lower half
3. Main bearing No.2 – 5 upper halves with oil groove and 1 hole
4. Main bearing No.2 – 5 lower halves
I8C50A140075-01

General Information
• Service main bearings are available in standard size
and 0.25 mm (0.0098 in.) undersize, and each of them
has five kinds of bearings differing in tolerance.
• Upper bearing half (1) has oil groove (2) as shown in
figure.
Install this half with oil groove to cylinder block (3).
• Lower bearing half does not have oil groove.

I7V20A141117-01

Visual Inspection
Check bearings for pitting, scratches, wear or damage.
If any defect is found, replace both upper and lower
halves. Never replace either half without replacing the
other half.
1D-142 Engine Mechanical: K12M

Main Bearing Clearance 5) After three minutes, remove main bearing cap and
using scale (2) on gauging plastic envelope,
NOTE measure gauging plastic (1) width at the widest
Do not rotate crankshaft while gauging point.
plastic is fitted.
Main bearing No.1 clearance
Check clearance using gauging plastic according to the Standard: 0.014 – 0.032 mm (0.00056 – 0.00125
following procedure. in.)
Limit: 0.055 mm (0.00216 in.)
1) Remove main bearing caps.
2) Clean bearings and main journals. Main bearing No.2 – 5 clearance
Standard: 0.016 – 0.034 mm (0.00063 – 0.00133
3) Place a piece of gauging plastic (1) to full width of in.)
bearing (parallel to crankshaft) on journal, avoiding Limit: 0.050 mm (0.00197 in.)
oil hole.
1
1 2

I7V20A141119-01
I7V20A141118-01
If measured clearance is less than standard or more
4) Without applying engine oil, install main bearing cap
than service limit, replace main bearings with new
referring to Step 10) – 11) in “installation” under
ones referring to “Selection of Main Bearing”: K12M
“Main Bearing, Crankshaft and Cylinder Block
(Page 1D-143) and recheck main bearing clearance.
Removal and Installation”: K12M (Page 1D-136).
If measured clearance with new bearing is out of
standard, select other bearing according to the
following procedure and recheck main bearing
clearance.
• More than standard:
Replace bearing with one size thicker or regrind
crankshaft journal to undersize and use 0.25 mm
(0.0098 in.) undersize bearing.
• Less than standard:
Replace bearing with one size thinner or regrind
crankshaft journal to undersize and use 0.25 mm
(0.0098 in.) undersize bearing.
 Engine Mechanical: K12M 1D-143

Selection of Main Bearing 2) Check bearing cap bore diameter without bearing.
Standard size bearing On mating surface of cylinder block, six alphabets or
If engine is under one of the following conditions, select numbers are stamped as shown in figure (1).
a new standard bearing as follows, and install it. Six kinds of alphabets (“A” – “F”) or numbers (“1” –
• Bearing is defective. “6”) represent the following cap bore diameters.
Stamped alphabets or numbers on cylinder block
• Bearing clearance is out of specification.
represent bearing cap bore diameter marked with an
• Crankshaft or cylinder block is replaced. arrow in figure respectively.
1) Check journal diameter. As shown in figure, crank For example, stamped “A” or “1” indicates that
web No.4 has stamped numbers. corresponding bearing cap bore diameter is 49.0000
Six kinds of numbers (“1” – “6”) represent the – 49.0030 mm (1.92914 – 1.92925 in.).
following journal diameters.
Crankshaft bearing cap bore
Stamped numbers on crank web No.4 represent
diameters of journal indicated with an arrow in figure Stamped alphabets Bearing cap bore diameter
respectively. (numbers) (without bearing)
For example stamped number “1” indicates that 49.0000 – 49.0030 mm
A or 1
corresponding journal diameter is 45.0150 – 45.0180 (1.92914 – 1.92925 in.)
mm (1.77225 – 1.77236 in.). 49.0031 – 49.0060 mm
B or 2
(1.92926 – 1.92937 in.)
Crankshaft journal diameter 49.0061 – 49.0090 mm
C or 3
Stamped numbers Journal diameter (1.92938 – 1.92948 in.)
45.0150 – 45.0180 mm 49.0091 – 49.0120 mm
1 D or 4
(1.77225 – 1.77236 in.) (1.92950 – 1.92960 in.)
45.0120 – 45.0149 mm 49.0121 – 49.0150 mm
2 E or 5
(1.77213 – 1.77224 in.) (1.92962 – 1.92972 in.)
45.0090 – 45.0119 mm 49.0151 – 49.0180 mm
3 F or 6
(1.77201 – 1.77212 in.) (1.92973 – 1.92984 in.)
45.0060 – 45.0089 mm
4
(1.77189 – 1.77200 in.)
45.0030 – 45.0059 mm
5
(1.77178 – 1.77188 in.)
45.0000 – 45.0029 mm
6
(1.77166 – 1.77176 in.)
2

1
1 I9P60A141015-01

2. Crankshaft pulley side

I9P60A141014-01

1. Crankshaft pulley side

1D-144 Engine Mechanical: K12M

3) There are five kinds of standard bearing thickness

and they are painted in the following colors.
Each color indicates the following thickness at the
center of bearing.
Standard size crankshaft main bearing No.1
thickness
Color
Bearing thickness
painted
Pink 1.991 – 1.994 mm (0.07839 – 0.07950 in.)
Purple 1.994 – 1.997 mm (0.07951 – 0.07862 in.)
Brown 1.997 – 2.000 mm (0.07863 – 0.07874 in.)
Green 2.000 – 2.003 mm (0.07875 – 0.07885 in.)
Black 2.003 – 2.006 mm (0.07886 – 0.07897 in.)

Standard size crankshaft main bearing No.2 –

5thickness
Color
Bearing thickness
painted
Pink 1.990 – 1.993 mm (0.07835 – 0.07846 in.)
Purple 1.993 – 1.996 mm (0.07847 – 0.07858 in.)
Brown 1.996 – 1.999 mm (0.07859 – 0.07870 in.)
Green 1.999 – 2.002 mm (0.07871 – 0.07881 in.)
Black 2.002 – 2.005 mm (0.07882 – 0.07893 in.)

1
IFAE0A140144-01

1. Paint
 Engine Mechanical: K12M 1D-145

4) From number stamped on crank web No.4 and alphabets or numbers stamped on cylinder block, determine new
standard bearing to be installed to journal, referring to the following table.
For example, if number stamped on crank web No.4 is “1” and alphabet stamped on cylinder block is “B”, install a
new standard bearing painted in “Pink” to its journal.
Main bearing cross-reference selection table (standard size)
Number stamped on crank web No.4
1 2 3 4 5 6
Upper Pink Pink Pink Purple Purple Brown
A or 1
Lower Pink Pink Purple Purple Brown Brown
Upper Pink Pink Purple Purple Brown Brown
B or 2
Lower Pink Purple Purple Brown Brown Green
Alphabet or Upper Pink Purple Purple Brown Brown Green
C or 3
number Lower Purple Purple Brown Brown Green Green
stamped on Upper Purple Purple Brown Brown Green Green
D or 4
cylinder block Lower Purple Brown Brown Green Green Black
Upper Purple Brown Brown Green Green Black
E or 5
Lower Brown Brown Green Green Black Black
Upper Brown Brown Green Green Black Black
F or 6
Lower Brown Green Green Black Black Black

5) Using scale (2) and gauging plastic (1), check

bearing clearance with newly selected standard
bearing.
If clearance still exceeds its limit, use next thicker
bearing and recheck clearance, referring to “Main
Bearing Clearance”: K12M (Page 1D-142).

1
2

I7V20A141119-01
1D-146 Engine Mechanical: K12M

Undersize bearing (0.25 mm)

• There are five kinds of undersize bearing thickness and they are painted in the following colors.
Each color indicates the following thickness at the center of bearing.
Undersize crankshaft main bearing No.1 thickness
Color painted Bearing thickness
Red & Pink 2.116 – 2.119 mm (0.08331 – 0.08342 in.)
Red & Purple 2.119 – 2.122 mm (0.08343 – 0.08354 in.)
Red & Brown 2.122 – 2.125 mm (0.08355 – 0.08366 in.)
Red & Green 2.125 – 2.128 mm (0.08367 – 0.08378 in.)
Red & Black 2.128 – 2.131 mm (0.08379 – 0.08389 in.)

Undersize crankshaft main bearing No.2 – 5 thickness

Color painted Bearing thickness
Red & Pink 2.1150 – 2.1180 mm (0.08327 – 0.08338 in.)
Red & Purple 2.1180 – 2.1210 mm (0.08339 – 0.08350 in.)
Red & Brown 2.1210 – 2.1240 mm (0.08351 – 0.08362 in.)
Red & Green 2.1240 – 2.1270 mm (0.08363 – 0.08374 in.)
Red & Black 2.1270 – 2.1300 mm (0.08375 – 0.08385 in.)

1
IFAE0A140145-01

1. Paint

• If necessary, regrind crankshaft journal and select undersize bearing to use with crankshaft as follows.
1) Regrind journal to the following finished diameter.
Finished journal diameter
44.7500 – 44.7680 mm (1.76182 – 1.76251 in.)
2) Using micrometer, measure reground journal diameter.
Measurement should be taken in two directions perpendicular to each other to check for out-of-roundness.
3) Using journal diameter measured above and alphabets or numbers stamped on cylinder block, select an undersize
bearing referring to the following table.
Check bearing clearance with newly selected undersize bearing.

I2RH0B140144-01
 Engine Mechanical: K12M 1D-147

Main bearing cross–reference table (undersize)

Measured journal diameter
44.7650 – 44.7620 – 44.7590 – 44.7560 – 44.7530 – 44.7500 –
44.7680 mm 44.7649 mm 44.7619 mm 44.7589 mm 44.7559 mm 44.7529 mm
(1.76241 – (1.76229 – (1.76217 – (1.76205 – (1.76193 – (1.76182 –
1.76251 in.) 1.76239 in.) 1.76227 in.) 1.76216 in.) 1.76204 in.) 1.76192 in.)
Upper Red & Pink Red & Pink Red & Pink Red & Purple Red & Purple Red & Brown
A or 1
Lower Red & Pink Red & Pink Red & Purple Red & Purple Red & Brown Red & Brown
Upper Red & Pink Red & Pink Red & Purple Red & Purple Red & Brown Red & Brown
Alphabet B or 2
Lower Red & Pink Red & Purple Red & Purple Red & Brown Red & Brown Red & Green
or
Upper Red & Pink Red & Purple Red & Purple Red & Brown Red & Brown Red & Green
number C or 3
Lower Red & Purple Red & Purple Red & Brown Red & Brown Red & Green Red & Green
stamped
Upper Red & Purple Red & Purple Red & Brown Red & Brown Red & Green Red & Green
on D or 4
Lower Red & Purple Red & Brown Red & Brown Red & Green Red & Green Red & Black
cylinder
Upper Red & Purple Red & Brown Red & Brown Red & Green Red & Green Red & Black
block E or 5
Lower Red & Brown Red & Brown Red & Green Red & Green Red & Black Red & Black
Upper Red & Brown Red & Brown Red & Green Red & Green Red & Black Red & Black
F or 6
Lower Red & Brown Red & Green Red & Green Red & Black Red & Black Red & Black

Main Bearing Cap Bolt Sensor Plate Inspection

Measure each thread diameter at specified points on AENJCA0A1426044

main bearing cap bolts (1) using a micrometer (3). Check sensor plate for crack and damage.
Calculate difference in diameters (“c” – “d”). If any defect is found, replace it.
If it exceeds limit, replace main bearing cap bolt with new
one.
Main bearing cap bolt diameter measurement points
“a”: 40 mm (1.6 in.)
“b”: 64 mm (2.5 in.)
Main bearing cap bolt diameter difference
Limit (“c” – “d”): 0.2 mm (0.0078 in.)

1 I7V20A141122-01
“c” “d”

Cylinder Block Inspection

AENJCA0A1426045

“a”
Distortion of Gasket Surface
“b” Using straightedge and feeler gauge, check gasket
I9P60A141079-01 surface for distortion. If distortion exceeds its limit, repair
it.
If repair is not possible, replace cylinder block.
3
Cylinder block flatness
Limit: 0.03 mm (0.0011 in.)
2

I9T401142032-01

2. Thread

I2RH01140199-01
1D-148 Engine Mechanical: K12M

I7V20A141126-01

Specifications
Tightening Torque Specifications
AENJCA0A1427001
NOTE
For fastener(s) with * (asterisk) below, refer to the specified procedure in “Repair Instructions”.

Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Cylinder head cover bolt* 3.0 Nm → 5.0 Nm → 7.5 Nm (0.31 kgf-m (Page 1D-88)
→ 0.51 kgf-m→ 0.76 kgf-m, 2.5 lbf-ft → 4.0
lbf-ft → 5.5 lbf-ft)
VVT actuator bolt 60 6.1 44.5 (Page 1D-91)
Camshaft housing bolt* 5.0 Nm → 8.0 Nm → 11 Nm (0.51 kgf-m (Page 1D-92)
→ 0.82 kgf-m → 1.1 kgf-m, 4.0 lbf-ft → 6.0
lbf-ft → 8.5 lbf-ft)
Exhaust camshaft timing sprocket bolt 60 6.1 44.5 (Page 1D-93)
Timing chain cover plug 25 2.5 18.5 (Page 1D-94)
Engine harness ground bolt 11 1.1 8.5 (Page 1D-102)
Engine left mounting nut 55 5.6 40.5 (Page 1D-103)
Engine left mounting bolt 55 5.6 40.5 (Page 1D-103)
Engine right mounting nut 65 6.6 48.0 (Page 1D-103)
Engine right mounting bolt 65 6.6 48.0 (Page 1D-103)
Timing chain cover bolt No.1* 25 2.5 18.5 (Page 1D-106)
Timing chain cover bolt No.2* 25 2.5 18.5 (Page 1D-106)
Crankshaft pulley bolt* 19 Nm → +75° (1.9 kgf-m → +75°, 14.0 lbf- (Page 1D-107)
ft → +75°)
OCV bolt 11 1.1 8.5 (Page 1D-108)
Flywheel bolt 83 8.5 61.5 (Page 1D-109)
Timing chain guide bolt 11 1.1 8.5 (Page 1D-112)
Timing chain tensioner bolt 25 2.5 18.5 (Page 1D-112)
Timing chain tensioner adjuster bolt 11 1.1 8.5 (Page 1D-113)
Cylinder head bolt* 20 Nm → 40 Nm → +60° → +60° (2.0 kgf- (Page 1D-117)
m → 4.1 kgf-m → +60° → +60°, 15.0 lbf-ft
→ 29.5 lbf-ft → +60° → +60°)
Venturi plug 3.5 0.36 2.5 (Page 1D-120)
Connecting rod bolt* 15 Nm → +65° (1.5 kgf-m → +65°, 11.0 lbf- (Page 1D-128)
ft → +65°)
Sensor plate screw 11 1.1 8.5 (Page 1D-137)
Main bearing cap bolt* 20 Nm → 40 Nm → +60° (2.0 kgf-m → 4.1 (Page 1D-139)
kgf-m → +60°, 15.0 lbf-ft → 29.5 lbf-ft →
+60°)
Oil seal housing bolt 11 1.1 8.5 (Page 1D-140)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
 Engine Mechanical: K12M 1D-149

“Air Cleaner Components”: K12M (Page 1D-81)

“Cylinder Head Cover Components”: K12M (Page 1D-86)
“Camshaft and Tappet Components”: K12M (Page 1D-89)
“Engine Mounting Components”: K12M (Page 1D-99)
“Timing Chain Cover Components”: K12M (Page 1D-104)
“Timing Chain and Chain Tensioner Components”: K12M (Page 1D-110)
“Valve and Cylinder Head Components”: K12M (Page 1D-115)
“Piston, Piston Ring and Connecting Rod Components”: K12M (Page 1D-125)
“Main Bearing, Crankshaft and Cylinder Block Components”: K12M (Page 1D-135)
“Fasteners Information” in Section 0A (Page 0A-6)

Special Tools and Equipment

Recommended Service Material
AENJCA0A1428001
Material SUZUKI recommended product or Specification Note
Sealant SUZUKI Bond No.1207F P/No.: 99000–31250 (Page 1D-87)
SUZUKI Bond No.1217G P/No.: 99000–31260 (Page 1D-106) / (Page
1D-139)

NOTE
Required service material(s) is also described in:
“Cylinder Head Cover Components”: K12M (Page 1D-86)
“Camshaft and Tappet Components”: K12M (Page 1D-89)
“Timing Chain Cover Components”: K12M (Page 1D-104)
“Timing Chain and Chain Tensioner Components”: K12M (Page 1D-110)
“Valve and Cylinder Head Components”: K12M (Page 1D-115)
“Piston, Piston Ring and Connecting Rod Components”: K12M (Page 1D-125)
“Main Bearing, Crankshaft and Cylinder Block Components”: K12M (Page 1D-135)

Special Tool
AENJCA0A1428002
09910M66820 09911M05120
Engine hook Box end wrench (14 mm)
(Page 1D-102) (Page 1D-93)

09911M16300 09911M97720
Oil seal installer Oil seal installer
(Page 1D-139) (Page 1D-140)

09913M66710 09913M70123
Bearing puller Bearing installer
(Page 1D-105) (Page 1D-97)
1D-150 Engine Mechanical: K12M

09913M75821 09915M64512
Bearing installer attachment Compression gauge
(Page 1D-109) (Page 1D-77)

09915M64530 09915M64550
Compression gauge hose Compression gauge
attachment (B)
(Page 1D-77) (Page 1D-77)

09915M67311 09916M14510
Vacuum gauge Valve lifter
(Page 1D-78) (Page 1D-118) /
(Page 1D-120)

09916M14522 09916M34542
Valve spring compressor Reamer handle
attachment
(Page 1D-118) / (Page 1D-118) /
(Page 1D-120) (Page 1D-119)

09916M34570 09916M37320
Valve guide reamer (5 mm) Valve guide outer reamer
(10.5 mm)
(Page 1D-119) (Page 1D-118)

09916M44310 09916M56011
Valve guide remover (5 mm) Valve guide installer
attachment (protrusion: 11.5
mm)
(Page 1D-118) (Page 1D-119)

09916M57330 09916M58210
Valve guide installer handle Valve guide installer handle
(Page 1D-119) (Page 1D-119)

09916M77310 09916M84511
Piston ring compressor (50 - Forceps
125 mm)
(Page 1D-127) (Page 1D-118) /
(Page 1D-120)
 Engine Mechanical: K12M 1D-151

09917M68222 09917M98221
Crankshaft pulley holder Valve guide stem
attachment
(Page 1D-105) / (Page 1D-119)
(Page 1D-107)

09921M20210 09924M17811
Bearing remover (12 mm) Flywheel holder
(Page 1D-108) (Page 1D-108) /
(Page 1D-109)

09926M58010 09930M30104
Bearing remover attachment Sliding shaft
(Page 1D-105) (Page 1D-108)

SUZUKI scan tool (Suzuki

SDT-II)
—
(Page 1D-78)
1E-1 Engine Lubrication System: K10B and Bi-Fuel CNG

Engine Lubrication System

Engine

K10B and Bi-Fuel CNG

General Description
Engine Lubrication Description
AENJCA0A1511001
The oil pump is a trochoid type, installed in the timing chain cover and is driven by the crankshaft.
Oil is drawn up through the oil pump strainer and passes through the pump to the oil filter. The filtered oil flows into the
main oil gallery in the cylinder block. Oil from the main gallery is supplied to the crankshaft main bearings and cylinder
head. Other oil passages are connected to backside of crankshaft No.1 main bearing. The following devices are
lubricated or pressurized by delivered oil as follows.
• Crankshaft journal
Main bearings supporting crankshaft journals are lubricated and the oil is supplied to the connecting rod bearings by
means of intersecting passages drilled in the crankshaft, and then splashed from the big end of each connecting rod
to lubricate cylinder wall, piston pin, piston and piston rings.
• Timing chain oil jet
Oil from an oil passage connected to No.1 main bearing back side is supplied to the jet and injected for lubrication
of the timing chain, timing sprockets, timing chain tensioner and timing chain guide.
• Tensioner adjuster
Oil from an oil passage connected to No.1 main bearing back side provides pressure to the tensioner adjuster for
adjustment of the chain tension.
• Cylinder head
Oil from the main gallery goes up to cylinder head and supplied to camshaft No.1 housing via a venturi plug and
then divided to intake camshaft and exhaust camshaft.
– Camshaft journal
Camshaft journals are lubricated by oil injected from small holes in each hollow camshaft.
– Cam surface and tappet
Oil flowing out of camshaft journal lubricates each cam surface and corresponding tappet.
The oil pump is equipped with a relief valve. This valve relieves oil pressure when the pressure exceeds specified
value.
The oil filter also provides a relief valve to bypass oil when oil pressure exceeds specified filtration resistance caused
by clogging of the filter element due to poor maintenance (without changing the filter as scheduled). In this situation,
dusty oil will circulate in the engine without filtration and causes the engine damage.
 Engine Lubrication System: K10B and Bi-Fuel CNG 1E-2

Cam surface & Tappet Pressurized oil

Splashed oil
Return oil
Bypass line

Intake camshaft Exhaust camshaft Piston ring Piston pin

Cylinder wall Piston

Crankshaft pin - Connecting rod

Chain cover Camshaft No.1 housing

Crankshaft main bearing - Main journal

Venturi plug

Tensioner adjuster
Cylinder head
Timing chain oil jet Timing chain - Chain
tensioner - Chain guide

Cylinder block (main gallery)

Oil filter
Oil filter
relief valve

Cylinder block

Oil pump
Oil pump
relief valve

Oil strainer

Oil pan
IJCA0A151001-03
1E-3 Engine Lubrication System: K10B and Bi-Fuel CNG

Diagnostic Information and Procedures

Oil Pressure Check 3) Install special tools to threaded hole where oil
AENJCA0A1514001 pressure switch was removed.
! CAUTION
Special tool
Touching a hot exhaust system component (A): 09915M77311
will cause a burn. (B): 09915M78211
Do not perform any service work on and
around the exhaust system until the exhaust
system is cool. (A)

NOTE
Before checking oil pressure, check the (B)
following points.
• Oil level in oil pan
If oil level is too low, add oil up to FULL
level mark (hole) (1) on oil level gauge.
(Page 1E-4)

IJCA0A151002-01

4) Start engine and warm it up to normal operating

temperature.
5) Measure oil pressure at 4,000 rpm.
Oil pressure specification
300 – 500 kPa (3.1 – 5.1 kgf/cm2, 43.5 – 72.5 psi)
at 4,000 rpm
6) Stop engine and remove special tools.
IYSQ01020012-01
7) Install oil pressure switch. (Page 1E-6)
2. Low level mark (hole)
8) Start engine and check oil pressure switch for oil
• Oil quality leakage. If oil leakage is found, repair incorrect
If oil is discolored or deteriorated, change installation of oil pressure switch.
it. (Page 1E-4)
• Oil leakage
If leakage is found, repair leaky point.

1) For M/T model, place gear shift lever in “Neutral” and

apply parking brake.
For auto gear shift model, place shift selector in “N”
and apply parking brake.
2) Remove oil pressure switch. (Page 1E-6)
 Engine Lubrication System: K10B and Bi-Fuel CNG 1E-4

Repair Instructions
Engine Oil and Filter Change 7) Loosen oil filter using special tool and remove oil
AENJCA0A1516001 filter.
! CAUTION
Special tool
There is an increased risk of severe personal (A): 09915M47341
injury or health problems if the procedure
described below is performed without taking
proper precautions.
• Engine oil has an adverse health effect.
Read and understand the instructions in (A)
“General Precautions” in Section 00 (Page
00-1) and follow all the instructions.
• Check that the engine is not running when
performing Step 1) – 12) of the procedure.
• Adequately ventilate the working area
when starting the engine in Step 13).
I7V20A151009-02
Before draining engine oil, check engine for oil leakage.
8) Wipe oil filter mounting surface of oil pan clean.
If any evidence of leakage is found, correct defective
part before proceeding to the following procedure. 9) Apply engine oil to new oil filter gasket.
1) Remove oil filler cap and oil level gauge from engine.
2) Hoist vehicle.
3) Drain engine oil by removing drain plug (1).
4) Remove drain plug gasket.
5) Wipe drain plug and its mounting surface.
6) 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) IYSQ01020009-01

10) Install the oil filter according to the following

procedure.
a) Tighten the oil filter (1) by hand until its gasket
touches the oil pan.
b) Using the special tool, rotate the oil filter three-
quarters of one turn (2) to tighten it.

NOTE
When tightening oil filter using torque
1, (a) wrench, apply 14 Nm (1.4 kgf-m, 10.5 lbf-ft).
I8C50B150002-01
Special tool
(A): 09915M47341

(A)
1

IBP60A151001-01
1E-5 Engine Lubrication System: K10B and Bi-Fuel CNG

11) Add oil up to FULL level mark (hole) on oil level Oil Pressure Switch On-Vehicle Inspection
gauge (oil pan and oil filter capacity). The filler inlet is AENJCA0A1516002

at top of cylinder head cover. ! CAUTION

Use only engine oil of SL, SM or SN grade. Touching a hot exhaust system component
Select the appropriate oil viscosity according to the will cause a burn.
chart [A]. Do not perform any service work on and
SAE 0W-16 oil is the best choice for good fuel around the exhaust system until the exhaust
economy and good starting in cold weather. system is cool.
NOTE
1) Disconnect oil pressure switch lead wire.
• Engine oil capacity is as specified below. 2) Check for continuity between oil pressure switch
However, note that actual amount of oil terminal (1) and cylinder block (2) as shown.
required during oil change may somewhat If check result is not as specified, replace oil
differ from that indicated below depending pressure switch (3).
on such factors as temperature, viscosity,
etc. Oil pressure switch specification
During engine running: No continuity
• Engine oil specification and viscosity chart
At engine stop: Continuity exists
[A] indicated in this manual are typical
ones. For the specific information on the
engine oil and proper engine oil viscosity,
refer to “Engine Oil and Filter” section of
the Owner's Manual.
1
Engine oil specification
Oil change only: About 2.6 liters (5.49 / 4.58 US / 3
Imp pt.)
2
Oil and oil filter change: About 2.8 liters (5.92 /
4.93 US / Imp pt.)
After overhaul: About 3.0 liters (6.34 / 5.28 US /
Imp pt.)
IJCA0A151003-01
Proper engine oil viscosity chart
[A] 20W-40

15W-40

10W-30, 10W-40

0W-16, 0W-20, 5W-30

o
C -30 -20 -10 0 10 20 30 40
o -22
F -4 14 32 50 68 86 104
IJHB0A151001-01

12) Install oil filler cap and oil level gauge to engine.
13) Start engine and run it for 3 minutes. Stop it and wait
for 5 minutes before checking oil level. Add oil, if
necessary, to bring oil level to FULL level mark (hole)
(1) on oil level gauge.
14) Check oil filter and drain plug for oil leakage.

IYSQ01020012-01

2. LOW level mark (hole)

 Engine Lubrication System: K10B and Bi-Fuel CNG 1E-6

Oil Pressure Switch Removal and Installation Installation

AENJCA0A1516009
1) Apply sealant to thread portion of oil pressure switch
Removal (1), and then tighten oil pressure switch to specified
torque.
! CAUTION
NOTICE
Touching a hot exhaust system component
If sealant is applied to the hole when
will cause a burn.
applying sealant to thread portion of the oil
Do not perform any service work on and
pressure switch, the engine oil pressure light
around the exhaust system until the exhaust
will not operate properly due to clogging.
system is cool.
Avoid applying sealant to the oil pressure
switch hole.
1) Disconnect oil pressure switch lead wire (1).
2) Remove oil pressure switch (2) from cylinder block. “A”: Thread lock cement 99000–32150 (Thread
Lock Cement Super 1322)
Tightening torque
Oil pressure switch (a): 13 N·m (1.3 kgf-m, 9.5
lbf-ft)
2
1

1 “A”

1, (a)

IJCA0A151004-01

IJCA0A151005-01

2) Connect oil pressure switch lead wire.

1E-7 Engine Lubrication System: K10B and Bi-Fuel CNG

Oil Pan and Oil Pump Strainer Components

AENJCA0A1516003

(a)

5
1

OIL
1
OIL

4
(a) 4

3 1217G

(a)

10 (a) 11 (a)

12 (a)
6
8 (c)

13 (a)

7 (d)

9
OIL

(b)

(e)
IELA0B150001-01
 Engine Lubrication System: K10B and Bi-Fuel CNG 1E-8

1. O-ring 8. Oil filter stand : 14 Nm (1.4 kgf-m, 10.5 lbf-ft)

: Apply engine oil.
2. Strainer 9. Oil filter : 18 Nm (1.8 kgf-m, 13.5 lbf-ft)
: For tightening order, refer to “Engine Oil and Filter
Change”: K10B and Bi-Fuel CNG (Page 1E-4).
: Apply engine oil to oil filter gasket.
3. Oil pan 10. Oil pump strainer bolt : 35 Nm (3.6 kgf-m, 26.0 lbf-ft)
: Apply sealant 99000-31260 : For tightening order, refer to “Oil Pan and Oil Pump
to mating surface. Strainer Removal and Installation”: K10B and Bi-Fuel CNG
(Page 1E-8).
4. Dowel pin 11. Oil pump strainer bracket nut : 55 Nm (5.6 kgf-m, 40.5 lbf-ft)
: For tightening order, refer to “Oil Pan and Oil Pump
Strainer Removal and Installation”: K10B and Bi-Fuel CNG
(Page 1E-8).
5. Oil pan baffle plate 12. Oil pan bolt No.1 : Do not reuse.
: For tightening order, refer to “Oil Pan and Oil Pump
Strainer Removal and Installation”: K10B and Bi-Fuel CNG
(Page 1E-8).
6. Gasket 13. Oil pan bolt No.2
: For tightening order, refer to “Oil Pan and Oil Pump
Strainer Removal and Installation”: K10B and Bi-Fuel CNG
(Page 1E-8).
7. Drain plug : 11 Nm (1.1 kgf-m, 8.5 lbf-ft)

Oil Pan and Oil Pump Strainer Removal and

Installation
AENJCA0A1516004

Removal
1) Remove oil level gauge.
2) Hoist vehicle.
3) Drain engine oil. (Page 1E-4) 4
3
4) Remove exhaust pipe. (Page 1K-5)
5) Remove belt tensioner arm. (Page 1J-9)
6) Remove engine rear torque rod bracket. (Page
1D-23)
2
7) Remove oil filter. (Page 1E-4)
8) Remove transaxle bolts (1).
9) Remove oil pan bolts (2).
1

IELA0A150008-01

IFRA0B152007-01

10) Using a large flat-bladed screwdriver (heavy duty

type) or the like, open oil pan gradually and carefully
from the lug portions and remove it from cylinder
block.
11) Remove oil pump strainer (1) with O-ring (2) from
cylinder block.
12) Remove oil pan baffle plate (3) from cylinder block.
13) Remove stud bolt (4) from cylinder block, if
necessary.
1E-9 Engine Lubrication System: K10B and Bi-Fuel CNG

14) Remove oil filter stand (1) from oil pan using special 4) Install oil pan baffle plate (2) and then tighten oil pan
tool and wrenches, if necessary. baffle plate bolts (3) to specified torque.
Special tool Tightening torque
(A): 09915M47350 Oil pan baffle plate bolt (b): 11 N·m (1.1 kgf-m,
8.5 lbf-ft)

(A)

1 1,(a)

IFRA0A151015-01

Installation
1) Remove oil, old sealant and dust from sealing
surface.
3,(b)
2) Install oil filter stand (1) to oil pan, if removed, and IELA0A150009-01
tighten it with special tool to specified torque.
5) Apply engine oil to new O-ring (2) and then install O-
Special tool ring to oil pump strainer (1).
(A): 09915M47350 6) Install oil pump strainer with O-ring to oil pump and
Tightening torque then tighten bolt (3) first and nut (4) to specified
Oil filter stand (a): 18 N·m (1.8 kgf-m, 13.5 lbf-ft) torque.
Tightening torque
Oil pump strainer bolt (a): 11 N·m (1.1 kgf-m, 8.5
lbf-ft)
Oil pump strainer bracket nut (b): 11 N·m (1.1
(A) kgf-m, 8.5 lbf-ft)

1, (a)

IFRA0A151016-01

3) Install oil pan baffle plate stud bolt (1) if removed and
then tighten oil pan baffle plate stud bolt to specified 2
torque.
Tightening torque
Oil pan baffle plate stud bolt (a): 11 N·m (1.1 kgf- 4, (b)
m, 8.5 lbf-ft)
3, (a)
1
IELA0A150010-02
 Engine Lubrication System: K10B and Bi-Fuel CNG 1E-10

7) Install dowel pins (1) to oil pan and cylinder block. 11) Within 2 minutes after applying sealant, install oil pan
to cylinder block and then tighten oil pan bolts No.1
(1) and oil pan bolt No.2 (2) in numerical order (“1” –
“17”) evenly and gradually to specified torque.
Tightening torque
Oil pan bolt No.1 (a): 11 N·m (1.1 kgf-m, 8.5 lbf-
ft)
Oil pan bolt No.2 (b): 11 N·m (1.1 kgf-m, 8.5 lbf-
ft)
1
1 ,“9”,(a) 2 ,“1”,(b) 1 ,“7 ”,(a)
1 ,“5”,(a) 1 ,“3 ”,(a) 1 ,“1 3 ”,(a)

1,“11”,(a)

1,“15”,(a)
IELA0A150011-02 1,“16”,(a)

8) Clean mating surfaces of oil pan and cylinder block.

9) Apply engine oil to new O-ring (1) and then install O-
ring to the position as shown in figure.
1,“14”,(a)
10) Apply sealant to oil pan mating surface as shown in
1,“17”,(a)
figure.
“A”: Sealant 99000–31260 (SUZUKI Bond 1,“12”,(a)
No.1217G)
1 ,“8”,(a) 1 ,“2”,(a) 1 ,“10”,(a)
Sealant amount for oil pan 1 ,“4 ”,(a) 1 ,“6 ”,(a)
IELA0A150012-01
Width: “a”: 3 mm (0.12 in.)
Height “b”: 2 mm (0.08 in.) 12) Tighten transaxle bolts (1) to specified torque.
Tightening torque
Transaxle bolt (a): 55 N·m (5.6 kgf-m, 40.5 lbf-ft)

“a” 1, (a)
“A” 1 “A”
“b” I8C50B150010-01

13) Install oil filter. (Page 1E-4)

I8C50A150019-01 14) Install engine rear torque rod bracket. (Engine
Mounting Components) (Page 1D-23)
15) Install belt tensioner arm. (Page 1J-9)
16) Install exhaust pipe. (Page 1K-5)
17) Install oil level gauge.
18) Install drain plug and refill engine with engine oil.
(Page 1E-4)
19) Check that there is no engine oil leakage and
exhaust gas leakage.
1E-11 Engine Lubrication System: K10B and Bi-Fuel CNG

Oil Pump Assembly Components

AENJCA0A1516005

OIL

OIL
4
OIL

(a)
OIL

6
OIL

8 (b)
IJCA0A151006-01

1. Rotor plate 5. Inner rotor 9. Timing chain cover

: Apply engine oil.
: For installation, refer to “Oil Pump
Assembly Disassembly and
Reassembly”: K10B and Bi-Fuel CNG
(Page 1E-12).
2. O-ring 6. Relief valve : 11 Nm (1.1 kgf-m, 8.5 lbf-ft)
: Apply engine oil. : Apply engine oil.
3. Oil gallery pipe 7. Spring : 28 Nm (2.9 kgf-m, 21.0 lbf-ft)
: Apply engine oil.
4. Outer rotor 8. Retainer : Do not reuse.
: Apply engine oil.
: For installation, refer to “Oil Pump
Assembly Disassembly and
Reassembly”: K10B and Bi-Fuel CNG
(Page 1E-12).

Oil Pump Assembly Removal and Installation

AENJCA0A1516006
Oil pump is incorporated in timing chain cover.
For removal and installation, refer to “Timing Chain
Cover Removal and Installation”: K10B and Bi-Fuel CNG
in Section 1D (Page 1D-31).
 Engine Lubrication System: K10B and Bi-Fuel CNG 1E-12

Oil Pump Assembly Disassembly and 3) Install outer rotor (1) and inner rotor (2) to timing
Reassembly chain cover.
AENJCA0A1516007
NOTE
Disassembly When installing the outer rotor and inner
1) Remove rotor plate (1) by removing its mounting rotor, face the front marks (3) toward cylinder
bolts (2). block.

1
3

2 2 2
IJCA0A151007-01

2) Remove outer rotor (1) and inner rotor (2). IJCA0A151008-01

4) Apply engine oil to relief valve (1) and spring (2), and
1 install them to rotor plate (4).
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 1

I7V20A151021-01 4 2

3) Remove relief valve (1) and spring (2) by removing

retainer (3). 3,(a)

I7V20A151023-01

6) Install rotor plate and tighten all bolts to specified

torque. After installing plate, check that rotors turn
smoothly by hand.
Tightening torque
Oil pump rotor plate bolt (a): 11 N·m (1.1 kgf-m,
1 8.5 lbf-ft)
2

3
(a)
I7V20A151022-01

Reassembly
1) Clean and then dry all disassembled parts.
2) Apply thin coat of engine oil to inner and outer rotors,
oil seal lip portion, inside surfaces of timing chain
cover and plate.

(a) (a)
IJCA0A151009-01
1E-13 Engine Lubrication System: K10B and Bi-Fuel CNG

Oil Pump Inspection Radial clearance

AENJCA0A1516008 Check radial clearance between outer rotor (1) and
timing chain cover (2) using feeler gauge (3).
Oil Seal
If clearance is out of specification, replace rotor set or oil
Check oil seal lip for excessive wear or damage.
pump assembly.
Replace it if necessary.
Radial clearance between outer rotor and timing
chain cover
Standard: 0.135 – 0.205 mm (0.0054 – 0.0080 in.)
Limit: 0.210 mm (0.0083 in.)

I2RH0B150023-01
1
Oil Pump
2
• Check outer rotor (1), inner rotor (2), rotor plate and
IFRA0A151013-01
timing chain cover for excessive wear or damage.
Side clearance
1
Using straightedge (1) and feeler gauge (2), measure
side clearance.
If side clearance is out of specification, replace oil pump
assembly.
Side clearance of oil pump inner rotor
Standard: 0.024 – 0.069 mm (0.0010 – 0.0027 in.)
Limit: 0.103 mm (0.0041 in.)
Side clearance of oil pump outer rotor
2 Standard: 0.038 – 0.083 mm (0.0015 – 0.0032 in.)
Limit: 0.103 mm (0.0041 in.)
I7V20A151021-01

• Check that relief valve (1) is not excessively worn or

damaged and operates smoothly.
1

1
IFRA0A151014-01

I7V20A151025-01
 Engine Lubrication System: K10B and Bi-Fuel CNG 1E-14

Relief valve spring free length and load

Check relief valve spring free length and load as shown
in figure. If any of measurement is smaller than
specification, replace relief valve spring.
Relief valve spring free length and load
Standard Limit
32.7 mm
Free length —
(1.29 in.)
Load at spring
54.5 N 48.3 N
length
(5.6 kgf, 12.3 lbf) (4.9 kgf, 10.9 lbf)
26.0 mm (1.02 in.)

I2RH01150023-01

Specifications
Tightening Torque Specifications
AENJCA0A1517001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Engine oil drain plug 35 3.6 26.0 (Page 1E-4)
Oil pressure switch 13 1.3 9.5 (Page 1E-6)
Oil filter stand 18 1.8 13.5 (Page 1E-9)
Oil pan baffle plate stud bolt 11 1.1 8.5 (Page 1E-9)
Oil pan baffle plate bolt 11 1.1 8.5 (Page 1E-9)
Oil pump strainer bolt 11 1.1 8.5 (Page 1E-9)
Oil pump strainer bracket nut 11 1.1 8.5 (Page 1E-9)
Oil pan bolt No.1 11 1.1 8.5 (Page 1E-10)
Oil pan bolt No.2 11 1.1 8.5 (Page 1E-10)
Transaxle bolt 55 5.6 40.5 (Page 1E-10)
Oil relief valve retainer 28 2.9 21.0 (Page 1E-12)
Oil pump rotor plate bolt 11 1.1 8.5 (Page 1E-12)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Oil Pan and Oil Pump Strainer Components”: K10B and Bi-Fuel CNG (Page 1E-7)
“Oil Pump Assembly Components”: K10B and Bi-Fuel CNG (Page 1E-11)
“Fasteners Information” in Section 0A (Page 0A-6)
1E-15 Engine Lubrication System: K10B and Bi-Fuel CNG

Special Tools and Equipment

Recommended Service Material
AENJCA0A1518001
Material SUZUKI recommended product or Specification Note
Sealant SUZUKI Bond No.1217G P/No.: 99000–31260 (Page 1E-10)
Thread lock cement Thread Lock Cement Super 1322 P/No.: 99000–32150 (Page 1E-6)

NOTE
Required service material(s) is also described in:
“Oil Pan and Oil Pump Strainer Components”: K10B and Bi-Fuel CNG (Page 1E-7)
“Oil Pump Assembly Components”: K10B and Bi-Fuel CNG (Page 1E-11)

Special Tool
AENJCA0A1518002
09915M47341 09915M47350
Oil filter wrench socket Oil filter stand remover
(Page 1E-4) / (Page 1E-9) /
(Page 1E-4) (Page 1E-9)

09915M77311 09915M78211
Oil pressure gauge Oil pressure gauge
attachment
(Page 1E-3) (Page 1E-3)
 Engine Lubrication System: K12M 1E-16

K12M
General Description
Engine Lubrication Description
AENJCA0A1521001
The oil pump is a trochoid type, installed in the timing chain cover and is driven by the crankshaft.
Oil is drawn up through the oil pump strainer and passes through the pump to the oil filter. The filtered oil flows into the
main oil gallery in the cylinder block. Oil from the main gallery is supplied to the crankshaft main bearings and cylinder
head. Another oil passage is connected to backside of crankshaft No.1 main bearing. The following devices are
lubricated or pressurized by delivered oil as follows.
• Crankshaft journal
Main bearings and crankshaft journals are lubricated and the oil is supplied to the connecting rod bearings by
means of intersecting passages drilled in the crankshaft, and then splashed from the big end of each connecting rod
to lubricate cylinder wall, piston pin, piston and piston rings.
• Timing chain oil jet
Oil from an oil passage between the main gallery and No.1 main bearing is supplied to the jet and injected for
lubrication of the timing chain, timing sprockets, timing chain tensioner and timing chain guide.
• Tensioner adjuster
Oil from an oil passage connected to No.1 main bearing back side provides pressure to the tensioner adjuster for
adjustment of the chain tension.
• Cylinder head
Oil from the main gallery goes up to cylinder head and supplied to OCV through the timing chain cover and the rest
of oil is supplied to camshaft No.2 housing via a venturi plug and then divided to intake and exhaust camshafts.
– Intake VVT actuator
Oil is supplied through the timing chain cover, OCV, cylinder head, camshaft No.1 housing and intake camshaft
for the camshaft timing control.
– Camshaft journal
No.1 journals are lubricated by oil from OCV through passages in cylinder head and camshaft No.1 housing.
Journals from No.2 to No.5 are lubricated by oil through each hollow camshaft.
– Cam surface and tappet
Oil flowing out of camshaft journal lubricates each cam surface and corresponding tappet.
The oil pump is equipped with a relief valve. This valve relieves oil pressure when the pressure exceeds specified
value.
The oil filter also provides a relief valve to bypass oil when oil pressure exceeds specified filtration resistance caused
by clogging of the filter element due to poor maintenance (without changing the filter as scheduled). In this situation,
dusty oil will circulate in the engine without filtration and causes the engine damage.
1E-17 Engine Lubrication System: K12M

Pressurized oil
Splashed oil
Return oil
Tappet
Bypass line
Cam surface

VVT actuator

Piston ring Piston pin

Intake camshaft Exhaust camshaft
Piston
Cylinder wall
Cam No.2 housing

Crankshaft pin - Connecting rod

Cam No.1 housing
OCV
Chain cover Crankshaft Main bearing - Main journal

Venturi plug
Tensioner adjuster

Cylinder head Timing chain - Chain

Timing chain oil jet
tensioner - Chain guide

Cylinder block (main gallery)

Oil filter
Oil filter
relief valve

Cylinder block

Oil pump
Oil pump
relief valve

Oil strainer

Oil pan
IJHA0B150001-01
 Engine Lubrication System: K12M 1E-18

Diagnostic Information and Procedures

Oil Pressure Check 1) For M/T model, place gear shift lever in “Neutral” and
AENJCA0A1524001 apply parking brake.
! CAUTION For auto gear shift model, place shift selector in “N”
Touching a hot exhaust system component and apply parking brake.
will cause a burn. 2) Remove oil pressure switch. (Page 1E-20)
Do not perform any service work on and 3) Install special tools to threaded hole where oil
around the exhaust system until the exhaust pressure switch was removed.
system is cool.
Special tool
(A): 09915M77311
NOTE
(B): 09915M78211
Before checking oil pressure, check the
following points. (B)
(A)
• Oil level in oil pan
If oil level is low, add oil up to FULL level
mark (hole) (1) on oil level gauge. (Page
1E-19)

I7V20A151003-01

4) Start engine and warm it up to normal operating

temperature.
5) Measure oil pressure at 4,000 rpm.
IYSQ01020012-01
Oil pressure specification
2. LOW level mark (hole) 300 – 500 kPa (3.1 – 5.0 kgf/cm2, 43.6 – 72.5 psi, 3
– 5 bar) at 4,000 rpm
• Oil quality
If oil is discolored or deteriorated, change 6) Stop engine.
it. (Page 1E-19) 7) Remove special tools.
• Oil leakage 8) Install oil pressure switch. (Page 1E-20)
If leakage is found, repair leaky point. 9) Start engine and check oil pressure switch for oil
leakage. If oil leakage is found, repair incorrect
installation of oil pressure switch.
1E-19 Engine Lubrication System: K12M

Repair Instructions
Engine Oil and Filter Change 7) Loosen oil filter using special tool and remove oil
AENJCA0A1526001 filter.
! CAUTION
Special tool
There is an increased risk of severe personal (A): 09915M47341
injury or health problems if the procedure
described below is performed without taking
proper precautions.
• Engine oil has an adverse health effect.
Read and understand the instructions in (A)
“General Precautions” in Section 00 (Page
00-1) and follow all the instructions.
• Check that the engine is not running when
performing Step 1) – 12) of the procedure.
• Adequately ventilate the working area
when starting the engine in Step 13).
I7V20A151009-02
Before draining engine oil, check engine for oil leakage.
8) Wipe oil filter mounting surface of oil pan clean.
If any evidence of leakage is found, correct defective
part before proceeding to the following procedure. 9) Apply engine oil to new oil filter gasket.
1) Remove oil filler cap and oil level gauge from engine.
2) Hoist vehicle.
3) Drain engine oil by removing drain plug (1).
4) Wipe drain plug clean.
5) Replace gasket with new one.
6) Reinstall drain plug and tighten it to specified torque.
Tightening torque
Engine oil drain plug (a): 35 N·m (3.6 kgf-m, 26.0
lbf-ft)
IYSQ01020009-01

10) Install the oil filter according to the following

procedure.
a) Tighten the oil filter (1) by hand until its gasket
touches the oil pan.
b) Using the special tool, rotate the oil filter a three-
quarter turn (2) to tighten it.

NOTE
1, (a) When tightening oil filter using torque
wrench, apply 14 Nm (1.4 kgf-m, 10.5 lbf-ft).
I8C50B150002-01

Special tool
(A): 09915M47341

(A)
1

IFRA0A151001-01
 Engine Lubrication System: K12M 1E-20

11) Add oil until oil level is brought to FULL level mark Oil Pressure Switch On-Vehicle Inspection
(hole) on oil level gauge (oil pan and oil filter AENJCA0A1526002

capacity). It is recommended to use engine oil of SL, ! CAUTION

SM or SN grade. Select appropriate oil viscosity
according to engine oil viscosity chart [A] below.
SAE 0W-16 oil is the best choice for good fuel
economy and good starting in cold weather.
NOTE
Touching a hot exhaust system component
will cause a burn.
Do not perform any service work on and
around the exhaust system until the exhaust
system is cool.

• Engine oil capacity is as specified below. 1) Disconnect oil pressure switch lead wire (1).
However, note that actual amount of oil 2) Check for continuity between oil pressure switch
required during oil change may somewhat terminal (2) and cylinder block (3) as shown.
differ from that indicated below depending If check result is not as specified, replace oil
on such factors as temperature, viscosity, pressure switch (4). (Page 1E-20)
etc.
Oil pressure sensor specification
• Engine oil specification and viscosity chart
With engine running: No continuity
[A] indicated in this manual are typical
At engine stop: Continuity exists
ones.
For the specific information on the engine
oil and proper engine oil viscosity, refer to
“Engine Oil and Filter” section of the
2
Owner's Manual.
4 1
Engine oil specification
3
Oil change only: About 2.9 liters (6.13 / 5.10 US /
Imp pt.)
Oil and oil filter change: About 3.1 liter (6.55 /
5.46 US / Imp pt.)
After overhaul: About 3.4 liters (7.19 / 5.98 US /
Imp pt.) I7V20A151006-01

[A] 20W-40 Oil Pressure Switch Removal and Installation

AENJCA0A1526003
15W-40

10W-30, 10W-40 Removal

0W-16, 0W-20, 5W-30
o
! CAUTION
C -30 -20 -10 0 10 20 30 40
o -22
F -4 14 32 50 68 86 104 To avoid the danger of being burned, do not
IJHB0A151001-01
touch the exhaust system when the system is
12) Install oil filler cap and oil level gauge to engine. hot.
13) Start engine and run it for 5 minutes. Stop it and wait Any service on the exhaust system should be
for 5 minutes before checking oil level. Add oil, if performed when the system is cool.
necessary, to bring oil level to FULL level mark (hole)
(1) on oil level gauge. 1) Disconnect oil pressure switch lead wire (1).
2) Remove oil pressure switch (2) from cylinder block.

IYSQ01020012-01

2. LOW level mark (hole)

1
I7V20A151002-01
14) Check oil filter and drain plug for oil leakage.
1E-21 Engine Lubrication System: K12M

Installation
1) Apply sealant to thread portion of oil pressure switch
(1), and then tighten oil pressure switch to specified
torque.

NOTICE
If sealant is applied to the hole when
applying sealant to thread portion of the oil
pressure switch, the engine oil pressure light
will not operate properly due to clogging.
Avoid applying sealant to the oil pressure
switch hole.

“A”: Thread lock cement 99000–32150 (Thread

Lock Cement Super 1322)
Tightening torque
Oil pressure switch (a): 13 N·m (1.3 kgf-m, 9.5
lbf-ft)

“A” 1

1, (a)

I9R90A150004-01

2) Connect oil pressure switch lead wire (1).

I7V20A151005-01
 Engine Lubrication System: K12M 1E-22

Oil Pan and Oil Pump Strainer Components

AENJCA0A1526004

4
(e)

OIL
1
OIL

1
3 1217G

12 (e)

11 (e)

9 (e)

(a)
7
5 (c)
8 (b)

10 (e) OIL

6 (d)
IJCA0A152001-03

1. O-ring 7. Gasket : 55 Nm (5.6 kgf-m, 40.5 lbf-ft)

: Apply engine oil.
2. Strainer 8. Drain plug : 35 Nm (3.6 kgf-m, 26.0 lbf-ft)
3. Oil pan 9. Oil pan No.1 bolt : 18 Nm (1.8 kgf-m, 13.5 lbf-ft)
: Apply sealant 99000-31260 to : For tightening order, refer to “Oil Pan and Oil
cylinder block mating surface. Pump Strainer Removal and Installation”: K12M
(Page 1E-23).
4. Dowel pin 10. Oil pan No.2 bolt : 14 Nm (1.4 kgf-m, 10.5 lbf-ft)
: For tightening order, refer to “Oil Pan and Oil
Pump Strainer Removal and Installation”: K12M
(Page 1E-23).
5. Oil filter stand 11. Oil pump strainer bolt : 11 Nm (1.1 kgf-m, 8.5 lbf-ft)
6. Oil filter 12. Oil pump strainer nut : Do not reuse.
: For tightening order, refer to “Engine
Oil and Filter Change”: K12M (Page
1E-19).
: Apply engine oil to oil filter gasket.
1E-23 Engine Lubrication System: K12M

Oil Pan and Oil Pump Strainer Removal and 11) Remove oil filter stand (1) from oil pan using special
Installation tool and wrenches, if necessary.
AENJCA0A1526005
Special tool
Removal (A): 09915M47350
1) Remove oil level gauge.
2) Hoist vehicle and remove right side splash cover.
3) Remove belt tensioner arm and belt tensioner pulley.
(Page 1J-27)
(A)
4) Drain engine oil by removing drain plug.
5) Remove oil filter. (Page 1E-19)
6) Remove exhaust pipe. (Page 1K-10) 1
7) Remove transaxle bolts (1).
8) Remove oil pan bolts (2).

IFRA0A151015-01

Installation
2 1) Remove oil, old sealant and dust from sealing
surface.
2) Install oil filter stand (1) to oil pan, if removed, and
tighten it with special tool to specified torque.
Special tool
1 (A): 09915M47350
I7V20A151012-01
Tightening torque
9) Using a large flat-bladed screwdriver (heavy duty Oil filter stand (a): 18 N·m (1.8 kgf-m, 13.5 lbf-ft)
type) or the like, open oil pan gradually and carefully
from the lug portions and remove it from cylinder
block.
10) Remove oil pump strainer (1) with O-ring (2) and
washer (3). (A)

1, (a)

IFRA0A151016-01

1
IFRA0A151003-01
 Engine Lubrication System: K12M 1E-24

3) Install strainer stud bolt (1) if removed, and tighten it 7) Clean mating surfaces of oil pan and cylinder block.
to specified torque. 8) Apply engine oil to new O-ring (1), and install it to
Tightening torque position as shown in figure.
Strainer stud bolt (a): 11 N·m (1.1 kgf-m, 8.5 lbf- 9) Apply sealant to oil pan mating surface as shown in
ft) figure.
4) Apply engine oil to new O-ring (2) and then install O- “A”: Sealant 99000–31260 (SUZUKI Bond
ring to oil pump strainer (3). No.1217G)
5) Install oil pump strainer with O-ring and washer (4) Sealant bead size for oil pan
and then tighten oil pump strainer bolt (5) and nut (6) Width “a”: 3 mm (0.12 in.)
to specified torque. Height “b”: 2 mm (0.08 in.)
Tightening torque
Oil pump strainer bolt (b): 11 N·m (1.1 kgf-m, 8.5
lbf-ft)
Oil pump strainer nut (c): 11 N·m (1.1 kgf-m, 8.5
lbf-ft)

“A” “a”
“A”
“b”

1, (a) IFRA0A151017-01
2
10) Within 2 minutes after applying sealant, install oil pan
4
to cylinder block and then tighten oil pan No.1 bolts
(1) and oil pan No.2 bolt (2) in numerical order (“1” –
“17”) evenly and gradually to specified torque.
3

5, (b) 6, (c)
Tightening torque
IFRA0A151004-01 Oil pan No.1 bolt (a): 11 N·m (1.1 kgf-m, 8.5 lbf-
6) Check that dowel pins (1) are installed in oil pan and ft)
cylinder block. Oil pan No.2 bolt (b): 11 N·m (1.1 kgf-m, 8.5 lbf-
ft)

1, “9”, (a) 1, “5”, (a) 1, “7”, (a)

1, “11”, (a) 2, “1”, (b) 1, “3”, (a) 1, “13”, (a)
1
1, “15”, (a)
1, “16”, (a)

1, “14”, (a)
1
1, “17”, (a)

1, “12”, (a) 1, “4”, (a) 1, “6”, (a)

IFRA0A151005-01 1, “8”, (a) 1, “2”, (a) 1, “10”, (a)
IFRA0A151006-01
1E-25 Engine Lubrication System: K12M

11) Tighten transaxle bolts (1) to specified torque.
Tightening torque
Transaxle bolt (a): 55 N·m (5.6 kgf-m, 40.5 lbf-ft)
12) Install exhaust pipe. (Page 1K-10)
13) Install oil filter. (Page 1E-19)
14) Install belt tensioner arm and belt tensioner pulley.
(Page 1J-27)
15) Install drain plug and refill engine with engine oil.
(Page 1E-19)
16) Install right side splash cover.
17) Install oil level gauge.
18) Check that there is no engine oil leakage and
exhaust gas leakage at each connection.

1, (a)

I9P60A151006-01

Oil Pump Assembly Components

AENJCA0A1526006

(b)

4
OIL
OIL

3 2

9 8
OIL

5
OIL

7 (a)

IJCA0A152002-01

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.
 Engine Lubrication System: K12M 1E-26

Oil Pump Assembly Removal and Installation Reassembly

AENJCA0A1526007
Oil pump is incorporated in timing chain cover. 1) Clean and then dry all disassembled parts.
For removal and installation, refer to “Timing Chain 2) Apply thin coat of engine oil to the following parts.
Cover Removal and Installation”: K12M in Section 1D • Inner rotor
(Page 1D-105). • Outer rotor
• Inside surfaces of timing chain cover
Oil Pump Assembly Disassembly and
3) Install outer rotor (1) and inner rotor (2) to timing
Reassembly
AENJCA0A1526008 chain cover.

Disassembly NOTE
1) Remove rotor plate (1) by removing rotor plate bolts. When installing the outer rotor and inner
rotor, face the front marks (3) toward cylinder
block.

IFRA0A151009-01
2
2) Remove outer rotor (1) and inner rotor (2).

IFRA0A151011-01

4) Apply engine oil to relief valve (1) and relief valve

spring (2), and install them to rotor plate (4).
5) Tighten retainer (3) to specified torque.
1
Tightening torque
Retainer (a): 28 N·m (2.9 kgf-m, 21.0 lbf-ft)

2
1

IFRA0A151010-01

3) Remove relief valve (1), relief valve spring (2) and 4 2

retainer (3).
3,(a)

I7V20A151023-01

I8C50A150023-02

4. Rotor plate
1E-27 Engine Lubrication System: K12M

6) Install rotor plate and tighten rotor plate bolts to • Check that relief valve (1) is not excessively worn or
specified torque. After installing plate, check that damaged and operates smoothly.
rotors turned smoothly by hand.
Tightening torque
Oil pump rotor plate bolt (a): 11 N·m (1.1 kgf-m,
8.5 lbf-ft)

(a)

I8C50A150024-02

Oil Pump Inspection I8C50A150029-01

AENJCA0A1526009
Radial clearance
Oil Seal Check radial clearance between outer rotor (1) and
Check oil seal lip for defects and damage. Replace it if timing chain cover (2) using feeler gauge (3).
necessary. If clearance is out of specification, replace oil pump
assembly.
Radial clearance between outer rotor and case of oil
pump
Standard: 0.135 – 0.205 mm (0.0054 – 0.0080 in.)
Limit: 0.225 mm (0.0088 in.)

I2RH0B150023-01

Oil Pump
1
• Check outer rotor (1), inner rotor (2), rotor plate and
timing chain cover for excessive wear or damage. 2
IFRA0A151013-01

IFRA0A151011-01

3. Front mark
 Engine Lubrication System: K12M 1E-28

Side clearance Relief valve spring free length and load

Using straightedge (1) and feeler gauge (2), measure Check free length and load of relief valve spring as
side clearance. shown in figure. If any of measurement is smaller than
If side clearance is out of specification, replace oil pump specification, replace relief valve spring.
assembly.
Relief valve spring free length and load
Side clearance of oil pump inner rotor Standard Limit
Standard: 0.024 – 0.069 mm (0.00095 – 0.00271 in.) 32.7 mm (1.29
Limit: 0.103 mm (0.00405 in.) Free length —
in.)
Side clearance of oil pump outer rotor Load at spring
54.5 N (5.6 kgf, 48.3 N (5.0 kgf,
Standard: 0.038 – 0.083 mm (0.0015 – 0.0032 in.) length
12.3 lbf) 10.9 lbf)
Limit: 0.103 mm (0.00405 in.) 26.0 mm (1.02 in.)

IFRA0A151014-01

I2RH01150023-01

Specifications
Tightening Torque Specifications
AENJCA0A1527001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Engine oil drain plug 35 3.6 26.0 (Page 1E-19)
Oil pressure switch 13 1.3 9.5 (Page 1E-21)
Oil filter stand 18 1.8 13.5 (Page 1E-23)
Strainer stud bolt 11 1.1 8.5 (Page 1E-24)
Oil pump strainer bolt 11 1.1 8.5 (Page 1E-24)
Oil pump strainer nut 11 1.1 8.5 (Page 1E-24)
Oil pan No.1 bolt 11 1.1 8.5 (Page 1E-24)
Oil pan No.2 bolt 11 1.1 8.5 (Page 1E-24)
Transaxle bolt 55 5.6 40.5 (Page 1E-25)
Retainer 28 2.9 21.0 (Page 1E-26)
Oil pump rotor plate bolt 11 1.1 8.5 (Page 1E-27)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Oil Pan and Oil Pump Strainer Components”: K12M (Page 1E-22)
“Oil Pump Assembly Components”: K12M (Page 1E-25)
“Fasteners Information” in Section 0A (Page 0A-6)
1E-29 Engine Lubrication System: K12M

Special Tools and Equipment

Recommended Service Material
AENJCA0A1528001
Material SUZUKI recommended product or Specification Note
Sealant SUZUKI Bond No.1217G P/No.: 99000–31260 (Page 1E-24)
Thread lock cement Thread Lock Cement Super 1322 P/No.: 99000–32150 (Page 1E-21)

NOTE
Required service material(s) is also described in:
“Oil Pan and Oil Pump Strainer Components”: K12M (Page 1E-22)
“Oil Pump Assembly Components”: K12M (Page 1E-25)

Special Tool
AENJCA0A1528002
09915M47341 09915M47350
Oil filter wrench socket Oil filter stand remover
(Page 1E-19) / (Page 1E-23) /
(Page 1E-19) (Page 1E-23)

09915M77311 09915M78211
Oil pressure gauge Oil pressure gauge
attachment
(Page 1E-18) (Page 1E-18)
 Engine Cooling System: K10B and Bi-Fuel CNG 1F-1

Engine Cooling System

Engine

K10B and Bi-Fuel CNG

Precautions
Precautions for Cooling System
AENJCA0A1610001
! WARNING
If the radiator cap is removed while the engine is hot and pressure is high, the inside coolant will
instantaneously boil up and spew out. This could cause severe burns or could cause a fire if coolant is
splashed over the hot engine and exhaust system components, as the coolant contains a flammable
anti-freeze material.
Never check the coolant level or add coolant by removing the radiator cap. Instead, check the coolant
level only on the coolant reservoir and, if necessary, add coolant to the reservoir.
Also, check that the engine coolant temperature is cold before removing any part of cooling system.

! CAUTION

• If service operations are performed on the engine cooling system with the battery connected, there
is a risk of injury by accidental movement of the radiator cooling fan or other electric components.
Disconnect the negative (–) cable at the battery terminal before performing any service operations
on the engine cooling system.
• The radiator cooling fan can come on whenever the ignition is “ON”. This electric fan starts
automatically anytime the ECT sensor senses a coolant temperature higher than a predetermined
level even when the engine is not running.
When the ignition is “ON”, keep hands, tools, clothing, and other items away from the radiator
cooling fan.
1F-2 Engine Cooling System: K10B and Bi-Fuel CNG

General Description
Cooling System Description Cooling Fan Operation Description
AENJCA0A1611001 AENJCA0A1611003
The cooling system consists of the radiator, coolant Radiator cooling fan motor is controlled by ECM as
reservoir, water pump, cooling fan and thermostat. The follows.
radiator is a tube-and-fin type.
[A]
Coolant Description
AENJCA0A1611002
The coolant recovery system is a standard system,
[B]
which allows part of coolant to flow from the radiator into
the coolant reservoir when it expands by heat. When the
95.0 97.0 (°C)
cooling system cools down, the coolant in the coolant
203.0 206.6 (°F)
reservoir is drawn back into the radiator. IJCA0A161001-01
The cooling system has been filled with a SUZUKI long [A]: ON [B]: OFF
life coolant (coolant color: Yellow) that is a 30/70 mixture
of ethylene glycol antifreeze and deionized water. This The following controls are also performed when A/C
coolant solution provides freezing protection to –14.5 °C switch is ON.
(5.9 °F). Cooling fan operates when A/C refrigerant pressure is
• This 30/70 mixture coolant also provides protection more than specified value of 1.1 MPa (11.2kgf/cm2, 160
against corrosion and loss of coolant from boiling. psi) or vehicle speed is lower than 30 km/h (19 mile/h).
Keep cooling system filled with this coolant even
where freezing temperatures are not expected. Fail-Safe
• When replenishing the system due to loss of coolant, Cooling fan operates at high speed if malfunction related
the same ethylene glycol base coolant should be used to ECT sensor is detected.
in order to ensure the same level of protection against
freezing and corrosion.

NOTICE
Using alcohol or methanol base coolant or
plain water alone may cause damage to the
cooling system.
Use the specified coolant.

Coolant table
°C –14.5
Freezing temperature
°F 5.9
Antifreeze / Anti-corrosion
% 30
coolant concentration

Coolant capacity
Petrol:
• Engine, radiator and heater: 2.9 liters (6.13/5.10
US/Imp pt.)
• Reservoir: 0.4 liters (0.85/0.70 US/Imp pt.)
• Total: 3.3 liters (6.97/5.81 US/Imp pt.)
Bi-fuel CNG:
• Engine, radiator and heater: 3.0 liters (6.34/5.28
US/Imp pt.)
• Reservoir: 0.4 liters (0.85/0.70 US/Imp pt.)
• Total: 3.4 liters (7.19/5.98 US/Imp pt.)
 Engine Cooling System: K10B and Bi-Fuel CNG 1F-3

Schematic and Routing Diagram

Coolant Circulation
AENJCA0A1612001

[A] [C]
7 8

5
4

3
2
1

[B] [C]
7 8

5
4

3
2
1

IJCA0A161002-02

[A]: Engine is cool (thermostat closed) 2. Radiator outlet hose 6. Radiator

[B]: Engine is normal at operating temperature (thermostat open) 3. Thermostat 7. Heater core
[C]: Bi-fuel CNG 4. Water pump 8. CNG pressure regulator
1. Radiator inlet hose 5. Engine
1F-4 Engine Cooling System: K10B and Bi-Fuel CNG
Radiator Cooling Fan Control System Circuit Diagram
2
1 BLU
+BB
4
GRY BLU 3 BLK
A1 B1
[A] C01
10 9 8 7 6 5 4 3 2 1
65 64 63 62 61 20 19 18 17 16 15 14 13 12 11
70 69 68 67 66 30 29 28 27 26 25 24 23 22 21
75 74 73 72 71 40 39 38 37 36 35 34 33 32 31
80 79 78 77 76 50 49 48 47 46 45 44 43 42 41
60 59 58 57 56 55 54 53 52 51
[A]: ECM connector (View: [a])
A1: Radiator cooling fan relay power supply circuit (switch side)
B1: Radiator cooling fan motor drive circuit
C1: Radiator cooling fan motor ground circuit
Diagnostic Information and Procedures
Engine Cooling Symptom Diagnosis
Condition Possible cause
Engine overheats Loose or broken water pump belt
(Radiator fan operates)
Not enough coolant
Faulty thermostat
Faulty water pump
Dirty or bent radiator fins
Coolant leakage on cooling system
Clogged radiator
Faulty radiator cap
Dragging brakes
Slipping clutch
Poorly charged battery
Poor electricity generated by generator Check generator. (Page 1J-5)
Faulty ECT sensor
Faulty radiator cooling fan motor
Faulty ECM
Faulty radiator cooling fan relay
Faulty wiring or grounding
Too many optional electric devices
AENJCA0A1612002
5
LT GRN E01-22
C1
6 5V
BLU C01-36
GRY C01-39
E01
[a]
9 8 7 6 5 4 3 2 1
57 56 55 18 17 16 15 14 13 12 11 10
60 59 58 27 26 25 24 23 22 21 20 19
63 62 61 36 35 34 33 32 31 30 29 28
66 65 64 45 44 43 42 41 40 39 38 37
54 53 52 51 50 49 48 47 46
IJCA0A161003-02
1. To main relay 5. ECM
2. Radiator cooling fan relay 6. ECT sensor
3. Radiator cooling fan motor
4. “RDTR” fuse
AENJCA0A1614001
Correction / Reference Item
Adjust or replace water pump belt. (Page 1J-
7)
Check coolant level and add if necessary.
(Page 1F-8)
Replace thermostat assembly. (Page 1F-11)
Replace water pump. (Page 1F-16)
Clean or repair. (Page 1F-15)
Check cooling system for leakage. (Page
1F-8)
Replace radiator. (Page 1F-15)
Check radiator cap. (Page 1F-8)
Check brake. (Page 4A-2)
Check clutch. (Page 5C-1)
Check battery. (Page 1J-4)
Check ECT sensor. (Page 1C-11)
Check radiator cooling fan motor. (Page 1F-
12)
Check ECM and its circuit.
• Petrol: (Page 1A-103)
• Bi-fuel CNG: (Page 1A-347)
Check radiator cooling fan relay. (Page 1F-
13)
Repair wiring.
Remove electrical devices.
 Engine Cooling System: K10B and Bi-Fuel CNG 1F-5

Condition Possible cause Correction / Reference Item

Engine overheats Blown fuse Check fuse.
(Radiator fan does not Faulty radiator cooling fan relay Check radiator cooling fan relay. (Page 1F-
operate) 13)
Faulty ECT sensor Check ECT sensor. (Page 1C-11)
Faulty radiator cooling fan motor Check radiator cooling fan motor. (Page 1F-
12)
Faulty wiring or grounding Repair wiring.
Faulty ECM Check ECM and its circuit.
• Petrol: (Page 1A-103)
• Bi-fuel CNG: (Page 1A-347)

Radiator Cooling Fan System Check

AENJCA0A1614002
Circuit Diagram

5
2
1 BLU LT GRN E01-22
+BB
4
GRY BLU 3 BLK
A1 B1 C1

6 5V
BLU C01-36

GRY C01-39

[A] C01 E01

10 9 8 7 6 5 4 3 2 1
65 64 63 62 61 20 19 18 17 16 15 14 13 12 11
70 69 68 67 66 30 29 28 27 26 25 24 23 22 21
75 74 73 72 71 40 39 38 37 36 35 34 33 32 31
80 79 78 77 76 50 49 48 47 46 45 44 43 42 41
60 59 58 57 56 55 54 53 52 51
[a]
9 8 7 6 5 4 3 2 1
57 56 55 18 17 16 15 14 13 12 11 10
60 59 58 27 26 25 24 23 22 21 20 19
63 62 61 36 35 34 33 32 31 30 29 28
66 65 64 45 44 43 42 41 40 39 38 37
54 53 52 51 50 49 48 47 46

IJCA0A161003-02

[A]: ECM connector (View: [a]) 1. To main relay 5. ECM

A1: Radiator cooling fan relay power supply circuit (switch side) 2. Radiator cooling fan relay 6. ECT sensor
B1: Radiator cooling fan motor drive circuit 3. Radiator cooling fan motor
C1: Radiator cooling fan motor ground circuit 4. “RDTR” fuse

Troubleshooting

NOTE
• For details of engine cooling fan operation, refer to “Cooling Fan Operation Description”: K10B and
Bi-Fuel CNG (Page 1F-2).
• Before beginning troubleshooting, read “Precautions for Engine”.
– Petrol: (Page 1-1)
– Bi-fuel CNG: (Page 1-4)
• When measuring circuit voltage, resistance and/or pulse signal of ECM, refer to “Inspection of ECM
and its Circuits”.
– Petrol: (Page 1A-103)
– Bi-fuel CNG: (Page 1A-347)
1F-6 Engine Cooling System: K10B and Bi-Fuel CNG

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.
• Petrol: (Page 1A-22)
• Bi-fuel CNG: (Page 1A-293)

Is there DTC(s)?
2 Radiator cooling fan operation control check Radiator cooling fan Go to Step 3.
1) Check radiator cooling fan control operation. (Page control system is in
1F-12) good condition.

Is check result OK?

3 Radiator cooling fan relay power supply circuit (switch Go to Step 4. Repair “A1” circuit.
side) check
1) Set ignition “OFF” and remove radiator cooling fan relay
from individual circuit fuse box No.1.
2) Check for proper connection to radiator cooling fan relay
at each terminal.
3) If OK, measure voltage between “A1” circuit and ground.

Is it 10 – 14 V?
4 Radiator cooling fan relay check Go to Step 5. Replace radiator cooling
1) Check radiator cooling fan relay. (Page 1F-13) fan relay.

Is check result OK?

5 Radiator cooling fan motor drive circuit check Go to Step 6. Repair “B1” circuit.
1) Set ignition “OFF” and disconnect radiator cooling fan
motor connector.
2) Check for proper connection to radiator cooling fan
motor at each terminal.
3) If OK, check the following points.
• Resistance of “B1” circuit: 1 Ω or less
• Resistance between “B1” circuit and ground: infinity
• Voltage of “B1” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

6 Radiator cooling fan motor ground circuit check Go to Step 7. Repair “C1” circuit.
1) Measure resistance between “C1” circuit and ground.

Is resistance 1 Ω or less?
7 Radiator cooling fan motor check Replace ECM and Replace radiator cooling
1) Check radiator cooling fan motor. (Page 1F-12) recheck radiator cooling fan motor. (Page 1F-
fan system. (Page 14)
Is check result OK? 1C-3)
 Engine Cooling System: K10B and Bi-Fuel CNG 1F-7

Repair Instructions
Cooling System Components
AENJCA0A1616001

6
8
1

(d)
2
[a] 3
(f)

5
(e)
11 4

10

(e)

[b]
7
12 9 18
19
[a]

7
13 20 (b)

(a) 17
16
28
18

15
26
(a)

31
30
22
25
21
(a)
(a)
[A] (c)
27
[B] (g)

(a)
24
14 (a) 30

[b] 23 1207F

29

31
IJCA0A161004-04
1F-8 Engine Cooling System: K10B and Bi-Fuel CNG

[A]: For galvanized bolt
[B]: For paint coated bolt
1. Radiator
2. Radiator cooling fan
3. Radiator cooling fan shroud
4. Radiator cooling fan motor
5. Heat insulator
6. Radiator support upper mount
7. Radiator support lower mount
8. Radiator cap
9. Drain plug
10. Reservoir hose
11. Reservoir cap
12. Reservoir
13. Radiator inlet hose 27. Heater outlet hose
14. Radiator outlet hose 28. CNG water inlet hose (Bi-fuel CNG)
15. Thermostat cap 29. CNG water outlet hose (Bi-fuel CNG)
16. Thermostat 30. To heater core
: For installation, refer to “Thermostat Removal
and Installation”: K10B and Bi-Fuel CNG (Page
1F-11).
17. Thermostat case 31. To CNG pressure regulator (Bi-fuel CNG)
18. Gasket : 25 Nm (2.5 kgf-m, 18.5 lbf-ft)
: Match gasket with a shape of the mating face
of cylinder head.
19. Cylinder head : 12 Nm (1.2 kgf-m, 9.0 lbf-ft)
20. ECT sensor : 11 Nm (1.1 kgf-m, 8.5 lbf-ft)
21. Water inlet pipe : 5.5 Nm (0.56 kgf-m, 4.0 lbf-ft)
22. O-ring : 3.5 Nm (0.36 kgf-m, 2.5 lbf-ft)
23. Water pump : 2.5 Nm (0.25 kgf-m, 2.0 lbf-ft)
: Apply sealant 99000-31250 referring to “Water
Pump Removal and Installation”: K10B and Bi-
Fuel CNG (Page 1F-16).
24. Generator arm : 20 Nm (2.0 kgf-m, 15.0 lbf-ft)
25. Water pump pulley : Do not reuse.
26. Heater inlet hose

Coolant Level Check Engine Cooling System Inspection

AENJCA0A1616002
Before performing the following procedure, observe
“Precautions for Cooling System”: K10B and Bi-Fuel
CNG (Page 1F-1).
It is not necessary to remove radiator cap to check
coolant level.
When engine is cool, check coolant level in reservoir (1).
Normal coolant level should be between “FULL” mark (2)
and “LOW” mark (3) on reservoir.
If coolant level is below “LOW” mark, remove reservoir
cap (4) and add proper coolant to reservoir to bring
coolant level up to “FULL” mark.
NOTE
If proper quality antifreeze is used, there is
no need to add extra rust inhibitors or other
additives that claim to improve system. They
may be harmful to proper operation of
system, and are unnecessary expense.
AENJCA0A1616003
Before performing the following procedure, observe
“Precautions for Cooling System”: K10B and Bi-Fuel
CNG (Page 1F-1).
1) Check cooling system for leakage or damage.
2) Remove radiator cap.
3) Check coolant for proper level and freeze protection.
4) Check cooling system for coolant leakage according
to the following procedure.
a) Attach pressure tester (1) to radiator, and then
apply specified pressure to cooling system.
Cooling system holding pressure
123 kPa (1.3 kgf/cm2, 17.8 psi, 1.23 bar)

3
I8T401162005-01
4 b) Check that cooling system holds the pressure.
If cooling system does not hold applied pressure,
check cooling system for leakage.

IJCA0A161005-01

5) Check radiator cap according to the following
procedure.
a) Attach pressure tester (1) to radiator cap (2), and
then apply specified pressure.
Radiator cap valve opening pressure
93 – 123 kPa (0.9 – 1.3 kgf/cm2, 13.5 – 17.8 psi,
0.93 – 1.23 bar)
1 2
IFRA0A161006-01
b) If radiator cap valve opening pressure is out of
specification, replace radiator cap.
6) Detach pressure tester and rinse off spilled coolant.
7) Install radiator cap on radiator.
Cooling System Draining
AENJCA0A1616004
Before performing the following procedure, observe
“Precautions for Cooling System”: K10B and Bi-Fuel
CNG (Page 1F-1).
1) Remove radiator cap.
2) Drain coolant from drain plug (1).
3) Tighten drain plug securely.
NOTICE
If drain plug is tightened excessively, the
plug could be damaged.
Do not tighten the drain plug too much.
Tightening torque
Drain plug (reference torque) (a): 1.0 N·m (0.10
kgf-m, 1.0 lbf-ft)
1, (a)
IJCA0A161006-01
Engine Cooling System: K10B and Bi-Fuel CNG 1F-9
Cooling System Refilling
AENJCA0A1616005
Before performing the following procedure, observe
“Precautions for Cooling System”: K10B and Bi-Fuel
CNG (Page 1F-1).
1) Fill reservoir (1) with coolant up to “FULL” mark (2).
2) Install reservoir cap (3) on reservoir.
2
1
IJCA0A161007-01
3) Fill radiator with coolant up to bottom of radiator filler
neck and install radiator cap. (Page 1F-2)
4) Run engine at idle speed until radiator fan motor is
operated.
5) Stop engine and wait until engine cools down fully.
6) Add coolant to radiator up to bottom of radiator filler
neck, and install radiator cap.
7) Repeat Step 4) – 6).
8) Check that coolant level in reservoir is at “FULL”
mark. If coolant is insufficient, add coolant.
9) Check cooling system for leakage. (Page 1F-8)
1F-10 Engine Cooling System: K10B and Bi-Fuel CNG

Water Inlet Pipe Removal and Installation Installation

AENJCA0A1616006 Reverse removal procedure noting the following points.
Removal • Use new O-ring (2).
1) Drain coolant. (Page 1F-9) • Apply coolant to O-ring and insert water inlet pipe (1)
all the way into cylinder block.
2) For auto gear shift model, remove auto gear shift
actuator unit. (Page 5D-104)
3) Remove intake manifold. (Page 1D-9)
4) Disconnect the following hoses and clamps from
water inlet pipe.
• Heater outlet hose (1)
• Radiator outlet hose (2)
• CNG water outlet hose (Bi-fuel CNG) (3)
2

1 1
IJCA0A161011-01

• Tighten thermostat case nut (1) to specified torque.

3 Tightening torque
Thermostat case nut (a): 25 N·m (2.5 kgf-m, 18.5
lbf-ft)

2
IJCA0A161008-01

5) Remove thermostat case nut (1) and water inlet pipe

bolt (2) from water inlet pipe (3).

1, (a)

1 2 IJCA0A161012-01

• If there is matchmark on each of hose and pipe, install

the hose aligning matchmark on hose with matchmark
on pipe and then install each clamp in proper position.
3 • For auto gear shift model, install auto gear shift
actuator unit. (Page 5D-104)
IJCA0A161009-01 • Refill cooling system with coolant. (Page 1F-9)
6) Remove water inlet pipe (1) with O-ring (2). • Check cooling system for leakage. (Page 1F-8)

1
IJCA0A161010-01
 Engine Cooling System: K10B and Bi-Fuel CNG 1F-11

Thermostat Removal and Installation • Tighten thermostat cap bolts (1) to specified torque.
AENJCA0A1616007
Removal Tightening torque
1) Drain coolant. (Page 1F-9) Thermostat cap bolt (a): 25 N·m (2.5 kgf-m, 18.5
lbf-ft)
2) Remove thermostat cap (1) from thermostat case
(2).

1, (a)

IJCA0A161016-01

• Refill cooling system with coolant. (Page 1F-9)

IJCA0A161013-01

3) Remove thermostat (1) from thermostat case (2). • Check cooling system for leakage. (Page 1F-8)

Thermostat Inspection
AENJCA0A1616008

2 • Check that air bleed valve (1) is clean.

• Check that valve seat (2) is free from foreign material
that would prevent valve from seating tight.
• Check thermostat seal (3) for breakage, deterioration
or any other damage.
1

IJCA0A161014-01

Installation
Reverse removal procedure noting the following points.
• Install thermostat (1) to thermostat case (2) by
aligning air bleed valve (3) of thermostat with mark (4) I3RM0A160008-01
of thermostat case.

4
3

2
1

IJCA0A161015-01
1F-12 Engine Cooling System: K10B and Bi-Fuel CNG

• Check thermostat operation as follows. Radiator Cooling Fan Assembly On-Vehicle

a. Immerse thermostat (1) in water, and heat water Inspection
AENJCA0A1616009
gradually.
Radiator Cooling Fan Operation
b. Check that wax pellet starts to open at specific
1) Connect SUZUKI scan tool to DLC (1) with ignition
temperature.
“OFF”.
Temperature at which valve starts to open (lift
Special tool
0.05 mm (0.002 in))
(A): SUZUKI scan tool (Suzuki SDT-II)
86.5 – 89.5 °C (187.7 – 193.1 °F)
Temperature at which valve becomes fully
open
100 °C (212 °F)
Valve lift
More than 8 mm (0.31 in) at 100 °C (212 °F) 1

(A)

I2RH01160012-01 IJCA0A181004-01

2. Thermometer 3. Heater 2) Set ignition “ON” and clear DTC.

• Petrol: (Page 1A-23)
• If check result is not as specified, replace thermostat. • Bi-fuel CNG: (Page 1A-23)
(Page 1F-11)
3) Select “Radiator Fan” function in “Active Test”.
4) Check radiator cooling fan operation.
If any abnormality is found, check cooling fan control
system. (Page 1F-5)

Radiator Cooling Fan Motor

1) Disconnect radiator cooling fan motor connector (1).

IJCA0A161017-01
 Engine Cooling System: K10B and Bi-Fuel CNG 1F-13

2) Using service wire, connect radiator cooling fan 4) Disconnect radiator cooling fan motor connector (1).
motor connector and battery as shown in figure. 5) Disconnect radiator outlet hose (2).

IJCA0A161018-01
IJCA0A161020-01
3) Check that radiator cooling fan motors rotate
smoothly and properly. 6) Remove radiator cooling fan shroud bolts (1) and
If any abnormality is found, replace radiator cooling radiator cooling fan assembly (2) from radiator.
fan motor.
1
Reference: Fan motor specified current at 12 V
10 – 11 A 1

Radiator Cooling Fan Relay Inspection 2

AENJCA0A1616010
Refer to “Control Relay Inspection” in Section 10B (Page
10B-51).

Radiator Cooling Fan Assembly Removal and

Installation
AENJCA0A1616011

Removal IJCA0A161021-01

1) Disconnect negative (–) cable at battery.

2) Drain coolant. (Page 1F-9)
3) Remove reservoir (1).

1 1
IJCA0A161022-01

IJCA0A161019-01
1F-14 Engine Cooling System: K10B and Bi-Fuel CNG

Installation Radiator Cooling Fan Disassembly and

Reverse removal procedure noting the following points. Reassembly
AENJCA0A1616012
• Tighten radiator cooling fan shroud bolts (1) to
specified torque.
Disassembly
Tightening torque 1) Remove radiator cooling fan (1) from radiator cooling
Radiator cooling fan shroud bolt (a): 5.5 N·m ( fan motor (2).
0.56 kgf-m, 4.0 lbf-ft) 2) Remove radiator cooling fan motor from radiator
cooling fan shroud (3).
1, (a)

NOTE
1, (a)
Turn radiator cooling fan motor nut clockwise
to loosen it.

3) Remove heat insulator (4) from radiator cooling fan

shroud.

1
3

IJCA0A161023-01
4

IJCA0A161025-01

1, (a) 1, (a)
IJCA0A161024-01

• If there is matchmark on each of hose and pipe, install

the hose aligning matchmark on hose with matchmark
on pipe and then set each clamp to the original
position.
• Refill cooling system with coolant. (Page 1F-9)
• Check cooling system for leakage. (Page 1F-8)
 Engine Cooling System: K10B and Bi-Fuel CNG 1F-15

Reassembly Radiator Removal and Installation

Reverse disassembly procedure noting the following AENJCA0A1616014

point.
Removal
• Tighten radiator cooling fan nut, radiator cooling fan
1) Disconnect negative (–) cable at battery.
motor screws and heat insulator screws to specified
torque. 2) Drain coolant. (Page 1F-9)
3) Remove radiator cooling fan assembly. (Page 1F-
NOTE 13)
Turn radiator cooling fan motor nut 4) Remove front bumper. (Page 9H-3)
counterclockwise to tighten it.
5) Remove condenser upper and lower bolts. (Page
Tightening torque 7B-35)
Radiator cooling fan nut (a): 3.5 N·m (0.36 kgf-m, NOTICE
2.5 lbf-ft)
Radiator cooling fan motor screw (b): 3.5 N·m ( The A/C condenser assembly may be
0.36 kgf-m, 2.5 lbf-ft) damaged if it hits against or interferes with
Heat insulator screw (c): 2.5 N·m (0.25 kgf-m, 2.0 other parts.
lbf-ft) Suspend the removed A/C condenser
assembly in a place where no damage will be
caused during removal and installation of the
radiator.
(c)
(a)
6) Disconnect radiator inlet hose (1) from radiator.

(b)

IJCA0A161026-01

Radiator On-Vehicle Inspection and Cleaning 1

AENJCA0A1616013
Inspection
Check radiator for leakage or damage. Straighten bent
fins, if any.
IJCA0A161027-01

Cleaning 7) Support front lower crossmember (1) with jack (2).

Clean frontal area of radiator cores. 8) Remove front lower crossmember bolts (3), and then
lower jack and remove radiator with front lower
crossmember.

3 3
I2RH01160014-01

1 2

IJCA0A161028-01

9) Remove radiator from front lower crossmember.

1F-16 Engine Cooling System: K10B and Bi-Fuel CNG

Installation 3) Within 2 minutes after applying sealant, install water

Reverse removal procedure noting the following points. pump (1) with generator arm (3) to cylinder block
• If there is matchmark on each of hose and pipe, install and tighten bolts and nuts to specified torque.
the hose aligning matchmark on hose with matchmark Tightening torque
on pipe and then install each clamp in proper position. Water pump bolt (a): 25 N·m (2.5 kgf-m, 18.5 lbf-
• Refill cooling system with coolant. (Page 1F-9) ft)
• Check cooling system for leakage. (Page 1F-8) Water pump nut (b): 25 N·m (2.5 kgf-m, 18.5 lbf-
ft)
Water Pump Removal and Installation 4) Install water pump pulley (2) and tighten bolts to
AENJCA0A1616015
specified torque.
Removal
1) Drain coolant. (Page 1F-9) Tightening torque
Water pump pulley bolt (c): 11 N·m (1.1 kgf-m,
2) Remove water pump / generator drive belt. (Page
8.5 lbf-ft) (Galvanized bolt)
1J-8)
Water pump pulley bolt (d): 20 N·m (2.0 kgf-m,
3) Remove generator upper bolt. 15.0 lbf-ft) (Paint coated bolt)
4) Remove water pump pulley (2).
5) Remove water pump (1) with generator arm (3). 1
(a)

1
2

3 (c), (d)
(b)
IJCA0A161029-01

5) Tighten generator upper bolt. (Page 1J-10)

6) Install water pump / generator drive belt. (Page 1J-
IJHA0A160019-01 8)
Installation 7) Refill cooling system with coolant. (Page 1F-9)
1) Clean mating surfaces of water pump and cylinder 8) Check cooling system for leakage. (Page 1F-8)
block.
2) Apply sealant to mating surface of water pump as
Water Pump Inspection
AENJCA0A1616016
shown in figure. Rotate water pump by hand to check for smooth
“A”: Sealant 99000–31250 (SUZUKI Bond operation. If pump does not rotate smoothly or makes
No.1207F) abnormal noise, replace it.

“A”

“a”

“b”

“A”
I7V20A161015-01
I2RH0B160019-01
“a”: 3 mm (0.12 in.) “b”: 2 mm (0.08 in.)
 Engine Cooling System: K10B and Bi-Fuel CNG 1F-17

Specifications
Tightening Torque Specifications
AENJCA0A1617001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Drain plug (reference torque) 1.0 0.10 1.0 (Page 1F-9)
Thermostat case nut 25 2.5 18.5 (Page 1F-10)
Thermostat cap bolt 25 2.5 18.5 (Page 1F-11)
Radiator cooling fan shroud bolt 5.5 0.56 4.0 (Page 1F-14)
Radiator cooling fan nut 3.5 0.36 2.5 (Page 1F-15)
Radiator cooling fan motor screw 3.5 0.36 2.5 (Page 1F-15)
Heat insulator screw 2.5 0.25 2.0 (Page 1F-15)
Water pump bolt 25 2.5 18.5 (Page 1F-16)
Water pump nut 25 2.5 18.5 (Page 1F-16)
Water pump pulley bolt (Page 1F-
11 1.1 8.5
16)(Galvanized bolt)
Water pump pulley bolt (Page 1F-16)(Paint
20 2.0 15.0
coated bolt)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Cooling System Components”: K10B and Bi-Fuel CNG (Page 1F-7)
“Fasteners Information” in Section 0A (Page 0A-6)

Special Tools and Equipment

Recommended Service Material
AENJCA0A1618001
Material SUZUKI recommended product or Specification Note
Sealant SUZUKI Bond No.1207F P/No.: 99000–31250 (Page 1F-16)

NOTE
Required service material(s) is also described in:
“Cooling System Components”: K10B and Bi-Fuel CNG (Page 1F-7)

Special Tool
AENJCA0A1618002
SUZUKI scan tool (Suzuki
SDT-II)
—
(Page 1F-12)
1F-18 Engine Cooling System: K12M

K12M
Precautions
Precautions for Cooling System
AENJCA0A1620001
! WARNING
If the radiator cap is removed while the engine is hot and pressure is high, the inside coolant will
instantaneously boil up and spew out. This could cause severe burns or could cause a fire if coolant is
splashed over the hot engine and exhaust system components, as the coolant contains a flammable
anti-freeze material.
Never check the coolant level or add coolant by removing the radiator cap. Instead, check the coolant
level only on the coolant reservoir and, if necessary, add coolant to the reservoir.
Also, check that the engine coolant temperature is cold before removing any part of cooling system.

! CAUTION

• If service operations are performed on the engine cooling system with the battery connected, there
is a risk of injury by accidental movement of the radiator cooling fan or other electric components.
Disconnect the negative (–) cable at the battery terminal before performing any service operations
on the engine cooling system.
• The radiator cooling fan can come on whenever the ignition is “ON”. This electric fan starts
automatically anytime the ECT sensor senses a coolant temperature higher than a predetermined
level even when the engine is not running.
When the ignition is “ON”, keep hands, tools, clothing, and other items away from the radiator
cooling fan.

General Description
Cooling System Description NOTICE
AENJCA0A1621001
The cooling system consists of the radiator, coolant Using alcohol or methanol base coolant or
reservoir, water pump, cooling fan and thermostat. The plain water alone may cause damage to the
radiator is a tube-and-fin type. cooling system.
Use the specified coolant.
Coolant Description Coolant table
AENJCA0A1621002
The coolant recovery system is a standard system, °C –14.5
Freezing temperature
which allows part of coolant to flow from the radiator into °F 5.9
the coolant reservoir when it expands by heat. When the Antifreeze / Anti-corrosion
% 30
cooling system cools down, the coolant in the coolant coolant concentration
reservoir is drawn back into the radiator.
The cooling system has been filled with a SUZUKI long Coolant capacity
life coolant (coolant color: Yellow) that is a 30/70 mixture Engine, radiator and heater: 3.4 liters (7.19/5.98
of ethylene glycol antifreeze and deionized water. This US/Imp pt.)
coolant solution provides freezing protection to –14.5 °C Reservoir: 0.4 liters (0.84/0.70 US/Imp pt.)
(5.9 °F). Total: 3.8 liters (8.03/6.69 US/Imp pt.)
• This 30/70 mixture coolant also provides protection
against corrosion and loss of coolant from boiling.
Keep cooling system filled with this coolant even
where freezing temperatures are not expected.
• When replenishing the system due to loss of coolant,
the same ethylene glycol base coolant should be used
in order to ensure the same level of protection against
freezing and corrosion.
 Engine Cooling System: K12M 1F-19

Cooling Fan Operation Description The following controls are also performed when A/C
AENJCA0A1621003 switch is ON.
Radiator cooling fan motor is controlled by ECM as Low speed:
follows. Cooling fan operates at low speed when A/C refrigerant
pressure is more than specified value of 1.1 MPa (11.2
[A] kgf/cm2, 160 psi) or vehicle speed is lower than 30 km/h
(19 mile/h).
[B] High speed:
Cooling fan speed changes from low to high speed when
[C] A/C refrigerant pressure exceeds specified value of 1.5
MPa (15.3 kgf/cm2, 218 psi).
95 97 100 102 (°C)
203.0 206.6 212.0 215.6 (°F)
IFRA0A161001-01 Fail-Safe
[A]: High [C]: OFF Cooling fan operates at high speed if malfunction related
[B]: Low to ECT sensor is detected.

Schematic and Routing Diagram

Coolant Circulation
AENJCA0A1622001

[A]

5 7
4

3
2
1

[B]

5 7
4

3
2
1

IJCA0A162001-01

[A]: Engine is cool. (thermostat closed) 2. Radiator outlet hose 5. Engine

[B]: Engine is normal at operating temperature. (thermostat open) 3. Thermostat 6. Radiator
1. Radiator inlet hose 4. Water pump 7. Heater core
1F-20 Engine Cooling System: K12M

Radiator Cooling Fan Control System Circuit Diagram

AENJCA0A1622002

7
1 BLU
2
+BB
6 LT GRN E02-2
GRY
A1 BLU
GRN
3 B1 4 GRN E02-27
L+
H+ L-
PNK 5 BLK

A2 H- C1 C2
B2
LT BLU
8 5V
A3
BLU C02-20

GRY C02-4

[A] C02 E02

[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

IJCA0A162002-01

[A]: ECM connector (View: [a]) C1: Radiator cooling fan motor ground circuit 5. Radiator cooling fan motor
A1: Radiator cooling fan relay No.1 power supply circuit (switch side) C2: Radiator cooling fan relay No.3 ground circuit 6. “RDTR” fuse
A2: Radiator cooling fan relay No.2 power supply circuit (switch side) 1. To main relay 7. ECM
A3: Radiator cooling fan relay No.3 power supply circuit (switch side) 2. Radiator cooling fan relay No.1 8. ECT sensor
B1: Radiator cooling fan motor drive circuit (low speed) 3. Radiator cooling fan relay No.2
B2: Radiator cooling fan motor drive circuit (high speed) 4. Radiator cooling fan relay No.3

Diagnostic Information and Procedures
Engine Cooling Symptom Diagnosis
Condition Possible cause
Engine overheats Loose or broken water pump belt
(Radiator fan operates)
Not enough coolant
Faulty thermostat
Faulty water pump
Dirty or bent radiator fins
Coolant leakage on cooling system
Clogged radiator
Faulty radiator cap
Dragging brakes
Slipping clutch (M/T model)
Poorly charged battery
Poor electricity generated by generator Check generator. (Page 1J-23)
Faulty ECT sensor
Faulty radiator cooling fan motor
Faulty ECM
Faulty radiator cooling fan relay
Faulty wiring or grounding
Too many optional electric devices
Engine overheats Blown fuse
(Radiator fan does not Faulty radiator cooling fan relay
operate)
Faulty ECT sensor
Faulty radiator cooling fan motor
Faulty wiring or grounding
Faulty ECM
Engine Cooling System: K12M 1F-21
AENJCA0A1624001
Correction / Reference Item
Adjust or replace water pump belt. (Page 1J-
25)
Check coolant level and add if necessary.
(Page 1F-26)
Replace thermostat assembly. (Page 1F-29)
Replace water pump. (Page 1F-33)
Clean or repair. (Page 1F-32)
Check cooling system for leakage. (Page
1F-26)
Replace radiator. (Page 1F-32)
Check radiator cap. (Page 1F-26)
Check brake. (Page 4A-2)
Check clutch. (Page 5C-1)
Check battery. (Page 1J-22)
Check ECT sensor. (Page 1C-28)
Check radiator cooling fan motor. (Page 1F-
30)
Check ECM and its circuit. (Page 1A-254)
Check radiator cooling fan relay. (Page 1F-
31)
Repair wiring.
Remove electrical devices.
Check fuse.
Check radiator cooling fan relay. (Page 1F-
31)
Check ECT sensor. (Page 1C-28)
Check radiator cooling fan motor. (Page 1F-
30)
Repair wiring.
Check ECM and its circuit. (Page 1A-254)
1F-22 Engine Cooling System: K12M

Radiator Cooling Fan System Check

AENJCA0A1624002
Circuit Diagram

7
1 BLU
2
+BB
6 LT GRN E02-2
GRY
A1 BLU
GRN
3 B1 4 GRN E02-27
L+
H+ L-
PNK 5 BLK

A2 H- C1 C2
B2
LT BLU
8 5V
A3
BLU C02-20

GRY C02-4

[A] C02 E02

[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

IJCA0A162002-01

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

Troubleshooting

NOTE
• For details of engine cooling fan operation, refer to “Cooling Fan Operation Description”: K12M
(Page 1F-19).
• Before beginning troubleshooting, read “Precautions for Engine (K12M)” in Section 1 (Page 1-2).
• When measuring circuit voltage, resistance and/or pulse signal of ECM, refer to “Inspection of ECM
and Its Circuits”: K12M in Section 1A (Page 1A-254).

Step Action Yes No

1 DTC check Go to applicable DTC Go to Step 2.
1) Set ignition “OFF” and connect SUZUKI scan tool to troubleshooting and
DLC. recheck DTC.
2) Set ignition “ON” and check DTC. (Page 1A-140)

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-30)

Is check result OK?

 Engine Cooling System: K12M 1F-23

Step Action Yes No

3 Radiator cooling fan high-speed operation control Radiator cooling fan Go to Step 8.
check control system is in
1) Check radiator cooling fan control for high-speed good condition.
operation. (Page 1F-30)

Is check result OK?

4 Radiator cooling fan relay No.1 power supply circuit Go to Step 5. Repair “A1” circuit.
(switch side) check
1) Set ignition “OFF” and remove radiator cooling fan relay
No.1 from individual circuit fuse box No.1.
2) Check for proper connection to radiator cooling fan relay
No.1 at each terminal.
3) If OK, measure voltage between “A1” circuit and ground.

Is it 10 – 14 V?
5 Radiator cooling fan relay No.1 check Go to Step 6. Replace radiator cooling
1) Check radiator cooling fan relay No.1. (Page 1F-31) fan relay No.1.

Is check result OK?

6 Radiator cooling fan motor drive circuit (low speed) Go to Step 7. Repair “B1” circuit.
check
1) Set ignition “OFF” and disconnect radiator cooling fan
motor connector.
2) Check for proper connection to radiator cooling fan
motor at each terminal.
3) If OK, check the following points.
• Resistance of “B1” circuit: 1 Ω or less
• Resistance between “B1” circuit and ground: infinity
• Voltage of “B1” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

7 Radiator cooling fan motor ground circuit check Go to Step 14. Repair “C1” circuit.
1) Measure resistance between “C1” circuit and ground.

Is resistance 1 Ω or less?
8 Radiator cooling fan relay No.2 power supply circuit Go to Step 9. Repair “A2” circuit.
(switch side) check
1) Set ignition “OFF” and remove radiator cooling fan relay
No.2 from individual circuit fuse box No.1.
2) Check for proper connection to radiator cooling fan relay
No.2 at each terminal.
3) If OK, measure voltage between “A2” circuit and ground.

Is it 10 – 14 V?
9 Radiator cooling fan relay No.2 check Go to Step 10. Replace radiator cooling
1) Check radiator cooling fan relay No.2. (Page 1F-31) fan relay No.2.

Is check result OK?

1F-24 Engine Cooling System: K12M

Step Action Yes No

10 Radiator cooling fan motor drive circuit (high speed) Go to Step 11. Repair “B2” circuit.
check
1) Set ignition “OFF” and disconnect radiator cooling fan
motor connector.
2) Check for proper connection to radiator cooling motor at
each terminal.
3) If OK, check the following points.
• Resistance of “B2” circuit: 1 Ω or less
• Resistance between “B2” circuit and ground: infinity
• Voltage of “B2” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

11 Radiator cooling fan relay No.3 power supply circuit Go to Step 12. Repair “A3” circuit.
(switch side) check
1) Set ignition “OFF” and remove radiator cooling fan relay
No.3 from individual circuit fuse box No.1.
2) Check for proper connection to radiator cooling fan relay
No.3 at each terminal.
3) If OK, check the following points.
• Resistance of “A3” circuit: 1 Ω or less
• Resistance between “A3” circuit and ground: infinity
• Voltage of “A3” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

12 Radiator cooling fan relay No.3 check Go to Step 13. Replace radiator cooling
1) Check radiator cooling fan relay No.3. (Page 1F-31) fan relay No.3.

Is check result OK?

13 Radiator cooling fan relay No.3 ground circuit check Go to Step 14. Repair “C2” circuit.
1) Measure resistance between “C2” circuit and ground.

Is resistance 1 Ω or less?
14 Radiator cooling fan motor check Replace ECM and Replace radiator cooling
1) Check radiator cooling fan motor. (Page 1F-30) recheck radiator cooling fan motor. (Page 1F-
fan system. (Page 32)
Is check result OK? 1C-22)
 Engine Cooling System: K12M 1F-25

Repair Instructions
Cooling System Components
AENJCA0A1626001

13

8
11 (b)
5
6 5 9 (a)
[B] (c)
10 [C] (d)

4
(a) 13
12 (a)
3

2
15 21

20
[a]

19 1207F
16
1

7 18
14

7 18

17

(e) (f) [A]

22

23

24
25

(g)

26
28
27

IJCA0A162004-03
1F-26 Engine Cooling System: K12M
[A]: View: [a]
[B]: For galvanized bolt
[C]: For paint coated bolt
1. Radiator
2. Reservoir
3. Reservoir cap
4. Reservoir hose
5. Radiator support upper mounting
6. Radiator cap
7. Radiator support lower mounting
8. Radiator inlet hose
9. Thermostat cap
10. Thermostat
: For installation, refer to “Thermostat
Removal and Installation”: K12M (Page
1F-29).
Coolant Level Check
AENJCA0A1626002
Before performing the following procedure, observe
“Precautions for Cooling System”: K12M (Page 1F-18).
It is not necessary to remove radiator cap to check
coolant level.
When engine is cool, check coolant level in reservoir (1).
Normal coolant level should be between “FULL” mark (2)
and “LOW” mark (3) on reservoir.
If coolant level is below “LOW” mark, remove reservoir
cap (4) and add proper coolant to reservoir to bring
coolant level up to “FULL” mark.
NOTE
If proper quality antifreeze is used, there is
no need to add extra rust inhibitors or other
additives that claim to improve system. They
may be harmful to proper operation of
system, and are unnecessary expense.
3
4
11. ECT sensor 24. Radiator cooling fan
12. Thermostat case 25. Radiator cooling fan motor
13. Gasket 26. Radiator cooling fan shroud
: Match gasket with a shape of the mating face
of cylinder head.
14. Radiator outlet hose 27. Heat shield
15. Water inlet pipe 28. Drain plug
.
16. Heater inlet hose : 25 Nm (2.5 kgf-m, 18.5 lbf-ft)
17. Heater outlet hose : 12 Nm (1.2 kgf-m, 9.0 lbf-ft)
18. To heater core : 11 Nm (1.1 kgf-m, 8.5 lbf-ft)
19. Water pump : 20 Nm (2.0 kgf-m, 15.0 lbf-ft)
: Apply sealant 99000-31250 referring to “Water
Pump Removal and Installation”: K12M (Page
1F-33).
20. Generator arm : 4.0 Nm (0.41 kgf-m, 3.0 lbf-ft)
21. Water pump pulley : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
22. Retainer clip 2.2 Nm (0.22 kgf-m, 2.0 lbf-ft)
23. Torque washer : Do not reuse.
Engine Cooling System Inspection
AENJCA0A1626003
Before performing the following procedure, observe
“Precautions for Cooling System”: K12M (Page 1F-18).
1) Check cooling system for leakage or damage.
2) Remove radiator cap.
3) Check coolant for proper level and freeze protection.
4) Check cooling system for coolant leakage according
to the following procedure.
a) Attach pressure tester (1) to radiator, and then
apply specified pressure to cooling system.
Cooling system holding pressure
123 kPa (1.3 kgf/cm2, 17.8 psi, 1.23 bar)
I8T401162005-01
2
b) Check that cooling system holds the pressure.
If cooling system does not hold applied pressure,
check cooling system for leakage.
IJCA0A162005-01
 Engine Cooling System: K12M 1F-27

5) Check radiator cap according to the following 4) Remove reservoir (1) and drain coolant in reservoir.
procedure. 5) Install reservoir securely and tighten reservoir bolt.
a) Attach pressure tester (1) to radiator cap (2), and
then apply specified pressure.
Radiator cap valve opening pressure
93 – 123 kPa (0.9 – 1.3 kgf/cm2, 13.5 – 17.8 psi,
0.93 – 1.23 bar)

1 2

IFRA0A161006-01
IJCA0A162007-01
b) If radiator cap valve opening pressure is out of
specification, replace radiator cap. Cooling System Refilling
6) Detach pressure tester and rinse off spilled coolant. AENJCA0A1626005
Before performing the following procedure, observe
7) Install radiator cap on radiator. “Precautions for Cooling System”: K12M (Page 1F-18).
1) Fill reservoir (1) with coolant up to “FULL” mark (2).
Cooling System Draining
AENJCA0A1626004 2) Install reservoir cap (3) on reservoir.
Before performing the following procedure, observe
“Precautions for Cooling System”: K12M (Page 1F-18).
1) Remove radiator cap.
2) Drain coolant from drain plug (1).
3) Tighten drain plug securely.

NOTICE
2
If drain plug is tightened excessively, the
plug could be damaged.
Do not tighten the drain plug too much.
3
Tightening torque
Drain plug (reference torque) (a): 1.0 N·m (0.10
kgf-m, 1.0 lbf-ft)

IJCA0A162008-01

3) Fill radiator with coolant up to bottom of radiator filler

neck and install radiator cap. (Page 1F-18)
4) Run engine at idle speed until radiator fan motor is
operated.
1, (a) 5) Stop engine and wait until engine cools down fully.
IJCA0A162006-01 6) Add coolant to radiator up to bottom of radiator filler
neck, and install radiator cap.
7) Repeat Step 4) – 6).
8) Check that coolant level in reservoir is at “FULL”
mark. If coolant is insufficient, add coolant.
9) Check cooling system for leakage. (Page 1F-26)
1F-28 Engine Cooling System: K12M

Water Inlet Pipe Removal and Installation 6) Remove water inlet pipe (1) with O-ring (2).
AENJCA0A1626006

Removal
1
1) Drain coolant. (Page 1F-27)
2) Remove intake manifold. (Page 1D-85)
3) For auto gear shift model, remove auto gear shift
actuator unit. (Page 5D-104)
4) Disconnect the following hoses and clamp from
water inlet pipe.
• Heater inlet hose (1)
• Heater outlet hose (2) 2

• Radiator outlet hose (3) IJCA0A162011-01

• Clamp
Installation
Reverse removal procedure noting the following points.
• Use new O-ring (2).
• Apply coolant to O-ring and insert water inlet pipe (1)
3 all the way into cylinder block.

1
2

IJCA0A162012-01

• Tighten thermostat case nut (1) to specified torque.

Tightening torque
Thermostat case nut (a): 25 N·m (2.5 kgf-m, 18.5
lbf-ft)
IJCA0A162009-01

5) Remove thermostat case nut (1) and water inlet pipe

bolt (2) from water inlet pipe (3). 1, (a)

2
1

IJCA0A162013-01

3 • If there is matchmark on each of hose and pipe, install

the hose aligning matchmark on hose with matchmark
IJCA0A162010-01 on pipe and then install each clamp in proper position.
• Refill cooling system with coolant. (Page 1F-27)
• Check cooling system for leakage. (Page 1F-26)
 Engine Cooling System: K12M 1F-29

Thermostat Removal and Installation • Tighten thermostat cap bolts (1) to specified torque.
AENJCA0A1626007
Removal Tightening torque
1) Drain coolant. (Page 1F-27) Thermostat cap bolt (a): 25 N·m (2.5 kgf-m, 18.5
lbf-ft)
2) Remove thermostat cap (1) from thermostat case
(2).

1, (a)

IJCA0A162019-01

• Refill cooling system with coolant. (Page 1F-27)

IJCA0A162015-01

3) Remove thermostat (1) from thermostat case (2). • Check cooling system for leakage. (Page 1F-26)

Thermostat Inspection
AENJCA0A1626008
• Check that air bleed valve (1) is clean.
• Check that valve seat (2) is free from foreign material
that would prevent valve from seating tight.
• Check thermostat seal (3) for breakage, deterioration
or any other damage.

1
IJCA0A162017-01

Installation
Reverse removal procedure noting the following points.
I3RM0A160008-01
• Install thermostat (1) to thermostat case (2) by
aligning air bleed valve (3) of thermostat with mark (4)
of thermostat case.

4 3

2 1

IJCA0A162018-01
1F-30 Engine Cooling System: K12M

• Check thermostat operation as follows. Radiator Cooling Fan Assembly On-Vehicle

a. Immerse thermostat (1) in water, and heat water Inspection
AENJCA0A1626009
gradually.
Radiator Cooling Fan Operation
b. Check that wax pellet starts to open at specific
1) Connect SUZUKI scan tool to DLC (1) with ignition
temperature.
“OFF”.
Temperature at which valve starts to open (lift
Special tool
0.05 mm (0.002 in))
(A): SUZUKI scan tool (Suzuki SDT-II)
86.5 – 89.5 °C (187.7 – 193.1 °F)
Temperature at which valve becomes fully
open
100 °C (212 °F)
Valve lift
More than 8 mm (0.31 in) at 100 °C (212 °F) 1

(A)

I2RH01160012-01 IJCA0A181004-01

2. Thermometer 3. Heater 2) Set ignition “ON” and clear DTC. (Page 1A-141)
3) Select “Radiator Fan” function in “Active Test”.
• If check result is not as specified, replace thermostat. 4) Check radiator cooling fan operation at low and high
(Page 1F-29) modes.
If any abnormality is found, check cooling fan control
system. (Page 1F-22)
Radiator cooling fan operation
Radiator cooling fan motor
OFF OFF
Low mode Low speed
High mode High speed

Radiator Cooling Fan Motor

1) Disconnect radiator cooling fan motor connector (1).

IJCA0A162020-01
 Engine Cooling System: K12M 1F-31

2) Using service wire, connect radiator cooling fan 4) Remove reservoir (1) and disconnect radiator inlet
motor connector and battery as shown in figure. hose (2) from radiator.

[A] [B]

2 1
IJCA0A162021-01

[A]: Low speed [B]: High speed

IJCA0A162023-01
3) Check that radiator cooling fan motors rotate
5) Remove radiator cooling fan assembly from radiator.
smoothly and properly.
If any abnormality is found, replace radiator cooling
Installation
fan motor.
Reverse removal procedure noting the following points.
Reference: Fan motor specified current at 12 V • Tighten radiator cooling fan shroud bolts (1) to
Low speed: 5.0 – 5.5 A specified torque.
High speed: 8.5 – 9.35 A
Tightening torque
Radiator cooling fan shroud bolt (a): 10 N·m (1.0
Radiator Cooling Fan Relay Inspection
AENJCA0A1626010 kgf-m, 7.5 lbf-ft)
Refer to “Control Relay Inspection” in Section 10B (Page
10B-51).

Radiator Cooling Fan Assembly Removal and

Installation
AENJCA0A1626011

Removal
1) Disconnect negative (–) cable at battery.
2) Drain coolant. (Page 1F-27)
3) Disconnect radiator cooling fan motor connector (1). 1, (a)
IJCA0A162029-01

• If there is matchmark on each of hose and pipe, install

the hose aligning matchmark on hose with matchmark
on pipe and then set each clamp to the original
position.
• Refill cooling system with coolant. (Page 1F-27)
• Check cooling system for leakage. (Page 1F-26)
1

IJCA0A162020-01
1F-32 Engine Cooling System: K12M

Radiator Cooling Fan Disassembly and Radiator On-Vehicle Inspection and Cleaning
AENJCA0A1626013
Reassembly Inspection
AENJCA0A1626012
Check radiator for leakage or damage. Straighten bent
Disassembly fins, if any.
1) Remove retainer clip (1) and torque washer (2).
Cleaning
2) Remove radiator cooling fan (3) from radiator cooling
Clean frontal area of radiator cores.
fan motor (4).
3) Remove radiator cooling fan motor from radiator
cooling fan shroud (5).
4) Remove heat shield (6).

1
2

3
4 I2RH01160014-01

Radiator Removal and Installation

AENJCA0A1626014
5
6
IJCA0A162024-01 Removal
1) Disconnect negative (–) cable at battery.
Reassembly
Reverse disassembly procedure noting the following 2) Drain coolant. (Page 1F-27)
point. 3) Remove front bumper. (Page 9H-3)
• Tighten radiator cooling fan motor screws and heat 4) Remove condenser upper and lower bolts. (Page
shield screws to specified torque. 7B-35)
Tightening torque NOTICE
Radiator cooling fan motor screw (a): 4.0 N·m (
The A/C condenser assembly may be
0.41 kgf-m, 3.0 lbf-ft)
damaged if it hits against or interferes with
Heat shield screw (b): 2.2 N·m (0.22 kgf-m, 2.0 lbf-
other parts.
ft)
Suspend the removed A/C condenser
• Insert new retainer clip (1) to fit the opening to assembly in a place where no damage will be
protrusion (2) on radiator cooling fan (3). caused during removal and installation of the
radiator.
1
3
5) Disconnect radiator inlet hose (1) and radiator outlet
(a) hose (2).

(b)

IJCA0A162025-01 2 1

IJCA0A162026-01
 Engine Cooling System: K12M 1F-33

6) Disconnect radiator cooling fan connector (1). Water Pump Removal and Installation
AENJCA0A1626015
Removal
1) Drain coolant. (Page 1F-27)
2) Remove air cleaner assembly and air cleaner
suction hose. (Page 1D-82)
3) Remove water pump / generator drive belt. (Page
1J-26)
4) Remove generator upper bolt (1).
1
5) Remove water pump pulley (2).
6) Remove water pump (3) with generator arm (4).

IJCA0A162020-01
2
7) Support front lower crossmember (1) with jack (2).
8) Remove front lower crossmember bolts (3), and then
lower the jack and remove radiator assembly (4) with
front lower crossmember.
4
NOTE
When lowering jack, push radiator down to
disconnect the radiator from the radiator
support upper mountings.
1
IJCA0A162028-01

Installation
1) Clean mating surfaces of water pump and cylinder
block.
2) Apply sealant to mating surface of water pump as
shown in figure.
“A”: Sealant 99000–31250 (SUZUKI Bond
No.1207F)

“A”
3 1 2 4 3
IJCA0A162027-01

9) Remove radiator assembly from front lower

crossmember.
“a”
10) Remove radiator cooling fan assembly from radiator.
(Page 1F-31) “b”

“A”
Installation I7V20A161015-01
Reverse removal procedure noting the following points. “a”: 3 mm (0.12 in.) “b”: 2 mm (0.08 in.)
• Tighten condenser bolts to specified torque in
numerical order. (Page 7B-35) 3) Within 2 minutes after applying sealant, install water
• If there is matchmark on each of hose and pipe, install pump (1) with generator arm (3) to cylinder block
the hose aligning matchmark on hose with matchmark and tighten bolts and nuts to specified torque.
on pipe and then install each clamp in proper position. Tightening torque
• Refill cooling system with coolant. (Page 1F-27) Water pump bolt (a): 25 N·m (2.5 kgf-m, 18.5 lbf-
• Check cooling system for leakage. (Page 1F-26) ft)
Water pump nut (b): 25 N·m (2.5 kgf-m, 18.5 lbf-
ft)
1F-34 Engine Cooling System: K12M

4) Install water pump pulley (2) and tighten bolts to 6) Install water pump / generator drive belt. (Page 1J-
specified torque. 26)
Tightening torque 7) Install air cleaner assembly and air cleaner suction
Water pump pulley bolt (c): 11 N·m (1.1 kgf-m, hose. (Page 1D-82)
8.5 lbf-ft) (Galvanized bolt) 8) Refill cooling system with coolant. (Page 1F-27)
Water pump pulley bolt (d): 20 N·m (2.0 kgf-m, 9) Check cooling system for leakage. (Page 1F-26)
15.0 lbf-ft) (Paint coated bolt)
Water Pump Inspection
1 AENJCA0A1626016
(a)
Rotate water pump by hand to check for smooth
operation. If pump does not rotate smoothly or makes
2 abnormal noise, replace it.

(c), (d)
(b)
IJCA0A162030-01

5) Tighten generator upper bolt. (Page 1J-28)

I2RH0B160019-01

Specifications
Tightening Torque Specifications
AENJCA0A1627001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Drain plug (reference torque) 1.0 0.10 1.0 (Page 1F-27)
Thermostat case nut 25 2.5 18.5 (Page 1F-28)
Thermostat cap bolt 25 2.5 18.5 (Page 1F-29)
Radiator cooling fan shroud bolt 10 1.0 7.5 (Page 1F-31)
Radiator cooling fan motor screw 4.0 0.41 3.0 (Page 1F-32)
Heat shield screw 2.2 0.22 2.0 (Page 1F-32)
Water pump bolt 25 2.5 18.5 (Page 1F-33)
Water pump nut 25 2.5 18.5 (Page 1F-33)
Water pump pulley bolt (Page 1F-
11 1.1 8.5
34)(Galvanized bolt)
Water pump pulley bolt (Page 1F-34)(Paint
20 2.0 15.0
coated bolt)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Cooling System Components”: K12M (Page 1F-25)
“Fasteners Information” in Section 0A (Page 0A-6)
 Engine Cooling System: K12M 1F-35

Special Tools and Equipment

Recommended Service Material
AENJCA0A1628001
Material SUZUKI recommended product or Specification Note
Sealant SUZUKI Bond No.1207F P/No.: 99000–31250 (Page 1F-33)

NOTE
Required service material(s) is also described in:
“Cooling System Components”: K12M (Page 1F-25)

Special Tool
AENJCA0A1628002
SUZUKI scan tool (Suzuki
SDT-II)
—
(Page 1F-30)
1G-1 Fuel System: Petrol

Fuel System
Engine

Petrol
Precautions
Precautions for Fuel System Service • When any pit and/or crack is found in fuel
AENJCA0A1710001 tank, never repair the tank but always
! WARNING replace it with a new fuel tank.
Service operation of any type performed on • As fuel tank is made of plastic, when
the fuel system involves a risk of fire and solvent such as grease and sealant is
personal injury if proper precautions are not allowed to contact fuel tank, some
taken. chemical reaction may occur, causing fuel
Take the following precautions whenever tank to be swollen, hardened or deformed,
working on the fuel system. resulting in fuel leakage from fuel tank.
Wipe off any solvent adhered on tank
• Disconnect the negative (–) cable at the
without delay.
battery.
• Do not smoke. Put up no smoking signs
NOTICE
around the work area.
• Have CO2 fire extinguishers ready. If a leaded or low-lead fuel is used for this
engine, the engine itself and the emission
• Perform service operations only in a well- control system will be damaged.
ventilated area away from any open flames Use only unleaded fuel.
such as gas water heaters.
• Wear safety glasses.
• Remove the fuel filler cap from the fuel
filler neck to relieve the fuel tank of fuel
vapor pressure, and then reinstall the cap.
• Before loosening or disconnecting the fuel
feed line, relieve the fuel system of fuel
pressure by following “Fuel Pressure
Relief Procedure”: Petrol (Page 1G-19).
• When disconnecting a fitting on the fuel
line, cover the fitting with a shop cloth to
soak up the small amount of fuel that may
flow out from the disconnected fuel line.
Put the used cloth in an approved
container.
• Since fuel hose connections vary with the
pipe type, connect and clamp each hose
using the correct method for each specific
connection. (Page 1G-16)
After connecting a hose, check that there
is no twist or kink in the hose.
• When installing a fuel injector or a fuel
feed pipe, lubricate its O-rings with
gasoline.
• Handle the fuel tank carefully. Do not allow
it to touch sharp edges or hot surfaces. Do
not drop it. If the tank is dropped, the tank
and all components on and in it should be
replaced because they may have been
damaged.
 Fuel System: Petrol 1G-2

General Description
Fuel System Description Also, fuel vapor generated in fuel tank is led through the
AENJCA0A1711001 fuel vapor line into the EVAP canister.
The main components of the fuel system are fuel tank,
For system diagram, refer to “Fuel Delivery System
fuel pump assembly (with fuel level sensor and fuel
Diagram”: Petrol (Page 1G-2).
pressure regulator), fuel filter, fuel feed line and fuel
vapor line.
For the details of fuel flow, refer to “Fuel Delivery System Fuel Pump Description
AENJCA0A1711003
Diagram”: Petrol (Page 1G-2). The fuel pump (1) is an in-tank type electric pump.
Incorporated in the pump assembly are;
Fuel Delivery System Description fuel pressure regulator (2) and fuel level sensor (3).
AENJCA0A1711002
The fuel delivery system consists of the fuel tank, fuel
pump assembly (with fuel level sensor and fuel pressure
regulator), fuel filter, delivery pipe, injectors and fuel feed
line.
2
The fuel in the fuel tank is pumped up by the fuel pump,
sent into fuel filter beside the tank and delivery pipe and 1
injected by the fuel injectors. 3
The fuel feed line is connected to the pressure regulator
in the fuel pump assembly and the fuel pressure is
regulated to the specified level.
The excess fuel at fuel pressure regulation process is
returned back into the fuel tank. IBP80A171001-01

Schematic and Routing Diagram

Fuel Delivery System Diagram
AENJCA0A1712001

13

12 10
11

6 7 14
2

8 3
[A]

9
1

5
IJCA0A171001-01

[A]: K12M model 5. Fuel injector 10. Fuel vapor line

1. Fuel tank 6. Fuel feed line 11. Intake manifold
2. Fuel pump assembly 7. Fuel filter 12. EVAP canister
3. Fuel pressure regulator 8. Fuel level sensor 13. EVAP canister purge valve
4. Fuel delivery pipe 9. Fuel pump 14. Fuel cut valve
1G-3 Fuel System: Petrol

Fuel Injector Control System Circuit Diagram

AENJCA0A1712002

K10B model

A1 4 A2
C01-77 PNK 1
B1 5 B2
C01-78 WHT
C1 6 C2
C01-79 RED

3
E01-19 WHT 2

[A] C01 E01

10 9 8 7 6 5 4 3 2 1
65 64 63 62 61 20 19 18 17 16 15 14 13 12 11
70 69 68 67 66 30 29 28 27 26 25 24 23 22 21
75 74 73 72 71 40 39 38 37 36 35 34 33 32 31
80 79 78 77 76 50 49 48 47 46 45 44 43 42 41
60 59 58 57 56 55 54 53 52 51
[a]
9 8 7 6 5 4 3 2 1
57 56 55 18 17 16 15 14 13 12 11 10
60 59 58 27 26 25 24 23 22 21 20 19
63 62 61 36 35 34 33 32 31 30 29 28
66 65 64 45 44 43 42 41 40 39 38 37
54 53 52 51 50 49 48 47 46

IJCA0A171002-02

[A]: ECM connector (View: [a]) C1: Fuel injector No.3 drive circuit 4. Fuel injector No.1
A1: Fuel injector No.1 drive circuit C2: Fuel injector No.3 power supply circuit 5. Fuel injector No.2
A2: Fuel injector No.1 power supply circuit 1: To main relay 6. Fuel injector No.3
B1: Fuel injector No.2 drive circuit 2. To ignition power supply 7. ECM
B2: Fuel injector No.2 power supply circuit 3. “IG COIL” fuse (without keyless entry system) or
“IG” fuse (with keyless entry system)
 Fuel System: Petrol 1G-4

K12M model

A1 4 A2
C02-31 PNK 1
B1 5 B2
C02-11 WHT
C1 6 C2
C02-10 RED
D1 7 D2
C02-12 GRN

3
E02-1 WHT 2

[A] C02 E02

[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

IJCA0A171003-02

[A]: ECM connector (View: [a]) C2: Fuel injector No.3 power supply circuit 4. Fuel injector No.1
A1: Fuel injector No.1 drive circuit D1: Fuel injector No.4 drive circuit 5. Fuel injector No.2
A2: Fuel injector No.1 power supply circuit D2: Fuel injector No.4 power supply circuit 6. Fuel injector No.3
B1: Fuel injector No.2 drive circuit 1. To main relay 7. Fuel injector No.4
B2: Fuel injector No.2 power supply circuit 2. To ignition power supply 8. ECM
C1: Fuel injector No.3 drive circuit 3. “IG COIL” fuse (without keyless entry system) or
“IG” fuse (with keyless entry system)
1G-5 Fuel System: Petrol

Fuel Pump Control System Circuit Diagram

AENJCA0A1712003

6
B1 A1
4
[A]: E01-38
1
[B]: E02-24 YEL

BLK 5 PNK

B3 B2 A2

[A]: E01-19 3
[B]: E02-1 WHT 2

C01
[C]
10 9 8 7 6 5 4 3 2 1
65 64 63 62 61 20 19 18 17 16 15 14 13 12 11
70 69 68 67 66 30 29 28 27 26 25 24 23 22 21
75 74 73 72 71 40 39 38 37 36 35 34 33 32 31
80 79 78 77 76 50 49 48 47 46 45 44 43 42 41
60 59 58 57 56 55 54 53 52 51
E01
[a]
9 8 7 6 5 4 3 2 1
57 56 55 18 17 16 15 14 13 12 11 10
60 59 58 27 26 25 24 23 22 21 20 19
63 62 61 36 35 34 33 32 31 30 29 28
66 65 64 45 44 43 42 41 40 39 38 37
54 53 52 51 50 49 48 47 46

C02 E02

[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

IJCA0A171004-03

[A]: K10B model B1: Fuel pump relay drive circuit 3. “IG COIL” fuse (without keyless entry system) or
“IG” fuse (with keyless entry system)
[B]: K12M model B2: Fuel pump power supply circuit 4. Fuel pump relay
[C]: ECM connector (View: [a]) B3: Fuel pump ground circuit 5. Fuel pump
A1: Fuel pump relay power supply circuit (coil side) 1. To main relay 6. ECM
A2: Fuel pump relay power supply circuit (switch side) 2. To ignition power supply

Diagnostic Information and Procedures

Fuel System Inspection
AENJCA0A1714001

Step Action Yes No

1 Fuel pump inspection Go to Step 2. Check fuel pump circuit.
1) Remove fuel filler cap and set ignition “ON”. (Page 1G-10)
2) Check that fuel pump operating sound can be heard
from fuel filler port for about 2 seconds.

Is check result OK?

2 Fuel pressure check Go to Step 3. Repair defective part.
1) Check fuel pressure. (Page 1G-12)

Is check result OK?

 Fuel System: Petrol 1G-6

Step Action Yes No

3 Power balance test Fuel system is in good Go to Step 4.
1) Check power balance. (Page 1G-6) condition.

Is check result OK?

4 Fuel injector circuit check Go to Step 5. Repair defective part.
1) Check fuel injector circuit. (Page 1G-7)

Is check result OK?

5 Fuel injector check Replace ECM and Replace fuel injector.
1) Check fuel injector. (Page 1G-24) recheck fuel system. (Page 1G-22)
• K10B model: (Page
Is check result OK?
1C-3)
• K12M model:
(Page 1C-22)

Power Balance Test 5) Using SUZUKI scan tool, select “Fuel Injector” in
AENJCA0A1714002 “Active Test” and turn off each fuel injector.
NOTICE
6) With each fuel injector turned off, check that engine
The engine could be damaged if it is speed decreases from specified idle speed.
accelerated to a high rpm with a fuel injector
7) If decreasing rates of engine speed are not in scale,
connector disconnected.
check the following items.
Always perform power balance test with
engine running at an idle speed. • Fuel injector circuit: (Page 1G-7)
• Fuel injector: (Page 1G-24)
1) For M/T model, place gear shift lever in “Neutral” and • Spark plug
apply parking brake.
For auto gear shift model, place shift selector in N – K10B model: (Page 1H-7)
range and apply parking brake. – K12M model: (Page 1H-17)
2) Connect SUZUKI scan tool to DLC (1) with ignition • Ignition coil circuit
“OFF”. – K10B model: (Page 1H-4)
Special tool – K12M model: (Page 1H-13)
(A): SUZUKI scan tool (Suzuki SDT-II) • Ignition coil
– K10B model: (Page 1H-7)
– K12M model: (Page 1H-18)
• Engine compression
– K10B model: (Page 1D-1)
– K12M model: (Page 1D-77)
1

(A)
IJCA0A181004-01

3) Clear DTC.
• K10B model: (Page 1A-23)
• K12M model: (Page 1A-141)
4) Warm up engine to normal operating temperature.
1G-7 Fuel System: Petrol

Fuel Injector Circuit Check

AENJCA0A1714003
Circuit Diagram

K10B model

A1 4 A2
C01-77 PNK 1
B1 5 B2
C01-78 WHT
C1 6 C2
C01-79 RED

3
E01-19 WHT 2

[A] C01 E01

10 9 8 7 6 5 4 3 2 1
65 64 63 62 61 20 19 18 17 16 15 14 13 12 11
70 69 68 67 66 30 29 28 27 26 25 24 23 22 21
75 74 73 72 71 40 39 38 37 36 35 34 33 32 31
80 79 78 77 76 50 49 48 47 46 45 44 43 42 41
60 59 58 57 56 55 54 53 52 51
[a]
9 8 7 6 5 4 3 2 1
57 56 55 18 17 16 15 14 13 12 11 10
60 59 58 27 26 25 24 23 22 21 20 19
63 62 61 36 35 34 33 32 31 30 29 28
66 65 64 45 44 43 42 41 40 39 38 37
54 53 52 51 50 49 48 47 46

IJCA0A171002-02

[A]: ECM connector (View: [a]) C1: Fuel injector No.3 drive circuit 4. Fuel injector No.1
A1: Fuel injector No.1 drive circuit C2: Fuel injector No.3 power supply circuit 5. Fuel injector No.2
A2: Fuel injector No.1 power supply circuit 1. To main relay 6. Fuel injector No.3
B1: Fuel injector No.2 drive circuit 2. To ignition power supply 7. ECM
B2: Fuel injector No.2 power supply circuit 3. “IG COIL” fuse (without keyless entry system) or
“IG” fuse (with keyless entry system)
 Fuel System: Petrol 1G-8

K12M model

A1 4 A2
C02-31 PNK 1
B1 5 B2
C02-11 WHT
C1 6 C2
C02-10 RED
D1 7 D2
C02-12 GRN

3
E02-1 WHT 2

[A] C02 E02

[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

IJCA0A171003-02

[A]: ECM connector (View: [a]) C2: Fuel injector No.3 power supply circuit 4. Fuel injector No.1
A1: Fuel injector No.1 drive circuit D1: Fuel injector No.4 drive circuit 5. Fuel injector No.2
A2: Fuel injector No.1 power supply circuit D2: Fuel injector No.4 power supply circuit 6. Fuel injector No.3
B1: Fuel injector No.2 drive circuit 1. To main relay 7. Fuel injector No.4
B2: Fuel injector No.2 power supply circuit 2. To ignition power supply 8. ECM
C1: Fuel injector No.3 drive circuit 3. “IG COIL” fuse (without keyless entry system) or
“IG” fuse (with keyless entry system)

Troubleshooting
Step Action Yes No
1 Fuel injector check for operating sound Fuel injectors circuit is Go to Step 2.
1) Remove air cleaner assembly, if necessary. in good condition.
• K10B model: (Page 1D-6)
• K12M model: (Page 1D-82)
2) Using sound scope, check each fuel injector for
operating sound at engine running or cranking.

Do all fuel injectors make operating sound?

2 Fuel injector resistance check Go to Step 3. Replace fuel injector.
1) Set ignition “OFF”, disconnect connectors from fuel (Page 1G-22)
injectors.
2) Check for proper terminal connection to fuel injector
connectors.
3) If connections are OK, check all fuel injectors for
resistance. (Page 1G-21)

Is check result OK?

3 Fuel injector insulation resistance check Go to Step 4. Replace fuel injector.
1) Check that resistance between each fuel injector (Page 1G-22)
terminal and ground is infinity.

Is check result OK?

1G-9 Fuel System: Petrol

Step Action Yes No

4 Fuel injector power supply circuit check Go to Step 5. Repair fuel injector
1) Set ignition “ON”. power supply circuit.
2) Check that voltage between each of “A2”, “B2”, “C2” and
“D2” (K12M model) and ground is battery voltage.

Is check result OK?

5 Fuel injector drive circuit check Go to Step 6. Repair fuel injector drive
1) Set ignition “OFF”, disconnect ECM connectors. circuit.
2) Check for proper terminal connection to ECM
connectors.
3) If connections are OK, check the following points.
• Resistance of “A1”, “B1”, “C1” and “D1” (K12M model)
circuits: less than 1 Ω
• Resistance between each of “A1”, “B1”, “C1” and “D1”
(K12M model) circuits and ground: infinity
• Resistance between “A1” circuit terminal and “A2”
circuit terminal at fuel injector connector: infinity
• Resistance between “B1” circuit terminal and “B2”
circuit terminal at fuel injector connector: infinity
• Resistance between “C1” circuit terminal and “C2”
circuit terminal at fuel injector connector: infinity
• Resistance between “D1” circuit terminal and “D2”
circuit terminal at fuel injector connector: infinity
(K12M model)
• Voltage of “A1”, “B1”, “C1” and “D1” (K12M model)
circuits: approx. 0 V (When ignition is “ON”)

Is check result OK?

6 Fuel injector check Replace ECM and Replace fuel injector.
1) Check fuel injector. (Page 1G-24) recheck fuel injector (Page 1G-22)
operation.
Is check result OK? • K10B model: (Page
1C-3)
• K12M model:
(Page 1C-22)
 Fuel System: Petrol 1G-10

Fuel Pump and Its Circuit Check

AENJCA0A1714004
Circuit Diagram

6
B1 A1
4
[A]: E01-38
1
[B]: E02-24 YEL

BLK 5 PNK

B3 B2 A2

[A]: E01-19 3
[B]: E02-1 WHT 2

C01
[C]
10 9 8 7 6 5 4 3 2 1
65 64 63 62 61 20 19 18 17 16 15 14 13 12 11
70 69 68 67 66 30 29 28 27 26 25 24 23 22 21
75 74 73 72 71 40 39 38 37 36 35 34 33 32 31
80 79 78 77 76 50 49 48 47 46 45 44 43 42 41
60 59 58 57 56 55 54 53 52 51
E01
[a]
9 8 7 6 5 4 3 2 1
57 56 55 18 17 16 15 14 13 12 11 10
60 59 58 27 26 25 24 23 22 21 20 19
63 62 61 36 35 34 33 32 31 30 29 28
66 65 64 45 44 43 42 41 40 39 38 37
54 53 52 51 50 49 48 47 46

C02 E02

[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

IJCA0A171004-03

[A]: K10B model B1: Fuel pump relay drive circuit 3. “IG COIL” fuse (without keyless entry system) or
“IG” fuse (with keyless entry system)
[B]: K12M model B2: Fuel pump power supply circuit 4. Fuel pump relay
[C]: ECM connector (View: [a]) B3: Fuel pump ground circuit 5. Fuel pump
A1: Fuel pump relay power supply circuit (coil side) 1. To main relay 6. ECM
A2: Fuel pump relay power supply circuit (switch side) 2. To ignition power supply
1G-11 Fuel System: Petrol

Troubleshooting
Step Action Yes No
1 Fuel pump control system check Fuel pump circuit is in Go to Step 2.
1) Remove fuel filler cap. good condition.
Reinstall fuel filler cap.
2) Set ignition “ON”.
3) Check that fuel pump operating sound is heard from fuel
filler for about 2 seconds.

Is check result OK?

2 Fuel pump relay power supply circuit check Go to Step 3. Repair fuel pump relay
1) Reinstall fuel filler cap. power supply circuit.
2) Set ignition “OFF”.
3) Remove fuel pump relay from individual circuit fuse box
No.1.
4) Check for proper terminal connection to fuel pump relay
connector.
5) If connections are OK, set ignition “ON”.
6) Check that voltage between each of “A1” and “A2” and
ground is battery voltage.

Is check result OK?

3 Fuel pump relay check Go to Step 4. Replace fuel pump
1) Check fuel pump relay. (Page 10B-51) relay.

Is check result OK?

4 Fuel pump relay drive circuit check Go to Step 5. Repair fuel pump relay
1) Set ignition “OFF”. drive circuit.
2) Disconnect ECM connectors.
3) Check for proper terminal connection to ECM
connectors.
4) If connections are OK, check the following points.
• Resistance of “B1” circuit: less than 1 Ω
• Resistance between “B1” circuit and ground: infinity
• Resistance between “B1” circuit terminal and other
terminal at fuel pump relay connector: infinity
• Voltage of “B1” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

5 Fuel pump relay drive circuit signal check Go to Step 6. Replace ECM and
1) Set ignition “OFF”. recheck fuel pump
operation.
2) Connect ECM connectors.
• K10B model: (Page
3) Using service wire, connect fuel pump relay.
1C-3)
4) Check that voltage between “B1” and ground is approx.
0 V for 2 sec. after the ignition is “ON”. • K12M model:
(Page 1C-22)
Is check result OK?
6 Fuel pump power supply circuit check 1 Go to Step 7. Repair fuel pump power
1) Check that ignition is “OFF”. supply circuit.
2) Remove fuel tank. (Page 1G-26)
3) Disconnect fuel pump connector.
4) Check that resistance between “B2” and ground is
infinity.

Is check result OK?

 Fuel System: Petrol 1G-12

Step Action Yes No

7 Fuel pump power supply circuit check 2 Go to Step 8. Repair fuel pump power
1) Connect service wire between “B1” and ground. supply circuit.
2) Set ignition “ON”.
3) Check that voltage between “B2” and ground is battery
voltage.

Is check result OK?

8 Fuel pump ground circuit check Replace fuel pump. Repair fuel pump
1) Set ignition “OFF”. (Page 1G-29) ground circuit.
2) Check that resistance between “B3” and ground is less
than 1 Ω

Is check result OK?

Fuel Pressure Check

AENJCA0A1714005
System Diagram
Special tool
(A): 09912M58442
(B): 09912M58432
(C): 09912M58490

IJCA0A171005-01

[A]: K12M model 2. Fuel delivery pipe 4. Fuel filter

1. Fuel injector 3. Fuel pump assembly
1G-13 Fuel System: Petrol

Troubleshooting

NOTE
Before using the following flow, check that battery voltage is 11 V or more. If it is lower, fuel pressure
becomes lower than specification even if fuel pump and line are in good condition.

Step Action Yes No

1 Was “Fuel Pump and Its Circuit Check” performed? Go to Step 2. Go to “Fuel Pump and
Its Circuit Check”: Petrol
(Page 1G-10).
2 Fuel pressure check 1 Go to Step 3. Go to Step 5.
1) Check fuel pressure. (Page 1G-14)

Is check result OK?

3 Fuel pressure check 2 Go to Step 4. Go to Step 5.
1) Start engine and warm it up to normal operating
temperature.
2) Keep engine speed at 4,000 rpm.

Does fuel pressure show about the same value as Step 2?

4 Fuel line check Fuel system is in good Repair defective part.
1) Check fuel hose, pipe and joint for fuel leakage, damage condition.
or deformation.

Is check result OK?

5 Fuel line check Go to Step 6. Repair defective part.
1) Check fuel hose, pipe and joint for damage or
deformation.

Is check result OK?

6 Fuel pressure check 3 End. Replace fuel pump
1) Replace fuel filter. (Page 1G-29) assembly. (Page 1G-
29)
2) Recheck fuel pressure. (Page 1G-14)

Is check result OK?

 Fuel System: Petrol 1G-14

Fuel Pressure Basic Check 5) Check that battery voltage is 11 V or more.

AENJCA0A1714006
Before performing the following procedure, observe 6) Measure fuel pressure as follows.
“Precautions for Fuel System Service”: Petrol (Page 1G- If measured pressure is out of specification, refer to
1). “Fuel Pressure Check”: Petrol (Page 1G-12) and
check each possible defective part. Replace if found
1) Relieve fuel pressure from fuel feed line. (Page
defective.
1G-19)
a) Set ignition “ON” to operate fuel pump and turn it
2) Remove air cleaner assembly.
“OFF” after 2 seconds. Repeat this 3 or 4 times
• K10B model: (Page 1D-6) and then check fuel pressure.
• K12M model: (Page 1D-82)
Fuel pressure specification
3) Disconnect fuel feed hose from fuel delivery pipe. 368.6 – 391.4 kPa (3.8 – 3.9 kgf/cm2, 53.5 –
4) Connect special tools and hose between fuel feed 56.7 psi, 3.686 – 3.914 bar)
hose (1) and fuel delivery pipe as shown in figure,
7) Relieve fuel pressure. (Page 1G-19)
and clamp hoses securely to check that no leakage
occurs during check. 8) Remove special tools from fuel delivery pipe and fuel
feed hose.
Special tool
9) Connect fuel feed hose to fuel delivery pipe and
(A): 09912M58442
clamp it securely.
(B): 09912M58432
(C): 09912M58490 10) With engine stopped and ignition “ON”, check for fuel
leakage. (Page 1G-20)
K10B model 11) Install air cleaner assembly.
• K10B model: (Page 1D-6)
(A) • K12M model: (Page 1D-82)
(B)

(C)

IJCA0A171007-01

K12M model

(B)
(A)

1
(C)

IGSB0A173005-01
1G-15 Fuel System: Petrol

Repair Instructions
Fuel System Components
AENJCA0A1716001

(d)
17
13

12 16

11

10
14

18

(c)

15
9

21

20
19
[A]
4 (a) 7
3 8
5
2

1 (b)

[B] 6
4 (a)

2 5

2
IJCA0A171008-02

[A]: K10B model 9. Fuel pipe (pump to filter) 19. Fuel tank belt
[B]: K12M model 10. Fuel tank 20. EVAP hose
1. Fuel injector 11. Fuel pump assembly 21. To EVAP canister
: For installation, refer to “Fuel Injector
Removal and Installation”: Petrol (Page 1G-
22).
2. Injector O-ring 12. O-ring : 25 Nm (2.5 kgf-m, 18.5 lbf-ft)
: Apply a bit of fuel to install.
3. Fuel injector clip 13. Fuel pump lock nut : 14 Nm (1.4 kgf-m, 10.5 lbf-ft)
: For installation, refer to “Fuel Injector : For tightening procedure, refer to “Fuel Pump
Removal and Installation”: Petrol (Page 1G- Assembly Removal and Installation”: Petrol
22). (Page 1G-29).
4. Fuel delivery pipe 14. Breather hose : 5.5 Nm (0.56 kgf-m, 4.0 lbf-ft)
5. Fuel feed hose 15. Fuel tank filler hose : 3.0 Nm (0.31 kgf-m, 2.5 lbf-ft)
6. Fuel feed pipe 16. Fuel filler neck : Do not reuse.
7. Fuel pipe (filter to pipe) 17. Fuel filler cap
8. Fuel filter 18. Heat insulator
 Fuel System: Petrol 1G-16

Fuel Hose Disconnection and Reconnection

AENJCA0A1716002
Before performing the following procedure, observe “Precautions for Fuel System Service”: Petrol (Page 1G-1).

Non-Quick Joint Connections

Clamp around fuel tank

NOTE
Install hose in the raised part of pipe securely.

3
2 “f” 3 1 5

“e”
2
1 “a”
5
“a”

“a”
5 [a]
3
“e”

2
1

2 3 “c”
4

1
“b” “e”

[A]

“a” “g”
3
2
“e”
1 3
5
1
6
“d”

2
“a” “f”
IJCA0A171009-01

[A]: View [a] “e”: 22.5° 3. Clamp

“a”: 3 – 7 mm (0.12 – 0.27 in.) “f”: 0° 4. Vehicle leftward
“b”: 0 – 8 mm (0 – 0.31 in.) “g”: 40° 5. Vehicle rightward
“c”: 5 – 12 mm (0.20 – 0.47 in.) 1. Pipe 6. Vehicle backward
“d”: 45 – 48 mm (1.78 – 1.88 in.) 2. Hose
1G-17 Fuel System: Petrol

Fuel Tank Filler Hose Reconnection

Disconnection 1) Install fuel tank filler hose (1) to fuel tank (2).
1) Remove fuel filler cap.
NOTE
2) Insert hose of hand operated pump into fuel tank
through fuel filler neck. Install the fuel tank filler hose with
identification marks on the hose end facing
NOTICE up (approximately).
The hose of the hand operated pump could
2) Position fuel tank filler hose clamp (3) as specified.
damage the fuel tank inlet valve if excessive
force is applied when inserting or removing it Clearance between fuel tank and fuel tank side
from the fuel tank. clamp
Do not apply excessive force when inserting “a”: 3 – 7 mm (0.12 – 0.27 in.)
or removing the hose of the hand operated
Position of clamp mid-point within range
pump.
“b”: 0°
3) Pump out fuel in space “a” shown in figure.
“b”
! WARNING 2 3

There is a risk of fire or explosion due to

static electricity if the drained fuel is stored in
an open container or plastic container. 1
Store the fuel in a sealed metal container. “a”

1
1

“a” 2

IBP70A170006-01

1. Fuel tank filler hose 3

IJCA0A171011-01
4) Remove hose of hand operated pump from fuel filler 3) Rotate plastic clamp (1) in arrow direction.
neck.
5) Hoist vehicle.
6) Remove clamp (1).
7) Loosen fuel tank filler hose clamps (2).
8) Remove fuel tank filler hose (3).
1

3
IJCA0A171012-01
1

2
IJCA0A171010-01
 Fuel System: Petrol 1G-18

4) Apply fuel to all around the outer circumference of
fuel tank filler hose attachment section of the fuel
filler neck.
NOTICE
Remaining lint from cloth may cause fuel
leakage.
Use lint-free cloth to apply fuel.
7) Visually check bulge on fuel tank filler hose. Repeat
Step 4) – 6) if check result is not as specified.
Fuel tank filler hose bulge is in good shape
Bulge “A” = “B”: In uniform contact with pipe
“A”

NOTE
Apply fuel to insert fuel tank filler hose into
proper position.

5) Insert fuel tank filler hose (1) to fuel filler neck.

6) Position fuel tank filler hose clamp (2) as specified.
Clearance between spool and fuel filler hose end
“a”: 0 – 8 mm (0 – 0.31 in.) “B”
IGSB0A173012-01

Position of clamp mid-point within range Fuel tank filler hose bulge is not in good shape
“b”: 22.5° Bulge “C”: In excess contact with pipe
Clearance between fuel tank filler hose clamp Bulge “D”: In poor contact with pipe
and fuel filler hose end
“C”
“c”: 5 – 12 mm (0.20 -– 0.47 in.)

“a”
1 2
“D”
IGSB0A173013-01

8) Turn the plastic clamp, and clamp the hoses.

9) Lower vehicle.
“b”
“c”
IJCA0A171013-01
10) If fuel is drained, return fuel to fuel tank.
11) Install fuel filler cap.
1G-19 Fuel System: Petrol

Clamp other than around fuel tank 3) Disconnect quick joint from pipe.

1
2 (A)

2
1
I4RS0A170019-01

Reconnection
Insert quick joint to fuel pipe until they lock securely (a
click is heard), and check that quick joint is not
disconnected by hand.

Fuel Pressure Relief Procedure

AENJCA0A1716003
I7V20A171005-01 NOTICE
[A]: With short pipe, fit hose as far as it 1. Pipe Performing this procedure when the engine
reaches the end of pipe joint as shown.
is still hot can damage the catalyst.
[B]: With the above type pipe, fit hose as far 2. Hose
as it reaches bulge on fuel pipe. Wait until the engine has cooled down before
“a”: 3 – 7 mm (0.12 – 0.28 in.) 3. Clamp performing this procedure.

Quick Joint Connections 1) Check that engine is cold.

Type A (lock button type) 2) For M/T model, place gear shift lever in “Neutral”,
Disconnection apply parking brake and block drive wheels.
1) Remove mud, dust and/or foreign material between For auto gear shift model, place shift selector in N
pipe (1) and quick joint (2) using compressed air. range, apply parking brake and block drive wheels.
2) Disconnect quick joint from fuel pipe while pushing 3) Remove fuel pump relay (1) from individual circuit
lock button (3) on joint. fuse box No.1.
4) Remove fuel filler cap to release fuel vapor pressure
1 from fuel tank, and then reinstall fuel filler cap.
5) Start engine and run it until engine stops for lack of
fuel. Repeat cranking engine 2 – 3 times for about 3
seconds each time to dissipate fuel pressure in lines.
Fuel connections are now safe for servicing.
2 6) After servicing, install fuel pump relay to individual
3
I8T401171011-01
circuit fuse box No.1 and install individual circuit fuse
box No.1 cover.
Reconnection
Insert quick joint to fuel pipe until they lock securely (a
click is heard), and check that quick joint is not
disconnected by hand.
1
Type B (special tool inserting type)
Disconnection
1) Remove mud, dust and/or foreign material between
pipe (1) and quick joint (2) by blowing compressed
air.
2) Unlock joint lock by inserting special tool between
pipe and quick joint.
Special tool
(A): 09919M47020 IJCA0A171014-01
 Fuel System: Petrol 1G-20

Fuel Leakage Check Procedure 3) Disconnect fuel pipe (filter to pipe) and fuel hose
AENJCA0A1716004 from fuel feed pipe (1) and disconnect EVAP hoses
After performing any service on fuel system, check that
from EVAP pipe (2). (Page 1G-16)
there is no fuel leakage as follows.
4) Mark the location of clamps (3) on fuel feed pipe and
1) Set ignition “ON” for 2 seconds (to operate fuel
EVAP pipe, so that the clamps can be reinstalled to
pump) and then to “OFF”. Repeat this cycle of
the original position.
operation 3 or 4 times.
Fuel pressure should now be established in fuel 5) Remove fuel feed pipe and EVAP pipe.
system and felt by hand on fuel feed hose. NOTICE
2) Check that there is no fuel leakage from any part of
Fuel feed pipe and EVAP pipe may be bent or
fuel system.
damaged if you are not careful when
unclamping them.
Fuel Line On-Vehicle Inspection Properly support fuel feed pipe and EVAP
AENJCA0A1716005
Visually check fuel lines for evidence of fuel leakage, pipe when removing clamps.
hose crack and deterioration or damage.
Check that all clamps are secure. [A]
Replace parts if necessary.

IJCA0A171016-01

IJCA0A171015-01 [B]

Fuel Pipe Removal and Installation

AENJCA0A1716006
Before performing the following procedure, observe
“Precautions for Fuel System Service”: Petrol (Page 1G-
2
1).

Removal
1
1) Relieve fuel pressure from fuel feed line. (Page
1G-19) 3
IJCA0A171017-01
2) Disconnect negative (–) cable at battery.
[C]

3
1

IJCA0A171018-01

[A]: Engine side-K10B model [C]: Fuel tank side

[B]: Engine side-K12M model
1G-21 Fuel System: Petrol

Installation Fuel Injector On-Vehicle Inspection

1) Install fuel feed pipe and EVAP pipe to vehicle.
2) Install clamps to marked position on pipes. If clamp
is deformed or has bent or broken claws, replace it
with new one.
3) Connect fuel pipe (filter to pipe) and fuel hose to fuel
feed pipe (1) and connect EVAP hoses to EVAP pipe
(2). (Page 1G-16)
[A]
AENJCA0A1716007
1) Remove air cleaner assembly, if necessary.
• K10B model: (Page 1D-6)
• K12M model: (Page 1D-82)
2) Using sound scope (1) or the like, check operating
sound of fuel injector (2) when engine is running or
cranking.
Cycle of operating sound should vary according to
engine speed.
If no sound or unusual sound is heard, check fuel
injector circuit (wire or connector) or fuel injector.

IJCA0A171019-01

[B]
I2RH0B170007-01

3) Disconnect connector (1) from fuel injector, connect

ohmmeter between terminals of fuel injector and
check resistance.
If resistance is out of reference value greatly, replace
2
injector.
Reference resistance of fuel injector
1 11.6 – 12.4 Ω at 20 °C (68 °F)

IJCA0A171020-01

[C]

1
[A]: Engine side-K10B model
[B]: Engine side-K12M model
I2RH0B170008-01
4) Connect connector to fuel injector securely.
IJCA0A171021-01 5) Install air cleaner assembly.
[C]: Fuel tank side • K10B model: (Page 1D-6)
• K12M model: (Page 1D-82)

4) Connect negative (–) cable at battery.

5) With engine stopped, set ignition “ON” and check for
fuel leakage. (Page 1G-20)
 Fuel System: Petrol 1G-22

Fuel Injector Removal and Installation 5) Disconnect PCV hose (1).

AENJCA0A1716008
Before performing the following procedure, observe 6) Disconnect fuel feed hose (2) from fuel delivery pipe
“Precautions for Fuel System Service”: Petrol (Page 1G- (3).
1). 7) Remove fuel delivery pipe with fuel injectors.
K10B model
NOTICE
If injectors are removed without observing 1 3 2
the following precautions, nozzle sleeve (1)
may fall off and enter the combustion
chamber, possibly causing the engine
damage.
• Remove the injectors straight, evenly and
gently.
• After removal, check that the tip is fitted.

IJCA0A171022-01

K12M model

1 2 3

IJHA0B170007-01

Removal
1) Relieve fuel pressure. (Page 1G-19)
2) Disconnect negative (–) cable at battery.
3) Remove air cleaner assembly.
• K10B model: (Page 1D-6)
IJCA0A171024-01
• K12M model: (Page 1D-82)
8) Remove fuel injector from fuel delivery pipe as
4) Disconnect fuel injector connectors and engine follows.
harness clamps.
a) Expand fuel injector clip (1) in arrow “1”
directions to unhook it and remove it in arrow “2”
direction.
b) Remove fuel injector (2).

“1”

“1”

“2”
1

2
IDLA0A170019-01
1G-23 Fuel System: Petrol

Installation
3
NOTICE
4
Failure to take the following precautions may
6
affect injector O-rings and cause leakage of
high pressure fuel.
4
• Replace O-rings in clean condition.
6
• To avoid damaging injector, do not use
2
metal tool for removal of O-rings.
• Check injector groove for cleanliness 2
before fitting O-rings. 5
• Fit new O-rings with a minimum stretch.
5
• Do not reuse O-rings once removed. 1

• After fitting O-rings, check for proper IDLA0A170022-01

seating and cleanliness. 2) Install fuel delivery pipe with injectors to cylinder
head as follows.
1) Install fuel injectors to fuel delivery pipe as follows.
a) Apply thin coat of fuel to fuel injector nozzle side
a) Install new injector O-rings (1) to injector (2). injector O-rings.
b) Fit injectors (1) to cylinder head.
c) Tighten fuel delivery pipe nuts (2) to specified
torque.
Tightening torque
2 1 Fuel delivery pipe nut (a): 25 N·m (2.5 kgf-m,
18.5 lbf-ft)

K10B model

IFRA0A171051-01

b) Install fuel injector clip (1) to injector (3) inserting

its cutout (2) to slot (4) and fitting tabs (5) aligned
with protrusion (6).

4 1
2, (a)
IJCA0A171025-01

6 5 K12M model
2
2, (a)
3

IDLA0A170021-01

c) Apply thin coat of fuel to fuel delivery pipe side

injector O-ring.
d) Insert fuel injector to fuel delivery pipe (3) with
fuel injector clip (1) aligning slot (2) with
protrusion (4) and then fit slots (5) to protrusions
(6).
1
IJCA0A171026-01
 Fuel System: Petrol 1G-24

d) Check that injectors (1) can be rotated smoothly

(2). (B)
If not, probable cause is incorrect installation of
injector O-ring. In such a case, replace the O-
ring with new one again.

(A) (C)

1 (D)

1
(C)
2

IFRA0A171026-01

3) Connect fuel feed hose to fuel delivery pipe.

IFRA0A171027-01
4) Connect fuel injector connectors and engine harness
clamps. 3) Install suitable vinyl tube (1) onto injector nozzle to
prevent fuel from splashing out during injection.
5) Connect PCV hose.
4) Put graduated cylinder (2) under fuel injector.
6) Connect negative (–) cable at battery.
5) Connect one of terminal of special tool (D) to battery
7) After completing installation, check fuel line
positive (+) terminal.
connections for leakage with engine not running and
ignition “ON”. (Page 1G-20) ! WARNING
8) Install air cleaner assembly.
There is an increased risk of personal injury
• K10B model: (Page 1D-6)
and fire if the following procedure is
• K12M model: (Page 1D-82) performed without taking proper precautions.
Put fuel injectors as far away from the battery
Fuel Injector Inspection as possible when connecting / disconnecting
AENJCA0A1716009
the test lead to / from the battery.
Before performing the following procedure, observe
“Precautions for Fuel System Service”: Petrol (Page 1G-
1). Special tool
(D): 09930M86310
1) Remove fuel injector. (Page 1G-22)
2) Set special tools as follows.
Special tool
(A): 09912M58421
(D)
(B): 09912M57610
(C): 09912M97110
(D): 09930M86310
a) Install special tool (A) and special tool (C) to fuel
injector (1). 1

b) Connect special tool (D) to fuel injector.

c) Install special tool (B) to special tool (A). 2

d) Connect fuel feed hose to special tool (A). IFRA0A171028-01

1G-25 Fuel System: Petrol

6) Operate fuel pump and apply fuel pressure to fuel

injector as follows: 1
Using SUZUKI scan tool:
a) Connect SUZUKI scan tool to DLC (1) with
ignition “OFF”.
b) Set ignition “ON”, clear DTC and select “Active
Test” mode on scan tool.
c) Operate fuel pump on using scan tool.
Special tool
(A): SUZUKI scan tool (Suzuki SDT-II)

1 IJCA0A171027-01

7) Apply battery voltage to fuel injector for 15 sec. and

8) Check fuel leakage from injector nozzle. Do not
(A)
IJCA0A181004-01
Without using SUZUKI scan tool:
a) Remove fuel pump relay from individual circuit
fuse box No.1.
b) Connect two terminals of relay connector using
service wire (1) as shown in figure.
measure injected fuel volume with graduated
cylinder. Test each fuel injector two or three times. If
injected volume is out of reference value greatly,
replace fuel injector.
Reference injected fuel volume
Approx. 56 – 58 cm3/15 sec. (56 – 58 ml, 1.90 –
1.96 US.oz, 1.97 – 2.04 Imp.oz/15 sec.)
operate fuel injector for this check (but fuel pump
should be at work). If fuel leaks (1) more than the
following specification, replace fuel injector.
Fuel leakage
Less than 1 drop/min.

NOTICE
If the service wire is connected between the
wrong terminals, the ECM, wire harness, etc.
may be damaged.
Connect the service wire to the correct 1
terminals.

c) Set ignition “ON”.

IFRA0A171031-01

9) Release fuel pressure in fuel feed line according to

steps below and remove fuel injector from special
tools.
a) Stop operation of fuel pump.
b) Put graduated cylinder under fuel injector.
c) Apply battery voltage to fuel injector until no fuel
is injected from fuel injector.
10) Carry out Step 2) – 9) on each fuel injector to obtain
4 readings.
 Fuel System: Petrol 1G-26

11) After checking, remove special tools from fuel NOTICE

injector and fuel feed hose.
12) Install fuel injectors to cylinder head. (Page 1G-22)
13) Connect fuel feed hose to delivery pipe.
14) Install fuel pump relay to individual circuit fuse box
No.1, if removed.
15) Check for fuel leakage. (Page 1G-20)
The hose of the hand operated pump could
damage the fuel tank inlet valve if excessive
force is applied when inserting or removing it
from the fuel tank.
Do not apply excessive force when inserting
or removing the hose of the hand operated
pump.

Fuel Filler Cap Inspection

AENJCA0A1716010 1
NOTICE
Failure to use correct cap can result in EVAP “a”
leakage.
If cap requires replacement, use a cap with
genuine SUZUKI parts. IBP70A170006-01

5) Hoist vehicle and remove clamps (1).

Remove cap (1), and check gasket for even filler neck
imprint, deterioration or any damage. If gasket (2) is
defective, replace cap.
2
6) Disconnect breather hose (2) and fuel filler hose (3),
and turn plastic clamp (4).
NOTICE
The plastic clamp could be damaged if
excessive force is applied when turning it.
Turn plastic clamp carefully.

1
1

I9W10P170020-01
3 2

Fuel Tank Removal and Installation

AENJCA0A1716011
Before performing the following procedure, observe
“Precautions for Fuel System Service”: Petrol (Page 1G-
1).

Removal 4
1) Relieve fuel pressure from fuel feed line. (Page IJCA0A171028-01

1G-19) 7) Disconnect ground cable (1), quick joint (2) and

2) Disconnect negative (–) cable at battery. EVAP hose (3). (Page 1G-16)
3) Remove fuel filler cap.
4) Insert hose of a hand operated pump into fuel filler
hose (1) and pump out fuel in space “a” shown in
figure. 2

! WARNING
There is a risk of fire or explosion due to
static electricity if the drained fuel is stored in
an open container or plastic container. 3
Store the fuel in a sealed metal container. 1

IJCA0A171029-01
1G-27 Fuel System: Petrol

8) Remove muffler. Installation

• K10B model: (Page 1K-5)
• K12M model: (Page 1K-10)
9) Support fuel tank (1) with jack (2) and remove its
mounting bolts.
10) Lower fuel tank a little to disconnect fuel pump
connector (3), and then remove fuel tank.
NOTICE
Applying tension to the fuel pump harness
will cause damage to the fuel pump and the
fuel pump harness when lowering the fuel
1) If removed, install fuel tank components.
tank.
Disconnect the fuel pump connector with the
fuel tank lowered to a height at which tension
is not applied to the fuel pump harness.
3
! WARNING
Failure to take proper precautions when
reinstalling the fuel tank connections can
result in fuel leakage or damage.
Clean the outside surface of the pipe where
each quick joint is to be installed, push the
pipe into the joint until the joint lock clicks,
and then check that the pipe is connected
securely.
• Fuel pump: (Page 1G-29)
• Fuel filter: (Page 1G-29)
• Fuel EVAP hose, fuel filler hose and breather
hose: (Page 1G-16)
• Heat insulator (1)
• Fuel tank belt (2)

2
IJCA0A171031-01

2) Raise fuel tank with jack and connect fuel pump

2 connector.
IJCA0A171030-01 3) Install fuel tank (1) to vehicle and tighten new fuel
11) If necessary, remove fuel tank components. tank bolts (2) to specified torque.
• Fuel pump: (Page 1G-29) NOTICE
• Fuel filter: (Page 1G-29)
The fuel tank bolts are pre-coated with
• Fuel EVAP hose, fuel filler hose and breather friction stabilizer. If the bolts are reused, they
hose: (Page 1G-16) may work loose.
• Heat insulator (1) Use the new fuel tank bolts.
• Fuel tank belt (2)
Tightening torque
1 Fuel tank bolt (a): 14 N·m (1.4 kgf-m, 10.5 lbf-ft)

2, (a) 1

2 2, (a)
IJCA0A171031-01

IJCA0A171032-01
 Fuel System: Petrol 1G-28

4) Connect fuel filler hose (1), breather hose (2) and Fuel Tank Inspection
clamps (3) securely. AENJCA0A1716012

For proper installation, refer to “Fuel Hose • Check fuel tank for crack, deformation or damage.
Disconnection and Reconnection”: Petrol (Page 1G- • Check fuel tank inlet valve for damage, smooth
16). opening and closing.
5) Turn plastic clamp (4). If faulty condition is found, replace fuel tank.
• Check fuel pump O-ring for fuel leakage.
NOTICE If faulty condition is found, replace O-ring and fuel
The plastic clamp could be damaged if pump lock nut.
excessive force is applied when turning it. • Check hoses and pipes connected to fuel tank for
Turn plastic clamp carefully. leakage, loose connections, deterioration or damage.
If faulty condition is found, replace hoses and/or
pipes.
3

Fuel Tank Flushing Procedure

AENJCA0A1716013
1 2
! WARNING
This flushing procedure cannot remove all
fuel vapors in the fuel tank completely, so
using a flame or electric heater to dry the fuel
tank will increase the risk of an explosion
which may cause human injury.
4
Do not use a flame and/or electric heater to
IJCA0A171033-01 dry the fuel tank.
6) Connect fuel feed hose (1) and EVAP hose (2).
(Page 1G-16) Before performing the following procedure, observe
“Precautions for Fuel System Service”: Petrol (Page 1G-
7) Install ground cable (3) and tighten fuel ground cable
1).
bolt (4) to specified torque.
1) After removing fuel tank, remove all hoses, pipes
Tightening torque and fuel pump assembly from fuel tank.
Fuel ground cable bolt (a): 3.0 N·m (0.31 kgf-m,
2) Drain all remaining fuel from tank.
2.5 lbf-ft)
3) Place fuel tank to flushing area.
4) Fill tank with warm water or tap water, agitate water
vigorously, and drain water out of tank. Repeat this
process until inside of tank is clean.
1 4, (a)
5) Completely flush out remaining water.
6) Dry fuel tank assembly thoroughly in a place free of
direct sunlight.

2
3

IJCA0A171034-01

8) Install muffler.
• K10B model: (Page 1K-5)
• K12M model: (Page 1K-10)
9) Install fuel filler cap.
10) Connect negative (–) cable at battery.
11) With engine stopped, set ignition “ON” and check for
fuel leakage. (Page 1G-20)
1G-29 Fuel System: Petrol

Fuel Pump On-Vehicle Inspection Fuel Filter Removal and Installation

AENJCA0A1716014 AENJCA0A1716019
NOTE Removal
Fuel pressure regulator is an integral part of 1) Relieve fuel pressure. (Page 1G-19)
fuel pump assembly. 2) Disconnect quick joints (1) from fuel filter (2).
Fuel pressure regulator cannot be (Page 1G-16)
individually checked. 3) Remove fuel filter from fuel filter bracket (3) as
shown in figure.
1) Remove fuel filler cap and set ignition “ON”. Fuel
pump operation sound should be heard from fuel
filler (1) for about 2 seconds. Reinstall fuel filler cap.
If check result is not as specified, go to “Fuel Pump
and Its Circuit Check”: Petrol (Page 1G-10). 1

“2”

1 2
“1” 3
IJCA0A171036-01

Installation
Reverse removal procedure noting the following point.
• After completing installation, check fuel line
connections for leakage with engine not running and
ignition “ON”. (Page 1G-20)
IAW101170034-01

2) Set ignition “OFF” and leave it over 10 seconds as it
is.
3) Fuel pressure should be felt at fuel feed hose (1) for
about 2 seconds after setting ignition “ON”.
If fuel pressure is not felt, go to “Fuel Pressure
Check”: Petrol (Page 1G-12).
1 Do not remove each of the fuel pump
Fuel Pump Assembly Removal and Installation
AENJCA0A1716015
NOTICE
The fuel pump assembly components except
the fuel level sensor will lose their original
performance if each part is removed from the
fuel pump assembly.
assembly components except the fuel level
sensor. If any faulty condition is found,
replace the fuel pump assembly with a new
one.

Removal
1) Remove fuel tank from vehicle. (Page 1G-26)
2) Disconnect quick joints (1) from fuel pump assembly
(2). (Page 1G-16)

IJCA0A171035-01 1

IJCA0A171037-01
 Fuel System: Petrol 1G-30

3) Remove fuel pump lock nut (1) from fuel tank (2) 2) Install new O-ring (1) to fuel tank (2).
using special tool.
Special tool 1
(A): 09941M51013
2

(A)

IFRA0A171044-01

3) Install fuel pump assembly (1) to fuel tank (2) as

follows.
a) Align arrow mark (3) on fuel pump assembly with
1 cutout (4) of fuel tank.
2
IJCA0A171038-01 b) Push fuel pump assembly down by hand until
4) Remove fuel pump assembly (1) and O-ring (2) from fuel pump assembly comes into contact with fuel
fuel tank (3). tank as shown in figure.

2 2

3
1

IFRA0A171043-01

5
Installation 3

! WARNING 1

Failure to take proper precautions when

reinstalling the fuel tank connections can 4
result in fuel leakage or damage.
2
Clean the outside surface of the pipe where IFRA0A171045-01
each quick joint is to be installed, push the
5. O-ring
pipe into the joint until the joint lock clicks,
and then check that the pipe is connected
securely. c) In the state of Step b), tighten new fuel pump
lock nut (1) by hand.
NOTE
Before fitting fuel pump assembly, check that
wiring harness is not in contact with
surrounding parts.

1) Clean mating surfaces of fuel pump assembly and

fuel tank.
1G-31 Fuel System: Petrol

NOTICE 4) Connect quick joints (1) to fuel pump assembly (2).

Removed fuel pump lock nut cannot assure (Page 1G-16)
adequate sealing. If the fuel pump lock nut is
reused, it may cause fuel leakage.
Never reuse the fuel pump lock nut.

NOTE 1

Tighten lock nut while pressing straight on it

so that it will not tilt.

IJCA0A171037-01

5) Install fuel tank to vehicle. (Page 1G-26)

1
Fuel Pump Inspection
AENJCA0A1716016

1
4 • Check fuel pump assembly for damage.
• Check fuel suction filter for contamination.
2 If contaminated, replace or clean the filter and check
fuel tank inside for presence of dirt.

3
Fuel Level Sensor Removal and Installation
AENJCA0A1716017
IFRA0A171046-01 NOTICE
2. Fuel pump assembly 4. O-ring
Failure to take proper precautions when
3. Fuel tank
removing or installing the fuel level sensor
can result in damage.
d) Using special tool, tighten fuel pump lock nut (1)
To prevent failure of the fuel level sensor, be
until indexes (3) of fuel pump lock nut and fuel
careful not to touch the resistor plate (1) or
tank (2) are aligned.
deform the arm (2) when performing the
NOTE service operations described below.

• Indexes are aligned when fuel pump lock

nut is tightened by approx. 1 rotation.
• After tightening fuel pump lock nut, check 1
for loosening and play.

Special tool
(A): 09941M51013

(A)
IAW101170039-01

1 2
3 3
IJCA0A171039-01
 Fuel System: Petrol 1G-32

Removal Fuel Level Sensor Inspection

AENJCA0A1716018
1) Remove fuel pump assembly from fuel tank. (Page
1G-29) • Check that resistance between terminals “1” and “2”
of fuel level sensor changes depending on float
2) Disconnect fuel level sensor connector (1). position.
3) Release lock (2), and remove fuel level sensor (3) • Check resistance between terminals “1” and “2” at
from fuel pump (4) by sliding it in arrow direction as each float position in the following table.
shown in figure. If check result is not as specified, replace fuel level
sensor.
1
Fuel level sensor specifications
Float Position Resistance (Ω)
2 “a” 122.6 mm (4.827 in.) 40 ± 2.0
“b” 78.6 mm (3.094 in.) 160 ± 10.0
“c” 18.7 mm (0.736 in.) 280 ± 3.3
3
3

2 1
1
4 4 3
IJCA0A171040-01
2

Installation
Reverse removal procedure.
“a”
“b”
“c”

IJCA0A171041-01

Specifications
Tightening Torque Specifications
AENJCA0A1717001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Fuel delivery pipe nut 25 2.5 18.5 (Page 1G-23)
Fuel tank bolt 14 1.4 10.5 (Page 1G-27)
Fuel ground cable bolt 3.0 0.31 2.5 (Page 1G-28)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Fuel System Components”: Petrol (Page 1G-15)
“Fasteners Information” in Section 0A (Page 0A-6)
1G-33 Fuel System: Petrol

Special Tools and Equipment

Special Tool
AENJCA0A1718001
09912M57610 09912M58421
Injector checking tool plate Checking tool set
(Page 1G-24) This kit includes the
following items. 1. Tool body
and washer 2. Body plug 3.
Body attachment-1 4. Holder
5. Return hose and clamp 6.
Body attachment-2 and
washer 7. Hose attachment-
1, 8. Hose attachment-2
(Page 1G-24)
09912M58432 09912M58442
Fuel pressure gauge hose Fuel pressure gauge
This tool is included in fuel This tool is included in fuel
pressure gauge set (09912- pressure gauge set (09912-
58413). 58413).
(Page 1G-12) / (Page 1G-12) /
(Page 1G-14) (Page 1G-14)
09912M58490 09912M97110
3-way joint & hose Checking tool attachment
(Page 1G-12) / (Page 1G-24)
(Page 1G-14)

09919M47020 09930M86310
Quick joint remover Injector test harness
(Page 1G-19) (Page 1G-24) /
(Page 1G-24)

09941M51013 SUZUKI scan tool (Suzuki

SDT-II)
Lock ring wrench —
(Page 1G-30) / (Page 1G-6) /
(Page 1G-31) (Page 1G-25)
 Fuel System: Bi-Fuel CNG 1G-34

Bi-Fuel CNG
Precautions
Precautions for Fuel System Service • When any pit and/or crack is found in fuel
AENJCA0A1720001 tank, never repair the tank but always
! WARNING replace it with a new fuel tank.
Service operation of any type performed on • As fuel tank is made of plastic, when
the fuel system involves a risk of fire and solvent such as grease and sealant is
personal injury if proper precautions are not allowed to contact fuel tank, some
taken. chemical reaction may occur, causing fuel
Take the following precautions whenever tank to be swollen, hardened or deformed,
working on the fuel system. resulting in fuel leakage from fuel tank.
Wipe off any solvent adhered on tank
• Disconnect the negative (–) cable at the
without delay.
battery.
• Before servicing CNG devices, turn
• Do not smoke. Put up no smoking signs
manual CNG cylinder valve on CNG
around the work area.
cylinder to close position and relieve the
• Have CO2 fire extinguishers ready. fuel pressure by following “Fuel Pressure
• Perform service operations only in a well- Relief Procedure”: Bi-Fuel CNG (Page 1G-
ventilated area away from any open flames 55).
such as gas water heaters. • Never remove the CNG cylinder valve from
• Do not perform any actions that will spark, the cylinder assembly.
if gas leak is detected. • Even if the CNG from CNG cylinder is
• Wear safety glasses. consumed till the engine stops, some
• Remove the fuel filler cap from the fuel amount of CNG will be left in the cylinder
filler neck to relieve the fuel tank of fuel under pressure.
(petrol) vapor pressure, and then reinstall
the cap. NOTICE
• Before loosening or disconnecting the fuel If a leaded or low-lead fuel is used for this
feed line, relieve the fuel system of fuel engine, the engine itself and the emission
pressure by following “Fuel Pressure control system will be damaged.
Relief Procedure”: Bi-Fuel CNG (Page 1G- Use only unleaded fuel.
55).
• When disconnecting a fitting on the petrol
fuel line, cover the fitting with a shop cloth
to soak up the small amount of fuel that
may flow out from the disconnected fuel
line. Put the used cloth in an approved
container.
• Since fuel hose connections vary with the
pipe type, connect and clamp each hose
using the correct method for each specific
connection. (Page 1G-54)
After connecting a hose, check that there
is no twist or kink in the hose.
• When installing petrol fuel injector, CNG
fuel injector, CNG fuel filter or CNG
pressure gauge, lubricate its O-rings with
gasoline.
• Handle the fuel tank carefully. Do not allow
it to touch sharp edges or hot surfaces. Do
not drop it. If the tank is dropped, the tank
and all components on and in it should be
replaced because they may have been
damaged.
1G-35 Fuel System: Bi-Fuel CNG

General Description
Fuel System Description Fuel Pump Description
AENJCA0A1721001 AENJCA0A1721003
This model adopts a bi-fuel system capable of utilizing Refer to “Fuel Pump Description”: Petrol (Page 1G-2).
two types of fuel, petrol and CNG appropriately.
This system operates in three fuel modes: “Petrol CNG Receptacle Description
MODE”, “Forced CNG MODE” and “AUTO MODE”, each AENJCA0A1721004
of which can be selected with the selector switch. The vehicle is refueled with gas through the CNG
For more information on the system control, refer to “Bi- receptacle.
Fuel CNG System Description”: Bi-Fuel CNG in Section When refueling, a refueling nozzle is connected to the
1A (Page 1A-275). CNG receptacle. As the pressure increases on the
Petrol and CNG fuel systems contain the following nozzle side, the one-way valve inside the CNG
principle components. receptacle opens to admit gas to the CNG cylinder.
• Petrol fuel system
Fuel tank, fuel pump assembly (with built-in petrol fuel CNG Cylinder Description
AENJCA0A1721005
pressure regulator), petrol fuel filter, petrol fuel The CNG cylinder is made of chrome molybdenum steel.
delivery pipe, petrol fuel injectors, petrol fuel feed line, The vehicle is equipped with one CNG cylinder with a
fuel return line and fuel vapor line. capacity of 60 liters (126.80/105.59 US/Imp pt.) in the
• CNG fuel system luggage compartment.
CNG receptacle, CNG cylinder, CNG cylinder valve, The CNG cylinder valve located on the outlet port is
CNG pressure gauge, CNG pressure regulator, CNG equipped with a safety mechanism.
fuel filter, CNG fuel injector assembly and CNG fuel
feed line. Specifications
Volume 60 liters (126.80/105.59 US/Imp pt.)
Fuel Delivery System Description Maximum fueling
20 MPa (203.9 kgf/cm2, 2900 psi)
AENJCA0A1721002 pressure
Petrol Delivery System Vessel weight Approximately 62 kg (137 lb)
Refer to “Fuel Delivery System Description”: Petrol Material Chrome molybdenum steel
(Page 1G-2).

CNG Delivery System

Gas contained in the CNG cylinder passes through the
CNG fuel pipe to the CNG pressure regulator when the
shut-off valve of the CNG cylinder valve is opened. High
pressure gas is decompressed to a suitable pressure for
fuel injection by the CNG pressure regulator. The
decompressed gas passes through the CNG fuel filter to
remove oil, etc. The gas is then injected from CNG fuel
injector.
For system diagram, refer to “Fuel Delivery System
Diagram”: Bi-Fuel CNG (Page 1G-38).

CNG Cylinder Valve Description
The CNG cylinder valve, which is attached on the outlet port of the CNG cylinder (6), is equipped with manual CNG
cylinder valve (2), shut-off valve (3), and excess flow valve (1). Additionally, fusible plug (4) and pressure relief device
(5) are fitted as safety devices.
Manual CNG Cylinder Valve
Rotating the handle clockwise shuts off the main path in
the CNG cylinder valve, and stops the discharge of gas.
This valve has to be open when driving the vehicle
normally or when refueling the CNG cylinder, and it has
to be shut in unusual circumstances, such as when an
accident has occurred or when the vehicle will not be
used for an extended period of time.
Excess Flow Valve
The excess flow valve is a safety valve that operates
automatically on the difference between the internal
pressure of the CNG cylinder and the pressure at the
outlet, when gas flow becomes abnormal due to
damaged CNG fuel pipe, etc.
When the difference between the internal pressure of the
CNG cylinder and the pressure at the outlet is within
normal range, the valve plate of the excess flow valve is
held by a spring. Thus the excess flow valve opens
under normal circumstances.
Fuel System: Bi-Fuel CNG 1G-36
AENJCA0A1721006
I9R90A172048-02
When pressure at the outlet lowers due to such
occurrences as a damaged CNG fuel pipe, the internal
pressure of the CNG cylinder becomes bigger than the
spring force. As a result, the valve plate is pushed
against the spring and the gas path is closed.
When the excess flow valve operates, its state is
maintained. The excess flow valve can be returned to its
normal state by closing the manual CNG cylinder valve
to its full extent for a period of time and fully opening the
manual CNG cylinder valve again.
Shut-Off Valve
The shut-off valve is an electromagnetic isolation valve
in the fuel path that opens and shuts in response to a
signal from the CNG control module. For more
information on valve opening and closing controls, refer
to “Bi-Fuel CNG System Description”: Bi-Fuel CNG in
Section 1A (Page 1A-275).
When electric current is supplied to the coil based on a
signal from the CNG control module, the plunger lifts,
placing the shut-off valve in an open state.
1G-37 Fuel System: Bi-Fuel CNG

This area is also equipped with a one-way valve
mechanism, so that even when the engine is stopped for
refueling (with the valve shut, with no current passing
through it), increased gas pressure on the refueling
nozzle side will open the valve, admitting gas to the CNG
cylinder.
Fusible Plug
To prevent the CNG cylinder from burst, when the gas or
the atmospheric temperature exceeds a specified
temperature (approximately 90 – 110 °C (194 – 230 °F)),
the fuse metal melts and the fuel gas in the cylinder is
released into the atmosphere.
Pressure Relief Device
To prevent the CNG cylinder from burst, when the gas
pressure inside the CNG cylinder exceeds a specified
value (approximately 30 MPa (305.9 kgf/cm2, 4351 psi)),
the valve opens to relieve the gas into atmosphere.
CNG Fuel Filter Description
AENJCA0A1721007
The CNG fuel filter is located downstream from the CNG
pressure regulator to remove any impurities (mostly oil)
from the fuel gas.

CNG Pressure Regulator Description

AENJCA0A1721008
CNG pressure regulator is a device to decompress the high pressure gas in the CNG cylinder to a suitable extent for
injection by the injector attached beside the battery in the engine compartment.
Gas decompression is performed by a diaphragm in single stage to a suitable pressure for fuel injection.
The CNG pressure regulator contains a mechanically operating relief valve, which operates when pressure exceeds a
specified value, venting gas outside.
The pressure sensor that measures the pressure on the high-pressure side, and the shut-off valve that opens and
shuts in response to a signal from the CNG control module are attached to the fuel gas inlet. For more information on
valve opening and closing controls, refer to “Bi-Fuel CNG System Description”: Bi-Fuel CNG in Section 1A (Page 1A-
275).
While the CNG pressure regulator is in operation, some operating parts may freeze due to adiabatic expansion inside
the CNG pressure regulator. Engine coolant is circulating through the CNG pressure regulator to prevent freezing.

A-A B-B C-C

B C

3
A

2
IJCA0A172001-01

1. Pressure regulation area 2. Inlet CNG 3. Outlet CNG

 Fuel System: Bi-Fuel CNG 1G-38

Schematic and Routing Diagram

Fuel Delivery System Diagram
AENJCA0A1722001
Petrol System
Refer to “Fuel Delivery System Diagram”: Petrol (Page 1G-2).

CNG System

5 4
10 11 9 8 5 7

3
6

12
IJCA0A172002-01

1. CNG cylinder 5. Shut-off valve 9. CNG fuel filter

2. CNG receptacle 6. CNG pressure gauge 10. CNG fuel rail
3. CNG cylinder valve 7. CNG pressure sensor 11. CNG pressure and temperature sensor
4. Manual CNG cylinder valve 8. CNG pressure regulator 12. CNG fuel injector
1G-39 Fuel System: Bi-Fuel CNG

Fuel Injector Control System Circuit Diagram

AENJCA0A1722002
NOTE
For identification of each ignition coil assembly, refer to “Ignition System Component Location”: K10B
and Bi-Fuel CNG in Section 1H (Page 1H-3).

Circuit Diagram

12
3
1 GRN WHT E01-19
4
A1 6 B1 E1
2 BLU PNK C12-6 YEL C01-77
C12-8
A2 7 B2 E2
WHT C12-14 C12-16 BRN C01-78
A3 8 B3 E3
RED C12-5 C12-7 GRN 1
C01-79

RED

C1 9 D1
WHT C12-1
C2 10 D2
GRY C12-10
C3 11 D3
BLU C12-18

[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
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

[a]
10 9 8 7 6 5 4 3 2 1 9 8 7 6 5 4 3 2 1
65 64 63 62 61 20 19 18 17 16 15 14 13 12 11 57 56 55 18 17 16 15 14 13 12 11 10
70 69 68 67 66 30 29 28 27 26 25 24 23 22 21 60 59 58 27 26 25 24 23 22 21 20 19
75 74 73 72 71 40 39 38 37 36 35 34 33 32 31 63 62 61 36 35 34 33 32 31 30 29 28
80 79 78 77 76 50 49 48 47 46 45 44 43 42 41 66 65 64 45 44 43 42 41 40 39 38 37
60 59 58 57 56 55 54 53 52 51 54 53 52 51 50 49 48 47 46

IJCA0A172003-02

[A]: CNG control module connector (View: [a]) C3: CNG fuel injector No.3 power supply circuit 4. CNG control module
[B]: ECM connector (View: [a]) D1: CNG fuel injector No.1 drive circuit 5. “CNG” fuse
A1: Fuel injector No.1 power supply circuit D2: CNG fuel injector No.2 drive circuit 6. Fuel injector No.1
A2: Fuel injector No.2 power supply circuit D3. CNG fuel injector No.3 drive circuit 7. Fuel injector No.2
A3: Fuel injector No.3 power supply circuit E1. Fuel injector No.1 control signal from ECM circuit 8. Fuel injector No.3
B1: Fuel injector No.1 drive circuit E2. Fuel injector No.2 control signal from ECM circuit 9. CNG fuel injector No.1
B2: Fuel injector No.2 drive circuit E3. Fuel injector No.3 control signal from ECM circuit 10. CNG fuel injector No.2
B3: Fuel injector No.3 drive circuit 1. To ignition power supply 11. CNG fuel injector No.3
C1: CNG fuel injector No.1 power supply circuit 2. To main relay 12. ECM
C2: CNG fuel injector No.2 power supply circuit 3. “IG COIL” fuse
 Fuel System: Bi-Fuel CNG 1G-40

Fuel Pump Control System Circuit Diagram

AENJCA0A1722003
Circuit Diagram
Refer to “Fuel Pump Control System Circuit Diagram”: Petrol (Page 1G-5).

Diagnostic Information and Procedures

Fuel System Inspection
AENJCA0A1724001
Petrol System
Troubleshooting
Step Action Yes No
1 Fuel pump inspection Go to Step 2. Check fuel pump circuit.
1) Remove fuel filler cap and set ignition “ON”. (Page 1G-46)
2) Confirm that fuel pump operating sound can be heard
from fuel filler port for about 2 seconds.

Is check result OK?

2 Fuel pressure check Go to Step 3. Repair or replace
1) Check fuel pressure. (Page 1G-47) defective part.

Is check result OK?

3 Power balance test Fuel system is in good Go to Step 4.
1) Check power balance. (Page 1G-41) condition.

Is check result OK?

4 Fuel injector circuit check Go to Step 5. Repair or replace
1) Check fuel injector circuit. (Page 1G-41) defective part.

Is check result OK?

5 Fuel injector check Replace ECM and Replace fuel injector.
1) Check fuel injector. (Page 1G-66) recheck fuel system. (Page 1G-65)
(Page 1C-3)
Is check result OK?

CNG System
Troubleshooting
Step Action Yes No
1 DTC check Go to applicable DTC Go to Step 2.
1) Check DTC. (Page 1A-293) troubleshooting and
recheck DTC.
Is there DTC(s)?
2 Shut-off valve operation sound check Go to Step 3. Replace CNG cylinder
1) Select “Forced CNG MODE” and check the shut-off with valve or CNG
valve operation sound of CNG cylinder valve and shut- pressure regulator.
off valve of CNG pressure regulator.

Do all shut-off valves make operating sound?

3 CNG fuel pressure check Go to Step 4. Repair or replace
1) Check CNG fuel pressure. (Page 1G-46) defective part.

Is check result OK?

4 Power balance test 1 CNG fuel system is in Go to Step 5.
1) Check power balance. (Page 1G-41) good condition.

Is check result OK?

1G-41 Fuel System: Bi-Fuel CNG

Step Action Yes No

5 CNG fuel injector circuit check Go to Step 6. Repair or replace
1) Check CNG fuel injector circuit. (Page 1G-41) defective part.

Is check result OK?

6 Power balance test 2 END. Replace CNG control
1) Replace CNG fuel injector assembly. (Page 1G-65) module and recheck
DTC. If malfunction
2) Check power balance. (Page 1G-41)
continues, replace ECM
Is check result OK? and recheck DTC.

Power Balance Test 3) Clear DTC. (Page 1A-294)

AENJCA0A1724002
NOTICE
The engine could be damaged if it is
accelerated to a high rpm with a fuel injector
connector disconnected.
Always perform power balance test with
engine running at an idle speed.
1) Place gear shift lever in “Neutral” and apply parking
brake.
2) Connect scan tool to DLC (1) with ignition “OFF”.
Special tool
(A): SUZUKI scan tool (Suzuki SDT-II)
1
4) For checking petrol system, select “Petrol MODE”
with selector switch.
For checking CNG system, select “Forced CNG
MODE” with selector switch.
5) Warm up engine to normal operating temperature.
6) Using SUZUKI scan tool, select “Fuel Injector” in
“Active Test” and turn off each fuel injector.
7) With each fuel injector turned off, check that engine
speed decreases from specified idle speed.
8) If decreasing rates of engine speed are not in scale,
check the following items.
• Fuel injector circuit: (Page 1G-41)
• Fuel injector: (Page 1G-66)
• CNG fuel injector: (Page 1G-65)
• Spark plug: (Page 1H-7)
• Ignition coil circuit: (Page 1H-4)
• Ignition coil: (Page 1H-7)
• Engine compression: (Page 1D-1)

(A)
IJCA0A181004-01

Fuel Injector Circuit Check

AENJCA0A1724003
NOTE
• Before troubleshooting, read “Precautions for Fuel System Service”: Bi-Fuel CNG (Page 1G-34).
• When measuring circuit voltage and/or pulse signal at ECM connector, connect service wire to fuel
injector and fuel injector connectors.
• Function of fuel injector can be inspected by “Fuel Injector” in “Active Test” using SUZUKI scan
tool.
• For checking petrol system, select “Petrol MODE” with selector switch.
For checking CNG system, select “Forced CNG MODE” with selector switch.
 Fuel System: Bi-Fuel CNG 1G-42

Circuit Diagram

12
3
1 GRN WHT E01-19
4
A1 6 B1 E1
2 BLU PNK C12-6 YEL C01-77
C12-8
A2 7 B2 E2
WHT C12-14 C12-16 BRN C01-78
A3 8 B3 E3
RED C12-5 C12-7 GRN 1
C01-79

RED

C1 9 D1
WHT C12-1
C2 10 D2
GRY C12-10
C3 11 D3
BLU C12-18

[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
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

10 9 8 7 6 5 4 3 2 1
65 64 63 62 61 20 19 18 17 16 15 14 13 12 11
70 69 68 67 66 30 29 28 27 26 25 24 23 22 21
75 74 73 72 71 40 39 38 37 36 35 34 33 32 31
80 79 78 77 76 50 49 48 47 46 45 44 43 42 41
60 59 58 57 56 55 54 53 52 51
[a]
9 8 7 6 5 4 3 2 1
57 56 55 18 17 16 15 14 13 12 11 10
60 59 58 27 26 25 24 23 22 21 20 19
63 62 61 36 35 34 33 32 31 30 29 28
66 65 64 45 44 43 42 41 40 39 38 37
54 53 52 51 50 49 48 47 46

IJCA0A172003-02

[A]: CNG control module connector (View: [a]) C3: CNG fuel injector No.3 power supply circuit 4. CNG control module
[B]: ECM connector (View: [a]) D1: CNG fuel injector No.1 drive circuit 5. “CNG” fuse
A1: Fuel injector No.1 power supply circuit D2: CNG fuel injector No.2 drive circuit 6. Fuel injector No.1
A2: Fuel injector No.2 power supply circuit D3: CNG fuel injector No.3 drive circuit 7. Fuel injector No.2
A3: Fuel injector No.3 power supply circuit E1: Fuel injector No.1 control signal from ECM circuit 8. Fuel injector No.3
B1: Fuel injector No.1 drive circuit E2: Fuel injector No.2 control signal from ECM circuit 9. CNG fuel injector No.1
B2: Fuel injector No.2 drive circuit E3: Fuel injector No.3 control signal from ECM circuit 10. CNG fuel injector No.2
B3: Fuel injector No.3 drive circuit 1. To ignition power supply 11. CNG fuel injector No.3
C1: CNG fuel injector No.1 power supply circuit 2. To main relay 12. ECM
C2: CNG fuel injector No.2 power supply circuit 3. “IG COIL” fuse
1G-43 Fuel System: Bi-Fuel CNG

Troubleshooting
Petrol system
Step Action Yes No
1 Fuel injector check for operating sound Petrol fuel injector Go to Step 2.
1) Remove air cleaner assembly, if necessary. (Page 1D- circuit is in good
6) condition.
2) Using sound scope, check each fuel injector for
operating sound at engine running or cranking.

Do all fuel injectors make operating sound?

2 Fuel injector resistance check Go to Step 3. Replace fuel injector.
1) Set ignition “OFF”, disconnect connectors from fuel (Page 1G-65)
injectors.
2) Check for proper terminal connection to fuel injector
connectors.
3) If connections are OK, check all fuel injectors for
resistance. (Page 1G-65)

Is check result OK?

3 Fuel injector insulation resistance check Go to Step 4. Replace fuel injector.
1) Check that resistance between each fuel injector (Page 1G-65)
terminal and ground is infinity.

Is check result OK?

4 Fuel injector power supply circuit check Go to Step 5. Repair or replace fuel
1) Set ignition “ON”. injector power supply
circuit.
2) Check that voltage between each of “A1”, “A2” and “A3”
and ground is battery voltage.

Is check result OK?

5 Fuel injector drive circuit check Go to Step 6. Repair or replace fuel
1) Set ignition “OFF”, disconnect “C12” and “E23” injector drive circuit.
connectors from CNG control module.
2) Check for proper terminal connection to “C12” and “E23”
connectors.
3) If connections are OK, check the following points.
• Resistance of “B1”, “B2” and “B3” circuits: less than 1
Ω
• Resistance between each of “B1”, “B2” and “B3”
circuits and ground: infinity
• Resistance between “A1” circuit terminal and “B1”
circuit terminal at fuel injector connector: infinity
• Resistance between “A2” circuit terminal and “B2”
circuit terminal at fuel injector connector: infinity
• Resistance between “A3” circuit terminal and “B3”
circuit terminal at fuel injector connector: infinity
• Voltage of “B1”, “B2” and “B3” circuits: approx. 0 V
(When ignition is “ON”)

Is check result OK?

 Fuel System: Bi-Fuel CNG 1G-44

Step Action Yes No

6 Fuel injector control signal from ECM circuit check Go to Step 7. Repair or replace fuel
1) Set ignition “OFF”, disconnect “C01” and “E01” injector control signal
connectors from ECM. from ECM circuit.
2) Check for proper terminal connection to “C01” and “E01”
connectors.
3) If connections are OK, check the following points.
• Resistance of “E1”, “E2” and “E3” circuits: less than 1
Ω
• Resistance between each of “E1”, “E2” and “E3”
circuits and ground: infinity
• Resistance between “B1” circuit terminal and “E1”
circuit terminal at CNG control module connector:
infinity
• Resistance between “B2” circuit terminal and “E2”
circuit terminal at CNG control module connector:
infinity
• Resistance between “B3” circuit terminal and “E3”
circuit terminal at CNG control module connector:
infinity
• Voltage of “E1”, “E2” and “E3” circuits: approx. 0 V
(When ignition is “ON”)

Is check result OK?

7 Fuel injector check Replace CNG control Replace fuel injector.
1) Check fuel injector. (Page 1G-66) module and recheck (Page 1G-65)
DTC. If malfunction
Is check result OK? continues, replace ECM
and recheck fuel injector
operation.

CNG system
Step Action Yes No
1 DTC check in CNG control module Go to applicable DTC Go to Step 2.
1) Check DTC. (Page 1A-293) troubleshooting and
recheck.
Is there DTC(s)?
2 CNG fuel injector check for operating sound 1 CNG fuel injector circuit Go to Step 3.
1) Remove air cleaner assembly. (Page 1D-6) is in good condition.
2) Using sound scope, check each CNG fuel injector for
operating sound at engine running or cranking.

Do all CNG fuel injectors make operating sound?

3 CNG fuel injector resistance check Go to Step 4. Replace CNG fuel
1) Set ignition “OFF”, disconnect connectors from CNG fuel injector. (Page 1G-65)
injectors.
2) Check for proper terminal connection to CNG fuel
injector connectors.
3) If connections are OK, check all CNG fuel injectors for
resistance. (Page 1G-65)

Is check result OK?

4 CNG fuel injector insulation resistance check Go to Step 5. Replace CNG fuel
1) Check that resistance between each fuel injector injector. (Page 1G-65)
terminal and ground is infinity.

Is check result OK?

1G-45 Fuel System: Bi-Fuel CNG

Step Action Yes No

5 CNG fuel injector power supply circuit check Go to Step 6. Repair or replace CNG
1) Set ignition “ON”. fuel injector power
supply circuit.
2) Check that voltage between each of “C1”, “C2” and “C3”
and ground is battery voltage.

Is check result OK?

6 CNG fuel injector drive circuit check Go to Step 7. Repair or replace CNG
1) Set ignition “OFF”, disconnect “C12” and “E23” fuel injector drive circuit.
connectors from CNG control module.
2) Check for proper terminal connection to “C12” and “E23”
connectors.
3) If connections are OK, check the following points.
• Resistance of “D1”, “D2” and “D3” circuits: less than 1
Ω
• Resistance between each of “D1”, “D2” and “D3”
circuits and ground: infinity
• Resistance between “C1” circuit terminal and “D1”
circuit terminal at CNG fuel injector connector: infinity
• Resistance between “C2” circuit terminal and “D2”
circuit terminal at CNG fuel injector connector: infinity
• Resistance between “C3” circuit terminal and “D3”
circuit terminal at CNG fuel injector connector: infinity
• Voltage of “D1”, “D2” and “D3” circuits: approx. 0 V
(When ignition is “ON”)

Is check result OK?

7 Fuel injector control signal from ECM circuit check Go to Step 8. Repair fuel injector
1) Set ignition “OFF”, disconnect “C01” and “E01” control signal from ECM
connectors from ECM. circuit.
2) Check for proper terminal connection to “C01” and “E01”
connectors.
3) If connections are OK, check the following points.
• Resistance of “E1”, “E2” and “E3” circuits: less than 1
Ω
• Resistance between each of “E1”, “E2” and “E3”
circuits and ground: infinity
• Resistance between “D1” circuit terminal and “E1”
circuit terminal at CNG control module connector:
infinity
• Resistance between “D2” circuit terminal and “E2”
circuit terminal at CNG control module connector:
infinity
• Resistance between “D3” circuit terminal and “E3”
circuit terminal at CNG control module connector:
infinity
• Voltage of “E1”, “E2” and “E3” circuits: approx. 0 V
(When ignition is “ON”)

Is check result OK?

8 CNG fuel injector check Replace CNG control Replace CNG fuel
1) Check CNG fuel injector. (Page 1G-66) module and recheck injector. (Page 1G-65)
DTC. If malfunction
Is check result OK? continues, replace ECM
and recheck CNG fuel
injector operation.
 Fuel System: Bi-Fuel CNG 1G-46

Fuel Pump and Its Circuit Check

AENJCA0A1724004
Circuit Diagram
Refer to “Fuel Pump Control System Circuit Diagram”: Petrol (Page 1G-5).

Troubleshooting
Refer to “Troubleshooting” under “Fuel Pump and Its Circuit Check”: Petrol (Page 1G-10).

Fuel Pressure Check

AENJCA0A1724005
Petrol System
Refer to “Fuel Pressure Check”: Petrol (Page 1G-12).

CNG System

NOTICE
If petrol mixes in the CNG fuel line, it could damage the CNG fuel injector.
Do not use special tools that were used for a petrol fuel line.

Troubleshooting

NOTE
Before performing the following troubleshooting, check that the manual CNG cylinder valve of the
cylinder valve is open.

Step Action Yes No

1 DTC check Go to applicable DTC Go to Step 2.
1) Check DTC. (Page 1A-293) troubleshooting and
recheck.
Is there DTC(s)?
2 CNG fuel feed line check 1 Go to Step 3. Replace defective part.
1) Check CNG fuel pipe, CNG fuel hose and joint for
damage or deformation.

Are they in good condition?

3 Shut-off valve operation sound check Go to Step 4. Replace CNG cylinder
1) Select “Forced CNG MODE” and check the shut-off with valve or CNG
valve operation sound of CNG cylinder valve and shut- pressure regulator.
off valve of CNG pressure regulator.

Do all shut-off valves make operating sound?

4 CNG fuel feed line check 2 Go to Step 5. Replace defective part.
1) Check CNG fuel pipe, CNG fuel hose and joint for CNG
fuel leakage. (Page 1G-56)

Are they in good condition?

5 CNG fuel pressure check Go to Step 6. Replace CNG pressure
1) Check CNG fuel pressure. (Page 1G-47) regulator.

Is check result OK?

6 CNG fuel filter check CNG system is in good Replace CNG fuel filter.
1) Check CNG fuel filter for evidence of dirt and condition. (Page 1G-63)
contamination. (Page 1G-63)

Is check result OK?

1G-47 Fuel System: Bi-Fuel CNG

Fuel Pressure Basic Check CNG fuel pressure specification

AENJCA0A1724006 At specified idle speed: 200 kPa (2.0 kg/cm2, 29.0
Petrol System
psi, 2 bar)
Refer to “Fuel Pressure Basic Check”: Petrol (Page 1G-
14).
Fuel Cut Operation Check
AENJCA0A1724007
CNG System Petrol System
NOTICE 1) Place gear shift lever in “Neutral” and apply parking
brake.
If petrol mixes in the CNG fuel line, it could
damage the CNG fuel injector. 2) Warm up engine to normal operating temperature.
Do not use special tools that were used for a 3) Remove air cleaner assembly, if necessary. (Page
petrol fuel line. 1D-6)
4) Select “Petrol MODE” with selector switch.
1) Connect SUZUKI scan tool to DLC (1) with ignition
5) While listening to sound of injector (2) by using
“OFF”.
sound scope (1) or the like, increase engine speed
Special tool to higher than 3,000 rpm.
(A): SUZUKI scan tool (Suzuki SDT-II)

2
1

1
IJCA0A172005-01

6) Check that injector operation sound stops when

throttle valve is closed instantly and it is heard again
when engine speed decreases to approx. 2,000 rpm
or less.
(A) 7) If injector sound is not heard, perform “Fuel Injector
IJCA0A181004-01 Circuit Check”: Bi-Fuel CNG (Page 1G-41).
2) Check that CNG cylinder pressure is more than 1
MPa (10.2 kgf/cm2, 145 psi, 10 bar) using SUZUKI
scan tool. Otherwise, refill CNG cylinder with CNG.
3) Place gear shift lever in “Neutral” and apply parking
brake.
4) Clear DTC. (Page 1A-294)
5) Select “Forced CNG MODE” with selector switch.
6) Warm up engine to normal operating temperature.
7) Select “CNG/LPG Pressure” under “Data List” mode
on SUZUKI scan tool. Check CNG low pressure at
idling.
• If measured pressure is out of specification, there
is possibility of the following cause.
– CNG low pressure filter clogged. Check CNG
fuel filter for evidence of dirt and contamination.
(Page 1G-63)
– CNG fuel leakage. (Page 1G-56)
– CNG vacuum hose faulty.
– CNG pressure regulator faulty.
 Fuel System: Bi-Fuel CNG 1G-48

CNG System
1) Place gear shift lever in “Neutral” and apply parking
brake.
2) Warm up engine to normal operating temperature.
3) Remove air cleaner assembly. (Page 1D-6)
4) Select “Forced CNG MODE” with selector switch.
5) While listening to sound of injector (2) by using
sound scope (1) or the like, increase engine speed
to higher than 3,000 rpm.
6) Check that injector operation sound stops when
throttle valve is closed instantly and it is heard again
when engine speed decreases to approx. 2,000 rpm
or less.

IJCA0A172006-01

7) If injector sound is not heard, perform “Fuel Injector

Circuit Check”: Bi-Fuel CNG (Page 1G-41).
1G-49 Fuel System: Bi-Fuel CNG

Repair Instructions
Fuel System Components
AENJCA0A1726001
Petrol System

(a)

4
3

(d)
21

[c] 20
22
18
19

17
23

23 (c)

16 8
10 [b]
[c]

(b)
11

[a]

9
12
13 7

14
(b)
[b]

[a]
6

15

IJCA0A172007-01
 Fuel System: Bi-Fuel CNG 1G-50

1. Fuel injector 11. Heat insulator 21. Fuel filler cap

: For installation, refer to “Fuel Injector
Removal and Installation”: Bi-Fuel CNG
(Page 1G-65).
2. Injector O-ring 12. Fuel tank belt 22. Fuel EVAP hose
: Apply a bit of fuel to install.
3. Fuel injector clip 13. Fuel pump lock nut 23. To EVAP canister
: For installation, refer to “Fuel Injector : For tightening procedure, refer to “Fuel Pump
Removal and Installation”: Bi-Fuel CNG Assembly Removal and Installation”: Bi-Fuel CNG
(Page 1G-65). (Page 1G-73).
4. Fuel delivery pipe 14. O-ring : 25 Nm (2.5 kgf-m, 18.5 lbf-ft)
5. Fuel feed hose 15. Fuel pump assembly : 14 Nm (1.4 kgf-m, 10.5 lbf-ft)
6. Fuel feed pipe 16. Fuel tank filler hose : 5.5 Nm (0.56 kgf-m, 4.0 lbf-ft)
7. Fuel pipe (filter to pipe) 17. Breather hose : 3.0 Nm (0.31 kgf-m, 2.5 lbf-ft)
8. Fuel pipe (pump to filter) 18. Fuel filler neck : Do not reuse.
9. Fuel filler 19. Air suction filter
10. Fuel tank 20. Fuel filler neck protector
1G-51 Fuel System: Bi-Fuel CNG

CNG System
Engine side

6
12 (b)
9

6 6 (a)

13

3 10 (d)

(f)

6
6 11 (g)

(e) 5
17
(e)
1
3

(e) 7
(c)

2 14
16

15

IJCA0A172096-01

1. CNG fuel injector assembly
: Do not disassemble.
2. Injector O-ring
: Apply a bit of fuel to install.
3. CNG fuel hose
4. CNG pressure-and-temperature sensor
: Apply a bit of fuel to O-ring.
5. CNG adapter pipe
6. O-ring
: Apply a bit of fuel to install.
7. CNG fuel filter assembly
8. CNG fuel filter upper case
9. CNG fuel filter element
10. CNG fuel filter lower case : 22 Nm (2.2 kgf-m, 16.5 lbf-ft)
11. CNG pressure regulator : 17 Nm (1.7 kgf-m, 12.5 lbf-ft)
12. CNG pressure gauge : 15 Nm (1.5 kgf-m, 11.0 lbf-ft)
: For installation, refer to “CNG Pressure Gauge
Removal and Installation”: Bi-Fuel CNG (Page
1G-70).
13. CNG pressure regulator bracket : 11 Nm (1.1 kgf-m, 8.5 lbf-ft)
14. CNG fuel pipe No.1 : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
15. CNG vacuum hose : 9.0 Nm (0.92 kgf-m, 7.0 lbf-ft)
16. To intake manifold : Do not reuse.
17. CNG hose chamber
: 25 Nm (2.5 kgf-m, 18.5 lbf-ft)
 Fuel System: Bi-Fuel CNG 1G-52

Rear side

15 (c)

15 (c) 16 (c)

16 (c)

4
2 14 (a)
(g)
2
14 (a) 5
14 (a) 14 (a)
3
1 (f)

6
(g)

(d) (e)

13 (g)

(g)
9
8

(b)
(b) 10
(b)
(e)

(b)
(e)
(e)

12
(b)
11

IJCA0A172009-02
1G-53 Fuel System: Bi-Fuel CNG

1. CNG cylinder assembly 9. CNG fuel pipe No.2 : 60 Nm (6.1 kgf-m, 44.5 lbf-ft)
: For installation, refer to “CNG Cylinder with
Valve Removal and Installation”: Bi-Fuel CNG
(Page 1G-74).
2. CNG cylinder band 10. CNG fuel pipe joint : 40 Nm (4.1 kgf-m, 29.5 lbf-ft)

3. CNG inlet pipe ventilation hose 11. CNG fuel pipe No.1 : 35 Nm (3.6 kgf-m, 26.0 lbf-ft)
4. Protector 12. CNG cylinder holder : 19 Nm (1.9 kgf-m, 14.0 lbf-ft)
5. CNG receptacle 13. Spare tire rear carrier : 17 Nm (1.7 kgf-m, 12.5 lbf-ft)
6. Washer 14. CNG cylinder band mounting bolt : 3.0 Nm (0.31 kgf-m, 2.5 lbf-ft)
7. CNG ventilation hose 15. CNG cylinder band adjusting bolt : 1.7 Nm (0.17 kgf-m, 1.5 lbf-ft)
: For tightening order, refer to “CNG Cylinder with
Valve Removal and Installation”: Bi-Fuel CNG
(Page 1G-74).
8. CNG ventilation duct 16. CNG cylinder band locking nut : Do not reuse.
: For installation, refer to “Fuel Pipe Removal : For tightening order, refer to “CNG Cylinder with
and Installation”: Bi-Fuel CNG (Page 1G-58). Valve Removal and Installation”: Bi-Fuel CNG
(Page 1G-74).
 Fuel System: Bi-Fuel CNG 1G-54

Fuel Hose Disconnection and Reconnection

AENJCA0A1726002
Before performing the following procedure, observe “Precautions for Fuel System Service”: Bi-Fuel CNG (Page 1G-
34).

Non-Quick Joint Connections

Clamp around fuel tank

NOTE
Install hose in the raised part of pipe securely.

“c”
2 3 4

“b” “e”

1 3 5
“f”
3
2
“e” [A]
2
“a”
1
5
“a”

“a” 5 “f”
3 1 “a” 3

“e”

2 1 2 7

[A]

“g”

“a”
3
2
“e”

1 “d”
6

IJCA0A172010-01

“a”: 3 – 7 mm (0.12 – 0.27 in.) “f”: 0° 4. Vehicle leftward

“b”: 0 – 8 mm (0 – 0.31 in.) “g”: 40° 5. Vehicle rightward
“c”: 5 – 12 mm (0.20 – 0.47 in.) 1. Pipe 6. Vehicle backward
“d”: 37 – 40 mm (1.46 – 1.57 in.) 2. Hose 7. Vehicle forward
“e”: 22.5° 3. Clamp
1G-55 Fuel System: Bi-Fuel CNG

Fuel Tank Filler Hose 4) Connect SUZUKI scan tool to DLC (1) with ignition
Refer to “Fuel Tank Filler Hose” under “Fuel Hose “OFF”.
Disconnection and Reconnection”: Petrol (Page 1G-16).
Special tool
(A): SUZUKI scan tool (Suzuki SDT-II)
Quick Joint Connections
Refer to “Quick Joint Connections” under “Fuel Hose
Disconnection and Reconnection”: Petrol (Page 1G-16).

Fuel Pressure Relief Procedure

AENJCA0A1726003
NOTE
1
For checking petrol system, select “Petrol
MODE” with selector switch.
For checking CNG system, select “Forced
CNG MODE” with selector switch.

Petrol System
Refer to “Fuel Pressure Relief Procedure”: Petrol (Page
1G-19).

CNG System

NOTICE
(A)
Performing this procedure when the engine
IJCA0A181004-01
is still hot can damage the catalyst.
Wait until the engine has cooled down before 5) Set ignition “ON” and clear DTC. (Page 1A-294)
performing this procedure. 6) Select “Service CNG/ LPG Mode” function in “Active
Test”.
1) Check that engine is cold. 7) Select “Forced CNG MODE” with fuel select switch.
2) Place gear shift lever in “Neutral”, apply parking 8) Start engine and run it until engine stops for lack of
brake and block drive wheels. CNG.
3) Turn manual CNG cylinder valve (1) of CNG cylinder 9) Set ignition “OFF” and repeat Step 5) – 7) and
valve to close position. cranking for about 3 seconds.
10) Repeat Step 8) 2 – 3 times to dissipate CNG fuel
pressure in lines.
1 CNG fuel feed line connections are now safe for
servicing.

IJCA0A172011-01
 Fuel System: Bi-Fuel CNG 1G-56

Fuel Leakage Check Procedure

AENJCA0A1726004
Petrol System
Refer to “Fuel Leakage Check Procedure”: Petrol (Page 1G-20).

CNG System

NOTE
• Clean inspection points with mild detergent if they are particularly dirty.
• Any parts that have been deformed should be replaced with new ones, even if CNG fuel leakage
check does not detect any leakage.

After performing any service on CNG system, check that there is no CNG fuel leakage as follows.
1) Clean inspection points.
2) Visually inspect CNG fuel pipes, joints, and operating parts for damage, corrosion, and wear.
3) Set ignition “ON” and select “Forced CNG MODE” with selector switch.
4) Check that sufficient amount of CNG is available in the CNG cylinder. Otherwise, refill CNG cylinder with CNG.

NOTE
It is suggested to check that the CNG fuel pressure in the tank is above 12 MPa (122 kgf/cm2, 1740 psi,
120 bar) for better diagnosis of the leakage.
CNG cylinder pressure can be checked in “CNG Cylinder Pressure” under “Data List” mode on
SUZUKI scan tool.
1G-57 Fuel System: Bi-Fuel CNG

5) Check the inspection points on CNG feed line, which are pointed by arrows in figure, for CNG fuel leakage using
gas leak detector as follows.
• For inspection points of low pressure CNG fuel feed line
a. Start engine and run it at idle speed.
b. Check the inspection points for CNG fuel leakage.
• For inspection points of high pressure CNG fuel feed line
a. Start engine and run it at idle speed for 1 minute, and then stop engine.
b. Check the inspection points for CNG fuel leakage.

NOTE
• Use gas leak detector capable of detecting methane gas concentrations of less than 0.2%.
• Use duct to suck away any vehicle exhaust gas, as gas leak detectors will react to it.
• Let gas leak detectors absorb gas for at least 10 seconds in each position.
Because of way they are constructed, there is small time lag before gas leak detectors react to gas.

:1 :2
IJCA0A172097-01

1. Inspection point of low pressure CNG fuel feed line 2. Inspection point of high pressure CNG fuel feed line
 Fuel System: Bi-Fuel CNG 1G-58

IJCA0A172098-01

1. Gas leak detector

6) If CNG fuel leakage has been detected, relieve CNG fuel pressure and then replace the faulty parts or retighten
CNG fuel pipe nuts. Recheck CNG fuel leakage after replacing the faulty parts or retightening CNG fuel pipe nuts.

Fuel Line On-Vehicle Inspection NOTICE

AENJCA0A1726005
Fuel feed pipe and purge pipe may be bent or
Petrol System damaged if you are not careful when
Refer to “Fuel Line On-Vehicle Inspection”: Petrol (Page unclamping them.
1G-20). Properly support fuel feed pipe and purge
pipe when removing clamps.
CNG System
Check CNG fuel feed lines for CNG fuel leakage.
[A]
(Page 1G-56)
Visually check CNG fuel feed lines for CNG fuel hose
crack, deterioration and damage.
Check that all clamps are secure.
Replace parts if necessary.

Fuel Pipe Removal and Installation 2

AENJCA0A1726006
Before performing the following procedure, observe
“Precautions for Fuel System Service”: Bi-Fuel CNG
(Page 1G-34). 1
3
Petrol System IJCA0A172015-01

Removal
1) Relieve fuel pressure from fuel feed line. (Page [B]

1G-55)
2) Disconnect negative (–) cable at battery.
3) Disconnect fuel feed hose and fuel pipe (filter to
pipe) from fuel feed pipe (1) and disconnect purge 3
hose and purge pipe (canister to pipe) from purge 1
pipe (2). (Page 1G-54)
4) Mark the location of clamps (3) on fuel feed pipe and
purge pipe, so that the clamps can be reinstalled to 2
the original position.
5) Remove fuel feed pipe and purge pipe.
IJCA0A172016-01

[A]: Engine side [B]: Fuel tank side

1G-59 Fuel System: Bi-Fuel CNG

Installation CNG System

1) Install fuel feed pipe and purge pipe to vehicle.
2) Install clamps to marked positions on pipes. If clamp
is deformed or its claw is bent or broken, replace it
with new one.
3) Connect fuel feed hose and fuel pipe (filter to pipe) to
fuel feed pipe (1) and disconnect purge hose and
purge pipe (canister to pipe) to purge pipe (2).
(Page 1G-54)
CNG fuel pipe No.1
Removal
1) Relieve petrol and CNG fuel pressure from each fuel
feed line. (Page 1G-55)
2) Disconnect negative (–) cable at battery.
3) Disconnect air suction hose (1), breather hose (2)
and fuel tank filler hose (3) from fuel filler neck (4).
4) Remove fuel filler neck bolt (5).

[A]

5 2

1
3

IJCA0A172017-01 IJCA0A172019-01

5) Remove parking brake cable bolt (1).

[B] 6) Disconnect ground cable (2) from fuel tank.

IJCA0A172018-01 1

[A]: Engine side [B]: Fuel tank side

IJCA0A172020-01

7) Disconnect CNG fuel pipe No.1 (1) from CNG

4) Connect negative (–) cable at battery.
pressure regulator (2) and CNG fuel pipe joint (3) at
5) Set ignition “ON” and check for fuel leakage. both front and rear ends.
(Page 1G-56)
 Fuel System: Bi-Fuel CNG 1G-60

8) Mark the location of clamps (4) on CNG fuel pipe
No.1, so that the clamps can be reinstalled to the
original positions.
Engine side
3) Connect CNG fuel pipe No.1 (1) to CNG pressure
regulator (2) and CNG fuel pipe joint (3) and tighten
CNG fuel pipe nuts (4) to specified torque.
NOTE
For exact tightening of the nut, use of a
spanner type torque wrench is necessary.

Tightening torque
CNG fuel pipe nut (a): 17 N·m (1.7 kgf-m, 12.5
lbf-ft)

2 Engine side

1
IJCA0A172099-01

Rear side

4, (a)
2

4 1
3
IJCA0A172100-01

Rear side

IJCA0A172022-01 1
9) Remove CNG fuel pipe No.1.
3
NOTICE
CNG fuel pipe No.1 may be bent or damaged
4, (a)
if you are not careful when unclamping.
Properly support CNG fuel pipe No.1 when
disconnecting it from clamps.

Installation IJCA0A172024-01

1) Position CNG fuel pipe No.1 on vehicle.

2) Connect CNG fuel pipe No.1 to clamps at marked
position on the pipe. If clamps are deformed or
damaged, replace them with new ones.
1G-61 Fuel System: Bi-Fuel CNG

4) Put ground cable (1) in the original position and
tighten fuel ground cable bolt (2) to specified torque.
Tightening torque
Fuel ground cable bolt (a): 3.0 N·m (0.31 kgf-m,
2.5 lbf-ft)
2, (a)
CNG fuel pipe No.2
Removal
1) Relieve CNG fuel pressure from CNG fuel feed line.
(Page 1G-55)
2) Disconnect negative (–) cable at battery.
3) Disconnect CNG ventilation hose (1) from CNG
cylinder (2) and CNG ventilation duct (3).

1
2

IJCA0A172025-01

5) Tighten parking brake cable bolt to specified torque.

(Page 4D-1)
6) Tighten fuel filler neck bolt (1) to specified torque.
Tightening torque
Fuel filler neck bolt (a): 5.5 N·m (0.56 kgf-m, 4.0
lbf-ft)

1
3
IJCA0A172028-01

4) Disconnect CNG fuel pipe No.2 (1) from CNG

cylinder (2) in luggage compartment and CNG fuel
1, (a) pipe joint (3) at outside of rear floor panel (wheel
housing side).
5) Detach CNG fuel pipe No.2 from clamp (4) in CNG
ventilation duct.
Luggage compartment side

IJCA0A172026-01

7) Connect air breather hose and fuel tank filler hose to

fuel filler neck. (Page 1G-54)
2
8) Connect air suction hose (1) to fuel filler neck (2).

2
1 IJCA0A172029-01

IJCA0A172027-01

9) Connect negative (–) cable at battery.

10) Check for petrol and CNG fuel leakage. (Page 1G-
56)
 Fuel System: Bi-Fuel CNG 1G-62

Wheel housing side Installation

1) While aligning cutout (1) on rear floor panel with
protrusion (2) on CNG ventilation duct, fit duct from
3
body inside.

1
[A]

IJCA0A172030-01

6) Remove CNG fuel pipe No.2 from vehicle.

2 1
7) Remove CNG ventilation hose (1) from CNG fuel
pipe No.2 (2), if necessary.
IJCA0A172033-01

[A]: Vehicle inside

2) Insert CNG fuel pipe No.2 (2) into CNG ventilation

hose (1), if removed.

IJCA0A172031-01
2
8) Remove CNG ventilation duct (1) from rear floor
panel, if necessary.
1

IJCA0A172031-01

IJCA0A172032-01
1G-63 Fuel System: Bi-Fuel CNG

3) Install CNG fuel pipe No.2 as follows. 4) Tighten CNG ventilation hose clamps (1) to specified
a) Fix CNG fuel pipe No.2 (1) to clamp (2) in CNG torque.
ventilation duct. Tightening torque
b) Tighten CNG fuel pipe nuts (3) to specified CNG ventilation hose clamp (a): 1.7 N·m (0.17
torque. kgf-m, 1.5 lbf-ft)
NOTE
For exact tightening of the nut, use of a
spanner type torque wrench is necessary.

Tightening torque 1, (a)

CNG fuel pipe nut (a): 17 N·m (1.7 kgf-m,
12.5 lbf-ft)

Luggage compartment side

1, (a)
3, (a)

IJCA0A172092-01
IJCA0A172034-01 5) Connect negative (–) cable at battery.
6) Check for CNG fuel leakage. (Page 1G-56)
Wheel housing side
Fuel Filter Removal and Installation
AENJCA0A1726007
Before performing the following procedure, observe
3, (a) “Precautions for Fuel System Service”: Bi-Fuel CNG
(Page 1G-34).

1 Petrol System
Refer to “Fuel Filter Removal and Installation”: Petrol
(Page 1G-29).

IJCA0A172035-02
 Fuel System: Bi-Fuel CNG 1G-64

CNG System Installation

Removal
1) Relieve CNG fuel pressure from CNG fuel feed line.
(Page 1G-55)
2) Disconnect negative (–) cable at battery.
3) Disconnect CNG fuel hose (1) from CNG fuel filter
assembly (2).
4) Remove CNG fuel filter assembly and O-ring from
CNG pressure regulator.
1 kgf-m, 11.0 lbf-ft)
1) Check CNG fuel filter for evidence of dirt and
contamination.
If the filter is faulty, replace CNG fuel filter.
2) Install CNG fuel filter as follows.
a) Wipe off the accumulated oil in CNG fuel filter
lower case completely.
b) Apply a bit of fuel to new O-rings (1).
c) Install O-rings to CNG fuel filter upper case (2)
and lower case (3).
d) Install CNG fuel filter (4) and CNG fuel filter
lower case.
e) Tighten CNG fuel filter lower case to specified
torque.
Tightening torque
CNG fuel filter lower case (a): 15 N·m (1.5

IJCA0A172101-01
3, (a)
5) Remove CNG adapter pipe (1) and O-ring (2) from
CNG filter assembly, if necessary.
1

2
4

1
2

IJCA0A172095-01

3) Install CNG adapter pipe (1) as follows, if removed.

IJCA0A172037-01
a) Apply a bit of fuel to new O-ring (2).
6) Remove CNG fuel filter lower case (1) from CNG fuel b) Install O-ring to CNG adapter pipe.
filter upper case (2), and then remove CNG fuel filter c) Install CNG adapter pipe to CNG fuel filter
element (3) and O-rings (4). assembly.
d) Tighten CNG adapter pipe bolt (3) to specified
torque.
Tightening torque
CNG adapter pipe bolt (a): 11 N·m (1.1 kgf-
1
m, 8.5 lbf-ft)
4
2

4
3, (a)
1

IJCA0A172038-01

IJCA0A172040-01
1G-65 Fuel System: Bi-Fuel CNG

4) Install CNG fuel filter assembly (1) as follows.
a) Apply a bit of fuel to new O-ring (2).
b) Install O-ring to CNG fuel filter assembly.
c) Install CNG fuel filter assembly to CNG pressure
regulator.
d) CNG fuel filter assembly bolts (3) to specified
torque.
Tightening torque
CNG fuel filter assembly bolt (a): 11 N·m (1.1
kgf-m, 8.5 lbf-ft)
2
Fuel Injector On-Vehicle Inspection
AENJCA0A1726008
Petrol System
Refer to “Fuel Injector On-Vehicle Inspection”: Petrol
(Page 1G-21).
CNG System
1) Place gear shift lever in “Neutral” and apply parking
brake.
2) Remove air cleaner assembly. (Page 1D-6)
3) Select “Forced CNG MODE” with selector switch.
4) Using sound scope (1) or the like, check operating
sound of CNG fuel injector (2) when engine is
running or cranking. Cycle of operating sound should
vary according to engine speed.
If no sound or unusual sound is heard, check CNG
fuel injector circuit or CNG fuel injector.

3, (a)

3, (a)

1
1
IJCA0A172039-01 IJCA0A172005-01

5) Connect CNG fuel hose (1) to CNG fuel filter 5) Install air cleaner assembly. (Page 1D-6)
assembly.
Fuel Injector Removal and Installation
AENJCA0A1726009
Before performing the following procedure, observe
“Precautions for Fuel System Service”: Bi-Fuel CNG
(Page 1G-34).

Petrol System
Refer to “Fuel Injector Removal and Installation”: Petrol
(Page 1G-22).
1

CNG System
Removal
1) Relieve CNG fuel pressure from CNG fuel feed line.
IJCA0A172102-01
(Page 1G-55)
6) Connect negative (–) cable at battery.
2) Disconnect negative (–) cable at battery.
7) Check for CNG fuel leakage. (Page 1G-56)
3) Remove air cleaner assembly and air cleaner outlet
hose. (Page 1D-6)
4) Disconnect CNG fuel injector connectors and CNG
pressure-and-temperature sensor connector.
 Fuel System: Bi-Fuel CNG 1G-66

5) Disconnect CNG fuel hose (1) from CNG fuel injector c) Install CNG fuel injector assembly (1).
assembly (2). d) Tighten CNG fuel injector assembly bolts (2) to
6) Remove CNG fuel injector assembly and injector O- specified torque.
rings from intake manifold.
Tightening torque
CNG fuel injector assembly bolt (a): 11 N·m (
1.1 kgf-m, 8.5 lbf-ft)
1

2, (a)

IJCA0A172042-01

7) Remove CNG pressure-and-temperature sensor, if 2, (a)

necessary. (Page 1C-16) IJCA0A172044-01

3) Connect CNG fuel hose (1) to CNG fuel injector

Installation
assembly (2).
1) Install CNG pressure-and-temperature sensor, if
removed. (Page 1C-16)
2) Install CNG fuel injector assembly as follows.
1
a) Apply a bit of fuel to new injector O-rings.
b) Install injector O-rings (1) to CNG fuel injector
2
assembly.

IJCA0A172042-01

4) Connect CNG fuel injector connectors and CNG

1
pressure-and-temperature sensor connector.
5) Install air cleaner outlet hose and air cleaner
1
assembly. (Page 1D-6)
6) Connect negative (–) cable at battery.
1
IJCA0A172043-01
7) Check for CNG fuel leakage. (Page 1G-56)

Fuel Injector Inspection

AENJCA0A1726010

Petrol System
Refer to “Fuel Injector Inspection”: Petrol (Page 1G-24).
1G-67 Fuel System: Bi-Fuel CNG
CNG System
Connect ohmmeter between terminals of CNG fuel
injector and check resistance.
If resistance is out of reference value greatly, replace
CNG fuel injector assembly.
Reference resistance of CNG fuel injector
1.44 –1.56 Ω at 20 °C (68 °F)
IJCA0A172045-01
CNG Pressure Regulator On-Vehicle Inspection
AENJCA0A1726011
1) Check CNG pressure regulator for coolant leakage,
deformation and damage. If any faulty condition is
found, replace CNG pressure regulator.
2) Check CNG pressure regulator for CNG fuel
leakage. If faulty condition is found, replace CNG
pressure regulator. (Page 1G-56)
3) Check the shut-off valve operation sound as follows.
a) Set ignition “ON”.
b) Select “Forced CNG MODE” with selector switch
and check the shut-off valve operation sound. If
operating sound of shut-off valve is not heard,
replace CNG pressure regulator.
4) Check CNG cylinder pressure sensor as follows.
a) Connect SUZUKI scan tool to DLC (1) with
ignition “OFF”.
Special tool
(A): SUZUKI scan tool (Suzuki SDT-II)
1
(A)
IJCA0A181004-01
b) Set ignition “ON” and select “Forced CNG
MODE” with selector switch.
c) Select “CNG Cylinder Pressure” in “Data List”
mode on SUZUKI scan tool. Check CNG fuel
pressure displayed on SUZUKI 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 pressure regulator.
CNG Pressure Regulator Removal and
Installation
AENJCA0A1726012
Before performing the following procedure, observe
“Precautions for Fuel System Service”: Bi-Fuel CNG
(Page 1G-34).
Removal
1) Relieve CNG fuel pressure from CNG fuel feed line.
(Page 1G-55)
2) Drain coolant. (Page 1F-9)
3) Disconnect negative (–) cable at battery.
4) Disconnect CNG pressure regulator connectors (1).
IJCA0A172103-01
 Fuel System: Bi-Fuel CNG 1G-68

5) Disconnect CNG fuel hose (1) from CNG adapter 10) Remove CNG pressure regulator bracket (1) from
pipe. CNG pressure regulator, if necessary.
6) Disconnect CNG water inlet hose (2) and CNG water
outlet hose (3) from CNG pressure regulator.
7) Disconnect CNG vacuum hose (4) from CNG
pressure regulator.

IJCA0A172050-01

4 11) Remove CNG fuel filter assembly, if necessary.

3
(Page 1G-63)
12) Remove CNG pressure gauge, if necessary.
IJCA0A172104-01 (Page 1G-70)
8) Disconnect CNG fuel pipe No.1 (1) from CNG
pressure regulator. Installation
1) Install CNG pressure gauge, if removed. (Page
1G-81)
2) Install CNG fuel filter assembly, if removed. (Page
1G-63)
3) Install CNG pressure regulator bracket (1) to CNG
pressure regulator.
4) Tighten CNG pressure regulator bolts (2) to specified
torque, if removed.
Tightening torque
CNG pressure regulator bolt (a): 25 N·m (2.5 kgf-
m, 18.5 lbf-ft)
1
IJCA0A172048-01

9) Remove CNG pressure regulator assembly (1) with

CNG pressure regulator bracket (2) from vehicle.

2
2, (a)
IJCA0A172051-01

IJCA0A172049-01
1G-69 Fuel System: Bi-Fuel CNG

5) Install CNG pressure regulator assembly (1) with 11) Connect CNG fuel hose (1).
CNG pressure regulator bracket (2).
6) Tighten CNG pressure regulator bracket nuts (3) to
specified torque.
1
Tightening torque
CNG pressure regulator bracket nut (a): 9.0 N·m
(0.92 kgf-m, 7.0 lbf-ft) 2

3, (a)
3, (a)
4
3
1

IJCA0A172104-01
2
12) Connect CNG pressure regulator connectors (1).
3, (a)
3, (a)

IJCA0A172052-01

7) Connect CNG fuel pipe No.1 (1) to CNG pressure

1
regulator.
8) Tighten CNG fuel pipe nut (2) to specified torque.

NOTE
For exact tightening of the nut, use of a
spanner type torque wrench is necessary.
IJCA0A172103-01

Tightening torque 13) Connect negative (–) cable at battery.

CNG fuel pipe nut (a): 17 N·m (1.7 kgf-m, 12.5 14) Refill cooling system with coolant. (Page 1F-9)
lbf-ft)
15) Check cooling system for leakage. (Page 1F-8)
16) Check for CNG fuel leakage. (Page 1G-56)

CNG Pressure Regulator Inspection

AENJCA0A1726013

Shut-Off Valve
Resistance check
Check resistance between terminals of shut-off valve (1).
2, (a)
If check result is not as specified, replace CNG pressure
regulator.
Reference resistance of shut-off valve
1 10.1 – 11.1 Ω at 20 °C (68 °F)
IJCA0A172053-01

9) Connect CNG vacuum hose (4) from CNG pressure

regulator.
10) Connect CNG water inlet hose (2) and CNG water
outlet hose (3).
1

IJCA0A172054-01
 Fuel System: Bi-Fuel CNG 1G-70

Operation check
Check that shut-off valve (1) operates with click sound
when battery voltage is applied. If check result is not as
specified, replace CNG pressure regulator.

1
2

IJCA0A172057-01

d) Tighten CNG pressure gauge (1) to CNG

pressure regulator by hand fully.
e) Turning CNG pressure gauge counterclockwise
within one turn, adjust the gauge in specified
position as shown.
IJCA0A172055-01
f) Holding CNG pressure gauge in the position,
tighten CNG pressure gauge nut (2) until it is
CNG Pressure Gauge Removal and Installation seated.
AENJCA0A1726027
Before performing the following procedure, observe g) Tighten pressure gauge nut to specified torque
“Precautions for Fuel System Service”: Bi-Fuel CNG and check that clearance “a” is within specified
(Page 1G-34). dimension.

Removal NOTE
1) Relieve CNG fuel pressure from CNG fuel feed line. For exact tightening of the nut, use of a
(Page 1G-55) spanner type torque wrench is necessary.
2) Disconnect negative (–) cable at battery.
Tightening torque
3) Loosen CNG pressure gauge nut (1). CNG pressure gauge nut (a): 22 N·m (2.2
4) Remove CNG pressure gauge (2) with O-ring. kgf-m, 16.5 lbf-ft)

1 1

2, (a)

IJCA0A172105-01

Installation
1) Install CNG pressure gauge as follows.
a) Put CNG pressure gauge nut (1) in uppermost
position.
b) Apply a bit of fuel to new O-ring (2).
c) Fit O-ring to CNG pressure gauge.
“a”

IJCA0A172106-01

“a”: 1.9 – 3.8 mm (0.075 – 0.149 in.)

1G-71 Fuel System: Bi-Fuel CNG

2) Connect negative (–) cable at battery. 5) Hoist vehicle and remove clamps (1).
3) Check for CNG fuel leakage. (Page 1G-56) 6) Disconnect breather hose (2), fuel tank filler hose
(3), air suction hose (4) and turn plastic clamp (5).
Fuel Filler Cap Inspection NOTICE
AENJCA0A1726014
Refer to “Fuel Filler Cap Inspection”: Petrol (Page 1G- The plastic clamp could be damaged if
26). excessive force is applied when turning it.
Turn plastic clamp carefully.
Fuel Tank Removal and Installation
AENJCA0A1726015
Before performing the following procedure, observe
“Precautions for Fuel System Service”: Bi-Fuel CNG
(Page 1G-34).

Removal 1
1
1) Relieve fuel pressure from fuel feed line. (Page
1G-55) 5
2) Disconnect negative (–) cable at battery.
3 2
3) Remove fuel filler cap.
4) Insert hose of a hand operated pump into fuel tank
filler hose (1) and pump out fuel in space “a” shown 4
in figure.
IJCA0A172059-01

! WARNING 7) Disconnect ground cable (1) and quick joints (2).

(Page 1G-54)
There is a risk of fire or explosion due to
static electricity if the drained fuel is stored in
an open container or plastic container.
Store the fuel in a sealed metal container.

NOTICE
The hose of the hand operated pump could
damage the fuel tank inlet valve if excessive
2
force is applied when inserting or removing
1
it.
Do not apply excessive force when inserting
or removing the hose of the hand operated
pump.
IJCA0A172060-01

8) Remove muffler. (Page 1K-5)

1

“a”

IBP70A170006-01
 Fuel System: Bi-Fuel CNG 1G-72

9) Support fuel tank (1) with jack (2) and remove its
mounting bolts.
10) Lower fuel tank a little to disconnect fuel pump
connector (3), and then remove fuel tank.
NOTICE
Applying tension to the fuel pump harness
will cause damage to the fuel pump and the
fuel pump harness when lowering the fuel
tank.
Disconnect the fuel pump connector with the
fuel tank lowered to a height at which tension
is not applied to the fuel pump harness.
3
1 • Fuel tank belt (2)
Installation
! WARNING
Failure to take proper precautions when
reinstalling the fuel tank connections can
result in fuel leakage or damage.
Clean the outside surface of the pipe where
each quick joint is to be installed, push the
pipe into the joint until the joint lock clicks,
and then check that the pipe is connected
securely.
1) If removed, install fuel tank components.
• Fuel pump: (Page 1G-73)
• Fuel filter: (Page 1G-63)
• EVAP canister: (Page 1B-5)
• Breather hose and fuel tank filler hose: (Page
1G-54)
• Heat insulator (1)

IJCA0A172061-01
2
11) If necessary, remove fuel tank components.
IJCA0A172062-01
• Fuel pump: (Page 1G-73)
2) Raise fuel tank with jack and connect fuel pump
• Fuel filter: (Page 1G-63) connector.
• EVAP canister: (Page 1B-5) 3) Install fuel tank (1) to vehicle and tighten new fuel
• Breather hose and fuel tank filler hose: (Page tank bolts (2) to specified torque.
1G-54)
NOTICE
• Heat insulator (1)
The fuel tank bolts are pre-coated with
• Fuel tank belt (2)
friction stabilizer. If the bolts are reused, they
1
may work loose.
Use the new fuel tank bolts.

Tightening torque
Fuel tank bolt (a): 14 N·m (1.4 kgf-m, 10.5 lbf-ft)

2, (a) 2, (a)

2
IJCA0A172062-01

2, (a)
2, (a) 1

IJCA0A172063-01
1G-73 Fuel System: Bi-Fuel CNG

4) Connect air suction hose (1), fuel tank filler hose (2), Fuel Tank Flushing Procedure
breather hose (3) and clamps (4) securely. AENJCA0A1726017

For proper installation, refer to “Fuel Hose Refer to “Fuel Tank Flushing Procedure”: Petrol (Page
Disconnection and Reconnection”: Bi-Fuel CNG 1G-28).
(Page 1G-54).
5) Turn plastic clamp (5).
Fuel Pump On-Vehicle Inspection
AENJCA0A1726018
Refer to “Fuel Pump On-Vehicle Inspection”: Petrol
NOTICE
(Page 1G-29).
The plastic clamp could be damaged if
excessive force is applied when turning it. Fuel Pump Relay Inspection
Turn plastic clamp carefully. AENJCA0A1726019
Refer to “Control Relay Inspection” in Section 10B (Page
10B-51).

CNG Valve Control Relay Inspection

AENJCA0A1726020
Refer to “Control Relay Inspection” in Section 10B (Page
4 10B-51).
4

Fuel Pump Assembly Removal and Installation

2 5 AENJCA0A1726021
Refer to “Fuel Pump Assembly Removal and
3
Installation”: Petrol (Page 1G-29).

Fuel Pump Inspection

1 AENJCA0A1726022
IJCA0A172064-01 Refer to “Fuel Pump Inspection”: Petrol (Page 1G-31).
6) Connect quick joints (1). (Page 1G-54)
7) Install ground cable (2) and tighten fuel ground cable Fuel Level Sensor Removal and Installation
bolt (3) to specified torque. AENJCA0A1726028
Refer to “Fuel Level Sensor Removal and Installation”:
Tightening torque Petrol (Page 1G-31).
Fuel ground cable bolt (a): 3.0 N·m (0.31 kgf-m,
2.5 lbf-ft) Fuel Level Sensor Inspection
AENJCA0A1726029
Refer to “Fuel Level Sensor Inspection”: Petrol (Page
1G-32).

CNG Cylinder with Valve On-Vehicle Inspection

AENJCA0A1726023
1) Check CNG cylinder and CNG cylinder valve for
3, (a) cracks, deformation or damage. If any faulty
1 condition is found, replace CNG cylinder assembly.
2 2) Check CNG cylinder and CNG cylinder valve for
CNG fuel leakage. If faulty condition is found,
replace CNG cylinder assembly. (Page 1G-56)
3) Check the shut-off valve resistance and operation
IJCA0A172065-01
sound as follows.
8) Install muffler. (Page 1K-5) a) Disconnect negative (–) cable at battery.
9) Install fuel filler cap. b) Disconnect shut-off valve connector.
10) Connect negative (–) cable at battery.
11) With engine stopped, set ignition “ON” and check for
fuel leakage. (Page 1G-56)

Fuel Tank Inspection

AENJCA0A1726016
Refer to “Fuel Tank Inspection”: Petrol (Page 1G-28).
 Fuel System: Bi-Fuel CNG 1G-74

c) Check resistance between terminals of shut-off 5) Remove spare tire rear carrier bolt (4) and remove
valve (1). spare tire rear carrier.
If check result is not as specified, replace CNG
cylinder assembly.
Reference resistance of shut-off valve 3
10.1 – 11.1 Ω at 20 °C (68 °F)
1

4
2

IJCA0A172068-02

6) Disconnect shut-off valve connector (1).

7) Disconnect CNG inlet pipe ventilation hose (2) and
CNG ventilation hose (3) from CNG cylinder
IJCA0A172066-01 assembly.
d) Check that shut-off valve (1) operates with click
2
sound when battery voltage is applied. If check
result is not as specified, replace CNG cylinder
assembly.

IJCA0A172069-03

8) Disconnect lower pipe (1) of CNG receptacle and

CNG fuel pipe No.2 (2) from CNG cylinder assembly.

IJCA0A172067-01 1

CNG Cylinder with Valve Removal and

Installation
AENJCA0A1726024
Before performing the following procedure, observe
“Precautions for Fuel System Service”: Bi-Fuel CNG
(Page 1G-34).

! WARNING 2

If CNG cylinder drops, personal injury may

occur. IJCA0A172070-01

Carefully remove and install CNG cylinder by

2 or more persons.

Removal
1) Relieve CNG fuel pressure from CNG fuel feed line.
(Page 1G-55)
2) Disconnect negative (–) cable at battery.
3) Remove rear seatback assembly. (Page 9G-16)
4) Remove spare tire rear carrier screw (1), open spare
tire rear carrier (2) and remove spare tire (3).
1G-75 Fuel System: Bi-Fuel CNG

9) Put matchmarks (1) on CNG cylinder (2), CNG 15) Remove CNG cylinder holder (1), if necessary.
cylinder bands (3) and CNG cylinder holder (4) as
shown in figure.

2
1 1

3 3

1 IJCA0A172074-01

4 Installation
IJCA0A172071-01
1) Install CNG cylinder holder (1), if removed.
10) Loosen CNG cylinder band locking nuts (1), and
then loosen CNG cylinder band adjusting bolts (2). 2) Tighten CNG cylinder holder bolts (2) to specified
torque.
11) Remove CNG cylinder band mounting bolts and take
off CNG cylinder bands (3) from CNG cylinder Tightening torque
holder. CNG cylinder holder bolt (a): 40 N·m (4.1 kgf-m,
29.5 lbf-ft)
2

2, (a)
2
1
1
1
3
2, (a)
3

2, (a)

2, (a)

IJCA0A172072-01
IJCA0A172075-01
12) Remove CNG cylinder assembly (1).
3) Connect floor harness clamp to CNG cylinder holder,
if disconnected.
1
4) Install CNG fuel pipe No.2, if removed. (Page 1G-
58)

IJCA0A172073-01

13) Remove CNG fuel pipe No.2, if necessary. (Page

1G-58)
14) Disconnect floor harness clamp from CNG cylinder
holder, if necessary.
 Fuel System: Bi-Fuel CNG 1G-76

5) Put CNG cylinder assembly (1) on CNG cylinder

holder as shown in figure and check matchmarks (2)
1
on the cylinder and cylinder holder are aligned.

1
3, (a)
1

3, (a)

“a”

3, (a)
3, (a)
IJCA0A172076-01
2
“a”: 90°
IJCA0A172077-01

6) Fix CNG cylinder assembly installing CNG cylinder
bands as follows.
a) Install CNG cylinder bands (1) to CNG cylinder
holder (2) and tighten new CNG cylinder band
mounting bolts (3) to specified torque.
b) Turning CNG cylinder band adjusting bolts (1),
adjust CNG cylinder bands so that the
matchmarks (2) on CNG cylinder (3) and CNG
cylinder band (4) drawn before removal are
aligned.

NOTICE
The CNG cylinder band mounting bolts are
3
pre-coated with adhesive. If the bolts are 2 2
reused, they may work loose.
1 1
Replace the CNG cylinder band mounting
bolts with new ones once they are removed.
4 4
Tightening torque
CNG cylinder band mounting bolt (a): 60
N·m (6.1 kgf-m, 44.5 lbf-ft)

IJCA0A172078-01
1G-77 Fuel System: Bi-Fuel CNG

c) Tighten CNG cylinder band adjusting bolts (1) to 11) Tighten CNG ventilation hose clamp (2) to specified
specified torque. torque.
Tightening torque Tightening torque
CNG cylinder band adjusting bolt (a): 35 N·m CNG ventilation hose clamp (a): 1.7 N·m (0.17
(3.6 kgf-m, 26.0 lbf-ft) kgf-m, 1.5 lbf-ft)
d) After 2 hours, retighten CNG cylinder band
adjusting bolts to specified torque.
e) Tighten CNG cylinder band locking nuts (2) to
specified torque.
Tightening torque
CNG cylinder band locking nut (b): 35 N·m (
3.6 kgf-m, 26.0 lbf-ft)
1 2, (a)

1, (a)

2, (b)
IJCA0A172081-01
1, (a)
12) Connect shut-off valve connector (1).

2, (b)

IJCA0A172079-01

7) Connect lower pipe (1) of CNG receptacle and CNG

fuel pipe No.2 (2) to CNG cylinder assembly. 1

8) Tighten CNG fuel pipe nuts (3) to specified torque.

NOTE
For exact tightening of the nut, use of a IJCA0A172082-01
spanner type torque wrench is necessary. 13) Put spare tire rear carrier (1) and tighten spare tire
rear carrier bolt (2) to specified torque.
Tightening torque
CNG fuel pipe nut (a): 17 N·m (1.7 kgf-m, 12.5 Tightening torque
lbf-ft) Spare tire carrier bolt (a): 40 N·m (4.1 kgf-m,
29.5 lbf-ft)
1 14) Install spare tire (3), close spare tire rear carrier and
tighten spare tire rear carrier screw (4) to specified
torque.
3, (a) Tightening torque
Spare tire carrier screw (b): 19 N·m (1.9 kgf-m,
14.0 lbf-ft)
3, (a)

2
3

IJCA0A172080-01 4, (b)

9) Connect CNG inlet pipe ventilation hose referring to

Step 8) – 9) in “Installation” under “CNG Receptacle
Removal and Installation”: Bi-Fuel CNG (Page 1G-
78).
2, (a)
1
10) Connect CNG ventilation hose (1) to CNG cylinder
assembly.
IJCA0A172083-02
 Fuel System: Bi-Fuel CNG 1G-78

15) Install rear seatback assembly. (Page 9G-16) 5) Remove CNG receptacle screws (1) and washers
16) Connect negative (–) cable at battery. (2).
17) Check for CNG fuel leakage. (Page 1G-56) 6) Remove CNG receptacle assembly (3) from vehicle.

CNG Receptacle On-Vehicle Inspection

AENJCA0A1726025
• Check CNG receptacle for cracks, deformation or 1
damage. 3
If any faulty condition is found, replace CNG
receptacle.
2
• Check pipe for cracks, deformation or damage.
If any faulty condition is found, replace CNG
receptacle. 1

• Check CNG receptacle for CNG fuel leakage. If faulty

condition is found, replace CNG receptacle. (Page
1G-56) IJCA0A172086-01

7) Remove CNG inlet pipe ventilation hose (1) from

CNG Receptacle Removal and Installation CNG receptacle assembly, if necessary.
AENJCA0A1726026
Before performing the following procedure, observe
1
“Precautions for Fuel System Service”: Bi-Fuel CNG
(Page 1G-34).

Removal
1) Relieve CNG fuel pressure from CNG fuel feed line.
(Page 1G-55)
2) Disconnect negative (–) cable at battery.
IJCA0A172087-01
3) Disconnect CNG inlet pipe ventilation hose (1) from
CNG cylinder assembly.
Installation
1) Install CNG inlet pipe ventilation hose (1) to CNG
receptacle assembly, if necessary.
2) Position CNG inlet pipe ventilation hose and CNG
1
inlet pipe ventilation hose clamp (2) as specified.
Clearance between CNG receptacle and end of
CNG inlet pipe ventilation hose
“a”: 23 – 28 mm (0.91 – 1.10 in.)
Clearance between CNG inlet pipe ventilation
hose end and CNG inlet pipe ventilation hose
clamp
“b”: 5 – 8 mm (0.20 – 0.31 in.)
IJCA0A172084-01

4) Disconnect lower pipe (1) of CNG receptacle from Position of clamp mid-point
CNG cylinder assembly. “c”: 0 – 45°

IJCA0A172085-01
1G-79 Fuel System: Bi-Fuel CNG

3) Tighten CNG inlet pipe ventilation hose clamp to NOTE

specified torque. For exact tightening of the nut, use of a
Tightening torque spanner type torque wrench is necessary.
CNG inlet pipe ventilation hose clamp (a): 1.7
N·m (0.17 kgf-m, 1.5 lbf-ft) Tightening torque
CNG receptacle with pipe nut (a): 17 N·m (1.7
kgf-m, 12.5 lbf-ft)
3
1 “a”
“c”

2, (a)
1

“b”

2, (a)

IJCA0A172091-01

1 8) Position CNG inlet pipe ventilation hose clamp (1) as

specified.
Position of clamp mid-point
“a”: 0 – 45°
9) Tighten CNG inlet pipe ventilation hose clamp to
IJCA0A172088-01
specified torque.
3. Upward
Tightening torque
4) Install CNG receptacle assembly (1) to vehicle. CNG inlet pipe ventilation hose clamp (a): 1.7
N·m (0.17 kgf-m, 1.5 lbf-ft)
5) Install CNG receptacle screws (2) and washers (3),
and tighten CNG receptacle screws to specified
torque.
Tightening torque
CNG receptacle screw (a): 3.0 N·m (0.31 kgf-m,
2.5 lbf-ft) “a”

[f]

2, (a)

1, (a)
3

2, (a)

IJCA0A172089-01

IJCA0A172090-01 [f]: Vehicle forward

6) Install lower pipe (1) of CNG receptacle to CNG

cylinder assembly. 10) Connect negative (–) cable at battery.
7) Tighten CNG fuel pipe nut (2) to specified torque. 11) Check for CNG fuel leakage. (Page 1G-56)
 Fuel System: Bi-Fuel CNG 1G-80

CNG Hose Chamber Removal and Installation

AENJCA0A1726030
Removal
1) Relieve CNG fuel pressure from CNG fuel feed line.
(Page 1G-55)
2) Disconnect negative (–) cable at battery.
3) Disconnect CNG fuel hoses (1) from CNG hose
chamber (2) and remove CNG hose chamber.

IJCA0A172107-01

Installation
Reverse removal procedure noting the following point.
• Check for CNG fuel leakage. (Page 1G-56)
1G-81 Fuel System: Bi-Fuel CNG

Specifications
Tightening Torque Specifications
AENJCA0A1727001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
CNG fuel pipe nut (Page 1G-60) /
(Page 1G-63) /
17 1.7 12.5
(Page 1G-69) /
(Page 1G-77)
Fuel ground cable bolt (Page 1G-61) /
3.0 0.31 2.5
(Page 1G-73)
Fuel filler neck bolt 5.5 0.56 4.0 (Page 1G-61)
CNG ventilation hose clamp (Page 1G-63) /
1.7 0.17 1.5
(Page 1G-77)
CNG fuel filter lower case 15 1.5 11.0 (Page 1G-64)
CNG adapter pipe bolt 11 1.1 8.5 (Page 1G-64)
CNG fuel filter assembly bolt 11 1.1 8.5 (Page 1G-65)
CNG fuel injector assembly bolt 11 1.1 8.5 (Page 1G-66)
CNG pressure regulator bolt 25 2.5 18.5 (Page 1G-68)
CNG pressure regulator bracket nut 9.0 0.92 7.0 (Page 1G-69)
CNG pressure gauge nut 22 2.2 16.5 (Page 1G-70)
Fuel tank bolt 14 1.4 10.5 (Page 1G-72)
CNG cylinder holder bolt 40 4.1 29.5 (Page 1G-75)
CNG cylinder band mounting bolt 60 6.1 44.5 (Page 1G-76)
CNG cylinder band adjusting bolt 35 3.6 26.0 (Page 1G-77)
CNG cylinder band locking nut 35 3.6 26.0 (Page 1G-77)
Spare tire carrier bolt 40 4.1 29.5 (Page 1G-77)
Spare tire carrier screw 19 1.9 14.0 (Page 1G-77)
CNG inlet pipe ventilation hose clamp (Page 1G-79) /
1.7 0.17 1.5
(Page 1G-79)
CNG receptacle screw 3.0 0.31 2.5 (Page 1G-79)
CNG receptacle with pipe nut 17 1.7 12.5 (Page 1G-79)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Fuel System Components”: Bi-Fuel CNG (Page 1G-49)
“Fasteners Information” in Section 0A (Page 0A-6)

Special Tools and Equipment

Special Tool
AENJCA0A1728001
SUZUKI scan tool (Suzuki
SDT-II)
—
(Page 1G-41) /
(Page 1G-47) /
(Page 1G-55) /
(Page 1G-67)
 Ignition System: K10B and Bi-Fuel CNG 1H-1

Ignition System
Engine

K10B and Bi-Fuel CNG

General Description
Ignition System Construction
AENJCA0A1811001
The ignition system is an electronic ignition type which consists of the following components.
• ECM
It monitors the engine and vehicle conditions through the signals from the sensors, determines the most suitable
ignition timing and duration and sends a signal to the ignition coil assembly.
• Ignition coil assembly
One ignition coil assembly is provided for each cylinder.
The ignition coil assembly turns on and off the current to the primary coil according to the signal from ECM. When
the current flow to the primary coil is turned off, a high voltage is induced in the secondary coil.
• Spark plugs
• CMP sensor and CKP sensor
Using signals from these sensors, ECM identifies the specific cylinder whose piston is in the compression stroke,
detects the crank angle and adjusts initial ignition timing automatically.
• TP sensor, ECT sensor, MAP sensor, IAT sensor, knock sensor and other sensors / switches
Using signals from these sensors / switches, the ECM corrects the initial ignition timing and sets the optimum timing
according to the engine conditions.
1H-2 Ignition System: K10B and Bi-Fuel CNG

Schematic and Routing Diagram

Ignition System Circuit Diagram
AENJCA0A1812001

A1
A2 3 11
WHT 4 B1
B2 6 5V
7 C1 5V
YEL C01-17
C2
GRN C01-18
A3
5
WHT B3
8 5V
C3
PNK C01-19
2
1 WHT E01-19

+B
5V
9
PPL C01-58

5V
10

PNK C01-60

GRY

[A] C01 E01

10 9 8 7 6 5 4 3 2 1
65 64 63 62 61 20 19 18 17 16 15 14 13 12 11
70 69 68 67 66 30 29 28 27 26 25 24 23 22 21
75 74 73 72 71 40 39 38 37 36 35 34 33 32 31
80 79 78 77 76 50 49 48 47 46 45 44 43 42 41
60 59 58 57 56 55 54 53 52 51
[a]
9 8 7 6 5 4 3 2 1
57 56 55 18 17 16 15 14 13 12 11 10
60 59 58 27 26 25 24 23 22 21 20 19
63 62 61 36 35 34 33 32 31 30 29 28
66 65 64 45 44 43 42 41 40 39 38 37
54 53 52 51 50 49 48 47 46

IJCA0A181001-02

[A]: ECM connector (View: [a]) 2. “IG COIL” fuse (without keyless entry system) or 7. Spark plug No.2
“IG” fuse (with keyless entry system)
A1 – A3: Ignition coil assembly power supply circuits 3. Ignition coil assembly No.1 8. Spark plug No.3
B1 – B3: Ignition coil assembly drive circuits 4. Ignition coil assembly No.2 9. CMP sensor
C1 – C3: Ignition coil assembly ground circuits 5. Ignition coil assembly No.3 10. CKP sensor
1. To ignition power supply 6. Spark plug No.1 11. ECM
 Ignition System: K10B and Bi-Fuel CNG 1H-3

Component Location
Ignition System Component Location
AENJCA0A1813001

3
4
5

IJCA0A181002-01

1. ECM 3. Ignition coil assembly No.1 5. Ignition coil assembly No.3

2. CKP sensor 4. Ignition coil assembly No.2 6. CMP sensor
1H-4 Ignition System: K10B and Bi-Fuel CNG

Diagnostic Information and Procedures

Ignition System Check
AENJCA0A1814001
Circuit Diagram

A1
A2 3 11
WHT 4 B1
B2 6 5V
7 C1 5V
YEL C01-17
C2
GRN C01-18
A3
5
WHT B3
8 5V
C3
PNK C01-19
2
1 WHT E01-19

+B
5V
9
PPL C01-58

5V
10

PNK C01-60

GRY

[A] C01 E01

10 9 8 7 6 5 4 3 2 1
65 64 63 62 61 20 19 18 17 16 15 14 13 12 11
70 69 68 67 66 30 29 28 27 26 25 24 23 22 21
75 74 73 72 71 40 39 38 37 36 35 34 33 32 31
80 79 78 77 76 50 49 48 47 46 45 44 43 42 41
60 59 58 57 56 55 54 53 52 51
[a]
9 8 7 6 5 4 3 2 1
57 56 55 18 17 16 15 14 13 12 11 10
60 59 58 27 26 25 24 23 22 21 20 19
63 62 61 36 35 34 33 32 31 30 29 28
66 65 64 45 44 43 42 41 40 39 38 37
54 53 52 51 50 49 48 47 46

IJCA0A181001-02

[A]: ECM connector (View: [a]) 2. “IG COIL” fuse (without keyless entry system) or 7. Spark plug No.2
“IG” fuse (with keyless entry system)
A1 – A3: Ignition coil assembly power supply circuits 3. Ignition coil assembly No.1 8. Spark plug No.3
B1 – B3: Ignition coil assembly drive circuits 4. Ignition coil assembly No.2 9. CMP sensor
C1 – C3: Ignition coil assembly ground circuits 5. Ignition coil assembly No.3 10. CKP sensor
1. To ignition power supply 6. Spark plug No.1 11. ECM

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: (Page 1A-
20)
• Bi-fuel CNG: (Page
1A-291)
 Ignition System: K10B and Bi-Fuel CNG 1H-5

Step Action Yes No

2 Ignition spark test 1 Go to Step 3. Go to Step 4.
1) Perform ignition spark test. (Page 1H-6)

Is test result OK?

3 Ignition timing check Ignition system is in Repair or replace
1) Check ignition timing. (Page 1H-8) good condition. defective part.

Is check result OK?

4 Confirmation of malfunctioning cylinder Go to Step 7. Go to Step 5.
1) Check cylinder(s) that failed in ignition spark test.

Did all cylinders fail in ignition spark test?

5 Ignition spark test 2 Replace spark plug. Go to Step 6.
1) Replace spark plug of each malfunctioning cylinder with (Page 1H-7)
normal cylinder’s one.
2) Perform ignition spark test. (Page 1H-6)

Is test result OK?

6 Ignition spark test 3 Replace ignition coil. Go to Step 7.
1) Replace ignition coil of each malfunctioning cylinder with (Page 1H-7)
normal cylinder’s one.
2) Perform ignition spark test. (Page 1H-6)

Is test result OK?

7 Ignition coil assembly power supply and ground circuit Go to Step 8. Repair or replace
check defective wiring
1) Check power supply (“A1”, “A2” and “A3”) and ground harness.
(“C1”, “C2” and “C3”) circuits of each ignition coil
assembly for open, short and poor connection.

Is check result OK?

8 Ignition coil assembly drive circuit check Go to Step 9. Repair or replace
1) When ignition is “OFF”, disconnect “C01” and “E01” defective wiring
connectors from ECM. harness.
2) Check for proper terminal connection to “C01” and “E01”
connectors.
3) If connections are OK, check the following points.
• Resistance of “B1”, “B2” and “B3” circuits: less than 1
Ω
• Resistance between each of “B1”, “B2” and “B3”
circuits and ground: infinity
• Resistance between “B1” circuit terminal and other
terminal at ignition coil connector: infinity
• Resistance between “B2” circuit terminal and other
terminal at ignition coil connector: infinity
• Resistance between “B3” circuit terminal and other
terminal at ignition coil connector: infinity
• Voltage of “B1”, “B2” and “B3” circuits: approx. 0 V
(When ignition is “ON”)

Is check result OK?

9 CKP sensor and CMP sensor check Replace ECM and Replace CKP sensor or
1) Check CKP sensor and CMP sensor. recheck ignition spark. CMP sensor.
(Page 1C-3)
• CKP sensor: (Page 1C-13)
• CMP sensor: (Page 1C-12)

Is check result OK?

1H-6 Ignition System: K10B and Bi-Fuel CNG

Ignition Spark Test

AENJCA0A1814002
! WARNING
If this test is performed without disconnecting the injector connectors, a spark from a plug may ignite
fuel vapor coming out of the spark plug holes during the test, causing a fire or explosion.
Disconnect the injector connectors from the injectors before performing this test.

1) Remove spark plugs. (Page 1H-7)

2) Check spark plugs. (Page 1H-7)
3) Disconnect all fuel injector connectors.
4) Connect ignition coil connector (1) to ignition coil assembly (3).
5) Connect spark plug (2) to ignition coil assembly, and ground spark plug.

1 3

I8C50A180004-01

6) Crank engine and check if each spark plug sparks.

7) If no spark is emitted, check the related parts. (Page 1H-4)
8) Connect all fuel injector connectors.
9) Install spark plugs. (Page 1H-7)
 Ignition System: K10B and Bi-Fuel CNG 1H-7

Repair Instructions
Spark Plug Removal and Installation
AENJCA0A1816001
Removal
1) Remove ignition coil assemblies. (Page 1H-7)
2) Remove spark plugs.

Installation
1) Install spark plugs and tighten them to specified
torque.
Tightening torque
Spark plug: 18 N·m (1.8 kgf-m, 13.5 lbf-ft)
2) Install ignition coil assemblies. (Page 1H-7)
IYSQ01181012-01

Spark Plug Inspection

AENJCA0A1816002 Ignition Coil Assembly Removal and Installation
Check spark plug for: AENJCA0A1816003
Removal
• Electrode wear
1) Disconnect ignition coil connectors.
• Carbon deposits
2) Remove ignition coil bolts (1) and then pull out
• Insulator damage ignition coil assemblies (2).
• Spark plug air gap
Check spark plug air gap “a” using special tool.
If out of specification of the air gap or any other
abnormality is found with iridium spark plug, replace it 1
with new plug.
Special tool
(A): 09930M77410
Spark plug air gap “a”
: 0.95 – 1.05 mm (0.038 to 0.041 in.)
Spark plug type 2
NGK: KR6A-10
IJCA0A181003-01

Installation
Reverse removal procedure.

Ignition Coil Assembly Inspection

AENJCA0A1816004
Check ignition coil assembly for the following points:
• Damage
• Deterioration
IHSB0A181001-01 • Corrosion on terminals
If check result is not OK, replace ignition coil assembly.
1H-8 Ignition System: K10B and Bi-Fuel CNG

Ignition Timing Inspection 6) Fix ignition timing using “Fixed Spark” function in
AENJCA0A1816005 “Active Test” mode on scan tool.
NOTE
Initial ignition timing
For identification of each ignition coil
Fixed with SUZUKI scan tool: 5 ± 7° BTDC (at
assembly, refer to “Ignition System
specified idle speed)
Component Location”: K10B and Bi-Fuel
CNG (Page 1H-3). Ignition order
1–3–2
1) Connect SUZUKI scan tool to DLC (1) with ignition
“OFF”. 2, (A)

Special tool
(A): SUZUKI scan tool (Suzuki SDT-II)

1
3 1

IJCA0A181005-01

2, (A)

4
5

(A)
IJCA0A181004-01

2) Start engine and warm it up to normal operating

temperature.
3) Check that all electrical loads except ignition system
are switched off. IJHA0A180005-01

4) Check that idle speed is within specification referring 4. TDC 6. 10° BTDC
5. 5° BTDC
to “Idle Speed Inspection” or “Idle Speed and IAC
Throttle Valve Opening Inspection”.
7) If check result is not as specified, check the following
• Petrol: (Page 1A-116)
points.
• Bi-fuel CNG: (Page 1A-365)
• CKP sensor and sensor plate: (Page 1C-13)
5) Grip ignition coil No.1 harness (1) by probe of timing
• ECM and its circuit
light (2) directing arrow (3) at ignition coil side, and
check that ignition is within specification. – Petrol: (Page 1A-103)
– Bi-fuel CNG: (Page 1A-347)
Special tool
(A): 09930M76311 • CMP sensor: (Page 1C-12)
• Signal rotor: (Page 1D-11)
• Crankshaft: (Page 1D-63)
• Crankshaft pulley
• Crankshaft sprocket key
8) After checking initial ignition timing, release ignition
timing fixation using scan tool.
 Ignition System: K10B and Bi-Fuel CNG 1H-9

9) With engine idling (throttle opening at default If check result is not as specified, check the following
position and vehicle stopped), check that ignition points.
timing is about 5 to 15° BTDC (Constant variation • ECM and its circuit
within a few degrees from 5 to 15° BTDC indicates
– Petrol: (Page 1A-103)
no abnormality but proves operation of ignition
timing control system.) Also, check that increasing – Bi-fuel CNG: (Page 1A-347)
engine speed advances ignition timing. • TP sensor: (Page 1C-5)
• APP sensor: (Page 1C-7)

Specifications
Tightening Torque Specifications
AENJCA0A1817001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Spark plug 18 1.8 13.5 (Page 1H-7)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Fasteners Information” in Section 0A (Page 0A-6)

Special Tools and Equipment

Special Tool
AENJCA0A1818001
09930M76311 09930M77410
Timing light Plug gap gauge
(Page 1H-8) (Page 1H-7)

SUZUKI scan tool (Suzuki

SDT-II)
—
(Page 1H-8)
1H-10 Ignition System: K12M

K12M
General Description
Ignition System Construction
AENJCA0A1821001
The ignition system is an electronic ignition type which consists of the following components.
• ECM
It monitors the engine and vehicle conditions through the signals from the sensors, determines the most suitable
ignition timing and duration and sends a signal to the ignition coil assembly.
• Ignition coil assembly
One ignition coil assembly is provided for each cylinder.
The ignition coil assembly turns on and off the current to the primary coil according to the signal from ECM. When
the current flow to the primary coil is turned off, a high voltage is induced in the secondary coil.
• Spark plugs
• CMP sensor and CKP sensor
Using signals from these sensors, ECM identifies the specific cylinder whose piston is in the compression stroke,
detects the crank angle and adjusts initial ignition timing automatically.
• TP sensor, ECT sensor, MAP sensor, IAT sensor, knock sensor and other sensors / switches
Using signals from these sensors / switches, the ECM corrects the initial ignition timing and sets the optimum timing
according to the engine conditions.
 Ignition System: K12M 1H-11

Schematic and Routing Diagram

Ignition System Circuit Diagram
AENJCA0A1822001

A1
3 13
A2
4
WHT
B1
B2 7
8 C1 5V
BLK
C2
BLK 5V
YEL C02-44
GRN C02-33
A3
A4 5
6
WHT B3
B4 9
10 C3
BLK
C4 5V
BLK
5V
PNK C02-34

BEG C02-35
2
1 WHT E02-1

+B
5V
11
PPL C02-30

5V
12

PNK C02-39

GRY

[A] C02 E02

[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

IJCA0A182001-01

[A]: ECM connector (View: [a]) 3. Ignition coil assembly No.1 9. Spark plug No.3
A1 – A4: Ignition coil assembly power supply circuits 4. Ignition coil assembly No.2 10. Spark plug No.4
B1 – B4: Ignition coil assembly drive circuits 5. Ignition coil assembly No.3 11. CMP sensor
C1 – C4: Ignition coil assembly ground circuits 6. Ignition coil assembly No.4 12. CKP sensor
1. To ignition power supply 7. Spark plug No.1 13. ECM
2. “IG COIL” fuse (without keyless entry system) or 8. Spark plug No.2
“IG” fuse (with keyless entry system)
1H-12 Ignition System: K12M

Component Location
Ignition System Component Location
AENJCA0A1823001

1 2 3 4

IJCA0A182002-02

1. Ignition coil assembly No.1 4. Ignition coil assembly No.4 7. CMP sensor
2. Ignition coil assembly No.2 5. ECM
3. Ignition coil assembly No.3 6. CKP sensor
 Ignition System: K12M 1H-13

Diagnostic Information and Procedures

Ignition System Check
AENJCA0A1824001
Circuit Diagram

A1
3 13
A2
4
WHT
B1
B2 7
8 C1 5V
BLK
C2
BLK 5V
YEL C02-44
GRN C02-33
A3
A4 5
6
WHT B3
B4 9
10 C3
BLK
C4 5V
BLK
5V
PNK C02-34

BEG C02-35
2
1 WHT E02-1

+B
5V
11
PPL C02-30

5V
12

PNK C02-39

GRY

[A] C02 E02

[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

IJCA0A182001-01

[A]: ECM connector (View: [a]) 3. Ignition coil assembly No.1 9. Spark plug No.3
A1 – A4: Ignition coil assembly power supply circuits 4. Ignition coil assembly No.2 10. Spark plug No.4
B1 – B4: Ignition coil assembly drive circuits 5. Ignition coil assembly No.3 11. CMP sensor
C1 – C4: Ignition coil assembly ground circuits 6. Ignition coil assembly No.4 12. CKP sensor
1. To ignition power supply 7. Spark plug No.1 13. ECM
2. “IG COIL” fuse (without keyless entry system) or 8. Spark plug No.2
“IG” fuse (with keyless entry system)
1H-14 Ignition System: K12M

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”: K12M
in Section 1A (Page 1A-
138).
2 Ignition spark test 1 Go to Step 3. Go to Step 4.
1) Perform ignition spark test. (Page 1H-16)

Is test result OK?

3 Ignition timing check Ignition system is in Repair or replace
1) Check ignition timing. (Page 1H-18) good condition. defective part.

Is check result OK?

4 Confirmation of malfunctioning cylinder Go to Step 7. Go to Step 5.
1) Check cylinder(s) that failed in ignition spark test.

Did all cylinders fail in ignition spark test?

5 Ignition spark test 2 Replace spark plug. Go to Step 6.
1) Replace spark plug of each malfunctioning cylinder with (Page 1H-17)
normal cylinder’s one.
2) Perform ignition spark test. (Page 1H-16)

Is test result OK?

6 Ignition spark test 3 Replace ignition coil. Go to Step 7.
1) Replace ignition coil of each malfunctioning cylinder with (Page 1H-17)
normal cylinder’s one.
2) Perform ignition spark test. (Page 1H-16)

Is test result OK?

7 Ignition coil assembly power supply and ground circuit Go to Step 8. Repair or replace
check defective wiring
1) Check power supply (“A1”, “A2”, “A3” and “A4”) and harness.
ground (“C1”, “C2”, “C3” and “C4”) circuits of each
ignition coil assembly for open, short and poor
connection.

Is check result OK?

 Ignition System: K12M 1H-15

Step Action Yes No

8 Ignition coil assembly drive circuit check Go to Step 9. Repair or replace
1) When ignition is “OFF”, disconnect “C01” and “E01” defective wiring
connectors from ECM. harness.
2) Check for proper terminal connection to “C01” and “E01”
connectors.
3) If connections are OK, check the following points.
• Resistance of “B1”, “B2”, “B3” and “B4” circuits: less
than 1 Ω
• Resistance between each of “B1”, “B2”, “B3” and “B4”
circuits and ground: infinity
• Resistance between “B1” circuit terminal and other
terminal at ignition coil connector: infinity
• Resistance between “B2” circuit terminal and other
terminal at ignition coil connector: infinity
• Resistance between “B3” circuit terminal and other
terminal at ignition coil connector: infinity
• Resistance between “B4” circuit terminal and other
terminal at ignition coil connector: infinity
• Voltage of “B1”, “B2”, “B3” and “B4” circuits: approx. 0
V (When ignition is “ON”)

Is check result OK?

9 CKP sensor and CMP sensor check Replace ECM and Replace CKP sensor or
1) Check CKP sensor and CMP sensor. recheck ignition spark. CMP sensor.
(Page 1C-22)
• CKP sensor: (Page 1C-31)
• CMP sensor: (Page 1C-30)

Is check result OK?

1H-16 Ignition System: K12M

Ignition Spark Test

AENJCA0A1824002
! WARNING
If this test is performed without disconnecting the injector connectors, a spark from a plug may ignite
fuel vapor coming out of the spark plug holes during the test, causing a fire or explosion.
Disconnect the injector connectors from the injectors before performing this test.

1) Remove spark plugs. (Page 1H-17)

2) Check spark plugs. (Page 1H-17)
3) Remove air cleaner assembly. (Page 1D-82)
4) Disconnect all fuel injector connectors.
5) Connect ignition coil connector (1) to ignition coil assembly (3).
6) Connect spark plug (2) to ignition coil assembly, and ground spark plug.

3
IJCA0A182004-01

7) Crank engine and check if each spark plug sparks.

8) If no spark is emitted, check the related parts. (Page 1H-13)
9) Connect all fuel injector connectors.
10) Install air cleaner assembly. (Page 1D-82)
11) Install spark plugs and ignition coils. (Page 1H-17)
 Ignition System: K12M 1H-17

Repair Instructions
Spark Plug Removal and Installation
AENJCA0A1826001
Removal
1) Remove ignition coil assemblies. (Page 1H-17)
2) Remove spark plugs.

Installation
1) Install spark plugs and tighten them to specified
torque.
Tightening torque
Spark plug: 18 N·m (1.8 kgf-m, 13.5 lbf-ft)
2) Install ignition coil assemblies. (Page 1H-17)
IYSQ01181012-01

Spark Plug Inspection

AENJCA0A1826002 Ignition Coil Assembly Removal and Installation
Check spark plug for: AENJCA0A1826003
Removal
• Electrode wear
1) Disconnect ignition coil connectors.
• Carbon deposits
2) Remove ignition coil bolts (1) and then pull out
• Insulator damage ignition coil assemblies (2).
• Spark plug air gap
Check spark plug air gap “a” using special tool.
If out of specification of the air gap or any other 1

abnormality is found with iridium spark plug, replace it

with new plug.
Special tool
(A): 09930M77410
Spark plug air gap “a”
: 0.95 – 1.05 mm (0.037 to 0.041 in.) 2

Spark plug type IJHA0A180004-01

NGK: LKR6F-10
Installation
Reverse removal procedure.

IHSB0A181001-01
1H-18 Ignition System: K12M

Ignition Coil Assembly Inspection 6) Fix ignition timing using “Fixed Spark” function in
AENJCA0A1826004 “Active Test” mode on scan tool.
Check ignition coil assembly for the following points:
• Damage Initial ignition timing
Fixed with SUZUKI scan tool: 5 ± 3° BTDC (at
• Deterioration
specified idle speed)
• Corrosion on terminals
If check result is not OK, replace ignition coil assembly. Ignition order
1–3–4–2
Ignition Timing Inspection
AENJCA0A1826005 2, (A)
NOTE
For identification of each ignition coil, refer
to “Ignition System Component Location”:
K12M (Page 1H-12).

1) Connect SUZUKI scan tool to DLC (1) with ignition

“OFF”.
Special tool 3 1
(A): SUZUKI scan tool (Suzuki SDT-II)
IFRA0A180006-03

2, (a)

1 4
5
6

(A)
IJCA0A182003-01
IJCA0A181004-01
4. TDC 6. 10° BTDC
2) Start engine and warm it up to normal operating
5. 5° BTDC
temperature.
3) Check that all electrical loads except ignition system 7) If check result is not as specified, check the following
are switched off. points.
4) Check that idle speed is within specification referring • CKP sensor: (Page 1C-31)
to “Idle Speed Inspection”: K12M in Section 1A
(Page 1A-270). • Sensor plate: (Page 1D-147)
5) Grip ignition coil No.1 harness (1) by probe of timing • ECM and its circuit: (Page 1A-254)
light (2) directing arrow (3) at ignition coil side, and • CMP sensor: (Page 1C-30)
check that ignition is within specification. • Signal rotor: (Page 1D-95)
Special tool • Crankshaft: (Page 1D-140)
(A): 09930M76311 • Crankshaft pulley
• Crankshaft sprocket key
8) After checking initial ignition timing, release ignition
timing fixation using scan tool.
 Ignition System: K12M 1H-19

9) With engine idling (throttle opening at default If check result is not as specified, check the following
position and vehicle stopped), check that ignition points.
timing is about 15° BTDC to 5° ATDC (Constant • ECM and its circuit: (Page 1A-254)
variation within a few degrees from 15° BTDC to 5°
• TP sensor: (Page 1C-23)
ATDC indicates no abnormality but proves operation
of ignition timing control system.) Also, check that • APP sensor: (Page 1C-25)
increasing engine speed advances ignition timing.

Specifications
Tightening Torque Specifications
AENJCA0A1827001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Spark plug 18 1.8 13.5 (Page 1H-17)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Fasteners Information” in Section 0A (Page 0A-6)

Special Tools and Equipment

Special Tool
AENJCA0A1828001
09930M76311 09930M77410
Timing light Plug gap gauge
(Page 1H-18) (Page 1H-17)

SUZUKI scan tool (Suzuki

SDT-II)
—
(Page 1H-18)
1I-1 Starting System:

Starting System
Engine

General Description
Cranking System Description
AENJCA0A1901001
Cranking Circuit
The cranking circuit consists of the battery, starting motor, starting motor control relay, ignition switch, ECM (M/T
model) or TCM (auto gear shift model) and related electrical wiring.

Starting Motor Circuit

In the circuit shown in “Cranking System Circuit Diagram” (Page 1I-2), the coil of the magnetic switch in starting motor
is energized when the engine starts. The resulting movement of the plunger and pinion drive lever causes the pinion to
engage with the flywheel, 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.

Starter Count Information (M/T Model)

ECM controls starting motor control relay to protect starting motor from damage. For more detail of starting motor
operation, refer to “Starting motor control system” under “Electronic Control System Description”.
• K10B model: (Page 1A-7)
• K12M model: (Page 1A-123)
• Bi-fuel CNG model: (Page 1A-276)
ECM counts information of starting motor control system, and the information can be displayed on scan tool. For more
detail of the information, refer to “Scan Tool Data” in Section 1A.
• K10B model: (Page 1A-30)
• K12M model: (Page 1A-153)
• Bi-fuel CNG model: (Page 1A-298)
When replacing starting motor, perform “Starter Count Information Clear (M/T Model)” (Page 1I-15) using SUZUKI
scan tool.
 Starting System: 1I-2

Schematic and Routing Diagram

Cranking System Circuit Diagram
AENJCA0A1902001

[D] 11

GRN C15-21

10
[C] 8
6 [E]
7 [A]: E01-11
RED GRN
[B]: E02-38

5 9
[A]: E01-24
GRN LT BLU
[B]: E02-43

WHT
3 YEL

1
M

[F] C15

10 9 8 7 6 5 4 3 2 1

23 22 21 20 19 18 17 16 15 14 13 12 11 [a]

28 27 26 25 24

C01 E01
[G]
[a]
10 9 8 7 6 5 4 3 2 1 9 8 7 6 5 4 3 2 1
65 64 63 62 61 20 19 18 17 16 15 14 13 12 11 57 56 55 18 17 16 15 14 13 12 11 10
70 69 68 67 66 30 29 28 27 26 25 24 23 22 21 60 59 58 27 26 25 24 23 22 21 20 19
75 74 73 72 71 40 39 38 37 36 35 34 33 32 31 63 62 61 36 35 34 33 32 31 30 29 28
80 79 78 77 76 50 49 48 47 46 45 44 43 42 41 66 65 64 45 44 43 42 41 40 39 38 37
60 59 58 57 56 55 54 53 52 51 54 53 52 51 50 49 48 47 46

C02 E02

[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

IJCA0A190001-03

[A]: K10B model [G]: ECM connector (view: [a]) 6. Ignition switch
[B]: K12M model 1. Battery 7. “ST SIG” fuse (in individual circuit fuse box No.2)
[C]: Without keyless entry system 2. Main fuse box 8. Starting motor control relay
[D]: Auto gear shift model 3. Starting motor 9. “ST SIG” fuse (in individual circuit fuse box No.1)
[E]: M/T model 4. “IGN2” fuse (Without keyless entry system) 10. ECM
or “KEY2” fuse (With keyless entry system)
[F]: TCM connector (view: [a]) 5. “ST” fuse 11. TCM (Auto gear shift model)
1I-3 Starting System:

Diagnostic Information and Procedures

Cranking System Symptom Diagnosis
AENJCA0A1904001
Possible symptoms of engine 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.
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
5) Check the following scan tool parameter.
• Starter Count Information (Overrun)
• Starter Count Information (Overcranking)
• Starter Count Information (Inching)
• Starter Count Information (Starter Relay Slow Response)
Condition Possible cause Correction / Reference Item
Starting motor not Malfunction of shift selector (auto gear Check shift selector. (Page 5D-103)
running (No operating shift model)
sound of magnetic Battery voltage is too low Check battery.
switch) • K10B model: (Page 1J-4)
• K12M model: (Page 1J-22)
Impossible charging due to deteriorated Replace battery.
battery • K10B model: (Page 1J-6)
• K12M model: (Page 1J-24)
Poor battery terminal connection Check terminal connection or replace battery.
• K10B model: (Page 1J-6)
• K12M model: (Page 1J-24)
Poor ground cable connection Tighten ground cable.
Blown fuse Replace fuse and check its circuit.
Faulty magnetic switch Check magnetic switch. (Page 1I-11)
Poor magnetic switch lead wire Check connector connection. (Page 1I-5)
connector connection
Open circuit in pull-in coil Check pull-in coil circuit. (Page 1I-11)
Defective brushes and/or brush springs Check brushes and brush springs. (Page 1I-
11)
Poor sliding of plunger and/or pinion Check plunger and pinion. (Page 1I-11)
Faulty starting motor control relay Check starting motor control relay. (Page 1I-
5)
Faulty ignition switch Check ignition switch. (Page 6B-12)
Malfunction of TCM (auto gear shift Check TCM. (Page 5D-43)
model)
Malfunction of ECM (M/T model) Check ECM.
• K10B model: (Page 1A-103)
• K12M model: (Page 1A-254)
• Bi-fuel CNG model: (Page 1A-347)
 Starting System: 1I-4

Condition Possible cause Correction / Reference Item

Starting motor not Battery voltage is too low Check battery.
running (Operating sound • K10B model: (Page 1J-4)
of magnetic switch heard)
• K12M model: (Page 1J-22)
Impossible charging due to deteriorated Replace battery.
battery • K10B model: (Page 1J-6)
• K12M model: (Page 1J-24)
Poor battery terminal connection Check terminal connection or replace battery.
• K10B model: (Page 1J-6)
• K12M model: (Page 1J-24)
Poor ground terminal connection Tighten ground cable.
Faulty magnetic switch Check magnetic switch. (Page 1I-11)
Defective brushes and/or brush springs Check brushes and brush springs. (Page 1I-
11)
Defective brush holder Check brush holder. (Page 1I-11)
Burnt commutator Check commutator. (Page 1I-11)
Short circuit between commutator and Check commutator. (Page 1I-11)
armature
Poor starting motor cable connection Check starting motor cable connection.
(Page 1I-5)
Open circuit between battery and Repair circuit.
magnetic switch
Obstructed crankshaft rotation Repair engine assembly.
Starting motor running Faulty magnetic switch Check magnetic switch. (Page 1I-11)
but too slow (small Low battery voltage Check battery.
torque) • K10B model: (Page 1J-4)
• K12M model: (Page 1J-22)
Impossible charging due to deteriorated Replace battery.
battery • K10B model: (Page 1J-6)
• K12M model: (Page 1J-24)
Poor battery terminal connection Check terminal connection or replace battery.
• K10B model: (Page 1J-6)
• K12M model: (Page 1J-24)
Short circuit between commutator and Check commutator. (Page 1I-11)
armature
Burnt commutator Check commutator. (Page 1I-11)
Defective brushes and/or brush springs Check brushes and brush springs. (Page 1I-
11)
Defective brush holder Check brush holder. (Page 1I-11)
Defective rear bracket bushing Check rear bracket bushing. (Page 1I-11)
Starting motor running, Worn pinion tip Replace overrunning clutch. (Page 1I-7)
but not cranking engine Poor sliding of overrunning clutch Check overrunning clutch. (Page 1I-11)
Slipping overrunning clutch Replace overrunning clutch. (Page 1I-7)
Worn teeth of ring gear Replace flywheel.
• K10B model: (Page 1D-33)
• K12M model: (Page 1D-108)
Noise Abnormally worn bushing Replace bushing. (Page 1I-7)
Worn teeth of pinion Replace overrunning clutch. (Page 1I-7)
Worn teeth of ring gear Replace flywheel.
• K10B model: (Page 1D-33)
• K12M model: (Page 1D-108)
1I-5 Starting System:

Condition Possible cause Correction / Reference Item

Starting motor does not Poor return of magnetic switch (plunger) Check magnetic switch. (Page 1I-11)
stop (cranking sound is Starting motor control relay stays on Check starting motor control relay. (Page 1I-
heard) 5)
Poor return of ignition switch from Check ignition switch. (Page 6B-12)
START position
Short circuit between battery (+) cable Repair circuit.
and magnetic switch lead wire
Starting motor does not Welded contact point in magnetic switch Check magnetic switch. (Page 1I-11)
stop (Free rotating sound Poor return of magnetic switch Check magnetic switch. (Page 1I-11)
is heard)

Repair Instructions
Starting Motor Control Relay Inspection
AENJCA0A1906001
Refer to “Control Relay Inspection” in Section 10B (Page 10B-51).

Starting Motor Removal and Installation

AENJCA0A1906002
Removal
1) Disconnect negative (–) cable at battery.
2) For M/T model, disconnect gear shift control cable from cable bracket.
• K10B model: (Page 5B-10)
• K12M model: (Page 5B-51)
For auto gear shift model, remove auto gear shift actuator unit. (Page 5D-104)
 Starting System: 1I-6

3) Remove starting motor mounting bolt (upper side) (1).

4) Disconnect magnetic switch lead wire (2) and starting motor cable (3) from starting motor.
5) Remove starting motor mounting bolt (lower side) (4).
6) Remove starting motor (5).

I9P60A191003-02

Installation
Reverse removal procedure noting the following points.
• Tighten starting motor cable nut (1) to specified torque.
Tightening torque
Starting motor cable nut (a): 11 N·m (1.1 kgf-m, 8.5 lbf-ft)

IFRA0A191003-01

• For M/T model, if starting motor is replaced with new one, perform “Starter Count Information Clear (M/T Model)”
(Page 1I-15) using SUZUKI scan tool.
1I-7 Starting System:

Starting Motor Components

AENJCA0A1906003

8
(c)
7
5

(a)

3 A

(b)

2 A

1
IJCA0A190003-01

1. Armature housing 5. Yoke : 7.0 Nm (0.71 kgf-m, 5.5 lbf-ft)

2. Shaft assembly 6. Armature : 6.0 Nm (0.61 kgf-m, 4.5 lbf-ft)
: Apply grease referring to “Starting Motor
Disassembly and Reassembly” (Page 1I-8).
3. Drive lever assembly 7. Brush assembly : 4.8 Nm (0.49 kgf-m, 3.5 lbf-ft)
: Apply grease referring to “Starting Motor
Disassembly and Reassembly” (Page 1I-8).
4. Magnetic switch 8. End housing : Do not reuse.
 Starting System: 1I-8

Starting Motor Disassembly and Reassembly 4) Remove bolts (1) and then separate yoke (2) from
AENJCA0A1906004 armature housing (3).
Disassembly
1) Before disassembly, draw matchmarks (1) and (2) as 3
shown in figure to assure proper alignment when
reassembled. 2

1
IJCA0A190007-01

5) Remove planetary gears (1) from shaft assembly (2).

2
IJCA0A190004-01 2

2) Remove nut (1) and disconnect lead wire (2) from

magnetic switch (3).

3
1

1
IJCA0A190008-02
1
6) Remove shaft assembly (1) together with drive lever
2
(2) from armature housing (3).

IJCA0A190005-01 2
3) Remove bolts (1) and pull out magnetic switch (2)
from starting motor assembly.

2
1
IJCA0A190009-01

IJCA0A190006-01
1I-9 Starting System:

7) Remove end housing (1) and brush assembly (2) Reassembly

from yoke (3). 1) Install armature (1) to yoke (2).
3 2

2
1
1

IJCA0A190012-01

2) Install brush springs (2) and brushes (1) to brush

IJCA0A190010-01 holder (3).
8) Remove armature (1) and internal gear (2) from yoke
(3).

3
1 1

3
1

2 2

IJCA0A190011-01

9) Remove brushes (1) and brush springs (2) from 1 1

I6JB01190015-01
brush holder (3).
3) Install brush assembly (1) to armature (2) while
pushing 4 brushes (3) outward.

1 1 1

2
2 2

1 1
IJCA0A190029-01 3

3
IJCA0A190013-01
 Starting System: 1I-10

4) Install end housing (1) to yoke (2) while aligning 9) Install yoke, armature, brush assembly and end
matchmarks (3) drawn before disassembly. housing (1) to armature housing (2).
10) Tighten end housing bolts (3) to specified torque.
Tightening torque
End housing bolt (a): 4.8 N·m (0.49 kgf-m, 3.5
lbf-ft)
1
2
2

1
3

IJCA0A190014-01

5) Apply grease to spline of gear shaft (1) and teeth of

internal gear (2).
6) Apply grease to planetary gears (3) and install
planetary gears to gear shaft.
“A”: Grease 99000–25011 (SUZUKI Super
Grease A) 3, (a)
IJCA0A190017-02

7) Install internal gear to gear shaft. 11) Install magnetic switch (1) to armature housing (2)
while aligning matchmarks (3) drawn before
disassembly as shown in figure.
2 12) Tighten new magnetic switch bolts (4) to specified
3 torque.
1
NOTICE
The magnetic switch bolts are precoated with
adhesive. If the bolts are reused, it may work
loose.
Replace the magnetic switch bolts with new
ones.

Tightening torque
“A”
IJCA0A190015-01
Magnetic switch bolt (a): 6.0 N·m (0.61 kgf-m,
8) Apply grease to drive lever (1) and insert shaft 4.5 lbf-ft)
assembly (2) into armature housing (3).
“A”: Grease 99000–25011 (SUZUKI Super 4, (a)
Grease A)
1

2
3
1

IJCA0A190018-01

“A”
IJCA0A190016-01
1I-11 Starting System:

13) Connect lead wire (1) to “M” terminal and tighten
lead wire nut (2) to specified torque.
Tightening torque
Lead wire nut (a): 7.0 N·m (0.71 kgf-m, 5.5 lbf-ft)
1) Perform pull-in test as follows.
a) Disconnect lead wire (2) from “M” terminal (3).
b) Connect battery to magnetic switch as shown in
figure.
c) Check that plunger and pinion move outward.
If plunger and pinion do not move, replace
magnetic switch.

3
2, (a)
1
1

2
IJCA0A190019-01

14) Check starting motor for operation. (Page 1I-11)

Starting Motor Inspection IJCA0A190020-01

AENJCA0A1906005
1. “S” terminal
Starting Motor Operation Check
2) Perform hold-in test as follows.
! CAUTION a) From the state of Step 1) with plunger and pinion
Sparks resulting from a short circuit between in “out” position, disconnect negative (–) lead
the positive (+) and negative (–) terminals from “M” terminal.
during connections to the battery may cause b) Check that plunger and pinion remain in “out”
burns. position.
Be careful not to short circuit the positive (+) If plunger and pinion return inward, replace
and negative (–) cables, and connect them magnetic switch.
only to the correct terminals.

NOTICE
If battery power is applied too long in any of
the following tests, coil of the magnetic
switch may burn.
Each test must be completed within 3 – 5
seconds to avoid burning of the coil.

IJCA0A190021-01
 Starting System: 1I-12

3) Perform plunger and pinion return test as follows. Plunger

a) From the state of Step 2) with plunger and pinion Check plunger for wear. Replace magnetic switch, if
in “out” position, disconnect negative (–) lead defective.
from starting motor body.
b) Check that plunger and pinion return inward.
If plunger and pinion do not return, replace
magnetic switch.

I7V20A192005-02

Magnetic Switch
Check that plunger quickly returns to its original position
when plunger is pushed in with a finger and released. If
check result is not OK, replace magnetic switch.

IJCA0A190022-01

4) Perform no-load performance test as follows.

a) Fix starting motor with vice or the like.
b) Connect battery and ammeter to starting motor
as shown in figure.
c) Check that starting motor rotates smoothly and
steadily with pinion moving out. I7V20A192006-01

d) Check that ammeter indicates specified current.

If check result is not as specified, repair or
replace starting motor.
Specified current (No-load performance test)
70 A MAX. at 11.7 V
Pull-in coil open circuit test
Check for continuity between magnetic switch “S”
terminal (1) and “M” terminal (2). If there is no continuity,
replace magnetic switch.

IJCA0A190023-01 IJCA0A190024-01
1I-13 Starting System:

Hold-in coil open circuit test Spring

Check for continuity between magnetic switch “S”
terminal (1) and coil case. If there is no continuity,
replace magnetic switch.
1
Check brush springs for wear, damage or other
abnormal conditions. Replace brush assembly if
defective.
Brush spring tension
Standard: 10.0 – 11.0 N (1.0 – 1.1 kgf, 2.2 – 2.5 lbf)
Limit: 5.8 N (0.59 kgf, 1.30 lbf)

Brush Holder
• Check brush holder for brush movement problems,
distortion, and dirt on sliding surface.
Clean or correct brush holder if defective.
• Check for continuity between insulated brush (positive
IJCA0A190025-01 (+) side) and grounded brush (negative (–) side).
If there is continuity, replace brush assembly.
End Housing Bushing
Check end housing bushing for wear or damage.
Replace end housing if defective.

I4RS0A190004-01

Armature
• Check commutator for dirt or burn. Correct
IJCA0A190026-01
commutator with sandpaper or lathe, if defective.
Brush
• Check brushes for wear.
Measure length of each brush. If length is less than
the limit, replace brush assembly.
Brush length
Standard: 10.9 mm (0.42 in.)
Limit: 4.35 mm (0.17 in.)

I7RW01190005-02

1. Sandpaper of #300 – 400

I2RH01190013-01

• After installing brushes into their holders, check that

movement of brushes is smooth.
 Starting System: 1I-14

• Check commutator for uneven wear with armature (1) • Check commutator (1) for insulator (2) depth. Correct
supported on V-blocks (2) using dial gauge (4). If dial insulator depth if it is smaller than limit.
gauge deflection exceeds the limit, repair commutator
Commutator insulator depth “a”
or replace armature.
Standard: 0.4 – 0.6 mm (0.015 – 0.023 in.)
Commutator out of round Limit: 0.1 mm (0.004 in.)
Standard: 0.025 mm (0.00098 in.) or less
Limit: 0.1 mm (0.004 in.)

I2RH01190016-01

3. Magnetic stand

• Check commutator for wear and measure diameter of

commutator. If diameter of commutator is lower than I3RH0A190005-01
the limit, replace armature.
[A]: Correct [B]: Incorrect
Commutator outside diameter
Standard: 26 mm (1.02 in.) • Check insulation between commutator and armature
Limit: 25 mm (0.98 in.) core. If there is continuity, replace armature.

I2RH01190019-01
I2RH01190017-01
• Check for continuity between segments. If there is no
continuity at any test point, replace armature.

I2RH01190020-01
1I-15 Starting System:

Gear Armature Housing Bushing

Check internal gear and planetary gears for wear, Check bushing for wear and damage. Replace armature
damage or other abnormal conditions. Replace shaft housing if defective.
assembly if defective.

I2RH01190024-01

I2RH01190021-01
Starter Count Information Clear (M/T Model)
Pinion and Overrunning Clutch
• Check pinion for wear, damage or other abnormal
conditions.
• Check that clutch locks when turned in normal rotation
direction and rotates freely when turned in reverse
direction. Replace shaft assembly if defective.
AENJCA0A1906006
1) With ignition “OFF” and connect SUZUKI scan tool to
DLC.
Special tool
: SUZUKI scan tool (Suzuki SDT-II)
2) Set ignition “ON”, select “Engine” in “Active Test”
mode on SUZUKI scan tool and then execute
“Starter Count Information Clear”.
3) Set ignition “OFF” and disconnect SUZUKI scan tool
from DLC.

IJCA0A190027-01

• Check spline teeth for wear or damage. If check result

is not OK, replace shaft assembly.
• Check pinion for smooth movement.

IJCA0A190028-01
 Starting System: 1I-16

Specifications
Cranking System Specifications
AENJCA0A1907001
Voltage 12 V
Output 1.0 kW
Rating 30 seconds
Direction of rotation Clockwise as viewed from pinion side
Number of pinion teeth 8
Performance Voltage Current Torque Revolution speed
No-load characteristic 11.7 V 70 A MAX — 3,200 rpm MIN
6.0 Nm (0.61 kgf-m,
Loaded characteristic 10.3 V 290 A MAX 2,000 rpm MIN
4.5 lbf-ft) MIN
At around 20 °C
12 Nm (1.2 kgf-m, 9.0
(68 °F) Locked characteristic 8.9 V 550 A MAX 950 rpm MIN
lbf-ft) MIN
Magnetic switch
8 V MIN
operating voltage

Tightening Torque Specifications

AENJCA0A1907002
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Starting motor cable nut 11 1.1 8.5 (Page 1I-6)
End housing bolt 4.8 0.49 3.5 (Page 1I-10)
Magnetic switch bolt 6.0 0.61 4.5 (Page 1I-10)
Lead wire nut 7.0 0.71 5.5 (Page 1I-11)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Starting Motor Components” (Page 1I-7)
“Fasteners Information” in Section 0A (Page 0A-6)

Special Tools and Equipment

Recommended Service Material
AENJCA0A1908001
Material SUZUKI recommended product or Specification Note
Grease SUZUKI Super Grease A P/No.: 99000–25011 (Page 1I-10) / (Page 1I-
10)

NOTE
Required service material(s) is also described in:
“Starting Motor Components” (Page 1I-7)

Special Tool
AENJCA0A1908002
SUZUKI scan tool (Suzuki
SDT-II)
—
(Page 1I-15)
1J-1 Charging System: K10B and Bi-Fuel CNG
Charging System
Engine
K10B and Bi-Fuel CNG
Precautions
Precautions for Handling Battery
AENJCA0A1A10001
! 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 (electrolyte) 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
NOTICE
• Battery electrolyte lowers the level during
normal use and continuous use of battery
with the electrolyte under the lower level
will extremely deteriorate the battery.
For battery with removable filler plugs (1)
or vent caps and visible level lines, always
take the following precautions.
– Do not continue to use the battery with
the electrolyte under the lower level (2).
– Add distilled water up to the upper level
(3) if the level is below the midpoint of
upper and lower levels.
– Wash away spilled electrolyte after
fitting filler plugs or vent caps.
• Overfilled electrolyte exceeding the upper
level may overspill while the vehicle is
running and it may cause damage to the
parts near the battery.
Add distilled water up to the upper level.
IJCA0A1A1036-01
periodical attentions.
• Keep battery carrier clean.
• Prevent rust formation on the terminal posts.
• Even if the battery is MF (maintenance-free) type,
electrolyte decreases slowly compared with
conventional one.
• Keep electrolyte up to upper level uniformly in all
cells, if filler plugs or vent caps are removable.
• If battery does not have level lines but filler plugs
or vent caps are removable, add distilled water
until all electrodes are immersed uniformly.

• Some MF batteries are completely sealed except
small vent holes and adding distilled water is not
possible.
• 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.
– The battery discharges even if it is not used,
while vehicle is stored. Battery electrolyte can
freeze and battery case can crack in cold
ambient condition if the battery is not properly
charged.
General Description
Battery Description
AENJCA0A1A11001
The battery has three major functions in the electrical
system.
• It is a source of electrical energy for cranking engine.
• It acts as a voltage stabilizer for the electrical system.
• It can, for a limited time, provide energy when the
electrical load exceeds the output of generator.
Carrier and Hold-Down
The battery carrier should be in good condition so that it
supports the battery securely and keeps it level. Before
installing battery, check that the battery carrier and hold-
down clamp are clean and free from corrosion and that
there is no foreign material in the carrier.
To prevent battery from shaking in its carrier, the hold-
down battery band nuts should be tightened enough but
not over-tightened.
Generator Description
The generator is 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 more detail of LIN communication, refer to
“Communication System Description” in Section 10H (Page 10H-1).
The generator features are as follows:
Charging System: K10B and Bi-Fuel CNG 1J-2
2) Keep the battery cable connections clean.
The cable connections, particularly at the positive (+)
terminal post, tend to become corrode. The
corrosion or rust on the mating faces of conductors
resists the flow of current.
Clean the terminals and fittings periodically to
ensure good metal-to-metal contact.
3) Periodically check the state of charge of battery. For
battery with filler plugs or vent caps 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-4)
Electrolyte Freezing
The freezing point of electrolyte depends on its specific
gravity. Since freezing may ruin a battery, it should be
protected against freezing by keeping it in a fully
charged condition. If the battery freezes accidentally, it
should not be charged until it will unfreeze.
Sulfation
If battery is left for a long period in discharged condition,
the lead sulfate becomes converted into a hard,
crystalline substance, which will not easily turn back to
the active material again during the subsequent
recharging. “Sulfation” means the result as well as the
process of that reaction. Such a battery can be revived
by very slow charging and may be restored to usable
condition but its capacity will be lower than before.
AENJCA0A1A11002
1J-3 Charging System: K10B and Bi-Fuel CNG

• Solid state regulator is mounted inside the generator.

• All regulator components are enclosed into a solid mold.
• The IC regulator attached to the brush holder.
• 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
2

LIN
6

IJCA0A1A1001-02

1. Generator 4. Diode 7. Battery

2. IC regulator 5. Field coil (rotor coil) 8. Electric load
3. Stator coil 6. ECM

10
6
3 9 11
5
8

12 7

IJCA0A1A1002-01

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. Regulator assembly 12. Drive end frame
 Charging System: K10B and Bi-Fuel CNG 1J-4

Diagnostic Information and Procedures

Battery Inspection
AENJCA0A1A14001
Common Causes of Failure
There are the following causes for the fall of battery function.
• Accessories left on overnight or for an extended period without the generator operation.
• Frequent driving at low speed for short periods.
• Electrical load exceeds generator output, particularly due to additional fitting of aftermarket equipment.
• Defects in charging system. (Page 1J-4)
• Failure to fix terminals or making hold-down clamps too loose or too tight.
• Mechanical problems in electrical system such as short-circuit or pinched wires.
• Deterioration of battery due to long-term use.
• Deterioration of battery due to long-term storage.

Visual Inspection
Check for visible damage, such as a cracked or broken case or cover, which may lead to loss of electrolyte. If visible
damage is noted, replace battery. Determine cause of damage and make corrections if necessary.

Battery Electrolyte Inspection

Check electrolyte level whether it is between upper and lower lines.
Add distilled water up to upper level uniformly in all cells if the level is below the midpoint of upper and lower levels.

Generator Symptom Diagnosis

AENJCA0A1A14002
Trouble in charging system will show up as one or more of the following conditions.

Charge Warning Light Operation

Condition Possible cause Correction / Reference Item
Charge warning light Blown fuse Replace fuse.
does not light with Faulty combination meter Replace combination meter. (Page 9C-25)
ignition “ON” and engine Faulty ECM Check ECM.
off • Petrol: (Page 1A-103)
• Bi-fuel CNG: (Page 1A-347)
Faulty CAN communication line Repair or replace CAN communication line.
(Page 10H-7)
Faulty wiring Repair wiring.
Faulty IC regulator or field coil Repair or replace generator. (Page 1J-12)
Charge warning light Loose or worn drive belt Adjust or replace drive belt. (Page 1J-7)
does not go out with Faulty combination meter Replace combination meter. (Page 9C-25)
engine running (battery Faulty ECM Check ECM.
requires frequent • Petrol: (Page 1A-103)
recharging)
• Bi-fuel CNG: (Page 1A-347)
Faulty IC regulator or generator Repair or replace generator. (Page 1J-12)
Faulty wiring Repair wiring.

Battery Charge Failure

Condition
Undercharged battery
Overcharged battery
Possible cause Correction / Reference Item
Loose or worn drive belt Adjust or replace drive belt. (Page 1J-7)
Loose or corroded battery terminal Tighten battery terminal or replace battery.
(Page 1J-6)
Faulty rectifier, rotor and/or IC regulator Repair or replace generator. (Page 1J-12)
Faulty IC regulator Repair or replace generator. (Page 1J-12)
1J-5 Charging System: K10B and Bi-Fuel CNG

Noise
Condition Possible cause Correction / Reference Item
Noisy generator Loose mounting bolts Tighten mounting bolts. (Page 1J-10)
Dirty, worn and/or faulty bearings Repair or replace generator. (Page 1J-12)
Faulty rotor, diode and/or stator Repair or replace generator. (Page 1J-12)

Generator Test 2) Turn off all electrical loads (5).

AENJCA0A1A14003
This condition, as evidenced by slow cranking or low 3) Connect voltmeter (3) and ammeter (2) as shown in
specific gravity, can be caused by one or more of the figure.
following conditions even though warning light operates 4) Start engine and warm it up to normal operating
normally. temperature.
• Check that undercharged condition has not been
caused by accessories being left on for an extended
period.
• Check generator drive belt for wear and tension.
(Page 1J-7)
• If battery defect is suspected, refer to “Battery
Description”: K10B and Bi-Fuel CNG (Page 1J-2).
• Check wiring for defects. Check all connections for
tightness and cleanliness, battery cable connections
at battery, generator, starting motor and ignition
I9P60A1A1018-01
ground cable.
1. Generator 6. Switch
No-Load Check 4. Battery 7. “B” terminal

NOTE 5) Run engine around 2,000 rpm and read meters.

Use fully charged battery. • If voltage is higher than standard value, check
ground circuit of brushes. (Page 1J-16)
1) Check for DTC. If brushes are not grounded, replace brush holder
If there is any DTC, perform troubleshooting for assembly.
applicable DTC and then clear DTC. • If voltage is lower than standard value, check
• DTC check rotor, stator and rectifier. (Page 1J-16)
– Petrol: (Page 1A-22) Specification (No-load check)
– Bi-fuel CNG: (Page 1A-293) Current: Approx. 10 A
• Troubleshooting Regulated voltage: 10.3 – 16.3 V (at 25 °C, 77
– Petrol: (Page 1A-24) °F)
– Bi-fuel CNG: (Page 1A-295)
Load Check
• DTC clearance
– Petrol: (Page 1A-23) NOTE
– Bi-fuel CNG: (Page 1A-294) Use fully charged battery.

1) Connect ammeter in the same way as “No-Load

Check”: K10B and Bi-Fuel CNG (Page 1J-5).
2) Run engine around 2,000 rpm and turn on the
following electrical loads.
• Headlight (high beam)
• Blower motor (maximum speed)
3) Read ammeter.
If meter reading is lower than specified value, repair
or replace generator.
Specification (Load check)
Current: 20 A
 Charging System: K10B and Bi-Fuel CNG 1J-6

Repair Instructions
Jump-Starting in Case of Emergency With Charging Equipment
AENJCA0A1A16001
With Booster Battery NOTICE
Both booster and discharged battery should be treated
Using 24-volt charging equipment to jump-
carefully when using jumper cables. Follow the
start the engine will cause serious damage to
procedure outlined as follows, being careful not to cause
electric and electronic system components.
sparks.
Use only 12-volt charging equipment to
! WARNING jump-start the engine.

Failure to take proper precautions when jump

starting a vehicle may result in serious Battery Removal and Installation
AENJCA0A1A16002
personal injury and/or damage to electronic Removal
components of either the vehicle with a dead 1) Disconnect negative (–) cable (1) at battery.
battery or the vehicle used for jump starting.
2) Disconnect positive (+) cable (2) at battery.
• Never expose the battery to open flame or
electric spark. A battery generates highly 3) Remove battery band (3).
flammable and explosive hydrogen gas. 4) Remove battery (4) and battery cover (5).
• Remove rings, watches and other jewelry.
Wear approved eye protector. 1
3
• Battery fluid (electrolyte) is a corrosive
acid. Do not allow it to contact eyes, skin,
fabrics or painted surfaces of the vehicle. If 4
the fluid contacts any of them, immediately
and thoroughly flush the affected area with
water.
• To avoid a danger of short circuit, do not 5
2
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. IJCA0A1A1003-01

5) Disconnect harness clamps from battery tray, if

1) For M/T model, place gear shift control lever in necessary.
“Neutral”.
6) Remove battery tray (1), if necessary.
For auto gear shift model, place shift selector in “N”.
2) Apply parking brake.
3) Set ignition “OFF”. 1

4) Turn off lights and all other electrical loads.

5) 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).
6) Attach one end of the remaining negative (–) cable to
negative (–) terminal of booster battery, and other
end to solid engine ground (such as exhaust
manifold) at least 45 cm (18 in.) away from battery of IJCA0A1A1004-01

vehicle being started.

7) Start engine of vehicle with booster battery and turn
off its electrical loads. Then start engine of vehicle
with discharged battery.
8) Disconnect jumper cables in exact reverse order.
1J-7 Charging System: K10B and Bi-Fuel CNG

Installation
Reverse removal procedure noting the following points. 1
• Tighten new battery tray bolts (1) and new nut (2) to
specified torque.

NOTICE
The battery tray bolts and nut are pre-coated.
If these bolts and nut are reused, they may 4, (b) 2
work loose.
Replace the battery tray bolts and nut with
new ones whenever they are removed.

Tightening torque 2
Battery tray bolt (a): 15 N·m (1.5 kgf-m, 11.0 lbf-ft) 3, (a)
Battery tray nut (b): 15 N·m (1.5 kgf-m, 11.0 lbf-ft)

IJCA0A1A1006-03

2, (b)
• Initialize electrical devices if necessary.

Water Pump / Generator Drive Belt Tension

Inspection and Adjustment
AENJCA0A1A16003
1, (a)
1) Check water pump / generator drive belt for cracks,
cuts, deformation, wear and cleanliness. If any
defect is found, replace it. (Page 1J-8)
2) When engine is cool, turn crankshaft 720° to
IJCA0A1A1005-01 stabilize water pump / generator drive belt and check
• Face notch (1) of battery band inside. the belt for tension.
• Tighten battery band nuts (2) securely. • Using sonic tension meter (Gates 508C or
• Tighten positive (+) cable nut (3) and negative (–) equivalent):
cable nut (4) to specified torque, and then fix positive a. Enter the input data following instructions in
(+) cable end cap. the tension meter manual.
NOTE Recommended belt tension meter
specification
Fix cable end at fully fitted position to battery
MASS: 75.4 g/m
terminal.
WIDTH: 1.0 mm/R
Tightening torque SPAN: 182 mm
Positive (+) cable nut (a): 5.0 N·m (0.51 kgf-m, 4.0 b. Flip belt (1) at span to vibrate the belt and
lbf-ft) measure the belt tension.
Negative (–) cable nut (b): 5.0 N·m (0.51 kgf-m, If belt tension is not as specified, go to next
4.0 lbf-ft) steps.
Water pump / generator drive belt tension
“a”
Existing belt: 525 ± 50N (53.5 ± 5.1 kgf,
118.0 ± 11.2 lbf)
New belt: 825 ± 100N (84.1 ± 10.2 kgf, 185.5
± 22.5 lbf)
 Charging System: K10B and Bi-Fuel CNG 1J-8

• Without using sonic tension meter (Pushing 6) If check result is not as specified, repeat Step 3) – 5)
belt span): again.
a. Push belt (2) at span with finger force of 100 N 7) After adjustment, tighten generator belt adjusting
(10.2 kgf, 22.5 lbf) to bend the belt and bolt (1) to specified torque.
measure the bending value.
Tightening torque
If belt tension is not as specified, go to next
Generator belt adjusting bolt (a): 5.0 N·m (0.51
steps.
kgf-m, 4.0 lbf-ft)
Water pump / generator drive belt tension
“b”
Existing belt: 5.0 – 5.8 mm (0.20 – 0.22 in.)
as deflection / 100 N (10.2 kgf, 22.5 lbf)
between water pump pulley and generator 1, (a)
pulley
New belt: 3.3 – 4.1 mm (0.13 – 0.16 in.) as
deflection / 100 N (10.2 kgf, 22.5 lbf)
between water pump pulley and generator
pulley

IJCA0A1A1037-01

1, “a” Water Pump / Generator Drive Belt Removal and

“b”
Installation
AENJCA0A1A16004
Removal
1) Disconnect negative (–) cable at battery.
2) Hoist vehicle and remove right side splash cover.
3) Remove compressor drive belt. (Page 7B-51)
4) Loosen tensioner pulley bolt (1) and generator belt
IJCA0A1A1007-01 adjusting bolt (2).
3) Loosen tensioner pulley bolt (1), and then adjust belt 5) Remove water pump / generator drive belt (3).
tension to specification described at Step 3) by
loosening / tightening generator belt adjusting bolt
(2).
4) Tighten tensioner pulley bolt to specified torque. 3

Tightening torque
Tensioner pulley bolt (a): 55 N·m (5.6 kgf-m, 40.5 2
lbf-ft)
1

2 IJCA0A1A1009-01

1, (a)

IJCA0A1A1008-01

5) Check belt tension for specification after turning

crankshaft two revolutions clockwise.
1J-9 Charging System: K10B and Bi-Fuel CNG

Installation 4) Remove generator belt adjusting bolt (1).

1) Install water pump / generator drive belt (1) to water 5) Remove tensioner pulley bolt (2), and then remove
pump pulley (2), crankshaft pulley (3), belt tensioner belt tensioner pulley (3) and generator belt adjuster
pulley (4) and generator pulley (5). (4).

NOTE
Check that drive belt is installed in grooves 1
of each pulley correctly.

2) Adjust belt tension. (Page 1J-7)

2 3

4
2

IGJA0A1A1010-01

Installation
5
1) Install belt tensioner pulley (1) to belt tensioner arm
3
4 (2) so that cutout (3) in belt tensioner pulley is
IJCA0A1A1010-01 aligned with slot (4) in belt tensioner arm.
3) Install compressor drive belt. (Page 7B-51)
4) Install right side splash cover.
1
5) Connect negative (–) cable at battery.

Belt Tensioner Arm and Belt Tensioner Pulley

3
Removal and Installation
AENJCA0A1A16011
Removal
1) Remove right side splash cover. 2

2) Remove water pump / generator drive belt. (Page

1J-8)
3) Remove belt tensioner arm with belt tensioner pulley
(1). 4

IJCA0A1A1012-01

2) Install generator belt adjuster (1) and tighten

tensioner pulley bolt (2) temporarily.
3) Install generator belt adjusting bolt (3).

IJCA0A1A1011-01

IGJA0A1A1012-01
 Charging System: K10B and Bi-Fuel CNG 1J-10

4) Install belt tensioner arm with belt tensioner pulley as Installation

shown in figure. Reverse removal procedure noting the following points.
5) Tighten belt tensioner arm bolts (1) to specified • Tighten generator upper bolt (1) and lower bolt (2) as
torque. follows.
Tightening torque a. Put generator (3) on cylinder block and tighten
Belt tensioner arm bolt (a): 25 N·m (2.5 kgf-m, generator upper bolt and lower bolt temporarily.
18.5 lbf-ft) b. Tighten generator lower bolt to 30 Nm (3.1 kgf-m,
22.5 lbf-ft) and check that bushing (4) in generator
is in contact with generator bracket, and then
loosen the bolt.
c. Tighten generator upper bolt and lower bolt to
specified torque.
Tightening torque
Generator upper bolt (a): 30 N·m (3.1 kgf-m,
22.5 lbf-ft)
Generator lower bolt (b): 48 N·m (4.9 kgf-m,
35.5 lbf-ft)
1, (a) • Insert lugs (5) of “B” terminal wire (6) into groove (7)
1, (a)
and then tighten “B” terminal nut (8) to specified
IJCA0A1A1013-01
torque.
6) Install water pump / generator drive belt. (Page 1J-
8) Tightening torque
7) Install right side splash cover. “B” terminal nut (c): 7.9 N·m (0.81 kgf-m, 6.0 lbf-
ft)
Generator Removal and Installation
AENJCA0A1A16005 8, (c)
Removal 5
1) Disconnect negative (–) cable at battery.
2) Remove water pump / generator drive belt. (Page 7 1, (a)
1J-8)
6
3) Remove belt tensioner arm. (Page 1J-9)
4) Remove nut (1) and disconnect “B” terminal wire (3),
and then disconnect generator connector (4) from
generator (2).
5) Remove generator upper bolt (5) and lower bolt (6)
and then remove generator.

5 3
1 2, (b)
3

4
4 IJCA0A1A1015-01

2
6

IJCA0A1A1014-01
1J-11 Charging System: K10B and Bi-Fuel CNG

Generator Arm and Generator Bracket Removal Installation

and Installation 1) Install generator bracket and then tighten generator
AENJCA0A1A16006
bracket bolts in numerical order (“1” – “4”) evenly
Removal
and gradually to specified torque.
1) Remove water pump / generator drive belt. (Page
1J-8) Tightening torque
2) Remove water pump pulley. (Page 1F-16) Generator bracket bolt* (a): 25 N·m (2.5 kgf-m,
18.5 lbf-ft)
3) Remove generator arm (1).

“3”, (a)
1 “1”, (a)

“4”, (a) “2”, (a)

IJHA0A1A0016-01

2) Install generator arm (1) and then tighten water

IJCA0A1A1016-01 pump nut (2) to specified torque.
4) Remove generator. (Page 1J-10)
Tightening torque
5) Remove generator bracket (1). Water pump nut (a): 25 N·m (2.5 kgf-m, 18.5 lbf-
ft)

1
1
2, (a)

IJHA0A1A0015-01

IJCA0A1A1017-01

3) Install generator. (Page 1J-10)

4) Install water pump pulley. (Page 1F-16)
5) Install water pump / generator drive belt. (Page 1J-
8)

Belt Tensioner Pulley Inspection

AENJCA0A1A16007
Check belt tensioner pulley (1) for wear and smoothly
rotation. If check result is not OK, replace belt tensioner
pulley.

1
IGJA0A1A1022-01
 Charging System: K10B and Bi-Fuel CNG 1J-12

Generator Components
AENJCA0A1A16008

(b)

1 (a)

5
6

9
13 (d)
7

10 12 (e) (e)

(c)
11
IJCA0A1A1018-01

1. Pulley nut 7. Rotor 13. Regulator assembly screw No.2

2. Pulley 8. Stator assembly : 85 Nm (8.7 kgf-m, 63.0 lbf-ft)
3. Drive end frame 9. Regulator assembly : 3.3 Nm (0.34 kgf-m, 2.5 lbf-ft)
4. Bearing 10. Bush cover : 5.5 Nm (0.56 kgf-m, 4.0 lbf-ft)
5. Bearing retainer 11. Rear end cover : 1.8 Nm (0.18 kgf-m, 1.5 lbf-ft)
6. Collar 12. Regulator assembly screw No.1 : 3.5 Nm (0.36 kgf-m, 2.5 lbf-ft)

Generator Disassembly and Reassembly

AENJCA0A1A16009
1
Disassembly
1) To facilitate reinstallation, provide matchmarks (1) on
drive end frame (2) and stator assembly (3) as
shown.

3
IJCA0A1A1019-01
1J-13 Charging System: K10B and Bi-Fuel CNG

2) Remove rear end cover (1).

IFRA0A1A1023-01
IJCA0A1A1020-01
6) Hold shaft using hexagonal wrench (1), remove
3) Remove brush cover (1) and regulator assembly (2) pulley nut, and then pull out pulley (2).
from stator assembly.

2
1

IJCA0A1A1023-01

7) Remove rotor (1) from drive end frame (2) by tapping

shaft (3) lightly using plastic hammer.

IJCA0A1A1021-01

4) Remove stator assembly bolts (1).

2
1
IFRA0A1A1024-01
1
8) Remove collar (1) from rotor, if necessary.

IJCA0A1A1022-01

5) With lever inserted between stator assembly (1) and

drive end frame (2), separate generator into drive
end frame and stator assembly.
IJCA0A1A1024-01
 Charging System: K10B and Bi-Fuel CNG 1J-14

9) Remove bearing retainer screws (1), if necessary. Reassembly

1) Using special tool, install new bearing to drive end
1
frame. Check the bearing for smooth rotation, if
removed.

NOTICE
When installing the bearing, the bearing and
the drive end frame may become damaged if
pressing any section other than the outer
race.
Press the outer race of the bearing when
1
installing it.
IJCA0A1A1025-01

10) Remove bearing retainer (1), and then remove Special tool
bearing (2) from drive end frame (3) using special (A): 09913M76010
tool, if necessary.

NOTE
If necessary, when removing bearing heat
drive end frame to a temperature of 80 – 100 (A)
°C (176 – 212 °F) so that it will not be
distorted.

Special tool
(A): 09925M96710

2
ICV00P1A0021-01

2) Install bearing retainer (1) to drive end frame (2), if

removed.

2
IJCA0A1A1026-01

IJCA0A1A1027-01

3) Tighten bearing retainer screws (1) to specified

torque.
(A)
Tightening torque
Bearing retainer screw (a): 3.3 N·m (0.34 kgf-m,
2.5 lbf-ft)

1, (a)
ICV00P1A0018-01

1, (a)
IJCA0A1A1028-01
1J-15 Charging System: K10B and Bi-Fuel CNG

4) Install collar (1) to rotor, if removed. 7) Install stator assembly (1) to drive end frame (2)
while aligning matchmarks (3) drawn before
disassembly.
8) Tighten rear end frame bolts to specified torque.
Tightening torque
1 Rear end frame bolt (a): 5.5 N·m (0.56 kgf-m, 4.0
lbf-ft)

IJCA0A1A1024-01

5) Install rotor (1) to drive end frame (2).

1 (a)

IJCA0A1A1031-01
2
9) Install regulator assembly (1) using the following
procedure:
a) Push brushes (2) in arrow direction.
b) Install regulator assembly to stator assembly,
IJCA0A1A1029-01 and then tighten regulator assembly screws No.
6) Install pulley (1), hold shaft using hexagonal wrench 1 (3) and No. 2 (4) to specified torque.
(2), and then tighten pulley nut (3) to specified Tightening torque
torque. Regulator assembly screw No. 1 (a): 3.5 N·m
Tightening torque (0.36 kgf-m, 2.5 lbf-ft)
Pulley nut (a): 85 N·m (8.7 kgf-m, 63.0 lbf-ft) Regulator assembly screw No. 2 (b): 1.8 N·m
(0.18 kgf-m, 1.5 lbf-ft)
c) Install brush cover (5).

2
3, (a)

1 1
1
4, (b)

IJCA0A1A1030-01
5

3, (a)

IJCA0A1A1032-01
 Charging System: K10B and Bi-Fuel CNG 1J-16

10) Install rear end cover (1) to stator assembly, and 2) Using ohmmeter (1), check that there is no continuity
then tighten rear end cover bolts (2) to specified between slip ring (2) and rotor core (3). If there is
torque. continuity, replace rotor assembly.
Tightening torque
Rear end cover bolt (a): 3.5 N·m (0.36 kgf-m, 2.5
lbf-ft)

2, (a)

ICC50A1A0012-01

3) Check slip rings and blades for damage. If any

abnormality is found, replace rotor assembly.
1 4) Check slip rings for roughness or scoring. If rough or
scored, replace rotor.
Using a vernier caliper, measure the slip ring
diameter. If the diameter is less than service limit,
IJCA0A1A1033-01 replace the rotor.
Slip ring diameter
Generator Inspection Standard: 14.0 mm (0.551 in.)
AENJCA0A1A16010
Limit: 13.8 mm (0.543 in.)
Rotor
1) Using ohmmeter (1), check for continuity between
slip rings (2) of rotor. If there is no continuity, replace
rotor assembly.
Standard resistance between slip rings of rotor
2.20 Ω

IYSQ011A0044-01

Bearing
Check bearing for smooth rotation.
If any abnormality is found, replace rotor assembly.

NOTE
ICC50A1A0011-01 Bearing (1) shown in figure is combined with
rotor (2) and check it as it is.

2 1

ICV00P1A0016-01
1J-17 Charging System: K10B and Bi-Fuel CNG

Stator Brush
• Using ohmmeter, check continuity between each of Check each brush for wear by measuring its length as
stator coil terminals (A1 / A2 / A3). If there is no shown. If brush has worn down to service limit, replace
continuity, replace stator assembly. regulator assembly.
• Using ohmmeter, check continuity between each of Exposed brush length “a”
stator coil terminals (A1 / A2 / A3) and corresponding Standard: 15.5 mm (0.61 in.)
terminals (A4 / A5 / A6). If there is no continuity, Limit: 7.5 mm (0.30 in.)
replace stator assembly.
• Using diode range of circuit tester, check continuity
between “B” terminal (1) and stator coil terminals (A4 / “a”

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
assembly.

NOTE IJCA0A1A1035-01

For diode test, refer to the instruction manual

of circuit tester. Rectifier

NOTE
2 Rectifiers are combined with stator assembly
and inspection for individual rectifier is not
possible.
1

A4 A3
A2
A1
A5 A6

A1 A4 1
A5

A2

LIN
A3 A6

E
2
IJCA0A1A1034-01

Specifications
Charging System Specifications
AENJCA0A1A17001
Battery
Battery specification
: 34B19L (33AH/20HR, 27AH 5HR) 12V

Generator
Type 70 A type
Rated voltage 12 V
 Charging System: K10B and Bi-Fuel CNG 1J-18

Nominal output 70 A
Permissible max. speed 18,000 rpm
No-load speed 1,000 – 1,200 rpm
Regulated voltage 10.6 – 16.0 V at 25 °C (77 °F)
Permissible ambient temperature –30 to 120 °C (–22 to 248 °F)
Polarity Negative ground
Rotation Clockwise viewed from pulley side

Tightening Torque Specifications

AENJCA0A1A17002
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
Battery tray bolt 15 1.5 11.0 (Page 1J-7)
Battery tray nut 15 1.5 11.0 (Page 1J-7)
Positive (+) cable nut 5.0 0.51 4.0 (Page 1J-7)
Negative (–) cable nut 5.0 0.51 4.0 (Page 1J-7)
Tensioner pulley bolt 55 5.6 40.5 (Page 1J-8)
Generator belt adjusting bolt 5.0 0.51 4.0 (Page 1J-8)
Belt tensioner arm bolt 25 2.5 18.5 (Page 1J-10)
Generator upper bolt 30 3.1 22.5 (Page 1J-10)
Generator lower bolt 48 4.9 35.5 (Page 1J-10)
“B” terminal nut 7.9 0.81 6.0 (Page 1J-10)
Generator bracket bolt* 25 2.5 18.5 (Page 1J-11)
Water pump nut 25 2.5 18.5 (Page 1J-11)
Bearing retainer screw 3.3 0.34 2.5 (Page 1J-14)
Pulley nut 85 8.7 63.0 (Page 1J-15)
Rear end frame bolt 5.5 0.56 4.0 (Page 1J-15)
Regulator assembly screw No. 1 3.5 0.36 2.5 (Page 1J-15)
Regulator assembly screw No. 2 1.8 0.18 1.5 (Page 1J-15)
Rear end cover bolt 3.5 0.36 2.5 (Page 1J-16)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Generator Components”: K10B and Bi-Fuel CNG (Page 1J-12)
“Fasteners Information” in Section 0A (Page 0A-6)

Special Tools and Equipment

Special Tool
AENJCA0A1A18001
09913M76010 09925M96710
Bearing installer Bearing installer
(Page 1J-14) (Page 1J-14)
1J-19 Charging System: K12M
K12M
Precautions
Precautions for Handling Battery
AENJCA0A1A20001
! 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 (electrolyte) 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
NOTICE
• Battery electrolyte lowers the level during
normal use and continuous use of battery
with the electrolyte under the lower level
will extremely deteriorate the battery.
For battery with removable filler plugs (1)
or vent caps and visible level lines, always
take the following precautions.
– Do not continue to use the battery with
the electrolyte under the lower level (2).
– Add distilled water up to the upper level
(3) if the level is below the midpoint of
upper and lower levels.
– Wash away spilled electrolyte after
fitting filler plugs or vent caps.
• Overfilled electrolyte exceeding the upper
level may overspill while the vehicle is
running and it may cause damage to the
parts near the battery.
Add distilled water up to the upper level.
IJCA0A1A1036-01
periodical attentions.
• Keep battery carrier clean.
• Prevent rust formation on the terminal posts.
• Even if the battery is MF (maintenance-free) type,
electrolyte decreases slowly compared with
conventional one.
• Keep electrolyte up to upper level uniformly in all
cells, if filler plugs or vent caps are removable.
• If battery does not have level lines but filler plugs
or vent caps are removable, add distilled water
until all electrodes are immersed uniformly.
• Some MF batteries are completely sealed except
small vent holes and adding distilled water is not
possible.

• 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.
– The battery discharges even if it is not used,
while vehicle is 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.
General Description
Battery Description
AENJCA0A1A21001
The battery has three major functions in the electrical
system.
• It is a source of electrical energy for cranking engine.
• It acts as a voltage stabilizer for the electrical system.
• It can, for a limited time, provide energy when the
electrical load exceeds the output of generator.
Carrier and Hold-Down
The battery carrier should be in good condition so that it
supports the battery securely and keeps it level. Before
installing battery, check that the battery carrier and hold-
down clamp are clean and free from corrosion and that
there is no foreign material in the carrier.
To prevent battery from shaking in its carrier, the hold-
down clamp nuts should be tightened enough but not
over-tightened.
Generator Description
The generator is 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 more detail of LIN communication, refer to
“Communication System Description” in Section 10H (Page 10H-1).
The generator features are as follows:
Charging System: K12M 1J-20
The cable connections, particularly at the positive (+)
terminal post, tend to become corrode. The
corrosion or rust on the mating faces of conductors
resists the flow of current.
Clean the terminals and fittings periodically to
ensure good metal-to-metal contact.
3) Periodically check the state of charge of battery. For
battery with filler plugs or vent caps 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)
Electrolyte Freezing
The freezing point of electrolyte depends on its specific
gravity. Since freezing may ruin a battery, it should be
protected against freezing by keeping it in a fully
charged condition. If the battery freezes accidentally, it
should not be charged until it will unfreeze.
Sulfation
If battery is left for a long period in discharged condition,
the lead sulfate becomes converted into a hard,
crystalline substance, which will not easily turn back to
the active material again during the subsequent
recharging. “Sulfation” means the result as well as the
process of that reaction. Such a battery can be revived
by very slow charging and may be restored to usable
condition but its capacity will be lower than before.
AENJCA0A1A21002
1J-21 Charging System: K12M

• 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 stator assembly.
• 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

3 4

7 8
2

LIN
6

IFRA0B1A2005-01

1. Generator 4. Diode 7. Battery

2. IC regulator 5. Field coil (rotor coil) 8. Electric load
3. Stator coil 6. ECM

IFRA0A1A1002-01

1. Pulley 6. Rotor 11. LIN terminal

2. Pulley nut 7. Stator assembly 12. Drive end frame
3. Rotor fan 8. Brush holder assembly 13. Bushing
4. Bearing 9. Rear end cover
5. Bearing retainer 10. Generator output (“B” terminal)
 Charging System: K12M 1J-22

Diagnostic Information and Procedures

Battery Inspection
AENJCA0A1A24001
Common Causes of Failure
There are the following causes for the fall of battery function.
• Accessories left on overnight or for an extended period without the generator operation.
• Frequent driving at low speed for short periods.
• Electrical load exceeds generator output, particularly due to additional fitting of aftermarket equipment.
• Defects in charging system. (Page 1J-22)
• Failure to fix terminals or making hold-down clamps too loose or too tight.
• Mechanical problems in electrical system such as short-circuit or pinched wires.
• Deterioration of battery due to long-term use.
• Deterioration of battery due to long-term storage.

Visual Inspection
Check for visible damage, such as a cracked or broken case or cover, which may lead to loss of electrolyte. If visible
damage is noted, replace battery. Determine cause of damage and make corrections if necessary.

Battery Electrolyte Inspection

Check electrolyte level whether it is between upper and lower lines.
Add distilled water up to upper level uniformly in all cells if the level is below the midpoint of upper and lower levels.

Generator Symptom Diagnosis

AENJCA0A1A24002
Trouble in charging system will show up as one or more of the following conditions.

Charge Warning Light Operation

Condition
Charge warning light
does not light with
ignition “ON” and engine
off
Charge warning light
does not go out with
engine running (battery
requires frequent
recharging)
Possible cause Correction / Reference Item
Blown fuse Replace fuse.
Faulty combination meter Replace combination meter. (Page 9C-25)
Faulty ECM Check ECM. (Page 1A-254)
Faulty CAN communication line Repair or replace CAN communication line.
(Page 10H-7)
Faulty wiring Repair wiring.
Faulty IC regulator or field coil Repair or replace generator. (Page 1J-30)
Loose or worn drive belt Adjust or replace drive belt. (Page 1J-25)
Faulty combination meter Replace combination meter. (Page 9C-25)
Faulty ECM Check ECM. (Page 1A-254)
Faulty IC regulator or generator Repair or replace generator. (Page 1J-30)
Faulty wiring Repair wiring.

Battery Charge Failure

Condition
Undercharged battery
Overcharged battery
Possible cause Correction / Reference Item
Loose or worn drive belt Adjust or replace drive belt. (Page 1J-25)
Loose or corroded battery terminal Tighten battery terminal or replace battery.
(Page 1J-24)
Faulty rectifier, rotor and/or IC regulator Repair or replace generator. (Page 1J-30)
Faulty IC regulator Repair or replace generator. (Page 1J-30)

Noise
Condition Possible cause Correction / Reference Item
Noisy generator Loose mounting bolts Tighten mounting bolts. (Page 1J-28)
Dirty, worn and/or faulty bearings Repair or replace generator. (Page 1J-30)
Faulty rotor, diode and/or stator Repair or replace generator. (Page 1J-30)
1J-23 Charging System: K12M

Generator Test 5) Run engine around 2,000 rpm and read meters.
AENJCA0A1A24003
This condition, as evidenced by slow cranking or low • If voltage is higher than standard value, check
specific gravity, can be caused by one or more of the ground circuit of brushes. (Page 1J-34)
following conditions even though warning light operates If brushes are not grounded, replace brush holder
normally. assembly.
• Check that undercharged condition has not been • If voltage is lower than standard value, check
caused by accessories being left on for an extended rotor, stator and rectifier. (Page 1J-34)
period. Specification (No-load check)
• Check generator drive belt for wear and tension. Current: 10 A
(Page 1J-25) Regulated voltage: 10.3 – 16.3 V (at 25 °C, 77
• If battery defect is suspected, refer to “Battery °F)
Description”: K12M (Page 1J-20).
Load Check
• Check wiring for defects. Check all connections for
tightness and cleanliness, battery cable connections NOTE
at battery, generator, starting motor and ignition
Use fully charged battery.
ground cable.
1) Connect ammeter in the same way as “No-Load
No-Load Check Check”: K12M (Page 1J-23).
NOTE 2) Run engine around 2,000 rpm and turn on the
following electrical loads.
Use fully charged battery.
• Headlight (high beam)
1) Check for DTC. • Rear defogger
If there is any DTC, perform troubleshooting for • Blower motor (maximum speed)
applicable DTC and then clear DTC.
3) Read ammeter.
• DTC check: (Page 1A-140) If meter reading is lower than specified value, repair
• Troubleshooting: (Page 1A-142) or replace generator.
• DTC clearance: (Page 1A-141)
Specification (Load check)
2) Turn off all electrical loads (5). Current: 20 A
3) Connect voltmeter (3) and ammeter (2) as shown in
figure.
4) Start engine and warm it up to normal operating
temperature.

I9P60A1A1018-01

1. Generator 6. Switch
4. Battery 7. “B” terminal
 Charging System: K12M 1J-24

Repair Instructions
Jump-Starting in Case of Emergency
AENJCA0A1A26001
With Booster Battery
NOTICE
Trying to start a M/T vehicle equipped with a
catalytic converter by pushing or towing it
may cause damage to the emission control
system and/or other components.
Do not start a M/T vehicle by pushing or
towing it.
Both booster and discharged battery should be treated
carefully when using jumper cables. Follow the
procedure outlined as follows, being careful not to cause
sparks.
! WARNING
Failure to take proper precautions when jump
starting a vehicle may result in serious
personal injury and/or damage to electronic
components of either the vehicle with a dead
battery or the vehicle used for jump starting.
• Never expose the battery to open flame or
electric spark. A battery generates highly
flammable and explosive hydrogen gas.
7) Start engine of vehicle with booster battery and turn
off its electrical loads. Then start engine of vehicle
with discharged battery.
8) Disconnect jumper cables in exact reverse order.
With Charging Equipment
NOTICE
Using 24-volt charging equipment to jump-
start the engine will cause serious damage to
electric and electronic system components.
Use only 12-volt charging equipment to
jump-start the engine.
Battery Removal and Installation
AENJCA0A1A26002
Removal
1) Disconnect negative (–) cable (1) at battery.
2) Disconnect positive (+) cable (2) at battery.
3) Remove battery band (3).
4) Remove battery (4) and battery cover (5).
1
3

• Remove rings, watches and other jewelry.

Wear approved eye protector.
• Battery fluid (electrolyte) 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 5
2 4
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 IJCA0A1A2001-01

the positive terminal of the battery (or a 5) If necessary, remove battery tray as follows.
metal piece in contact with it) and any a) Disconnect harness clamps from battery tray (1).
metal part of the vehicle at the same time.
b) Remove battery tray.
1) For M/T model, place gear shift control lever in
“Neutral”.
For auto gear shift model, place shift selector in “N”.
2) Apply parking brake.
3) Set ignition “OFF”.
4) Turn off lights and all other electrical loads.
5) 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 1
engine).
6) Attach one end of the remaining negative (–) cable to
negative (–) terminal of booster battery, and other
end to solid engine ground (such as exhaust IJCA0A1A2002-01
manifold) at least 45 cm (18 in.) away from battery of
vehicle being started.
1J-25 Charging System: K12M

Installation NOTE
Reverse removal procedure noting the following points. Fix cable end at fully fitted position to battery
NOTICE terminal.

The battery tray bolts and nut are pre-coated. Tightening torque
If these bolts and nut are reused, they may Positive (+) cable nut (a): 5.0 N·m (0.51 kgf-m, 4.0
work loose. lbf-ft)
Replace the battery tray bolts and nut with Negative (–) cable nut (a): 5.0 N·m (0.51 kgf-m,
new ones whenever they are removed. 4.0 lbf-ft)

• Tighten new battery tray bolts (1) and nut (2) to

specified torque.
3, (b)
Tightening torque
Battery tray bolt (a): 15 N·m (1.5 kgf-m, 11.0 lbf-ft)
Battery tray nut (b): 15 N·m (1.5 kgf-m, 11.0 lbf-ft)
1

2, (b) 2, (a)

IJCA0A1A2007-01

• Initialize electrical devices if necessary.

Water Pump / Generator Drive Belt Inspection

1, (a) and Adjustment
AENJCA0A1A26003
1) Check water pump / generator drive belt for cracks,
IJCA0A1A2003-01 cuts, deformation, wear and cleanliness. If any
• Face notch (1) of battery band inside. defect is found, replace it. (Page 1J-26)
2) When engine is cool, turn crankshaft 720° to
1 stabilize water pump / generator drive belt and check
the belt for tension.
• Using sonic tension meter (Gates 508C or
equivalent):
a. Enter the input data following instructions in
the tension meter manual.
Recommended belt tension meter
specification
MASS: 75.4 g/m
WIDTH: 1.0 mm/R
SPAN: 182 mm
b. Flip belt (1) at span to vibrate the belt and
measure the belt tension.
If belt tension is not as specified, go to next
IJCA0A1A2004-01
steps.
• Tighten battery band nuts (1) securely.
Water pump / generator drive belt tension
• Tighten positive (+) cable nut (2) and negative (–)
“a”
cable nut (3) to specified torque, and then fix positive
Existing belt: 525 ± 50N (54 ± 5 kgf, 118.0 ±
(+) cable end cap.
11.2 lbf)
New belt: 825 ± 100N (84 ± 10 kgf, 185.5 ±
22.5 lbf)
 Charging System: K12M 1J-26

• Without using sonic tension meter (Pushing 7) After adjustment, tighten generator belt adjusting
belt span): bolt (1) to specified torque.
Push belt (2) at span with finger force of 100 N
Tightening torque
(10.2 kgf, 22.5 lbf) to bend the belt and measure
Generator belt adjusting bolt (a): 5.0 N·m (0.51
the bending value.
kgf-m, 4.0 lbf-ft)
If belt tension is not as specified, go to next steps.
Water pump / generator drive belt tension “b”
Existing belt: 5.2 – 6.0 mm (0.21 – 0.23 in.) as
deflection / 100 N (10.2 kgf, 22.5 lbf) between
water pump pulley and generator pulley
New belt: 3.5 – 4.2 mm (0.14 – 0.16 in.) as
deflection / 100 N (10.2 kgf, 22.5 lbf) between 1, (a)

water pump pulley and generator pulley

1, “a”
IJCA0A1A2006-01

Water Pump / Generator Drive Belt Removal and

“b”
IJCA0A1A2005-01
3) Loosen tension pulley bolt (1) and then adjust belt
tension to specification described at Step 2) by
loosening / tightening generator belt adjusting bolt
(2).
4) Tighten tension pulley bolt to specified torque.
Tightening torque
Tension pulley bolt (a): 55 N·m (5.6 kgf-m, 40.5
Installation
AENJCA0A1A26004
Removal
1) Disconnect negative (–) cable at battery.
2) Hoist vehicle and remove right side splash cover.
3) Remove compressor drive belt. (Page 7B-51)
4) Loosen tension pulley bolt (1).
5) Loosen generator belt adjusting bolt (2), and then
remove water pump / generator drive belt (3).
3

lbf-ft)
2

2 1

IGJA0A1A1007-01

1, (a)
IGJA0A1A1006-01

5) Check belt tension for specification after turning

crankshaft two revolutions clockwise.
6) If check result is not as specified, repeat Step 3) – 5)
again.
1J-27 Charging System: K12M

Installation 5) Remove generator belt adjusting bolt (1).

1) Install water pump / generator drive belt (1) to water 6) Remove tension pulley bolt (2), and then remove belt
pump pulley (2), crankshaft pulley (3) belt tensioner tensioner pulley (3) and generator belt adjuster (4).
pulley (4) and generator pulley (5).

NOTE 1
Check that drive belt is installed in grooves
of each pulley correctly.

4
2
3
IGJA0A1A1010-01

5 Installation
1) Install belt tensioner pulley (1) to belt tensioner arm
4
(2) so that cutout (3) in belt tensioner pulley is
aligned with slot (4) in belt tensioner arm.
IGJA0A1A1008-01

2) Adjust belt tension. (Page 1J-25)

3) Install compressor drive belt. (Page 7B-51) 1
4) Install right side splash cover.
5) Connect negative (–) cable at battery.
3
Belt Tensioner Arm and Belt Tensioner Pulley
Removal and Installation
AENJCA0A1A26011 2

Removal
1) Disconnect negative (–) cable at battery.
2) Hoist vehicle and remove right side splash cover. 4
3) Loosen tension pulley bolt (1), and then loosen IJHA0B1A0001-01
generator belt adjusting bolt (2).
2) Install generator belt adjuster (1) and tighten tension
4) Remove belt tensioner arm (3) with belt tensioner pulley bolt (2) temporarily.
pulley (4).
3) Install generator belt adjusting bolt (3).

2
3

3
2

IGJA0A1A1009-01

IGJA0A1A1012-01
 Charging System: K12M 1J-28

4) Install belt tensioner arm (1) with belt tensioner Installation

pulley (2) as shown in figure. Reverse removal procedure noting the following points.
5) Tighten belt tensioner arm bolts to specified torque. • Tighten generator upper bolt (1) and lower bolt (2) as
follows.
Tightening torque
Belt tensioner arm bolt (a): 25 N·m (2.5 kgf-m, a. Put generator (3) on cylinder block and tighten
18.5 lbf-ft) generator upper bolt and lower bolt temporarily.
b. Tighten generator lower bolt to 30 Nm (3.1 kgf-m,
22.5 lbf-ft) and check that bushing (4) in generator
is in contact with generator bracket, and then
loosen the bolt.
c. Tighten generator upper bolt and lower bolt to
specified torque.
1 2
Tightening torque
Generator upper bolt (a): 30 N·m (3.1 kgf-m,
22.5 lbf-ft)
(a)
Generator lower bolt (b): 48 N·m (4.9 kgf-m,
35.5 lbf-ft)

(a) • Insert lugs (5) of “B” terminal wire (6) into groove (7)
IGJA0A1A1013-01
and then tighten “B” terminal nut (8) to specified
torque.
6) Adjust belt tension. (Page 1J-25)
7) Install right side splash cover. Tightening torque
8) Connect negative (–) cable at battery. “B” terminal nut (c): 7.9 N·m (0.81 kgf-m, 6.0 lbf-
ft)
Generator Removal and Installation
AENJCA0A1A26005 8, (c)
Removal 5

1) Disconnect negative (–) cable at battery. 6

2) Remove water pump / generator drive belt. (Page

1J-26)
3) Remove belt tensioner arm. (Page 1J-27) 7

4) Remove exhaust pipe. (Page 1K-10) 1, (a)

5) Remove nut (1) and disconnect “B” terminal wire (2),

and then disconnect generator connector (3) from
generator (4).
6) Remove generator upper bolt (5) and lower bolt (6), 3
and then remove generator.
2, (b)
4
IJHA0A1A0012-01
3 • Adjust belt tension. (Page 1J-25)
5
1

4
6

IJHA0A1A0011-01
1J-29 Charging System: K12M

Generator Arm and Generator Bracket Removal Installation

and Installation Reverse removal procedure noting the following points.
AENJCA0A1A26012
• Tighten generator bracket bolts in numerical order (“1”
Removal
– “4”) to specified torque.
1) Disconnect negative (–) cable at battery.
2) Remove right side splash cover. Tightening torque
Generator bracket bolt* (a): 25 N·m (2.5 kgf-m,
3) Remove water pump / generator drive belt. (Page 18.5 lbf-ft)
1J-26)
4) Remove water pump pulley. (Page 1F-33) “3”, (a) “1”, (a)
5) Remove generator bolt (1) and then remove
generator arm (2).

“4”, (a)
“2”, (a)
IGJA0A1A1021-01

• Tighten generator arm bolts to specified torque.

(Page 1F-33)
• Install generator. (Page 1J-28)
IGJA0A1A1019-01

6) Remove belt tensioner arm and generator. (Page
1J-28)
7) Remove generator bracket (1).
Belt Tensioner Pulley Inspection
AENJCA0A1A26007
Check belt tensioner pulley (1) for wear and smoothly
rotation. If check result is not OK, replace belt tensioner
pulley.

1
1 IGJA0A1A1022-01
IGJA0A1A1020-01
 Charging System: K12M 1J-30

Generator Components
AENJCA0A1A26008

1 (a)

4
5

(b)
9 6

7
8

(d)
(c)

(e)
10

IFRA0A1A1018-01

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 2) Remove rear end cover (2) and bushing (1).
AENJCA0A1A26009

Disassembly
1
1) To facilitate reinstallation, provide matchmarks (1) on
drive end frame (2) and stator assembly (3) as
shown.

1
2
2

IFRA0A1A1020-01

IFRA0A1A1019-01
1J-31 Charging System: K12M

3) Remove brush holder assembly (1) from stator 6) Remove pulley as follows.
assembly. a) Hold rotor (1) using vise (2).

NOTICE
The rotor assembly may be damaged if it is
not held in a vise in the specified method and
1 at the indicated parts when loosening the
pulley nut.
Hold the rotor assembly in the vise via a
clean cloth (3) at the iron parts (4). Never hold
the rotor assembly at other parts (5).

b) Remove pulley (6).

6
IFRA0A1A1021-01
5
4) Remove stator assembly bolts (1).

1 3
2 4 1
1 IEL10A1A1009-01

7) Remove rotor (1) from drive end frame (2) by tapping

shaft (3) lightly using plastic hammer.

IFRA0A1A1022-01

5) With lever inserted between stator assembly (1) and

drive end frame (2), separate generator into drive
end frame and stator assembly.

3
1

2
IFRA0A1A1024-01

IFRA0A1A1023-01
 Charging System: K12M 1J-32

8) If necessary, remove bearing retainer screws and Reassembly

bearing retainer (1), and then remove bearing (2) 1) Using special tool, install new bearing to drive end
from drive end frame (3) using special tool. frame. Check the bearing for smooth rotation, if
removed.
NOTE
If necessary, when removing bearing heat NOTICE
drive end frame to a temperature of 80 – 100 When installing the bearing, the bearing and
°C (176 – 212 °F) so that it will not be the drive end frame may become damaged if
distorted. pressing any section other than the outer
race.
Special tool Press the outer race of the bearing when
(A): 09925M96710 installing it.
2
Special tool
(A): 09913M76010

3 (A)

1
IFRA0A1A1025-01

ICV00P1A0021-01
(A) 2) Install bearing retainer (1) to drive end frame (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)

IGSB0A1A3009-01

2
(a)

1
IFRA0A1A1026-01
1J-33 Charging System: K12M

3) Install rotor (1) to drive end frame(2). 6) Install stator assembly (1) to drive end frame (2).
7) Tighten stator assembly bolts to specified torque.
1
Tightening torque
Stator assembly bolt (a): 5.9 N·m (0.60 kgf-m,
4.5 lbf-ft)

(a)

2
IEL10A1A1013-01

8) Install brush holder assembly (1) using the following

2 procedure:
IJCA0A1A2008-01

4) Install pulley as follows. a) Push brushes (2) in arrow direction.

a) Hold rotor (1) using vise (2). b) Hold brushes in compressed position, by
inserting a pin (3) into stopper hole (4).
NOTICE
NOTE
The rotor may be damaged if it is not held in a
vise in the specified method and at the Recommended pin diameter: About 1.0 mm
specified parts when tightening the pulley (0.04 in.)
nut.
c) Install brush holder assembly to stator assembly
Hold the rotor in the vise via a clean cloth (3)
(5), and then tighten brush holder assembly
at the iron parts (4). Never hold the rotor at
screws (6) to specified torque.
other parts (5).
Tightening torque
b) Tighten pulley nut (6) to specified torque. Brush holder assembly screw (a): 1.8 N·m (
Tightening torque 0.18 kgf-m, 1.5 lbf-ft)
Pulley nut (a): 133 N·m (13.6 kgf-m, 98.5 lbf-
ft) 6, (a)
2
6, (a)
5 1 4
5

1
3

3 4 1
2
IEL10A1A1012-01 IFRA0A1A1027-02

5) Install bearing bush to stator assembly. d) Remove pin from brush holder assembly.
 Charging System: K12M 1J-34

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.
Tightening torque
Rear end cover bolt (a): 4.6 N·m (0.47 kgf-m, 3.5
lbf-ft)
1 abnormality is found, replace rotor.
3) Check slip rings and blades for damage. If any
abnormality is found, replace rotor.
Bearing
Check bearing for smooth rotation.
If any abnormality is found, replace rotor assembly.
NOTE
Bearing (1) shown in figure is combined with
rotor (2) and check it as it is. If any

3, (a)

2 2 1

ICV00P1A0016-01
IFRA0A1A1028-01

Stator
Generator Inspection
AENJCA0A1A26010 • Using ohmmeter, check continuity between each of
stator coil terminals (A1 / A2 / A3). If there is no
Rotor continuity, replace stator assembly.
1) Using ohmmeter (1), check for continuity between • Using ohmmeter, check continuity between each of
slip rings (2) of rotor. If there is no continuity, replace stator coil terminals (A1 / A2 / A3) and corresponding
rotor assembly. terminals (A4 / A5 / A6). If there is no continuity,
Standard resistance between slip rings of rotor replace stator assembly.
1.85 – 2.25 Ω

I8G0011A0010-01

2) Using ohmmeter (1), check that there is no continuity

between slip ring (2) and rotor core (3). If there is
continuity, replace rotor assembly.

I8G0011A0011-01
1J-35 Charging System: K12M

• Using diode range of circuit tester, check continuity Brush

between “B” terminal (1) and stator coil terminals (A4 / Check each brush for wear by measuring its length as
A5 / A6), and ground (2) and stator coil terminals (A4 / shown. If brush has worn down to service limit, replace
A5 / A6). brush holder assembly.
Check both directions by reversing probes of circuit
Exposed brush length “a”
tester and, if there is continuity in both directions or
Standard: 10.5 mm (0.41 in.)
there is no continuity in both directions, replace stator
Limit: 1.5 mm (0.06 in.)
assembly.

NOTE
For diode test, refer to the instruction manual
of circuit tester.
“a”

1
A4

A1 I8T4011A0022-01

Rectifier

2 NOTE
A3 Rectifiers are combined with stator assembly
and inspection for individual rectifier is not
A6 possible.
A5
A2

A1
B
A4
1
A5

A2

A3 LIN
A6

E
2
IFRA0A1A1029-01

Specifications
Charging System Specifications
AENJCA0A1A27001
Battery
Battery specification
: 34B19L (JIS) (33AH/20H) 12V

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 10.3 – 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
 Charging System: K12M 1J-36

Tightening Torque Specifications

AENJCA0A1A27002
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
Battery tray bolt 15 1.5 11.0 (Page 1J-25)
Battery tray nut 15 1.5 11.0 (Page 1J-25)
Positive (+) cable nut 5.0 0.51 4.0 (Page 1J-25)
Negative (–) cable nut 5.0 0.51 4.0 (Page 1J-25)
Tension pulley bolt 55 5.6 40.5 (Page 1J-26)
Generator belt adjusting bolt 5.0 0.51 4.0 (Page 1J-26)
Belt tensioner arm bolt 25 2.5 18.5 (Page 1J-28)
Generator upper bolt 30 3.1 22.5 (Page 1J-28)
Generator lower bolt 48 4.9 35.5 (Page 1J-28)
“B” terminal nut 7.9 0.81 6.0 (Page 1J-28)
Generator bracket bolt* 25 2.5 18.5 (Page 1J-29)
Bearing retainer screw 2.3 0.23 2.0 (Page 1J-32)
Pulley nut 133 13.6 98.5 (Page 1J-33)
Stator assembly bolt 5.9 0.60 4.5 (Page 1J-33)
Brush holder assembly screw 1.8 0.18 1.5 (Page 1J-33)
Rear end cover bolt 4.6 0.47 3.5 (Page 1J-34)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Generator Components”: K12M (Page 1J-30)
“Fasteners Information” in Section 0A (Page 0A-6)

Special Tools and Equipment

Special Tool
AENJCA0A1A28001
09913M76010 09925M96710
Bearing installer Bearing installer
(Page 1J-32) (Page 1J-32)
1K-1 Exhaust System: K10B and Bi-Fuel CNG

Exhaust System
Engine

K10B and Bi-Fuel CNG

General Description
Exhaust System Description
AENJCA0A1B11001
The exhaust system consists of an exhaust manifold, a three-way catalytic converter (TWC) in the exhaust manifold,
exhaust pipes, a muffler and seals, gasket, and so on.
The three-way catalytic converter is emission control device added to the exhaust system to lower the levels of
Hydrocarbon (HC), Carbon Monoxide (CO), and Oxides of Nitrogen (NOx) pollutants in exhaust gases.

Diagnostic Information and Procedures

Exhaust System Check
AENJCA0A1B14001
! CAUTION
Touching a hot exhaust system component will cause a burn.
Do not perform any service work on the exhaust system until the exhaust system is cool.

Exhaust system should be checked as follows at specified periodic maintenance intervals and on every occasion of
service operations performed with vehicle hoisted.
• Check rubber mountings for damage, deterioration and dislocation.

IYSY011B0003-01

• Check mating surface of cylinder head with exhaust manifold for distortion.
• Check exhaust system for leakage, loose connection, dent and damage.
• If bolts or nuts are loosened, and then tighten them to specified torque. (Page 1K-2)
• Check for any damages, holes or crack, which may permit exhaust gas to enter the vehicle.
• Check that exhaust system components have enough clearance from underbody components to avoid overheating
and possible damage to these components.
• Check for any defects and fix them whenever found.
 Exhaust System: K10B and Bi-Fuel CNG 1K-2

Repair Instructions
Exhaust System Components
AENJCA0A1B16001

10

(a)

(a)
3 (b)
5 11
1
6 4 (b)

14
8 (d)
7

12
9 (d) [a]

(c) 18

19

17
(d)

(c)

[a]
15

16 17 18
13

(c)

16
IJCA0A1B1001-02
1K-3 Exhaust System: K10B and Bi-Fuel CNG

1. Exhaust manifold 9. Exhaust manifold stiffener nut 17. Mounting No.2

: For tightening order, refer to “Exhaust : For installation, refer to “Exhaust Pipe and
Manifold Removal and Installation”: K10B Muffler Removal and Installation”: K10B and
and Bi-Fuel CNG (Page 1K-3). Bi-Fuel CNG (Page 1K-5).
2. Exhaust manifold gasket 10. HO2S bracket 18. Mounting No.3
3. HO2S-1 11. HO2S-2 bracket 19. Muffler hanger bracket
4. HO2S-2 12. Seal ring No.1 : 60 Nm (6.1 kgf-m, 44.5 lbf-ft)
5. Exhaust manifold bracket 13. Seal ring No.2 : 45 Nm (4.6 kgf-m, 33.5 lbf-ft)
6. Exhaust manifold bracket bolt 14. Exhaust pipe : 43 Nm (4.4 kgf-m, 32.0 lbf-ft)
7. Exhaust manifold stiffener 15. Muffler : 25 Nm (2.5 kgf-m, 18.5 lbf-ft)
8. Exhaust manifold stiffener bolt 16. Mounting No.1 : Do not reuse.
: For tightening order, refer to “Exhaust
Manifold Removal and Installation”: K10B
and Bi-Fuel CNG (Page 1K-3).

Exhaust Manifold Removal and Installation 4) Remove exhaust pipe (1) from exhaust manifold.
AENJCA0A1B16002

! CAUTION
Touching a hot exhaust system component
will cause a burn.
Do not perform any service work on the
exhaust system until the exhaust system is
cool. 1

Removal

NOTICE
I7V20A1B1003-01
Applying a shock to the exhaust manifold
may cause damage to the three-way catalytic 5) Remove exhaust manifold stiffener (1).
converter inside the exhaust manifold. 6) Remove exhaust manifold (2) and its gasket from
Handle the exhaust manifold carefully. Be cylinder head.
careful not to drop it or hit it against
something.

1) Remove HO2S-1 and HO2S-2 clamps (1).

2) Disconnect HO2S-1 (2) and HO2S-2 (3) connectors
and then detach from HO2S bracket (4).
3) Remove HO2S-1 and HO2S-2, if necessary. 2
(Page 1C-11)

4
1
1
IJCA0A1B1003-01

3
IJCA0A1B1002-01
 Exhaust System: K10B and Bi-Fuel CNG 1K-4

Installation • Tighten exhaust pipe bolts to specified torque.

Reverse removal procedure noting the following points.
Tightening torque
• Use new gasket and seal ring. Exhaust pipe bolt (a): 43 N·m (4.4 kgf-m, 32.0 lbf-
• Tighten exhaust manifold bolts (1) and nuts (2) to ft)
specified torque.
Tightening torque
Exhaust manifold bolt (a): 60 N·m (6.1 kgf-m, 44.5
lbf-ft)
Exhaust manifold nut (b): 60 N·m (6.1 kgf-m, 44.5
lbf-ft)

2, (b)

2, (b) (a)
I9P60A1B1004-01

• Run engine and check for exhaust gas leakage.

Exhaust Manifold Inspection

AENJCA0A1B16003
1, (a)
Using straightedge and feeler gauge, check gasket
surface for distortion. If distortion exceeds its limit, repair
IJCA0A1B1004-01
it.
• Install HO2S-1 and HO2S-2, if removed. (Page 1C- If repair is not possible, replace exhaust manifold.
11)
Distortion of exhaust manifold [a] – [d]
• Install exhaust manifold stiffener as follows. Limit: 0.3 mm (0.012 in.)
a. Install exhaust manifold stiffener (1) and then
tighten exhaust manifold stiffener nut (2) by hand. Distortion of exhaust manifold [e] – [h]
Limit: 0.7 mm (0.028 in.)
b. Tighten exhaust manifold stiffener bolt (3) to
specified torque. [a] [b] [c] [d]

Tightening torque [g]

[e]
Exhaust manifold stiffener bolt (a): 25 N·m (
2.5 kgf-m, 18.5 lbf-ft) [f]
[h]
c. Tighten exhaust manifold stiffener nut to specified
torque.
Tightening torque
IJCA0A1B1006-01
Exhaust manifold stiffener nut (b): 25 N·m (
2.5 kgf-m, 18.5 lbf-ft)

3, (a)

2, (b)

IJCA0A1B1005-02
1K-5 Exhaust System: K10B and Bi-Fuel CNG

Exhaust Pipe and Muffler Removal and

Installation
AENJCA0A1B16004 3

! CAUTION
Touching a hot exhaust system component
will cause a burn. 1
Do not perform any service work on the
exhaust system until the exhaust system is
cool.

Removal
4
1) Remove exhaust pipe (1). IJCA0A1B1009-02
2) Remove seal rings (2) from exhaust pipe and 4) Remove muffler hanger bracket (1), if necessary.
exhaust manifold (3).
1
1

IJCA0A1B1011-01

Installation
Reverse removal procedure noting the following points.
1
• Use new seal rings.
2 3
• Install mounting No.2 (1) positioning its cavity (2)
3 longitudinally.
IJCA0A1B1007-01

3) Suspend muffler (1) and remove muffler from

1
mounting No.1 (2), No.2 (3) and No.3 (4), and then
remove muffler.
2

[f]
1
2 IJCA0A1B1010-01

[f]: Forward

IJCA0A1B1008-01
• Tighten bolts and nuts to specified torque when
reassembling. (Page 1K-2)
• Run engine and check for exhaust gas leakage.
 Exhaust System: K10B and Bi-Fuel CNG 1K-6

Specifications
Tightening Torque Specifications
AENJCA0A1B17001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Exhaust manifold bolt 60 6.1 44.5 (Page 1K-4)
Exhaust manifold nut 60 6.1 44.5 (Page 1K-4)
Exhaust manifold stiffener bolt 25 2.5 18.5 (Page 1K-4)
Exhaust manifold stiffener nut 25 2.5 18.5 (Page 1K-4)
Exhaust pipe bolt 43 4.4 32.0 (Page 1K-4)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Exhaust System Components”: K10B and Bi-Fuel CNG (Page 1K-2)
“Fasteners Information” in Section 0A (Page 0A-6)
1K-7 Exhaust System: K12M

K12M
General Description
Exhaust System Description
AENJCA0A1B21001
The exhaust system consists of an exhaust manifold, a three-way catalytic converter (TWC) in the exhaust manifold,
exhaust pipes, a muffler and seals, gasket, and so on.
The three-way catalytic converter is emission control device added to the exhaust system to lower the levels of
Hydrocarbon (HC), Carbon Monoxide (CO), and Oxides of Nitrogen (NOx) pollutants in exhaust gases.

Diagnostic Information and Procedures

Exhaust System Check
AENJCA0A1B24001
! CAUTION
Touching a hot exhaust system component will cause a burn.
Do not perform any service work on the exhaust system until the exhaust system is cool.

Exhaust system should be checked as follows at specified periodic maintenance intervals and on every occasion of
service operations performed with vehicle hoisted.
• Check rubber mountings for damage, deterioration and dislocation.

IYSY011B0003-01

• Check mating surface of cylinder head with exhaust manifold for distortion.
• Check exhaust system for leakage, loose connection, dent and damage.
• If bolts or nuts are loosened, and then tighten them to specified torque. (Page 1K-8)
• Check for any damages, holes or crack, which may permit exhaust gas to enter the vehicle.
• Check that exhaust system components have enough clearance from underbody components to avoid overheating
and possible damage to these components.
• Check for any defects and fix them whenever found.
 Exhaust System: K12M 1K-8

Repair Instructions
Exhaust System Components
AENJCA0A1B26001

9 (d)
16
(a)
5
3 (b)
7 (d) 6

10 (d) 15

8 4 (b)
(d) (d)
11

12

13
(c)

14 15 16
11
(c)

14
IJCA0A1B2001-03

1. Exhaust manifold 8. Exhaust manifold stiffener No.1 bolt 15. Mounting No.2
: For tightening order, refer to “Exhaust : For installation, refer to “Exhaust Manifold
Manifold Removal and Installation”: K12M Removal and Installation”: K12M (Page 1K-
(Page 1K-9). 9).
2. Exhaust manifold gasket 9. Exhaust manifold stiffener No.2 nut 16. Mounting No.3
: For tightening order, refer to “Exhaust
Manifold Removal and Installation”: K12M
(Page 1K-9).
3. HO2S-1 10. Exhaust manifold stiffener No.2 bolt : 60 Nm (6.1 kgf-m, 44.5 lbf-ft)
: For tightening order, refer to “Exhaust
Manifold Removal and Installation”: K12M
(Page 1K-9).
4. HO2S-2 11. Seal ring : 45 Nm (4.6 kgf-m, 33.5 lbf-ft)
5. Exhaust manifold stiffener No.1 12. Exhaust pipe : 43 Nm (4.4 kgf-m, 32.0 lbf-ft)
6. Exhaust manifold stiffener No.2 13. Muffler : 25 Nm (2.5 kgf-m, 18.5 lbf-ft)
7. Exhaust manifold stiffener No.1 nut 14. Mounting No.1 : Do not reuse.
: For tightening order, refer to “Exhaust
Manifold Removal and Installation”: K12M
(Page 1K-9).
1K-9 Exhaust System: K12M

Exhaust Manifold Removal and Installation 5) Remove exhaust manifold stiffener No.1 (1).
AENJCA0A1B26002
6) Remove exhaust manifold stiffener No.2 (2).
! CAUTION 7) Remove exhaust manifold (3) and its gasket from
Touching a hot exhaust system component cylinder head.
will cause a burn.
Do not perform any service work on the
exhaust system until the exhaust system is
cool.

Removal
3
NOTICE
Applying a shock to the exhaust manifold
1
may cause damage to the three-way catalytic
converter inside the exhaust manifold.
Handle the exhaust manifold carefully. Be
careful not to drop it or hit it against 2
something. IFRA0A1B1003-01

1) Remove HO2S-1 and HO2S-2 clamps (1). Installation

2) Disconnect HO2S-1 (2) and HO2S-2 (3) connectors Reverse removal procedure noting the following points.
and then detach from HO2S bracket (4). • Use new gasket and seal ring.
3) Remove HO2S-1 and HO2S-2, if necessary. • Tighten exhaust manifold bolts (1) and nuts (2) to
(Page 1C-29) specified torque.

2
Tightening torque
3 Exhaust manifold bolt (a): 60 N·m (6.1 kgf-m, 44.5
4 lbf-ft)
Exhaust manifold nut (b): 60 N·m (6.1 kgf-m, 44.5
1
lbf-ft)

2, (b)
1, (a) 2, (b)
1, (a)

IJCA0A1B2002-01 1, (a)
2, (b)
4) Remove exhaust pipe (1) from exhaust manifold.

IFRA0A1B1004-01

• Install HO2S-1 and HO2S-2, if removed. (Page 1C-

29)

I7V20A1B1003-01
 Exhaust System: K12M 1K-10

• Install exhaust manifold stiffeners as follows. Exhaust Manifold Inspection

AENJCA0A1B26003
a. Install exhaust manifold stiffener No.1 (1) and Using straightedge and feeler gauge, check gasket
No.2 (2) to cylinder block temporarily. surface for distortion. If distortion exceeds its limit, repair
b. Tighten exhaust manifold stiffener No.1 nut (3) it.
and No.2 nut (4) by hand. If repair is not possible, replace exhaust manifold.
c. Tighten all bolts and nuts in numerical order (“1” – Distortion of exhaust manifold [a] – [e]
“4”) to specified torque. Limit: 0.3 mm (0.012 in.)
Tightening torque Distortion of exhaust manifold [f] – [i]
Exhaust manifold stiffener bolt (a): 25 N·m ( Limit: 0.7 mm (0.028 in.)
2.5 kgf-m, 18.5 lbf-ft)
Exhaust manifold stiffener nut (b): 25 N·m ( [b] [c] [d] [e]
2.5 kgf-m, 18.5 lbf-ft) [h]
[f]

[g]
[i]
[a]

IFKA0P1B0005-01

Exhaust Pipe and Muffler Removal and

4, “4”, (b) “2”, (a) Installation
1 AENJCA0A1B26004
3, “3”, (b)
! CAUTION
Touching a hot exhaust system component
2
“1”, (a) will cause a burn.
IJCA0A1B2009-01 Do not perform any service work on the
• Tighten exhaust pipe bolts to specified torque. exhaust system until the exhaust system is
cool.
Tightening torque
Exhaust pipe bolt (a): 43 N·m (4.4 kgf-m, 32.0 lbf-
Removal
ft)
1) Remove exhaust pipe (1).

(a)
I9P60A1B1004-01
IJCA0A1B2003-01
• Run engine and check for exhaust gas leakage.
1K-11 Exhaust System: K12M

2) Suspend muffler (1) and remove muffler from 4) Remove muffler hanger bracket (1), if necessary.
mounting No.1 (2), No.2 (3) and No.3 (4), and then
remove muffler. 1

IJCA0A1B2007-01

1 Installation
Reverse removal procedure noting the following points.
2
• Use new gasket and seal rings.
IJCA0A1B2004-01
• Install mounting No.2 (1) positioning its cavity (2)
longitudinally.

4
IJCA0A1B2005-01

3) Remove seal rings (1) from exhaust pipe (2) and [f]
exhaust manifold (3). IJCA0A1B2008-01

[f]: Forward

• Tighten bolts and nuts to specified torque when

reassembling. (Page 1K-8)
• Run engine and check for exhaust gas leakage.
1
2 3

IJCA0A1B2006-01

Specifications
Tightening Torque Specifications
AENJCA0A1B27001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Exhaust manifold bolt 60 6.1 44.5 (Page 1K-9)
Exhaust manifold nut 60 6.1 44.5 (Page 1K-9)
Exhaust manifold stiffener bolt 25 2.5 18.5 (Page 1K-10)
Exhaust manifold stiffener nut 25 2.5 18.5 (Page 1K-10)
Exhaust pipe bolt 43 4.4 32.0 (Page 1K-10)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Exhaust System Components”: K12M (Page 1K-8)
“Fasteners Information” in Section 0A (Page 0A-6)

Section 2
Suspension
CONTENTS
Precautions .................................................2-1
Precautions............................................................. 2-1
Precautions for Suspension .................................. 2-1
Suspension General Diagnosis.............. 2A-1
Diagnostic Information and Procedures............2A-1
Suspension, Wheel and Tire Symptom
Diagnosis .......................................................... 2A-1
Repair Instructions ..............................................2A-4
Suspension System Check ................................. 2A-4
Front Suspension .................................... 2B-1
Precautions...........................................................2B-1
Precautions for Handling of Front Strut............... 2B-1
General Description .............................................2B-2
Front Suspension Description ............................. 2B-2
Front Wheel Alignment Description..................... 2B-2
Repair Instructions ..............................................2B-2
Front Wheel Alignment Inspection and
Adjustment ........................................................ 2B-2
Front Strut Assembly Components ..................... 2B-5
Front Strut Assembly Removal and
Installation ......................................................... 2B-6
Front Strut Assembly Disassembly and
Reassembly ...................................................... 2B-8
Front Strut Inspection.......................................... 2B-9
Coil Spring, Strut Bearing and Strut Support
Check................................................................ 2B-9
Suspension Arm Components .......................... 2B-10
Suspension Arm Removal and Installation ....... 2B-10
Suspension Arm Check .................................... 2B-12
Front Suspension Frame and Stabilizer Bar
Components.................................................... 2B-14
Front Suspension Frame, Stabilizer Bar and
Bushing Removal and Installation................... 2B-15
Front Stabilizer Bar Removal and Installation
(If Equipped) ................................................... 2B-17
Front Suspension Frame Check ....................... 2B-18
Front Stabilizer Bar, Bushing and Joint Check
(If equipped).................................................... 2B-18
Front Suspension Fastener Check ................... 2B-18
Specifications.....................................................2B-19
Table of Contents 2- i
Tightening Torque Specifications......................2B-19
2
Special Tools and Equipment ...........................2B-19
Special Tool ......................................................2B-19
Rear Suspension ..................................... 2C-1
Precautions...........................................................2C-1
Precautions for Handling of Rear Shock
Absorber............................................................2C-1
General Description .............................................2C-1
Rear Suspension Description..............................2C-1
Repair Instructions ..............................................2C-2
Rear Wheel Alignment Inspection.......................2C-2
Rear Suspension Components ...........................2C-3
Rear Shock Absorber Removal and
Installation .........................................................2C-4
Rear Shock Absorber Inspection ........................2C-6
Rear Coil Spring and Spring Seat Removal
and Installation ..................................................2C-6
Rear Coil Spring and Spring Seat Check............2C-8
Rear Axle Removal and Installation ....................2C-8
Rear Axle Check .................................................2C-9
Rear Suspension Fastener Inspection ................2C-9
Specifications .......................................................2C-9
Tightening Torque Specifications........................2C-9
Wheels and Tires ..................................... 2D-1
Precautions...........................................................2D-1
Precautions for Servicing Wheel and Tire...........2D-1
General Description .............................................2D-1
Tire Description ...................................................2D-1
Replacement Tire Description.............................2D-2
Wheel Description ...............................................2D-2
Replacement Wheel Description.........................2D-2
Wheel-Tire Assembly Description .......................2D-2
Tire Placard Description......................................2D-2
Repair Instructions ..............................................2D-3
Wheel (with Tire) Removal and Installation.........2D-3
Tire Inspection.....................................................2D-4
Wheel Inspection.................................................2D-5
Tire Rotation........................................................2D-5
Specifications .......................................................2D-5
Tightening Torque Specifications........................2D-5
2-1 Precautions:

Precautions
Suspension

Precautions
Precautions for Suspension
AENJCA0A2000001
General Precautions
Refer to “General Precautions” in Section 00 (Page 00-1).

Precautions for Electrical Circuit Service

Refer to “Precautions for Electrical Circuit Service” in Section 00 (Page 00-3).

Caution for Fastener

Refer to “Caution for Fastener” in Section 00 (Page 00-6).

Caution for Suspension

Refer to “Caution for Suspension” in Section 00 (Page 00-6).

Warning for Wheel and Tire

Refer to “Warning for Wheel and Tire” in Section 00 (Page 00-6).

Warning for Airbag

Refer to “Warning for Airbag” in Section 00 (Page 00-7).

Suspension General Diagnosis
Suspension
Diagnostic Information and Procedures
Suspension, Wheel and Tire Symptom Diagnosis
Condition Possible cause
Vehicle pulls to one side Mismatched or unevenly worn tires
(leads) Tires not adequately inflated
Broken or sagging coil springs
Abnormal lateral force created by radial Replace tire. (Page 2D-3)
tire
Disturbed wheel alignment
Brake dragging in one wheel
Loose, bent or broken front or rear
suspension parts
Excessive tire wear Broken or sagging coil springs
Wheel out of balance
Disturbed wheel alignment
Faulty front strut assembly (shock
absorber)
Hard driving
Overloaded vehicle
Not rotated tires
Worn or loose wheel bearing
Wheel or tire wobbles
Tires not adequately inflated
Wheel tramp Blister or bump on tire
Improper front strut assembly (shock
absorber) action
Suspension General Diagnosis: 2A-1
AENJCA0A2104001
Correction / Reference Item
Replace tires. (Page 2D-3)
Adjust tire pressure.
Replace coil springs.
• Front: (Page 2B-8)
• Rear: (Page 2C-6)
Check and adjust wheel alignment. (Page
2B-2)
Adjust or repair brake.
Tighten or replace related suspension parts.
(Page 2A-4)
Replace coil springs.
• Front: (Page 2B-8)
• Rear: (Page 2C-6)
Adjust balance or replace tire.
Check and adjust wheel alignment. (Page
2B-2)
Replace front strut assembly (shock absorber).
(Page 2B-8)
Replace tires. (Page 2D-3)
Replace tires. (Page 2D-3)
Replace or rotate tires.
Replace wheel bearing and/or wheel hub
assembly.
• Front: (Page 3A-10)
• Rear: (Page 3A-18)
Replace wheel or tire. (Page 2D-3)
Adjust tire pressure.
Replace tire. (Page 2D-3)
Replace front strut assembly (shock absorber).
(Page 2B-8)
2A-2 Suspension General Diagnosis:
Condition Possible cause
Shimmy, shake or Wheel out of balance
vibration
Loose wheel bearings
Worn tie-rod ends
Worn suspension arm joints
Excessive tire or wheel run-out
Blister or bump on tire
Excessive radial runout of tire / wheel
assembly
Disturbed wheel alignment
Loose or worn steering linkage
Loose steering gear case bolts
Abnormal noise Damaged front strut assembly (shock
absorber) or mountings
Damaged rear shock absorber or
mountings
Worn, sticky or loose tie-rod ends
Worn or damaged suspension arm joints Replace suspension arm. (Page 2B-10)
Worn, sticky or loose tie-rod ball joints Replace tie-rod. (Page 6B-17)
Worn, sticky or loose drive shaft joints Replace drive shaft joints. (Page 3A-4)
Worn suspension arm front bushings
Worn suspension arm rear bushings
Loose stabilizer bar
Loose wheel nuts
Loose suspension bolts or nuts
Broken or damaged wheel bearings
Broken coil springs
Poorly lubricated or worn strut bearings Replace strut bearings. (Page 2B-8)
Steering system malfunction
Deteriorated rear axle bushings
Too low or uneven trim Broken or sagging coil springs
heights
NOTE
Overloaded vehicle
See NOTE *1.
Incorrect coil springs
Poorly inflated tires
Correction / Reference Item
Balance wheel(s) or replace tire(s) and/or
wheel(s).
Replace wheel bearing and/or wheel hub
assembly.
• Front: (Page 3A-10)
• Rear: (Page 3A-18)
Replace tie-rod ends. (Page 6B-15)
Replace suspension arm. (Page 2B-10)
Repair or replace wheel and/or tire. (Page
2D-3)
Replace tire. (Page 2D-3)
Replace tire or wheel. (Page 2D-3)
Check and adjust wheel alignment. (Page
2B-2)
Check steering system.
• Steering wheel: (Page 6C-31)
• Steering shaft joint: (Page 6B-8)
• Pinion shaft: (Page 6B-18)
• Tie-rod end: (Page 6B-16)
Tighten steering gear case bolts. (Page 6B-
16)
Repair or replace front strut assembly (shock
absorber) or mountings. (Page 2B-8)
Replace rear shock absorber. (Page 2C-4)
Replace tie-rod ends. (Page 6B-15)
Replace suspension arm. (Page 2B-10)
Replace suspension arm. (Page 2B-10)
Tighten bolts or nuts and/or replace bushings.
(Page 2B-14)
Tighten wheel nuts. (Page 2D-3)
Tighten suspension bolts or nuts. (Page 2B-
10)
Replace wheel bearing and/or wheel hub
assembly.
• Front: (Page 3A-10)
• Rear: (Page 3A-18)
Replace coil springs.
• Front: (Page 2B-8)
• Rear: (Page 2C-6)
Check and correct malfunction. (Page 6A-1)
Replace rear axle. (Page 2C-8)
Replace coil springs.
• Front: (Page 2B-8)
• Rear: (Page 2C-6)
Check loading.
Replace coil springs.
• Front: (Page 2B-8)
• Rear: (Page 2C-6)
Adjust tire pressure.
 Suspension General Diagnosis: 2A-3

Condition Possible cause Correction / Reference Item

Too soft ride Faulty front strut assembly (shock
absorber)
Faulty rear shock absorber
Suspension bottoms Overloaded vehicle
Faulty front strut assembly (shock
absorber)
Incorrect, broken or sagging coil springs
Body leans or sways in Loose stabilizer bar (if equipped)
corners
Faulty front strut assembly (shock
absorber) or mounting
Faulty rear shock absorber
Broken or sagging coil springs
Overloaded vehicle
Cupped tires Disturbed wheel alignment
Faulty front strut assembly
Worn wheel bearings
Excessive tire or wheel run-out
Worn suspension arm joints
Wheel out of balance
Replace front strut assembly (shock absorber).
(Page 2B-8)
Replace rear shock absorber. (Page 2C-4)
Check loading.
Replace front strut assembly (shock absorber).
(Page 2B-8)
Replace coil springs.
• Front: (Page 2B-8)
• Rear: (Page 2C-6)
Tighten stabilizer bar bolts or nuts, or replace
bushings. (Page 2B-14)
Replace front strut assembly (shock absorber)
or tighten mounting. (Page 2B-8)
Replace rear shock absorber. (Page 2C-4)
Replace coil springs.
• Front: (Page 2B-8)
• Rear: (Page 2C-6)
Check loading.
Check and adjust wheel alignment. (Page
2B-2)
Replace front strut assembly. (Page 2B-8)
Replace wheel bearing and/or wheel hub
assembly.
• Front: (Page 3A-10)
• Rear: (Page 3A-18)
Repair or replace tire and/or wheel. (Page
2D-3)
Replace suspension arm. (Page 2B-10)
Adjust balance or replace tire.

NOTE
*1: Right-to-left trim height (“h”) difference should be within 15 mm (0.6 in.) with curb weight. (The
same applies to both front and rear suspensions.)

I8C50A210002-01
2A-4 Suspension General Diagnosis:

Repair Instructions
Suspension System Check
AENJCA0A2106001
Hoist vehicle and check the following parts. Retighten,
repair or replace defective part with new one if
necessary.

Front Suspension
• Front suspension frame: (Page 2B-18)
• Suspension arm: (Page 2B-12)
• Front strut assembly: (Page 2B-9)
• Coil spring, strut bearing and strut support: (Page
2B-9)
• Front stabilizer bar and joint (if quipped): (Page 2B-
18)

IJCA0A210001-01

Rear Suspension
• Rear axle: (Page 2C-9)
• Rear shock absorber: (Page 2C-6)
• Rear coil spring: (Page 2C-8)

IJCA0A210002-01
 Front Suspension: 2B-1

Front Suspension
Suspension

Precautions
Precautions for Handling of Front Strut
AENJCA0A2200001
! WARNING
Since a high-pressure gas is sealed inside
each front strut (1), there is a risk of personal
injury if you do not take proper precautions
when handling them.
• Do not disassemble any front strut.
• Do not put it into fire.
• Do not store a front strut where it gets hot.
• Before disposing of a front strut, drill an
approximately 3 mm (0.12 in.) diameter
hole (2) in it at the point indicated in the
figure and let the gas and oil out of the
cylinder.
• Wear eye protection when drilling a gas
release hole. Although the gas itself is
harmless, metal chips produced by the
drilling can injure your eyes.

1 2

IDL10A220001-01
2B-2 Front Suspension:

General Description
Front Suspension Description
AENJCA0A2201001
• Front suspension employs a McPherson strut type
combined with suspension frame (1).
6
• The suspension frame supports steering gear case
assembly (2), engine rear torque rod (3) and 5
suspension arms (4), to reduce vehicle vibration.
• Front strut assembly consists of a sealed cylindrical
strut (5) filled with high-pressure gas and a coil spring
(6).
• The front suspension also includes stabilizer bar (if 2

equipped) (7), to improve anti-rolling performance of

vehicle.

4
1
3 7
IJCA0A220001-01

Front Wheel Alignment Description

AENJCA0A2201002
Among factors for front wheel alignment, only toe setting
can be adjusted. Camber and caster cannot be adjusted.
Therefore, should camber or caster be out of
specification due to the damage caused by hazardous
road conditions or collision, whether the damage is in
body or in suspension should be determined. If body is
damaged, it should be repaired. If suspension is
damaged, it should be replaced.

Repair Instructions
Front Wheel Alignment Inspection and • Check that each suspension part is free from bend,
Adjustment dent, wear or damage.
AENJCA0A2206001
• Place vehicle in non-loaded state on level surface.
Preparation
Perform the following items before checking and • Set steering wheel in straight ahead position.
adjusting front wheel alignment. • Bounce vehicle up and down several times to stabilize
• Check each tire as follows: suspension.
– Check that tire is the specified size. Replace tire • Check that ground clearance at the right and left is
with correct one if necessary. almost the same.
– Check that tire is inflated correctly. Adjust pressure
if necessary.
– Check that tire does not have abnormal wear and is
not worn more than the other tires. Replace tire
with proper one if necessary.
– Check that tire is the same brand as the other tires.
Replace tire with one of correct brands if
necessary.
• Check that wheel bearing is not damaged. Replace
wheel bearing if defective.
• Check wheel (with tire) for deflection. If necessary,
repair or replace.
• Check if each suspension part is installed properly. If
faulty condition is found, repair or replace.
 Front Suspension: 2B-3

Toe Inspection
Measure toe using toe-in gauge (1).
If toe is out of specification, adjust it at tie-rod.
“a”

IFRA0A220002-01

4) Tighten tie-rod end lock nuts to specified torque.

I6RS0C220007-01
(Page 6B-14)
Front toe (Total) “b” – “a”
: IN 1 ± 1 mm (IN 0.04 ± 0.04 in.) Side slip
When checked with side slip tester, side slip should be
[f] within the following value.
Side slip (with a driver)
“a” Reference: 0 to IN 3 mm/m (0 to IN 0.12 in./3.3 ft.)
If side slip deviates from the above value greatly, adjust
it at the tie-rod.

Toe angle
Front toe angle measured with total wheel alignment
tester or the like will be as follows.
Front toe angle (Total)
Reference: IN 0° 06’ ± 0° 05’
“b”
I7V10A220002-02
If the toe angle is out of the above value, adjust it at the
tie-rod.
[f]: Forward

Camber, Caster and Kingpin Inclination Angle

Toe Adjustment
NOTICE
The rack boot may break if it is twisted.
Check that the rack boot does not get twisted
during adjustment of front wheel alignment.
NOTE
Never adjust only right or left tie-rod, adjust
both tie-rods by the same amount.
1) Loosen tie-rod end lock nuts.
2) Tighten or loosen right and left tie-rods by the same
amount to adjust toe to specification.
3) Check that length “a” on right tie-rod is equal to that
on left tie-rod. If they are not equal, readjust toe.
Inspection
Check camber, caster and kingpin inclination angle
using camber caster kingpin gauge (1) and turning
radius gauge (2). If measured value is not as specified,
check the following items for damage, deformation and
crack. Repair or replace any defective part.
• Strut assembly components
• Suspension arms and bushings
• Front suspension frame
• Front wheel hubs, steering knuckles and wheel
bearings
• Vehicle body

I7RS0A220003-01
2B-4 Front Suspension:

Front camber “a” Steering Angle Inspection and Adjustment

155/80 R13: 0° 21’ ± 1° 00’ When tie-rod or tie-rod end is replaced, check toe and
165/70 R14: 0° 12’ ± 1° 00’ then also steering angle using turning radius gauge. If
measured value is not as specified, check and adjust
Front caster “b”
toe.
155/80 R13: 3° 52’ ± 2° 00’
165/70 R14: 3° 56’ ± 2° 00’ Inside steering angle
155/80 R13: 39° 48’ ± 2° 00’
Kingpin inclination angle “c”
165/70 R14: 39° 36’ ± 2° 00’
Reference:
• 155/80 R13: 9° 49’ Outside steering angle
• 165/70 R14: 10° 02’ Reference:
• 155/80 R13: 34° 42’
NOTE • 165/70 R14: 34° 30’
Camber, caster and kingpin inclination angle
are not adjustable. If they are out of
specification, repair vehicle body or replace
related part.

[A] [k]
2

“c”
[t]

[s]

“d” 1

“a”

[B]
“b”

[f]

“d”

IFJA0P220001-03

[A]: Camber and kingpin [t]: Center line of wheel

inclination angle (Front view)
[B]: Caster (Side view) “d”: 90°
[f]: Forward 1. Suspension arm joint
[k]: Center line of kingpin 2. Strut support
[s]: Vehicle body center
 Front Suspension: 2B-5

Front Strut Assembly Components

AENJCA0A2206002

11

6
(a)

10

(a)
5

4 1
8

(b)
3

12

13

[f]

IJCA0A220002-02

[f]: Forward 6. Coil spring upper seat 12. Steering knuckle

1. Front strut 7. Strut bearing 13. Strut bracket bolt
: Insert from vehicle front side.
2. Coil spring lower seat 8. Strut bearing plate : 50 Nm (5.1 kgf-m, 37.0 lbf-ft)
3. Coil spring 9. Strut support : 90 Nm (9.2 kgf-m, 66.5 lbf-ft)
4. Bump stopper 10. Rebound stopper : Do not reuse.
: Install in correct direction. (Page 2B-8)
5. Dust cover 11. Strut rod cap
: For installation, refer to “Front Strut
Assembly Disassembly and Reassembly”
(Page 2B-8).
2B-6 Front Suspension:

Front Strut Assembly Removal and Installation 6) Remove front brake hose bolt (1), and then detach
AENJCA0A2206003 brake hose (2) from front strut bracket.
NOTICE 7) Disconnect clips (3) and grommet (4) from strut (5),
The strut bracket nut is pre-coated with and then detach front wheel speed sensor harness
friction stabilizer. If the nut is reused, it may (6) from front strut bracket.
work loose. 8) Remove strut bracket bolts (7) and nuts (8).
Never reuse the strut bracket nut.
3 5
NOTE
Pulling steering knuckle outward with drive
shaft fixed to steering knuckle could cause
drive shaft to be removed from transaxle. 4
Do not pull steering knuckle outward.
If drive shaft is removed, replace drive shaft
circlip with new one.
5
Removal
1) For left side, with ECM connectors connected,
detach ECM and bracket from body. 6
• K10B model and bi-fuel CNG model: (Page 1C-
3) 7 1
• K12M model: (Page 1C-22)
2) For right side of bi-fuel CNG model, with CNG
control module connectors connected, detach CNG 2
control module and bracket from body. (Page 1C- 8
4) 5
3) Remove strut rod cap.

NOTE
When servicing strut assembly components,
loosen strut support upper nut a little before 3
removing strut assembly. This will facilitate
service work. Note that the nut must not be IJCA0A220003-01

removed at this point. 9) Remove stabilizer joint nut while holding stud using
hexagon wrench (1), and then disconnect stabilizer
4) Hoist vehicle, allowing front suspension to be free of upper joint (2) from strut bracket (3), if equipped.
vehicle weight.
5) Remove front wheel. (Page 2D-3)

IGJA0A220003-02
 Front Suspension: 2B-7

10) Remove strut support upper nut (1) and rebound • Install stabilizer joint and tighten stabilizer joint nut (1)
stopper (2), and then remove front strut assembly to specified torque while holding stud using hexagon
from vehicle. wrench, if equipped.

NOTE Tightening torque

Stabilizer joint nut (a): 50 N·m (5.1 kgf-m, 37.0 lbf-
Hold strut assembly by hand so that it will
ft)
not fall off.

1, (a)

1
IA1J0P220004-01
IFKA0P220005-01

Installation • Tighten wheel nuts to specified torque. (Page 2D-3)

Reverse removal procedure noting the following points. • Lower hoist with vehicle in unloaded condition, and
• Insert strut bracket bolts (1) in the direction as shown then tighten strut support upper nut (1) to specified
in figure. torque.
• Use new strut bracket nuts (2). Tightening torque
• Tighten strut bracket nuts and front brake hose bolt (3) Strut support upper nut (a): 50 N·m (5.1 kgf-m,
to specified torque. 37.0 lbf-ft)
NOTE 1, (a)
Do not twist brake hose and front wheel
speed sensor harness when installing them.

Tightening torque
Strut bracket nut (a): 90 N·m (9.2 kgf-m, 66.5 lbf-
ft)
Front brake hose bolt (b): 26 N·m (2.7 kgf-m, 19.5
lbf-ft)
IE3J0P220015-01

• After completing installation, check front wheel

alignment. (Page 2B-2)
3, (b)

[f]

1
2, (a)

IJCA0A220004-01

[f]: Forward
2B-8 Front Suspension:

Front Strut Assembly Disassembly and Special tool

Reassembly (A): 09943M25010
AENJCA0A2206004
“a”
! WARNING
Failure to take proper precautions when
compressing the coil spring can result in
severe personal injury. (A)
[u] [l]
• Attach the spring compressors to the
positions that allow compressing the
spring evenly.
• Do not use an impact wrench when I9P60A220009-02
compressing the coil spring. [u]: Upper side (large diameter) [l]: Lower side (small diameter)
• When using commercially available spring
compressors, follow the manufacturer’s 2) Install coil spring lower seat (2) to front strut by fitting
instructions described in the manual its protrusion (1) into hole (3) in front strut.
attached to the spring compressors.

Disassembly
1) Attach special tool (A) to coil spring as shown. Screw 2
in special tool bolts (1) alternately until coil spring
tension is released from strut. Rotate strut to check
that it is free of coil spring tension. Record total 1
length of compressed coil spring when it is
compressed.
Special tool
(A): 09943M25010
3
(A)
1

IJCA0A220020-01

3) Install compressed coil spring (1) to front strut (2) by

ICV00P220001-02
2) While keeping coil spring compressed using special
tool, remove strut support lower nut (1) using
hexagon wrench (2) as shown in figure.
fitting coil spring end (3) with protrusion of coil spring
lower seat (4) as shown in figure.
1

2
IFRA0A220031-01

3) Disassemble front strut assembly. (Page 2B-5)

3

Reassembly
1) Compress coil spring using special tool (spring
compressor) evenly until total length “a” becomes 4 “a”
the same length as recorded in disassembly. IFKA0P220007-01

“a”: 8 mm (0.31 in.) or less

 Front Suspension: 2B-9

4) Install bump stopper (1) directing slit side (2) 9) Remove special tool (spring compressor) from coil
downward. spring. Then check that coil spring end does not ride
on protrusion of spring lower seat.
1
Front Strut Inspection
AENJCA0A2206005
• Check each front strut for oil leakage, damage or
deformation. If check result is not OK, replace front
strut as an assembly, as it is not repairable.
2

IJCA0A220021-01

5) Set strut dust cover (1) over three claws (2) of

damper cap (3).

1
2
IDAA0A220010-01
6) Pull strut rod as far up as possible and take care not
to allow it to retract into strut.
7) Install coil spring upper seat.
8) Install strut bearing, strut bearing plate, strut support
and strut support lower nut in this sequence.
(Page 2B-5)
Then tighten strut support lower nut (1) to specified
torque while holding stud using hexagon wrench.
Tightening torque
Strut support lower nut (a): 50 N·m (5.1 kgf-m,
37.0 lbf-ft)
1, (a)
IJCA0A220022-01
• Check front strut function as follows. If check result is
not OK, replace front strut as an assembly, because it
is not repairable.
a. Check and adjust tire pressures as specified.
b. Bounce vehicle body up and down 3 or 4 times
continuously by pushing front end of vehicle side
body to check front strut.
Also, note how many times vehicle body rebounds
to stop after force application.
c. Repeat the same procedure to the other front strut
to check that both struts equally function.
If conditions of front struts are in doubt, compare
them with known-good vehicle or front strut.
Coil Spring, Strut Bearing and Strut Support
Check
AENJCA0A2206006
• Check coil spring for weakening, crack, deformation
and damage.
• Check bump stopper, strut dust cover, coil spring
upper seat, coil spring lower seat and strut support for
crack, deformation and damage.
• Check strut bearing for wear, abnormal noise and
damage.
If check result is not OK, replace defective parts with
new ones.

IFRA0A220032-02
2B-10 Front Suspension:

Suspension Arm Components Removal

AENJCA0A2206007
1) Hoist vehicle and remove front wheel. (Page 2D-3)
2) Remove splash cover. (Page 9H-13)
1 3) Remove clip (1).
4) Loosen suspension arm joint nut (2) until nut end
becomes flush with stud end of suspension arm joint.

2
(a)
(a)

(b)
[f]
1
IJCA0A220005-02

[f]: Forward : 95 Nm (9.7 kgf-m, 70.0 lbf-ft)

1. Suspension arm : 55 Nm (5.6 kgf-m, 40.5 lbf-ft)
2. Clip : Do not reuse.

IJCA0A220006-02
Suspension Arm Removal and Installation 5) Disconnect suspension arm joint (1) from steering
AENJCA0A2206008
knuckle (2) using puller (3).
NOTICE
! CAUTION
• Unless you pay adequate attention when
removing the suspension arm joint from Ball joint puller may fall off when suspension
the steering knuckle, the dust cover of the arm joint is disconnected and cause an
suspension arm joint may be damaged by injury.
the puller. Suspend the ball joint puller from the vehicle
When you remove the suspension arm body using a rope to prevent the puller from
joint from the steering knuckle, be careful falling off.
not to damage the dust cover of the
suspension arm joint.
2
• The following bolts are pre-coated with
friction stabilizer. If these bolts are reused,
they may work loose.
Never reuse the following bolts.
– Suspension arm front bushing bolt
– Front suspension frame bolt

1 3
IJCA0A220007-01

6) Remove suspension arm joint nut.

 Front Suspension: 2B-11

7) Remove suspension arm front bushing bolt (1) and 3) Insert new clip (2) to suspension arm joint.
front suspension frame bolt (2), and then remove
suspension arm (3).

1, (a)

1 3

IJCA0A220010-01
2
IJCA0A220008-01
4) Install front wheel and tighten wheel nuts to specified
torque. (Page 2D-3)
Installation 5) Lower hoist and bounce vehicle up and down
1) Install suspension arm (1) and tighten new several times to stabilize suspension. Then, tighten
suspension arm front bushing bolt (2) and new front suspension arm front bushing bolt (1) and front
suspension frame bolt (3) temporarily by hand. suspension frame bolt (2) to specified torque.
Tightening torque
Suspension arm front bushing bolt (a): 95 N·m (
9.7 kgf-m, 70.0 lbf-ft)
Front suspension frame bolt (b): 95 N·m (9.7
kgf-m, 70.0 lbf-ft)

2 1

3 1, (a)

IJCA0A220009-01

2) Connect suspension arm joint to steering knuckle

and then tighten new suspension arm joint nut (1) to
specified torque.
2, (b)
NOTE
IJCA0A220011-01
If grease is stuck on taper surface of 6) Install splash cover. (Page 9H-13)
suspension arm joint and knuckle, remove it
7) Lower hoist, and then check front wheel alignment.
before connecting these parts.
(Page 2B-2)
Tightening torque
Suspension arm joint nut (a): 55 N·m (5.6 kgf-m,
40.5 lbf-ft)
2B-12 Front Suspension:

Suspension Arm Check 5) Push suspension arm up at near ball joint by hand
AENJCA0A2206009 with force of about 20 to 30 N (2.0 to 3.1 kgf, 4.5 to
6.7 lbf) and hold this state for 2 to 3 seconds, and
Arm then read dial gauge.
Check body of suspension arm (1) for damage and
deterioration. Replace suspension arm if check result is 6) Reversing direction of force, pull suspension arm
not OK. down at near ball joint by hand with force of about 20
to 30 N (2.0 to 3.1 kgf, 4.5 to 6.7 lbf) and hold this
Bushing state for 2 to 3 seconds, and then read dial gauge.
Check suspension arm front bushing (2) for damage, 7) Check total “a” of readings in Steps 4) – 5), amount
wear and deterioration. Replace suspension arm if of looseness.
check result is not OK. If measured looseness exceeds specified range,
Check suspension arm rear bushing (3) for damage, replace suspension arm.
wear and deterioration. Replace suspension arm if Amount of looseness in suspension arm ball
check result is not OK. joint
“a”: less than 0.2 mm (0.008 in.)
1

2
IA1J0P220010-01

3 “a”
Joint
1) Remove front wheel. (Page 2D-3) 0
90 10
2) Using washers (2) and nuts (3) other than the wheel
nuts, fix front brake disc (1) diagonally. 20
80

NOTE 30
70 1
2
Removed wheel nuts can be used to fix front 60 40
50
brake disc facing the top (flat side) toward
the brake disc.
If wheel nut is a cap nut type, fix brake disc IA1J0P020019-01

using nuts other than wheel nuts. 8) Lightly push ball joint dust cover (1) with fingers to
check whether there is water inside.
If water is found to come out, replace suspension
1 arm.

IJCA0A220012-01

3) Set dial gauge (2) using magnetic stand (1) placed

ICP50A220001-01
on front brake disc.

NOTE
Apply measuring tip of dial gauge
perpendicular to bottom center surface of
ball joint as much as possible.

4) Set pointer to 0 (zero) by turning dial (3).

 Front Suspension: 2B-13

9) Push top end (1) of ball joint dust cover down to

check for rust on ball stud’s surface (2) in contact
with dust cover.
If surface is found rusted, replace suspension arm.

ICP50A220002-01

10) Move top end of ball joint dust cover back to original
position.
11) Check ball joint dust cover (1) for crack and damage.
If it is cracked or damaged, replace suspension arm.

ICP50A220003-01

12) Detach ball joint stud from steering knuckle. (Page

2B-10)
13) Check that ball joint stud (1) moves without sticking.
If not, replace suspension arm.

ICP70A220001-01

14) Connect suspension arm ball joint to steering

knuckle. (Page 2B-10)
15) Remove nuts and washers holding the front brake
disc.
16) Install front wheel and tighten wheel nuts to specified
torque. (Page 2D-3)
2B-14 Front Suspension:

Front Suspension Frame and Stabilizer Bar Components

AENJCA0A2206011

A “1”
6 (a)

“2”

4
3
5

7 (b)

(b)

1
(c)

10 (d)

2
10 (d)

11
[f]

8
IJCA0A220013-02

[f]: Forward
1. Front suspension frame
2. Torque rod cover
: For installation, refer to “Front Suspension
Frame, Stabilizer Bar and Bushing Removal
and Installation” (Page 2B-15).
3. Stabilizer bar (if equipped)
: For installing direction of stabilizer bar,
refer to “Front Stabilizer Bar Removal and
Installation (If Equipped)” (Page 2B-17).
4. Stabilizer mounting bracket (if equipped)
5. Stabilizer bar bushing (if equipped)
: For installing direction of stabilizer bar
bushing, refer to “Front Stabilizer Bar
Removal and Installation (If Equipped)”
(Page 2B-17).
Front Suspension Frame, Stabilizer Bar and
Bushing Removal and Installation
AENJCA0A2206012
! CAUTION
• If the front suspension frame is not stably
supported on a transmission jack or other
supporting equipment during its removal
and installation, the frame could drop and
cause personal injury.
Check that the front suspension frame is
supported at the frame’s center and well
balanced on the support.
• Touching a hot exhaust system component
will cause a burn.
Do not perform any service work on the
exhaust system until the exhaust system is
cool.
NOTICE
• The front suspension frame bolt, front
suspension frame rear bolt and steering
gear case bolt are pre-coated with friction
stabilizer. If these bolts are reused, they
may work loose.
Never reuse the front suspension frame
bolt, front suspension frame rear bolt and
steering gear case bolt.
• If steering gear packing is reused, it will
lose the sealing performance and water
may enter the gearbox.
Do not reuse the steering gear packing.
Front Suspension: 2B-15
6. Stabilizer mounting bracket bolt (if : 30 Nm (3.1 kgf-m, 22.5 lbf-ft)
equipped)
: For tightening order, refer to “Front
Stabilizer Bar Removal and Installation (If
Equipped)” (Page 2B-17).
7. Stabilizer joint (if equipped) : 50 Nm (5.1 kgf-m, 37.0 lbf-ft)
8. Suspension arm : 75 Nm (7.6 kgf-m, 55.5 lbf-ft)
9. Engine rear torque rod : 95 Nm (9.7 kgf-m, 70.0 lbf-ft)
: Distinguish top and bottom.
• K10B model and bi-fuel CNG model:
(Page 1D-23)
• K12M model: (Page 1D-99)
10. Front suspension frame bolt : Do not reuse.
: For tightening order, refer to “Front
Suspension Frame, Stabilizer Bar and
Bushing Removal and Installation” (Page
2B-15).
11. Suspension arm front bushing bolt
: For tightening order, refer to “Suspension
Arm Removal and Installation” (Page 2B-
10).
Removal
1) Disconnect steering lower shaft from pinion shaft.
(Page 6B-12)
2) Hoist vehicle and remove front wheels. (Page 2D-
3)
3) Remove front fender lining and splash cover at each
of right and left sides.
4) Disconnect muffler mounting from front suspension
frame.
• K10B model and bi-fuel CNG model: (Page 1K-
2)
• K12M model: (Page 1K-8)
5) Remove stabilizer joint nut (1) while holding stud
using hexagon wrench (2), and then disconnect
stabilizer lower joint (3) from stabilizer bar (4), if
equipped.
2
4
3
1
IJCA0A220014-01
6) Disconnect tie-rod end from steering knuckle.
(Page 6B-15)
2B-16 Front Suspension:

7) Remove exhaust pipe.

• K10B model and bi-fuel CNG model: (Page 1K-
5)
• K12M model: (Page 1K-10)
8) Remove engine rear torque rod bolt.
• K10B model and bi-fuel CNG model: (Page 1D-
23)
• K12M model: (Page 1D-99) 1
9) Support front suspension frame (1) using
transmission jack (2). 2
1
10) Remove front suspension frame bolts (3) and front
suspension frame rear bolts (4), and then lower [f]
2
transmission jack to remove suspension frame
together with stabilizer bar (if equipped), torque rod,
torque rod cover and steering gear case from vehicle
body. IJCA0A220016-01

[f]: Forward
3 3
1
4) Install steering gear case assembly to front
suspension frame. (Page 6B-16)
5) Install suspension arm to front suspension frame,
and then tighten new suspension arm front bushing
bolts temporarily by hand. (Page 2B-10)
6) Put front suspension frame (1) on transmission jack
(2) and raise jack.
2 7) Fix front suspension frame with bolts as follows.
3 3
a) Tighten new front suspension frame bolts (3), (4)
and front suspension frame rear bolts (5)
4 4 temporarily.
IJCA0A220015-01
b) Tighten front suspension frame bolts (4) to
specified torque.
11) Remove suspension arm. (Page 2B-10)
c) Tighten front suspension frame bolts (3) and
12) Remove steering gear case assembly from front
front suspension frame rear bolts to specified
suspension frame. (Page 6B-16)
torque.
13) Remove torque rod cover from front suspension
frame. (Page 2B-14) Tightening torque
Front suspension frame bolt (a): 95 N·m (9.7
14) Remove torque rod from front suspension frame.
kgf-m, 70.0 lbf-ft)
• K10B model and bi-fuel CNG model: (Page 1D- Front suspension frame rear bolt (b): 75 N·m
23) (7.6 kgf-m, 55.5 lbf-ft)
• K12M model: (Page 1D-99)
15) Remove stabilizer bar from front suspension frame, if 3, (a) 3, (a)
equipped. (Page 2B-17) 1

Installation
1) Install front stabilizer bar, if equipped. (Page 2B-
17)
2) Install torque rod to front suspension frame.
• K10B model and bi-fuel CNG model: (Page 1D-
23) 2
• K12M model: (Page 1D-99) 4, (a) 4, (a)

3) Install torque rod cover (1) to front suspension frame

(2) as shown in figure. 5, (b) 5, (b)

IJCA0A220017-01

8) Lower transmission jack.

 Front Suspension: 2B-17

9) Tighten engine rear torque rod bolt to specified Front Stabilizer Bar Removal and Installation (If
torque. Equipped)
AENJCA0A2206013
• K10B model and bi-fuel CNG model: (Page 1D-
23)
Removal
• K12M model: (Page 1D-99)
1) Remove front suspension frame. (Page 2B-15)
10) Install exhaust pipe.
2) Remove steering gear case assembly from front
• K10B model and bi-fuel CNG model: (Page 1K- suspension frame. (Page 6B-16)
5)
3) Remove stabilizer mounting bracket (1) and
• K12M model: (Page 1K-10) stabilizer bar bushing (2).
11) Connect suspension arm joint to steering knuckle. 4) Remove stabilizer bar (3).
(Page 2B-10)
12) Connect tie-rod end to steering knuckle. (Page 6B-
15)
13) Install stabilizer lower joint (1) and tighten stabilizer
joint nut (2) to specified torque while holding stud 1
using hexagon wrench (3), if equipped.
Tightening torque 2
Stabilizer joint nut (a): 50 N·m (5.1 kgf-m, 37.0
lbf-ft)

2, (a)
3
IFKA0P220016-01

IJCA0A220018-01

4. Stabilizer bar

14) Install muffler mounting to front suspension frame.

• K10B model and bi-fuel CNG model: (Page 1K-
2)
• K12M model: (Page 1K-8)
15) Install front wheels and tighten wheel nuts to
specified torque. (Page 2D-3)
16) Connect steering lower shaft to pinion shaft. (Page
6B-12)
17) Lower hoist and bounce vehicle up and down
several times to stabilize suspension. And then,
tighten suspension arm front bushing bolts to
specified torque. (Page 2B-10)
18) Install front fender lining and splash cover at each of
right and left sides.
19) Check front wheel alignment. (Page 2B-2)
2B-18 Front Suspension:

Installation Front Suspension Frame Check

AENJCA0A2206014
1) Install front stabilizer bar (1), bushings (2) and Check front suspension frame for crack, deformation
mounting brackets (3) to front suspension frame as and damage. Replace front suspension frame if check
follows. result is not OK. (Page 9K-37)
a) Position stabilizer bar with identification painting
(4) facing up at right side.
b) Position stabilizer bar bushing with its slit (5)
facing frontward and its end closely fit against
rings (6) of stabilizer bar.

3
2
6
IGJA0A220014-01

2 3
Front Stabilizer Bar, Bushing and Joint Check
(If equipped)
AENJCA0A2206015
Stabilizer Bar
5
Check stabilizer bar for damage and deformation.
4
Replace stabilizer bar if check result is not OK.
1
Stabilizer Bar Bushing
Check stabilizer bar bushing for damage and
2 3
deterioration. Replace stabilizer bar bushing if check
result is not OK.

Stabilizer Joint
• Check ball stud for smooth movement.
[f] 5 • Check ball stud for looseness.
IJCA0A220019-01 • Check dust cover for damage and crack.
[f]: Forward • Check rod for damage and deformation.

c) Tighten stabilizer bar mounting bracket bolts (1) NOTE

to specified torque. Stabilizer joint cannot be disassembled.
Tightening torque If check result is not OK, replace stabilizer joint
Stabilizer bar mounting bracket bolt (a): 30 assembly.
N·m (3.1 kgf-m, 22.5 lbf-ft)
Front Suspension Fastener Check
1, (a) AENJCA0A2206016
Check bolts and nuts fastening suspension parts for
tightness. Tighten loose fastener, if any, to specified
torque.
For specified torque, refer to:
• “Front Strut Assembly Components” (Page 2B-5)
• “Suspension Arm Components” (Page 2B-10)
• “Front Suspension Frame and Stabilizer Bar
Components” (Page 2B-14)

IFKA0P220018-01

2) Install steering gear case assembly to front

suspension frame. (Page 6B-16)
3) Install front suspension frame. (Page 2B-15):
 Front Suspension: 2B-19

Specifications
Tightening Torque Specifications
AENJCA0A2207001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Strut bracket nut 90 9.2 66.5 (Page 2B-7)
Front brake hose bolt 26 2.7 19.5 (Page 2B-7)
Stabilizer joint nut (Page 2B-7) /
50 5.1 37.0
(Page 2B-17)
Strut support upper nut 50 5.1 37.0 (Page 2B-7)
Strut support lower nut 50 5.1 37.0 (Page 2B-9)
Suspension arm joint nut 55 5.6 40.5 (Page 2B-11)
Suspension arm front bushing bolt 95 9.7 70.0 (Page 2B-11)
Front suspension frame bolt (Page 2B-11) /
95 9.7 70.0
(Page 2B-16)
Front suspension frame rear bolt 75 7.6 55.5 (Page 2B-16)
Stabilizer bar mounting bracket bolt 30 3.1 22.5 (Page 2B-18)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Front Strut Assembly Components” (Page 2B-5)
“Suspension Arm Components” (Page 2B-10)
“Front Suspension Frame and Stabilizer Bar Components” (Page 2B-14)
“Fasteners Information” in Section 0A (Page 0A-6)

Special Tools and Equipment

Special Tool
AENJCA0A2208001
09943M25010
Spring compressor
(Page 2B-8) /
(Page 2B-8)
2C-1 Rear Suspension:

Rear Suspension
Suspension

Precautions
Precautions for Handling of Rear Shock ! WARNING
Absorber
AENJCA0A2300002 Since a high-pressure gas is sealed inside
each rear shock absorber (1), there is a risk
of personal injury if you do not take proper
precautions when handling it.
• Do not disassemble any shock absorber.
• Do not put it into fire.
• Do not store a shock absorber where it
gets hot.
• Before disposing of a shock absorber, drill
an approximately 3 mm (0.12 in.) diameter
hole (2) in it at the point indicated in the
figure and let the gas and oil out of the
cylinder.
• Wear eye protection when drilling a gas
release hole. Although the gas itself is
harmless, metal chips produced by the
drilling can injure your eyes.

2
1

IFRA0A230001-01

General Description
Rear Suspension Description
AENJCA0A2301001
Rear suspension is a torsion beam type having rear axle connected with torsion beam.
 Rear Suspension: 2C-2

Repair Instructions
Rear Wheel Alignment Inspection
AENJCA0A2306001
Preparation
Before checking rear wheel alignment, perform the
following items.
• Empty luggage compartment.
• Check tires for specified size.
If not, replace tires with those of the specified size.
• Check that inflation pressure of each tire is adjusted
properly. If necessary, adjust tire pressure, repair or
replace tire.
• Check all tires for even wear and that they are the
same brand. Replace tire(s) if necessary.
• Check that wheel bearing is not damaged. Replace
wheel hub assembly if defective.
• Check each wheel (with tire) for deflection. If
necessary, repair or replace wheel.
• Check that each suspension part is installed properly.
If faulty condition is found, repair or replace part.
• Check that each suspension part is free from bend,
dent, wear or damage.
• Place vehicle in non-loaded state on level surface.
• Bounce vehicle up and down several times to stabilize
suspension.
• Check that ground clearance at the right and left is
almost the same.

Inspection
Measure toe and camber. (Page 2B-2)

NOTE
Rear toe and camber are not adjustable. If
they are out of specification, replace
reference part.

Rear toe (Total)

155/80 R13: IN 2.4 ± 4.3 mm (IN 0.09 ± 0.16 in.)
165/70 R14: IN 2.5 ± 4.3 mm (IN 0.10 ± 0.16 in.)
Rear camber
: –1° ± 1° 00’
If measured value is not as specified, check the following
parts for damage, deformation and crack.
• Rear axle (torsion beam)
• Wheel hub assembly
• Vehicle body

Toe angle
Rear toe angle measured with total wheel alignment
tester or the like will be as follows.
Rear toe angle (Total)
Reference:
• 155/80 R13: IN 0° 15’ ± 0° 26’
• 165/70 R14: IN 0° 15’ ± 0° 25’
2C-3 Rear Suspension:

Rear Suspension Components

AENJCA0A2306002

(c)

7
5

8 3

2
1
(b)

(a)

IJCA0A230001-01

1. Rear axle 6. Rear spring upper seat : 75 Nm (7.6 kgf-m, 55.5 lbf-ft)
2. Rear shock absorber 7. Rear coil spring : 28 Nm (2.9 kgf-m, 21.0 lbf-ft)
: For installing direction of rear coil
spring, refer to “Rear Coil Spring and
Spring Seat Removal and Installation”
(Page 2C-6).
3. Rear shock absorber No.2 bushing 8. Rear spring lower seat : Do not reuse.
: For installing direction of shock absorber upper bushing No.2,
refer to “Rear Shock Absorber Removal and Installation”
(Page 2C-4).
4. Rear shock absorber No.1 bushing 9. Rear shock absorber cap
: For installing direction of shock absorber upper bushing No.1,
refer to “Rear Shock Absorber Removal and Installation”
(Page 2C-4).
5. Rear shock absorber upper washer : 78 Nm (8.0 kgf-m, 57.5 lbf-ft)
 Rear Suspension: 2C-4

Rear Shock Absorber Removal and Installation 6) Remove upper nut (1), shock absorber upper
AENJCA0A2306003 washer (2) and shock absorber No.1 bushing (3).
NOTICE 7) Remove shock absorber (4) and shock absorber
Lowering the rear axle too much may cause No.2 bushing (5).
damage to the flexible brake hose, wheel
[A]
speed sensor lead wire and parking brake
cable.
Limit lowering the rear axle to the minimum
distance necessary.

Removal
1) Remove quarter lower rear trim. (Page 9H-25)
1
2) Remove rear shock absorber cap (1).
2

[B]

1 4

IJCA0A230002-01

3) Hoist vehicle and remove rear wheel. (Page 2D-3)

4) Support rear axle using floor jack (1) to prevent it
from lowering.
5) Remove rear shock absorber lower bolt (2). IJCA0A230004-01

[A]: Luggage compartment side [B]: Wheel housing side

IJCA0A230003-01
2C-5 Rear Suspension:

Installation 4) Lower hoist. With vehicle in unloaded condition,

tighten shock absorber upper nut (1) and lower bolt
NOTICE (2) to specified torque.
• The rear shock absorber upper nut is a Tightening torque
self-locking nut. If this nut is reused, it may Rear shock absorber upper nut (a): 28 N·m (2.9
work loose. kgf-m, 21.0 lbf-ft)
Never reuse the rear shock absorber upper Rear shock absorber lower bolt (b): 75 N·m (7.6
nut. kgf-m, 55.5 lbf-ft)
• The rear shock absorber lower bolt is pre-
coated with friction stabilizer. If this bolt is [A]
reused, it may work loose.
Never reuse the rear shock absorber lower
bolt.

1) Install shock absorber upper bushings (1), shock

absorber (2), shock absorber upper washer (3), new
shock absorber upper nut (4) and new shock
absorber lower bolt (5) as shown in figure. 1, (a)
Tighten shock absorber upper nut and lower bolt
temporarily.

4
3 [B]

2, (b)
2

IJCA0A230006-01

[A]: Luggage compartment side [B]: Wheel housing side

5) Install rear shock absorber cap (1).

IJCA0A230005-01

6. Body panel

1
2) Remove floor jack from rear axle.
3) Install rear wheel. (Page 2D-3)
IJCA0A230002-01

6) Install quarter lower rear trim. (Page 9H-25)

 Rear Suspension: 2C-6

Rear Shock Absorber Inspection
AENJCA0A2306004
• Check shock absorber for deformation or damage.
• Check shock absorber upper bushings for wear or
damage.
• Check shock absorber for evidence of oil leakage.
• Check shock absorber for deterioration.
If check result is not OK, replace shock absorber with
new one.
Rear Coil Spring and Spring Seat Removal and
Installation
AENJCA0A2306005
4) Remove rear shock absorber lower bolts (1).
5) Lower rear axle gradually for removing coil spring(s)
(2).
NOTICE
Lowering the rear axle too much may cause
damage to the flexible brake hose, wheel
speed sensor lead wire and parking brake
cable.
Limit lowering the rear axle to the minimum
distance necessary.
6) Remove coil spring(s).

Removal
1) Hoist vehicle and remove rear wheels. (Page 2D- 2
3)
2) Paint identification mark to lower side of coil spring.
3) Support both ends of rear axle (1) using two floor
jacks (2) to prevent it from lowering.

IJCA0A230007-01
2 1 7) Remove spring upper seat(s) (1) from vehicle body
2
IGJA0A231002-01
and spring lower seat(s) (2) from rear axle.

IJCA0A230008-01
2C-7 Rear Suspension:

Installation NOTE

NOTICE To avoid abnormal noise from rear

suspension, position spring seats and
The rear shock absorber lower bolt is pre- springs correctly.
coated with friction stabilizer. If this bolt is
reused, it may work loose.
Never reuse the rear shock absorber lower
bolt.
5
4
1) Install spring upper seat(s) (1) to vehicle body.

2
2

3
[A] [B]
5 5

1
6 6
7 7
IJCA0A230009-01
1 1
2) Install spring lower seat(s) (1) to rear axle. At this IJCA0A230014-01
time, fit hooks (2) of spring lower seat into holes (3) [A]: Left side [B]: Right side
in rear axle.
3) Facing identification mark (4) downward, install coil 4) Jack up rear axle, and then connect shock absorber
spring(s) (5). At this time, align identification mark (6) (1) lower end to rear axle on both right and left sides.
with protrusion (7) of spring lower seat as shown in 5) Install new shock absorber lower bolt(s) (2) and
figure. tighten bolt(s) temporarily by hand.

IJCA0A230010-01

6) Remove floor jack from rear axle.

7) Install rear wheels. (Page 2D-3)
8) Lower hoist and bounce vehicle up and down
several times to stabilize suspension.
 Rear Suspension: 2C-8

9) Tighten shock absorber lower bolt(s) to specified 7) While supporting rear axle at both ends using floor
torque. jacks, remove right and left rear shock absorber
lower bolts, and then remove rear coil springs from
Tightening torque
rear axle. (Page 2C-6)
Rear shock absorber lower bolt: 75 N·m (7.6
kgf-m, 55.5 lbf-ft) 8) Remove right and left rear axle bolts (1), and then
remove rear axle from vehicle by lowering the jacks
gradually.
Rear Coil Spring and Spring Seat Check
AENJCA0A2306006
• Check rear coil spring for crack, damage and
deformation.
• Check spring seat for crack, damage and
deformation.
If check result is not OK, replace rear coil spring and / or
spring seat with new one.

Rear Axle Removal and Installation

AENJCA0A2306007

NOTICE
• Brake fluid is extremely damaging to
painted surfaces. 1
If brake fluid contacts a painted surface,
immediately wipe it off and flush the
surface with water thoroughly. IJCA0A230012-01

• The rear axle bolts are pre-coated with

Installation
friction stabilizer. If these bolts are reused,
they may work loose. 1) Place rear axle on floor jacks and align its front ends
Never reuse the rear axle bolts. with mounting positions on vehicle body.
2) Insert new right and left rear axle bolts (1) and
Removal tighten them temporarily.
1) Hoist vehicle and remove rear wheels. (Page 2D-
3)
2) Remove rear wheel hub assembly. (Page 3A-18)
3) Using a rope, hold rear brake assembly.
4) Remove parking brake cable (1) from rear axle (2)
on both right and left sides.
5) Remove brake pipes (3) from brake hose (4) on both
right and left sides.
6) Remove E-ring (5), and then remove brake hose
from rear axle on both right and left sides.

5 3
1

IJCA0A230012-01
4 3) Install coil springs, and then insert new right and left
rear shock absorber lower bolts to rear axle and
tighten them temporarily. (Page 2C-6)

1
2

IJCA0A230011-01
2C-9 Rear Suspension:

4) Install brake hoses (1) to rear axle, and then install
brake pipes (2) and tighten brake pipe flare nuts (3)
to specified torque. (Page 4A-13)
3 2
11) Tighten rear axle bolts to specified torque.
Tightening torque
Rear axle bolt: 78 N·m (8.0 kgf-m, 57.5 lbf-ft)
12) Check that rear brakes are free from dragging and
proper braking is obtained.
13) Check all installed parts for brake fluid leakage.

Rear Axle Check

AENJCA0A2306008
1
• Check rear axle (1) for deformation and damage.
• Check rear axle bushings (2) for crack, deformation
and damage. If check result is not OK, replace rear
axle with new one. (Page 2C-8)

IJCA0A230013-01 2
5) Install parking brake cable to rear axle. (Page 4D-
1)
6) Install rear wheel hub assembly. (Page 3A-18) 2
7) Bleed brake system. (Page 4A-6) IGJA0A231006-01

8) Install rear wheels. (Page 2D-3)

9) Lower hoist and bounce vehicle up and down
several times to stabilize suspension.
10) Tighten right and left shock absorber lower bolts to
specified torque. (Page 2C-4)
Rear Suspension Fastener Inspection
AENJCA0A2306009
Check bolts and nuts fastening suspension parts for
tightness. Tighten loose fastener, if any, to specified
torque. (Page 2C-3)

Specifications
Tightening Torque Specifications
AENJCA0A2307001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Rear shock absorber upper nut 28 2.9 21.0 (Page 2C-5)
Rear shock absorber lower bolt (Page 2C-5) /
75 7.6 55.5
(Page 2C-8)
Rear axle bolt 78 8.0 57.5 (Page 2C-9)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Rear Suspension Components” (Page 2C-3)
“Fasteners Information” in Section 0A (Page 0A-6)
 Wheels and Tires: 2D-1

Wheels and Tires

Suspension

Precautions
Precautions for Servicing Wheel and Tire
AENJCA0A2400001
! WARNING
Using tires of different types such as radial, bias and bias-belted tires on the same vehicle may
increase stress on drivetrain components. In addition, as this affects vehicle handling, there is an
increased risk of loss of control and an accident.
Do not use different types of tires on the same vehicle except in an emergency.

Repairs by any means including welding, heating or peening are not permitted. All damaged wheels should be
replaced.

General Description
Tire Description NOTE
AENJCA0A2401001
This vehicle is equipped with tubeless tires of the • Tire inflation pressure should be checked
following specifications. when tires are cool.
• The tire inflation pressure will change due
NOTE
to changes in atmospheric pressure and
If you cannot prepare tires with the specified temperature as well as in temperature of
load index rate and speed symbol, select tire itself when driving. It is important to
tires with higher load index rate and speed check and adjust the tire pressures when
symbol. the tires are cold. Tires that appear to be at
the specified pressure when checked after
Tire specification driving (when the tires are warm) will have
: 155/80 R13 79S, 155/80 R13 79T or 165/70 R14 81S pressure below the specification when the
tires cool down. Also, tires that are inflated
to the specified pressure in a warm garage
may have pressure below the specification
when the vehicle is driven outside in very
cold temperature. If the tire pressure is
adjusted in a place warmer than the
outside, add 1.2 kPa (0.01 kgf/cm2, 0.17 psi,
0.01 bar) to the recommended cold tire
inflation pressure for every 1 °C (1.8 °F)
increase in the temperature of the
adjustment place compared to the outside
air temperature.
• Specified tire inflation pressure is
indicated on the “Tire Placard” or in the
vehicle’s Owner’s Manual.

The tires are designed to operate satisfactorily with

loads up to the full rated load capacity when inflated to
the recommended inflation pressure.
Correct tire pressures and driving habits have an
important influence on tire life. Hard cornering,
excessively rapid acceleration, and unnecessary hard
braking increase tire wear.
2D-2 Wheels and Tires:

Replacement Tire Description The “high spot” of the tire is originally marked by paint
AENJCA0A2401002 dot on the outboard sidewall.
Replacement tires should be the same size, load range The “low spot” of the wheel is originally marked by paint
and construction as those originally installed on the dot on the wheel rim-flange. When assembling, the
vehicle refer to the “Tire Placard”. Using tires of any wheel rims’ paint dot (1) (blue) should be aligned with
other size or type may affect ride, handling, the tires’ paint dot (2) (red) as shown in figure.
speedometer / odometer calibration, vehicle ground Whenever a tire is dismounted from its wheel, it should
clearance and tire or snow chain clearance to the body be remounted so that the tire and wheel are matched. If
and chassis. the tire’s paint dot (2) cannot be located, a line should be
It is recommended that new tires be installed in pairs on scribed on the tire and wheel before dismounting to
the same axle. If replacing only one tire is unavoidable, it assure that it is remounted in the same position.
should be paired with the tire of the best tread condition
to equalize tire-road friction during braking.
The tire inflation pressure is indicated in kilo-pascal
(kPa) while it is also indicated in kgf/cm2 and psi on the
“Tire Placard”. Metric tire gauges are available from tool
suppliers. The table below shows unit conversion for
commonly used inflation pressures.
kPa kgf/cm2 psi
Conversion: 160 1.6 23
1 psi = 6.895 kPa 180 1.8 26
1 kgf/cm2 = 98.066 kPa 200 2.0 29
220 2.2 32
240 2.4 35
260 2.6 38
280 2.8 41
IYSQ01240005-01
300 3.0 44
320 3.2 47
340 3.4 50 Tire Placard Description
AENJCA0A2401007
The “Tire Placard” is located on the driver’s side door
Wheel Description lock pillar and should be referred to for tire information.
AENJCA0A2401003
Wheel Maintenance The placard lists the tire size, rim size and cold tire
Wheels must be replaced if they have any of the pressure.
following conditions: bends, dents, excessive lateral or
radial runout, air leakage through welds, elongated bolt
holes, failure of lug nuts to stay tight, heavy rust. Wheels
with great runout will cause objectionable vibrations.
Wheel specification
: 13 X 4 1/2J inset 45 or 14 x 5J inset 45

Replacement Wheel Description

AENJCA0A2401004
Replacement wheels must be equivalent to the originally
installed wheels in load capacity, diameter, rim width,
offset and mounting configuration.
Using wheel in improper size or type may affect its and
bearing life, brake cooling performance, speedometer /
odometer calibration, ground clearance and clearance to
the body and chassis.

Wheel-Tire Assembly Description

AENJCA0A2401005
Tires and wheels are match mounted at the assembly
plant.
This means that the radially stiffest part of the tire, or
“high spot”, is matched to the smallest radius or “low
spot” of the wheel.
This is done to provide the smoothest possible ride.
 Wheels and Tires: 2D-3

Repair Instructions
Wheel (with Tire) Removal and Installation
AENJCA0A2406001
Removal
1
NOTICE
Using heat to loosen a tight wheel nut for 2
removal may shorten the life of the wheel and
damage the wheel bearings.
Never use heat to loosen a wheel nut for
removal. IGRA0A240002-01

• Check that any foreign material, rust, oil and

1) Loosen wheel nuts by approximately 180°. grease are removed from thread part of wheel nut
(1) and hub bolts (2).

I7V10A240001-01

2) Hoist vehicle.
3) Remove wheel with tire.

Installation
1) Before installing wheels, check the following points.
• Check for buildup of corrosion / foreign material
on mating surfaces of wheel (1) and brake disc /
drum (2), and remove any buildup if any. 2 2
IGRA0A240003-01

2) Install each wheel nut by hand and if it is not

screwed until nut comes in contact with seat of wheel
hole or any abnormality is found, replace wheel nut
and/or hub bolt.

2
IGRA0A240001-01

• Check for roughness, scoring or stepped wear on

surfaces of nut taper (1) and wheel holes (2), and
if any abnormality is found, repair or replace wheel
nut and/or wheel. IGRA0A240004-01
2D-4 Wheels and Tires:

3) Lower vehicle and tighten wheel nuts in numerical Wheel alignment should be checked if one of the
order (“1” – “4”) to specified torque. following conditions is noted.
Tightening order • Front tires wear unevenly.
“1” – “2” – “3” – “4” • Uneven wear between both sides of tread on the
same front tire.
Tightening torque
Wheel nut* (a): 100 N·m (10.2 kgf-m, 74.0 lbf-ft) • Front tire treads show scuffs with “feather” edges on
one side of tread ribs or blocks.

I8C50A240002-01

Tire Inspection
AENJCA0A2406002
Irregular and/or Premature Wear
Irregular and/or premature wear occurs due to incorrect
inflation pressures, lack of tire rotation, rough driving,
improper alignment. If one of the following conditions is
noted, tire rotation is necessary.
• Front tires wear differently from rear tires.
I3RH0A240002-01
• Uneven wear between both sides of tread on the
[A]: Hard cornering, under inflation or non-rotated tires
same tire.
[B]: Incorrect wheel alignment, use of tires of different types or wheel
• Both front tires wear unevenly. heavy acceleration

• Both rear tires wear unevenly.

Tread Wear Indicator
• Abnormal wear such as cupping or flat spotting is
Originally installed tires have built-in tread wear
noted.
indicators (1).
These indicators appear when the tire tread depth
becomes 1.6 mm (0.063 in). If a tire has the indicators
appearing across 3 or more tread grooves at 6 locations,
replacement of the tire is recommended.
Tire wear
Limit: 1.6 mm (0.063 in)

I2RH01240005-01
 Wheels and Tires: 2D-5

Wheel Inspection Tire Rotation

AENJCA0A2406003 AENJCA0A2406004
Wheels must be replaced if they are bent, dented, have To equalize tire wear, rotate tires periodically as shown
excessive lateral or radial runout, air leakage through in figure.
welds, have elongated nut holes, if wheel nuts do not
stay tight, or if they are heavily rusted. Wheels with [f]

greater runout than shown in the figure may cause

objectionable vibrations.
To measure the wheel runout, it is necessary to use
accurate dial indicator.
The tire may be on or off the wheel. The wheel should be
installed to the wheel balancer or the like for proper
measurement.
Take measurements of both lateral runout and radial
runout at both inside and outside of the rim flange. With
dial indicator set in place securely, turn the wheel one full
revolution slowly and record every reading the indicator.
When the measured runout exceeds the specification
and correction by the balancer adjustment is impossible,
replace the wheel. If the reading is affected by welding,
paint or scratch, it should be ignored.
IJCA0A240001-01
Wheel lateral runout limit [f]: Vehicle forward
“a”: 0.90 mm (0.035 in.)
Wheel radial runout limit
“b”: 0.70 mm (0.027 in.)

“a”

“b”

IAW101240001-02

Specifications
Tightening Torque Specifications
AENJCA0A2407001
NOTE
For fastener(s) with * (asterisk) below, refer to the specified procedure in “Repair Instructions”.

Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Wheel nut* 100 10.2 74.0 (Page 2D-4)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Fasteners Information” in Section 0A (Page 0A-6)
2D-6 Wheels and Tires:

Section 3
Driveline / Axle
CONTENTS
Precautions .................................................3-1
Precautions............................................................. 3-1
Precautions for Driveline / Axle ............................. 3-1
Drive Shaft / Axle ..................................... 3A-1
Front .........................................................................3A-1
General Description .............................................3A-1
Front Drive Shaft Construction............................ 3A-1
Diagnostic Information and Procedures............3A-1
Front Drive Shaft Symptom Diagnosis ................ 3A-1
Repair Instructions ..............................................3A-2
Front Drive Shaft Components ........................... 3A-2
Front Drive Shaft Assembly On-Vehicle
Inspection.......................................................... 3A-2
Front Drive Shaft Assembly Removal and
Installation ......................................................... 3A-3
Front Drive Shaft Assembly Disassembly and
Reassembly ...................................................... 3A-4
Table of Contents 3- i
Front Wheel Hub and Steering Knuckle
Components......................................................3A-9
Front Wheel Bearing Check ..............................3A-10
Front Wheel Hub, Steering Knuckle and
Wheel Bearing Removal and Installation ........3A-10
Specifications .....................................................3A-15 3
Tightening Torque Specifications......................3A-15
Special Tools and Equipment ...........................3A-15
Recommended Service Material .......................3A-15
Special Tool ......................................................3A-15
Rear ........................................................................3A-17
Repair Instructions ............................................3A-17
Rear Axle Components .....................................3A-17
Rear Wheel Bearing Check...............................3A-18
Rear Wheel Hub Assembly Removal and
Installation .......................................................3A-18
Specifications .....................................................3A-19
Tightening Torque Specifications......................3A-19
3-1 Precautions:

Precautions
Driveline / Axle

Precautions
Precautions for Driveline / Axle
AENJCA0A3000001
General Precautions
Refer to “General Precautions” in Section 00 (Page 00-1).

Caution for Fastener

Refer to “Caution for Fastener” in Section 00 (Page 00-6).

Warning for Airbag

Refer to “Warning for Airbag” in Section 00 (Page 00-7).
 Drive Shaft / Axle: Front 3A-1

Drive Shaft / Axle

Driveline / Axle

Front
General Description
Front Drive Shaft Construction
AENJCA0A3111001
Both right and left side drive shaft assemblies use a constant velocity ball joint on the wheel side and a tripod type
constant velocity joint on the differential side. The tripod joint allows each drive shaft to slide in the extension /
contraction direction.

Diagnostic Information and Procedures

Front Drive Shaft Symptom Diagnosis
AENJCA0A3114001

Condition Possible cause Correction / Reference Item

Abnormal noise Wear or breakage of drive shaft joint Replace drive shaft joint. (Page 3A-4)
Wear or breakage of the wheel bearing Replace wheel bearing. (Page 3A-10)
3A-2 Drive Shaft / Axle: Front

Repair Instructions
Front Drive Shaft Components
AENJCA0A3116001

3
1
5

6 7
12

11 5

13
8

[A]
10 (a)
IJCA0A311001-01

[A]: Wheel side 8. Wheel side boot

: Apply black grease from the service kit to wheel side boot.
1. Circlip 9. Wheel side joint assembly
: Never disassemble.
: Apply black grease from the service kit to wheel side joint assembly.
2. Differential side joint housing 10. Drive shaft nut
: Apply brown grease from the service kit to differential : After tightening nut to specified torque, caulk nut securely.
side joint housing.
3. Snap ring 11. Damper (right side drive shaft only)
4. Tripod joint 12. Damper band (right side drive shaft only)
: Never disassemble.
: Apply brown grease from the service kit to tripod joint.
5. Boot band (Big) 13. Drive shaft washer (K10B model and bi-fuel CNG model)
6. Differential side boot : 175 Nm (17.8 kgf-m, 129.0 lbf-ft)
: Apply brown grease from the service kit to differential
side boot.
7. Boot band (Small) : Do not reuse.

Front Drive Shaft Assembly On-Vehicle

Inspection
AENJCA0A3116002
• Check boots for breakage, leakage, tear or
deterioration.
• Check boot bands for looseness, crack or damage.
• Check drive shafts for crack or damage.
• Check wheel side joint for smooth rotation and no
rattle.
• Check differential side joint for smooth rotation.
Replace if any abnormalities are found.
 Drive Shaft / Axle: Front 3A-3

Front Drive Shaft Assembly Removal and 8) Pull out drive shaft joint (1) using tire lever (2).
Installation
AENJCA0A3116003 NOTE
Turning drive shaft while pulling out drive
! WARNING
shaft joint may facilitate release of the circlip
Touching a hot exhaust system component fitting of joint spline.
will cause a burn.
Do not perform any service work on the
exhaust system until the exhaust system is [A]
cool.
1

Removal
1) Hoist vehicle and remove front wheel. (Page 2D-3)
2) Release caulking (1) and remove drive shaft nut (2)
with brake pedal depressed.

1 2

[B]

2
IBK80P311002-01

3) Drain transaxle oil.

1
• M/T model
2
– K10B model and bi-fuel CNG model: (Page
5B-8)
– K12M model: (Page 5B-49)
• Auto gear shift model: (Page 5D-99)
IJCA0A311002-01
4) Disconnect tie-rod end from steering knuckle.
(Page 6B-15) [A]: Left side shaft [B]: Right side shaft

5) Disconnect suspension arm joint from steering

9) Remove drive shaft assembly.
knuckle. (Page 2B-10)
6) Remove exhaust pipe. Installation
• K10B model and bi-fuel CNG model: (Page 1K-
5) NOTICE
• K12M model: (Page 1K-10) Failure to take proper precautions when
installing the drive shaft may result in
7) Remove engine rear torque rod bracket.
damage to or breakage of the drive shaft
• K10B model and bi-fuel CNG model: (Page 1D- assembly.
23)
• Be careful not to damage the oil seals and
• K12M model: (Page 1D-99) boots.
• Insert joints only by hand. Never hit joint
boots with a hammer.
• Check that the differential side joint is fully
inserted and the circlip is seated in
position.
3A-4 Drive Shaft / Axle: Front

Reverse removal procedure noting the following points. Differential side joint
• Use new differential side joint circlip. 1) Using nose pliers (2), disengage hooks of boot big
• Apply grease lightly to end face of wheel bearing band (1) and remove band.
inside inner ring. (Page 3A-10)
• Tighten new drive shaft nut (1) to specified torque.

NOTICE
Once the drive shaft nut is removed, it will no
longer have the necessary fastening
performance.
Never reuse the drive shaft nut.

Tightening torque
Drive shaft nut (a): 175 N·m (17.8 kgf-m, 129.0 lbf-
ft)
I9R90A311004-01
• Caulk drive shaft nut as shown. 2) Remove differential side joint housing from tripod
joint.
3) Wipe off grease from shaft, and use snap ring pliers
(2) to remove snap ring (1).

1,(a)

IBK80P311004-01

2. Caulking part

• Connect suspension arm joint. (Page 2B-10)

• Connect tie-rod end to steering knuckle. (Page 6B-
15)
• Install front wheel. (Page 2D-3)
4) Use 3-arm puller (2) to remove tripod joint (1).
• Fill transaxle with transaxle oil as specified.
– M/T model
– K10B model and bi-fuel CNG model: (Page
5B-8)
– K12M model: (Page 5B-49)
– Auto gear shift model: (Page 5D-99)
• Check front wheel alignment. (Page 2B-2)
I9R90A311006-01
NOTICE
Except for the housing, washing the tripod
joint parts with a washing solution may cause
problems with the joint.
Do not use a washing solution to clean any
tripod joint parts other than the housing. Use
a cloth to remove grease from tripod joints.

Front Drive Shaft Assembly Disassembly and

Reassembly
AENJCA0A3116004

Disassembly 1

NOTICE
Disassembly of the wheel side joint or the
tripod joint can cause performance
problems.
I9P60A311005-01
If anything abnormal (damage, noise, etc.) is
found with either of these joints, replace the
joint as an assembly.
 Drive Shaft / Axle: Front 3A-5

5) Using flat-bladed screwdriver (1) or the like, release NOTE

caulking (2) of boot small band (3). Use nippers to cut boot band if it is a welded
type.
Take care not to damage boot while cutting
band.
2
1

3
2
I8V101311031-01 1
6) Pull out differential side boot from shaft.
7) For right side drive shaft, use flat-bladed screwdriver
3
(1) or the like, release caulking (2) of damper band
(3). I8V101311031-01

3) Pull out wheel side boot from shaft.

Reassembly
2 If abnormalities of component parts are found during
1
visual check before / after disassembly, prepare
replacing parts and proceed to reassembly.
Check that wheel side joint assembly (1) and differential
3
side joint housing (2) are washed thoroughly and air-
IFFA0A311003-01 dried.
8) For right side drive shaft, remove damper from shaft.
NOTICE
Wheel side joint Inadequate or insufficient lubricant will
1) Using nose pliers (2), disengage hooks of boot big reduce durability of the joint.
band (1) and remove band. Lubricate each joint with specified amount of
specified grease following instructions
shown below.

NOTE
If removed joint boot(s) (3) is to be reused,
wiping off the inside grease with shop cloth
is recommended.

I9R90A311004-01

2) Using flat-bladed screwdriver (1) or the like, release

caulking (2) of boot small band (3).

I4RS0A310007-01

[A]: Wheel side [B]: Differential side

3A-6 Drive Shaft / Axle: Front

Wheel side joint

1) Wash disassembled parts (except boot). After
washing parts, air-dry them completely.
“a”
2) Clean boots with shop cloth.
3) Apply grease from the service kit to wheel side joint.
Grease specification for front drive shaft wheel
side joint
1
Engine type Grease color Grease amount
K10B model and 70 – 80 g
Black (A)
bi-fuel CNG model (2.46 – 2.82 oz)
IDLA0A311010-01
80 – 90 g
K12M model Black 8) For right side drive shaft, place new damper band (1)
(2.82 – 3.17 oz)
onto damper (4) putting band outer end (2) against
4) Install wheel side boot on shaft. forward rotation (3), and install them to specified
position on shaft as shown in figure.
5) Insert flat-bladed screwdriver or the like into boot (1)
and allow air to enter boot so that air pressure in Drive shaft damper installing position “a”
boot becomes the same as the atmospheric K10B model and bi-fuel CNG model: 483.4 –
pressure at boot fixing position. 489.4 mm (19.03 – 19.26 in.)
K12M model: 445.5 – 451.5 mm (17.53 – 17.77 in.)
1
2

IFRA0A311007-01 3

6) Place new boot big band (3) and new boot small
band (4) onto boot putting each band outer end (1)
against forward rotation (2) as shown in figure.
IFFA0A311004-01

1
“a” 4
IJCA0A311003-01

9) For right side drive shaft, fasten damper band (1) as

IHSB0A311013-01
shown in figure.
7) Fasten new boot small band (1) using special tool as Special tool
shown in figure. (A): 09943M57011
Special tool Damper band fastening distance
(A): 09943M57011 “a”: less than 1.5 mm (0.06 in.)
Boot small band fastening distance
“a”: less than 1.5 mm (0.06 in.)

“a”

(A)
IAV10A311009-01
 Drive Shaft / Axle: Front 3A-7

Differential side joint

1) Wash disassembled parts (except boot and tripod
joint). After washing parts, air-dry them completely.
2) Clean boot and tripod joint with shop cloth.
3) Place new boot small band onto differential side boot
putting band outer end (1) against forward rotation
(2) as shown in figure, and then install them on shaft.

I4RS0B310003-01

6) Fit boot (1) to grooves of shaft and differential side

7) Insert flat-bladed screwdriver or the like into boot
IJCA0A311004-01
4) Install tripod joint (1) on shaft using special tool with
hammer, directing its chamfered spline (3) toward
wheel side, and then fasten tripod joint with new
snap ring (2) using snap ring pliers (4).
Special tool
(A): 09925M98221
joint housing (2).
and allow air to enter boot so that air pressure in
boot becomes the same as atmospheric pressure at
boot fixing position.
Drive shaft boot fixing position (distance
between differential side joint end and boot small
band center) “a”
K10B model and bi-fuel CNG model: 145.7 –
151.7 mm (5.73 – 5.97 in.)
K12M model: 143.7 – 149.7 mm (5.65 – 5.89 in.)
1 2

3
“a”
IFRA0A311010-01

I8G001311014-01
1

2
I8C50A311008-01

8) Place new boot big band onto boot putting each

band outer end (1) against forward rotation (2) as
shown in figure.
I9R90A311012-01

5) Apply grease “A” from the service kit to tripod joint

and joint housing (1).
Grease specification for differential side joint of
front drive shaft
Engine type Grease color Grease amount
K10B model and 90 – 100 g
Brown
bi-fuel CNG model (3.17 – 3.52 oz)
101 – 111 g
K12M model Brown
(3.56 – 3.91 oz)
IJCA0A311005-01
3A-8 Drive Shaft / Axle: Front

9) Fasten boot bands using special tool as shown in

figure.

NOTICE
Squeezing or distorting the boot will reduce
its durability.
Do not force air out of the boot by squeezing
or distorting it when fastening it with boot
bands.

• Big band:
Fasten boot band (1) by pinching hooks (2) with
special tool and engage hooks (3) as shown in
figure.
Special tool
(A): 09943M57021

(A)

3 2

I8C50A311034-01

• Small band:
Fasten boot band (1) using special tool as shown
in figure.
Special tool
(B): 09943M57011
Boot band fastening distance
“a”: less than 1.5 mm (0.06 in.)

“a”

(B)
IDL10A311008-01
 Drive Shaft / Axle: Front 3A-9

Front Wheel Hub and Steering Knuckle Components

AENJCA0A3116005

5
4

3 A

1
IJCA0A311006-01

1. Front wheel hub 4. Front brake disc dust cover : Do not reuse.
2. Circlip 5. Steering knuckle
3. Wheel bearing 6. Hub bolt
: Apply grease 99000-25011 to end face of wheel bearing
inside inner ring. (Page 3A-10)
3A-10 Drive Shaft / Axle: Front

Front Wheel Bearing Check

AENJCA0A3116006
1) Hoist vehicle and remove front wheel. (Page 2D-3)
2) Using washers (2) and nuts (3) other than the wheel
nuts, fix front brake disc (1) diagonally.

NOTE
Removed wheel nuts can be used to fix front
brake disc facing the top (flat side) toward
the brake disc.
If wheel nut is a cap nut type, fix brake disc
using nuts other than wheel nuts.

IJCA0A311008-01
3 4) Install front wheel. (Page 2D-3)
5) Check wheel bearing for rattle by shaking wheel in
axial direction, and for noise and smooth rotation by
turning wheel.
If check result is not OK, replace wheel bearing.
IJCA0A311007-01

3) Check thrust play of front wheel bearing as follows.

If measured value exceeds the limit, replace wheel
bearing.
a) Apply measuring tip of dial gauge to the end of
boss on front wheel hub.

NOTE
Apply measuring tip of dial gauge
perpendicular to the end of boss on front
wheel hub as much as possible.

b) Gripping brake disc at the top and bottom, apply I3RM0A230050-01

push pull force to the disc.

Front Wheel Hub, Steering Knuckle and Wheel
Front wheel bearing thrust play
Limit: 0.05 mm (0.002 in.) Bearing Removal and Installation
AENJCA0A3116007

NOTICE
• When front wheel hub is pulled out using
special tool, wheel bearings could be
affected by the shock.
Replace wheel bearing and circlip with new
ones once the hub is removed.
• If the steering knuckle is not removed and
installed carefully, the front brake disc dust
cover may damage the dust boots of the
suspension arm joints.
When removing and installing the steering
knuckle, be careful not to damage the
suspension arm joint dust boots.
 Drive Shaft / Axle: Front 3A-11

Removal
1) Hoist vehicle and remove front wheel. (Page 2D-3)
2) Remove drive shaft nut. (Page 3A-3)
3) Remove brake disc. (Page 4B-4)
4) Pull out wheel hub (1) with special tools.
11) Remove front brake disc dust cover (1) after
releasing caulking with chisel or the like.
1

NOTE
Outside of wheel bearing inner race comes
out together with wheel hub.

Special tool
(A): 09943M17912
(B): 09942M15511

(A)

(B)

1
IJCA0A311011-01
1
12) Remove circlip (1) from steering knuckle.
IJCA0A311009-01

5) Disconnect tie-rod end from steering knuckle.

(Page 6B-15) 1
6) Remove front wheel speed sensor from steering
knuckle. (Page 4E-34)
7) Remove strut bracket nuts and bolts. (Page 2B-6)
8) Disconnect suspension arm joint from steering
knuckle. (Page 2B-10)
9) Remove steering knuckle from drive shaft.
10) For proper alignment position when installing, make
a matchmark (1) on front brake disc dust cover and
on steering knuckle.
I9P60A311016-02

IJCA0A311010-01
3A-12 Drive Shaft / Axle: Front

13) Using hydraulic press (1), bearing puller (2) and 15) Pry wheel bearing outside inner race (1) a little using
special tool, push out wheel bearing. chisel or the like.
Special tool 16) Remove wheel bearing outside inner race from
(A): 09913M75810 wheel hub using special tools as shown in figure.
Special tool
(A): 09913M65810
(B): 09925M88210
1

(A)

IJCA0A311012-01

14) Remove hub bolts (1) with copper hammer or

hydraulic press (2), if necessary.

I7V20A311014-01
2
Installation
1) Insert new hub bolt (1) in hub hole, if removed.
1 Rotate hub bolt slowly to assure that serrations are
aligned with those made by original bolt.

I8C50A311020-01

I2RH01220040-01

2) Put new wheel bearing (1) on steering knuckle (2).

NOTICE
The used wheel bearing may not operate
properly.
Whenever the wheel hub is removed, replace
the wheel bearing with a new one.
 Drive Shaft / Axle: Front 3A-13

3) Press-fit new wheel bearing into steering knuckle NOTICE

using special tools as shown in figure.
• The dust cover can easily get deformed.
Special tool Be careful when driving the dust cover
(A): 09913M75520 onto the knuckle.
(B): 09913M75510 • If the dust cover is reused, the dust cover
(C): 09951M18211 can come off and damage the brake
system.
Install new dust cover.

1
3
2

[A]: K10B model and bi-fuel CNG model
4) Install new circlip (1).
IDLA0A311006-01
IJCA0A311013-01
6) Align matchmark (1) on new front brake disc dust
[B]: K12M model
cover with matchmark (2) on steering knuckle, and
then install front brake disc dust cover.

I9P60A311016-02 IJCA0A311014-01
5) Make a matchmark (2) on new front brake disc dust 7) Press-fit new front brake disc dust cover (1) into
cover (1). steering knuckle (2) using hydraulic press (3) and
Make a matchmark (4) on same place of the special tools.
removed front brake disc dust cover (3).
Special tool
(A): 09951M15810
(B): 09951M17010
(C): 09951M18211
3A-14 Drive Shaft / Axle: Front

3 3 2 1

[A]: (A)
[B]: (B) 1

4
“A”
I8C50A311024-01
(C)
IJCA0A311015-01 2. Steering knuckle 4. Front wheel hub
[A]: K10B model and bi-fuel CNG model [B]: K12M model 3. Wheel bearing

8) Caulk more than 4 points with a small cold chisel.
1 16) Install brake disc and brake caliper. (Page 4B-4)
11) Install steering knuckle to drive shaft.
12) Connect steering knuckle to suspension arm.
(Page 2B-10)
13) Install strut bracket bolts and nuts. (Page 2B-6)
14) Install front wheel speed sensor. (Page 4E-34)
15) Connect tie-rod end to steering knuckle. (Page 6B-
15)
17) Tighten new drive shaft nut. (Page 3A-3)
18) Install front wheel. (Page 2D-3)
19) Check front wheel alignment. (Page 2B-2)

IJCA0A311016-01

1. Caulking

9) Using special tools and hydraulic press, press-fit

wheel hub (1) into wheel bearing (2).
Special tool
(A): 09913M75810
(B): 09951M18211

I8C50A311035-01

10) Apply grease lightly to end face of wheel bearing

inside inner ring (1).
“A”: Grease 99000–25011 (SUZUKI Super
Grease A)
 Drive Shaft / Axle: Front 3A-15

Specifications
Tightening Torque Specifications
AENJCA0A3117001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Drive shaft nut 175 17.8 129.0 (Page 3A-4)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Front Drive Shaft Components”: Front (Page 3A-2)
“Fasteners Information” in Section 0A (Page 0A-6)

Special Tools and Equipment

Recommended Service Material
AENJCA0A3118001
Material SUZUKI recommended product or Specification Note
Grease SUZUKI Super Grease A P/No.: 99000–25011 (Page 3A-14)

NOTE
Required service material(s) is also described in:
“Front Drive Shaft Components”: Front (Page 3A-2)
“Front Wheel Hub and Steering Knuckle Components”: Front (Page 3A-9)

Special Tool
AENJCA0A3118002
09913M65810 09913M75510
Crankshaft bearing puller Bearing installer
(Page 3A-12) (Page 3A-13)

09913M75520 09913M75810
Bearing installer Bearing installer
(Page 3A-13) (Page 3A-12) /
(Page 3A-14)

09925M88210 09925M98221
Bearing puller attachment Bearing installer
(Page 3A-12) (Page 3A-7)

09942M15511 09943M17912
Sliding hammer Wheel hub remover
(Page 3A-11) (Page 3A-11)
3A-16 Drive Shaft / Axle: Front

09943M57011 09943M57021
Band compressor Low-profile clamp pliers
(Page 3A-6) / (Page 3A-8)
(Page 3A-6) /
(Page 3A-8)

09951M15810 09951M17010
Brake disc dust cover Brake disc dust cover
installer installer
(Page 3A-13) (Page 3A-13)

09951M18211
Oil seal remover & installer
No. 2
(Page 3A-13) /
(Page 3A-13) /
(Page 3A-14)
 Drive Shaft / Axle: Rear 3A-17

Rear
Repair Instructions
Rear Axle Components
AENJCA0A3126001

2
4

[A]

(a)
IJCA0A312001-02

[A]: Forward 3. Rear drum brake assembly : 77 Nm (7.9 kgf-m, 57.0 lbf-ft)
1. Rear axle 4. Rear wheel hub assembly : Do not reuse.
: For installing direction of rear wheel hub
assembly, refer to “Rear Wheel Hub
Assembly Removal and Installation”: Rear
(Page 3A-18).
2. Rear brake drum 5. Hub bolt
3A-18 Drive Shaft / Axle: Rear
Rear Wheel Bearing Check
AENJCA0A3126002
1) Hoist vehicle and remove rear wheel. (Page 2D-3)
2) Remove rear brake drum. (Page 4C-3)
3) Check thrust play of rear wheel bearing as follows.
If measured value exceeds the limit, replace wheel
hub assembly.
a) Apply measuring tip of dial gauge at the center of
hub.
NOTE
Apply measuring tip of dial gauge
perpendicular to the center of rear wheel hub
assembly as much as possible.
b) Gripping hub, apply push pull force to the hub.
Rear wheel bearing thrust play
Limit: 0.05 mm (0.002 in.)
IJCA0A312002-01
4) Check wheel bearing for rattle by shaking wheel in
axial direction, and for noise and smooth rotation by
turning wheel.
If check result is not OK, replace rear wheel hub
assembly.
I3RM0A230050-01
Rear Wheel Hub Assembly Removal and
Installation
AENJCA0A3126003
NOTICE
• The rear hub mounting bolts are pre-
coated with friction stabilizer. If the bolts
are reused, they may work loose.
Use new rear hub mounting bolts.
• Removing the hub bolts will break the
serrations on the hub bolts.
Avoid removing the hub bolts unless their
replacement is absolutely necessary. If the
hub bolts are removed, never reuse the
bolts.
Replace them with new bolts.
Removal
1) Hoist vehicle and remove rear wheel. (Page 2D-3)
2) Remove rear brake drum. (Page 4C-3)
3) Disconnect rear wheel speed sensor connector and
detach clips and grommet. (Page 4E-35)
4) Remove rear hub mounting bolts (1), and then
remove rear wheel hub assembly (2) together with
rear wheel speed sensor.
5) Using a rope, hold rear drum brake assembly (3)
with brake pipe connected.
1 1 1
2
IJCA0A312003-01
6) Remove rear wheel speed sensor from rear wheel
hub assembly. (Page 4E-35)
 Drive Shaft / Axle: Rear 3A-19

7) Remove hub bolts (1) with copper hammer or 2) Install rear wheel speed sensor to rear wheel hub
hydraulic press, if necessary. assembly. (Page 4E-35)
3) Install rear wheel hub assembly (1) and tighten new
rear hub mounting bolts (3) to specified torque.
Locate socket (2) installed with the speed sensor in
Step 2) to the lower side.
Tightening torque
1 Rear hub mounting bolt (a): 77 N·m (7.9 kgf-m,
57.0 lbf-ft)

1
IDLA0A312003-01

Installation
1) Insert new hub bolts (1) in hub holes, if removed.
Rotate each hub bolt slowly to assure that serrations
are aligned with those made by original bolt and then
press-fit one by one.
3, (a)
2
IJCA0A312004-01

4) Connect rear wheel speed sensor connector and

install clips and grommet. (Page 4E-35)
5) Install rear brake drum. (Page 4C-3)
6) Install rear wheel. (Page 2D-3)
7) Check rear wheel alignment. (Page 2C-2)

IDLA0A312004-01

Specifications
Tightening Torque Specifications
AENJCA0A3127001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Rear hub mounting bolt 77 7.9 57.0 (Page 3A-19)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Rear Axle Components”: Rear (Page 3A-17)
“Fasteners Information” in Section 0A (Page 0A-6)
3A-20 Drive Shaft / Axle: Rear

Section 4
Brakes
CONTENTS
Precautions .................................................4-1
Precautions............................................................. 4-1
Precautions for Brakes.......................................... 4-1
Brake Control System and Diagnosis ... 4A-1
Precautions...........................................................4A-1
Precautions for Brake Service ............................ 4A-1
General Description .............................................4A-2
Brake System Description................................... 4A-2
Diagnostic Information and Procedures............4A-2
Brake Symptom Diagnosis.................................. 4A-2
Repair Instructions ..............................................4A-4
Brake Fluid Level Inspection ............................... 4A-4
Brake Fluid Level Switch Inspection ................... 4A-5
Brake Fluid Replacement.................................... 4A-5
Air Bleeding of Brake System ............................. 4A-6
Brake Pedal Components ................................... 4A-8
Brake Pedal Assembly Removal and
Installation ......................................................... 4A-9
Brake Pedal Free Height Inspection ................. 4A-10
Brake Pedal Play Inspection ............................. 4A-11
Excessive Pedal Travel Inspection ................... 4A-11
Brake Light Switch ON-Vehicle Inspection........ 4A-11
Brake Light Switch Removal and Installation .... 4A-12
Brake Light Switch Inspection ........................... 4A-12
Brake Flexible Hose and Pipe Components ..... 4A-13
Brake Flexible Hose and Pipe Removal and
Installation ....................................................... 4A-14
Brake Flexible Hose and Pipe Inspection ......... 4A-16
Brake Master Cylinder Components ................. 4A-16
Brake Master Cylinder Assembly On-Vehicle
Inspection........................................................ 4A-17
Brake Master Cylinder Assembly Removal
and Installation ................................................ 4A-17
Brake Master Cylinder Reservoir Removal
and Installation ................................................ 4A-18
Brake Master Cylinder Assembly Inspection..... 4A-19
Brake Booster Components .............................. 4A-20
Brake Booster Function Check ......................... 4A-21
Brake Booster Removal and Installation ........... 4A-22
Brake Booster Inspection .................................. 4A-23
Brake Booster Piston Rod Adjustment.............. 4A-23
Specifications.....................................................4A-24
Tightening Torque Specifications...................... 4A-24
Table of Contents 4- i
Special Tools and Equipment ...........................4A-24
Recommended Service Material .......................4A-24
Special Tool ......................................................4A-24
Front Brakes ............................................ 4B-1
General Description .............................................4B-1
Front Brake Description ......................................4B-1
Repair Instructions ..............................................4B-1
Front Brake Components ....................................4B-1
Front Brake Pad On-Vehicle Inspection..............4B-2 4
Front Brake Pad Removal and Installation..........4B-2
Front Brake Pad Inspection.................................4B-4
Front Brake Disc Removal and Installation .........4B-4
Front Brake Disc Inspection ................................4B-5
Front Brake Caliper Removal and Installation.....4B-6
Front Brake Caliper Disassembly and
Reassembly ......................................................4B-7
Front Brake Caliper Inspection..........................4B-10
Specifications .....................................................4B-11
Tightening Torque Specifications......................4B-11
Special Tools and Equipment ...........................4B-11
Recommended Service Material .......................4B-11
Rear Brakes.............................................. 4C-1
General Description .............................................4C-1
Rear Drum Brake Description .............................4C-1
Repair Instructions ..............................................4C-2
Rear Drum Brake Components...........................4C-2
Rear Brake Shoe On-Vehicle Inspection ............4C-3
Rear Brake Drum Removal and Installation........4C-3
Rear Brake Drum and Shoe Inspection ..............4C-3
Rear Brake Shoe Removal and Installation ........4C-4
Rear Brake Adjuster and Brake Shoe Lever
Check ................................................................4C-5
Wheel Cylinder Removal and Installation ...........4C-5
Wheel Cylinder Inspection ..................................4C-6
Brake Backing Plate Removal and Installation ....4C-6
Specifications .......................................................4C-7
Tightening Torque Specifications........................4C-7
Special Tools and Equipment .............................4C-7
Recommended Service Material .........................4C-7
Special Tool ........................................................4C-7
Parking Brake .......................................... 4D-1
4-ii Table of Contents
General Description .............................................4D-1
Parking Brake Description...................................4D-1
Repair Instructions ..............................................4D-1
Parking Brake Components ................................4D-1
Parking Brake Inspection ....................................4D-2
Parking Brake Adjustment...................................4D-2
Parking Brake Cable Inspection..........................4D-2
Parking Brake Cable Removal and
Installation .........................................................4D-3
Parking Brake Lever Removal and Installation ....4D-3
Parking Brake Switch Removal and
Installation .........................................................4D-4
Parking Brake Switch Inspection.........................4D-4
Specifications.......................................................4D-5
Tightening Torque Specifications........................4D-5
ABS............................................................4E-1
Precautions........................................................... 4E-1
Precautions for ABS............................................ 4E-1
Precautions for Diagnosing Trouble.................... 4E-1
General Description ............................................. 4E-1
ABS Description .................................................. 4E-1
OBD System Description .................................... 4E-3
Warning Light Description ................................... 4E-3
DLC Description .................................................. 4E-4
CAN Communication System Description........... 4E-4
Schematic and Routing Diagram........................ 4E-4
ABS Diagram ...................................................... 4E-4
ABS Input / Output Diagram................................ 4E-5
ABS Circuit Diagram ........................................... 4E-6
Component Location ........................................... 4E-8
ABS Component Location................................... 4E-8
Diagnostic Information and Procedures............ 4E-9
ABS Check.......................................................... 4E-9
Visual Inspection ...............................................4E-11
ABS Symptom Diagnosis ..................................4E-11
Warning Light Check.........................................4E-12
DTC Check........................................................ 4E-13
DTC Clearance ................................................. 4E-14
DTC Table.........................................................4E-15
Fail-Safe Table..................................................4E-16
Scan Tool Data ................................................. 4E-18
ABS Warning Light Does Not Come ON after
Setting Ignition “ON” ....................................... 4E-19
ABS Warning Light Comes ON Steady .............4E-20
Brake System Warning Light Does Not Come
ON after Setting Ignition “ON” .........................4E-20
Brake System Warning Light Comes ON
Steady .............................................................4E-20
DTC C1021 / C1022 / C1025 / C1026 / C1031
/ C1032 / C1033 / C1035 / C1036...................4E-22
DTC C1041 / C1042 / C1045 / C1046 / C1051
/ C1052 / C1055 / C1056 / C1063...................4E-25
DTC C1057 .......................................................4E-26
DTC C1061 .......................................................4E-27
DTC C1062 .......................................................4E-28
DTC C1071 .......................................................4E-28
DTC U0073 .......................................................4E-28
DTC U0100 .......................................................4E-28
ABS Control Module Power Supply and
Ground Circuit Check......................................4E-29
Repair Instructions ............................................4E-30
ABS Hydraulic Unit Operation Check................4E-30
ABS Hydraulic Unit / Control Module
Assembly Components ...................................4E-31
ABS Hydraulic Unit / Control Module
Assembly On-Vehicle Inspection ....................4E-32
ABS Hydraulic Unit / Control Module
Assembly Removal and Installation ................4E-32
Front and Rear Wheel Speed Sensor On-
Vehicle Inspection ...........................................4E-33
Front Wheel Speed Sensor Removal and
Installation .......................................................4E-34
Rear Wheel Speed Sensor Removal and
Installation .......................................................4E-35
Front and Rear Wheel Speed Sensor
Inspection........................................................4E-35
Front Wheel Speed Sensor Ring Removal
and Installation ................................................4E-35
Rear Wheel Speed Sensor Encoder Removal
and Installation ................................................4E-35
Front Wheel Speed Sensor Ring and Rear
Wheel Speed Sensor Encoder Inspection ......4E-36
Specifications .....................................................4E-36
Tightening Torque Specifications......................4E-36
Special Tools and Equipment ...........................4E-36
Special Tool ......................................................4E-36
 Precautions: 4-1

Precautions
Brakes

Precautions
Precautions for Brakes
AENJCA0A4000001
General Precautions
Refer to “General Precautions” in Section 00 (Page 00-1).

Precautions for Electrical Circuit Service

Refer to “Precautions for Electrical Circuit Service” in Section 00 (Page 00-3).

Caution for Fastener

Refer to “Caution for Fastener” in Section 00 (Page 00-6).

Warning for Wheel and Tire

Refer to “Warning for Wheel and Tire” in Section 00 (Page 00-6).

Warning for Brake

Refer to “Warning for Brake” in Section 00 (Page 00-7).

Warning for Airbag

Refer to “Warning for Airbag” in Section 00 (Page 00-7).

Reassembling Note for Wiring Harness

Observe “Reassembling Note for Wiring Harness” in Section 9A (Page 9A-132) whenever installing wiring harness.
Otherwise, electrical trouble may occur.
4A-1 Brake Control System and Diagnosis:

Brake Control System and Diagnosis

Brakes

Precautions
Precautions for Brake Service
AENJCA0A4100001
Road Test

NOTE
Brakes should be tested on dry, clean, reasonably level, and smooth road. Road test brakes by
applying brake with both light and heavy pedal forces at various speeds to determine if the vehicle
stops evenly and effectively. Also drive vehicle to see if it pulls to one side without brake application. If
it does, check the tire pressure, front wheel alignment and installing condition of front suspensions.
See diagnosis table for other causes.

Brake Fluid Leakage

NOTE
Check the brake fluid level. Although a slight drop results from normal lining wear, an abnormally low
level indicates leakage of brake fluid. In such a case, check the entire brake system for leakage. If even
a slight evidence of leakage is noted, the cause should be corrected or defective parts should be
replaced.

Substandard or Contaminated Brake Fluid

Substandard or contaminated brake fluid with mineral oil or moisture will lower fade resistance or deteriorate rubber
parts resulting in the leakage of brake fluid.
In case improper brake fluid as mentioned above entered into the brake system, or in case such doubt exists,
disassemble the system and clean the parts with alcohol. For the parts which cannot be disassembled, replace them
as an assembly. Rubber parts and brake hoses should be replaced with new ones.
 Brake Control System and Diagnosis: 4A-2

General Description
Brake System Description
AENJCA0A4101001
When the foot brake pedal is depressed, hydraulic pressure is developed in the brake master cylinder to actuate
pistons (two in front disc brakes and 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.

5
3
4 7
1

6
[a] 2

8 7

IJCA0A410001-01

[a]: Forward 3. Secondary side 6. Parking brake lever

1. Brake booster 4. Primary side 7. Parking brake cable
2. Brake master cylinder 5. ABS hydraulic unit / control module assembly 8. Brake 4-way joint

Diagnostic Information and Procedures

Brake Symptom Diagnosis
AENJCA0A4104001

Condition Possible cause Correction / Reference Item

Not enough braking force Brake fluid leakage from brake lines Locate leaking point and repair. (Page 4A-
16)
Brake disc or pads stained with fluid, Clean or replace.
grease or other oil • Front brake disc: (Page 4B-4)
• Front brake pad: (Page 4B-2)
Overheated brakes Determine cause and repair.
Poor contact of shoes on brake drum Repair for proper contact. (Page 4C-3)
Brake drum and/or shoe stained with oil Replace.
or wet with water • Rear brake drum: (Page 4C-3)
• Rear brake shoe: (Page 4C-4)
Badly worn brake pad and/or shoe Replace.
• Front brake pad: (Page 4B-2)
• Rear brake shoe: (Page 4C-4)
Defective wheel cylinders Repair or replace. (Page 4C-5)
Malfunctioning brake caliper assembly Repair or replace. (Page 4B-6)
Air in system Bleed brake system. (Page 4A-6)
Brake booster internal failure Replace brake booster. (Page 4A-22)
Inadequate negative pressure for brake Check engine condition and vacuum hose.
booster
Malfunctioning ABS Check system and replace if necessary.
(Page 4E-9)
4A-3 Brake Control System and Diagnosis:
Condition Possible cause
Vehicle pulls to one side Pad, disc, shoe and/or drum are wet
(Brakes not working with water or stained with oil in some
uniformly) brakes
Drum-to-shoe clearance out of
adjustment in some brake
(Malfunctioning auto adjusting
mechanism)
Disc and/or drum are out of round in
some brakes
Tires are inflated unequally
Malfunction in wheel cylinders
Disturbed front wheel alignment
Unmatched tires on the same axle
Restricted brake pipes or hoses
Malfunctioning brake caliper assembly
Loose suspension parts
Loose brake calipers
Noise (High pitched Contact of wear indicator to brake disc
squeak without brake Worn rear brake shoe
applied)
Excessive pedal travel Brake fluid leakage
(Pedal stroke too large)
Air in system (soft / spongy pedal)
Badly worn brake pad and/or shoe
Rear brake system not adjusted
(malfunctioning auto adjusting
mechanism)
Bent brake shoes
Brake locked Malfunctioning ABS
Dragging brakes (A very Master cylinder pistons not returning
light drag is present in all correctly
brakes immediately after Restricted brake pipes or hoses
pedal is released)
Incorrect parking brake adjustment on
rear brakes
Weakened or broken return springs in
brake
Sluggish parking brake cables or linkage
Wheel cylinder or brake caliper piston
sticking
Badly worn piston seal in brake caliper
Improper brake pedal free height
Correction / Reference Item
Clean or replace.
• Front brake disc: (Page 4B-4)
• Front brake pad: (Page 4B-2)
• Rear brake drum: (Page 4C-3)
• Rear brake shoe: (Page 4C-4)
Check for inoperative auto adjusting
mechanism. (Page 4C-5)
Replace.
• Front brake disc: (Page 4B-4)
• Rear brake drum: (Page 4C-3)
Inflate equally.
Repair or replace. (Page 4C-5)
Adjust as specified. (Page 2B-2)
Tires with approximately the same amount of
tread should be used on the same axle.
Check for damage and replace pipes and/or
hoses if necessary. (Page 4A-16)
Check for stuck or sluggish pistons and proper
lubrication of caliper slide pin. (Page 4B-10)
Check all suspension mountings. (Page 2A-
4)
Check and tighten bolts to specified torque.
(Page 4B-6)
Replace brake pad. (Page 4B-2)
Replace brake shoe. (Page 4C-4)
Locate leaking point and repair. (Page 4A-
16)
Bleed brake system. (Page 4A-6)
Replace.
• Front brake pad: (Page 4B-2)
• Rear brake shoe: (Page 4C-4)
Repair auto adjusting mechanism.
Adjust rear brakes. (Page 4D-2)
Replace brake shoes. (Page 4C-4)
Perform ABS check. (Page 4E-9)
Replace brake master cylinder. (Page 4A-
17)
Check for damage and replace pipes and/or
hoses if necessary. (Page 4A-16)
Check and adjust to correct specifications.
(Page 4D-2)
Replace. (Page 4C-4)
Repair or replace. (Page 4D-3)
Repair if necessary.
• Front brake caliper piston: (Page 4B-7)
• Rear brake wheel cylinder: (Page 4C-5)
Replace piston seal. (Page 4B-7)
Check brake pedal free height. (Page 4A-10)
 Brake Control System and Diagnosis: 4A-4

Condition Possible cause Correction / Reference Item

Pedal pulsation (Pedal Damaged or loose front and/or rear Replace front wheel bearing and/or rear wheel
pulsates when depressed wheel bearings hub assembly.
for braking) • Front: (Page 3A-10)
• Rear: (Page 3A-18)
Distorted steering knuckle or rear wheel Replace.
hub assembly • Knuckle: (Page 3A-10)
• Rear wheel hub: (Page 3A-18)
Excessive disc lateral runout Check per instructions. If not as specified,
replace or machine disc. (Page 4B-5)
Rear drums out of round Check runout.
Repair or replace drum if necessary. (Page
4C-3)
Braking noise Glazed brake pad and/or brake shoe Repair or replace brake pad and/or brake
shoe.
• Front brake pad: (Page 4B-2)
• Rear brake shoe: (Page 4C-4)
Worn or distorted brake shoe Replace brake shoe. (Page 4C-4)
Loose front and/or rear wheel bearings Replace front wheel bearing and/or rear wheel
hub assembly.
• Front: (Page 3A-10)
• Rear: (Page 3A-18)
Distorted backing plates or loose Replace or retighten securing bolts. (Page
mounting bolts 4C-6)
Contact of wear indicator to brake disc Replace brake pads. (Page 4B-2)

Repair Instructions
Brake Fluid Level Inspection
AENJCA0A4106001
• Use brake fluid indicated on brake master cylinder reservoir cap or in Owner’s Manual.
• Check that brake fluid level is between MAX and MIN marks on reservoir of brake master cylinder.

NOTE
If brake system warning light comes on during driving or brake fluid level on brake master cylinder
reservoir is “MIN” mark or lower, check the following points:
• Thickness of front brake pads and rear brake shoes
• Fluid leakage from piston seal of front brake caliper
• Fluid leakage from rear brake wheel cylinder
• Crack or damage to brake hoses and brake pipes
• Fluid leakage from brake master cylinder and reservoir
In case any abnormality is found, repair or replace affected parts.
After the check and repair are completed, replenish brake fluid so that fluid level falls between “MAX”
and “MIN” marks on brake master cylinder reservoir.
4A-5 Brake Control System and Diagnosis:

Brake Fluid Level Switch Inspection NOTE

AENJCA0A4106002
Check continuity between terminals of brake fluid level • When replacing brake fluid, start with the
switch connector (1). If check result is not as specified, brake closest to the brake master cylinder.
replace reservoir. • To prevent air from getting into reservoir,
Brake fluid level switch specification be careful not to let the reservoir be short
MAX position (float up): No continuity of fluid while operating brake pedal.
MIN position (float down): Continuity exists
1) Using a dropper or the like, extract some brake fluid
from reservoir of brake master cylinder.

IJCA0A410002-01
IJCA0A410003-01

Brake Fluid Replacement 2) Add new brake fluid to reservoir of brake master
AENJCA0A4106003 cylinder.
NOTICE
Brake fluid specification
• Using improper or contaminated brake : Refer to reservoir cap
fluid can cause brake system failure. Using
shock absorber fluid or any other fluid that 3) Remove bleeder plug cap on brake caliper. Attach a
contains mineral oil for the brake fluid will vinyl tube (1) to bleeder plug, and insert the other
cause the rubber parts in the brake end into container (2).
hydraulic system to swell or distort. If
water is mixed in the brake fluid, the
boiling point will be lowered.
– Use only the specified brake fluid from a
sealed container.
– Do not use a container that has been
used for a mineral oil or is wet with
water for refilling the brake system.
– Keep all fluid containers capped to
prevent contamination and entry of
moisture. I2RH01410015-01
• Brake fluid is extremely damaging to 4) Depress brake pedal several times with bleeder plug
painted surfaces. loosened.
If brake fluid contacts painted surfaces,
5) If new brake fluid starts coming out, tighten bleeder
immediately wipe it off and flush the
plug to specified torque.
surfaces with water thoroughly.
• Front: (Page 4B-1)
• Rear: (Page 4C-2)
6) Perform Step 3) – 5) for remaining wheels as well.
7) If necessary, bleed brake system. (Page 4A-6)
 Brake Control System and Diagnosis: 4A-6

Air Bleeding of Brake System NOTE

AENJCA0A4106004
NOTICE
• Using improper or contaminated brake
fluid can cause brake system failure. Using
shock absorber fluid or any other fluid that
contains mineral oil for the brake fluid will
cause the rubber parts in the brake
hydraulic system to swell or distort. If
water is mixed in the brake fluid, the
Perform bleeding operation starting from the
brake farthest from brake master cylinder
and then at the brake on the same brake line.
Do the same on the other brake line.
[a]
1 3

boiling point will be lowered.

– Use only the specified brake fluid from a
sealed container.
– Do not use a container that has been
used for a mineral oil or is wet with
water for refilling the brake system.
– Keep all fluid containers capped to
prevent contamination and entry of
moisture. 2 4
• Brake fluid is extremely damaging to IJCA0A410004-01
painted surfaces. [a]: Forward 3. Rear right wheel cylinder
If brake fluid contacts painted surfaces, 1. Front right brake caliper 4. Rear left wheel cylinder
immediately wipe it off and flush the 2. Front left brake caliper
surfaces with water thoroughly.
• If ABS depressurization check is 1) Fill brake master cylinder reservoir with new brake
performed when air is trapped in brake fluid and keep the reservoir at least one-half full of
line, air may be taken in hydraulic unit. To fluid during bleeding operation.
prevent this, bleed brake system before Brake fluid specification
performing hydraulic unit operation check. Refer to reservoir cap (1) of brake master
cylinder or Owner’s Manual.
Hydraulic brake system must be bled whenever air
enters the system. 1
As the system is a diagonal split configuration, if pipe or
hose is disconnected from one brake, the line concerned
must be bled not only at the end of that brake but also at
the end of the diagonally opposite brake.
If any joint on master cylinder or any intermediate joint
between master cylinder and a brake is disconnected,
then the system must be bled at all four brakes.

IJCA0A410005-01
4A-7 Brake Control System and Diagnosis:

2) Remove bleeder plug cap. Attach a vinyl tube (1) to

bleeder plug, and insert the other end into container
(2).

I2RH01410015-01

3) Depress brake pedal several times, and then while

holding it depressed, loosen bleeder plug about one-
third to one-half a turn.
4) When fluid pressure in cylinder is almost completely
released, retighten bleeder plug.
5) Repeat this operation until air is completely removed
from hydraulic line.

I2RH01410016-01

6) When air bubbles disappear from fluid flowing into

container, depress and hold brake pedal and tighten
bleeder plug.
• Front: (Page 4B-1)
• Rear: (Page 4C-2)

I2RH01410017-01

7) Attach bleeder plug cap.

8) After completing bleeding operation, apply fluid
pressure to brake lines and check for leakage.
9) Replenish reservoir with new fluid up to specified
level. (Page 4A-4)
10) Check brake pedal stroke. If the stroke is so large,
repeat entire procedure of bleeding.
 Brake Control System and Diagnosis: 4A-8

Brake Pedal Components

AENJCA0A4106005

10 (a)

(b)

3
4

3 5

9 (a)

9 (a)

2
[A]

[B]
IJCA0A410006-01
4A-9 Brake Control System and Diagnosis:

[A]: M/T model 4. Spacer 9. Brake booster nut

: For tightening order, refer to “Brake Pedal
Assembly Removal and Installation” (Page
4A-9).
[B]: Auto gear shift model 5. Pedal spring 10. Brake pedal bracket nut
: Apply grease 99000-25011 to inside : For tightening order, refer to “Brake Pedal
of spring. Assembly Removal and Installation” (Page
4A-9).
1. Brake pedal 6. Brake pedal bracket : 13 Nm (1.3 kgf-m, 9.5 lbf-ft)
: Apply grease 99000-25011 to inside
of hole.
2. Pedal pad 7. Brake light switch : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
3. Pedal bushing 8. Accelerator pedal bracket
: Apply grease 99000-25011 to all
around surface.

Brake Pedal Assembly Removal and Installation 7) Remove brake pedal assembly.
AENJCA0A4106006
Removal 8) Remove brake light switch, if necessary. (Page
4A-12)
1) Remove steering column lower cover. (Page 6B-4)
2) Disconnect brake light switch connector (1). Installation
3) Disconnect harness clamp (2) from brake pedal 1) Install brake light switch, if removed. (Page 4A-12)
bracket (3).
2) Install brake pedal assembly and accelerator pedal
bracket to brake booster.
2
3) Tighten brake booster nuts (1) to specified torque.
Tightening torque
Brake booster nut (a): 13 N·m (1.3 kgf-m, 9.5 lbf-
ft)
3

IJCA0A410007-01

4) Remove accelerator pedal assembly and bracket.

• K10B model and bi-fuel CNG model: (Page 1C-
8)
• K12M model: (Page 1C-26) 1, (a) 1, (a)

5) Remove brake pedal bracket nut (1).

IJCA0A410009-01

IJCA0A410008-01

6) Remove clip, clevis pin and brake booster nuts from

brake pedal bracket. (Page 4A-22)
 Brake Control System and Diagnosis: 4A-10

4) Tighten brake pedal bracket nut (1) to specified

torque. 2

Tightening torque
Brake pedal bracket nut (a): 13 N·m (1.3 kgf-m,
9.5 lbf-ft)
3

1, (a)

IJCA0A410007-01

9) Install steering column lower cover. (Page 6B-4)

Brake Pedal Free Height Inspection

AENJCA0A4106007
NOTE
IJCA0A410010-01
The brake pedal to carpet clearance must be
5) Tighten accelerator pedal bracket nuts (1) to measured between the specified points that
specified torque. vary with steering wheel position and
Tightening torque transaxle type. Select the appropriate
Accelerator pedal bracket nut (a): 13 N·m (1.3 measuring point (1) according to the figure
kgf-m, 9.5 lbf-ft) below.

[A] [B]

1, (a) 1 1
IFRA0A410011-01

[A]: M/T model [B]: Auto gear shift model

2
Check brake pedal free height. If it is not within
specification, check and adjust the following items.
• Brake booster for installation.
IJCA0A410011-01
• Length of brake booster push rod.
2. Accelerator pedal bracket Brake pedal free height from carpet
“a”: 137 – 157 mm (5.39 – 6.18 in.)
6) Install accelerator pedal assembly.
• K10B model and bi-fuel CNG model: (Page 1C-
8)
• K12M model: (Page 1C-26)
7) Connect harness clamp (2) to brake pedal bracket
(3).
8) Connect brake light switch connector (1).

“a”

I8G001410006-01

1. Carpet
4A-11 Brake Control System and Diagnosis:

Brake Pedal Play Inspection
AENJCA0A4106008
With engine stopped, depress brake pedal several
times.
Depress brake pedal with a finger until resistance is felt
and measure distance to that point.
If brake pedal play is not as specified, check push rod
length. (Page 4A-23)
If push rod length is as specified, check cylinder push
rod clevis and clevis pin for installation condition and
looseness. Replace brake booster or clevis pin if they
are loose.
3) With brake pedal depressed with force of about 300
N (30.6 kgf, 67.4 lbf), measure clearance “a”
between brake pedal and carpet. If clearance “a” is
less than specification, check the following points.
• Air in brake system. (Page 4A-6)
• Brake fluid leakage
• Length of brake booster push rod. (Page 4A-23)
Brake pedal to carpet clearance “a”
When pedal is depressed at 300 N (30.6 kgf, 67.4
lbf): Over 79 mm (3.11 in.)

Brake pedal play “a”

: 1 – 8 mm (0.04 – 0.31 in.)

“a”
IBP80A410011-01

“a”
I3RH0A410010-01
Excessive Pedal Travel Inspection
AENJCA0A4106009
NOTE
The brake pedal to carpet clearance must be
measured between the specified points that
vary with steering wheel position and
transaxle type. Select the appropriate
measuring point (1) according to the figure
below.
Brake Light Switch ON-Vehicle Inspection
AENJCA0A4106010
Depress the brake pedal until brake light turns on and
measure the brake pedal stroke to that point.
If the pedal stroke is not as specified, remove and
reinstall brake light switch.
Brake pedal stroke until brake light turns on “a”
• M/T model: 4 – 14 mm (0.16 – 0.55 in.)
• Auto gear shift model: 4 – 12 mm (0.16 – 0.47 in.)

[A] [B]

1 1
IFRA0A410011-01

[A]: M/T model [B]: Auto gear shift model “a”

IAP70B410015-01

1) Start engine.
2) Depress brake pedal a few times.
 Brake Control System and Diagnosis: 4A-12

Brake Light Switch Removal and Installation 2) Connect brake light switch connector (3).
AENJCA0A4106011
Removal
1) Disconnect brake light switch connector.
2) Remove brake light switch (1) by turning it
3
counterclockwise viewed from above by approx. 90°.

IJCA0A410013-01

Brake Light Switch Inspection

2 AENJCA0A4106012
Check brake light switch for continuity between terminals
IJCA0A410012-01 at each shaft condition.
2. Brake pedal bracket 3. Bushing
If check result is not as specified, replace switch.
M/T model
Installation 2
1) While pulling up brake pedal (2) fully, install brake
light switch (1) pressing it to pedal bracket so that
the switch stroke becomes 0 (zero) and turning it
1
clockwise viewed from above by approx. 90°.

NOTE Terminal
1 2
Shaft condition
While installing brake light switch turning it Free
clockwise, the switch body rises from the Pushed
pedal bracket. IDLA0A410016-01
This movement automatically creates
specified clearance “a” between switch Auto gear shift model
screw end and the pedal bracket.
Clearance “a”: 1.0 to 1.9 mm (0.039 to 0.074 4 3
in.)

2 1

Terminal
1 2 3 4
Shaft condition
Free
Pushed
I9P60A410014-01

“a”

IBP80A410014-01

I8C50A410013-01
4A-13 Brake Control System and Diagnosis:

Brake Flexible Hose and Pipe Components

AENJCA0A4106013

5 6 (a)
13 12
(a)
(a)
(a) 3

3 10
(a)
8
16

2 7
10
1
4
4

12
(a)

10

11

[f]

(c)
(b)

14

13

(a)
9
10
(a)
11 (a)
10
5
16

(a)
(b) 10
(c) 6 7
15 17

(a)
14 (d) 17
IJCA0A410014-01

[f]: Forward
1. Brake master cylinder
2. ABS hydraulic unit / control module assembly
3. Pipe between master cylinder primary and ABS
hydraulic unit / control module assembly
4. Pipe between master cylinder secondary and
ABS hydraulic unit / control module assembly
5. Right pipe between ABS hydraulic unit / control
module assembly and brake 4-way joint
: For installation, refer to “ABS Hydraulic Unit /
Control Module Assembly Removal and
Installation” in Section 4E (Page 4E-32).
6. Left pipe between ABS hydraulic unit / control
module assembly and brake 4-way joint
: For installation, refer to “ABS Hydraulic Unit /
Control Module Assembly Removal and
Installation” in Section 4E (Page 4E-32).
7. Rear brake flexible hose
Brake Flexible Hose and Pipe Removal and Installation
NOTICE
Brake fluid is extremely damaging to painted surfaces.
If brake fluid contacts painted surfaces, immediately wipe it off and flush the surfaces with water
thoroughly.
Removal
1) Hoist vehicle and remove wheel. (Page 2D-3)
NOTE
This operation is not necessary when removing pipes connecting to brake master cylinder.
2) Remove dirt and foreign material from fittings at both flexible hose end and pipe end.
3) Drain brake fluid in reservoir. (Page 4A-5)
4) Remove the following parts according to the pipe:
Pipes Model
Pipe between master cylinder primary and ABS
hydraulic unit / control module assembly
ALL
Petrol
Bi-fuel CNG
Brake Control System and Diagnosis: 4A-14
8. Right pipe between rear brake flexible 16. Right pipe between brake 4-way joint
hose and wheel cylinder and rear brake flexible hose
9. Left pipe between rear brake flexible 17. Left pipe between brake 4-way joint
hose and wheel cylinder and rear brake flexible hose
10. E-ring : 16 Nm (1.6 kgf-m, 12.0 lbf-ft)
11. Front brake flexible hose : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
12. Right pipe between ABS hydraulic unit / : 26 Nm (2.7 kgf-m, 19.5 lbf-ft)
control module assembly and front
brake flexible hose
: For installation, refer to “ABS Hydraulic
Unit / Control Module Assembly
Removal and Installation” in Section 4E
(Page 4E-32).
13. Left pipe between ABS hydraulic unit / : 11 Nm (1.1 kgf-m, 8.5 lbf-ft)
control module assembly and front
brake flexible hose
: For installation, refer to “ABS Hydraulic
Unit / Control Module Assembly
Removal and Installation” in Section 4E
(Page 4E-32).
14. Flexible hose gasket : Do not reuse.
15. Brake 4-way joint
AENJCA0A4106014
Parts to be removed
• Air cleaner assembly
– K10B model and bi-fuel CNG model: (Page
1D-6)
– K12M model: (Page 1D-82)
• Suction hose and liquid hose: (Page 7B-34)
• Heater inlet hose and outlet hose
– K10B model and bi-fuel CNG model: (Page 1F-
7)
– K12M model: (Page 1F-25)
• Fuel feed pipe and EVAP pipe: (Page 1G-20)
• EVAP canister
– K10B model: (Page 1B-3)
– K12M model: (Page 1B-11)
• Fuel feed pipe and purge pipe: (Page 1G-58)
• CNG pressure regulator: (Page 1G-67)
4A-15 Brake Control System and Diagnosis:

Pipes Model Parts to be removed

• Pipe between master cylinder secondary and
ABS hydraulic unit / control module
assembly
• Right pipe between ABS hydraulic unit /
control module assembly and front brake
flexible hose
Left pipe between ABS hydraulic unit / control
module assembly and front brake flexible hose
Pipes between ABS hydraulic unit / control
module assembly and brake 4-way joint
Pipes between brake 4-way joint and rear
brake flexible hose
Pipes between rear brake flexible hose and
wheel cylinder
• Air cleaner assembly
– K10B model and bi-fuel CNG model: (Page
1D-6)
– K12M model: (Page 1D-82)
• Suction hose and liquid hose: (Page 7B-34)
ALL
• Heater inlet hose and outlet hose
– K10B model and bi-fuel CNG model: (Page 1F-
7)
– K12M model: (Page 1F-25)
• Brake booster: (Page 4A-22)
• Fuel feed pipe and EVAP pipe: (Page 1G-20)
• EVAP canister
Petrol
– K10B model: (Page 1B-3)
– K12M model: (Page 1B-11)
• Fuel feed pipe and purge pipe: (Page 1G-58)
Bi-fuel CNG
• CNG pressure regulator: (Page 1G-67)
ALL —
• Pipe between master cylinder primary and ABS
hydraulic unit / control module assembly
ALL
• Pipe between master cylinder secondary and ABS
hydraulic unit / control module assembly
ALL —
ALL —

5) Remove brake flexible hose or pipe.

Special tool
: 09950M78220

Installation – Petrol model: (Page 1G-15)

Reverse removal procedure noting the following points. – Bi-fuel CNG model: (Page 1G-49)
• Tighten flare nuts to specified torque referring to • Check that steering wheel is in straight-forward
“Brake Flexible Hose and Pipe Components” (Page position and flexible hoses are not twisted or kinked.
4A-13).
• Check that flexible hose is not in contact with any part
• Install all removed clamps properly. of suspension when steering wheel is turned fully right
– Brake pipe clamp: (Page 4A-13) and left.
– Fuel pipe clamp • Bleed brake system. (Page 4A-6)
– Petrol model: (Page 1G-15) • Check that brake system operates properly and there
– Bi-fuel CNG model: (Page 1G-49) is no fluid leakage.
• If suction hose and liquid hose are removed, evacuate
and charge A/C system referring to “Evacuation” and
“Charge” in “Operation Procedure for Refrigerant
Charge” in Section 7B (Page 7B-28).
• If heater inlet hose and outlet hose are removed,
check cooling system for leakage.
– K10B model and bi-fuel CNG model: (Page 1F-8)
– K12M model: (Page 1F-26)
• If fuel feed pipe, EVAP pipe, purge pipe and/or CNG
pressure regulator is removed, check fuel line
connections for leakage with engine not running and
ignition “ON”.
 Brake Control System and Diagnosis: 4A-16

Brake Flexible Hose and Pipe Inspection

AENJCA0A4106015

Flexible Hose
Check the following points. If check result is not OK,
replace brake flexible hose.
• Connection for leakage and other damage
• Blister, crack and other damage

IGJA0A410013-01

Pipe
Check brake pipe for damage, crack, dents and
corrosion. If check result is not OK, replace pipe.

Brake Master Cylinder Components

AENJCA0A4106016

4
1

5 FLD

(a) 6
IJCA0A410015-01

1. Reservoir filter 4. Reservoir 7. Brake master cylinder

2. Reservoir cap 5. Grommet : 13 Nm (1.3 kgf-m, 9.5 lbf-ft)
: Apply brake fluid.
3. Spring pin 6. O-ring : Do not reuse.
: Apply grease to O-ring included in spare part
for brake master cylinder or brake booster.
4A-17 Brake Control System and Diagnosis:

Brake Master Cylinder Assembly On-Vehicle 2) For bi-fuel CNG model, disconnect harness clamps
Inspection (1) and remove harness bracket bolt (2).
AENJCA0A4106017
Check brake master cylinder for crack, damage and
brake fluid leakage. If check result is not OK, replace
brake master cylinder.

2
1

IJCA0A410017-01

3) Disconnect brake fluid level switch connector (1) on

reservoir.

IJCA0A410016-01

Brake Master Cylinder Assembly Removal and

Installation
AENJCA0A4106018 1

NOTICE
• The brake master cylinder and brake
booster will lose their original performance
if they are disassembled and reassembled.
If any faulty condition is found in the brake
master cylinder or brake booster, replace
the part rather than trying to disassemble IJCA0A410002-01
and repair it. 4) Remove suction hose as follows.
• Brake fluid is extremely damaging to a) Recover refrigerant from A/C system using
painted surfaces. recovery and recycling equipment referring to
If brake fluid contacts painted surfaces, “Recovery” in “Operation Procedure for
immediately wipe it off and flush the Refrigerant Charge” in Section 7B (Page 7B-28).
surfaces with water thoroughly. b) Disconnect vacuum hose (1) from brake booster.
Removal
1) Remove air cleaner assembly.
• K10B model and bi-fuel CNG model: (Page 1D-
6)
• K12M model: (Page 1D-82)

IJCA0A410028-01

c) Remove suction hose. (Page 7B-34)

5) Clean external surface of brake master cylinder.
 Brake Control System and Diagnosis: 4A-18

6) Drain brake fluid in reservoir. Tightening torque

7) Loosen flare nuts with special tool and disconnect Brake pipe flare nut: 16 N·m (1.6 kgf-m, 12.0 lbf-
brake pipes (1) from brake master cylinder. ft)

Special tool • Install suction hose as follows.

: 09950M78220 a. Apply compressor oil to new O-rings of suction
hose.
8) Remove brake master cylinder fixing nuts (2).
: Compressor oil 95590–58D30 (Compressor
oil (ND-OIL8))
b. Install suction hose. (Page 7B-34)
c. Connect vacuum hose to brake booster.
d. Evacuate and charge A/C system referring to
“Evacuation” and “Charge” in “Operation
2
Procedure for Refrigerant Charge” in Section 7B
1 (Page 7B-28).
• Bleed brake system. (Page 4A-6)
• Check installed parts for brake fluid leakage.
• Check brake pedal for play. (Page 4A-11)
2
• Check that brake system operates properly without
1 fluid leakage.

IJCA0A410019-01
Brake Master Cylinder Reservoir Removal and
9) Remove brake master cylinder (1) and O-ring (2). Installation
AENJCA0A4106019

1 NOTICE
Brake fluid is extremely damaging to painted
surfaces.
If brake fluid contacts painted surfaces,
immediately wipe it off and flush the surfaces
with water thoroughly.

Removal
1) Clean outside surface of reservoir.
2) Remove brake master cylinder together with
reservoir from brake booster. (Page 4A-17)
2
3) Remove spring pin (1) using special tool.
Special tool
(A): 09922M85811
IJCA0A410020-01

Installation
Reverse removal procedure noting the following points.
• Apply grease included in spare part for brake master
cylinder or brake booster to new O-ring, and install it
to brake master cylinder assembly.
• Tighten new brake master cylinder fixing nuts to
specified torque.
Tightening torque
Brake master cylinder fixing nut: 13 N·m (1.3 kgf-
m, 9.5 lbf-ft) (A)

• Connect brake pipes to brake master cylinder and

tighten flare nuts to specified torque.
1
IJCA0A410021-01
4A-19 Brake Control System and Diagnosis:

4) Remove reservoir (1) and grommets (2).

2 (A)

IJCA0A410023-01

2. Secondary port 3. Brake master cylinder assembly

2) Apply pressure to brake master cylinder assembly

IJCA0A410022-01
Installation
1) Lubricate new grommets with the same brake fluid
as the one to fill reservoir before fitting grommets
into master cylinder.
2) Install reservoir to brake master cylinder.
3) Insert new spring pin (2) from chamfered end (1) of
brake master cylinder using special tool until both
right and left ends are the same length “a”.
Special tool
(A): 09922M85811
with special tool (A) and check that pressure does
not build up in cylinder.
If pressure builds up, brake master cylinder
assembly is defective and must be replaced.
3) Repeat Step 1) – 2) for secondary port as well.
Air Tightness Inspection
1) With brake master cylinder assembly (1) fixed in vise
(2) as shown below, fit special tool to primary port.
NOTE
When using vise, put clean cloth between
brake master cylinder and vise so as not to
cause damage to brake master cylinder.
Special tool
(A): 09918M78230

1
2
“a”
2

(A) 1

“a” “a”
IFJA0P410021-01

4) Install brake master cylinder with reservoir to brake

booster. (Page 4A-17)

Brake Master Cylinder Assembly Inspection

AENJCA0A4106020

No-Load Inspection (A)

1) Fit special tool to primary port (1) as shown below.

IJCA0A410024-01

Special tool “a”: 50 mm (2.0 in.)

(A): 09918M78230
 Brake Control System and Diagnosis: 4A-20

2) Using special tool, apply pressure of 50 kPa (0.5 kgf/ If above pressure does not build up, brake master
cm2, 7.25 psi, 0.5 bar) to brake master cylinder cylinder assembly is defective and must be replaced.
assembly. 3) Repeat Step 1) – 2) for secondary port.

Brake Booster Components

AENJCA0A4106021

(b)
3

(a)

2
6

1
5

(c) 8

10
IJCA0A410025-01

1. Brake booster 6. Vacuum hose : 26 Nm (2.7 kgf-m, 19.5 lbf-ft)

2. Gasket 7. Clevis : 13 Nm (1.3 kgf-m, 9.5 lbf-ft)
3. Clevis pin 8. Vacuum pipe : 11 Nm (1.1 kgf-m, 8.5 lbf-ft)
4. Clip 9. Stud cover : Do not reuse.
5. Hose clamp 10. To intake manifold
4A-21 Brake Control System and Diagnosis:

Brake Booster Function Check Operation Check

AENJCA0A4106022
NOTE 1) With engine stopped, depress brake pedal several
times with the same force and check that pedal
Check that no air is in hydraulic line before travel does not change.
this check.

Air Tightness Check

1) Start engine.
2) Stop engine after running for 1 to 2 minutes.
3) Depress brake pedal several times with the same
force as in ordinary braking to see how pedal travel
changes. Brake booster is air tight if pedal travel
decreases every time the pedal is depressed.

I2RH01410007-01

2) Start engine while depressing brake pedal. If pedal

travel increases a little, brake booster operation is
satisfactory. No change in pedal travel indicates
malfunction of brake booster.

I2RH01410005-01

1. 1st 3. 3rd
2. 2nd

4) If pedal travel does not change, brake booster is

defective in air tightness.

NOTE
If faulty condition is found, check vacuum
lines and sealing parts, and replace the faulty
part. After this, repeat the entire test.
I2RH01410008-01
Air Tightness Check under Loaded Condition
1) With engine running, depress brake pedal. Then
stop engine while holding brake pedal depressed.

I2RH01410006-01
I2RH01410009-01
1. 1st, 2nd, 3rd
H: Hold
 Brake Control System and Diagnosis: 4A-22

2) Hold brake pedal depressed for 30 seconds. If pedal Installation

height does not change, brake booster is in good
condition. If pedal height changes, brake booster is
not in good condition.
1) Install brake vacuum hose and pipe, if removed.
2) Remove steering column lower cover. (Page 6B-4)
3) Loosen brake pedal bracket nut (1).

I2RH01410010-01

H: Hold T: 30 seconds

Brake Booster Removal and Installation

AENJCA0A4106023 IJCA0A410008-01

4) Install brake booster to dash panel.

Removal
5) Connect clevis (1) to brake pedal arm with clevis pin
1) For K12M model, remove intake manifold. (Page (2) and new clip (3).
1D-85)
6) Tighten brake booster nuts (4) and brake pedal
2) Remove brake master cylinder. (Page 4A-17) bracket nut (5) in numerical order (“1” – “2”) to
3) Remove pipe between master cylinder primary and specified torque.
ABS hydraulic unit / control module assembly.
Tightening torque
(Page 4A-14)
Brake booster nut (a): 13 N·m (1.3 kgf-m, 9.5 lbf-
4) Remove clip (2) and clevis pin (3) from clevis (1). ft)
5) Remove brake booster nuts (4). Brake pedal bracket nut (b): 13 N·m (1.3 kgf-m,
9.5 lbf-ft)
1

5, “2”, (b)

4, “1”, (a)
4

3 1
3
2

IJCA0A410026-01

6) Remove brake booster from dash panel.

4, “1”, (a)
7) Remove brake vacuum hose and pipe, if necessary. IJCA0A410027-01

7) Install pipe between master cylinder primary and

ABS hydraulic unit / control module assembly.
(Page 4A-14)
8) Install brake master cylinder to brake booster.
(Page 4A-17)
9) For K12M model, install intake manifold. (Page
1D-85)
10) Bleed brake system. (Page 4A-6)
4A-23 Brake Control System and Diagnosis:

11) Check installed parts for brake fluid leakage. 1) Before adjusting brake booster piston rod, set jig (1),
12) Check brake pedal for play. (Page 4A-11) which is included in brake master cylinder supplied
as replacement part, to brake booster as shown in
13) Check that brake system operates properly without
figure. Check for clearance between jig and piston
brake fluid leakage.
rod adjust screw (2).
14) Install steering column lower cover. (Page 6B-4)
NOTE
Brake Booster Inspection Set jig so that there is no clearance between
AENJCA0A4106024
jig and brake booster.
• Check brake booster for damage.
• Check brake booster for operation referring to Clearance between jig and piston rod adjust
“Operation Check” under “Brake Booster Function screw
Check” (Page 4A-21). “a”: 0 mm (0 in.)
• Check boot for damage and deterioration.
• Check push rod length. 2
If check result is not as specified, adjust distance 1
between booster installation surface (without including
“a”
packing) and the center of clevis pin hole to standard
value “a” and tighten push rod nut (1) to specified
torque.
Push rod length
“a”: 114.5 – 115.5 mm (4.507 – 4.547 in.)
Tightening torque
Push rod nut (a): 26 N·m (2.7 kgf-m, 19.5 lbf-ft)

2
1

IFKA0P410022-01

2) If brake booster piston rod adjustment is required,

secure brake booster piston rod in place using
special tool as shown in figure, and then adjust
length of piston rod adjust screw (1).
Special tool
(A): 09952M16010

IGRA0A410007-01

(A)
Brake Booster Piston Rod Adjustment
AENJCA0A4106027
NOTE
Adjustment of brake booster piston rod is
required only when brake master cylinder is
replaced with a new one.

I8B701410008-02

3) After adjusting brake booster piston rod, check for

clearance between jig and piston rod adjust screw
again.
 Brake Control System and Diagnosis: 4A-24

Specifications
Tightening Torque Specifications
AENJCA0A4107001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Brake booster nut (Page 4A-9) /
13 1.3 9.5
(Page 4A-22)
Brake pedal bracket nut (Page 4A-10) /
13 1.3 9.5
(Page 4A-22)
Accelerator pedal bracket nut 13 1.3 9.5 (Page 4A-10)
Brake master cylinder fixing nut 13 1.3 9.5 (Page 4A-18)
Brake pipe flare nut 16 1.6 12.0 (Page 4A-18)
Push rod nut 26 2.7 19.5 (Page 4A-23)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Brake Pedal Components” (Page 4A-8)
“Brake Flexible Hose and Pipe Components” (Page 4A-13)
“Brake Master Cylinder Components” (Page 4A-16)
“Brake Booster Components” (Page 4A-20)
“Fasteners Information” in Section 0A (Page 0A-6)

Special Tools and Equipment

Recommended Service Material
AENJCA0A4108001
Material SUZUKI recommended product or Specification Note
Compressor oil Compressor oil (ND-OIL8) P/No.: 95590–58D30 (Page 4A-18)

NOTE
Required service material(s) is also described in:
“Brake Pedal Components” (Page 4A-8)
“Brake Master Cylinder Components” (Page 4A-16)

Special Tool
AENJCA0A4108002
09918M78230 09922M85811
Master cylinder leakage Spring pin remover (4.5 mm)
tester
(Page 4A-19) / (Page 4A-18) /
(Page 4A-19) (Page 4A-19)

09950M78220 09952M16010
Flare nut wrench (10 x 12 Booster piston rod adjuster
mm)
(Page 4A-15) / (Page 4A-23)
(Page 4A-18)
4B-1 Front Brakes:

Front Brakes
Brakes

General Description
Front Brake Description
AENJCA0A4201001
Front brake system is a ventilated disc brake type.

Repair Instructions
Front Brake Components
AENJCA0A4206001

3 4

17 (b)
(a)
(d)

(c) 5

12

8 9

19
10

13
9

11

14

15 18
11
16
IJCA0A420001-02
 Front Brakes: 4B-2

1. Steering knuckle 9. Pin boot 17. Bleeder plug

2. Front brake disc dust cover
3. Front wheel hub
4. Front brake disc
5. Front brake flexible hose
6. Front brake caliper
7. Flexible hose gasket
8. Bleeder plug cap
10. Pad spring 18. Brake pad
: Apply grease included in pad set of
supply part referring to “Front Brake
Pad Removal and Installation” (Page
4B-2).
11. Shim 19. Front brake caliper carrier
12. Slide pin without bushing : 27 Nm (2.8 kgf-m, 20.0 lbf-ft)
: Apply rubber grease included in pin boot set of
supply parts.
13. Slide pin with bushing : 6.0 Nm (0.61 kgf-m, 4.5 lbf-ft)
: Apply rubber grease included in pin boot set of
supply parts.
14. Brake piston : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
15. Piston seal : 85 Nm (8.7 kgf-m, 63.0 lbf-ft)
: Apply small amount of rubber grease included in
piston seal set of supply parts or specified brake fluid.
16. Piston boot : Do not reuse.
: Apply small amount of rubber grease included in
piston seal set of supply parts or specified brake fluid.

Front Brake Pad On-Vehicle Inspection
AENJCA0A4206002
Check pad linings (1) periodically according to
maintenance schedule and whenever wheels are
removed (for tire rotation or other reason). Check lining
thickness of outside and inside pads.
If lining is worn and its thickness (“a” in figure) is less
than the limit, all pads must be replaced at the same
time.
Front brake pad thickness (lining thickness) “a”
Standard: 9.5 mm (0.37 in.)
Limit: 1.5 mm (0.06 in.)
Front Brake Pad Removal and Installation
AENJCA0A4206003
NOTICE
Failure to take proper precautions during
front brake caliper removal may cause
damage to the front brake flexible hose and/
or the brake piston.
• Be careful not to damage the front brake
flexible hose during front brake pad
removal.
• Avoid depressing the brake pedal during
the front brake pad removal procedure to
prevent the brake piston from being forced
out of the cylinder.

NOTE
• Check for leakage of brake fluid when
removing front brake pads and repair front
brake caliper if leakage is found.
• Replace all brake pads at the same time
even if only one pad is defective.

Removal
1) Hoist vehicle and remove front wheel. (Page 2D-3)
2) Remove front brake caliper pin bolts (1).
I2RH01420001-01

IA1J0P420002-01
4B-3 Front Brakes:

3) Remove front brake caliper (1) from front brake Installation

caliper carrier (2).
NOTE
NOTICE When front brake pad (1) is replaced with a
If the removed front brake caliper is left hung new one, apply grease included in the brake
by the front brake flexible hose (6), the front pad set of supply parts to hatched areas “A”
brake flexible hose may be damaged due to of each brake pad.
the tension caused by the caliper’s weight.
Hang a removed front brake caliper with a “A”

wire hook (4) or the like to relieve the front

brake flexible hose of the tension.

4) Remove front brake pads (3) and pad springs (5)

from front brake caliper carrier.

4
5 1

“A”
IJCA0A420004-01
6 3
1) Fit outer shim (1) to front brake pad (2).

5
2

1 2

IA1J0P420003-01

5) Remove outer shim (1) from brake pad (2).

1
IDMA0P420001-01
2
2) Fit inner shim (1) to brake piston (2).

1
IA1J0P420024-02
1
6) Remove inner shim (1) from brake piston (2).

1
2 IA1J0P420005-01

IA1J0P420004-01
 Front Brakes: 4B-4

3) Install pad springs (1) and front brake pads (2) with Front Brake Pad Inspection
shims to front brake caliper carrier (4) as shown in AENJCA0A4206004

figure. NOTICE
NOTE If the front brake pad lining is polished with
Install inner pad at inside of caliper carrier sandpaper, abrading particles will be
with its wear indicator (3) positioned upside. embedded in the lining and will damage the
front brake disc.
Do not polish pad lining with sandpaper.
Replace the front brake pad with a new one.
1

3 NOTE

2 • Check for leakage of brake fluid when

removing front brake pads and repair front
brake caliper if leakage is found.
1 • Replace all brake pads at the same time
even if only one pad is defective.
4
Check thickness of each front brake pad lining. If any
IA1J0P420006-01
lining is thinner than limit or is excessively worn on one
4) Install front brake caliper (2) to front brake caliper side, replace all front brake pads.
carrier (3) and tighten front brake caliper pin bolts (1) Front brake pad thickness (lining thickness)
to specified torque. Standard: 9.5 mm (0.37 in.)
Limit: 1.5 mm (0.06 in.)
NOTICE
If the front brake flexible hose is twisted, the
hose will be damaged.
If it is twisted, reinstall it carefully without
giving twist.

Tightening torque
Front brake caliper pin bolt (a): 27 N·m (2.8 kgf-
m, 20.0 lbf-ft)

I7V20A420005-01

2
Front Brake Disc Removal and Installation
1, (a) AENJCA0A4206005

NOTICE
Failure to take proper precautions during
front brake caliper removal may cause
damage to the front brake flexible hose and/
3
or the brake piston.
• Hang removed front brake caliper with a
IA1J0P420007-01 wire hook or the like not to twist the front
5) Install front wheel. (Page 2D-3) brake flexible hose during front brake
caliper removal.
6) Check that brake system operates properly.
• Avoid depressing the brake pedal during
the brake disc removal procedure to
prevent the brake piston from being forced
out of the cylinder.

Removal
1) Hoist vehicle and remove front wheel. (Page 2D-3)
2) Remove front brake caliper and front brake pads
from front brake caliper carrier. (Page 4B-2)
4B-5 Front Brakes:

3) Remove front brake caliper carrier bolts (1) and Front Brake Disc Inspection
remove front brake caliper carrier (2) from steering AENJCA0A4206006

knuckle (3). • Using magnetic stand (1), set dial gauge (2) with prod
positioned about 10 mm (0.39 in.) inward from
periphery of disc, measure deflection of disc. If it
exceeds the limit, correct or replace the front brake
2 disc.
1 Front brake disc deflection
Limit: 0.10 mm (0.004 in.)

3
IA1J0P420008-01
2
4) Push out front brake disc by tightening two M8 bolts
(1) evenly into jack bolt holes.

IFRA0A420004-01

• Using micrometer, measure thickness of front brake

disc. If it is less than limit, replace front brake disc.
Front brake disc thickness “a”
Standard: 17.0 mm (0.67 in.)
Limit: 15.0 mm (0.60 in.)
1

I8B701420006-01

Installation “a”

1) Install front brake disc to front wheel hub.

2) Install front brake caliper carrier (2) to steering
knuckle (3) and tighten front brake caliper carrier
bolts (1) to specified torque.
Tightening torque
Front brake caliper carrier bolt (a): 85 N·m (8.7
kgf-m, 63.0 lbf-ft)
IAP70A420011-01

1, (a)

3
IA1J0P420009-01

3) Install front brake caliper and front brake pads.

(Page 4B-2)
4) Install front wheel. (Page 2D-3)
5) Check that brake system operates properly.
 Front Brakes: 4B-6

Front Brake Caliper Removal and Installation 6) Remove front brake pads from front brake caliper
AENJCA0A4206007 carrier.
! WARNING 7) Remove front brake caliper carrier bolts (1).
8) Remove front brake caliper carrier (2) from steering
If front brake flexible hose gaskets are
knuckle (3).
reused, brake fluid may leak, which could
result in an accident.
Always use new flexible hose gaskets when
reinstalling the flexible hose.

1
NOTICE
Failure to take proper precautions during
front brake caliper removal may cause
damage to the front brake flexible hose and/ 2

or the brake piston.

• Be careful not to damage the brake front
3
brake flexible hose during front brake IA1J0P420012-01
caliper removal.
• Avoid depressing the brake pedal during Installation
the front brake caliper removal procedure
to prevent the brake piston from being NOTICE
forced out of the cylinder. If the front brake flexible hose is twisted, the
hose will be damaged.
Removal If it is twisted, reinstall it carefully without
1) Hoist vehicle and remove front wheel. (Page 2D-3) giving twist.
2) Place a container below caliper to catch brake fluid.
1) Install front brake caliper carrier (2) to steering
3) Remove flexible hose joint bolt (1) from front brake knuckle (3).
caliper (2). Tighten front brake caliper carrier bolts (1) to
specified torque.
Tightening torque
Front brake caliper carrier bolt (a): 85 N·m (8.7
1 kgf-m, 63.0 lbf-ft)

1, (a)

IDL10A420002-01

4) Remove front brake caliper pin bolts (1). 2

5) Remove front brake caliper (2) from front brake

caliper carrier (3). 3
IA1J0P420014-01

2
1

IA1J0P420011-01
4B-7 Front Brakes:

2) Install front brake caliper to front brake caliper Front Brake Caliper Disassembly and
carrier. Reassembly
Tighten front brake caliper pin bolts (1) to specified AENJCA0A4206008

torque.
Disassembly
Tightening torque Caliper
Front brake caliper pin bolt (a): 27 N·m (2.8 kgf-
1) Clean surfaces around caliper with brake cleaner
m, 20.0 lbf-ft)
before disassembly.
2) Remove brake piston by blowing air into the hole for
front brake flexible hose joint bolt.
1, (a)
! CAUTION
If you place your fingers in front of the piston
when you push it out with compressed air,
you may hurt your fingers.
Do not place your fingers in front of the
piston when removing it using compressed
air.

IDL10A420003-02
3) Connect brake flexible hose (1) with new flexible
hose gaskets (2) to caliper as shown in figure.
Tighten front brake flexible hose joint bolt (3) to
specified torque.
Tightening torque
Front brake flexible hose joint bolt (a): 23 N·m (
2.3 kgf-m, 17.0 lbf-ft)
NOTICE
Failure to take proper precautions while
servicing front brake caliper and brake piston
may damage piston and/or brake caliper.
• Place a cloth (1) in front of the piston to
prevent it from jumping out.
• Do not scratch sealing surface (2) with air
blow gun.
• Use a moderate air pressure to push the
piston out of the cylinder slowly.

3, (a) 1

IFRA0A420005-01

4) Fill reservoir with brake fluid and bleed brake I2RH01420011-01

system. (Page 4A-6)
5) Check that there is no leakage of the brake fluid.
6) Install front wheel. (Page 2D-3)
7) Check that brake system operates properly.

IGRA0A420001-01
 Front Brakes: 4B-8

3) Remove piston boot (1) and bleeder plug (2) from Reassembly
brake caliper (3).
! WARNING
2
Failure to take proper precautions when
assembling the brake caliper can result in
brake system failure, which could lead to an
3
accident.
• Clean each part before installation using
the same brake fluid as that in the master
cylinder reservoir.
Never use any other brake fluid or volatile
solvent.
• Before installing the piston seal and piston
1 boot to the cylinder, apply rubber grease
IDL10A420005-01
included in the piston seal set or brake
4) Remove piston seal (1) from cylinder of front brake fluid to them.
caliper (3) using flat-bladed screwdriver (2) or the
like. • Fit a new piston seal securely into the
groove of the cylinder checking that it is
NOTICE not twisted.
If the inside surface of the cylinder (bore
wall) and outside surface of piston are Caliper
damaged, brake fluid leakage may result. 1) Perform the following steps before installing brake
Be extremely careful not to damage the piston to front brake caliper.
inside surface of the cylinder and outside a) Check entire periphery of brake piston and inside
surface of piston when removing the piston surface of cylinder for rust, corrosion and any
seal. other damage. If check result is not OK, replace
brake piston and/or front brake caliper.
3
b) After applying rubber grease included in piston
seal set of supply parts or specified brake fluid to
1
new piston seal (1), fit the seal into groove in
cylinder taking care not to twist the seal.
Brake fluid specification
Refer to reservoir cap of brake master
cylinder or Owner’s Manual.

2 1
I9P60A420026-01

Slide pin
Remove slide pins (2) and pin boots (3) from front brake
caliper carrier (1).

2
I2RH01420017-01

IA1J0P420025-01
4B-9 Front Brakes:

c) Apply rubber grease included in piston seal set 4) To check that piston boot (2) is fitted in its groove in
of supply parts or specified brake fluid to new cylinder properly, pull piston (1) a little outward
piston boot (1). And then install it onto brake without moving it fully out.
piston as shown.

1 1

[B] [A] 2

I9P60A420019-01

[A]: Caliper cylinder side [B]: Brake pad side

2 2
2) Fit piston boot (1) with piston into boot groove in
cylinder by hand as shown below.

IFKA0P420002-01

5) Insert piston into cylinder by hand.

6) Install bleeder plug to front brake caliper and tighten
IAP70A420017-01
it to specified torque.
3) Insert brake piston (1) into cylinder by hand and fit
piston boot (2) in boot groove on brake piston. Tightening torque
Bleeder plug: 6.0 N·m (0.61 kgf-m, 4.5 lbf-ft)
NOTE
Check that boot is securely fitted in boot Slide pin
grooves in piston and cylinder. 1) Check the following points before installing slide pins
to front brake caliper carrier.
a) Check slide pins for rust, corrosion and other
damage. Replace slide pin if defective.
b) Install new pin boots (1) to front brake caliper
carrier (2) with their ends directed as shown
below.

IAP70A420018-01

IDLA0A420008-01
 Front Brakes: 4B-10

c) Apply rubber grease included in pin boot set of Front Brake Caliper Inspection
supply parts to slide pin (1). AENJCA0A4206009
NOTE
Perform this inspection in the following
cases.
• When replacing front brake pads with new
ones.
1 • When removing front brake caliper.

Caliper Body and Carrier

IDLA0A420009-01
2) Install slide pin without bushing (1) into upper side
and slide pin with bushing (2) into lower side of front
brake caliper carrier (3) as shown.
Check brake caliper body and carrier for deformation,
crack, damage and rust. Replace front brake caliper and
carrier if defective.
Piston Boot
Check piston boot (1) for break and crack. Replace
piston boot if defective.

[A]

I8RW01420003-01
IJCA0A420003-01

[A]: Upward Slide Pin

Before installing caliper to carrier (2), check slide pins (1)
for smooth thrust movement.

2
IBP80A420013-01
4B-11 Front Brakes:

Specifications
Tightening Torque Specifications
AENJCA0A4207001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Front brake caliper pin bolt (Page 4B-4) /
27 2.8 20.0
(Page 4B-7)
Front brake caliper carrier bolt (Page 4B-5) /
85 8.7 63.0
(Page 4B-6)
Front brake flexible hose joint bolt 23 2.3 17.0 (Page 4B-7)
Bleeder plug 6.0 0.61 4.5 (Page 4B-9)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Front Brake Components” (Page 4B-1)
“Fasteners Information” in Section 0A (Page 0A-6)

Special Tools and Equipment

Recommended Service Material
AENJCA0A4208001
NOTE
Required service material(s) is also described in:
“Front Brake Components” (Page 4B-1)
 Rear Brakes: 4C-1

Rear Brakes
Brakes

General Description
Rear Drum Brake Description
AENJCA0A4301001
The rear brake is a leading-trailing drum type.
4C-2 Rear Brakes:

Repair Instructions
Rear Drum Brake Components
AENJCA0A4306001

13 (d)

17
(c)
15
16 (b)

9
10

14 7

(e)

11

5 4

8
6
8

12
(a)
3

8
6
2
8

IJCA0A430001-01

1. Rear brake drum 9. Wheel cylinder 17. Wheel cylinder rubber kit
: Apply small amount of rubber grease
or specified brake fluid.
2. Brake shoe 10. Brake backing plate : 77 Nm (7.9 kgf-m, 57.0 lbf-ft)
: After cleaning backing plate, apply heat-resistant
brake grease or grease included in supply part.
3. Shoe return spring 11. Rear wheel hub assembly : 8.5 Nm (0.87 kgf-m, 6.5 lbf-ft)
4. Brake adjuster (strut) 12. Parking brake cable : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
5. Strut retaining spring 13. Rear brake pipe : 16 Nm (1.6 kgf-m, 12.0 lbf-ft)
6. Shoe hold down spring 14. Plug : 11 Nm (1.1 kgf-m, 8.5 lbf-ft)
7. Shoe set pin 15. Rear axle : Do not reuse.
8. Shoe hold down retainer 16. Bleeder plug
 Rear Brakes: 4C-3

Rear Brake Shoe On-Vehicle Inspection

AENJCA0A4306002
Amount of brake shoe wear can be checked as follows. “a”

1) Hoist vehicle.
2) Remove rubber cover (plug) (1) from brake backing
plate.
3) Through hole in backing plate, visually check for
thickness “a” of brake shoe lining (2). If brake shoe
lining is found significantly worn, check rear brake
shoe lining thickness as follows. 1
a) Remove rear brake drum. (Page 4C-3)
b) Check rear brake shoe lining thickness referring
IBP80A430002-01
to “Rear Brake Shoe” under “Rear Brake Drum
and Shoe Inspection” (Page 4C-3). 3) Install rear brake drum to rear wheel hub assembly.
4) Adjust parking brake cable referring to “Parking
Rear brake shoe lining thickness “a” Brake Adjustment” in Section 4D (Page 4D-2).
Standard: 3.9 mm (0.15 in.)
Limit: 1.0 mm (0.04 in.) 5) Install rear wheel referring to “Wheel (with Tire)
Removal and Installation” in Section 2D (Page 2D-
2
3).
6) Check that brake drum does not drag and brake
provides proper braking. Perform brake test (foot
brake and parking brake).

Rear Brake Drum and Shoe Inspection

AENJCA0A4306004

Rear Brake Drum

1
I4RS0B430004-01
• Check rear brake drum for damage, deformation and
cracks. If check result is not OK, replace brake drum
Rear Brake Drum Removal and Installation with new one.
AENJCA0A4306003 • Check brake drum for wear.
Removal If drum inner diameter exceeds the limit or uneven or
1) Hoist vehicle and remove rear wheel. (Page 2D-3) stepped wear is excessive, replace brake drum with
2) Release parking brake. new one.
3) Remove rear brake drum (2) by screwing M8 bolts Rear brake drum inner diameter “a”
(1) evenly. Standard: 180 mm (7.09 in.)
Limit: 182 mm (7.17 in.)
2

1
IFRA0A430001-02

Installation “a”

1) Check that inside of rear brake drum and rear brake

shoes are free from dirt and oil.
2) Check outer diameter “a” of brake shoes. If it is out I9P60A431006-01
of the specified range below, adjust it by turning
adjuster (1).
Brake shoes outer diameter “a” =measured brake
drum inside diameter – 0.5 to 1.0 mm (0.02 to 0.04
in.)
4C-4 Rear Brakes:

Rear Brake Shoe 3) Remove shoe return springs, brake shoes and brake
• Check surface of lining (1) for hardening, excessive adjuster.
wear, peel-off and oil. 4) Disconnect brake shoe lever (1) from parking brake
• Measure brake shoe thickness “a” (not including cable (2).
backing plate) at least three points. If any measured
value is not as specified or if remarkable uneven wear
is found, replace all the shoes of the vehicle.
Rear brake shoe lining thickness “a”
Standard: 3.9 mm (0.15 in.)
Limit: 1.0 mm (0.04 in.)

2
1
IBP80A430004-01
“a”
1
Installation
I9P60A431014-01
Reverse removal procedure noting the following points.
2. Inspection point
• Before installing brake shoes to brake backing plate,
clean brake backing plate and apply grease “A”.
Rear Brake Shoe Removal and Installation
AENJCA0A4306005 “A”: Heat-resistant brake grease
NOTE
Replace both right and left brake shoes as a
set.

Removal
“A” “A”
1) Remove rear brake drum. (Page 4C-3)
2) Pushing and turning shoe hold down retainer (1),
remove shoe hold down retainer, shoe set pin (2)
and hold down spring (3) at both sides.
I9P60A431009-02

• Connect brake shoe lever to parking brake cable

1 securely.
3
1
2
• Install rear brake drum. (Page 4C-3)
• Adjust parking brake cable. (Page 4D-2)
• Check that brake drum is free from dragging and
check that brake system operates properly.

IJCA0A430002-01
 Rear Brakes: 4C-5

Rear Brake Adjuster and Brake Shoe Lever 3) Remove wheel cylinder mounting bolts. Disconnect
Check brake pipe from wheel cylinder and put bleeder plug
AENJCA0A4306006 cap (1) onto pipe to prevent fluid from spilling.
• Check ratchet of brake adjuster (1) for wear or
damage.
• Check shoe return springs, strut retaining spring, and
hold down springs for damage, corrosion and 1
weakening.
• Check for smooth movement of brake shoe lever (2)
along shoe rim.
If check result is not OK, repair or replace brake adjuster
and/or brake shoe lever.

2
I9P60A431011-01

1 Installation
Reverse removal procedure noting the following points.
• Install wheel cylinder to brake backing plate (1), and
then connect brake pipe (2) to wheel cylinder.
IBP80A430005-01 • Tighten wheel cylinder mounting bolts (3) and rear
brake pipe flare nut (4) to specified torque.
Wheel Cylinder Removal and Installation Tightening torque
AENJCA0A4306007
Wheel cylinder mounting bolt (a): 10 N·m (1.0 kgf-
NOTICE m, 7.5 lbf-ft)
Brake fluid is extremely damaging to painted Rear brake pipe flare nut (b): 16 N·m (1.6 kgf-m,
surfaces. 12.0 lbf-ft)
If brake fluid contacts any painted surface,
3, (a) 1
immediately wipe it off and flush the surface 3, (a)
with water thoroughly.
2

Removal
1) Remove rear brake shoes. (Page 4C-4)
2) Loosen brake pipe flare nut (1) but limit loosening to
extent in which fluid does not leak.
Special tool 4, (b)

: 09950M78220

IFRA0A430003-01

• Install rear brake drum. (Page 4C-3)

• Bleed brake system. (Page 4A-6)
• Adjust parking brake cable. (Page 4D-2)
• Check that brake drum is free from dragging and
check that brake system operates properly.

I9P60A431010-01
4C-6 Rear Brakes:

Wheel Cylinder Inspection Installation

AENJCA0A4306008
• Check wheel cylinder for fluid leakage and boots for
breakage, crack and damage. If check result is not
OK, replace boots and cups.
• Check wheel cylinder for wear, crack, corrosion or
damage. If check result is not OK, replace wheel
cylinder assembly with a new one.
Reverse removal procedure noting the following points.
• Install brake backing plate and rear wheel hub
assembly. (Page 3A-18)
• Install parking brake cable (1) to brake backing plate
and tighten parking brake cable cap nut (2) to
specified torque.
Tightening torque
Parking brake cable cap nut (a): 11 N·m (1.1 kgf-
m, 8.5 lbf-ft)

I7V20A430004-02

Brake Backing Plate Removal and Installation

AENJCA0A4306009 2, (a)

Removal
1) Remove wheel cylinder. (Page 4C-5)
2) Remove parking brake cable cap nut (1) and parking
brake cable (2) from brake backing plate.
2
IFRA0A430005-02
• Install rear brake drum. (Page 4C-3)
• Bleed brake system. (Page 4A-6)
• Adjust parking brake cable. (Page 4D-2)
• Check that brake drum is free from dragging and
check that brake system operates properly.

IFRA0B431002-01

3) Remove rear wheel hub assembly. (Page 3A-18)

4) Remove brake backing plate.
 Rear Brakes: 4C-7

Specifications
Tightening Torque Specifications
AENJCA0A4307001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Wheel cylinder mounting bolt 10 1.0 7.5 (Page 4C-5)
Rear brake pipe flare nut 16 1.6 12.0 (Page 4C-5)
Parking brake cable cap nut 11 1.1 8.5 (Page 4C-6)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Rear Drum Brake Components” (Page 4C-2)
“Fasteners Information” in Section 0A (Page 0A-6)

Special Tools and Equipment

Recommended Service Material
AENJCA0A4308001
Material SUZUKI recommended product or Specification Note
Heat-resistant brake — — (Page 4C-4)
grease

NOTE
Required service material(s) is also described in:
“Rear Drum Brake Components” (Page 4C-2)

Special Tool
AENJCA0A4308002
09950M78220
Flare nut wrench (10 x 12
mm)
(Page 4C-5)
4D-1 Parking Brake:

Parking Brake
Brakes

General Description
Parking Brake Description
AENJCA0A4401001
The parking brake system is mechanically controlled. The system applies braking force to only the rear wheels by
means of the cable and mechanical linkage system. The same brake shoes are used for parking and foot brakes.

Repair Instructions
Parking Brake Components
AENJCA0A4406001

(b)

(b)

4
(b)
7
1

(a) 5
(b)
(a)
(b)
(c)
3 4 6
2
(b)

[a] (b)
3
IJCA0A440001-01

[a]: Forward 4. Parking brake cable : 26 Nm (2.7 kgf-m, 19.5 lbf-ft)
1. Parking brake lever 5. Brake shoe lever : 11 Nm (1.1 kgf-m, 8.5 lbf-ft)
2. Equalizer 6. Parking brake cable end (shoe lever side) : 1.5 Nm (0.15 kgf-m, 1.5 lbf-ft)
3. Parking brake cable end (equalizer side) 7. Parking brake switch

Parking Brake Inspection
AENJCA0A4406002
NOTE
Check the following conditions before
parking brake inspection and adjustment.
• No air is trapped in brake system.
• Brake pedal travel is proper.
• Rear brake shoes are not worn beyond
limit.
• Check the following items. If check result is not OK,
adjust or replace parking brake cable.
a. Operation of parking brake lever is smooth.
b. Operate parking brake lever with force of 200 N
(20.4 kgf, 45.0 lbf) as shown, counting number of
clicks ratchet notches generate.
NOTE
One click sound corresponds to one notch.
Parking brake stroke “a”
When lever pulled up at 200 N (20.4 kgf, 45.0
lbf): 4 to 9 notches
I7V20A440002-01
• Release parking brake lever and check that brake
system warning light turns off. Then check that brake
system warning light turns on within 1 notch when
parking brake lever is pulled up. If check result is not
OK, check and, if necessary, repair the following
items.
NOTE
• Warning light should be checked when
ignition is “ON”.
• Check that ABS warning light is turned off.
a. Remaining amount of brake fluid: (Page 4A-4)
b. Brake fluid level switch (attached to brake master
cylinder reservoir): (Page 4A-5)
c. Parking brake switch: (Page 4D-4)
Parking Brake: 4D-2
Parking Brake Adjustment
AENJCA0A4406003
1) Remove floor console box. (Page 9H-34)
2) Release parking brake.
3) Loosen parking brake adjusting nut (1) until parking
brake cable becomes free of tension.
4) Start engine and depress brake pedal more than 15
times with about 150 N (15.3 kgf, 33.7 lbf) to obtain
proper drum-to-shoe clearance.
5) Stop engine and adjust parking brake lever stroke to
specified value with adjusting nut.
6) Check equalizer (2) inclination angle. If angle is not
as specified, check parking brake cable and rear
brake shoe linings. (Page 4C-3)
Equalizer inclination angle
“a”: within 15 degrees
1
2
“a”
2
IJCA0A440002-01
7) After completion of adjustment, check that brake
drum is not dragging.
Parking Brake Cable Inspection
AENJCA0A4406004
1) Check that clamps on parking brake cable are
properly installed and that cable is not twisted.
Correct if any faulty condition is found.
2) Check that parking brake cable is not damaged or
kinked. Replace if any faulty condition is found.
4D-3 Parking Brake:

3) Move inner cable (1) at input end of parking brake NOTE

cable by hand to check that inner cable (2) at If necessary to remove both right and left
opposite end moves smoothly. Replace parking parking brake cables, repeat above steps.
brake cable if either one of inner cables is stuck or
caught.
Installation
Reverse removal procedure noting the following points.
1
• Tighten each bolt to specified torque. (Page 4D-1)
• Check that parking brake cable end is installed to
equalizer and lever securely.
• Adjust parking brake cable. (Page 4D-2)
• After completion of the installation and adjustment of
parking brake lever stroke, check that brake system
operates properly.

Parking Brake Lever Removal and Installation

AENJCA0A4406006
Removal
1) Place gear shift lever in “1st” (M/T model) or shift
selector in “N” range (auto gear shift model), and
block drive wheels.
2) Remove floor console box. (Page 9H-34)
3) Disconnect parking brake switch connector (2) from
parking brake lever (1).

IJCA0A440003-01

2
Parking Brake Cable Removal and Installation
AENJCA0A4406005
Removal
1) Disconnect parking brake cable from brake shoe
lever. (Page 4C-4)
2) Remove floor console box. (Page 9H-34)
3) Loosen parking brake cable adjusting nut (1). 1

4) Remove parking brake cable (3) from equalizer (2).

IJCA0A440005-01

4) Loosen parking brake cable adjusting nut (1).

5) Remove parking brake cable (3) from equalizer (2).

2
3

IJCA0A440004-01
2
5) Disconnect parking brake cable from vehicle. 3
(Page 4D-1)
IJCA0A440004-01
 Parking Brake: 4D-4

6) Remove parking brake lever bolts (1) and then Installation

remove parking brake lever (2) together with
equalizer (3).
Reverse removal procedure noting the following point.
• Tighten parking brake screw (1) to specified torque.
Tightening torque
Parking brake screw (a): 1.5 N·m (0.15 kgf-m, 1.5
lbf-ft)

3 1, (a)

IJCA0A440007-01

Installation
Reverse removal procedure noting the following points.
• Tighten parking brake lever bolts (1) to specified
torque.
Tightening torque
IJCA0A440009-01
Parking brake lever bolt (a): 26 N·m (2.7 kgf-m,
19.5 lbf-ft)
Parking Brake Switch Inspection
AENJCA0A4406008
Check for continuity between parking brake switch
terminal and vehicle body ground as shown in figure. If
check result is not as specified, replace parking brake
switch.
Parking brake switch specification
Parking brake released: No continuity
Parking brake lever pulled up: Continuity exists

1, (a)

IJCA0A440008-01

• Connect parking brake cable to equalizer, and then

adjust parking brake cable. (Page 4D-2)
• Check that brake system operates properly.

Parking Brake Switch Removal and Installation 1

AENJCA0A4406007

Removal
IJCA0A440010-01
1) Remove floor console box. (Page 9H-34)
1. Parking brake switch 2. Parking brake lever
2) Disconnect parking brake switch connector from
parking brake lever.
3) Remove parking brake switch from parking brake
lever.
4D-5 Parking Brake:

Specifications
Tightening Torque Specifications
AENJCA0A4407001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Parking brake lever bolt 26 2.7 19.5 (Page 4D-4)
Parking brake screw 1.5 0.15 1.5 (Page 4D-4)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Parking Brake Components” (Page 4D-1)
“Fasteners Information” in Section 0A (Page 0A-6)
 ABS: 4E-1

ABS
Brakes

Precautions
Precautions for ABS • Follow trouble diagnosis procedure described in “ABS
AENJCA0A4500001 Check” (Page 4E-9). If trouble diagnosis procedure is
When disconnecting ABS control module connector,
not followed properly, incorrect diagnosis may result.
disconnect the negative (–) cable at battery since the
(If incorrect procedure is performed, other DTC may
battery voltage is constantly applied to ABS hydraulic
be stored in the ABS hydraulic unit / control module
unit / control module assembly.
assembly.)
• When disconnecting ABS control module connector
Precautions for Diagnosing Trouble (1), pull down the lock lever (2) of connector.
AENJCA0A4500002
To check that the trouble diagnosis is done accurately When connecting the connector, set the connector in
and smoothly, observe the following and follow “ABS position on ABS hydraulic unit / control module
Check” (Page 4E-9). assembly and pull up the lock lever until it locks.
• Before using scan tool, read its Operator’s Manual to
know how to use it.
• If the vehicle was operated in any of the following
conditions, ABS warning light may light momentarily
but this does not indicate any fault in ABS.
– The vehicle is driven with parking brake applied.
[A] [D]
– The vehicle is driven with brake dragging.
– The vehicle is stuck in mud, sand, etc.
2
– Wheel spins while driving. [C]
[B]
– Wheels are rotated while the vehicle is jacked up. 1
IFRA0A450022-02

[A]: Pull down to unlock [C]: Connect

[B]: Disconnect [D]: Pull up to lock

General Description
ABS Description
AENJCA0A4501001
The ABS (Anti-lock Brake System) controls the fluid
pressure applied to the caliper or wheel cylinder of each
brake from the master cylinder so that each wheel is not
locked even when hard braking is applied.
This ABS is equipped with EBD (Electronic Brake force
Distributions) function.
While brake pedal is depressed not so hard as to
activate ABS control, brake force is proportionally
distributed between front and rear brakes to prevent rear
wheels from being locked too early for better stability of
the vehicle.
If the EBD control is deactivated, the brake system
warning light lights to inform the driver of abnormality.
4E-2 ABS:

ABS Hydraulic Unit / Control Module Assembly Wheel Speed Sensor

• ABS hydraulic unit / control module assembly detects
wheel slip by the signal from wheel speed sensor of
each wheel and sends control signals to the hydraulic
unit.
ABS hydraulic unit / control module assembly also
monitors system conditions and stops the function of
ABS and lights the ABS warning light in case it judges
that the system is faulty.
• ABS hydraulic unit is composed of inlet solenoid
valves (4) (normally-opened valves), outlet solenoid
valves (5) (normally-closed valves), pumps (3), pump
motor (2), reservoirs (6) and check valves (7). It
activates inlet and outlet solenoid valves by the
signals from ABS hydraulic unit / control module
assembly and controls the brake fluid pressure
applied on each wheel brake. (The following figure
shows the circuit for one wheel, with inlet and outlet
solenoid valves in OFF positions.)
Front wheel speed sensor
The vehicle speed is detected by the hall IC type wheel
speed sensor (1) and sensor ring (2). The wheel speed
sensor is fixed to the steering knuckle and includes a hall
IC (3) having 2 hall elements. As sensor ring is located
on the drive shaft, it turns along with the wheel. The
wheel speed sensor outputs AC (Alternating Current).
The wheel speed sensor feeds pulse signals in
proportion to the wheel speed to ABS control module,
which then calculates the wheel speed based on such
signal information.
2
5 4
5
1 3

1 I8C50B450011-04

4. Magnet 5. Magnetic field lines

Rear wheel speed sensor

7
The vehicle speed is detected by the hall IC type wheel
speed sensor (1) and encoder (2). The wheel speed
7
3 2 sensor is fixed to the rear wheel hub and includes a hall
4
IC (3) having 2 hall elements.
7 5 The encoder consists of a permanent magnet which has
south poles and north poles. As it is located on the rear
8
wheel hubs it turns along with the wheel.
6 The wheel speed sensor feeds pulse signals in
proportion to the wheel speed to ABS control module,
which then calculates the wheel speed based on such
IFRA0B460028-01
signal information.
1. Master cylinder 8. Caliper or wheel cylinder

The hydraulic pressure control is performed in 3 modes:

4
pressure increase, pressure keeping and pressure N

reduction. S

• In the pressure increase mode, inlet and outlet 2 N

solenoid valves are turned OFF, and the brake fluid
S 1
pressure applied from the master cylinder to the 3
caliper or wheel cylinder is increased. N

• In the pressure keeping mode, the inlet solenoid valve S

is turned ON, and the brake fluid pressure in the

I8C50B450012-03
caliper or wheel cylinder is kept constant.
4. Magnetic field lines
• In the pressure reduction mode, inlet and outlet
solenoid valves are turned ON, and the brake fluid
pressure applied to the caliper or wheel cylinder is
released to the reservoir. Thus the brake pressure
applied to the wheel likely to be locked is reduced.
The brake fluid temporarily stored in the reservoir is
pumped back to the master cylinder.
 ABS: 4E-3

OBD System Description

AENJCA0A4501002 [A] 2 1
ABS control module is built in ABS hydraulic unit /
control module assembly and has the following
functions.

Self-Diagnosis Function
ABS hydraulic unit / control module assembly monitors
each input and output signal. When ABS hydraulic unit /
control module assembly detects any malfunction, ABS
warning light (2) and/or brake system warning light (1) is
turned ON to inform the driver of the abnormality.
• When ignition is set “ON”, ABS warning light and
brake system warning light turn ON for 2 seconds to [B]
check its circuit.
• When no abnormality is detected (the system is in
good condition), these lights turn OFF after 2
seconds. However, when parking brake is applied,
brake system warning light remains ON.
• When an abnormality in the system is detected, ABS
2 1
warning light and/or brake system warning light is
turned ON and DTC is stored in ABS hydraulic unit /
control module assembly.
IJCA0A450001-01

[A]: Without tachometer [B]: With tachometer

Fail-Safe Mode
If ABS hydraulic unit / control module assembly stores a
DTC, ABS hydraulic unit / control module assembly
stops ABS and/or EBD function corresponding to the
faulty area. It is possible to check the stopped function(s)
by the warning lights in combination meter. (Page 4E-
3)

Warning Light Description

AENJCA0A4501003
There are two warning lights controlled by ABS hydraulic unit / control module assembly in combination meter. They
give warning to driver by changing their modes: light ON / blinking / light OFF.

[A] [B]
2 1

2 1

IJCA0A450002-01

[A]: Without tachometer 1. Brake system warning light

[B]: With tachometer 2. ABS warning light
4E-4 ABS:

Condition and Operation of Warning Light

Warning light Condition and operation
ABS warning light If ABS control is deactivated by ABS failure, the light turns “ON”.
• If EBD control is deactivated by ABS failure, the light turns “ON”.
Brake system warning light • If brake fluid level in reservoir is lower than minimum level, the light turns “ON”.
• If parking brake lever is pulled up, the light turns “ON”.

DLC Description • Bi-fuel CNG model: (Page 1A-274)

AENJCA0A4501004
Refer to “DLC Description”.
CAN Communication System Description
• K10B model: (Page 1A-4) AENJCA0A4501005
• K12M model: (Page 1A-120) Refer to “Communication System Description” in Section
10H (Page 10H-1).

Schematic and Routing Diagram

ABS Diagram
AENJCA0A4502001

8
8
6
5

1 2
4
3

8
8

9 10 11
IFRA0A450025-01

1. ABS hydraulic unit / control module assembly 5. BCM 9. Electronic signal

2. ABS control module 6. Combination meter 10. CAN signal
3. Hydraulic unit 7. Brake light switch 11. Hydraulic circuit
4. ECM 8. Wheel speed sensor
 ABS: 4E-5

ABS Input / Output Diagram

AENJCA0A4502002

INPUT OUTPUT
ABS hydraulic unit / control module assembly

Battery power supply Solenoid valve power

supply driver

Right-front inlet solenoid valve

Right-front outlet solenoid valve

Left-front inlet solenoid valve

Wheel speed sensor (Right-Front)
Wheel speed sensor (Left-Front)
Wheel speed sensor (Right-Rear)
Wheel speed sensor (Left-Rear)
Left-front outlet solenoid valve
Solenoid valve
driver Right-rear inlet solenoid valve
CPU
Right-rear outlet solenoid valve
Left-rear inlet solenoid valve

Left-rear outlet solenoid valve

Pump motor Pump motor

driver

ECM CAN driver ECM

BCM TCM (auto gear shift model)

Combination meter
: CAN communication
IJCA0A450003-01
4E-6 ABS:

ABS Circuit Diagram

AENJCA0A4502003

4
5
[B] 10 6
[C] 11
[B] 7 [C] 8

9 22
BLU

BLU
BRN
BRN E08-5
E08-27 BLK
12

E08-1 WHT
13 14
1 E08-26 RED
23 BLK

25

M 27
15 23
17 26

WHT
16
RED 24

18
19
RED BLK 28
20
LT GRN

RED
WHT
29
RED E08-4
25 25 30
WHT E08-16

21
RED E08-3
YEL 25
WHT E08-15

[A] E08

GRN E08-20
32
PNK E08-34

26 1 GRN E08-17
33
GRY E08-30
3
28 15 31
4
29 16 BRN E08-8
5 34
YEL E08-19
30 17
6
31 18
7 WHT E08-18
32 19 35
8 LT GRN E08-6
33 20
9
34 21
10
35 22
11 [a]
36 23
12
37 24
13
38 25
14
27 2
: 36 : 37 : 5V : 12V
IJCA0A450004-01
 ABS: 4E-7

[A]: ABS hydraulic unit / control module 12. Combination meter 26. Pump motor relay
assembly connector (View: [a])
[B]: Without keyless entry system 13. ABS warning light 27. Pump motor
[C]: With keyless entry system 14. Brake system warning light 28. Solenoid valve power supply relay
1. Battery 15. Brake light switch 29. Solenoid valve
2. Relay box 16. Brake light 30. Solenoid valve relay
3. “ABS MOT” fuse 17. DLC 31. Wheel speed sensor driver
4. “ABS SOL” fuse 18. BCM 32. Left-front wheel speed sensor
5. Individual circuit fuse box No.2 19. Brake fluid level switch 33. Right-front wheel speed sensor
6. “ABS” fuse 20. Parking brake switch 34. Left-rear wheel speed sensor
7. “METER” fuse 21. ECM 35. Right-rear wheel speed sensor
8. “MTR” fuse 22. ABS hydraulic unit / control module assembly 36. Engine ground
9. “STOP” fuse 23. CPU 37. Ground
10. To ignition switch 24. Internal memory
11. To IG11 relay 25. CAN driver

Terminal Wire color Circuit

1 WHT Solenoid valve power supply circuit
3 RED CAN communication line (high) for ECM
4 RED CAN communication line (high) for BCM
5 BRN Ignition power supply circuit
6 LT GRN Right-rear wheel speed sensor signal circuit
8 BRN Left-rear wheel speed sensor power supply circuit
15 WHT CAN communication line (low) for ECM
16 WHT CAN communication line (low) for BCM
17 GRN Right-front wheel speed sensor power supply circuit
18 WHT 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 RED Pump motor power supply circuit
27 BLK ABS control module ground circuit
30 GRY Right-front wheel speed sensor signal circuit
34 PNK Left-front wheel speed sensor signal circuit
4E-8 ABS:

Component Location
ABS Component Location
AENJCA0A4503001

1
3

4
5

2 2

[A] [B]

6 7 8 6

10

IJCA0A450005-01
 ABS: 4E-9

[A]: Without tachometer 3. ECM 7. Brake system warning light

[B]: With tachometer 4. Relay box 8. ABS warning light
1. Rear wheel speed sensor 5. ABS hydraulic unit / control module assembly 9. Brake light switch
2. Front wheel speed sensor 6. Combination meter 10. BCM

Diagnostic Information and Procedures

ABS Check
AENJCA0A4504001
Refer to the description after the following general flow for details of each step.
Step Action Yes No
1 Malfunction analysis (Page 4E-9) Check and repair Go to Step 2.
1) Perform “Customer complaint analysis” (Page 4E-9). referring to applicable
DTC troubleshooting,
2) Perform “Problem symptom confirmation” (Page 4E-10).
and then go to Step 6.
3) Perform “DTC check, record and clearance” (Page 4E-
10) and recheck DTC.

Is the same DTC detected again after performing DTC

clearance?
2 Visual inspection Repair or replace Go to Step 3.
1) Perform “Step 2: Visual Inspection” (Page 4E-10). defective part, and then
go to Step 6.
Is there any faulty condition?
3 Road test Repair or replace Go to Step 4.
1) Perform “Step 3: Road Test” (Page 4E-11). defective part, and then
go to step 6.
Is malfunction detected?
4 Brake diagnosis Repair or replace Go to Step 5.
1) Check and repair brake system. (Page 4E-11) defective part, and then
go to step 6.
Is malfunction detected?
5 Intermittent problem check Repair or replace Go to Step 6.
1) Check for intermittent problems. (Page 4E-11) defective part, then go
to step 6.
Is malfunction detected?
6 Final confirmation test Go to Step 4. End.
1) Perform “Step 6: Final Confirmation Test” (Page 4E-11).

Is malfunction detected?

Step 1: Malfunction Analysis

Customer complaint analysis
Record details of the problem (failure, complaint) and how it occurred as described by the customer.
For this purpose, use of such a questionnaire form shown below table will facilitate collecting information required for
proper analysis and diagnosis.
4E-10 ABS:

Customer questionnaire form (Example)

IJCA0A450006-01

Problem symptom confirmation diagnosis, or temporary abnormality may occur,

If symptom in “Customer Questionnaire” is found or
reproduced in the vehicle, check that the symptom is
problem or not. (This step should be done with the
customer if possible.) Check warning light related to
brake system referring to “Brake System Warning Light
Check” and “ABS Warning Light Check” under “Warning
Light Check” (Page 4E-12).
therefore go to “Step 3: Road Test” (Page 4E-11) to
proceed to the diagnosis.
Step 2: Visual Inspection
As a preliminary step, perform visual check of the items
that support proper function of the ABS. (Page 4E-11)

DTC check, record and clearance

Perform “DTC Check” (Page 4E-13) procedure, record it
and then clear it. (Page 4E-14)
Recheck DTC. (Page 4E-13)
When DTC which is recorded at DTC check procedure is
detected again after performing DTC clearance, go to
“DTC Check” (Page 4E-13) to perform the diagnosis.
When DTC which is recorded at DTC check procedure is
not detected anymore after performing DTC clearance,
ABS control module does not perform the system
 ABS: 4E-11

Step 3: Road Test
! WARNING
If you do not select a suitable route and take
proper precautions when performing a road
test, an accident can occur.
• Select a level road with no traffic to
minimize the risk of accident.
• Perform the test extremely carefully.
• Perform the road test with 2 persons, a
driver and a tester.
NOTE
Limit the driving speed permissible in road
conditions and regulations.
Perform road test as follows to check if each warning
light lights up.
1) Drive at 40 km/h (25 mile/h) for over two minutes.
2) Turn right and left at over 10 km/h (6 mile/h) for over
a second by turning steering wheel over 45 degrees.
3) Drive at 60 km/h (37 mile/h) for over three seconds.
4) Stop the vehicle using foot brake from driving at 60
km/h (37 mile/h).
Step 4: Brakes Diagnosis
Check the parts or system suspected as a possible
cause referring to “Brake System Description” in Section
4A (Page 4A-2) and based on symptoms appearing on
the vehicle (symptoms observed through Step 1 – 3).
Repair faulty parts or replace them, if necessary.
Step 5: Intermittent Problem
Check parts that are prone to cause intermittent trouble
(e.g. wire harness, connector), referring to “Intermittent
Connection and Poor Contact Inspection” in Section 00
(Page 00-13) and the related circuit of which DTC is
recorded in Step 1 – 5.
Step 6: Final Confirmation Test
Check that the problem symptom is not observed any
more and ABS is free from any abnormal conditions. If
what has been repaired is related to malfunction DTC,
clear the DTC referring to “DTC Clearance” (Page 4E-
14), perform road test and confirm that the DTC is not
indicated.

Visual Inspection
AENJCA0A4504002
Visually check the following parts and systems.
Inspection item Referring section
• K10B model / Bi-fuel CNG model: “Battery Inspection”:
K10B and Bi-Fuel CNG in Section 1J (Page 1J-4)
Battery Fluid level, leakage
• K12M model: “Battery Inspection”: K12M in Section 1J
(Page 1J-22)
Connectors of electric wire “Intermittent Connection and Poor Contact Inspection” in
Disconnection, friction
harness Section 00 (Page 00-13)
Fuses Burning —
Brake fluid Level, leakage “Brake Fluid Level Inspection” in Section 4A (Page 4A-4)
ABS warning light Operation
“Warning Light Check” (Page 4E-12)
Brake System warning light Operation
Other parts that can be checked visually —

ABS Symptom Diagnosis

AENJCA0A4504003

Condition Possible cause Correction / Reference Item

ABS warning light Malfunctioning ABS function Perform ABS check. (Page 4E-9)
remains lit for more than 2 Malfunctioning ABS warning light circuit Check ABS warning light circuit. (Page 4E-
seconds after setting 20)
ignition “ON”
ABS warning light does Malfunctioning ABS function Perform ABS check. (Page 4E-9)
not turn ON after setting Malfunctioning CAN communication Check CAN communication system. (Page
ignition “ON” system function 10H-7)
Malfunctioning ABS warning light circuit Check ABS warning light circuit. (Page 4E-
19)
ABS warning light blinks Improper air bleed from ABS hydraulic Perform ABS hydraulic unit operation check.
unit / control module assembly (Page 4E-30)
4E-12 ABS:
Condition Possible cause
Brake system warning Parking brake applied
light remains lit for more
than 2 seconds after Insufficient amount of brake fluid
setting ignition “ON” Faulty parking brake switch circuit and/ Check BCM and its circuit.
or brake fluid level switch circuit
Faulty parking brake switch and/or
brake fluid level switch
Malfunctioning EBD control
Faulty ABS control module power
supply and ground circuit
Malfunctioning CAN communication
system
Faulty BCM
Faulty ABS control module
Malfunctioning brake system warning
light circuit
Brake system warning Malfunctioning EBD control
light does not turn ON Malfunctioning CAN communication
after setting ignition “ON” system
Malfunctioning brake system warning
light circuit
Warning Light Check
AENJCA0A4504004 [A]
ABS Warning Light
1) Set ignition “ON”.
2) Check that ABS warning light (1) comes ON for
about 2 seconds and then goes OFF. If ABS warning
light never lights up, go to “ABS Warning Light Does
Not Come ON after Setting Ignition “ON”” (Page 4E-
19). If ABS warning light remains ON and no DTC is
stored in ABS control module, go to “ABS Warning
Light Comes ON Steady” (Page 4E-20).
[B]
[A]: Without tachometer
Correction / Reference Item
Release parking brake and check that brake
system warning light turns OFF.
Check brake fluid level. (Page 4A-4)
• Without keyless entry system: (Page 10B-
30)
• With keyless entry system: (Page 10B-36)
Check parking brake switch and/or brake fluid
level switch.
• Parking brake switch: (Page 4D-4)
• Brake fluid level switch: (Page 4A-4)
Perform ABS check. (Page 4E-9)
Check ABS control module power supply and
ground circuits. (Page 4E-29)
Check CAN communication system. (Page
10H-7)
Check BCM and its circuit.
• Without keyless entry system: (Page 10B-
30)
• With keyless entry system: (Page 10B-36)
Replace ABS control module. (Page 4E-32)
Check brake system warning light circuit.
(Page 4E-20)
Perform ABS check. (Page 4E-9)
Check CAN communication system. (Page
10H-7)
Check brake system warning light circuit.
(Page 4E-20)
1
IJCA0A450007-01
[B]: With tachometer

Brake System Warning Light
NOTE
Perform this check on a level place.
1) Check brake fluid level. (Page 4A-4)
2) Pull parking brake lever.
3) Set ignition “ON”.
4) Check that brake system warning light (1) comes
ON. If brake system warning light never lights up, go
to “Brake System Warning Light Does Not Come ON
after Setting Ignition “ON”” (Page 4E-20).
[A]
[B]
1
IJCA0A450008-01
[A]: Without tachometer [B]: With tachometer
5) Release parking brake lever and check that brake
system warning light goes OFF. If brake system
warning light remains ON and no DTC is stored in
ABS control module, go to “Brake System Warning
Light Comes ON Steady” (Page 4E-20).
ABS: 4E-13
DTC Check
AENJCA0A4504005
1) Set ignition “OFF”.
2) Connect SUZUKI scan tool to DLC (1).
Special tool
(A): SUZUKI scan tool (Suzuki SDT-II)
3) Set ignition “ON”.
4) Read DTC according to instructions displayed on
SUZUKI scan tool and print it or write it down. Refer
to Operator's Manual of SUZUKI scan tool for further
details.
NOTE
1
If communication between SUZUKI scan tool
and ABS control module is not possible,
perform the following checks:
• Check communication condition between
PC and VCI (2) using SUZUKI scan tool
function.
• Check DLC power circuit and ground
circuit.
• Check DLC cable. If necessary, check DLC
cable by substituting a known-good DLC
cable.
• Check CAN communication system.
(“Control Module Communication Bus Off”
is detected in any control module.) (Page
10H-15)
• Check ABS control module power circuit
and ground circuit. (Page 4E-29)
1
(A)
IJCA0A111011-01
5) After completing the check, set ignition “OFF” and
disconnect SUZUKI scan tool from DLC.
4E-14 ABS:

DTC Clearance
AENJCA0A4504006
1) Set ignition “OFF”.
2) Connect SUZUKI scan tool to DLC (1).
Special tool
(A): SUZUKI scan tool (Suzuki SDT-II) 1

3) Set ignition “ON”.

4) Clear DTC according to instructions displayed on
SUZUKI scan tool. Refer to Operator's Manual of
SUZUKI scan tool for further details.

NOTE
• If communication between SUZUKI scan
tool and ABS control module is not 2
possible, perform the following checks:
– Check communication condition
between PC and VCI (2) using SUZUKI (A)
scan tool function. IJCA0A111011-01
– Check DLC power circuit and ground 5) After completing the clearance, set ignition “OFF”
circuit. and disconnect SUZUKI scan tool from DLC.
– 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-15)
– Check ABS control module power circuit
and ground circuit. (Page 4E-29)
• The following DTCs can be cleared when
ABS warning light is turned off after “Road
Test” under “ABS Check” (Page 4E-9) is
performed.
– C1022 / C1026 / C1032 / C1036
– C1061
 ABS: 4E-15

DTC Table
AENJCA0A4504007
NOTE
• Perform “ABS Check” (Page 4E-9) before diagnosing DTC.
• Skipping “ABS Check” (Page 4E-9) may show a false result.
• *: Whether ABS warning light or brake system warning light lights up or not depends on DTC
detecting condition.

Brake
ABS
system
DTC DTC name DTC detecting condition warning
warning
light
light
C1021 (Page 4E- Right-Front Wheel Speed Sensor Wheel speed sensor signal is out of Lights
OFF
22) Circuit Voltage specified range. up
C1022 (Page 4E- Right-Front Wheel Speed Sensor or Abnormal wheel speed sensor signal is Lights
OFF
22) Encoder Signal Performance detected continuously. up
C1025 (Page 4E- Left-Front Wheel Speed Sensor Wheel speed sensor signal is out of Lights
OFF
22) Circuit Voltage specified range. up
C1026 (Page 4E- Left-Front Wheel Speed Sensor or Abnormal wheel speed sensor signal is Lights
OFF
22) Encoder Signal Performance detected continuously. up
C1031 (Page 4E- Right-Rear Wheel Speed Sensor Wheel speed sensor signal is out of Lights
OFF
22) Circuit Voltage specified range. up
C1032 (Page 4E- Right-Rear Wheel Speed Sensor or Abnormal wheel speed sensor signal is Lights
OFF
22) Encoder Signal Performance detected continuously. up
Difference of wheel speed between the
wheels is more than specified value.
Abnormal wheel speed sensor signals
are detected continuously at three or
C1033 (Page 4E-
Wheel Speed Sensor Deviation more wheel speed sensors. * *
22)
ABS control is activated for more than
specified time.
Wheel speed sensor driver power
supply voltage is out of specified range.
C1035 (Page 4E- Left-Rear Wheel Speed Sensor Wheel speed sensor signal is out of Lights
OFF
22) Circuit Voltage specified range. up
C1036 (Page 4E- Left-Rear Wheel Speed Sensor or Abnormal wheel speed sensor signal is Lights
OFF
22) Encoder Signal Performance detected continuously. up
C1041 (Page 4E- Right-Front Inlet Solenoid Valve Solenoid output and solenoid monitor Lights Lights
25) Circuit Correlation data disagree. up up
C1042 (Page 4E- Right-Front Outlet Solenoid Valve Solenoid output and solenoid monitor Lights Lights
25) Circuit Correlation data disagree. up up
C1045 (Page 4E- Left-Front Inlet Solenoid Valve Solenoid output and solenoid monitor Lights Lights
25) Circuit Correlation data disagree. up up
C1046 (Page 4E- Left-Front Outlet Solenoid Valve Solenoid output and solenoid monitor Lights Lights
25) Circuit Correlation data disagree. up up
C1051 (Page 4E- Right-Rear Inlet Solenoid Valve Solenoid output and solenoid monitor Lights Lights
25) Circuit Correlation data disagree. up up
C1052 (Page 4E- Right-Rear Outlet Solenoid Valve Solenoid output and solenoid monitor Lights Lights
25) Circuit Correlation data disagree. up up
C1055 (Page 4E- Left-Rear Inlet Solenoid Valve Solenoid output and solenoid monitor Lights Lights
25) Circuit Correlation data disagree. up up
C1056 (Page 4E- Left-Rear Outlet Solenoid Valve Solenoid output and solenoid monitor Lights Lights
25) Circuit Correlation data disagree. up up
ABS control module power supply
C1057 (Page 4E- voltage is higher than specified value.
Power Supply Voltage * *
26) ABS control module power supply
voltage is lower than specified value.
4E-16 ABS:

Brake
ABS
system
DTC DTC name DTC detecting condition warning
warning
light
light
Pump motor power supply voltage is
out of specified range.
C1061 (Page 4E- Pump motor is activated although pump Lights Lights
Pump Motor Circuit Performance
27) motor control relay is OFF. up up
Pump motor is not activated although
pump motor control relay is ON.
Solenoid valve is activated for more
C1062 (Page 4E- Solenoid Valve Continuous Lights Lights
than specified time using “Active Test”
28) Operation Failure up up
of SUZUKI scan tool.
Solenoid valve power supply relay
output is “ON”, although monitored
C1063 (Page 4E- Solenoid Valve Power Supply output is “OFF”. Lights Lights
25) Driver Circuit Performance Solenoid valve power supply relay up up
output is “OFF”, although monitored
output is “ON”.
C1071 (Page 4E- ABS Control Module Internal ABS control module internal failure is Lights Lights
28) Failure detected. up up
U0073 (Page 4E- Control Module Communication Impossible to receive and transmit CAN
OFF OFF
28) Bus Off data.
U0100 (Page 4E- ECM message data is missing from
Lost Communication With ECM OFF OFF
28) CAN communication.

Fail-Safe Table
AENJCA0A4504008
When any of the following DTCs is detected, ABS control module changes the control to the fail-safe mode and ABS
and EBD functions are deactivated until ABS control module judges the system is normal.

NOTE
• O: Activated
• –: Deactivated
• *: Whether ABS is engaged in fail-safe mode or not depends on malfunction part. Fail-safe mode can
be checked by lighting status of ABS warning light or brake system warning light.
– When ABS warning light lights up, ABS control is deactivated.
– When brake system warning light lights up, EBD control is deactivated.

Fail-safe
DTC operation Fail-safe cancel condition
ABS EBD
C1021 (Page 4E- When ABS control module judges the system to be normal after switching ignition
– ○
22) from “OFF” to “ON”.
C1022 (Page 4E- When ABS control module judges the system to be normal and “Road Test” under
– ○
22) “ABS Check” (Page 4E-9) is performed after switching ignition from “OFF” to “ON”.
C1025 (Page 4E- When ABS control module judges the system to be normal after switching ignition
– ○
22) from “OFF” to “ON”.
C1026 (Page 4E- When ABS control module judges the system to be normal and “Road Test” under
– ○
22) “ABS Check” (Page 4E-9) is performed after switching ignition from “OFF” to “ON”.
C1031 (Page 4E- When ABS control module judges the system to be normal after switching ignition
– ○
22) from “OFF” to “ON”.
C1032 (Page 4E- When ABS control module judges the system to be normal and “Road Test” under
– ○
22) “ABS Check” (Page 4E-9) is performed after switching ignition from “OFF” to “ON”.
C1033 (Page 4E-
* *
22) When ABS control module judges the system to be normal after switching ignition
C1035 (Page 4E- from “OFF” to “ON”.
– ○
22)
 ABS: 4E-17

Fail-safe
DTC operation Fail-safe cancel condition
ABS EBD
C1036 (Page 4E- When ABS control module judges the system to be normal and “Road Test” under
– ○
22) “ABS Check” (Page 4E-9) is performed after switching ignition from “OFF” to “ON”.
C1041 (Page 4E-
– –
25)
C1042 (Page 4E-
– –
25)
C1045 (Page 4E-
– –
25) When ABS control module judges the system to be normal after switching ignition
C1046 (Page 4E- from “OFF” to “ON”.
– –
25)
C1051 (Page 4E-
– –
25)
C1052 (Page 4E-
– –
25)
C1055 (Page 4E-
– –
25) When ABS control module judges the system to be normal after switching ignition
C1056 (Page 4E- from “OFF” to “ON”.
– –
25)
C1057 (Page 4E-
* * When ABS control module judges the system to be normal.
26)
C1061 (Page 4E- When ABS control module judges the system to be normal and “Road Test” under
– –
27) “ABS Check” (Page 4E-9) is performed after switching ignition from “OFF” to “ON”.
When solenoid valve is sufficiently cooled down. (After continuous operation, inlet
C1062 (Page 4E-
– – solenoid valve requires 300 seconds of suspension and outlet solenoid valve
28)
requires 50 seconds of suspension.)
C1063 (Page 4E-
– – When ABS control module judges the system to be normal.
25)
C1071 (Page 4E-
– –
28)
U0073 (Page 4E- When ABS control module judges the system to be normal after switching ignition
○ ○
28) from “OFF” to “ON”.
U0100 (Page 4E-
○ ○
28)
4E-18 ABS:

Scan Tool Data

AENJCA0A4504009
As the data values are standard values estimated on the basis of values obtained from the normally operating vehicles
using a scan tool, use them as reference values. Even when the vehicle is in good condition, there may be cases
where the checked value does not fall within each specified data range. Therefore, judgment as abnormal should not
be made depending on these data alone.

NOTE
If communication between SUZUKI scan tool and ABS control module is not possible, perform the
following checks:
• Check communication condition between PC and VCI using SUZUKI scan tool function.
• Check DLC power circuit and ground circuit.
• Check DLC cable. If necessary, check DLC cable by substituting a known-good DLC cable.
• Check CAN communication system. (“Control Module Communication Bus Off” is detected in any
control module.) (Page 10H-15)
• Check ABS control module power circuit and ground circuit. (Page 4E-29)

Scan tool data Vehicle condition Condition / Reference value

RF Wheel Speed (Page
At stop (Stationary vehicle) 0 km/h (0 mph)
4E-18)
LF Wheel Speed (Page
At stop (Stationary vehicle) 0 km/h (0 mph)
4E-18)
RR Wheel Speed (Page
At stop (Stationary vehicle) 0 km/h (0 mph)
4E-18)
LR Wheel Speed (Page
At stop (Stationary vehicle) 0 km/h (0 mph)
4E-18)
Battery Voltage (Page 4E-
Ignition ON (Engine stopped) 10.0 – 14.0 V
18)
Pump Motor Driver (Page Inactive (Pump motor not working) 0.0 V
4E-18) Active (Pump motor working) 13.0 – 15.0 V
Brake Switch (Page 4E- Depressed brake pedal ON
18) Released brake pedal OFF

Scan Tool Data Definition

RF Wheel Speed, LF Wheel Speed, RR Wheel Speed and LR Wheel Speed (km/h, MPH): Wheel speed is ABS
control module internal parameter. It is computed by reference pulses from the wheel speed sensor.
Battery Voltage (V): Battery voltage is an analog input signal read by ABS control module. ABS control module
functions may be stopped if battery voltage falls below or rises above programmed thresholds.
Pump Motor Driver (V): This parameter indicates operational condition of pump motor driver (transistor).
Brake Switch (ON, OFF): These switch signals are provided to ABS control module whether the brake pedal is
depressed or not.
 ABS: 4E-19

ABS Warning Light Does Not Come ON after Setting Ignition “ON”
AENJCA0A4504010
System Description
Operation (ON/OFF) of ABS warning light is controlled by ABS control module through light driver module in
combination meter.
If ABS is in good condition, ABS control module turns ON ABS warning light when ignition “ON”, keeps the light ON for
2 seconds and then turns it OFF. If ABS control is deactivated by ABS failure, ABS warning light is turned ON
continuously by ABS control module. Also, the light is turned ON continuously by light driver module when the
connector of ABS control module is disconnected.

Troubleshooting
Step Action Yes No
1 Warning light check Go to Step 2. Go to Step 4.
1) Set ignition “ON”.

Do other indicator lights light up?

2 DTC check Go to “Troubleshooting Go to Step 3.
1) Check DTC. (Page 4E-13) for Communication Bus
Off” in Section 10H
Is DTC U0073 detected? (Page 10H-15).
3 Combination meter check Replace ABS hydraulic End.
1) Replace combination meter. (Page 9C-25) unit / control module
assembly and recheck
2) Set ignition “ON”.
warning light operation.
Does ABS warning light stay OFF? (Page 4E-32)
4 Fuse check Go to Step 5. Replace “METER” fuse
or “MTR” fuse and
Is “METER” fuse or “MTR” fuse in good condition? check for short circuit to
ground.
5 CAN communication circuit check Go to Step 6. Repair or replace
1) Check CAN communication circuit between combination defective wire harness.
meter and ABS control module. (Page 10H-15)

Is check result OK?

6 Combination meter power supply and ground circuit Replace combination Repair or replace
check meter and recheck defective wire harness.
1) Check combination meter power supply and ground warning light operation.
circuits. (Page 9C-21) If ABS warning light
does not come ON,
Is check result OK? replace ABS hydraulic
unit / control module
assembly and recheck
warning light operation.
• Combination meter:
(Page 9C-25)
• ABS hydraulic unit /
control module
assembly: (Page
4E-32)
4E-20 ABS:

ABS Warning Light Comes ON Steady

AENJCA0A4504011
System Description
Refer to “System Description” under “ABS Warning Light Does Not Come ON after Setting Ignition “ON”” (Page 4E-
19).

Troubleshooting
Step Action Yes No
1 ABS control module connector check Go to Step 2. Connect connector
1) Check for proper connection to ABS control module securely.
connector.

Is connection in good condition?

2 DTC check for ABS Go to applicable DTC Go to Step 3.
1) Perform “DTC Check” (Page 4E-13). troubleshooting.

Is there any DTC(s)?

3 ABS control module power supply and ground circuit Go to Step 4. Repair or replace
check defective wire harness.
1) Check ABS control module power supply circuit and
ground circuit. (Page 4E-29)

Is check result OK?

4 Combination meter check Replace ABS hydraulic End.
1) Replace combination meter. (Page 9C-25) unit / control module
assembly and recheck
2) Set ignition “ON”.
warning light operation.
Does ABS warning light stay on? (Page 4E-32)

Brake System Warning Light Does Not Come ON after Setting Ignition “ON”
AENJCA0A4504012
System Description
Refer to “System Description” under “Brake System Warning Light Comes ON Steady” (Page 4E-20).

Troubleshooting
Refer to “Troubleshooting” under “ABS Warning Light Does Not Come ON after Setting Ignition “ON”” (Page 4E-19).

Brake System Warning Light Comes ON Steady

AENJCA0A4504013
System Description
Brake system warning light is controlled by ABS control module and BCM through light driver module in combination
meter.
If EBD control is in good condition, ABS control module turns ON brake system warning light when ignition is set “ON”,
keeps it ON for 2 seconds and then turns it OFF.
Brake system warning light is turned ON continuously in the following conditions.
• EBD control is deactivated by ABS failure.
• Parking brake lever is pulled up.
• Brake fluid level is lower than minimum level.
The information of parking brake switch and brake fluid level is transmitted from BCM to light driver module in
combination meter through CAN communication line.
Also, the warning light is turned ON continuously by light driver module when the connector of ABS control module is
disconnected.
 ABS: 4E-21

Troubleshooting
Step Action Yes No
1 ABS control module connector check Go to Step 2. Connect connector
1) Check for proper connection to ABS control module securely.
connector.

Is connection in good condition?

2 Parking brake and brake fluid level check Go to Step 3. Release parking brake
1) Check the following points. and check brake fluid
level.
• Parking brake is completely released.
• Brake fluid level is above minimum level. (Page 4A-
4)

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-20).
Does ABS warning light stay ON?
4 Parking brake switch signal circuit and brake fluid level Go to Step 5. Repair or replace
switch signal circuit check defective part.
1) Check parking brake switch signal circuit and brake fluid
level switch signal circuit.
• Without keyless entry system: (Page 10B-30)
• With keyless entry system: (Page 10B-36)

Is check result OK?

5 DTC check Go to troubleshooting Go to Step 6.
1) Perform “DTC Check” (Page 4E-13). for applicable DTC.

Is DTC U0073 detected?

6 DTC check for BCM Go to “Troubleshooting Go to Step 7.
1) Check BCM for DTC. (Page 10B-13) for Communication Bus
Off” in Section 10H
Is DTC U0073 detected? (Page 10H-15).
7 Combination meter check Replace ABS hydraulic End.
1) Replace combination meter. (Page 9C-25) unit / control module
assembly and recheck
2) Set ignition “ON”.
warning light operation.
Does brake system warning light stay on? (Page 4E-32)
4E-22 ABS:

DTC C1021 / C1022 / C1025 / C1026 / C1031 / C1032 / C1033 / C1035 / C1036
AENJCA0A4504014
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C1021 / C1025 / C1031 / C1035: Right-Front / Left-Front / Right-Rear / Left- • Wheel speed sensor
Rear Wheel Speed Sensor Circuit Voltage • Wheel speed sensor circuit
Wheel speed sensor signal is out of specified range.
• Wheel speed sensor ring and/or
C1022 / C1026 / C1032 / C1036: Right-Front / Left-Front / Right-Rear / Left-
encoder
Rear Wheel Speed Sensor or Encoder Signal Performance
Abnormal wheel speed sensor signal is detected continuously. • ABS control module
C1033: Wheel Speed Sensor Deviation
• Difference of wheel speed between the wheels is more than specified value.
• Abnormal wheel speed sensor signals are detected continuously at three 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-14) and check
whether any abnormality exists or not by performing road test as described in Step 3 of “ABS Check”
(Page 4E-9).
• Vehicle is driven with parking brake lever pulled.
• Wheel spins while driving.
• Wheel(s) is rotated while vehicle is jacked up.

Circuit Diagram

5 [A] E08

A1
GRN E08-20 [a]
1
PNK E08-34 26 1
A2 3
B1 28 15
4
GRN E08-17 29 16
2 5
GRY E08-30 30 17
6
B2 31 18
7
32 19
C1 8
6 33 20
BRN E08-8 9
3 34 21
YEL E08-19 10
35 22
C2 11
36 23
D1 12
37 24
WHT E08-18 13
4 38 25
LT GRN E08-6 14
D2 27 2

IJCA0A450009-01

[A]: ABS control module connector (View: [a])
A1: Left-front wheel speed sensor power supply circuit
A2: Left-front wheel speed sensor signal circuit
B1: Right-front wheel speed sensor power supply circuit
B2: Right-front wheel speed sensor signal circuit
C1: Left-rear wheel speed sensor power supply circuit 2. Right-front wheel speed sensor
C2: Left-rear wheel speed sensor signal circuit 3. Left-rear wheel speed sensor
D1: Right-rear wheel speed sensor power supply circuit 4. Right-rear wheel speed sensor
D2: Right-rear wheel speed sensor signal circuit 5. ABS control module
1. Left-front wheel speed sensor 6. Wheel speed sensor driver
 ABS: 4E-23

DTC Confirmation Procedure

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

NOTE
• Limit the driving speed permissible in road conditions and regulations.
• Check that the following condition is met in this “DTC Confirmation Procedure”.
– DTC C1057 is not detected.

1) Set ignition “ON”.

2) Drive vehicle at 20 km/h (12 mile/h) or more for 1 minute or more.
3) Stop vehicle and set ignition “OFF”.
4) Repeat Step 1) – 3) 7 times.

DTC Troubleshooting
Step Action Yes No
1 Was “ABS Check” performed? Go to Step 2. Go to “ABS Check”
(Page 4E-9).
2 Tire pressure check Go to Step 3. Adjust tire pressure or
1) Check that tire pressure is at specified value. replace tire and recheck
DTC.
Is check result OK?
3 Wheel speed sensor power supply circuit and signal Go to Step 4. Repair or replace
circuit check defective wire harness.
1) Set ignition “OFF”.
2) Disconnect “E08” and each of wheel speed sensor
connectors.
3) Check for proper terminal connection to “E08” and each
of wheel speed sensor connectors.
4) If connections are OK, check the following points.
• Resistance of “A1”, “A2”, “B1”, “B2”, “C1”, “C2”, “D1”
and “D2” circuits: less than 1 Ω
• Resistance between each of “A1”, “A2”, “B1”, “B2”,
“C1”, “C2”, “D1” and “D2” circuits and ground: infinity
• Resistance between each terminal of “A1” – “A2”, “B1”
– “B2”, “C1” – “C2” and “D1” – “D2” circuits and each
terminal of “E08” connector: infinity
• Voltage of “A1”, “A2”, “B1”, “B2”, “C1”, “C2”, “D1” and
“D2” circuits: approx. 0 V (When ignition is “ON”)

Is check result OK?

4 Wheel speed sensor signal check Replace ABS hydraulic Go to Step 5.
1) Check applicable wheel speed sensor for output voltage unit / control module
and waveform. (Page 4E-33) assembly and recheck
DTC. (Page 4E-32)
Is check result OK?
4E-24 ABS:

Step Action Yes No

5 Wheel speed sensor check Go to Step 6. Clean, repair or replace
1) Check applicable wheel speed sensor. (Page 4E-35) wheel speed sensor.
• Front wheel speed
Is check result OK?
sensor: (Page 4E-
34)
• Rear wheel speed
sensor: (Page 4E-
35)
6 Wheel speed sensor ring and/or encoder check Replace ABS hydraulic Clean, repair or replace
1) Check applicable wheel speed sensor ring and/or unit / control module wheel speed sensor ring
encoder. (Page 4E-36) assembly and recheck and/or encoder.
DTC. (Page 4E-32) • Front wheel speed
Is check result OK?
sensor ring: (Page
4E-35)
• Rear wheel speed
sensor encoder:
(Page 4E-35)
 ABS: 4E-25

DTC C1041 / C1042 / C1045 / C1046 / C1051 / C1052 / C1055 / C1056 / C1063
AENJCA0A4504015
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C1041 / C1045 / C1051 / C1055: Right-Front / Left-Front / Right-Rear / • ABS control module power supply
Left-Rear Inlet Solenoid Valve Circuit Correlation circuit
C1042 / C1046 / C1052 / C1056: Right-Front / Left-Front / Right-Rear / • ABS control module ground circuit
Left-Rear Outlet Solenoid Valve Circuit Correlation
• ABS control module
Solenoid output and solenoid monitor data disagree.
C1063: Solenoid Valve Power Supply Driver Circuit Performance
• Solenoid valve power supply relay output is “ON”, although monitored
output is “OFF”.
• Solenoid valve power supply relay output is “OFF”, although monitored
output is “ON”.

Circuit Diagram

4
2
A1
3
1 WHT E08-1
[a]
5V

[A] E08
6

6
26 1
6 3
7 28 15
4
6 29 16
5
30 17
6
6 31 18
7
32 19
8
6 33 20
9
34 21
6 10
35 22
11
B1 36 23
6 12
37 24
BLK E08-27 13
38 25
14
27 2

IJCA0A450010-01

[A]: ABS control module connector (View: [a]) 2. Relay box 6. Solenoid valve
A1: Solenoid valve power supply circuit 3. “ABS SOL” fuse 7. CPU
B1: ABS control module ground circuit 4. ABS control module
1. Lead to battery 5. Solenoid valve power supply relay

DTC Troubleshooting
Step Action NoYes
1 Was “ABS Check” performed? Go to Step 2.
Go to “ABS Check”
(Page 4E-9).
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
(Page 4E-29) DTC. (Page 4E-32)

Is check result OK?

4E-26 ABS:

DTC C1057
AENJCA0A4504016
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C1057: Power Supply Voltage • ABS control module power supply circuit
• ABS control module power supply voltage is higher • ABS control module ground circuit
than specified value. • Charging system
• ABS control module power supply voltage is lower than • ABS control module
specified value.

Circuit Diagram

[A] E08

8 [a]
2
3 A1 26 1
WHT E08-1 9
A2 3
4 28 15
1 RED E08-26 10 4
29 16
5
30 17
6
C1 31 18
7
BLK E08-27 32 19
8
33 20
9
34 21
10
35 22
11
6 36 23
B1 12
7 37 24
5 BRN E08-5 13
38 25
14
27 2

IJCA0A450011-01

[A]: ABS control module connector (View: [a]) 1. Lead to battery 6. Individual circuit fuse box No.2
A1: Solenoid valve power supply circuit 2. Relay box 7. “ABS” fuse
A2: Pump motor power supply circuit 3. “ABS SOL” fuse 8. ABS control module
B1: Ignition power supply circuit 4. “ABS MOT” fuse 9. Lead to solenoid valve power supply relay
C1: ABS control module ground circuit 5. Ignition power supply 10. Lead to pump motor relay

DTC Troubleshooting
Step Action Yes No
1 Was “ABS Check” performed? Go to Step 2. Go to “ABS Check”
(Page 4E-9).
2 ABS control module power supply and ground circuits Go to Step 3. Repair or replace
check defective wire harness.
1) Check ABS control module power supply circuit and
ground circuit. (Page 4E-29)

Is check result OK?

3 ABS control module power supply voltage check Replace ABS hydraulic Check charging system.
1) Measure battery voltage with engine running at 3,000 unit / control module • K10B model / Bi-fuel
rpm. assembly and recheck CNG model: (Page
DTC. (Page 4E-32) 1J-5)
Is voltage between 9.0 V and 16.0 V?
• K12M model:
(Page 1J-23)
 ABS: 4E-27

DTC C1061
AENJCA0A4504017
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C1061: Pump Motor Circuit Performance • ABS control module (pump motor)
• Pump motor power supply voltage is out of specified range. power supply circuit
• Pump motor is activated although pump motor control relay is OFF. • ABS control module ground circuit
• Pump motor is not activated although pump motor control relay is ON. • ABS control module

Circuit Diagram

[A] E08
1

[a]
7 A1
26 1
6
5 RED E08-26 3
28 15
4
5V 29 16
5
30 17
6
31 18
7
32 19
2 3 8
33 20
9
34 21
10
B1 35 22
M 11
36 23
BLK E08-27 12
4 37 24
13
38 25
14
27 2

IJCA0A450012-01

[A]: ABS control module connector (View: [a]) 2. CPU 6. “ABS MOT” fuse
A1: Pump motor power supply circuit 3. Pump motor relay 7. Relay box
B1: ABS control module ground circuit 4. Pump motor
1. ABS control module 5. Lead to battery

DTC Troubleshooting
Step Action Yes No
1 Was “ABS Check” performed? Go to Step 2. Go to “ABS Check”
(Page 4E-9).
2 Pump motor power supply circuit check Go to Step 3. Repair or replace “A1”
1) Check that ignition is “OFF”. circuit.
2) Disconnect “E08” connector.
3) Check for proper connection to “E08-26” terminal.
4) If connection is OK, measure voltage between “E08-26”
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 “E08-27” terminal and unit / control module circuit.
ground. assembly and recheck
DTC. (Page 4E-32)
Is resistance less than 1 Ω?
4E-28 ABS:

DTC C1062
AENJCA0A4504018
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C1062: Solenoid Valve Continuous Operation Failure ABS control module
Solenoid valve is activated for more than specified time
using “Active Test” of SUZUKI scan tool.

DTC Troubleshooting
Step Action Yes No
1 DTC check Replace ABS hydraulic End.
1) Check that ignition is “OFF”. unit / control module
assembly and recheck
2) Leave vehicle for more than 5 minutes, for cooling down
DTC. (Page 4E-32)
of ABS.
3) Perform “DTC Check” (Page 4E-13).

Is DTC C1062 detected?

DTC C1071
AENJCA0A4504019
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C1071: ABS Control Module Internal Failure ABS control module
ABS control module internal failure is detected.

DTC Troubleshooting
Step Action Yes No
1 Was “ABS Check” performed? Go to Step 2. Go to “ABS Check”
(Page 4E-9).
2 DTC check Go to applicable DTC Replace ABS hydraulic
1) Perform “DTC Check” (Page 4E-13). troubleshooting. unit / control module
assembly and recheck
Is other DTC(s) than C1071 detected? DTC. (Page 4E-32)

DTC U0073
AENJCA0A4504021
Refer to “Troubleshooting for Communication Bus Off” in Section 10H (Page 10H-15).

DTC U0100
AENJCA0A4504022
Refer to “Troubleshooting for Lost Communication” in Section 10H (Page 10H-9).
 ABS: 4E-29

ABS Control Module Power Supply and Ground Circuit Check

AENJCA0A4504023
Circuit Diagram

[A] E08

8 [a]
2
3 A1 26 1
WHT E08-1 9
A2 3
4 28 15
1 RED E08-26 10 4
29 16
5
30 17
6
C1 31 18
7
BLK E08-27 32 19
8
33 20
9
34 21
10
35 22
11
6 36 23
B1 12
7 37 24
5 BRN E08-5 13
38 25
14
27 2

IJCA0A450011-01

[A]: ABS control module connector (View: [a]) 1. Lead to battery 6. Individual circuit fuse box No.2
A1: Solenoid valve power supply circuit 2. Relay box 7. “ABS” fuse
A2: Pump motor power supply circuit 3. “ABS SOL” fuse 8. ABS control module
B1: Ignition power supply circuit 4. “ABS MOT” fuse 9. Lead to solenoid valve power supply relay
C1: ABS control module ground circuit 5. Ignition power supply 10. Lead to pump motor relay

Circuit Description
When the ignition is set “ON”, power is supplied to ABS control module. Then power is supplied to pump motor and
solenoid valve in other line by the switching function in ABS control module.

Troubleshooting
Step Action Yes No
1 Fuse check Go to Step 2. Replace fuse and check
for short circuit to
Are “ABS MOT” fuse, “ABS SOL” fuse and “ABS” fuse in ground.
good condition?
2 Ignition power supply circuit check Go to Step 3. Repair or replace
1) Check that ignition is “OFF”. defective wire harness.
2) Disconnect “E08” connector.
3) Check for proper terminal connection to “E08” connector.
4) If connections are OK, set ignition “ON”.
5) Check that voltage between “B1” circuit and ground is
battery voltage.

Is check result OK?

3 Pump motor and solenoid valve power supply circuit Go to Step 4. Repair or replace
check defective wire harness.
1) Set ignition “OFF”.
2) Check the following points.
• Voltage between “A1” circuit and ground: Battery
voltage
• Voltage between “A2” circuit and ground: Battery
voltage

Is check result OK?

4E-30 ABS:

Step Action Yes No

4 ABS control module ground circuit check ABS control module Repair or replace
1) Check that ignition is “OFF”. power supply and defective wire harness.
ground circuit are in
2) Check that resistance between “C1” circuit and ground is
good condition.
less than 1 Ω.

Is check result OK?

Repair Instructions
ABS Hydraulic Unit Operation Check
AENJCA0A4506001
NOTE
• A false diagnosis may result if operation
check of the ABS hydraulic unit is
performed without satisfying all of the
specified conditions below.
Check that all the following conditions are
met before performing operation check of
the ABS hydraulic unit.
– Battery voltage is 12 V or more.
– No air is trapped in the brake system.
– Brakes do not drag.
– No DTC is stored in ABS hydraulic unit /
control module.
• Operation check must be performed by 2
persons.
• Lighting or blinking of warning light stops
when ignition is set “ON” after completing
ABS hydraulic unit operation check.
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.
6) Perform the following check with help of another
person.
• Depressurization check
Step on brake pedal and then select testing wheel
by SUZUKI scan tool and the wheel should be
turned by another person’s hand. At this time,
check whether the wheel rotates freely due to
brake depressurization.
NOTE
Depressurization by SUZUKI scan tool is
available for 0.5 seconds.

1) Check that ignition is “OFF”.

2) Connect SUZUKI scan tool to DLC (1).
Special tool
(A): SUZUKI scan tool (Suzuki SDT-II)

I8G001460007-01

7) Check all 4-wheels respectively.

1 8) Check that ABS warning light is turned off after
switching ignition from “OFF” to “ON”. Check for
DTC and repair problem if lights are still lit.
9) If any faulty condition is found in Step 6) – 7), replace
ABS hydraulic unit /control module assembly.
10) After completing the check, confirm that ignition is
“OFF” and then disconnect SUZUKI scan tool from
DLC.
2

(A)
IJCA0A111011-01

2. VCI
 ABS: 4E-31

ABS Hydraulic Unit / Control Module Assembly Components

AENJCA0A4506002

7 8 9 6

(a)

(a)

(a)

(c)
(a)

3 (b)

3 (b)

(c)

IJCA0A450013-01

1. ABS hydraulic unit / control module assembly 5. To master cylinder secondary 9. To left-rear brake
2. Actuator bracket 6. To right-front brake : 16 Nm (1.6 kgf-m, 12.0 lbf-ft)
3. Actuator mount nut 7. To left-front brake : 9.5 Nm (0.97 kgf-m, 7.0 lbf-ft)
4. To master cylinder primary 8. To right-rear brake : 26 Nm (2.7 kgf-m, 19.5 lbf-ft)
4E-32 ABS:
ABS Hydraulic Unit / Control Module Assembly
On-Vehicle Inspection
AENJCA0A4506003
Check the following points. Repair or replace defective
parts.
• Check ABS hydraulic unit / control module assembly
(1) for dents, crack, deformation and leakage.
• Check actuator bracket (2) and its mounting surface
for dents, crack and deformation.
• Check actuator mount nuts and actuator bracket nuts
for looseness.
• Check ABS control module connector (ABS control
module side and harness side) and its connector lock
mechanism for damage or crack.
• Check connector terminals for bend, corrosion or rust.
1
2
IJCA0A450014-01
ABS Hydraulic Unit / Control Module Assembly
Removal and Installation
AENJCA0A4506004
NOTICE
• Performing the following prohibited
operations will affect the original
performance of ABS hydraulic unit /
control module assembly.
– Do not disassemble the ABS hydraulic
unit / control module assembly.
– Do not loosen the blind plug.
– Do not remove the motor.
– Regarding ABS hydraulic unit / control
module assembly removal and
installation, check specified torque and
do not use impact tool.
– Use care not to allow dust to enter ABS
hydraulic unit / control module.
– Do not place ABS hydraulic unit / control
module on its side or upside down.
– Do not give an impact to hydraulic unit.
• Brake fluid is extremely damaging to
painted surfaces.
If brake fluid contacts painted surfaces,
immediately wipe it off and flush the
surfaces with water thoroughly.
• The bracket of the ABS hydraulic unit /
control module assembly may have some
burrs at the edge and may damage or
deform the bushing, resulting in abnormal
operation of the ABS.
Be careful not to scratch bushings with the
burr of the bracket when removing /
installing the ABS hydraulic unit / control
module assembly from / to the bracket.
Removal
1) Disconnect negative (–) cable at battery.
2) Disconnect ABS control module connector (1) by
pulling down the lock lever (2).
2 [a]
IFRA0A450024-02
[a]: Pull down to unlock
 ABS: 4E-33

3) Loosen flare nuts (1) using special tool and

disconnect brake pipes from ABS hydraulic unit / 1, (a)
control module assembly (2).
3, (c)
NOTE
Put bleeder plug cap or the like onto pipe to
prevent fluid from spilling.

Special tool
1, (a)
(A): 09950M78220
4) Remove actuator mount nuts (3).

1 2, (b)

(A)

3, (c)
IJCA0A450016-01
2
• Bleed brake system. (Brake fluid replacement)
• Check for leakage of brake fluid and perform ABS
hydraulic unit operation check. (Page 4E-30)
1

Front and Rear Wheel Speed Sensor On-Vehicle

Inspection
AENJCA0A4506005
NOTICE
3
Incorrect voltage or mis-connection will
IJCA0A450015-01
damage the wheel speed sensor.
5) Remove ABS hydraulic unit / control module Check that the power supply voltage and test
assembly from actuator bracket. connections are both correct before
connecting battery.
6) Remove actuator bracket, if necessary. (Page 4E-
31) Output Voltage Inspection
1) Hoist vehicle until tire can be rotated.
Installation
Reverse removal procedure noting the following points. 2) Disconnect wheel speed sensor connector (1).
• Tighten brake pipe flare nuts (1), actuator mount nuts 3) Set up measuring devices as shown in figure.
(2) and actuator bracket nuts (3) (if removed) to
specified torque. [a]
1
Tightening torque
Brake pipe flare nut (a): 16 N·m (1.6 kgf-m, 12.0
[A]
lbf-ft)
Actuator mount nut (b): 9.5 N·m (0.97 kgf-m, 7.0
lbf-ft)
3
Actuator bracket nut (c): 26 N·m (2.7 kgf-m, 19.5
lbf-ft)

IAP70A460014-02

[A]: Wheel speed sensor 3. Power supply (12 V)

connector (View: [a])
2. Resistance (100 Ω)
4E-34 ABS:

4) Measure voltage at both ends of resistance without

wheel rotation. If check result is not as specified,
check sensor, mating encoder and their installation
conditions.
Voltage at resistance (100 Ω) without wheel 1

rotation
600 to 800 mV or 1200 to 1600 mV
5) Measure voltage at both ends of resistance with
rotating wheel. Check that high (1) and low (2)
voltages are as specified. Check that waveform is
not discord.
2 1 3
Voltage at resistance (100 Ω) with wheel rotating
Low voltage: 600 to 800 mV
High voltage: 1200 to 1600 mV

IAP70A460015-01
4
Front Wheel Speed Sensor Removal and
Installation IJCA0A450017-01
AENJCA0A4506006

Removal
1) Hoist vehicle a little and remove front wheel.
2) Remove front fender lining. (Page 9J-4)
3) Remove clips (1) and grommets (2), and disconnect
front wheel speed sensor connector (3).
4) Remove front wheel speed sensor bolt (4).
5) Remove front wheel speed sensor (5) from steering
knuckle.
Installation
Reverse removal procedure noting the following points.
• Check that no iron powder is stuck to sensing area of
wheel speed sensor (1).
• Tighten front wheel speed sensor bolt (2) to specified
torque.
Tightening torque
Front wheel speed sensor bolt (a): 11 N·m (1.1
kgf-m, 8.5 lbf-ft)
• Check that there is no space between front wheel
speed sensor and steering knuckle (3).

[A] [B]
1 2,(a) 1 2,(a)
3 3

I9W10P460009-02

[A]: OK [B]: NG

• Install front wheel. (Page 2D-3)

 ABS: 4E-35

Rear Wheel Speed Sensor Removal and

Installation [A] [B]
AENJCA0A4506007 2 1,(a) 2 1,(a)
3 3

Removal
1) Hoist vehicle.
I9P60A460033-01
2) Disconnect rear wheel speed sensor connector and
clamp (1). [A]: OK [B]: NG

3) Remove clips (2) and grommet (3).

4) Remove rear wheel speed sensor bolt (4).
5) Remove rear wheel speed sensor (5) from rear
wheel hub assembly.
Front and Rear Wheel Speed Sensor Inspection
AENJCA0A4506008
Replace or clean wheel speed sensor if sensing area of
front and rear wheel speed sensor(s) is damaged or
covered with iron powder.

Front Wheel Speed Sensor Ring Removal and

Installation
AENJCA0A4506009
3 NOTE
Front wheel speed sensor ring is included in
wheel side joint assembly. If front wheel
2
speed sensor ring needs to be replaced,
1
replace wheel side joint assembly.

For removal and installation of front wheel speed sensor

ring (included in wheel side joint assembly), refer to
“Front Drive Shaft Assembly Disassembly and
Reassembly”: Front in Section 3A (Page 3A-4).

Rear Wheel Speed Sensor Encoder Removal

4 and Installation
AENJCA0A4506010
NOTE
2 Rear wheel speed sensor encoder is included
in rear wheel hub assembly. If rear wheel
speed sensor encoder needs to be replaced,
5
replace rear wheel hub assembly.
IJCA0A450018-01 For removal and installation of rear wheel speed sensor
encoder (included in rear wheel hub assembly), refer to
Installation “Rear Wheel Hub Assembly Removal and Installation”:
Reverse removal procedure noting the following points. Rear in Section 3A (Page 3A-18).
• Check that no iron powder is stuck to sensing area of
wheel speed sensor (2).
• Tighten rear wheel speed sensor bolt (1) to specified
torque.

NOTICE
When installing rear wheel speed sensor,
damaged O-ring may cause water to enter
into bearing.
Be careful not to damage O-ring when
installing rear wheel speed sensor.

Tightening torque
Rear wheel speed sensor bolt (a): 11 N·m (1.1
kgf-m, 8.5 lbf-ft)
• Check that there is no space between rear wheel
speed sensor and rear wheel hub assembly (3).
4E-36 ABS:

Front Wheel Speed Sensor Ring and Rear Replace wheel side joint assembly if defective.
Wheel Speed Sensor Encoder Inspection
AENJCA0A4506011 Rear Wheel Speed Sensor Encoder

Front Wheel Speed Sensor Ring NOTE

NOTE Rear wheel speed sensor encoder is included

Front wheel speed sensor ring is included in
wheel side joint assembly.
Replace wheel side joint assembly if front
wheel speed sensor ring needs to be
replaced.
Check front wheel speed sensor rings for crack, damage
or deformation.
in rear wheel hub assembly.
Replace rear wheel hub assembly if rear
wheel speed sensor encoder needs to be
replaced.
Check rear wheel speed sensor encoder for crack,
damage or deformation.
Replace rear wheel hub assembly if defective.

Specifications
Tightening Torque Specifications
AENJCA0A4507001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Brake pipe flare nut 16 1.6 12.0 (Page 4E-33)
Actuator mount nut 9.5 0.97 7.0 (Page 4E-33)
Actuator bracket nut 26 2.7 19.5 (Page 4E-33)
Front wheel speed sensor bolt 11 1.1 8.5 (Page 4E-34)
Rear wheel speed sensor bolt 11 1.1 8.5 (Page 4E-35)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“ABS Hydraulic Unit / Control Module Assembly Components” (Page 4E-31)
“Fasteners Information” in Section 0A (Page 0A-6)

Special Tools and Equipment

Special Tool
AENJCA0A4508001
09950M78220 SUZUKI scan tool (Suzuki
SDT-II)
Flare nut wrench (10 x 12 —
mm)
(Page 4E-33) (Page 4E-13) /
(Page 4E-14) /
(Page 4E-30)

Section 5
Transmission / Transaxle
CONTENTS
Precautions .................................................5-1
Precautions............................................................. 5-1
Precautions for Transmission / Transaxle............. 5-1
Manual Transmission/Transaxle ............ 5B-1
K10B Model..............................................................5B-1
General Description .............................................5B-1
Manual Transaxle Construction .......................... 5B-1
Diagnostic Information and Procedures............5B-6
Manual Transaxle Symptom Diagnosis............... 5B-6
Repair Instructions ..............................................5B-8
Manual Transaxle Oil Level Check ..................... 5B-8
Manual Transaxle Oil Change ............................ 5B-8
Differential Side Oil Seal Replacement ............... 5B-9
Gear Shift Control Lever and Cable
Components.................................................... 5B-10
Gear Shift Control Lever and Cable Removal
and Installation ................................................ 5B-11
Gear Select Control Cable Adjustment ............. 5B-12
Back Up Light Switch Removal and
Installation ....................................................... 5B-12
Back Up Light Switch Inspection....................... 5B-13
Manual Transaxle Unit Components................. 5B-13
Manual Transaxle Unit Dismounting and
Remounting..................................................... 5B-14
Gear Shift and Select Shaft Assembly
Components.................................................... 5B-15
Gear Shift and Select Shaft Assembly
Removal and Installation................................. 5B-15
Manual Transaxle Assembly Components........ 5B-17
Manual Transaxle Assembly Disassembly
and Reassembly ............................................. 5B-18
Transaxle Left Case Disassembly and
Reassembly .................................................... 5B-22
Transaxle Right Case Disassembly and
Reassembly .................................................... 5B-23
Input Shaft Components ................................... 5B-25
Input Shaft Disassembly and Reassembly........ 5B-25
Countershaft Components ................................ 5B-30
Countershaft Disassembly and Reassembly .... 5B-30
Gear Shift Shaft Components ........................... 5B-35
Gear Shift Shaft and Fork Inspection ................ 5B-35
Differential Components ................................... 5B-36
Differential Disassembly and Reassembly........ 5B-36
Table of Contents 5- i
Specifications .....................................................5B-39
Tightening Torque Specifications......................5B-39
Special Tools and Equipment ...........................5B-40
Recommended Service Material .......................5B-40
Special Tool ......................................................5B-40
K12M Model ...........................................................5B-42
General Description ...........................................5B-42
Manual Transaxle Construction ........................5B-42
Diagnostic Information and Procedures ..........5B-47
Manual Transaxle Symptom Diagnosis.............5B-47
Repair Instructions ............................................5B-49
Manual Transaxle Oil Level Check ...................5B-49
Manual Transaxle Oil Change...........................5B-49
Differential Side Oil Seal Replacement .............5B-50 5
Gear Shift Control Lever and Cable
Components....................................................5B-51
Gear Shift Control Lever and Cable Removal
and Installation ................................................5B-52
Gear Select Control Cable Adjustment .............5B-52
Back Up Light Switch Removal and
Installation .......................................................5B-53
Back Up Light Switch Inspection.......................5B-53
Manual Transaxle Unit Components.................5B-53
Manual Transaxle Unit Dismounting and
Remounting.....................................................5B-54
Gear Shift and Select Shaft Assembly
Components....................................................5B-55
Gear Shift and Select Shaft Assembly
Removal and Installation.................................5B-56
Manual Transaxle Assembly Components........5B-57
Manual Transaxle Assembly Disassembly
and Reassembly .............................................5B-58
Transaxle Left Case Disassembly and
Reassembly ....................................................5B-62
Transaxle Right Case Disassembly and
Reassembly ....................................................5B-64
Input Shaft Components ...................................5B-66
Input Shaft Disassembly and Reassembly........5B-66
Countershaft Components ................................5B-71
Countershaft Disassembly and Reassembly ....5B-71
Gear Shift Shaft Components ...........................5B-76
Gear Shift Shaft and Fork Inspection ................5B-76
Differential Components....................................5B-77
Differential Disassembly and Reassembly........5B-77
Specifications .....................................................5B-80
5-ii Table of Contents
Tightening Torque Specifications......................5B-80
Special Tools and Equipment ...........................5B-81
Recommended Service Material ....................... 5B-81
Special Tool ......................................................5B-81
Clutch ....................................................... 5C-1
General Description .............................................5C-1
Clutch (Cable Type) Construction .......................5C-1
Diagnostic Information and Procedures............5C-1
Clutch System Symptom Diagnosis ....................5C-1
Repair Instructions ..............................................5C-3
CPP Switch Removal and Installation.................5C-3
CPP Switch Inspection and Adjustment..............5C-3
Clutch Pedal Inspection ......................................5C-4
Clutch Cable Adjustment.....................................5C-4
Clutch Cable Components ..................................5C-5
Clutch Cable Removal and Installation ...............5C-5
Clutch Cable Inspection ......................................5C-7
Clutch Pedal Assembly Components..................5C-7
Clutch Pedal Assembly Removal and
Installation .........................................................5C-8
Clutch Cover and Clutch Disc Components........5C-9
Clutch Cover and Clutch Disc Removal and
Installation .........................................................5C-9
Clutch Cover and Clutch Disc Inspection..........5C-11
Clutch Release System Removal and
Installation .......................................................5C-11
Clutch Release System Inspection ...................5C-13
Specifications.....................................................5C-14
Tightening Torque Specifications......................5C-14
Special Tools and Equipment ...........................5C-14
Recommended Service Material .......................5C-14
Special Tool ......................................................5C-14
Automated Manual Transaxle ................ 5D-1
Precautions...........................................................5D-1
Precautions for Diagnosing Trouble....................5D-1
General Description .............................................5D-1
Auto Gear Shift Description.................................5D-1
Function of Auto Gear Shift Control System
Component .......................................................5D-9
Automatic Gear Shift Table ...............................5D-10
Auto Gear Shift Control System Description .....5D-11
Auto Gear Shift Diagnosis General
Description ......................................................5D-12
OBD System Description ..................................5D-12
CAN Communication System Description.........5D-13
Schematic and Routing Diagram......................5D-14
TCM Circuit Diagram.........................................5D-14
Electronic Shift Control Input / Output
Diagram ..........................................................5D-16
Component Location .........................................5D-17
Electronic Shift Control System Component
Location ..........................................................5D-17
Diagnostic Information and Procedures..........5D-18
Auto Gear Shift System Check .........................5D-18
Visual Inspection ...............................................5D-20
MIL Check .........................................................5D-20
Auto Gear Shift Warning Light Check ...............5D-20
DTC Check........................................................5D-21
DTC Clearance .................................................5D-21
DTC Table.........................................................5D-22
Fail-Safe Table ..................................................5D-28
Scan Tool Data .................................................5D-35
Auto Gear Shift Symptom Diagnosis.................5D-42
MIL Does Not Come ON with Ignition “ON”
and Engine Stopped (but Engine Can Be
Started) ...........................................................5D-42
MIL Remains ON after Engine Starts................5D-42
Auto Gear Shift Warning Light Does Not
Come ON at Ignition “ON” and Engine
Stopped...........................................................5D-42
Auto Gear Shift Warning Light Remains ON
after Engine Starts ..........................................5D-43
Starting Motor Control Relay Circuit Check ......5D-43
DTC P0070 .......................................................5D-44
DTC P0560 / P0562 / P1711.............................5D-46
DTC P0572 / P0573 ..........................................5D-47
DTC P0602 .......................................................5D-49
DTC P0604 / P060A / P062F / P1702 / P1704
/ P1982 / P1983 ..............................................5D-50
DTC P0615 .......................................................5D-50
DTC P0715 / P0716 ..........................................5D-52
DTC P0720 / P0721 ..........................................5D-54
DTC P0805 .......................................................5D-56
DTC P0840 / P0841 ..........................................5D-56
P0904 / P0914 ..................................................5D-57
DTC P080A / P185A / P185B ...........................5D-58
DTC P0944 .......................................................5D-59
DTC P0945 .......................................................5D-59
DTC P1706 .......................................................5D-61
DTC P1707 / P1985 ..........................................5D-61
DTC P1844 .......................................................5D-62
DTC P184A .......................................................5D-63
DTC P184B / P184C / P184D ...........................5D-64
DTC P184E / P184F / P1854 / P1855...............5D-65
DTC P1850 / P1851 / P1888 / P1889 ...............5D-66
DTC P1852 / P1853 ..........................................5D-67
DTC P185C.......................................................5D-67
DTC P185E / P185F / P1984 ............................5D-68
DTC P1884 .......................................................5D-69
DTC P1885 .......................................................5D-70
DTC P1886 .......................................................5D-71
DTC P188A / P188B / P188F............................5D-71
DTC P188C.......................................................5D-74
DTC P188D / P188E .........................................5D-76
DTC P1902 .......................................................5D-78
DTC P1903 / P1904 ..........................................5D-79
DTC P1905 .......................................................5D-81
DTC P1906 / P1907 / P1908 / P190A...............5D-82
DTC P1909 / P190B..........................................5D-84
DTC P190C.......................................................5D-85
DTC P190D.......................................................5D-86
DTC P190E .......................................................5D-87
DTC P190F .......................................................5D-87
DTC P1980 .......................................................5D-88
DTC P1981 .......................................................5D-88
DTC P1986 / P1987 ..........................................5D-89
DTC P2712 .......................................................5D-90

DTC P2789 .......................................................5D-90
DTC U0073 .......................................................5D-91
DTC U0100 .......................................................5D-91
DTC U0121 .......................................................5D-91
DTC U0140 .......................................................5D-91
DTC U0155 .......................................................5D-91
TCM Power Supply and Ground Circuit Check ..5D-91
Inspection of TCM and Its Circuits ....................5D-92
Repair Instructions ............................................5D-96
TCM and Clutch Initialization ............................5D-96
Auto Gear Shift Actuator Oil Level Check .........5D-98
Auto Gear Shift Transaxle Oil Level Check.......5D-98
Auto Gear Shift Transaxle Oil Change..............5D-99
Differential Side Oil Seal Replacement .............5D-99
Shift Selector Components .............................5D-100
Shift Selector Removal and Installation ..........5D-101
Shift Selector Disassembly and Reassembly..5D-101
Shift Selector Inspection .................................5D-103
Auto Gear Shift Actuator Unit Removal and
Installation .....................................................5D-104
Auto Gear Shift Oil Reservoir Tank Removal
and Installation ..............................................5D-109
Auto Gear Shift Electric Motor Removal and
Installation .....................................................5D-111
TCM Removal and Installation ........................5D-113
Gear Shift and Select Shaft Assembly
Components..................................................5D-114
Gear Shift and Select Shaft Assembly
Removal and Installation...............................5D-114
Clutch Speed Sensor Removal and
Installation .....................................................5D-115
Clutch Speed Sensor Inspection.....................5D-115
VSS Removal and Installation ........................5D-116
VSS Inspection ...............................................5D-116
Table of Contents 5-iii
Starting Motor Control Relay and Back Up
Light Relay Inspection...................................5D-117
Auto Gear Shift Unit Components...................5D-117
Auto Gear Shift Unit Dismounting and
Remounting...................................................5D-117
Auto Gear Shift Components ..........................5D-120
Auto Gear Shift Transaxle Disassembly and
Reassembly ..................................................5D-121
Transaxle Left Case Disassembly and
Reassembly ..................................................5D-125
Transaxle Right Case Disassembly and
Reassembly ..................................................5D-127
Input Shaft Components .................................5D-130
Input Shaft Disassembly and Reassembly......5D-130
Countershaft Components ..............................5D-135
Countershaft Disassembly and Reassembly ..5D-135
Gear Shift Shaft Components .........................5D-140
Gear Shift Shaft and Fork Inspection ..............5D-140
Differential Components..................................5D-141
Differential Disassembly and Reassembly......5D-141
Speed Sensor Ring Inspection........................5D-144
Clutch Cover and Clutch Disc Components....5D-145
Clutch Cover and Clutch Disc Removal and
Installation .....................................................5D-145
Clutch Cover and Clutch Disc Inspection........5D-146
Clutch Release System Component Removal
and Installation ..............................................5D-147
Clutch Release System Component
Inspection......................................................5D-149
Specifications ...................................................5D-149
Tightening Torque Specifications....................5D-149
Special Tools and Equipment .........................5D-150
Recommended Service Material .....................5D-150
Special Tool ....................................................5D-150
5-1 Precautions:

Precautions
Transmission / Transaxle

Precautions
Precautions for Transmission / Transaxle
AENJCA0A5000001
General Precautions
Refer to “General Precautions” in Section 00 (Page 00-1).

Precautions for Electrical Circuit Service

Refer to “Precautions for Electrical Circuit Service” in Section 00 (Page 00-3).

Caution for Fastener

Refer to “Caution for Fastener” in Section 00 (Page 00-6).

Warning for Airbag

Refer to “Warning for Airbag” in Section 00 (Page 00-7).

Reassembling Note for Wiring Harness

Observe “Reassembling Note for Wiring Harness” in Section 9A (Page 9A-132) whenever installing wiring harness.
Otherwise, electrical trouble may occur.
 Manual Transmission/Transaxle: K10B Model 5B-1

Manual Transmission/Transaxle
Transmission / Transaxle

K10B Model
General Description
Manual Transaxle Construction
AENJCA0A5211001
The transaxle provides five forward speeds and one reverse speed by means of three synchromesh devices and three
shafts: input shaft, countershaft and reverse gear shaft. All forward gears are in constant mesh, and reverse uses a
sliding idler gear arrangement.
The low speed synchronizer sleeve & hub is mounted on countershaft and engaged with countershaft 1st gear or 2nd
gear, while the high speed synchronizer sleeve & hub is mounted on input shaft and engaged with input shaft 3rd gear
or 4th gear. The 5th speed synchronizer sleeve & hub on input shaft is engaged with input shaft 5th gear mounted on
the input shaft.
The countershaft turns the final gear and differential assembly, thereby turning the front drive shafts which are
attached to the front wheels.
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.
New synchronizer rings are inhibited from being lapped with respective gear cones using lapping compound before
they are assembled.
5B-2 Manual Transmission/Transaxle: K10B Model

IJCA0A521001-01

1. 5th speed sleeve & hub
2. Input shaft 5th gear
3. Input shaft 4th gear
4. High speed synchronizer sleeve & hub
5. Input shaft 3rd gear
6. Left case
7. Reverse gear shaft
8. Reverse idler gear 15. Countershaft 2nd gear
9. Input shaft 16. Low speed synchronizer sleeve & hub
10. Right case 17. Countershaft 1st gear
11. Countershaft 5th gear 18. Final gear
12. Countershaft 4th gear 19. Differential case
13. Countershaft
14. Countershaft 3rd gear
 Manual Transmission/Transaxle: K10B Model 5B-3

Gear Shift Mechanism

The gear shifting control system consists of the following main parts. Movement of gear shift control lever is
transmitted to gear shift & select shaft through gear shift and gear select control cables.

11

5
10

7
8 9

IJCA0A521003-02

1. Gear shift control cable 5. Reverse gear shift lever 9. Gear shift & select lever
2. Gear select control cable 6. 5th & reverse gear shift shaft 10. Gear shift & select shaft assembly
3. Select cable lever 7. High speed gear shift shaft 11. Gear shift control lever assembly
4. Shift cable lever 8. Low speed gear shift shaft
5B-4 Manual Transmission/Transaxle: K10B Model

Reverse Shift Prevention Mechanism

Construction
In the gear shift guide case (1), the reverse shift limit yoke (2) which turns around reverse shift limit yoke retainer is
provided.
This reverse shift limit yoke restricts the movement of reverse interlock lever (3) to prevent erroneous reverse shifting.

2
4

1 3

IJCA0A521004-01

4. Gear shift & select shaft assembly

Operation
1) If shifting directly from 5th [a] to reverse [b] is attempted, the reverse interlock lever (1) is blocked by the projection
of the reverse shift limit yoke (2).

2 2

1 1

[f] [e] [f] [e]

[d] [c] [d] [c]
[b] [a] [b] [a]

IJCA0A521005-01

[c]: 3rd [e]: 1st

[d]: 4th [f]: 2nd
 Manual Transmission/Transaxle: K10B Model 5B-5

2) The reverse interlock lever (1) pushes the projection of the reverse shift limit yoke (2). The reverse shift limit yoke
rotates and pushes the reverse interlock lever toward the neutral position.

[f] [e]
[d] [c]
[b] [a]

2
1

IJCA0A521006-01

[a]: 5th [c]: 3rd [e]: 1st

[b]: Reverse [d]: 4th [f]: 2nd

3) If the reverse shifting force is still applied to the shift lever, the reverse interlock lever (1) rides over the projection
of the reverse shift limit yoke (2), and the gear is shifted into the 4th [d]. The reverse shift limit yoke returns to its
original position.

[f] [e]
[d] [c]
2
[b] [a]

IJCA0A521007-01

[a]: 5th [c]: 3rd [f]: 2nd

[b]: Reverse [e]: 1st
5B-6 Manual Transmission/Transaxle: K10B Model

Diagnostic Information and Procedures

Manual Transaxle Symptom Diagnosis
AENJCA0A5214001

Condition Possible cause Correction / Reference Item

Gears slipping out of Worn shift shaft Replace shift shaft.
mesh • Low speed gear shift shaft: (Page 5B-18)
• High speed gear shift shaft: (Page 5B-18)
• 5th & reverse gear shift shaft: (Page 5B-
18)
Worn shift shaft or synchronizer sleeve Replace shift shaft or synchronizer sleeve.
• Low speed gear shift shaft: (Page 5B-18)
• High speed gear shift shaft: (Page 5B-18)
• 5th & reverse gear shift shaft: (Page 5B-
18)
• Low speed synchronizer sleeve: (Page
5B-30)
• High speed synchronizer sleeve: (Page
5B-25)
• 5th speed synchronizer sleeve: (Page 5B-
25)
Worn bearings on input shaft or Replace input shaft bearing or countershaft
countershaft bearing.
• Input shaft bearing: (Page 5B-25)
• Countershaft bearing: (Page 5B-30)
Worn chamfered tooth on sleeve and Replace synchronizer sleeve and gear.
gear • Countershaft 1st gear and 2nd gear:
(Page 5B-30)
• Input shaft 3rd gear and 4th gear: (Page
5B-25)
• Input shaft 5th gear: (Page 5B-25)
• Low speed synchronizer sleeve: (Page
5B-30)
• High speed synchronizer sleeve: (Page
5B-25)
• 5th speed synchronizer sleeve: (Page 5B-
25)
 Manual Transmission/Transaxle: K10B Model 5B-7
Condition Possible cause
Hard shifting Insufficient lubricant
Maladjusted clutch cable
Distorted or broken clutch disc
Damaged clutch pressure plate
Worn synchronizer ring
Worn chamfered tooth on sleeve and
gear
Worn gear shift control shaft joint
bushing
Distorted shift shaft
Broken gear shift / select control cables Replace gear shift and select control cable.
Noise Insufficient lubricant
Damaged or worn bearing(s)
Damaged or worn gear(s)
Damaged or worn synchronizer parts
Correction / Reference Item
Add manual transaxle oil. (Page 5B-8)
Adjust clutch cable. (Page 5C-4)
Replace clutch disc. (Page 5C-9)
Replace clutch cover. (Page 5C-9)
Replace synchronizer ring.
• Low speed synchronizer ring: (Page 5B-
30)
• High speed synchronizer ring: (Page 5B-
25)
• 5th speed synchronizer ring: (Page 5B-
25)
Replace synchronizer sleeve and gear.
• Countershaft 1st gear and 2nd gear:
(Page 5B-30)
• Input shaft 3rd gear and 4th gear: (Page
5B-25)
• Input shaft 5th gear: (Page 5B-25)
• Low speed synchronizer sleeve: (Page
5B-30)
• High speed synchronizer sleeve: (Page
5B-25)
• 5th speed synchronizer sleeve: (Page 5B-
25)
Replace gear shift & select shaft assembly.
(Page 5B-15)
• Low speed gear shift shaft: (Page 5B-18)
• High speed gear shift shaft: (Page 5B-18)
• 5th & reverse gear shift shaft: (Page 5B-
18)
(Page 5B-11)
Add manual transaxle oil. (Page 5B-8)
Replace input shaft bearing or countershaft
bearing.
• Input shaft bearing: (Page 5B-25)
• Countershaft bearing: (Page 5B-30)
Replace gear.
• Countershaft 1st gear and 2nd gear:
(Page 5B-30)
• Input shaft 3rd gear and 4th gear: (Page
5B-25)
• Input shaft 5th gear: (Page 5B-25)
Replace synchronizer parts.
• Low speed synchronizer parts: (Page 5B-
30)
• High speed synchronizer parts: (Page 5B-
25)
• 5th speed synchronizer parts: (Page 5B-
25)
5B-8 Manual Transmission/Transaxle: K10B Model

Repair Instructions
Manual Transaxle Oil Level Check Manual Transaxle Oil Change
AENJCA0A5216001 AENJCA0A5216002
1) Hoist vehicle and remove left side splash cover. 1) Before changing oil, stop engine and hoist vehicle
2) Check manual transaxle for oil leakage. Repair leaky horizontally.
point, if any. 2) Hoist vehicle and remove left side splash cover.
3) Remove oil level / filler plug (1). Check oil 3) Check manual transaxle for oil leakage. Repair leaky
contamination and check that oil level (2) reaches point, if any.
lower end of oil level / filler plug hole using special 4) Remove oil level / filler plug (2).
tool.
5) Remove drain plug (1) and drain oil.
If oil is excessively dirty or insufficient, change oil or
add specified oil up to plug hole. 6) Apply sealant to thread of drain plug, and tighten it to
specified torque.
Special tool
(A): 09922M36310 “A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
4) Apply sealant to thread of oil level / filler plug, and
then tighten it to specified torque. Tightening torque
Transaxle oil drain plug (a): 21 N·m (2.1 kgf-m,
“A”: Sealant 99000–31260 (SUZUKI Bond 15.5 lbf-ft)
No.1217G)
7) Add new specified oil until oil level reaches lower
Tightening torque end of oil level / filler plug hole.
Transaxle oil level / filler plug (a): 21 N·m (2.1
kgf-m, 15.5 lbf-ft) NOTE
It is highly recommended to use “SUZUKI
GEAR OIL 75W”.
1, (a), “A”
Manual transaxle oil specification
: SUZUKI GEAR OIL 99000–22B27–036
: API GL-4 (For SAE classification, refer to
viscosity chart.)
Manual transaxle oil capacity
Reference: 1.5 liters (3.17/2.64 US/Imp. pt)
Viscosity chart

75W

C - 30 - 20 - 10 0 10 20 30 40
IJCA0A521008-01 F - 22 -4 14 32 50 68 86 104
[a]
IFFA0B521002-01

[a]: Temperature

2
8) Check oil level. (Page 5B-8)

(A)

IJW60P321037-01

5) Install left side splash cover.

 Manual Transmission/Transaxle: K10B Model 5B-9

9) Apply sealant to thread of oil level / filler plug, and
then tighten it to specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Transaxle oil level / filler plug (b): 21 N·m (2.1
kgf-m, 15.5 lbf-ft)
4) Install new oil seal (1) to specified position using
special tool.
NOTE
• When installing oil seal, face its spring
side inward.
• Check that oil seal is installed horizontally
to surface of case after installing oil seal.

Special tool
2, (b), “A” (A): 09944M88220
(B): 09924M74510
Distance from case end face to left oil seal
“a”: 1.0 to 2.0 mm (0.04 to 0.07 in.)
Distance from case end face to right oil seal
“b”: –0.5 to 0.5 mm (–0.02 to 0.01 in.)
5) Apply grease to oil seal lip. Then, check drive shaft
where oil seal contacts and check its smoothness.
“A”: Grease 99000–25011 (SUZUKI Super
1, (a), “A” Grease A)
IJCA0A521009-01
1, “A”
10) Install left side splash cover.

Differential Side Oil Seal Replacement

AENJCA0A5216003
1) Hoist vehicle and drain transaxle oil. (Page 5B-8)
2) Remove front drive shaft. (Page 3A-3) (B) (B)
(A) (A)
3) Remove oil seal (1) using special tool.
Special tool
(A): 09913M50121

“b”
“a”
IJCA0A521010-01

6) Insert front drive shaft. (Page 3A-3)

(A) 7) Add transaxle oil. (Page 5B-8)
1
I9P60A522004-01
5B-10 Manual Transmission/Transaxle: K10B Model

Gear Shift Control Lever and Cable Components

AENJCA0A5216004

A
4
2 (c)
7 (b)
1

10

5 (a)

IJCA0A521011-01

1. Gear shift control lever knob
2. Cable bracket bolt
3. Gear shift control cable
: Apply grease 99000-25011 to cable end.
4. Gear select control cable
: Apply grease 99000-25011 to cable end.
5. Gear shift control lever assembly mounting nut
6. Gear shift control lever assembly
7. Cable grommet cover bolt
8. Cable bracket
9. Shift control lever boot
10. Shift garnish
: 13 Nm (1.3 kgf-m, 9.5 lbf-ft)
: 5.5 Nm (0.56 kgf-m, 4.0 lbf-ft)
: 21 Nm (2.1 kgf-m, 15.5 lbf-ft)
: Do not reuse.
 Manual Transmission/Transaxle: K10B Model 5B-11

Gear Shift Control Lever and Cable Removal 7) Disconnect cable end (2) of gear shift control / gear
and Installation select control from joint pivot on gear shift & select
AENJCA0A5216005 shaft assembly (1) as follows.
! CAUTION a) Insert special tool between gear shift & select
shaft assembly and cable end.
Touching a hot exhaust system component
will cause a burn. Special tool
Do not perform any service work on the (A): 09922M75230
select cable until the exhaust system is cool. b) Pry cable end away pushing special tool in arrow
direction.
Removal
1) Remove floor console box. (Page 9H-34) (A)

2) Remove instrument panel lower cover and shift

garnish. (Page 9C-25) 2
3) Disconnect end (5) of gear shift control cable from
pivot (6) of gear shift control lever assembly (2).
4) Disconnect end (7) of gear select control cable from
pivot (8) of gear shift control lever assembly.
5) Disconnect gear shift and select control cables (1)
from gear shift control lever assembly while pulling 1
IJHB0A522008-01
quick joints (4) in arrow direction as shown in figure.
8) Disconnect gear shift and gear select control cables
6) Remove nuts (3) and remove gear shift control lever
from transaxle while puling up quick joint (1) in arrow
assembly from floor panel.
direction.
9) Remove cable grommet bolts (2), and then remove
5
gear shift and select control cables from floor panel.

6
1

4 1
2
3

2 IJCA0A521013-01

8 Installation
1 Reverse removal procedure noting the following points.
7
3 3
IJCA0A521012-01 • Tighten each bolt and nut to specified torque. (Page
5B-10)
• Adjust gear select control cable. (Page 5B-12)
5B-12 Manual Transmission/Transaxle: K10B Model

Gear Select Control Cable Adjustment
AENJCA0A5216006
1) Release lock plate (1) which restricts moving of
cable end holder (2).
2) Push cable end holder out from adjuster (4) using
appropriate tool (3) to disengage cable.
3) Apply grease to pivot (5) of gear shift control lever,
and then install adjuster (1) into pin of gear shift
control lever securely.
“A”: Grease 99000–25011 (SUZUKI Super
Grease A)
4) Push cable end holder (2) in direction [a].

NOTE
Do not apply force to adjuster in cable
operation direction [b].

5) Slide lock plate (3) in direction [c], until it gets over

the claw (4) of cable end holder.

[b]

I4RS0A520004-01
5, “A”
3 4 1

[c]
3
[a] 2

IJCA0A521014-01

Back Up Light Switch Removal and Installation

AENJCA0A5216007
Removal
1) Disconnect back up light switch connector (1).
2) Remove back up light switch (2).

IJCA0A521015-01
 Manual Transmission/Transaxle: K10B Model 5B-13

Installation Back Up Light Switch Inspection

1) Apply transaxle oil to new O-ring (1) and tighten
back up light switch (2) to specified torque.
Tightening torque
Back up light switch (a): 19 N·m (1.9 kgf-m, 14.0
lbf-ft)
1 2, (a)
AENJCA0A5216008
Check back up light switch function using ohmmeter.
Replace back up light switch if defective.
Back up light switch specification
Switch ON (Push): Continuity exists
Switch OFF (Release): No continuity

I3RH0A520006-01

2) Connect back up light switch connector.

I4RS0A520011-01

Manual Transaxle Unit Components

AENJCA0A5216011

(a)
(a)

(b)

(a)
IJCA0A521016-01

1. Engine : 55 Nm (5.6 kgf-m, 40.5 lbf-ft)

2. Transaxle : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
5B-14 Manual Transmission/Transaxle: K10B Model

Manual Transaxle Unit Dismounting and Remounting

AENJCA0A5216012
Dismounting
1) Remove battery and battery tray. (Page 1J-6)
2) Disconnect gear shift and gear select control cables from transaxle. (Page 5B-11)
3) Remove left side splash cover. (Page 9H-13)
4) Remove clutch cable. (Page 5C-5)
5) Disconnect back up light switch connector (1) and release wiring harness clamps (2).
6) Disconnect ground cable (3) and release ground cable clamp (4).
7) Disconnect engine harness protector (5) and release engine harness clamp (6).

5
3
4
IJCA0A521017-01

8) Drain transaxle oil. (Page 5B-8)
9) Remove exhaust pipe. (Page 1K-5)
10) Remove drive shaft assembly. (Page 3A-3)
11) Remove starting motor. (Page 1I-5)
12) Loosen bolts and nut fastening engine.
13) Remove engine rear torque rod bracket. (Page
1D-23)
14) Open hood as wide as possible and hold it using
rope.
15) Support engine assembly referring to “Engine
Assembly Removal and Installation”: K10B and Bi-
Fuel CNG in Section 1D (Page 1D-24).
16) Remove engine left mounting. (Page 1D-23)
17) Support transaxle with transmission jack.
18) Remove bolts and nut fastening engine and
transaxle and then detach transaxle from engine.
 Manual Transmission/Transaxle: K10B Model 5B-15

Remounting Gear Shift and Select Shaft Assembly

Reverse dismounting procedure noting the following Components
points. AENJCA0A5216013

NOTICE (a)

Failure to take proper precautions when

remounting the manual transaxle can cause
damage to parts. (a)
• When installing the transaxle, be careful
not to let the drive shaft scratch the oil
seal.
Oil leakage may occur if the oil seal lip is
2
scratched by the drive shaft.
• Do not use a hammer when installing the
drive shaft joint into the differential gear.
Hitting the drive shaft joint with a hammer
will damage the joint.

• Tighten the following bolts and nuts to specified

torque. 1
IJCA0A521019-01
– Transaxle to engine bolt and nut: (Page 5B-13)
1. Gear shift & select shaft : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
– Front drive shaft: (Page 3A-3) assembly
– Starting motor: (Page 1I-5) 2. Back up light switch bracket

– Engine left mounting, engine rear torque rod and

engine rear torque rod bracket: (Page 1D-23)
– Exhaust pipe: (Page 1K-5)
• Putting ground cable end as shown, tighten engine
harness ground bolt (1) to specified torque.
Tightening torque
Engine harness ground bolt (a): 25 N·m (2.5 kgf-
m, 18.5 lbf-ft)
Gear Shift and Select Shaft Assembly Removal
and Installation
AENJCA0A5216014
Removal
1) Remove battery and battery tray. (Page 1J-6)
2) Disconnect gear shift and gear select control cables
from transaxle. (Page 5B-11)
3) Disconnect back up light switch connector (1) and
release wiring harness clamps (2).

1, (a)
2

IJCA0A521018-01

• Set each clamp for wiring securely.

IJCA0A521020-01
• Add transaxle oil. (Page 5B-8)
• Adjust clutch cable. (Page 5C-4)
• Check function of engine, clutch and transaxle.
• Check that there is no oil leakage at each connection.
5B-16 Manual Transmission/Transaxle: K10B Model

4) Remove gear shift guide case bolts (1) and gear shift 2) Tighten gear shift & select shaft assembly bolts (1) to
& select shaft assembly (2). specified torque.
Tightening torque
Gear shift & select shaft assembly bolt (a): 23
N·m (2.3 kgf-m, 17.0 lbf-ft)

1, (a)

2
1

IJCA0A521021-01
1, (a)

Installation
1) Install gear shift & select shaft assembly to transaxle IJCA0A521022-01
left case as follows.
3) Connect back up light switch connector and wiring
a) Clean mating surfaces of gear shift & select shaft harness clamps.
assembly and left case.
4) Connect gear shift and gear select control cables to
b) Apply specified amount of sealant to left case as transaxle. (Page 5B-11)
shown in figure.
5) Install battery and battery tray. (Page 1J-6)
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Sealant amount for transaxle left case
“a”: 1.5 mm (0.059 in.)

“a”
“A”
“A” “a”

IDLA0A520029-01

c) Install gear shift & select shaft assembly to left

case.
 Manual Transmission/Transaxle: K10B Model 5B-17

Manual Transaxle Assembly Components

AENJCA0A5216015

28 (d)
3 1217G

OIL
19

21 1217G (b)
2 1217G
23

(a)

18
(c) 16 25
29
31 26

27
OIL

19

20 A

(a)
(a)
18
5

17
4

20 A (c)
13
15 14
1

(c)
22 1217G (b)
6
10
9 24
11 A
12
30

7
(a)
8
IJCA0A521023-01
5B-18 Manual Transmission/Transaxle: K10B Model

1. Transaxle right case 20. Oil seal

: Apply grease 99000-25011 to oil seal lip.
2. Transaxle left case 21. Oil level / filler plug
: Apply sealant 99000-31260 to mating surface of left case and : Apply sealant 99000-31260 to threads.
gear shift & select shaft assembly.
3. Gear shift & select shaft assembly 22. Oil drain plug
: For details, refer to “Gear Shift and Select Shaft Assembly : Apply sealant 99000-31260 to threads.
Removal and Installation”: K10B Model (Page 5B-15).
: Apply sealant 99000-31260 to mating surface of gear shift &
select shaft assembly and left case.
4. Input shaft and countershaft assembly 23. Transaxle case plug
: For details, refer to “Manual Transaxle Assembly
Disassembly and Reassembly”: K10B Model (Page 5B-18).
5. Differential assembly 24. Gasket
: For details, refer to “Differential Components”: K10B Model
(Page 5B-36).
6. Reverse gear shaft 25. Breather plug
7. Washer 26. Breather hose
8. Reverse idle gear 27. Breather union
9. Reverse gear shift lever 28. Back up light switch
10. Reverse gear shift locating ball assembly 29. Transmission hook
11. Input shaft oil seal 30. Countershaft right bearing
: Apply grease 99000-25011 to oil seal lip.
12. Countershaft oil channel 31. Cap
13. Bearing stopper plate : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
14. Input shaft oil channel : 21 Nm (2.1 kgf-m, 15.5 lbf-ft)
15. Magnet : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
16. Oil gutter : 19 Nm (1.9 kgf-m, 14.0 lbf-ft)
17. Countershaft circlip : Apply transaxle oil.

18. Dowel pin : Do not reuse.

19. O-ring

Manual Transaxle Assembly Disassembly and 3) Remove transaxle case bolts (1).
Reassembly
AENJCA0A5216016

Disassembly
1) Remove gear shift & select shaft assembly. (Page
5B-15)
1
2) Remove reverse gear shaft bolt (1) with gasket.

IDLA0A520034-01 IFRA0B522006-01
 Manual Transmission/Transaxle: K10B Model 5B-19

4) Remove transaxle case plug (1) with flat-bladed 6) Remove reverse gear shift lever bolts (1) and
screwdriver (2) or the like. reverse gear shift lever (2).
7) Remove reverse gear shaft (3), washer (4) and
reverse idler gear (5).
1

3
2

2
IDL70A540047-01

5) While expanding countershaft circlip (1) to unhook it IDLA0A520036-01

from bearing groove, remove transaxle left case (2)
from right case using special tool.
NOTE
When removing transaxle left case, circlip
comes out with left case and bearing remains
at countershaft side.
8) Remove magnet from right case.
9) Tapping input shaft end with plastic hammer, push it
out as assembly from case a little, and then take out
input shaft assembly (1), countershaft assembly (2),
5th and reverse gear shift shaft (3), high speed gear
shift shaft (4) and low speed gear shift shaft (5).

Special tool
(A): 09912M34510
4

5
3 3

2
1
IJCA0A521025-01

IDL70A540048-01 10) Remove differential assembly from transaxle right

case.

(A)

IJCA0A521024-01

3. Countershaft left bearing

5B-20 Manual Transmission/Transaxle: K10B Model

Reassembly
1) Install differential assembly into transaxle right case.
2) Join input shaft assembly (1), countershaft assembly
(2), 5th and reverse gear shift shaft (3), high speed (A)
1
gear shift shaft (4) and low speed gear shift shaft (5)
all together, and then install them into transaxle right
case so as not to damage oil seal by input shaft 2, (a)
spline.

NOTE
• Input shaft right bearing on shaft can be
installed into transaxle right case by
tapping shaft with plastic hammer. IGJA0A540069-01
• Check that countershaft is engaged with 6) Install reverse idler gear (1), washer (2) and reverse
final gear while installing. gear shaft (3).

NOTE
Position reverse gear shift lever (4) not to
touch outside diameter (5) of idler gear
4 sleeve.

5
3

5
2

IJCA0A521025-01

3) Install special tool to transaxle right case.

Special tool 3
(A): 09922M28111
4) Install reverse gear shift lever (1). 2
5) Tighten new reverse gear shift lever bolts (2) to
specified torque while pushing reverse gear shift
lever in arrow direction.

NOTICE 1
The reverse gear shift lever bolts are pre-
coated with adhesive. If these bolts are
reused, they may work loose. IGJA0A540070-01

Replace the reverse gear shift lever bolts with

new ones whenever they are removed.

Tightening torque
Reverse gear shift lever bolt (a): 10 N·m (1.0 kgf-
m, 7.5 lbf-ft)
 Manual Transmission/Transaxle: K10B Model 5B-21

7) Align matchmark (1) of reverse idler gear assembly
with matchmark (2) of transaxle right case.
10) While expanding countershaft circlip (1) not to fit it
into bearing groove (2), install transaxle left case
onto right case, and install transaxle case bolts
temporarily.
11) Turn transaxle assembly upside down so that
countershaft bearing fits in left case and circlip fits in
bearing groove.

2 NOTICE
Fitting failure of circlip into bearing groove
causes noise or breakage of countershaft
1 related parts because of wrong positioning of
countershaft.
IFRA0A521020-01
Fit circlip into bearing groove.
8) Install magnet (1) to right case and input shaft oil
channel (2) to input shaft.

2 2

1 1

IDL70A540057-01

12) Tighten transaxle case bolts (1) to specified torque.

IJCA0A521026-01
Tightening torque
Transaxle case bolt (a): 23 N·m (2.3 kgf-m, 17.0
9) Clean mating surfaces of both right and left cases,
lbf-ft)
and apply sealant to transaxle right case (1) as
shown in figure.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Sealant amount for transaxle right case
“a”: 1.5 mm (0.059 in.) 1, (a)

“a”

“A” “a”
1 “A”
1, (a)

IFRA0B522007-01

IFRA0A521021-01
5B-22 Manual Transmission/Transaxle: K10B Model

13) Tighten new reverse gear shaft bolt (1) with new
gasket to specified torque.
NOTICE
The reverse gear shaft bolt is pre-coated with
adhesive. If the bolt is reused, it may work
loose.
Replace the reverse gear shaft bolt with new
one whenever it is removed.
Transaxle Left Case Disassembly and
Reassembly
AENJCA0A5216017
Disassembly
1) Remove differential side oil seal from transaxle left
case, if necessary. (Page 5B-9)
2) Remove circlip (1) and oil gutter (2), if necessary.

Tightening torque
Reverse gear shaft bolt (a): 23 N·m (2.3 kgf-m,
17.0 lbf-ft)

1, (a)

IDLA0A520044-01

Reassembly
1) Install new circlip and oil gutter (1), if removed.

NOTE
IDLA0A520043-01 When installing oil gutter, fit its claws into
14) Install new transaxle case plug (1) using special holes of transaxle left case securely.
tools.
Special tool
(A): 09924M74590
(B): 09924M74510

(B)

(A)

1
IDL70A540062-02

2) Install new differential side oil seal to transaxle left

IDL70A540060-02
case, if removed. (Page 5B-9)
15) Install gear shift & select shaft assembly. (Page
5B-15)
 Manual Transmission/Transaxle: K10B Model 5B-23

Transaxle Right Case Disassembly and 4) Remove reverse gear shift locating ball assembly
Reassembly (1), if necessary.
AENJCA0A5216018

Disassembly
1) Remove differential side oil seal from transaxle right
1
case, if necessary. (Page 5B-9)
2) Remove input shaft oil seal (1) using special tool, if
necessary.
Special tool
(A): 09913M50121

(A)

IDLA0A520047-01

Reassembly
1) Install new input shaft oil seal (1) facing its spring
side upward up to bottom of transaxle right case
1
hole, if removed. Use special tools and hammer for
installation and apply grease to oil seal lip.
“A”: Grease 99000–25011 (SUZUKI Super
Grease A)
IDLA0A520045-01

3) Remove bearing stopper plate (1), countershaft right Special tool

bearing (2) and oil channel (3), using special tools, if (A): 09926M37610M003
necessary. (B): 09913M80113
Special tool
(A): 09930M30104 (B)
(B): 09941M64511

(A)
(A)

(B)
1

1, “A”
IDLA0A520048-01

IJCA0A521027-01
5B-24 Manual Transmission/Transaxle: K10B Model

2) Install countershaft oil channel (1) and new

countershaft right bearing (2), using special tool, if
removed.

NOTE
Install countershaft oil channel aligning its
ridge (3) with ridge (4) of transaxle right case.

Special tool
(A): 09913M70123

(A)

1 4

IJCA0A521028-01

3) Install bearing stopper plate (1) and tighten new

bearing stopper plate bolt (2) to specified torque.

NOTICE
The bearing stopper plate bolt is pre-coated
with adhesive. If the bolt is reused, it may
work loose.
Replace the bearing stopper plate bolt with
new one whenever it is removed.

Tightening torque
Bearing stopper plate bolt (a): 10 N·m (1.0 kgf-
m, 7.5 lbf-ft)

1 2, (a)
IDLA0A520050-01

4) Install reverse gear shift locating ball assembly, if

removed.
5) Install new differential side oil seal to transaxle right
case, if removed. (Page 5B-9)
 Manual Transmission/Transaxle: K10B Model 5B-25

Input Shaft Components

AENJCA0A5216019

8
6

OIL
3
7

1
4 17

OIL
OIL

15

OIL
12
16

11 14

13
9
OIL

3
OIL

10
OIL

IDL70A540069-01

1. Input shaft 8. Circlip 15. 5th gear synchronizer key

2. Input shaft right bearing 9. 4th gear synchronizer ring 16. 5th gear synchronizer hub plate
3. Needle bearing 10. Input shaft 4th gear 17. Input shaft left bearing
4. Input shaft 3rd gear 11. Input shaft 5th gear spacer : Apply transaxle oil.

5. 3rd gear synchronizer ring 12. Input shaft 5th gear : Do not reuse.
6. High speed synchronizer sleeve & hub 13. 5th gear synchronizer ring
7. High speed synchronizer key 14. 5th gear synchronizer sleeve & hub

Input Shaft Disassembly and Reassembly

AENJCA0A5216020

Disassembly
5
! CAUTION 1
2
Using an inappropriate hydraulic press or 4
bearing puller could cause personal injury.
Use the hydraulic press and bearing puller
which are capable of safely bearing a load of
at least 5 tons (11,000 lbs).
3 3
NOTICE IDL70A540070-01

Supporting the gear on the concave side of 5. Metal stick

the bearing puller can cause damage to the

gear.
Support the gear on the flat side of the
bearing puller.

1) Remove input shaft right bearing (2) and left bearing

(4) from input shaft (1) using bearing puller (3) and
hydraulic press.
5B-26 Manual Transmission/Transaxle: K10B Model

2) Remove circlip (1) using snap ring pliers (2). c) Remove 5th gear spacer (1) using bearing puller
(2) and hydraulic press.

2
IDL70A540071-01

3) Remove 5th gear synchronizer hub plate.

4) Remove 5th gear synchronizer sleeve & hub
assembly (1), 5th gear synchronizer ring and 5th
gear (2) from input shaft (3) using bearing puller and
IDL70A540074-01
hydraulic press.
7) Remove 4th gear, 4th gear synchronizer ring and 4th
gear needle bearing from input shaft.
4
1 8) Remove circlip (1) using snap ring pliers (2).
3

2
2

1
IDL70A540072-02

4. Metal stick

5) Remove 5th gear needle bearing from input shaft.

6) Remove 5th gear spacer according to the following
procedure.
IDL70A540075-02
a) Engage high speed synchronizer sleeve with 4th
gear. 9) Remove high speed synchronizer sleeve & hub
assembly (1) and 3rd gear (2) from input shaft (4)
b) Push down input shaft (1) a little using bearing
using bearing puller (3) and hydraulic press.
puller (2) and hydraulic press.

1 2

IDL70A540076-01

10) Remove 3rd gear needle bearing from input shaft.

11) Disassemble synchronizer sleeve & hub assembly.
IJCA0A521029-01
 Manual Transmission/Transaxle: K10B Model 5B-27

Reassembly 4) Install right bearing (1) to input shaft (2) using special
1) Clean all components thoroughly, check them for tool and hydraulic press.
any abnormality and replace them with new ones if Special tool
necessary. (A): 09913M80113
2) Check clearance “a” between synchronizer ring (2)
and gear (1) and replace with new one, if necessary.
Also, check gear teeth for damage.
(A)
Clearance “a” between synchronizer ring and
1
gear (3rd, 4th and 5th)
Standard: 0.40 – 1.10 mm (0.016 – 0.043 in.) 2
Service limit: 0.40 mm (0.016 in.)

IJCA0A521030-01

5) Install 3rd gear needle bearing and apply transaxle

oil to it, and then install 3rd gear (1) and 3rd gear
synchronizer ring (2) to input shaft.
2
6) Install high speed synchronizer hub (3) with long
flange downward using special tool and hydraulic
press.
“a”
NOTE
• Inside diameter of high speed
1 synchronizer hub is larger than that of 5th
IDLA0A520052-01
gear synchronizer hub.
3) To ensure lubrication of input shaft (1), blow air into
oil holes (2) as shown in figure and check that they • While press-fitting high speed
are free from any obstruction. synchronizer hub, check that synchronizer
ring key protrusions (4) are aligned with
key slots (5) on hub.
2 • Check free rotation of 3rd gear after press-
fitting hub.
1
Special tool
(A): 09913M84510

2
(A)
IDL70A540078-02

[b] 3
[a]

2
5

1
4

IJCA0A521032-01

[a]: 3rd gear side [b]: Long flange

5B-28 Manual Transmission/Transaxle: K10B Model

7) Fit high speed synchronizer sleeve (1) to hub (2) and
3 keys (3) as shown in figure.
NOTE
No specific direction is assigned to high
speed synchronizer sleeve or each key.
Synchronizer key installation position
3
NOTE
• Inside diameter of 5th gear synchronizer
hub is smaller than that of high speed
synchronizer hub.
• While press-fitting 5th gear synchronizer
hub, check that synchronizer ring key
protrusions (2) are aligned with key slots
(3) on hub.
• Check free rotation of 5th gear after press-
fitting hub.

Special tool
2 (A): 09913M80113

1
(A)

[a]

1 3

2
IDL70A540080-03 2

8) Install new circlip. IJCA0A521035-01

9) Install 4th gear needle bearing (2) and apply [a]: 5th gear side
transaxle oil to it, and then install synchronizer ring
(4) and 4th gear (3). 13) Fit 5th gear synchronizer sleeve (1) to hub (2) and 3
10) Install 5th gear spacer (1) using special tool and keys (3) as shown in figure.
hydraulic press. NOTE
Special tool No specific direction is assigned to each key.
(A): 09913M84510

Synchronizer key installation position

(A)

2 1
3
3
4

1
IDL70A540082-01

11) Install 5th gear needle bearing and apply transaxle

oil to it, and then install 5th gear and synchronizer
1
ring.
12) Install 5th gear synchronizer hub (1) using special
tool and hydraulic press.
[a]

2
IJCA0A521033-01

[a]: 5th gear side

 Manual Transmission/Transaxle: K10B Model 5B-29

14) Install 5th gear synchronizer hub plate.

15) Select new circlip (1) that makes thrust clearance “a”
of 5th gear synchronizer hub plate 0.1 mm (0.004 in)
or less and install it.
Available circlip thickness
Clearance “b” Circlip thickness
2.000 – 2.049 mm
2.00 mm (0.0787 in.)
(0.0787 – 0.0806 in.)
2.050 – 2.099 mm
2.05 mm (0.0807 in.)
(0.0807 – 0.0826 in.)
2.100 – 2.149 mm
2.10 mm (0.0827 in.)
(0.0827 – 0.0846 in.)
2.150 – 2.199 mm
2.15 mm (0.0846 in.)
(0.0846 – 0.0865 in.)
2.200 – 2.249 mm
2.20 mm (0.0866 in.)
(0.0866 – 0.0885 in.)
2.250 – 2.300 mm
2.25 mm (0.0886 in.)
(0.0886 – 0.0905 in.)

“a” “b”

IFRA0A521030-01

16) Press-fit left bearing (1) using special tool and

hydraulic press.
Special tool
(A): 09944M66060

(A)

IDL70A540086-01
5B-30 Manual Transmission/Transaxle: K10B Model

Countershaft Components
AENJCA0A5216021

OIL
7

6
9
4

OIL
8

OIL
2
15
5

3 14 1
1

OIL
13

1
12

OIL
7
10

11

1
IDL70A540087-02

1. Circlip 7. Needle bearing 13. Countershaft 1st gear

2. Countershaft left bearing 8. Countershaft 2nd gear 14. Countershaft
3. Countershaft 5th gear 9. 2nd gear synchronizer ring 15. Countershaft right bearing inner race
4. Countershaft 4th gear 10. Low speed synchronizer key : Apply transaxle oil.

5. Countershaft 3rd and 4th gear spacer 11. Low speed synchronizer sleeve & hub : Do not reuse.
6. Countershaft 3rd gear 12. 1st gear synchronizer ring

Countershaft Disassembly and Reassembly 1) Remove circlip (1) using snap ring pliers (2).
AENJCA0A5216022

Disassembly

! CAUTION 2

Using an inappropriate hydraulic press or

bearing puller could cause personal injury.
Use the hydraulic press and bearing puller
which are capable of safely bearing a load of 1
at least 5 tons (11,000 lbs).

NOTICE
IDL70A540088-02
Supporting the gear on the concave side of
the bearing puller can cause damage to the
gear.
Support the gear on the flat side of the
bearing puller.
 Manual Transmission/Transaxle: K10B Model 5B-31

2) Remove left bearing (1) using bearing puller (2) and 7) Remove 2nd gear synchronizer ring and 2nd gear
hydraulic press. needle bearing.
8) Remove circlip (1) using snap ring pliers (2).

1
3
1
2
2

IDL70A540089-01 IDL70A540093-02

3. Metal stick
9) Apply bearing puller (3) to 1st gear (2) and remove
low speed synchronizer sleeve & hub assembly (1),
3) Remove circlip (1) using snap ring pliers (2). 1st gear synchronizer ring and 1st gear using
hydraulic press.

2
1

1 2

IDL70A540090-02
4) Apply bearing puller (3) to 4th gear (2) and remove
5th gear (1) together with 4th gear using hydraulic
press.
IDL70A540094-01
10) Remove 1st gear needle bearing.
11) Remove circlip (1) using snap ring pliers (2).

IDL70A540095-02

IDL70A540091-01

5) Remove 3rd and 4th gear spacer.

6) Apply bearing puller (3) to 2nd gear (2) and remove
3rd gear (1) together with 2nd gear using hydraulic
press.

1
2

IDL70A540092-01
5B-32 Manual Transmission/Transaxle: K10B Model

12) Grind portion “a” of right bearing inner race (1) using Reassembly
grinder (2) as shown. 1) Clean all components thoroughly, check them for
any abnormality and replace them with new ones if
NOTICE
necessary.
The shaft (3) will be damaged if the bearing is
2) Check clearance “a” between synchronizer ring (2)
ground too much.
and gear (1) and replace with new one, if necessary.
Limit the grinding to a minimum necessary
Also, check gear teeth for damage.
amount.
Clearance “a” between synchronizer ring and
gear (1st and 2nd)
Standard: 0.40 – 1.10 mm (0.016 – 0.043 in.)
Service limit: 0.40 mm (0.016 in.)

2
3

“a”
1
3
1

IDL70A540096-01

13) Break the thinnest portion of bearing inner race (2)

with a chisel (1) and remove bearing inner race. 2

“a”
1

1
IDLA0A520052-01

3) To ensure lubrication of countershaft (1), blow air

into oil holes (2) as shown in figure and check that
they are free from any obstruction.

2 1
IDL70A540097-01 2

IDL70A540099-02
 Manual Transmission/Transaxle: K10B Model 5B-33

4) Install right bearing inner race (1) using special tool 8) Fit low speed synchronizer sleeve (1) to hub (2) and
and hydraulic press. 3 keys (3) as shown in figure.
Special tool NOTE
(A): 09913M80113
• No specific direction is assigned to each
key.
(A)
• When fitting sleeve to hub, raise the hub
1
and check that the sleeve comes off with
the self-weight.

IDL70A540098-01
2
5) Install new circlip.
6) Install 1st gear needle bearing and apply transaxle 1

oil to it, and then install 1st gear (1) and 1st gear
synchronizer ring to countershaft.
7) Install low speed synchronizer hub (2) using special 1
tool and hydraulic press.

NOTE
[a]
• No specific direction is assigned to low
speed synchronizer hub.
• While press-fitting low speed synchronizer
hub, check that synchronizer ring key 2
IJCA0A521037-01
protrusions (3) are aligned with key slots
[a]: 1st gear side
(4) on hub.
• Check free rotation of 1st gear after press- 9) Install new circlip.
fitting hub.
10) Install 2nd gear needle bearing and apply transaxle
Special tool oil to it, and then install 2nd gear synchronizer ring
(A): 09940M51710 and 2nd gear to countershaft.
11) Install 3rd gear (1) using special tool and hydraulic
(A) press.
Special tool
4 (A): 09925M18011
2

3
(A)

1 1

IJCA0A521036-01
[b]

[a]

IDL70A540102-01

[a]: 2nd gear side [b]: Long flange

5B-34 Manual Transmission/Transaxle: K10B Model

12) Install 3rd and 4th gear spacer (1) and then install 14) Select new circlip (1) that makes thrust clearance “a”
4th gear (2) using special tool and hydraulic press. of 5th gear 0.1 mm (0.004 in) or less and install it.
Special tool Available circlip thickness
(A): 09925M18011 Clearance “b” Circlip thickness
2.150 – 2.199 mm
2.15 mm (0.0846 in.)
(A) (0.0846 – 0.0865 in.)
2.200 – 2.249 mm
2 2.20 mm (0.0866 in.)
(0.0866 – 0.0885 in.)
2.250 – 2.299 mm
2.25 mm (0.0886 in.)
(0.0886 – 0.0905 in.)
1
2.300 – 2.349 mm
[b] 2.30 mm (0.0906 in.)
(0.0906 – 0.0924 in.)
[a] 2.350 – 2.399 mm
2.35 mm (0.0925 in.)
(0.0925 – 0.0944 in.)
2.400 – 2.450 mm
2.40 mm (0.0945 in.)
(0.0945 – 0.0964 in.)
IDL70A540103-01

[a]: 3rd and 4th gear spacer side [b]: Long flange

1
13) Install 5th gear (1) using special tool and hydraulic
press. 2

Special tool “a” “b”

(A): 09925M18011

(A) 3

1
4

[b] IDL70A540105-01

2. Countershaft 4. 4th gear

[a]
3. 5th gear

15) Install left bearing (1) using special tool and

hydraulic press.
IDL70A540104-01
Special tool
[a]: 4th gear side [b]: Long flange
(A): 09913M80113

(A)
[b]

[a]

IDL70A540106-01

[a]: 5th gear side [b]: Gloves

16) Install new circlip.

 Manual Transmission/Transaxle: K10B Model 5B-35

Gear Shift Shaft Components

AENJCA0A5216023

(a)

4
IDL70A540157-01

1. Low speed gear shift shaft 3. 5th and reverse gear shift shaft : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
2. High speed gear shift shaft 4. Reverse gear shift lever : Do not reuse.

Gear Shift Shaft and Fork Inspection

AENJCA0A5216024
1) Using feeler gauge, check clearance between fork
(1) and sleeve (2) and replace those parts if it
exceeds specified value.
Clearance “a” between fork and sleeve
Standard: 0.05 – 0.40 mm (0.002 – 0.016 in.)
Service limit: 0.40 mm (0.016 in.)

I2RH01520068-01

2) Insert each gear shift shaft into case and check that
it moves smoothly. If not, correct burns or dents with
oilstone, reamer or the like.
5B-36 Manual Transmission/Transaxle: K10B Model

Differential Components
AENJCA0A5216025

OIL
4

OIL
5

OIL
3
2
OIL

11 2

OIL
1

10
OIL

6
OIL

3
OIL

4
5
OIL

6
9 (a)

8
IJCA0A521038-01

1. Differential pinion washer 6. Differential side bearing 11. Differential pinion shaft pin
2. Differential pinion 7. Differential case : 100 Nm (10.2 kgf-m, 74.0 lbf-ft)
3. Differential side gear 8. Final gear : Apply transaxle oil.

4. Spring washer 9. Final gear bolt : Do not reuse.

5. Side gear washer 10. Differential pinion shaft

Differential Disassembly and Reassembly 2) Remove left side bearing (1) using special tool,
AENJCA0A5216026 bearing puller (2) and hydraulic press.
Disassembly Special tool
1) With final gear (1) fixed in soft jawed vise, remove (A): 09913M75821
final gear bolts (2), and then remove differential case
(3).
(A)
1

2
1
2

3
IJCA0A521040-01 IJCA0A521041-01
 Manual Transmission/Transaxle: K10B Model 5B-37

3) Remove right side bearing in the same manner as in Reassembly

Step 2). Judging from abnormality noted before disassembly and
4) Remove differential pinion shaft pin using special what is found through visual check of component parts
tool and hammer, and then disassemble component after disassembly, prepare replacing parts and proceed
parts. to reassembly. Check that all parts are clean.
1) Install side gear washers (6), spring washers (5),
Special tool
side gears (4), differential pinion washers (3) and
(A): 09922M85811
differential pinions (2) to differential case (1).
2) Install pinion shaft (7) to differential case.
(A)
1

6
2 5

IJCA0A521046-01

5) Remove pinion shaft (1) from differential case (2). 2

6
4 5
2 IE3J0P540076-01
1

IFKA0Q540129-01

6) Remove differential pinions (3), differential pinion

washers (1), side gears (4), spring washers (2) and
side gear washers (6) from differential case (5).

4
1
3

4
1

2
5
6
IFKA0Q540130-01
5B-38 Manual Transmission/Transaxle: K10B Model

3) Measure thrust play of differential side gear (1) at 4) Install new differential pinion shaft pin (1) from left
each side as follows. side until depth “a” becomes 4.70 – 5.70 mm (0.185
If measured value is out of specification, select – 0.224 in.) as shown using special tool.
suitable side gear washer (2) from the following
Special tool
available sizes, install it and check again.
(A): 09922M85811
Special tool
(A): 09900M20607
(A)
(B): 09900M20701
a) Hold differential assembly with soft jawed vise
and apply dial gauge to side gear as shown in “a”
figure.
b) Move side gear up and down by hand and read
dial gauge.
Differential side gear thrust play 1

0.03 – 0.31 mm (0.0012 – 0.0122 in.)

(A)
[A] IFKA0Q540131-01

5) Press-fit right side bearing (1) using special tool and

hydraulic press.
Special tool
(B) (A): 09913M70123
3
2 (A)

1 4

1
3

[B]

(A)
3

IJCA0A521043-01
4 (B)
1

2
3

1
IJCA0A521042-01

[A]: Right side 3. Differential case

[B]: Left side 4. Spring washer

Available side gear washer thickness

Thickness mm (in.) Thickness mm (in.)
0.60 mm (0.0236 in.) 0.85 mm (0.0335 in.)
0.65 mm (0.0256 in.) 0.90 mm (0.0354 in.)
0.70 mm (0.0276 in.) 0.95 mm (0.0374 in.)
0.75 mm (0.0295 in.) 1.00 mm (0.0394 in.)
0.80 mm (0.0315 in.) 1.05 mm (0.0413 in.)
 Manual Transmission/Transaxle: K10B Model 5B-39

6) Hold differential case with special tool (B) to prevent 7) With final gear (1) fixed in soft jawed vise, install
right side bearing from damaging, and press-fit left differential case (2), and then tighten new final gear
side bearing (1) using special tool (A) and hydraulic bolts (3) to specified torque.
press.
NOTICE
Special tool
The bolts may loosen during operation of the
(A): 09913M70123
differential if any bolts other than the
(B): 09925M88210
specified ones are installed.
(A)
Use only the specified new bolts.

Tightening torque
Final gear bolt (a): 100 N·m (10.2 kgf-m, 74.0 lbf-
1
ft)

3, (a)

(B)

IJCA0A521044-01
2
IJCA0A521045-01

Specifications
Tightening Torque Specifications
AENJCA0A5217001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Transaxle oil level / filler plug (Page 5B-8) /
21 2.1 15.5
(Page 5B-9)
Transaxle oil drain plug 21 2.1 15.5 (Page 5B-8)
Back up light switch 19 1.9 14.0 (Page 5B-13)
Engine harness ground bolt 25 2.5 18.5 (Page 5B-15)
Gear shift & select shaft assembly bolt 23 2.3 17.0 (Page 5B-16)
Reverse gear shift lever bolt 10 1.0 7.5 (Page 5B-20)
Transaxle case bolt 23 2.3 17.0 (Page 5B-21)
Reverse gear shaft bolt 23 2.3 17.0 (Page 5B-22)
Bearing stopper plate bolt 10 1.0 7.5 (Page 5B-24)
Final gear bolt 100 10.2 74.0 (Page 5B-39)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Gear Shift Control Lever and Cable Components”: K10B Model (Page 5B-10)
“Manual Transaxle Unit Components”: K10B Model (Page 5B-13)
“Gear Shift and Select Shaft Assembly Components”: K10B Model (Page 5B-15)
“Manual Transaxle Assembly Components”: K10B Model (Page 5B-17)
“Gear Shift Shaft Components”: K10B Model (Page 5B-35)
“Differential Components”: K10B Model (Page 5B-36)
“Fasteners Information” in Section 0A (Page 0A-6)
5B-40 Manual Transmission/Transaxle: K10B Model

Special Tools and Equipment

Recommended Service Material
AENJCA0A5218001
Material SUZUKI recommended product or Specification Note
Grease SUZUKI Super Grease A P/No.: 99000–25011 (Page 5B-9) / (Page 5B-
12) / (Page 5B-23)
Sealant SUZUKI Bond No.1217G P/No.: 99000–31260 (Page 5B-8) / (Page 5B-
8) / (Page 5B-9) / (Page
5B-16) / (Page 5B-21)

NOTE
Required service material(s) is also described in:
“Gear Shift Control Lever and Cable Components”: K10B Model (Page 5B-10)
“Manual Transaxle Assembly Components”: K10B Model (Page 5B-17)
“Input Shaft Components”: K10B Model (Page 5B-25)
“Countershaft Components”: K10B Model (Page 5B-30)
“Differential Components”: K10B Model (Page 5B-36)

Special Tool
AENJCA0A5218002
09900M20607 09900M20701
Dial gauge Magnetic stand
(Page 5B-38) (Page 5B-38)

09912M34510 09913M50121
Case separator Oil seal remover
(Page 5B-19) (Page 5B-9) /
(Page 5B-23)

09913M70123 09913M75821
Bearing installer Bearing installer attachment
(Page 5B-24) / (Page 5B-36)
(Page 5B-38) /
(Page 5B-39)

09913M80113 09913M84510
Bearing installer Bearing installer
(Page 5B-23) / (Page 5B-27) /
(Page 5B-27) / (Page 5B-28)
(Page 5B-28) /
(Page 5B-33) /
(Page 5B-34)
09922M28111 09922M36310
Reverse gear shift lever Oil level gauge
positioner
(Page 5B-20) (Page 5B-8)
 Manual Transmission/Transaxle: K10B Model 5B-41

09922M75230 09922M85811
Gear shift cable remover Spring pin remover (4.5 mm)
(Page 5B-11) (Page 5B-37) /
(Page 5B-38)

09924M74510 09924M74590
Bearing and oil seal handle Input shaft oil seal installer
attachment
(Page 5B-9) / (Page 5B-22)
(Page 5B-22)

09925M18011 09925M88210
Transmission gear, bush Bearing puller attachment
and bearing installer
(Page 5B-33) / (Page 5B-39)
(Page 5B-34) /
(Page 5B-34)

09926M37610M003 09930M30104
Bearing remover attachment Sliding shaft
(Page 5B-23) (Page 5B-23)

09940M51710 09941M64511
Bearing installer Bearing and oil seal remover
(30 mm min.)
(Page 5B-33) (Page 5B-23)

09944M66060 09944M88220
Bearing installer Oil seal installer
(Page 5B-29) (Page 5B-9)
5B-42 Manual Transmission/Transaxle: K12M Model

K12M Model
General Description
Manual Transaxle Construction
AENJCA0A5221001
The transaxle provides five forward speeds and one reverse speed by means of three synchromesh devices and three
shafts: input shaft, countershaft and reverse gear shaft. All forward gears are in constant mesh, and reverse uses a
sliding idler gear arrangement.
The low speed synchronizer sleeve & hub is mounted on countershaft and engaged with countershaft 1st gear or 2nd
gear, while the high speed synchronizer sleeve & hub is mounted on input shaft and engaged with input shaft 3rd gear
or 4th gear. The 5th speed synchronizer sleeve & hub on input shaft is engaged with input shaft 5th gear mounted on
the input shaft.
The countershaft turns the final gear and differential assembly, thereby turning the front drive shafts which are
attached to the front wheels.
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.
New synchronizer rings are inhibited from being lapped with respective gear cones using lapping compound before
they are assembled.
 Manual Transmission/Transaxle: K12M Model 5B-43

IFRA0A521004-03

1. 5th speed sleeve & hub
2. Input shaft 5th gear
3. Input shaft 4th gear
4. High speed synchronizer sleeve & hub
5. Input shaft 3rd gear
6. Left case
7. Reverse gear shaft
8. Reverse idler gear
9. Input shaft
10. Right case
11. Countershaft 5th gear
12. Countershaft 4th gear
13. Countershaft
14. Countershaft 3rd gear
15. Countershaft 2nd gear
16. Low speed synchronizer sleeve & hub
17. Countershaft 1st gear
18. Final gear
19. Differential case
5B-44 Manual Transmission/Transaxle: K12M Model

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 control cables.

12

3 3

5
4
11

9
7 5
8
9 10

IJCA0A522001-01

1. Gear shift control cable 5. Reverse gear shift lever 9. Gear shift & select lever
2. Gear select control cable 6. 5th & reverse gear shift shaft 10. Gear shift interlock bolt
3. Select cable lever 7. High speed gear shift shaft 11. Gear shift & select shaft assembly
4. Shift cable lever 8. Low speed gear shift shaft 12. Gear shift control lever assembly

Reverse Shift Prevention Mechanism

Construction
In the gear shift guide case (1), the reverse shift limit yoke (2) which turns around reverse shift limit yoke retainer is
provided.
This reverse shift limit yoke restricts the movement of reverse interlock lever (3) to prevent erroneous reverse shifting.

4
2

3
1

IDLA0A520003-01

4. Gear shift & select shaft assembly

 Manual Transmission/Transaxle: K12M Model 5B-45

Operation
1) If shifting directly from 5th [a] to reverse [b] is attempted, the reverse interlock lever (1) is blocked by the projection
of the reverse shift limit yoke (2).

2 2

1 1

[f] [f]
[e]
[e]
[d] [d]
[c]
[c]
[b] [b]
[a]
[a]

IDLA0A520004-01

[c]: 3rd [e]: 1st

[d]: 4th [f]: 2nd
5B-46 Manual Transmission/Transaxle: K12M Model

2) The reverse interlock lever (1) pushes the projection of the reverse shift limit yoke (2). The reverse shift limit yoke
rotates and pushes the reverse interlock lever toward the neutral position.

[f]
[e] 1
[d]
[c]
[b]
[a]

IDLA0A520005-01

[a]: 5th [c]: 3rd [e]: 1st

[b]: Reverse [d]: 4th [f]: 2nd

3) If the reverse shifting force is still applied to the shift lever, the reverse interlock lever (1) rides over the projection
of the reverse shift limit yoke (2), and the gear is shifted into the 4th [d]. The reverse shift limit yoke returns to its
original position.

1
[f] [e]
[d] [c]

[b] [a]

IDLA0A520006-01

[a]: 5th [c]: 3rd [f]: 2nd

[b]: Reverse [e]: 1st
 Manual Transmission/Transaxle: K12M Model 5B-47

Diagnostic Information and Procedures

Manual Transaxle Symptom Diagnosis
AENJCA0A5224001

Condition Possible cause Correction / Reference Item

Gears slipping out of Worn shift shaft Replace shift shaft.
mesh • Low speed gear shift shaft: (Page 5B-58)
• High speed gear shift shaft: (Page 5B-58)
• 5th & reverse gear shift shaft: (Page 5B-
58)
Worn shift shaft or synchronizer sleeve Replace shift shaft or synchronizer sleeve.
• Low speed gear shift shaft: (Page 5B-58)
• High speed gear shift shaft: (Page 5B-58)
• 5th & reverse gear shift shaft: (Page 5B-
58)
• Low speed synchronizer sleeve: (Page
5B-71)
• High speed synchronizer sleeve: (Page
5B-66)
• 5th speed synchronizer sleeve: (Page 5B-
66)
Worn bearings on input shaft or Replace input shaft bearing or countershaft
countershaft bearing.
• Input shaft bearing: (Page 5B-66)
• Countershaft bearing: (Page 5B-71)
Worn chamfered tooth on sleeve and Replace synchronizer sleeve and gear.
gear • Countershaft 1st gear and 2nd gear:
(Page 5B-71)
• Input shaft 3rd gear and 4th gear: (Page
5B-66)
• Input shaft 5th gear: (Page 5B-66)
• Low speed synchronizer sleeve: (Page
5B-71)
• High speed synchronizer sleeve: (Page
5B-66)
• 5th speed synchronizer sleeve: (Page 5B-
66)
5B-48 Manual Transmission/Transaxle: K12M Model
Condition Possible cause
Hard shifting Insufficient lubricant
Maladjusted clutch cable
Distorted or broken clutch disc
Damaged clutch pressure plate
Worn synchronizer ring
Worn chamfered tooth on sleeve and
gear
Worn gear shift control shaft joint
bushing
Distorted shift shaft
Broken gear shift / select control cables Replace gear shift and select control cable.
Noise Insufficient lubricant
Damaged or worn bearing(s)
Damaged or worn gear(s)
Damaged or worn synchronizer parts
Correction / Reference Item
Add manual transaxle oil. (Page 5B-49)
Adjust clutch cable. (Page 5C-4)
Replace clutch disc. (Page 5C-9)
Replace clutch cover. (Page 5C-9)
Replace synchronizer ring.
• Low speed synchronizer ring: (Page 5B-
71)
• High speed synchronizer ring: (Page 5B-
66)
• 5th speed synchronizer ring: (Page 5B-
66)
Replace synchronizer sleeve and gear.
• Countershaft 1st gear and 2nd gear:
(Page 5B-71)
• Input shaft 3rd gear and 4th gear: (Page
5B-66)
• Input shaft 5th gear: (Page 5B-66)
• Low speed synchronizer sleeve: (Page
5B-71)
• High speed synchronizer sleeve: (Page
5B-66)
• 5th speed synchronizer sleeve: (Page 5B-
66)
Replace gear shift & select shaft assembly.
(Page 5B-56)
• Low speed gear shift shaft: (Page 5B-58)
• High speed gear shift shaft: (Page 5B-58)
• 5th & reverse gear shift shaft: (Page 5B-
58)
(Page 5B-52)
Add manual transaxle oil. (Page 5B-49)
Replace input shaft bearing or countershaft
bearing.
• Input shaft bearing: (Page 5B-66)
• Countershaft bearing: (Page 5B-71)
Replace gear.
• Countershaft 1st gear and 2nd gear:
(Page 5B-71)
• Input shaft 3rd gear and 4th gear: (Page
5B-66)
• Input shaft 5th gear: (Page 5B-66)
Replace synchronizer parts.
• Low speed synchronizer parts: (Page 5B-
71)
• High speed synchronizer parts: (Page 5B-
66)
• 5th speed synchronizer parts: (Page 5B-
66)
 Manual Transmission/Transaxle: K12M Model 5B-49

Repair Instructions
Manual Transaxle Oil Level Check
AENJCA0A5226001
1) Hoist vehicle and remove left side splash cover.
2) Check manual transaxle for oil leakage. Repair leaky
point, if any.
3) Remove oil level / filler plug (1). Check oil
contamination and check that oil level (2) reaches
lower end of oil level / filler plug hole using special
tool.
If oil is excessively dirty or insufficient, change oil or
add specified oil up to plug hole.
Special tool
(A): 09922M36310
4) Apply sealant to thread of oil level / filler plug, and
then tighten it to specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Transaxle oil level / filler plug (a): 21 N·m (2.1
kgf-m, 15.5 lbf-ft)
Manual Transaxle Oil Change
AENJCA0A5226002
1) Before changing oil, stop engine and hoist vehicle
horizontally.
2) Hoist vehicle and remove left side splash cover.
3) Check manual transaxle for oil leakage. Repair leaky
point, if any.
4) Remove oil level / filler plug (1).
5) Remove drain plug (2) and drain oil.
6) Apply sealant to thread of drain plug, and tighten it to
specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Transaxle oil drain plug (a): 21 N·m (2.1 kgf-m,
15.5 lbf-ft)
7) Add new specified oil until oil level reaches lower
end of oil level / filler plug hole.
NOTE
It is highly recommended to use “SUZUKI
GEAR OIL 75W”.

Manual transaxle oil specification

: SUZUKI GEAR OIL 99000–22B27–036
: API GL-4 (For SAE classification, refer to
viscosity chart.)
Manual transaxle oil capacity
Reference: 1.5 liters (3.17/2.64 US/Imp. pt)
1, (a), “A”
Viscosity chart

75W

C - 30 - 20 - 10 0 10 20 30 40
F - 22 -4 14 32 50 68 86 104
IJCA0A522002-01
[a]
IFFA0B521002-01

[a]: Temperature

2 8) Check oil level. (Page 5B-49)

(A)

IJW60P321037-01

5) Install left side splash cover.

5B-50 Manual Transmission/Transaxle: K12M Model

9) Apply sealant to thread of oil level / filler plug, and
then tighten it to specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Transaxle oil level / filler plug (b): 21 N·m (2.1
kgf-m, 15.5 lbf-ft)
4) Install new oil seal (1) to specified position using
special tool.
NOTE
• When installing oil seal, face its spring
side inward.
• Check that oil seal is installed horizontally
to surface of case after installing oil seal.

Special tool
(A): 09944M88220
(B): 09924M74510
Distance from case end face to left oil seal
“a”: 1.0 to 2.0 mm (0.04 to 0.07 in.)
Distance from case end face to right oil seal
“b”: –0.5 to 0.5 mm (–0.02 to 0.01 in.)
1, (b), “A”
5) Apply grease to oil seal lip. Then, check drive shaft
where oil seal contacts and check its smoothness.
“A”: Grease 99000–25011 (SUZUKI Super
2, (a), “A” Grease A)
IJCA0A522003-01 1, “A”
10) Install left side splash cover.

Differential Side Oil Seal Replacement

AENJCA0A5226003
1) Hoist vehicle and drain transaxle oil. (Page 5B-49)
(B) (B)
2) Remove front drive shaft. (Page 3A-3) (A) (A)
3) Remove oil seal (1) using special tool.
Special tool
(A): 09913M50121

“b”
“a”
IJCA0A521010-01

6) Insert front drive shaft. (Page 3A-3)

7) Add transaxle oil. (Page 5B-49)
(A)
1
I9P60A522004-01
 Manual Transmission/Transaxle: K12M Model 5B-51

Gear Shift Control Lever and Cable Components

AENJCA0A5226004

2 (c)
7 (b)
1

8
10

5 (a)

IJCA0A522004-01

1. Gear shift control lever knob
2. Cable bracket bolt
3. Gear shift control cable
: Apply grease 99000-25011 to cable end.
4. Gear select control cable
: Apply grease 99000-25011 to cable end.
5. Gear shift control lever assembly mounting nut
6. Gear shift control lever assembly
7. Cable grommet cover bolt
8. Cable bracket
9. Shift control lever boot
10. Shift garnish
: 13 Nm (1.3 kgf-m, 9.5 lbf-ft)
: 5.5 Nm (0.56 kgf-m, 4.0 lbf-ft)
: 21 Nm (2.1 kgf-m, 15.5 lbf-ft)
: Do not reuse.
5B-52 Manual Transmission/Transaxle: K12M Model

Gear Shift Control Lever and Cable Removal 7) Disconnect cable end (2) of gear shift control / gear
and Installation select control from joint pivot on gear shift & select
AENJCA0A5226005 shaft assembly (1) as follows.
! CAUTION a) Insert special tool between gear shift & select
shaft assembly and cable end.
Touching a hot exhaust system component
will cause a burn. Special tool
Do not perform any service work on the (A): 09922M75230
select cable until the exhaust system is cool. b) Pry cable end away pushing special tool in arrow
direction.
Removal
1) Remove floor console box. (Page 9H-34) (A)

2) Remove instrument panel lower cover and shift

garnish. (Page 9C-25) 2
3) Disconnect end (5) of gear shift control cable from
pivot (6) of gear shift control lever assembly (2).
4) Disconnect end (7) of gear select control cable from
pivot (8) of gear shift control lever assembly.
5) Disconnect gear shift and select control cables (1)
from gear shift control lever assembly while pulling 1
IJHB0A522008-01
quick joints (4) in arrow direction as shown in figure.
8) Disconnect gear shift and gear select control cables
6) Remove nuts (3) and remove gear shift control lever
from transaxle while puling up quick joint (1) in arrow
assembly from floor panel.
direction.
9) Remove cable grommet bolts (2), and then remove
5
gear shift and select control cables from floor panel.

6
1

4 1
2
3

2 IJCA0A521013-01

8 Installation
1 Reverse removal procedure noting the following points.
7
3 3
IJCA0A521012-01 • Tighten each bolt and nut to specified torque. (Page
5B-51)
• Adjust gear select control cable. (Page 5B-52)

Gear Select Control Cable Adjustment

AENJCA0A5226006
Refer to “Gear Select Control Cable Adjustment”: K10B
Model (Page 5B-12).
 Manual Transmission/Transaxle: K12M Model 5B-53

Back Up Light Switch Removal and Installation

AENJCA0A5226007 1 2, (a)
Removal
1) Disconnect back up light switch connector (1).
2) Remove back up light switch (2).

I3RH0A520006-01

2) Connect back up light switch connector.

Back Up Light Switch Inspection

AENJCA0A5226008
Check back up light switch function using ohmmeter.
Replace back up light switch if defective.
1
Back up light switch specification
Switch ON (Push): Continuity exists
Switch OFF (Release): No continuity

IJCA0A522005-01

Installation
1) Apply transaxle oil to new O-ring (1) and tighten
back up light switch (2) to specified torque.
Tightening torque
Back up light switch (a): 19 N·m (1.9 kgf-m, 14.0
lbf-ft)
I4RS0A520011-01

Manual Transaxle Unit Components

AENJCA0A5226009

1
(a)

(a)

(b)

(a)
IJCA0A522006-01

1. Engine : 55 Nm (5.6 kgf-m, 40.5 lbf-ft)

2. Transaxle : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
5B-54 Manual Transmission/Transaxle: K12M Model

Manual Transaxle Unit Dismounting and Remounting

AENJCA0A5226010
Dismounting
1) Remove battery and battery tray. (Page 1J-24)
2) Disconnect gear shift and gear select control cables from transaxle. (Page 5B-52)
3) Remove left side splash cover. (Page 9H-13)
4) Remove clutch cable. (Page 5C-5)
5) Disconnect back up light switch connector (1) and release wiring harness clamps (2).
6) Disconnect ground cable (3) and release ground cable clamp (4).
7) Disconnect engine harness protector (5) and release engine harness clamp (6).

1 2

5
3
4
IJCA0A522007-01
 Manual Transmission/Transaxle: K12M Model 5B-55

8) Drain transaxle oil. (Page 5B-49) • Positioning ground cable to specified angle as shown,
9) Remove exhaust pipe. (Page 1K-10) tighten engine harness ground bolt (1) to specified
torque.
10) Remove drive shaft assembly. (Page 3A-3)
11) Remove starting motor. (Page 1I-5) Position range for ground cable
“a”: 45°
12) Loosen bolts and nut fastening engine.
13) Remove engine rear torque rod bracket. (Page Tightening torque
1D-99) Engine harness ground bolt (a): 25 N·m (2.5 kgf-
14) Open hood as wide as possible and hold it using m, 18.5 lbf-ft)
rope.
15) Support engine assembly, refer to “Engine Assembly
Removal and Installation”: K12M in Section 1D
(Page 1D-100).
16) Remove engine left mounting. (Page 1D-99)
17) Support transaxle with transmission jack.
18) Remove bolts and nut fastening engine and
transaxle and then detach transaxle from engine. “a”

Remounting
Reverse dismounting procedure noting the following 1, (a)
points.

NOTICE
Failure to take proper precautions when IJCA0A522008-01

remounting the manual transaxle can cause
damage to parts.
• When installing the transaxle, be careful
not to let the drive shaft scratch the oil
seal.
Oil leakage may occur if the oil seal lip is
scratched by the drive shaft.
• Do not use a hammer when installing the
drive shaft joint into the differential gear.
Hitting the drive shaft joint with a hammer
will damage the joint.
• Set each clamp for wiring securely.
• Add transaxle oil. (Page 5B-49)
• Adjust clutch cable. (Page 5C-4)
• Check function of engine, clutch and transaxle.
• Check that there is no oil leakage at each connection.
Gear Shift and Select Shaft Assembly
Components
AENJCA0A5226011
(a)

• Tighten the following bolts and nuts to specified

torque.
(a)
– Transaxle to engine bolt and nut: (Page 5B-53)
– Front drive shaft: (Page 3A-3)
– Starting motor: (Page 1I-5)
– Engine left mounting, engine rear torque rod and
engine rear torque rod bracket: (Page 1D-99)
– Exhaust pipe: (Page 1K-10)

IFRA0A521014-01

1. Gear shift & select shaft : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
assembly
5B-56 Manual Transmission/Transaxle: K12M Model

Gear Shift and Select Shaft Assembly Removal b) Apply specified amount of sealant to left case as
and Installation shown in figure.
AENJCA0A5226012
“A”: Sealant 99000–31260 (SUZUKI Bond
Removal No.1217G)
1) Remove battery and battery tray. (Page 1J-24) Sealant amount for transaxle left case
2) Disconnect gear shift and gear select control cables “a”: 1.5 mm (0.059 in.)
from transaxle. (Page 5B-52)
3) Disconnect back up light switch connector (1) and
release wiring harness clamps (2).

“a”
“A”
“A” “a”

IDLA0A520029-01

c) Install gear shift & select shaft assembly to left

case.
IJCA0A522009-01
2) Tighten gear shift & select shaft assembly bolts (1) to
specified torque.
4) Remove gear shift guide case bolts (1) and gear shift
& select shaft assembly (2). Tightening torque
Gear shift & select shaft assembly bolt (a): 23
N·m (2.3 kgf-m, 17.0 lbf-ft)

1, (a)

2 1

1, (a)
IJCA0A522010-01

Installation IJCA0A522011-01

1) Install gear shift & select shaft assembly to transaxle
left case as follows.
a) Clean mating surfaces of gear shift & select shaft
assembly and left case.
3) Connect back up light switch connector and wiring
harness clamps.
4) Connect gear shift and gear select control cables to
transaxle. (Page 5B-52)
5) Install battery and battery tray. (Page 1J-24)
 Manual Transmission/Transaxle: K12M Model 5B-57

Manual Transaxle Assembly Components

AENJCA0A5226013

(a)

28 (d)
29

OIL
19

3 1217G
21 1217G (b)

(c) 16
2 1217G 20 A

34 23
(a)

25
OIL

19 18
32 33 26
30 27

32

(a)
5

4
18 (c)
(a) 17
13
20 A 14
31
15
(c)
1 6
12 9 24
22 1217G (b)
10

11 A 7
8
(a)
IJCA0A522012-01

1. Transaxle right case 21. Oil level / filler plug

: Apply sealant 99000-31260 to threads.
2. Transaxle left case 22. Oil drain plug
: Apply sealant 99000-31260 to mating surface of left case and : Apply sealant 99000-31260 to threads.
gear shift & select shaft assembly.
3. Gear shift & select shaft assembly 23. Transaxle case plug
: For details, refer to “Gear Shift and Select Shaft Assembly
Removal and Installation”: K12M Model (Page 5B-56).
: Apply sealant 99000-31260 to mating surface of gear shift &
select shaft assembly and left case.
4. Input shaft and countershaft assembly 24. Gasket
: For details, refer to “Manual Transaxle Assembly
Disassembly and Reassembly”: K12M Model (Page 5B-58).
5. Differential assembly 25. Breather plug
: For details, refer to “Differential Components”: K12M Model
(Page 5B-77).
6. Reverse gear shaft 26. Breather hose
7. Washer 27. Breather union
8. Reverse idle gear 28. Back up light switch
9. Reverse gear shift lever 29. Back up light switch bracket
10. Reverse gear shift locating ball assembly 30. Transmission hook
11. Input shaft oil seal 31. Countershaft right bearing
: Apply grease 99000-25011 to oil seal lip.
12. Countershaft oil channel 32. Outer race
13. Bearing stopper plate 33. Differential side shim
14. Input shaft oil channel 34. Cap
15. Magnet : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
16. Oil gutter : 21 Nm (2.1 kgf-m, 15.5 lbf-ft)
17. Countershaft circlip : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
18. Dowel pin : 19 Nm (1.9 kgf-m, 14.0 lbf-ft)
19. O-ring : Apply transaxle oil.

20. Oil seal : Do not reuse.

: Apply grease 99000-25011 to oil seal lip.
5B-58 Manual Transmission/Transaxle: K12M Model

Manual Transaxle Assembly Disassembly and 4) Remove transaxle case plug (1) with flat-bladed
Reassembly screwdriver (2) or the like.
AENJCA0A5226014

Disassembly 1
1) Remove gear shift & select shaft assembly. (Page
5B-56)
2
2) Remove reverse gear shaft bolt (1) with gasket.

IDL70A540047-01

5) While expanding countershaft circlip (1) to unhook it

from bearing groove, remove transaxle left case (2)
from right case using special tool.

NOTE
IDLA0A520034-01
When removing transaxle left case, circlip
3) Remove transaxle case bolts (1). comes out with left case and bearing remains
at countershaft side.

Special tool
(A): 09912M34510

1 3

IDL70A540048-01

2
IFRA0A521019-01
(A)

IJCA0A521024-01

3. Countershaft left bearing

 Manual Transmission/Transaxle: K12M Model 5B-59

6) Remove reverse gear shift lever bolts (1) and NOTE

reverse gear shift lever (2).
• Input shaft right bearing on shaft can be
7) Remove reverse gear shaft (3), washer (4) and installed into transaxle right case by
reverse idler gear (5). tapping shaft with plastic hammer.
• Check that countershaft is engaged with
3
final gear while installing.

5 5
3

2
1

IDLA0A520036-01

8) Remove magnet from right case.

9) Tapping input shaft end with plastic hammer, push it
out as assembly from case a little, and then take out
input shaft assembly (1), countershaft assembly (2),
5th and reverse gear shift shaft (3), high speed gear 2
shift shaft (4) and low speed gear shift shaft (5). IJCA0A521025-01

3) Install special tool to transaxle right case.

Special tool
(A): 09922M28111
4
4) Install reverse gear shift lever (1).
5
5) Tighten new reverse gear shift lever bolts (2) to
3
specified torque while pushing reverse gear shift
1 lever in arrow direction.

NOTICE
The reverse gear shift lever bolts are pre-
coated with adhesive. If these bolts are
reused, they may work loose.
Replace the reverse gear shift lever bolts with
2 new ones whenever they are removed.
IJCA0A521025-01

10) Remove differential assembly from transaxle right Tightening torque

case. Reverse gear shift lever bolt (a): 10 N·m (1.0 kgf-
m, 7.5 lbf-ft)
Reassembly
1) Install differential assembly into transaxle right case.
2) Join input shaft assembly (1), countershaft assembly
(2), 5th and reverse gear shift shaft (3), high speed (A)
1
gear shift shaft (4) and low speed gear shift shaft (5)
all together, and then install them into transaxle right
2, (a)
case so as not to damage oil seal by input shaft
spline.

IGJA0A540069-01
5B-60 Manual Transmission/Transaxle: K12M Model

6) Install reverse idler gear (1), washer (2) and reverse 8) Install magnet (1) to right case and input shaft oil
gear shaft (3). channel (2) to input shaft.

NOTE
2
Position reverse gear shift lever (4) not to
touch outside diameter (5) of idler gear
sleeve.

5
IJCA0A521026-01

9) Clean mating surfaces of both right and left cases,

and apply sealant to transaxle right case (1) as
shown in figure.
3
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
2
Sealant amount for transaxle right case
“a”: 1.5 mm (0.059 in.)

“a”

1 “A” “a”
1 “A”

IGJA0A540070-01

7) Align matchmark (1) of reverse idler gear assembly

with matchmark (2) of transaxle right case.

IFRA0A521021-01
1

IFRA0A521020-01
 Manual Transmission/Transaxle: K12M Model 5B-61

10) While expanding countershaft circlip (1) not to fit it 13) Tighten new reverse gear shaft bolt (1) with new
into bearing groove (2), install transaxle left case gasket to specified torque.
onto right case, and install transaxle case bolts
temporarily. NOTICE
11) Turn transaxle assembly upside down so that The reverse gear shaft bolt is pre-coated with
countershaft bearing fits in left case and circlip fits in adhesive. If the bolt is reused, it may work
bearing groove. loose.
Replace the reverse gear shaft bolt with new
NOTICE one whenever it is removed.
Fitting failure of circlip into bearing groove
causes noise or breakage of countershaft Tightening torque
related parts because of wrong positioning of Reverse gear shaft bolt (a): 23 N·m (2.3 kgf-m,
countershaft. 17.0 lbf-ft)
Fit circlip into bearing groove.

1, (a)
2

IDLA0A520043-01

14) Install new transaxle case plug (1) using special

IDL70A540057-01 tools.
12) Tighten transaxle case bolts (1) to specified torque.
Special tool
Tightening torque (A): 09924M74590
Transaxle case bolt (a): 23 N·m (2.3 kgf-m, 17.0 (B): 09924M74510
lbf-ft)
(B)

(A)

1, (a)

1, (a)
IDL70A540060-02

15) Install gear shift & select shaft assembly. (Page

5B-56)

IFRA0A521022-01
5B-62 Manual Transmission/Transaxle: K12M Model

Transaxle Left Case Disassembly and Reassembly

Reassembly 1) Install new circlip and oil gutter (1), if removed.
AENJCA0A5226015
NOTE
Disassembly
When installing oil gutter, fit its claws into
1) Remove differential side oil seal from transaxle left holes of transaxle left case securely.
case, if necessary. (Page 5B-50)
2) Remove circlip (1) and oil gutter (2), if necessary.

1
IDLA0A520044-01
IDL70A540062-02
3) Remove differential side bearing outer race (1) and 2) Install new differential side oil seal to transaxle left
differential side shim using special tool. case, if removed. (Page 5B-50)
Special tool 3) Select differential side shim as follows.
(A): 09925M16510 a) Keep pushing outer race (4) with force of 35 N
(3.6 kgf, 7.9 lbf) by hand and turn differential
case 10 times or more.
b) Measure distance “a” of differential assembly (1).
(A)
c) Measure depth “b” of left case (2) and “c” of right
case (3).
d) Calculate shim thickness by the following
formula.
1 Shim thickness = Depth “b” + Depth “c” – Distance “a”

IGJA0A520021-01

IFRA0A521023-01
 Manual Transmission/Transaxle: K12M Model 5B-63

4) Select shim closest to calculated shim thickness 5) Install differential side shim(s) (1).
from the following available sizes.
1
Available shim thickness
Calculated shim thickness Applicable shim
0.491 – 0.530 mm
0.66 mm (0.0260 in.)
(0.01933 – 0.02086 in.)
0.531 – 0.570 mm
0.70 mm (0.0276 in.)
(0.02091 – 0.02244 in.)
0.571 – 0.610 mm
0.74 mm (0.0291 in.)
(0.02248 – 0.02401 in.)
0.611 – 0.650 mm
0.78 mm (0.0307 in.)
(0.02406 – 0.02559 in.)
0.651 – 0.690 mm
0.82 mm (0.0323 in.)
(0.02563 – 0.02716 in.)
0.691 – 0.730 mm IGJA0A520027-01
0.86 mm (0.0339 in.)
(0.02721 – 0.02874 in.) 6) Install countershaft right bearing outer race (1) using
0.731 – 0.770 mm special tool and hammer.
0.90 mm (0.0354 in.)
(0.02877 – 0.03031 in.)
Special tool
0.771 – 0.810 mm
0.94 mm (0.0370 in.) (A): 09913M85210
(0.03036 – 0.03188 in.)
0.811 – 0.850 mm
0.98 mm (0.0386 in.)
(0.03193 – 0.03346 in.) (A)
0.851 – 0.890 mm
1.02 mm (0.0402 in.)
(0.03351 – 0.03503 in.)
0.891 – 0.930 mm
1.06 mm (0.0417 in.)
(0.03508 – 0.03661 in.)
0.931 – 0.970 mm
1.10 mm (0.0433 in.)
(0.03666 – 0.03818 in.) 1
0.971 – 1.010 mm
1.14 mm (0.0449 in.)
(0.03823 – 0.03976 in.)
1.011 – 1.050 mm
1.18 mm (0.0465 in.)
(0.03981 – 0.04133 in.)
1.051 – 1.090 mm
1.22 mm (0.0480 in.)
(0.04138 – 0.04291 in.)
1.091 – 1.130 mm
1.26 mm (0.0496 in.) IGJA0A520028-01
(0.04296 – 0.04448 in.)
1.131 – 1.170 mm
1.30 mm (0.0512 in.)
(0.04453 – 0.04606 in.)
1.171 – 1.210 mm
1.34 mm (0.0528 in.)
(0.04611 – 0.04763 in.)
1.211 – 1.250 mm
1.38 mm (0.0543 in.)
(0.04768 – 0.04921 in.)
1.251 – 1.290 mm
1.42 mm (0.0559 in.)
(0.04926 – 0.05078 in.)
5B-64 Manual Transmission/Transaxle: K12M Model

Transaxle Right Case Disassembly and 4) Remove reverse gear shift locating ball assembly
Reassembly (1), if necessary.
AENJCA0A5226016

Disassembly
1) Remove differential side oil seal from transaxle right
1
case, if necessary. (Page 5B-50)
2) Remove input shaft oil seal (1) using special tool, if
necessary.
Special tool
(A): 09913M50121

(A)

IDLA0A520047-01

5) Remove differential side bearing outer race (1) using

special tool, if necessary.
Special tool
(A): 09925M16510
1

(A)
IDLA0A520045-01

3) Remove bearing stopper plate (1), countershaft right

bearing (2) and oil channel (3), using special tools, if
necessary.
Special tool 1

(A): 09930M30104
(B): 09941M64511

(A)

IGJA0A520029-01

(B) Reassembly
1
1) Install countershaft right bearing outer race (1) using
special tool and hammer.
Special tool
(A): 09913M85210

(A)

1
3

IJCA0A521027-01
IGJA0A520030-01
 Manual Transmission/Transaxle: K12M Model 5B-65

2) Install new input shaft oil seal (1) facing its spring 4) Install bearing stopper plate (1) and tighten new
side upward up to bottom of transaxle right case bearing stopper plate bolt (2) to specified torque.
hole, if removed. Use special tools and hammer for
installation and apply grease to oil seal lip. NOTICE
The bearing stopper plate bolt is pre-coated
“A”: Grease 99000–25011 (SUZUKI Super
with adhesive. If the bolt is reused, it may
Grease A)
work loose.
Special tool Replace the bearing stopper plate bolt with
(A): 09926M37610M003 new one whenever it is removed.
(B): 09913M80113
Tightening torque
Bearing stopper plate bolt (a): 10 N·m (1.0 kgf-
(B) m, 7.5 lbf-ft)

(A)

1, “A”
IDLA0A520048-01

3) Install countershaft oil channel (1) and new 1 2, (a)

countershaft right bearing (2), using special tool, if IDLA0A520050-01
removed.
5) Install reverse gear shift locating ball assembly, if
NOTE removed.
Install countershaft oil channel aligning its 6) Install new differential side oil seal to transaxle right
ridge (3) with ridge (4) of transaxle right case. case, if removed. (Page 5B-50)

Special tool
(A): 09913M70123

(A)

1 4

IJCA0A521028-01
5B-66 Manual Transmission/Transaxle: K12M Model

Input Shaft Components

AENJCA0A5226017

8
6

OIL
3
7

OIL
1
OIL

OIL
15 17
8

OIL
12

16

11
14
13
9
OIL

3
OIL

10
OIL

IFRA0A521024-01

1. Input shaft 8. Circlip 15. 5th gear synchronizer lever

2. Input shaft right bearing 9. 4th gear synchronizer ring 16. 5th gear synchronizer sleeve & hub
3. Needle bearing 10. Input shaft 4th gear 17. Input shaft left bearing
4. Input shaft 3rd gear 11. Input shaft 5th gear spacer : Apply transaxle oil.

5. 3rd gear synchronizer ring 12. Input shaft 5th gear : Do not reuse.
6. High speed synchronizer sleeve & hub 13. 5th gear synchronizer ring
7. High speed synchronizer key 14. 5th gear synchronizer washer

Input Shaft Disassembly and Reassembly

AENJCA0A5226018

Disassembly
5
! CAUTION 1
2
Using an inappropriate hydraulic press or 4
bearing puller could cause personal injury.
Use the hydraulic press and bearing puller
which are capable of safely bearing a load of
at least 5 tons (11,000 lbs).
3 3
NOTICE IDL70A540070-01

Supporting the gear on the concave side of 5. Metal stick

the bearing puller can cause damage to the

gear.
Support the gear on the flat side of the
bearing puller.

1) Remove input shaft right bearing (2) and left bearing

(4) from input shaft (1) using bearing puller (3) and
hydraulic press.
 Manual Transmission/Transaxle: K12M Model 5B-67

2) Remove circlip (1) using snap ring pliers (2). c) Remove 5th gear spacer (1) using bearing puller
(2) and hydraulic press.

2
IDL70A540071-01

3) Remove 5th gear synchronizer sleeve & hub

assembly (1), 5th gear synchronizer levers, 5th gear
synchronizer washer, 5th gear synchronizer ring and
5th gear (2) from input shaft (3) using bearing puller
and hydraulic press. IDL70A540074-01

6) Remove 4th gear, 4th gear synchronizer ring and 4th

4
gear needle bearing from input shaft.
1 7) Remove circlip (1) using snap ring pliers (2).
3

2
2

1
IDL70A540072-02

4. Metal stick

4) Remove 5th gear needle bearing from input shaft.

5) Remove 5th gear spacer according to the following
procedure.
a) Engage high speed synchronizer sleeve with 4th IDL70A540075-02

gear. 8) Remove high speed synchronizer sleeve & hub

b) Push down input shaft (1) a little using bearing assembly (1) and 3rd gear (2) from input shaft (4)
puller (2) and hydraulic press. using bearing puller (3) and hydraulic press.

1 2

IDL70A540076-01

9) Remove 3rd gear needle bearing from input shaft.

IJCA0A521029-01
10) Disassemble synchronizer sleeve & hub assembly.
5B-68 Manual Transmission/Transaxle: K12M Model

Reassembly 4) Install right bearing (1) to input shaft (2) using special
1) Clean all components thoroughly, check them for tool and hydraulic press.
any abnormality and replace them with new ones if Special tool
necessary. (A): 09913M80113
2) Check clearance “a” between synchronizer ring (2)
and gear (1) and replace with new one, if necessary.
Also, check gear teeth for damage.
(A)
Clearance “a” between synchronizer ring and
1
gear (3rd, 4th and 5th)
Standard: 0.40 – 1.10 mm (0.016 – 0.043 in.) 2
Service limit: 0.40 mm (0.016 in.)

IJCA0A521030-01

5) Install 3rd gear needle bearing and apply transaxle

oil to it, and then install 3rd gear (1) and 3rd gear
synchronizer ring (2) to input shaft.
2
6) Install high speed synchronizer hub (3) with long
flange downward using special tool and hydraulic
press.
“a”
NOTE
• Inside diameter of high speed
1 synchronizer hub is larger than that of 5th
IDLA0A520052-01
gear synchronizer hub.
3) To ensure lubrication of input shaft (1), blow air into
oil holes (2) as shown in figure and check that they • While press-fitting high speed
are free from any obstruction. synchronizer hub, check that synchronizer
ring key protrusions (4) are aligned with
key slots (5) on hub.
2 • Check free rotation of 3rd gear after press-
fitting hub.
1
Special tool
(A): 09913M84510

2
(A)
IDL70A540078-02

[b] 3
[a]

2
5

1
4

IJCA0A521032-01

[a]: 3rd gear side [b]: Long flange

 Manual Transmission/Transaxle: K12M Model 5B-69

7) Fit high speed synchronizer sleeve (1) to hub (2) and
3 keys (3) as shown in figure.
NOTE
• No specific direction is assigned to high
speed synchronizer sleeve or each key.
• When fitting sleeve to hub, raise the hub
and check that the sleeve comes off with
the self-weight.
11) Install 5th gear needle bearing and apply transaxle
oil to it, and then install 5th gear and synchronizer
ring.
12) Assemble 5th gear synchronizer sleeve (1), 5th gear
synchronizer hub (2), 5th gear synchronizer levers
(3), 5th gear synchronizer washer (4) and 5th speed
synchronizer ring (5) as follows.
1

Synchronizer key installation position 3

5
3
2

2
4

IFRA0A521025-01
1
a) Install 5th gear synchronizer hub (1) to 5th gear
synchronizer sleeve (2) in specified direction as
shown in figure.

[b] 1

1
[a]

2
2
IDL70A540080-03

8) Install new circlip.

9) Install 4th gear needle bearing (2) and apply IJCA0A522014-01
transaxle oil to it, and then install synchronizer ring
[a]: Chamfered side [b]: Long boss
(4) and 4th gear (3).
10) Install 5th gear spacer (1) using special tool and b) Apply transaxle oil to 5th gear synchronizer
hydraulic press. levers.
Special tool c) Fit 5th gear synchronizer levers (1) to 5th gear
(A): 09913M84510 synchronizer hub (2) by aligning protrusion (3) of
5th gear synchronizer levers with groove of 5th
gear synchronizer hub.
(A)

2 1 3

3
4 1
3

IDL70A540082-01

IFRA0A521027-01
5B-70 Manual Transmission/Transaxle: K12M Model

d) Install 5th gear synchronizer washer (2) and 5th 14) Select new circlip (1) that makes thrust clearance “a”
gear synchronizer ring (1) to 5th gear of 5th gear synchronizer hub plate 0.1 mm (0.004 in)
synchronizer hub (3) in specified direction as or less and install it.
shown in figure.
Available circlip thickness
Clearance “b” Circlip thickness
1
2.000 – 2.049 mm
2.00 mm (0.0787 in.)
(0.0787 – 0.0806 in.)
2.050 – 2.099 mm
2
2.05 mm (0.0807 in.)
(0.0807 – 0.0826 in.)
2.100 – 2.149 mm
2.10 mm (0.0827 in.)
(0.0827 – 0.0846 in.)
2.150 – 2.199 mm
3
2.15 mm (0.0846 in.)
(0.0846 – 0.0865 in.)
2.200 – 2.249 mm
2.20 mm (0.0866 in.)
(0.0866 – 0.0885 in.)
2.250 – 2.300 mm
IFRA0A521028-01 2.25 mm (0.0886 in.)
(0.0886 – 0.0905 in.)
13) Install 5th gear synchronizer sleeve & hub assembly
(1) using special tool and hydraulic press.

NOTE 1
Check free rotation of 5th gear after press-
fitting sleeve & hub assembly.
“a” “b”

Special tool
(A): 09913M80113

(A)
1

[a]
IFRA0A521030-01

15) Press-fit left bearing (1) using special tool and

hydraulic press.
Special tool
(A): 09944M66060

IJCA0A522015-01
(A)
[a]: 5th gear side

IDL70A540086-01
 Manual Transmission/Transaxle: K12M Model 5B-71

Countershaft Components
AENJCA0A5226019

OIL
7

6
9
4

OIL
8

OIL
2
15
5

3 14 1
1

OIL
13

1
12

OIL
7
10

11

1
IDL70A540087-02

1. Circlip 7. Needle bearing 13. Countershaft 1st gear

2. Countershaft left bearing 8. Countershaft 2nd gear 14. Countershaft
3. Countershaft 5th gear 9. 2nd gear synchronizer ring 15. Countershaft right bearing inner race
4. Countershaft 4th gear 10. Low speed synchronizer key : Apply transaxle oil.

5. Countershaft 3rd and 4th gear spacer 11. Low speed synchronizer sleeve & hub : Do not reuse.
6. Countershaft 3rd gear 12. 1st gear synchronizer ring

Countershaft Disassembly and Reassembly 1) Remove circlip (1) using snap ring pliers (2).
AENJCA0A5226020

Disassembly

! CAUTION 2

Using an inappropriate hydraulic press or

bearing puller could cause personal injury.
Use the hydraulic press and bearing puller
which are capable of safely bearing a load of 1
at least 5 tons (11,000 lbs).

NOTICE
IDL70A540088-02
Supporting the gear on the concave side of
the bearing puller can cause damage to the
gear.
Support the gear on the flat side of the
bearing puller.
5B-72 Manual Transmission/Transaxle: K12M Model

2) Remove left bearing (1) using bearing puller (2) and 7) Remove 2nd gear synchronizer ring and 2nd gear
hydraulic press. needle bearing.
8) Remove circlip (1) using snap ring pliers (2).

1
3
1
2
2

IDL70A540089-01 IDL70A540093-02

3. Metal stick
9) Apply bearing puller (3) to 1st gear (2) and remove
low speed synchronizer sleeve & hub assembly (1),
3) Remove circlip (1) using snap ring pliers (2). 1st gear synchronizer ring and 1st gear using
hydraulic press.

2
1

1 2

IDL70A540090-02
4) Apply bearing puller (3) to 4th gear (2) and remove
5th gear (1) together with 4th gear using hydraulic
press.
IDL70A540094-01
10) Remove 1st gear needle bearing.
11) Remove circlip (1) using snap ring pliers (2).

IDL70A540095-02

IDL70A540091-01

5) Remove 3rd and 4th gear spacer.

6) Apply bearing puller (3) to 2nd gear (2) and remove
3rd gear (1) together with 2nd gear using hydraulic
press.

1
2

IDL70A540092-01
 Manual Transmission/Transaxle: K12M Model 5B-73

12) Grind portion “a” of right bearing inner race (1) using Reassembly
grinder (2) as shown. 1) Clean all components thoroughly, check them for
any abnormality and replace them with new ones if
NOTICE
necessary.
The shaft (3) will be damaged if the bearing is
2) Check clearance “a” between synchronizer ring (2)
ground too much.
and gear (1) and replace with new one, if necessary.
Limit the grinding to a minimum necessary
Also, check gear teeth for damage.
amount.
Clearance “a” between synchronizer ring and
gear (1st and 2nd)
Standard: 0.40 – 1.10 mm (0.016 – 0.043 in.)
Service limit: 0.40 mm (0.016 in.)

2
3

“a”
1
3
1

IDL70A540096-01

13) Break the thinnest portion of bearing inner race (2)

with a chisel (1) and remove bearing inner race. 2

“a”
1

1
IDLA0A520052-01

3) To ensure lubrication of countershaft (1), blow air

into oil holes (2) as shown in figure and check that
they are free from any obstruction.

2 1
IDL70A540097-01 2

IDL70A540099-02
5B-74 Manual Transmission/Transaxle: K12M Model

4) Install right bearing inner race (1) using special tool 8) Fit low speed synchronizer sleeve (1) to hub (2) and
and hydraulic press. 3 keys (3) as shown in figure.
Special tool NOTE
(A): 09913M80113
• No specific direction is assigned to each
key.
(A)
• When fitting sleeve to hub, raise the hub
1
and check that the sleeve comes off with
the self-weight.

IDL70A540098-01
2
5) Install new circlip.
6) Install 1st gear needle bearing and apply transaxle 1

oil to it, and then install 1st gear (1) and 1st gear
synchronizer ring to countershaft.
7) Install low speed synchronizer hub (2) using special 1
tool and hydraulic press.

NOTE
[a]
• No specific direction is assigned to low
speed synchronizer hub.
• While press-fitting low speed synchronizer
hub, check that synchronizer ring key 2
IJCA0A521037-01
protrusions (3) are aligned with key slots
[a]: 1st gear side
(4) on hub.
• Check free rotation of 1st gear after press- 9) Install new circlip.
fitting hub.
10) Install 2nd gear needle bearing and apply transaxle
Special tool oil to it, and then install 2nd gear synchronizer ring
(A): 09940M51710 and 2nd gear to countershaft.
11) Install 3rd gear (1) using special tool and hydraulic
(A) press.
Special tool
4 (A): 09925M18011
2

3
(A)

1 1

IJCA0A521036-01
[b]

[a]

IDL70A540102-01

[a]: 2nd gear side [b]: Long flange

 Manual Transmission/Transaxle: K12M Model 5B-75

12) Install 3rd and 4th gear spacer (1) and then install 14) Select new circlip (1) that makes thrust clearance “a”
4th gear (2) using special tool and hydraulic press. of 5th gear 0.1 mm (0.004 in) or less and install it.
Special tool Available circlip thickness
(A): 09925M18011 Clearance “b” Circlip thickness
2.150 – 2.199 mm
2.15 mm (0.0846 in.)
(A) (0.0846 – 0.0865 in.)
2.200 – 2.249 mm
2 2.20 mm (0.0866 in.)
(0.0866 – 0.0885 in.)
2.250 – 2.299 mm
2.25 mm (0.0886 in.)
(0.0886 – 0.0905 in.)
1
2.300 – 2.349 mm
[b] 2.30 mm (0.0906 in.)
(0.0906 – 0.0924 in.)
[a] 2.350 – 2.399 mm
2.35 mm (0.0925 in.)
(0.0925 – 0.0944 in.)
2.400 – 2.450 mm
2.40 mm (0.0945 in.)
(0.0945 – 0.0964 in.)
IDL70A540103-01

[a]: 3rd and 4th gear spacer side [b]: Long flange

1
13) Install 5th gear (1) using special tool and hydraulic
press. 2

Special tool “a” “b”

(A): 09925M18011

(A) 3

1
4

[b] IDL70A540105-01

2. Countershaft 4. 4th gear

[a]
3. 5th gear

15) Install left bearing (1) using special tool and

hydraulic press.
IDL70A540104-01
Special tool
[a]: 4th gear side [b]: Long flange
(A): 09913M80113

(A)
[b]

[a]

IDL70A540106-01

[a]: 5th gear side [b]: Gloves

16) Install new circlip.

5B-76 Manual Transmission/Transaxle: K12M Model

Gear Shift Shaft Components

AENJCA0A5226021

(a)

4
IDL70A540157-01

1. Low speed gear shift shaft 3. 5th and reverse gear shift shaft : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
2. High speed gear shift shaft 4. Reverse gear shift lever : Do not reuse.

Gear Shift Shaft and Fork Inspection

AENJCA0A5226022
1) Using feeler gauge, check clearance between fork
(1) and sleeve (2) and replace those parts if it
exceeds specified value.
Clearance “a” between fork and sleeve
Standard: 0.05 – 0.40 mm (0.002 – 0.016 in.)
Service limit: 0.40 mm (0.016 in.)

I2RH01520068-01

2) Insert each gear shift shaft into case and check that
it moves smoothly. If not, correct burns or dents with
oilstone, reamer or the like.
 Manual Transmission/Transaxle: K12M Model 5B-77

Differential Components
AENJCA0A5226023

OIL
4

OIL
5

OIL
3
2
OIL

11 2

OIL
1

10
OIL

6
OIL

3
OIL

4
5
OIL

9 (a)

8
IJCA0A522016-01

1. Differential pinion washer 6. Differential side bearing 11. Differential pinion shaft pin
2. Differential pinion 7. Differential case : 100 Nm (10.2 kgf-m, 74.0 lbf-ft)
3. Differential side gear 8. Final gear : Apply transaxle oil.

4. Spring washer 9. Final gear bolt : Do not reuse.

5. Side gear washer 10. Differential pinion shaft

Differential Disassembly and Reassembly 2) Remove left side bearing (1) using special tool,
AENJCA0A5226024 bearing puller (2) and hydraulic press.
Disassembly Special tool
1) With final gear (1) fixed in soft jawed vise, remove (A): 09913M75821
final gear bolts (2), and then remove differential case
(3).
(A)
1

2 1

IEL70B520034-02

3
IJCA0A522017-01
5B-78 Manual Transmission/Transaxle: K12M Model

3) Remove right side bearing in the same manner as in Reassembly

Step 2). Judging from abnormality noted before disassembly and
4) Remove differential pinion shaft pin using special what is found through visual check of component parts
tool and hammer, and then disassemble component after disassembly, prepare replacing parts and proceed
parts. to reassembly. Check that all parts are clean.
1) Install side gear washers (6), spring washers (5),
Special tool
side gears (4), differential pinion washers (3) and
(A): 09922M85811
differential pinions (2) to differential case (1).
2) Install pinion shaft (7) to differential case.
(A)
1

6
2 5

IJCA0A521046-01

5) Remove pinion shaft (1) from differential case (2). 2

6
4 5
2 IE3J0P540076-01
1

IFKA0Q540129-01

6) Remove differential pinions (3), differential pinion

washers (1), side gears (4), spring washers (2) and
side gear washers (6) from differential case (5).

4
1
3

4
1

2
5
6
IFKA0Q540130-01
 Manual Transmission/Transaxle: K12M Model 5B-79

3) Measure thrust play of differential side gear (1) at 4) Install new differential pinion shaft pin (1) from left
each side as follows. side until depth “a” becomes 4.70 – 5.70 mm (0.185
If measured value is out of specification, select – 0.224 in.) as shown using special tool.
suitable side gear washer (2) from the following
Special tool
available sizes, install it and check again.
(A): 09922M85811
Special tool
(A): 09900M20607
(A)
(B): 09900M20701
a) Hold differential assembly with soft jawed vise
and apply dial gauge to side gear as shown in “a”
figure.
b) Move side gear up and down by hand and read
dial gauge.
Differential side gear thrust play 1

0.03 – 0.31 mm (0.0012 – 0.0122 in.)

(A)
[A] IFKA0Q540131-01

5) Press-fit right side bearing (1) using special tools

and hydraulic press.
Special tool
(B) (A): 09924M74510
3 (B): 09951M16060
2

1 4

(A)
(B)

1
1
3

[B]

(A)
3

IGRA0B522003-01

4 (B)
1

2
3

1
IJCA0A521042-01

[A]: Right side 3. Differential case

[B]: Left side 4. Spring washer

Available side gear washer thickness

Thickness mm (in.) Thickness mm (in.)
0.60 mm (0.0236 in.) 0.85 mm (0.0335 in.)
0.65 mm (0.0256 in.) 0.90 mm (0.0354 in.)
0.70 mm (0.0276 in.) 0.95 mm (0.0374 in.)
0.75 mm (0.0295 in.) 1.00 mm (0.0394 in.)
0.80 mm (0.0315 in.) 1.05 mm (0.0413 in.)
5B-80 Manual Transmission/Transaxle: K12M Model

6) Hold differential case with special tool (C) to prevent 7) With final gear (1) fixed in soft jawed vise, install
right side bearing from damaging, and press-fit left differential case (2), and then tighten new final gear
side bearing (1) using special tool (A), (B) and bolts (3) to specified torque.
hydraulic press.
NOTICE
Special tool
The bolts may loosen during operation of the
(A): 09924M74510
differential if any bolts other than the
(B): 09951M16060
specified ones are installed.
(C): 09913M85230
Use only the specified new bolts.

Tightening torque
Final gear bolt (a): 100 N·m (10.2 kgf-m, 74.0 lbf-
(A) ft)
(B)
1
1
3, (a)

(C)

IGRA0B522004-01

2
IJCA0A522018-01

Specifications
Tightening Torque Specifications
AENJCA0A5227001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Transaxle oil level / filler plug (Page 5B-49) /
21 2.1 15.5
(Page 5B-50)
Transaxle oil drain plug 21 2.1 15.5 (Page 5B-49)
Back up light switch 19 1.9 14.0 (Page 5B-53)
Engine harness ground bolt 25 2.5 18.5 (Page 5B-55)
Gear shift & select shaft assembly bolt 23 2.3 17.0 (Page 5B-56)
Reverse gear shift lever bolt 10 1.0 7.5 (Page 5B-59)
Transaxle case bolt 23 2.3 17.0 (Page 5B-61)
Reverse gear shaft bolt 23 2.3 17.0 (Page 5B-61)
Bearing stopper plate bolt 10 1.0 7.5 (Page 5B-65)
Final gear bolt 100 10.2 74.0 (Page 5B-80)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Gear Shift Control Lever and Cable Components”: K12M Model (Page 5B-51)
“Manual Transaxle Unit Components”: K12M Model (Page 5B-53)
“Gear Shift and Select Shaft Assembly Components”: K12M Model (Page 5B-55)
“Manual Transaxle Assembly Components”: K12M Model (Page 5B-57)
“Gear Shift Shaft Components”: K12M Model (Page 5B-76)
“Differential Components”: K12M Model (Page 5B-77)
“Fasteners Information” in Section 0A (Page 0A-6)
 Manual Transmission/Transaxle: K12M Model 5B-81

Special Tools and Equipment

Recommended Service Material
AENJCA0A5228001
Material SUZUKI recommended product or Specification Note
Grease SUZUKI Super Grease A P/No.: 99000–25011 (Page 5B-50) / (Page
5B-65)
Sealant SUZUKI Bond No.1217G P/No.: 99000–31260 (Page 5B-49) / (Page
5B-49) / (Page 5B-50) /
(Page 5B-56) / (Page
5B-60)

NOTE
Required service material(s) is also described in:
“Gear Shift Control Lever and Cable Components”: K12M Model (Page 5B-51)
“Manual Transaxle Assembly Components”: K12M Model (Page 5B-57)
“Input Shaft Components”: K12M Model (Page 5B-66)
“Countershaft Components”: K12M Model (Page 5B-71)
“Differential Components”: K12M Model (Page 5B-77)

Special Tool
AENJCA0A5228002
09900M20607 09900M20701
Dial gauge Magnetic stand
(Page 5B-79) (Page 5B-79)

09912M34510 09913M50121
Case separator Oil seal remover
(Page 5B-58) (Page 5B-50) /
(Page 5B-64)

09913M70123 09913M75821
Bearing installer Bearing installer attachment
(Page 5B-65) (Page 5B-77)

09913M80113 09913M84510
Bearing installer Bearing installer
(Page 5B-65) / (Page 5B-68) /
(Page 5B-68) / (Page 5B-69)
(Page 5B-70) /
(Page 5B-74) /
(Page 5B-75)
09913M85210 09913M85230
Bearing installer Bearing remover tool
(Page 5B-63) / (Page 5B-80)
(Page 5B-64)
5B-82 Manual Transmission/Transaxle: K12M Model

09922M28111 09922M36310
Reverse gear shift lever Oil level gauge
positioner
(Page 5B-59) (Page 5B-49)

09922M75230 09922M85811
Gear shift cable remover Spring pin remover (4.5 mm)
(Page 5B-52) (Page 5B-78) /
(Page 5B-79)

09924M74510 09924M74590
Bearing and oil seal handle Input shaft oil seal installer
attachment
(Page 5B-50) / (Page 5B-61)
(Page 5B-61) /
(Page 5B-79) /
(Page 5B-80)
09925M16510 09925M18011
Oil seal installer Transmission gear, bush
and bearing installer
(Page 5B-62) / (Page 5B-74) /
(Page 5B-64) (Page 5B-75) /
(Page 5B-75)

09926M37610M003 09930M30104
Bearing remover attachment Sliding shaft
(Page 5B-65) (Page 5B-64)

09940M51710 09941M64511
Bearing installer Bearing and oil seal remover
(30 mm min.)
(Page 5B-74) (Page 5B-64)

09944M66060 09944M88220
Bearing installer Oil seal installer
(Page 5B-70) (Page 5B-50)

09951M16060
Control arm bush remover
(Page 5B-79) /
(Page 5B-80)
 Clutch: 5C-1

Clutch
Transmission / Transaxle

General Description
Clutch (Cable Type) Construction
AENJCA0A5301001
The clutch is a diaphragm spring clutch of a dry single
disc type. The diaphragm spring is a tapering-finger
type, which is a solid ring in the outer diameter part, with
a series of tapered fingers pointing inward.
The disc, carrying three (K10B model and bi-fuel CNG
model) or four (K12M model) torsional coil springs, is
positioned on the transaxle input shaft with an involute
spline fit.
The clutch cover is secured to the flywheel, and carries
diaphragm spring in such a way that the peripheral edge
part of the spring pushes on the pressure plate against
flywheel (with the disc in between), when the clutch
release bearing is held back. This is the engaged
condition of the clutch.
Depressing the clutch pedal causes the release bearing
to advance and pushes on the tips of the tapered fingers
of the diaphragm spring. When this happens, diaphragm
spring pulls the pressure plate away from flywheel,
thereby interrupting the flow of drive from flywheel
through clutch disc to transaxle input shaft.

IDLA0A530001-01

1. Clutch cover 5. Input shaft

2. Clutch disc 6. Release bearing
3. Flywheel 7. Diaphragm spring
4. Release shaft 8. Pressure plate

Diagnostic Information and Procedures

Clutch System Symptom Diagnosis
AENJCA0A5304001

Condition Possible cause Correction / Reference Item

Slipping Maladjusted clutch cable
Worn or oily clutch disc facing
Warped disc, pressure plate or flywheel
surface
Weakened diaphragm spring
Rusted clutch cable
Adjust clutch cable. (Page 5C-4)
Replace clutch disc. (Page 5C-9)
Replace clutch disc, cover or flywheel.
• Clutch disc and cover: (Page 5C-9)
• Flywheel
– K10B model and bi-fuel CNG model:
(Page 1D-33)
– K12M model: (Page 1D-108)
Replace clutch cover. (Page 5C-9)
Replace clutch cable. (Page 5C-5)
5C-2 Clutch:

Condition Possible cause Correction / Reference Item

Dragging clutch Maladjusted clutch cable Adjust clutch cable. (Page 5C-4)
Weakened diaphragm spring or worn Replace clutch cover. (Page 5C-9)
spring tip
Rusted input shaft spline Lubricate input shaft spline.
Damaged or worn spline of transaxle Replace input shaft.
input shaft • K10B model and bi-fuel CNG mode:
(Page 5B-25)
• K12M model: (Page 5B-66)
Excessively wobbly clutch disc Replace clutch disc. (Page 5C-9)
Broken clutch facing or dirty clutch Replace clutch disc. (Page 5C-9)
facing with oil
Clutch vibration Glazed (glass-like) clutch facings Repair or replace clutch disc. (Page 5C-9)
Dirty clutch facing with oil Replace clutch disc. (Page 5C-9)
Release bearing does not slide Lubricate input shaft or replace release
smoothly bearing. (Page 5C-11)
Wobbly clutch disc or poor facing Replace clutch disc. (Page 5C-9)
contact
Weakened torsion springs in clutch discReplace clutch disc. (Page 5C-9)
Clutch disc rivets loose Replace clutch disc. (Page 5C-9)
Distorted pressure plate or flywheel Replace clutch cover or flywheel.
surface • Clutch disc and cover: (Page 5C-9)
• Flywheel
– K10B model and bi-fuel CNG model:
(Page 1D-33)
– K12M model: (Page 1D-108)
Weakened engine mounting or loosened Replace engine mounting or retighten engine
engine mounting bolt(s) and/or nut(s) mounting bolts and/or nuts.
• K10B model and bi-fuel CNG model:
(Page 1D-23)
• K12M model: (Page 1D-99)
Noisy clutch Worn or broken release bearing Replace release bearing. (Page 5C-11)
Input shaft right bearing worn down Replace input shaft right bearing.
• K10B model and bi-fuel CNG mode:
(Page 5B-25)
• K12M model: (Page 5B-66)
Excessive rattle of clutch disc hub Replace clutch disc. (Page 5C-9)
Cracked clutch disc Replace clutch disc. (Page 5C-9)
Rattle of pressure plate and diaphragm Replace clutch cover. (Page 5C-9)
spring
Grabbing clutch Clutch disc facings soaked with oil Replace clutch disc. (Page 5C-9)
Clutch disc facings excessively worn Replace clutch disc. (Page 5C-9)
Rivet heads protrude from clutch disc Replace clutch disc. (Page 5C-9)
facing surface
Weakened torsion springs Replace clutch disc. (Page 5C-9)
 Clutch: 5C-3

Repair Instructions
CPP Switch Removal and Installation CPP Switch Inspection and Adjustment
AENJCA0A5306003 AENJCA0A5306004
Removal
1) Remove steering column. (Page 6B-7) Inspection
Measure resistance between terminals under each
2) Disconnect CPP switch connector with ignition
condition below. If check result is not as specified,
“OFF”.
replace switch.
3) Remove CPP switch (1) from clutch pedal bracket.
CPP switch resistance
When switch shaft is pushed [A]: No continuity
1 When switch shaft is free [B]: Continuity exists

IJCA0A530001-01

Installation
1) Install CPP switch to clutch pedal bracket.
2) Adjust switch position. (Page 5C-3)
3) Connect connector to CPP switch securely.
4) Install steering column. (Page 6B-7)
I5JB0AA10009-01
Adjustment
With clutch pedal (1) pulled toward driver’s seat, adjust
CPP switch (2) position so that clearance “a” between
thread end and clutch pedal arm is within specification.
Then tighten lock nut to specified torque.
Clearance between thread end and clutch pedal arm
“a”: 1.0 – 2.0 mm (0.039 – 0.078 in.)
Tightening torque
CPP switch lock nut (a): 7.5 N·m (0.76 kgf-m, 5.5 lbf-
ft)

(a)
2

“a”

IJCA0A530002-01
5C-4 Clutch:

Clutch Pedal Inspection Clutch Pedal Free Travel

AENJCA0A5306005
Clutch Pedal Stroke 1) Depress clutch pedal (1), stop at the moment when
Measure distance between free position (1) and fully clutch resistance is felt, and measure its distance
depressed position (2) on clutch pedal which is shown (clutch pedal free travel).
by “a” in figure. If clutch pedal stroke is out of Free travel should be within the following
specification, adjust it by turning clutch pedal adjusting specification.
bolt (3). Tighten clutch pedal lock nut (4) after 2) If free travel is out of specification, adjust clutch
adjustment. cable. (Page 5C-4)
Clutch pedal stroke Clutch pedal free travel “a”
“a”: 130 – 140 mm (5.12 – 5.51 in.) : 10 – 15 mm (0.39 – 0.59 in.)
Tightening torque
Clutch pedal lock nut (a): 5.5 N·m (0.56 kgf-m, 4.0
lbf-ft)

I4SN0A531003-01

3) Recheck clutch pedal free travel.

If clutch pedal free travel is out of specification,
check clutch system.

Clutch Cable Adjustment

AENJCA0A5306006
1) Remove joint lock cap (1).
2) Adjust release arm free travel to specification with
cable joint nut (2).
Release arm free travel
“a”: 0 – 2 mm (0 – 0.08 in.)
IJCA0A530003-01

“a”

IDLA0A530004-01

3) Check clutch pedal free travel referring to “Clutch

Pedal Free Travel” under “Clutch Pedal Inspection”
(Page 5C-4).
4) Check clutch for proper function with engine running.
 Clutch: 5C-5

Clutch Cable Components

AENJCA0A5306007

1 A

(a)

(a)

4
5

3 A
IJCA0A530005-02

1. Clutch cable 4. Joint nut 7. Clutch pedal

: Apply grease 99000-25011 to cable fitting.
2. Release arm 5. Joint lock cap 8. Clutch cable bracket
3. Joint pin 6. Clutch cable clamp : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
: Apply grease 99000-25011 to joint pin.

Clutch Cable Removal and Installation

AENJCA0A5306008
Removal
1) Remove joint lock cap (1).
2) Remove joint nut (2) and joint pin (3) from clutch 1 2
cable (4). 4

3) Remove clutch cable from release arm (5).

3
5

IJCA0A530006-02
5C-6 Clutch:

4) Disconnect cable fitting (1) from clutch pedal (2). 7) Remove clutch cable (1) from bracket (2) by turning
casing cap (3) about 90° as shown.

2 3

IJCA0A530007-01

5) Remove clutch cable (1) from clutch cable clamp (2). IJCA0A530010-01

Installation
Reverse removal procedure noting the following points.
1
• Insert clutch cable from vehicle inside and securely fit
grommet to dash panel pulling it from engine
compartment side.
• Apply grease to cable fitting (1) and joint pin (2) before
installing cable.
“A”: Grease 99000–25011 (SUZUKI Super Grease
A)

IJCA0A530008-01

6) Remove cable grommet (1) from dash panel.

I8C50A530014-01

3: Release arm

• Adjust clutch cable. (Page 5C-4)

• Check clutch for proper function with engine running.

IJCA0A530009-01
 Clutch: 5C-7

Clutch Cable Inspection

AENJCA0A5306009
Check clutch cable, and if any of the following conditions
are found, replace clutch cable.
• Excessive cable friction
• Frayed cable
• Bent or kinked cable
• Broken boots
I8C50A530009-02
• Worn end

Clutch Pedal Assembly Components

AENJCA0A5306010

8, “2” (a)
9

(d)
1

(b)

(c)
8, “1” (a)

2 A
3
8, “1” (a)
2 A
6
7 A
6

IJCA0A530011-01

1. Clutch pedal bracket 6. Cushion : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)

2. Pedal bushing 7. Return spring : 5.5 Nm (0.56 kgf-m, 4.0 lbf-ft)
: Apply grease 99000-25011 to bushing. : Apply grease 99000-25011 to inside of spring.
3. Pedal shaft spacer 8. Clutch pedal bracket nut : 7.5 Nm (0.76 kgf-m, 5.5 lbf-ft)
: Tightening order: “1” → “2”
4. Clutch pedal 9. CPP switch
5. Pedal pad : 13 Nm (1.3 kgf-m, 9.5 lbf-ft)
5C-8 Clutch:

Clutch Pedal Assembly Removal and

Installation
AENJCA0A5306011
Removal
1) Remove steering column. (Page 6B-7)
2) Disconnect CPP switch connector.
3) Remove clutch cable from clutch pedal. (Page 5C-
5)
4) Remove clutch pedal assembly (1) by removing nuts
(2).

2 2

IJCA0A530012-01

5) Remove CPP switch, if necessary. (Page 5C-3)

Installation
Reverse removal procedure noting the following points.
• Tighten clutch pedal bracket nuts in numerical order
(“1” – “2”) to specified torque.
Tightening torque
Clutch pedal bracket nut (a): 13 N·m (1.3 kgf-m,
9.5 lbf-ft)

“2”, (a)

“1”, (a) “1”, (a)

IJCA0A530021-01

• Adjust clutch cable. (Page 5C-4)

• Apply grease to cable fitting. (Page 5C-5)
: Grease 99000–25011 (SUZUKI Super Grease A)
• Adjust CPP switch position, if removed. (Page 5C-
3)
• Connect connector to CPP switch securely.
 Clutch: 5C-9

Clutch Cover and Clutch Disc Components

AENJCA0A5306012

10

4 A

A
3

11 (a)

(a)
7 2 A

8
1 A

(a)

IJCA0A530013-02

1. Clutch release shaft seal 6. Return spring 11. Clutch cover bolt
: Apply grease 99000-25011 to seal lip. : For tightening order, refer to “Clutch Cover
and Clutch Disc Removal and Installation”
(Page 5C-9).
2. Clutch release shaft No.2 bushing 7. Clutch cover : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
: Apply grease 99000-25011 to bushing
inside.
3. Clutch release shaft 8. Clutch disc : Do not reuse.
: Apply grease 99000-25011 to the end
of release shaft arm.
4. Clutch release shaft No.1 bushing 9. Release arm
: Apply grease 99000-25011 to bushing : For installation, refer to “Clutch Release
inside. System Removal and Installation” (Page
5C-11).
5. Release bearing 10. Pin

Clutch Cover and Clutch Disc Removal and

Installation
AENJCA0A5306013

Removal
1) Dismount manual transaxle.
• K10B model and bi-fuel CNG model: (Page 5B-
14)
• K12M model: (Page 5B-54)
2) Hold flywheel with special tool and remove clutch
cover bolts (1), clutch cover (2) and clutch disc. I4RS0A530014-01

Special tool
(A): 09924M17811
5C-10 Clutch:

Installation

NOTE
Before assembling, check that flywheel
surface and pressure plate surface have
been cleaned and dried thoroughly. “A”

1) Hold flywheel with special tool (A).

2) Align clutch disc with crankshaft center using special
tool (B) and install clutch cover (1).
3) Install and tighten clutch cover bolts using the
following procedure:
a) Tighten 3 bolts (3) by hand.
b) Tighten other 3 bolts (4) evenly and gradually to
5.0 Nm (0.51 kgf-m, 4.0 lbf-ft).
c) Fully tighten all bolts (3), (4) evenly and gradually
to specified torque in numerical order (“1” – “6”)
starting from bolt nearby strut plate rivet (2).
IJHA0A530007-01
NOTE
5) Join manual transaxle with engine.
For centering of clutch disc spline, tighten
• K10B model and bi-fuel CNG model: (Page 5B-
clutch cover bolts while pushing clutch disc
14)
with special tool.
• K12M model: (Page 5B-54)
Special tool
NOTE
(A): 09924M17811
(B): 09923M36320 When inserting transaxle input shaft to clutch
disc, turn crankshaft little by little to match
Tightening torque the splines.
Clutch cover bolt* (a): 5.0 Nm → 23 Nm (0.51
kgf-m → 2.3 kgf-m, 4.0 lbf-ft → 17.0 lbf-ft)
Clutch cover bolt (b): 23 N·m (2.3 kgf-m, 17.0 lbf-
ft)

4, “4”, (a)

3, “2”, (b)
1

3, “1”, (b)
(B)

4, “5”, (a)
2

(A)

4, “6”, (a)

3, “3”, (b)
I9P60A531019-02

4) Apply a light coating of grease to clutch disc spline.

NOTE
When installing a new clutch disc,
application of grease is not required.

“A”: Grease 99000–25210 (SUZUKI Super

Grease I)
 Clutch: 5C-11

Clutch Cover and Clutch Disc Inspection a) Drive out clutch release shaft No.2 bushing and
AENJCA0A5306014 release shaft seal (1) together using special tool
(A) and hammer, and then remove release shaft
Clutch Disc seal.
At clutch cover side of clutch disc, measure depth “a” of
rivet head depression, i.e. distance between rivet head Special tool
and facing surface. (A): 09922M46010
If depression is found to have reached service limit at
any of rivet holes, replace clutch disc.
Rivet head depth
Standard Limit
K10B model and bi- Min. 0.9 mm 0.2 mm (0.0078 1
fuel CNG model (0.0354 in.) in.)
Min. 1.15 mm 0.35 mm
K12M model
(0.0452 in.) (0.0137 in.)

(A)

IJCA0A530014-01
I4RS0B540166-03
b) Pry out clutch release shaft No.2 bushing (1)
using pliers.
Clutch Cover
Check clutch cover as follows.
1) Check diaphragm spring (1) for abnormal wear or
1
damage.
2) Check pressure plate (2) for wear or heat spots.
3) Replace clutch cover if defective. Do not
disassemble it into diaphragm spring and pressure
plate.

IDLA0A530016-01

5) Remove release shaft with return spring.

6) Remove clutch release shaft No.1 bushing as
follows, if necessary.
a) Install tap (M16 X 1.5) (1) to clutch release shaft
No.1 bushing (2).
I3RM0A530015-01

Clutch Release System Removal and

Installation
AENJCA0A5306015

Removal
1) Remove release arm by removing its bolt.
2) Unhook return spring from clutch release shaft.
1 2
3) Remove release bearing by turning release shaft.
4) Remove clutch release shaft No.2 bushing and
release shaft seal as follows.
IDLA0A530017-01
5C-12 Clutch:

b) Connect special tools to tap (1) and pull out No.1

bushing.
Special tool
(B): 09923M46020
(C): 09930M30104
(A)

1, “A”

(C) (C) (B) 1

IJCA0A530015-01

4) Apply grease to release shaft seal (1) lip, and then

IDLA0A530018-01
install it with special tool facing its lip downward
(inside) until it is flush with case surface.
Installation “A”: Grease 99000–25011 (SUZUKI Super
1) Press-fit a new clutch release shaft No.1 bushing (1) Grease A)
using special tools and hammer, and then apply
grease to bushing inside. Special tool
(A): 09925M98221
“A”: Grease 99000–25011 (SUZUKI Super
Grease A)
1, “A”
Special tool
(A): 09943M88211
(B): 09923M46030

(A)

(B) 1, “A”
(A) IJCA0A530016-01

5) Caulk transaxle right case at [a] using caulking tool

and hammer.
IDLA0A530019-01

2) Install release shaft with return spring.

3) Apply grease to clutch release shaft No.2 bushing
(1) inside and press-fit it using the same special tool
used for removal.
“A”: Grease 99000–25011 (SUZUKI Super
Grease A)
Special tool
(A): 09922M46010

[a]

IJCA0A530017-01
 Clutch: 5C-13

6) Apply grease to release shaft (1), and then set Clutch Release System Inspection
release bearing (2). AENJCA0A5306016

“A”: Grease 99000–25011 (SUZUKI Super Clutch Release Bearing

Grease A) Check clutch release bearing (1) for smooth rotation. If
any abnormality is found, replace it.

NOTICE
2 If the release bearing is washed, the grease
1
contained within the release bearing may be
washed away, causing the bearing to seize
up.
Do not wash the release bearing.

“A”

IJCA0A530018-01

7) Hook return spring to clutch release arm.

8) Set release arm (1) to release shaft (2) aligning I7V20A531009-01
punch mark (3) of release arm with groove (4) of
release shaft. Then tighten release arm bolt to Clutch Release Shaft
specified torque. Check clutch release shaft and its pin for deflection or
Tightening torque damage.
Release arm bolt (a): 13 N·m (1.3 kgf-m, 9.5 lbf- If any abnormality is found, replace it.
ft)

(a)
2

1
3
4

IDLA0A530021-01 IJCA0A530020-01
5C-14 Clutch:

Specifications
Tightening Torque Specifications
AENJCA0A5307001
NOTE
For fastener(s) with * (asterisk) below, refer to the specified procedure in “Repair Instructions”.

Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
CPP switch lock nut 7.5 0.76 5.5 (Page 5C-3)
Clutch pedal lock nut 5.5 0.56 4.0 (Page 5C-4)
Clutch pedal bracket nut 13 1.3 9.5 (Page 5C-8)
Clutch cover bolt* 5.0 Nm → 23 Nm (0.51 kgf-m → 2.3 kgf- (Page 5C-10)
m, 4.0 lbf-ft → 17.0 lbf-ft)
Clutch cover bolt 23 2.3 17.0 (Page 5C-10)
Release arm bolt 13 1.3 9.5 (Page 5C-13)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Clutch Cable Components” (Page 5C-5)
“Clutch Pedal Assembly Components” (Page 5C-7)
“Clutch Cover and Clutch Disc Components” (Page 5C-9)
“Fasteners Information” in Section 0A (Page 0A-6)

Special Tools and Equipment

Recommended Service Material
AENJCA0A5308001
Material SUZUKI recommended product or Specification Note
Grease SUZUKI Super Grease A P/No.: 99000–25011 (Page 5C-6) / (Page 5C-
8) / (Page 5C-12) /
(Page 5C-12) / (Page
5C-12) / (Page 5C-13)
SUZUKI Super Grease I P/No.: 99000–25210 (Page 5C-10)

NOTE
Required service material(s) is also described in:
“Clutch Cable Components” (Page 5C-5)
“Clutch Pedal Assembly Components” (Page 5C-7)
“Clutch Cover and Clutch Disc Components” (Page 5C-9)

Special Tool
AENJCA0A5308002
09922M46010 09923M36320
Clutch bushing remover Clutch center guide (15 mm)
(Page 5C-11) / (Page 5C-10)
(Page 5C-12)

09923M46020 09923M46030
Joint pipe Joint pipe
(Page 5C-12) (Page 5C-12)
 Clutch: 5C-15

09924M17811 09925M98221
Flywheel holder Bearing installer
(Page 5C-9) / (Page 5C-12)
(Page 5C-10)

09930M30104 09943M88211
Sliding shaft Pinion bearing installer
(Page 5C-12) (Page 5C-12)
5D-1 Automated Manual Transaxle:

Automated Manual Transaxle

Transmission / Transaxle

Precautions
Precautions for Diagnosing Trouble
AENJCA0A5400001
• Before using scan tool, read its Operator’s Manual to know how to use it.
• When replacing TCM with used one, all learned gear change conditions which are stored in TCM memory should be
cleared after the replacement referring to “TCM and Clutch Initialization” (Page 5D-96).
• After replacing or reinstalling any one of the following parts, perform “TCM and Clutch Initialization” (Page 5D-96).
– Auto gear shift actuator unit
– Gear shift and select shaft assembly
– Clutch or related parts
– Manual transaxle or manual transaxle parts (separated from engine)
– Engine parts (after separation of manual transaxle from engine)
• Read “Precautions for Electrical Circuit Service” in Section 00 (Page 00-3) before inspection and observe what is
written there.
• Communication of TCM and other control module is established by CAN.
For more detail of CAN communication for TCM, refer to “CAN Communication System Diagnosis General
Description” in Section 10H (Page 10H-3).
Therefore, handle CAN communication line with care referring to “Precautions for Electrical Circuit Service” in
Section 00 (Page 00-3).
• Auto gear shift actuator fluid is not available as supply part. If shortage of the fluid is found, it is assumed internal
problem. In this case, replacement of auto gear shift actuator unit with new one which is filled with the fluid will be
required.

General Description
Auto Gear Shift Description
AENJCA0A5401001
• Auto gear shift is a transaxle developed in conjunction with an auto gear shift actuator unit (1), a gear shift and
select shaft assembly (2) and a conventional manual transaxle (3) and the clutch pedal is eliminated. Manual
transaxle has high mechanical efficiency of power transmission compared with A/T or CVT and, electronically
controlled clutch operation and gear shift are optimized for fuel economy almost equivalent to manual transaxle
model.
• Since the auto gear shift actuator directly operates the clutch release shaft and the gear shift and select shaft
assembly, the driver can drive vehicle without clutch operation and changing gears. This automated transaxle has
realized smooth shift feeling reducing the deceleration feeling compared with the conventional manual transaxle. In
addition, this system has a creep function for easy drive to put the vehicle into a garage or in a traffic jam.
• The TCM performs engagement / disengagement of the clutch and gear changes using the auto gear shift actuator
by electronic control based on the signals from ECM, BCM and other sensors. Cooperative control between engine
and auto gear shift through CAN communication has realized both excellent shift characteristic and low fuel
consumption to fit it to the vehicle conditions.
 Automated Manual Transaxle: 5D-2

IJCA0A540001-01

Auto Gear Shift Actuator Unit Construction

NOTE
The component parts of the auto gear shift actuator unit shown below are for explanation.
However, disassembling this unit is not permitted.

The auto gear shift actuator consists of the following devices.

• Actuator harness (1)
• Clutch actuator anchor (2)
• Clutch actuator boot (3)
• Electric motor (4)
• Reservoir tank (5)
• TCM (6)
• Clutch actuator (7)
• Clutch position sensor (8)
• Valve body (9)
• Oil pump (10)
• Accumulator (11)
The valve body in the auto gear shift actuator is equipped with the following components.
• Select actuator (12)
• Select piston (13)
• Select position sensor (14)
5D-3 Automated Manual Transaxle:

• Shift actuator (15)

• Shift piston (16)
• Shift position sensor (17)
• Pressure sensor (18)
• Shift solenoid valve 1 (19)
• Shift solenoid valve 2 (20)
• Clutch solenoid valve (21)
• Select solenoid valve (22)
The auto gear shift actuator is operated by the pressure of auto gear shift actuator fluid (hydraulic pressure) generated
by the electric oil pump and accumulated in the accumulator.
The hydraulic pressure is monitored by the pressure sensor and, when the pressure becomes lower than the specified
value, the electric oil pump is operated.
And, the pressure goes up to the specified value, the electric oil pump is stopped. While the ignition is off, the hydraulic
pressure is released and the auto gear shift actuator fluid is returned to the reservoir tank.
TCM supplies the hydraulic pressure to each actuator by controlling shift solenoid No. 1, shift solenoid No. 2, clutch
solenoid and select solenoid.

12
14
22

21
20
5
6 [a]
19

13

17

18
15
15 16

[a]
9

8
10

11 7 3 2

IK1K0A540002-01
 Automated Manual Transaxle: 5D-4

Auto gear shift actuator hydraulic circuit

IJCA0A540003-01

Clutch actuator
The clutch actuator consists of a clutch piston and clutch position sensor, and the clutch piston is operated by
hydraulic pressure from the clutch solenoid. The operation of the clutch piston turns the clutch release shaft via the
clutch release arm and then the clutch release bearing is actuated in push pull directions for disengage / engage of the
clutch.

Shift actuator
The shift actuator consists of a shift piston and shift position sensor, and the shift piston is operated by hydraulic
pressure from shift solenoid No. 1 and No. 2. This actuator turns the gear shift shaft in the gear shift and select shaft
assembly to shift the gear to 1 ↔ 2 speed, 3 ↔ 4 speed or 5 ↔ R speed.

Select actuator
The select actuator consists of a select piston and select position sensor, and the select piston is operated by
hydraulic pressure from the select solenoid. This actuator moves the gearshift shaft in the gear shift and select shaft
assembly up and down to select one of the shift positions in 1 ↔ 2 speed, 3 ↔ 4 speed and 5 ↔ R speed.

Auto Gear Shift Transaxle Construction

The auto gear shift 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.
5D-5 Automated Manual Transaxle:

18

19

17

16
15
14
12 11
13

2 1 6
4 3
5
10

9
7
IJCA0A540004-01

1. 5th speed synchronizer sleeve and hub 8. Clutch cover 15. Countershaft 2nd gear
2. Input shaft 5th gear 9. Clutch disc 16. Low speed synchronizer sleeve and hub
3. Input shaft 4th gear 10. Input shaft 17. Countershaft 1st gear
4. High speed synchronizer sleeve and hub 11. Countershaft 5th gear 18. Final gear
5. Input shaft 3rd gear 12. Countershaft 4th gear 19. Differential case
6. Left case 13. Countershaft
7. Right case 14. Countershaft 3rd gear

Gear Shift and Clutch Operating Mechanism

When the shift selector is operated, the TCM incorporated in auto gear shift actuator unit controls the auto gear shift
actuator unit based on the information inputted in it. The clutch solenoid valve causes the clutch to engage / disengage
by moving the release shaft, and shift solenoid valve 1, shift solenoid valve 2 and select solenoid valve cause the
gears to change by moving the shift fork.
System of the auto gear shift actuator unit to control clutch engagement / disengagement and gear change of the
transaxle consists of the shift selector, clutch solenoid valve, shift solenoid valve 1, shift solenoid valve 2, select
solenoid valve, VSS, clutch speed sensor, clutch position sensor, shift position sensor, select position sensor, brake
light switch, driver’s door switch and TCM and the auto gear shift actuator unit has the following functions. (Page
5D-17)
• Auto gear shift can be driven in D (drive) mode and M (manual) mode.
• Operation of shift selector from D to R or R to D is not effective when driver’s door is open and the gear stays in
neutral at this moment.
• If shift up operation by shift selector fails to engage gear to target position, shifting to higher gear is attempted. And,
if shift down operation by shift selector fails to engage gear, the gear remains in a position before the shift down.
 Automated Manual Transaxle: 5D-6

• The engine can be started only when the brake is applied and the shift selector is in N to prevent sudden movement
of vehicle.
• Gear change is controlled by TCM according to the accelerator operation similarly to automatic transmission and
creeping is also available with accelerator and brake pedal released.
• Similarly to conventional manual transaxle, it is possible to park the vehicle while the gear is engaged in reverse or
1st position with ignition “OFF”.
• The gear is shifted from reverse, D or M to neutral automatically to prevent risk of danger when any one of the
following conditions is met with engine running.
– Driver’s door is open without depressing brake pedal and accelerator pedal.
– Driver does no operation for 10 minutes.
– 5 seconds have passed after releasing brake pedal.
– Specific malfunction is detected.

Gear Shift Mechanism

When shift selector is operated, TCM controls shift solenoid No. 1, shift solenoid No. 2 and select solenoid based on
each input signal. And, hydraulic pressure accumulated in accumulator (1) operates shift piston (2) in the shift actuator
and select piston (3) in the select actuator. The shift piston turns the gearshift shaft in “a” directions (1 ↔ 2 speed, 3 ↔
4 speed or 5 ↔ R speed) to shift the gear, and the select piston changes the select position in “b” direction (1 ↔ 2
speed, 3 ↔ 4 speed or 5 ↔ R speed).
5D-7 Automated Manual Transaxle:

[A]
4

2 “b” 1

“a”

7
9

“b”
6

“a” 10

IJCA0A540005-02

[A]: Auto gear shift actuator unit viewed from bottom 6. Low speed gear shift shaft 9. Reverse gear shift lever
4. Oil pump 7. High speed gear shift shaft 10. Gear shift interlock bolt
5. Gear shift and select shaft assembly 8. 5th & reverse gear shift shaft
 Automated Manual Transaxle: 5D-8

Clutch Operating Mechanism

When the vehicle is stopped with the engine off, the clutch is engaged like a conventional manual transaxle.
And, when the engine is started, TCM starts up the clutch solenoid based on each input signal. And the hydraulic
pressure in the accumulator actuates clutch piston (1) in clutch actuator (2) to pull the clutch release arm (3). The
pulling extent of clutch release arm has been learned by TCM sensing the contact point between clutch release arm
and stopper for the arm on transaxle rib. According to this movement of clutch release arm, clutch release bearing (4)
is pushed out to press down clutch diaphragm spring and then the diaphragm spring separates pressure plate from the
flywheel and driving force from the engine is cut off.
In addition, creep function and half clutch function are controlled changing conducting ratio to the clutch solenoid.
While the vehicle is stopped with the parking lever pulled or brake pedal depressed, this creep function is disabled for
protection of the clutch disk. However, when the parking lever and brake pedal are released, the clutch is engaged
gradually and driving force is generated.

2 1

4 3

IJCA0A540006-01
5D-9 Automated Manual Transaxle:

Warning Buzzer Operation

The combination meter sounds the warning buzzer in two patterns as follows.
Buzzer operation
Condition
On (sec.) Off (sec.) Time
When gear is disengaged and shifted to neutral automatically for
safety reasons.
When shifting to reverse gear is inhibited due to vehicle condition.
0.08 0.08 2
When cranking without depressing brake pedal.
While the vehicle is still moving, shift selector is shifted to D, M or R
without depressing brake pedal. (garage shift)
When clutch is overheating.
0.18 0.32 1
When shift selector position and actual gear position disagree.

Depress Brake Pedal Indicator Operation

When any of the following operations is executed, depress brake pedal indicator (1) comes ON to warn the driver.
• While the vehicle is still moving, shift selector is shifted to D, M or R without depressing brake pedal. (garage shift)
• When cranking without depressing brake pedal.

[A] [B]

1
1

IJCA0A540007-01

[A]: Without tachometer [B]: With tachometer

Function of Auto Gear Shift Control System Component

AENJCA0A5401002
Part name Function
Clutch speed sensor Detects clutch speed.
Clutch position sensor Detects clutch position.
Shift position sensor Detects position of engage piston.
Select position sensor Detects position of select piston.
Pressure sensor Detects oil pressure in auto gear shift actuator unit.
Clutch solenoid valve Opens / closes oil circuit for moving clutch actuator.
Shift solenoid valve 1
Opens / closes oil circuit for moving engage piston.
Shift solenoid valve 2
Select solenoid valve Opens / closes oil circuit for moving select piston.
Clutch actuator Operated by clutch solenoid valve for clutch engagement / disengagement.
Moves gear shift and select shaft assembly according to shift solenoid
Engage piston
valves 1 and 2.
Moves gear shift and select shaft assembly according to select solenoid
Select piston
valve.
Electric motor Operates oil pump by demand from TCM.
Oil pump Generates oil pressure in auto gear shift actuator unit.
Accumulator Accumulates oil pressure generated by oil pump.
• Controls gear shift and clutch operation.
TCM
• Diagnoses auto gear shift control system components.
Transmits movement of engage piston and select piston in auto gear shift
Gear shift and select shaft assembly
actuator unit to gear shift shaft.
 Automated Manual Transaxle: 5D-10

Automatic Gear Shift Table

AENJCA0A5401003
Automatic gear shift schedule is shown in the following table. Road test the vehicle on a flat road in D range.

K10B model
Throttle Vehicle speed
Shift Remark
opening [%] (km/h (mile/h))
1st → 2nd 22 to 42 (14 to 26)
2nd → 3rd 53 to 75 (33 to 47)
80 to 100
3rd → 4th 85 to 115 (53 to 71)
4th → 5th 136 to 156 (85 to 97)
1st → 2nd 11 to 42 (7 to 26)
There is no sudden change in accelerator
2nd → 3rd 27 to 68 (17 to 42)
UP shift 40 to 70 opening.
3rd → 4th 43 to 97 (27 to 60)
Hard brake is not being applied.
4th → 5th 65 to 156 (40 to 97)
1st → 2nd 9 to 29 (5 to 18)
2nd → 3rd 19 to 39 (12 to 24)
10 to 30
3rd → 4th 26 to 49 (16 to 30)
4th → 5th 42 to 63 (26 to 39)
5th → 4th 89 to 135 (55 to 84)
4th → 3rd 51 to 91 (32 to 57)
80 to 100
3rd → 2nd 24 to 46 (15 to 29)
2nd → 1st 2 to 24 (1 to 15)
5th → 4th 37 to 80 (23 to 50)
There is no sudden change in accelerator
4th → 3rd 22 to 50 (13 to 31)
DOWN shift 40 to 70 opening.
3rd → 2nd 12 to 30 (7 to 19)
Hard brake is not being applied.
2nd → 1st 2 to 12 (1 to 7)
5th → 4th 37 to 47 (23 to 29)
4th → 3rd 19 to 30 (12 to 18)
10 to 30
3rd → 2nd 12 to 22 (7 to 13)
2nd → 1st 2 to 12 (1 to 7)

K12M model
Throttle Vehicle speed
Shift Remark
opening [%] (km/h (mile/h))
1st → 2nd 23 to 48 (14 to 30)
2nd → 3rd 57 to 90 (35 to 56)
80 to 100
3rd → 4th 92 to 130 (57 to 81)
4th → 5th 155 to 175 (97 to 109)
1st → 2nd 14 to 41 (9 to 26)
There is no sudden change in accelerator
2nd → 3rd 33 to 70 (21 to 44)
UP shift 40 to 70 opening.
3rd → 4th 45 to 103 (28 to 64)
Hard brake is not being applied.
4th → 5th 57 to 139 (36 to 87)
1st → 2nd 9 to 29 (6 to 18)
2nd → 3rd 21 to 41 (13 to 25)
10 to 30
3rd → 4th 29 to 49 (18 to 30)
4th → 5th 43 to 63 (27 to 39)
5th → 4th 104 to 155 (65 to 96)
4th → 3rd 59 to 108 (37 to 67)
80 to 100
3rd → 2nd 24 to 62 (15 to 38)
2nd → 1st 3 to 24 (2 to 15)
5th → 4th 38 to 93 (24 to 58)
There is no sudden change in accelerator
4th → 3rd 24 to 50 (15 to 31)
DOWN shift 40 to 70 opening.
3rd → 2nd 16 to 26 (10 to 16)
Hard brake is not being applied.
2nd → 1st 3 to 13 (2 to 8)
5th → 4th 38 to 48 (24 to 30)
4th → 3rd 24 to 34 (15 to 21)
10 to 30
3rd → 2nd 16 to 26 (10 to 16)
2nd → 1st 3 to 13 (2 to 8)
5D-11 Automated Manual Transaxle:
NOTE
The gear change is done at the shift point different from the above if any of the following conditions is
met. Bear this in mind when performing inspection.
Auto Gear Shift Control System Description
AENJCA0A5401007
When the driver's door is opened regardless of ignition
ON / OFF, electric oil pump is driven to raise the
hydraulic pressure if it is judged that the pressure
accumulated in the accumulator is lower than the
specified value according to the signal from the pressure
sensor. Through this pressure rising, smooth operation
of the shift / select and clutch actuator is realized right
after the ignition ON.
Cranking Control
The starting motor control relay operates only at the time
the brake pedal is depressed (stop light switch: ON) and
the shift selector is in N range. Therefore, unintended
starting out is prevented. Further, if ignition switch is
turned to start position without depressing the brake
pedal, the brake request indicator in the combination
meter is lit and the warning buzzer sounds to urge the
driver to depress the brake pedal.
Shift Control
TCM controls the shift solenoid No. 1, No. 2 and the
select solenoid for optimal gear shift corresponding to
the engine torque based on information of accelerator
opening, engine speed and torque.
Learning function
Assembled parts in the transaxle such as shift forks,
gears, etc. and gear shift and select shaft assembly
change engagement positions of the respective gears
caused by aging and manufacturing tolerance. In order
to compensate these factors and keep the smooth
shifting, TCM provides the following gear position
learning functions.
• Shift actuator position at engaged condition in each
gear (1 ↔ 2 speed, 3 ↔ 4 speed and 5 ↔ R speed).
• Shift actuator position in neutral.
• Select actuator position at selected condition in each
speed range (1 ↔ 2 speed, 3 ↔ 4 speed and 5 ↔ R
speed).
D (Drive) mode control
When the shift selector is in D range, shift solenoid No.
1, No. 2 and select solenoid are controlled for optimal
gear change. The solenoid valves are controlled based
on the programmed gear shift timing and adjusting it by
judging driving conditions according to the throttle
opening informed from ECM.
M (Manual) mode control
When the shift selector is in “M”, “+” (shift up) or “-” (shift
down) can be used for selecting gear position and the
driver can drive the vehicle in the desired gear position.
The selected gear position is displayed on the
information display in the combination meter.
Since the M (manual) mode is selected by driver’s
intention, the gear position is fixed in “M”. Therefore,
change to the D (drive) mode is not performed
automatically.
NOTE
Even if the TCM receives the shift request, if
the condition such as throttle opening,
engine speed and vehicle speed deviate from
the specified range, the shift may not be
executed in some cases.
Up shift
During M (manual) mode control, TCM executes shift up
when shifting up is operated by shift selector. However, if
the clutch rotational speed after shifting is less than the
specified value, the upshifting is canceled in order to
prevent the engine stall.
Down shift
During the M (manual) mode control, if the shift selector
is operated to shift down, TCM executes shift down.
However, if the clutch rotational speed after shifting is
over the specified value, shift down is canceled for the
engine protection.
Kickdown control (in D (drive) mode)
When the accelerator pedal is depressed more than the
specified value, TCM judges that the vehicle is in
acceleration state and performs a down shift to improve
acceleration performance.
Under speed control (in D (drive) mode and M
(manual) mode)
If the vehicle is running at low speed with a high gear
position like 4th gear or 5th gear, TCM executes a down
shift judging that driving torque is insufficient receiving
information such as the gear position and the engine
speed. This prevents engine stall. However, when down
shifting in M (manual) mode, the gear position is fixed
even if the vehicle speed increases.
Shift hold control when accelerator (throttle) is
quickly closed
When the accelerator is closed during acceleration and
the accelerator is depressed again, up shift is executed
usually because the gear change point for accelerator
0% opening is used as a reference value. However, this
shift hold control prevents unnecessary up shift holding
the gear in the position when the accelerator pedal is
released. In this way, the engine brake can be used
effectively and acceleration after that will be done
smoothly.

Shift hold control using estimated gradient of slope
While the vehicle is running, the gradient of the road
surface is constantly estimated based on the engine
torque information from ECM and the vehicle speed
signal. When it is judged that the estimated slope
exceeds the specified value, unnecessary shift change
is avoided. As a result, the engine brake can be used on
the down-hill slope and suitable gear position is
maintained on the up-hill slope.
Coast down control when brake is applied
When coasting of the vehicle is judged based on the
brake signal and vehicle deceleration (calculated from
the vehicle speed signal), this control changes the
normal gear position to the gear position for the
coasting. Consequently, at hard braking, down shift is
executed at a higher vehicle speed than the normal
down shift vehicle speed and is over during deceleration.
In this way, time lag at the time of re-acceleration
(without this control, down shift takes place after the
accelerator pedal is depressed) is eliminated for smooth
acceleration.
Clutch Control
TCM controls the clutch solenoid based on clutch
engagement characteristic programmed in advance and
judging the vehicle running conditions and the operation
state of the driver using the accelerator opening
information from the ECM and the vehicle speed signal.
Learning function
The clutch disc changes engagement point and torque
transmission characteristic caused by aging and
temperature of the disc. For smooth clutch engagement
at the gear change compensating the characteristic
changes, TCM has the learning function for the following
factors.
• Clutch engagement point: The point where the clutch
disk and the flywheel are fully engaged.
• Clutch torque transmission point: The point where the
clutch disc and the flywheel begin to contact and the
engine torque starts to be transmitted to the
transmission.
• Clutch torque characteristic: Index corresponding to
wear and temperature of the clutch disc.
• Clutch end stroke: The point where the clutch disc and
the flywheel are completely disengaged.
Vehicle start control
For the vehicle start, shift solenoid No. 1, No. 2 and
clutch solenoid are duty controlled on the basis of
accelerator opening. And, to realize smooth start, the
shift speed and the engagement speed of the clutch are
adjusted in response to the vehicle acceleration and
deceleration.
Automated Manual Transaxle: 5D-12
Creep control
For creep function, shift solenoid No. 1, No. 2 and the
clutch solenoid are duty controlled by the TCM when the
accelerator is closed and shift selector is in D, M or R
range. In this condition, the vehicle can run at the set
speed.
Clutch protection control
When estimated temperature of the clutch disc reaches
about 200 °C (392 °F) (K10B model) or about 240 °C
(464 °F) (K12M model), TCM sounds warning buzzer
and blinks transmission warning light to warn the driver.
This prevents the clutch temperature from rising to the
temperature at which the clutch generates odor due to
high temperature. In this condition, if the vehicle is driven
continuously, the clutch generates odor due to high
temperature. Further, if estimated temperature of the
clutch disc reaches about 250 °C (482 °F) (K10B model)
or about 290 °C (554 °F) (K12M model), sounding
warning buzzer and blinking transmission warning light
still continue and creep function is disabled for protection
of clutch disk and clutch slipping for vehicle start is
decreased. When this clutch protection control is
activated, the driver is required to stop the vehicle at a
safe place in order to cool the clutch and carry out
cooling of the clutch disc by stopping the engine, or run
the vehicle on a flat road at 10 km/h (6 mile/h) or more.
TCM Learning
The TCM monitors and learns conditions of the clutch
and manual transaxle for optimum gear change.
However, if clutch, gear shift and select shaft assembly,
auto gear shift actuator unit or manual transaxle is
removed or replaced, the learned values stored in the
TCM deviate from the actual state. Therefore, it is
necessary to clear the learned value in the past using
SUZUKI scan tool when removing or replacing these
parts and make the TCM initialize and learn necessary
values again for optimum control of the clutch and
transaxle. For the initialization, refer to “TCM and Clutch
Initialization” (Page 5D-96).
Auto Gear Shift Diagnosis General Description
AENJCA0A5401004
TCM has an OBD System which detects a malfunction in
this system.
When diagnosing a trouble in auto gear shift transaxle
control including this system, have full understanding of
“OBD System Description” (Page 5D-12) and each item
in “Precautions for Diagnosing Trouble” (Page 5D-1) and
execute diagnosis according to “Auto Gear Shift System
Check” (Page 5D-18) to obtain correct result smoothly.
OBD System Description
AENJCA0A5401005
TCM has the following functions.
• When TCM detects a malfunction in auto gear shift
control system, TCM turns on MIL (1) and/or auto
gear shift warning light (2) and stores malfunction
DTC in TCM memory.
5D-13 Automated Manual Transaxle:

• It is possible to communicate with TCM through DLC CAN Communication System Description
(3) using SUZUKI scan tool (4). (Diagnostic AENJCA0A5401006

information can be checked and cleared using Refer to “Communication System Description” in Section
SUZUKI scan tool.) 10H (Page 10H-1) for CAN communication system
description.
[A]

2 1

[B]

IJCA0A540008-01

[A]: Without tachometer [B]: With tachometer

• For information about warm-up cycle, driving cycle

and freeze frame data, refer to “OBD System
Description”.
– K10B model: (Page 1A-1)
– K12M model: (Page 1A-117)
 Automated Manual Transaxle: 5D-14

Schematic and Routing Diagram

TCM Circuit Diagram
AENJCA0A5402001

19

20 22
1

BLK C15-11

LT BLU C15-22 23
2

3 LT GRN C15-20
24

4 BLU C15-18

5 PPL C15-16 C15-3 BEG 25 26

6 WHT C15-14
27

7 RED C15-13 28 29
C15-1 LT GRN [a]
30
8 GRN C15-9 C15-2 GRN

9 BRN C15-17 31

GRY C15-4
32
C15-23 BRN

33

34 35
36
RED C15-7
10 21
WHT C15-10
C15-25 PPL

37
C15-24 WHT
11 38
C15-26 WHT
12
[B]
39 40
13 43

14 [A] IG2
[a] [A]
41 IG1 42 44
C15-28 BRN

15 ST 45
47
[B]
46
16 48
C15-19 RED
51
C15-21 GRN
17 49

18 52 50

: 53 : 54
IJCA0A540009-01
5D-15 Automated Manual Transaxle:

[A]: Without keyless entry system 18. Select solenoid valve 37. “AMT PUMP” fuse
[B]: With keyless entry system 19. Auto gear shift actuator unit 38. “AMT1” fuse
1. Shift selector 20. TCM 39. “IG1 SIG2” fuse
2. Hall sensor M1 21. CAN driver 40. IG11 relay
3. Hall sensor M2 22. Electric motor 41. “IG1 SIG” fuse
4. Hall sensor M3 23. Clutch position sensor 42. Ignition switch
5. Hall sensor M4 24. Clutch speed sensor 43. “KEY” fuse
6. Hall sensor M5 25. VSS 44. “IGN” fuse
7. Hall sensor H1 26. To main relay 45. “IGN2” fuse
8. Hall sensor H2 27. ECM 46. “KEY2” fuse
9. Hall sensor H3 28. Brake light switch 47. “ST SIG” fuse
10. To other control module connected by CAN 29. “AMT2” fuse 48. “ST” fuse
11. Valve body 30. “STOP” fuse 49. Main fuse box
12. Shift position sensor 31. Brake light 50. Battery
13. Select position sensor 32. Driver side front door switch 51. Starting motor control relay
14. Pressure sensor 33. BCM 52. Starting motor
15. Shift solenoid valve 1 34. Back up light 53. Engine ground
16. Shift solenoid valve 2 35. Back up light relay 54. Body ground
17. Clutch solenoid valve 36. “BACK” fuse
 Automated Manual Transaxle: 5D-16

Electronic Shift Control Input / Output Diagram

AENJCA0A5402002

INPUT OUTPUT

Auto gear shift actuator unit

Pressure sensor TCM Valve body

Shift solenoid valve 1
Activation Control
Shift position sensor

Shift solenoid valve 2

Select position sensor Cranking Control

Select solenoid valve

Clutch position sensor
VSS
Clutch speed sensor
Brake light switch
Gear shift control
- D (drive) mode control
- M (manual) mode control Clutch solenoid valve
- Kickdown control
- Under speed control
- Shift hold control when
accelerator (throttle) is quickly closed Electric motor
- Shift hold control using estimated
gradient of slope
- Coast down control when
brake is applied Starting motor control relay

Brake switch Back up light relay

Shift timing control

Driver side front door switch Shift selector power supply

Reverse control

Ignition “START” signal

Clutch control
- Start control
Shift selector - Creep control
Hall sensor: - Clutch protection control
- M1 signal
- M2 signal
Starting motor control
- M3 signal
- M4 signal
- M5 signal Protective function
- H1 signal
- Oil pump high temp. control
- H2 signal
- H3 signal

CAN communication function

ECM ECM
Fail-safe function

BCM BCM
Self diagnosis

ABS control module ABS control module

Warning function
Combination meter Combination meter

Signal on CAN
communincation line
IJCA0A540010-03
5D-17 Automated Manual Transaxle:

Component Location
Electronic Shift Control System Component Location
AENJCA0A5403001
NOTE
Numbers with asterisk (*) are not available as supply part.

[A] 2 [B]
5
3
1

3 4 4

7 8 9

12* 10*

12* 14* 11*

20*

16*

19*

18* 13
17*

15

IJCA0A540011-02
 Automated Manual Transaxle: 5D-18

[A]: Without tachometer
[B]: With tachometer
1. Driver side front door switch
2. MIL
3. Auto gear shift warning light
4. Depress brake pedal indicator
5. Brake light switch
6. Shift selector
7. Auto gear shift unit 15. Clutch speed sensor
8. Back up light relay 16. Clutch solenoid valve
9. Starting motor control relay 17. Shift solenoid valve 1
10. Auto gear shift actuator unit 18. Pressure sensor
11. TCM 19. Shift solenoid valve 2
12. Valve body 20. Select solenoid valve
13. VSS
14. Electric motor

Diagnostic Information and Procedures

Auto Gear Shift System Check
AENJCA0A5404001

Step Action Yes No

1 Customer complaint analysis Go to Step 2. Perform customer
1) Perform customer complaint analysis. (Page 5D-19) complaint analysis.

Was customer complaint analysis performed?

2 DTC / freeze frame data check, record and clearance Print DTC and freeze Go to Step 4.
1) Check for DTC. (Page 5D-20) frame data or write them
down and clear them
Is there any DTC(s)? referring to “DTC
Clearance” (Page 5D-
21). Then go to Step 3.
3 Visual inspection Repair or replace Go to Step 5.
1) Perform visual inspection. (Page 5D-20) defective part. Then go
to Step 11.
Is there any faulty condition?
4 Visual inspection Repair or replace Go to Step 8.
1) Perform visual inspection. (Page 5D-20) defective part. Then go
to Step 11.
Is there any faulty condition?
5 Trouble symptom confirmation Go to Step 6. Go to Step 7.
1) Check trouble symptom. (Page 5D-20)

Is trouble symptom identified?

6 Rechecking and record of DTC / freeze frame data Go to Step 9. Go to Step 8.
1) Recheck for and freeze frame data. (Page 5D-20)

Is there any DTC(s)?

7 Rechecking and record of DTC / freeze frame data Go to Step 9. Go to Step 10.
1) Recheck for DTC and freeze frame data. (Page 5D-
20)

Is there any DTC(s)?

8 Auto gear shift symptom diagnosis Go to Step 11. Check and repair
1) Check auto gear shift symptom diagnosis. (Page 5D- defective part. Then go
20) to Step 11.

Are check and repair complete?

9 Troubleshooting for DTC Go to Step 11. Check and repair
1) Perform troubleshooting for applicable DTC. (Page defective part. Then go
5D-20) to Step 11.

Are check and repair complete?

10 Check for intermittent problems Repair or replace Go to Step 11.
1) Check for intermittent problems. (Page 5D-20) defective part(s). Then
go to Step 11.
Is there any faulty condition?
5D-19 Automated Manual Transaxle:

Step Action Yes No

11 Final confirmation test Go to Step 6. End.
1) Clear DTC if any.
2) Perform final confirmation test. (Page 5D-20)

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 by the customer.
For this purpose, use of such a questionnaire from shown below will facilitate collecting information for proper analysis
and diagnosis.
Customer questionnaire form (Example)

I4RS0B540216-01

Step 2: DTC / Freeze Frame Data Check, Record and
Clearance
First, check DTC (current DTC). (Page 5D-21)
If DTC is indicated, print DTC and freeze frame data or
write them down and then clear them. (Page 5D-21)
Step 3 and 4: Visual Inspection
As a preliminary step, perform visual check of the items
that support proper function of the engine and auto gear
shift referring to “Visual Inspection” (Page 5D-20).
Step 5: Trouble Symptom Confirmation
Recheck DTC according to “DTC Confirmation
Procedure” described in each DTC troubleshooting.
Step 6 and 7: Rechecking and Record of DTC and
Freeze Frame Data
Refer to “DTC Check” (Page 5D-21) for checking
procedure.
Visual Inspection
Visually check the following parts and systems.
Inspection item
• Auto gear shift transaxle oil – level, leakage
• Engine mountings – play, looseness, damage
• Suspension – play, looseness
• Drive shafts – damage
• Battery – indicator condition, corrosion of terminal
• Connectors of electric wire harness – disconnection, friction
• Fuses – burning
• Parts – installation, damage
• Bolts – looseness
• Other parts that can be checked visually
Also check the following items at engine start, if possible.
• Auto gear shift warning light – Operation
• MIL – Operation
• Charging light – Operation
• Other parts that can be checked visually
MIL Check
AENJCA0A5404003
Refer to “MIL Check”.
• K10B model: (Page 1A-22)
• K12M model: (Page 1A-140)
Automated Manual Transaxle: 5D-20
Step 8: Auto Gear Shift Symptom Diagnosis
Check the parts of the system suspected as a possible
cause referring to “Auto Gear Shift Symptom Diagnosis”
(Page 5D-42).
Step 9: Troubleshooting for DTC
Perform applicable DTC troubleshooting and repair or
replace faulty parts.
Step 10: Intermittent Problem Check
Check parts related to detected DTC (e.g. wire harness,
connector, etc.). (Page 00-13)
Step 11: Final Confirmation Test
Check that the problem symptom has gone and the
vehicle is free from any abnormal conditions. If what has
been repaired is related to DTC, clear DTC once,
perform DTC confirmation procedure and check that no
DTC is indicated.
AENJCA0A5404002
Referring
“Auto Gear Shift Transaxle Oil Change” (Page 5D-99)
• K10B model: “Engine Assembly Removal and
Installation”: K10B and Bi-Fuel CNG in Section 1D
(Page 1D-24)
• K12M model:“Engine Assembly Removal and
Installation”: K12M in Section 1D (Page 1D-100)
“Suspension, Wheel and Tire Symptom Diagnosis” in
Section 2A (Page 2A-1)
“Front Drive Shaft Assembly On-Vehicle Inspection”:
Front in Section 3A (Page 3A-2)
• K10B model: “Battery Removal and Installation”:
K10B and Bi-Fuel CNG in Section 1J (Page 1J-6)
• K12M model: “Battery Removal and Installation”:
K12M in Section 1J (Page 1J-24)
“Electronic Shift Control System Component Location”
(Page 5D-17)
“Auto Gear Shift Warning Light Check” (Page 5D-20)
“MIL Check” (Page 5D-20)
• K10B model: “Generator Symptom Diagnosis”:
K10B and Bi-Fuel CNG in Section 1J (Page 1J-4)
• K12M model: “Generator Symptom Diagnosis”:
K12M in Section 1J (Page 1J-22)
Auto Gear Shift Warning Light Check
AENJCA0A5404004
1) Set ignition “ON”.
2) Check that auto gear shift warning light (1) lights for
about 2 sec. and then goes OFF. If anything faulty is
found, refer to “Auto Gear Shift Warning Light Does
5D-21 Automated Manual Transaxle:

Not Come ON at Ignition “ON” and Engine Stopped” NOTE

(Page 5D-42) or “Auto Gear Shift Warning Light If communication between SUZUKI scan tool
Remains ON after Engine Starts” (Page 5D-43). and TCM is not possible, perform the
following checks:
[A]
• Check communication condition between
PC and VCI (2) using SUZUKI scan tool
function.
• Check DLC power circuit and ground
circuit.
• Check DLC cable. If necessary, check DLC
cable by substituting a known-good DLC
1 cable.
• Check CAN communication system.
(“Control Module Communication Bus Off”
[B]
is detected in any control module.) (Page
10H-15)
• Check TCM power circuit and ground
circuit. (Page 5D-91)

IJCA0A540012-01

[A]: Without tachometer [B]: With tachometer

DTC Check
AENJCA0A5404005 1
NOTE
In case that MIL turns on, the malfunction(s)
is detected in either ECM or TCM and it
stores the trouble information (DTC, freeze
frame data, etc.) in its memory.
According to the varieties of scan tool, check
the trouble information as follows.
• SUZUKI scan tool: 2
It is necessary to check both ECM and
TCM.
• CAN communication OBD-II generic scan
(A)
tool:
IJCA0A111011-01
It is not necessary to check both ECM and
TCM separately because the trouble 5) After completing the check, set ignition “OFF” and
information of both modules can be read disconnect SUZUKI scan tool from DLC.
and displayed at once.
DTC Clearance
1) Set ignition “OFF”. AENJCA0A5404006

2) Connect SUZUKI scan tool to DLC (1). 1) Set ignition “OFF”.

Special tool
(A): SUZUKI scan tool (SUZUKI SDT-II)
3) Set ignition “ON”.
4) Read DTC and freeze frame data according to
instructions displayed on SUZUKI scan tool and print
them or write them down. Refer to Operator's
Manual of SUZUKI scan tool for further details.
2) Connect SUZUKI scan tool to DLC (1).
Special tool
(A): SUZUKI scan tool (SUZUKI SDT-II)
3) Set ignition “ON”.
4) Clear DTC according to instructions displayed on
SUZUKI scan tool. Refer to Operator's Manual of
SUZUKI scan tool for further details.
 Automated Manual Transaxle: 5D-22

NOTE 5) After completing DTC clearance, set ignition “OFF”

If communication between SUZUKI scan tool and disconnect SUZUKI scan tool from DLC.
and TCM is not possible, perform the NOTE
following checks:
Confirmed DTC and freeze frame data stored
• Check communication condition between
in TCM memory are also cleared in the
PC and VCI (2) using SUZUKI scan tool
following cases. Be careful not to clear them
function.
before recording them.
• Check DLC power circuit and ground
• When the same malfunction (DTC) is not
circuit.
detected again for 40 engine warm-up
• Check DLC cable. If necessary, check DLC cycles.
cable by substituting a known-good DLC
• Even though the pending and confirmed
cable.
DTCs are cleared, the permanent DTC will
• Check CAN communication system. not be cleared.
(“Control Module Communication Bus Off”
is detected in any control module.) (Page
10H-15)
• Check TCM power circuit and ground
circuit. (Page 5D-91)

(A)
IJCA0A111011-01

DTC Table
AENJCA0A5404007
NOTE
• DTC with in the following table cannot be read with CAN communication OBD-II generic scan
tool.
• For details of D/C (driving cycle), refer to “OBD System Description” (Page 5D-12).
• Two or more DTCs of P188A, P188B, P188C, P188D, P188E or P188F could be detected
simultaneously.

DTC Auto gear

DTC DTC name DTC detecting condition detection shift warning MIL
logic light
If any one of the following conditions
is met.
P0070 Ambient Air
• Ambient temperature sensor signal
( ) (Page Temperature Sensor 1 D/C Lights up Off
is more than specified value.
5D-44) Circuit
• Ambient temperature sensor signal
is less than specified value.
5D-23 Automated Manual Transaxle:

DTC Auto gear

DTC DTC name DTC detecting condition detection shift warning MIL
logic light
If any one of the following conditions
is met.
• Power supply voltage from battery
P0560
System Voltage to TCM is out of specified range. 1 D/C Lights up Off
(Page 5D-46)
• Power supply voltage from ignition
switch to TCM is out of specified
range.
P0562 Power supply voltage from battery to
System Voltage Low 1 D/C Lights up Off
(Page 5D-46) TCM is lower than specified range.
P0572 There is no signal from brake light
Brake Switch “A”
( ) (Page switch and brake switch for more than 1 D/C Lights up Off
Circuit Low
5D-47) specified time.
Vehicle is driven more than specified
P0573
Brake Switch “A” operating range, but brake light
( ) (Page 1 D/C Lights up Off
Circuit High switch cannot be changed (stays
5D-47)
ON).
P0602 Control Module TCM internal failure (data
1 D/C Off Off
(Page 5D-49) Programming Error programming error)
Internal Control
P0604 Module Random
TCM internal failure (RAM error) 1 D/C Lights up Off
(Page 5D-50) Access Memory
(RAM) Error
Internal Control
P060A Module Monitoring
TCM internal failure (SMP error) 1 D/C Lights up Off
(Page 5D-50) Processor
Performance
P0615
Request to starting motor control
( ) (Page Starter Relay Circuit 1 D/C Lights up Off
relay and feedback signal disagree.
5D-50)
Internal Control
P062F
Module EEPROM TCM internal failure (EEPROM error) 1 D/C Lights up Off
(Page 5D-50)
Error
There is no clutch speed sensor
P0715 Input / Turbine Speed signal for more than specified time or
1 D/C Lights up Off
(Page 5D-52) Sensor “A” Circuit clutch speed sensor signal is
incorrect.
Input / Turbine Speed
P0716
Sensor “A” Circuit Clutch speed rises rapidly. 1 D/C Lights up Off
(Page 5D-52)
Range / Performance
There is no VSS signal for more than
P0720 Output Speed Sensor
specified time or VSS signal is 1 D/C Lights up Lights up
(Page 5D-54) Circuit
incorrect.
Output Speed Sensor
P0721
Circuit Range / VSS signal rises rapidly. 1 D/C Lights up Lights up
(Page 5D-54)
Performance
If any one of the following conditions
is met.
• Clutch position sensor signal is
P0805 Clutch Position more than specified value for
1 D/C Lights up Off
(Page 5D-56) Sensor Circuit specified time.
• Clutch position sensor signal is
less than specified value for
specified time.
P080A Clutch-contact-point learning
Clutch Position Not
( ) (Page (recognition of clutch engaging point) 1 D/C Lights up Off
Learned
5D-58) is not completed.
 Automated Manual Transaxle: 5D-24

DTC Auto gear

DTC DTC name DTC detecting condition detection shift warning MIL
logic light
If any one of the following conditions
is met.
Transmission Fluid
P0840 • Pressure sensor signal is more
Pressure Sensor / 1 D/C Lights up Off
(Page 5D-56) than specified value.
Switch “A” Circuit
• Pressure sensor signal is less than
specified value.
Transmission Fluid
P0841 Pressure Sensor /
Pressure sensor signal rises rapidly. 1 D/C Lights up Off
(Page 5D-56) Switch “A” Circuit
Range / Performance
If any one of the following conditions
is met.
• Select position sensor signal is
P0904 Gate Select Position more than specified value for
1 D/C Lights up Off
(Page 5D-57) Circuit specified time.
• Select position sensor signal is
less than specified value for
specified time.
If any one of the following conditions
is met.
• Shift position sensor signal is more
P0914 Gear Shift Position than specified value for specified
1 D/C Lights up Lights up
(Page 5D-57) Circuit time.
• Shift position sensor signal is less
than specified value for specified
time.
P0944 Hydraulic Pressure Pressure sensor signal is less than
1 D/C Lights up Off
(Page 5D-59) Unit Loss of Pressure specified value.
Power supply voltage from battery to
P0945 Hydraulic Pump Relay
electric motor is lower than specified 1 D/C Lights up Off
(Page 5D-59) Circuit / Open
value.
Internal Control
P1702
Module Memory TCM internal failure (check sum error) 1 D/C Lights up Off
(Page 5D-50)
Check Sum Error
Internal Control
P1704 TCM internal failure (EEPROM
Module Memory 1 D/C Lights up Off
(Page 5D-50) memory error)
EEPROM Error
P1706 Torque Request
ECM detects abnormality of CAN
( ) (Page Communication Error 1 D/C Off Off
communication data from TCM.
5D-61) From TCM
P1707 TCM detects a condition which is not
Torque Reduction
( ) (Page acceptable for engine torque 1 D/C Off Off
Error From ECM
5D-61) reduction in ECM.
TCM power supply voltage from
P1711 TCM Power Input Low
battery is lower than specified value 1 D/C Lights up Off
(Page 5D-46) Voltage
for specified time.
P1844
Grid Position Not Grid learning (recognition of proper
( ) (Page 1 D/C Lights up Off
Learned gear engagement) is not completed.
5D-62)
P184A Oil pump functions for more than
Pump Off Failed 1 D/C Lights up Off
(Page 5D-63) specified time.
Solenoid Driver “A” Malfunction of solenoid driver “A”
P184B
Circuit Range / (driver for clutch solenoid valve and 1 D/C Lights up Off
(Page 5D-64)
Performance shift solenoid valve 1) is detected.
5D-25 Automated Manual Transaxle:

DTC Auto gear

DTC DTC name DTC detecting condition detection shift warning MIL
logic light
If any one of the following conditions
is met.
• Electric current of clutch solenoid is
higher than specified value for
specified time and feedback
Solenoid Driver “A”
P184C voltage is lower than specified
Feedback Signal 1 D/C Lights up Off
(Page 5D-64) value.
Range / Performance
• Electric current of clutch solenoid is
lower than specified value for
specified time and feedback
voltage is higher than specified
value.
Malfunction of solenoid driver “B”
Solenoid Driver “B”
P184D (driver for shift solenoid valve 2,
Circuit Range / 1 D/C Lights up Off
(Page 5D-64) select solenoid valve and back up
Performance
light relay) is detected.
P184E TCM Internal Supply Power supply for sub-microcomputer
1 D/C Lights up Off
(Page 5D-65) Voltage “B” Circuit is out of specified range.
P184F More than specified time has passed
TCM Internal Supply
( ) (Page after power OFF (latch circuit OFF), 1 D/C Lights up Off
Voltage “C” Circuit
5D-65) but TCM stays ON.
P1850 Gear Shift Odd Malfunction of shift solenoid valve 1 is
1 D/C Lights up Off
(Page 5D-66) Actuator Circuit detected.
P1851 Gear Shift Even Malfunction of shift solenoid valve 2 is
1 D/C Lights up Off
(Page 5D-66) Actuator Circuit detected.
If any one of the following conditions
is met.
• Power supply voltage for pressure
sensor, clutch position sensor and
P1852 Sensor Power Supply clutch speed sensor is higher than
1 D/C Lights up Off
(Page 5D-67) “A” specified value.
• Power supply voltage for pressure
sensor, clutch position sensor and
clutch speed sensor is lower than
specified value.
If any one of the following conditions
is met.
• Power supply voltage for shift
position sensor and select position
P1853 Sensor Power Supply sensor is higher than specified
1 D/C Lights up Off
(Page 5D-67) “B” value.
• Power supply voltage for shift
position sensor and select position
sensor is lower than specified
value.
P1854 TCM Internal Supply Power supply voltage for solenoid
1 D/C Lights up Off
(Page 5D-65) Voltage “A” Low drivers is lower than specified value.
More than specified time has passed
after power load relay for solenoid
P1855 TCM Internal Supply
drivers is OFF, power supply voltage 1 D/C Lights up Off
(Page 5D-65) Voltage “A” High
for solenoid drivers is higher than
specified value.
P185A Clutch-end-stroke-position learning
Clutch End Stroke
( ) (Page (recognition of clutch stopper 1 D/C Lights up Off
Position Self-tune
5D-58) position) is not completed.
 Automated Manual Transaxle: 5D-26

DTC Auto gear

DTC DTC name DTC detecting condition detection shift warning MIL
logic light
Clutch-stroke learning (recognition of
P185B
Clutch Stroke Self- distance between clutch closed
( ) (Page 1 D/C Lights up Off
tune position and clutch stopper) is not
5D-58)
possible.
If any one of the following conditions
is met.
• Feedback electric current of
electric motor is out of specified
P185C Hydraulic Pump Relay range.
1 D/C Lights up Off
(Page 5D-67) Circuit • Feedback voltage of electric motor
is out of specified range.
• Oil pressure is higher than
specified value without operation of
oil pump.
P185E TCM Safety Function TCM internal failure (safety function
1 D/C Lights up Off
(Page 5D-68) Failure control error)
P185F TCM Safety Integrity MMP failure is detected by SMP in
1 D/C Lights up Off
(Page 5D-68) Function Failure TCM.
Malfunction of back up light relay and
P1884
Reverse Lamp its circuit (open, shorted to power
( ) (Page 1 D/C Lights up Off
Control Circuit supply or shorted to ground) is
5D-69)
detected.
P1885
Driver side front door switch signal is
( ) (Page Door Switch Circuit 1 D/C Lights up Off
not inputted for specified time.
5D-70)
P1886 TCM internal failure (data integrity
Dual port RAM Check 1 D/C Lights up Off
(Page 5D-71) error)
P1888 Malfunction of clutch solenoid valve is
Clutch Actuator Circuit 1 D/C Lights up Off
(Page 5D-66) detected.
P1889 Gate Select Actuator Malfunction of select solenoid valve is
1 D/C Lights up Off
(Page 5D-66) Circuit detected.
Transmission Range
P188A None of shift selector position sensor
Sensor Circuit Fault 1 D/C Lights up Off
(Page 5D-71) signals is inputted.
Type “A”
Transmission Range
P188B None of M1, M2, M3, M4 and M5
Sensor Circuit Fault 1 D/C Lights up Off
(Page 5D-71) sensor signals is inputted.
Type “B”
Transmission Range
P188C One of M1, M2, H1, H2 or H3 sensor
Sensor Circuit Fault 1 D/C Lights up Off
(Page 5D-74) signals is not inputted or abnormal.
Type “C”
Transmission Range
P188D M3, M4 and M5 shift selector position
Sensor Circuit Fault 1 D/C Lights up Off
(Page 5D-76) sensor signals are not inputted.
Type “D”
Transmission Range
P188E One of M3, M4, M5 or H2 sensor
Sensor Circuit Fault 1 D/C Lights up Off
(Page 5D-76) signals is not inputted or abnormal.
Type “E”
Transmission Range Failure of shift selector position
P188F
Sensor Circuit Fault sensor signals except P188A, P188B, 1 D/C Lights up Off
(Page 5D-71)
Type “F” P188C, P188D and P188E
Request to shift selector power
P1902 Transmission Range
supply voltage and feedback signal 1 D/C Lights up Off
(Page 5D-78) Sensor Supply Circuit
disagree.
P1903 Clutch Not Opening Clutch is not released before gear
1 D/C Lights up Off
(Page 5D-79) Before Gear Shifting shifting.
P1904 Clutch Closing During Clutch is engaged during gear
1 D/C Lights up Off
(Page 5D-79) Engage shifting.
5D-27 Automated Manual Transaxle:

DTC Auto gear

DTC DTC name DTC detecting condition detection shift warning MIL
logic light
If any one of the following conditions
P1905 is met.
Clutch Control Error 1 D/C Lights up Off
(Page 5D-81) • Clutch is engaged suddenly.
• Clutch sticks at disengaged state.
P1906 Gear Box Disengage
Gear is not disengaged. 1 D/C Lights up Off
(Page 5D-82) Failed
P1907
Gear Box Shift Failed Gear is shifted to unintended position. 1 D/C Lights up Lights up
(Page 5D-82)
P1908 Gear Box Engage
Gear cannot be engaged. 1 D/C Lights up Lights up
(Page 5D-82) Failed
P1909 Gear Box Unintended Gear is disengaged without request of
1 D/C Lights up Lights up
(Page 5D-84) Gear Disengage disengagement.
P190A
Gear Box Shift Locked Gear shift is not completed. 1 D/C Lights up Lights up
(Page 5D-82)
P190B Gear Box Unintended Gear is engaged without gear shift
1 D/C Lights up Off
(Page 5D-84) Gear Engage request.
P190C Gear shift is not completed within
Gear shift Endless 1 D/C Lights up Lights up
(Page 5D-85) specified time.
P190D Clutch speed exceeds specified value
Clutch Overspeed 1 D/C Lights up Off
(Page 5D-86) while gear is engaged.
P190E Oil pump temperature exceeds
Pump Overheating 1 D/C Lights up Off
(Page 5D-87) specified value.
P190F
Accumulated oil volume exceeds
( ) (Page Accumulator Failed 1 D/C Lights up Off
specified limit.
5D-87)
If the following conditions are met.
• The number of gear shift exceeds
P1980
specified value during specified
( ) (Page System Misuse 1 D/C Off Off
period of time.
5D-88)
• Oil pump temperature exceeds
specified value.
P1981
CAN Invalid Data of
( ) (Page Engine torque value is incorrect. 1 D/C Off Off
Engine Torque
5D-88)
Internal Control
P1982 TCM internal failure (EEPROM
Module EEPROM 1 D/C Lights up Off
(Page 5D-50) application error)
Error (Application)
Internal Control
P1983 Module Monitoring TCM internal failure (monitoring
1 D/C Lights up Off
(Page 5D-50) Processor Output processor output failure)
Failure
P1984 TCM Safety Input TCM internal failure (safety input
1 D/C Lights up Off
(Page 5D-68) Preprocessing Failure preprocessing control error)
P1985 TCM detects a condition which is not
Torque Up Error From
( ) (Page acceptable for engine torque up in 1 D/C Off Off
ECM
5D-61) ECM.
Vehicle equipment
P1986
information self- TCM does not complete vehicle
( ) (Page 1 D/C Lights up Off
learning not equipment information self-learning.
5D-89)
completed
Vehicle equipment information does
P1987 Vehicle equipment
not match to vehicle equipment
( ) (Page information not 1 D/C Lights up Off
information self-learning results
5D-89) matched
stored into TCM.
 Automated Manual Transaxle: 5D-28

DTC Auto gear

DTC DTC name DTC detecting condition detection shift warning MIL
logic light
If any one of the following conditions
is met.
• Oil leakage exceeds specified
P2712 Hydraulic Power Unit
value while oil pump is not 1 D/C Lights up Off
(Page 5D-90) Leakage
operating.
• Oil leakage exceeds specified
value while oil pump is operating.
If any one of the following conditions
is met.
P2789
Clutch “A” Adaptive • Clutch closed position is more than
( ) (Page 1 D/C Lights up Off
Learning at Limit specified value.
5D-90)
• Clutch closed position is less than
specified value.
Control Module
U0073
Communication Bus 1 D/C Lights up Off
(Page 5D-91)
Off
U0100 Lost Communication
1 D/C Lights up Off
(Page 5D-91) With ECM
Lost Communication
U0121 Refer to “CAN DTC (Lost
With ABS/ESP® 1 D/C Lights up Off
(Page 5D-91) Communication and Communication
Control Module
Bus Off) Table” in Section 10H (Page
U0140 Lost Communication
10H-7).
( ) (Page With Body Control 1 D/C Lights up Off
5D-91) Module
Lost Communication
U0155 (Page With Instrument Panel
1 D/C Lights up Off
5D-91) Cluster (IPC) Control
Module

Fail-Safe Table
AENJCA0A5404008
TCM has fail-safe function that assures minimum driving performance even when the control system fails.
When any of the following DTC(s) is detected, TCM control enters the fail-safe mode as long as the failure condition
associated with the DTC continues.
DTC DTC name Fail-safe operation Fail-safe cancel condition
TCM functions assuming that
P0070 (Page Ambient Air Temperature
ambient temperature is 20 °C (68 Recovers normal condition.
5D-44) Sensor Circuit
°F).
TCM shifts gear to neutral if the
following conditions are met while
engine is running.
P0560 (Page • Vehicle is stopped.
System Voltage Recovers normal condition.
5D-46)
• Accelerator pedal is released.
• Gear is engaged.
• Brake pedal is released.
P0562 (Page Auto gear shift actuator unit cannot
System Voltage Low Recovers normal condition.
5D-46) shift gear to other than neutral.
P0572 (Page Brake Switch “A” Circuit • TCM inhibits creep control.
5D-47) Low • TCM substitutes brake switch Recovers normal condition.
P0573 (Page Brake Switch “A” Circuit (control signal) for brake light
5D-47) High switch (brake light signal).
P0602 (Page Control Module Execute reprogramming of TCM
TCM stops gear shift control.
5D-49) Programming Error correctly.
5D-29 Automated Manual Transaxle:

DTC DTC name Fail-safe operation Fail-safe cancel condition

Internal Control Module
P0604 (Page • TCM stops gear shift control.
Random Access Memory Recovers normal condition.
5D-50) • TCM stops cranking.
(RAM) Error
P060A Internal Control Module • TCM stops engine.
(Page 5D- Monitoring Processor • TCM stops gear shift control. Recovers normal condition.
50) Performance • TCM disengages clutch.
P0615 (Page TCM controls gear position to Recovers normal condition or
Starter Relay Circuit
5D-50) neutral when cranking. ignition is set to “ON”.
P062F • Auto gear shift is controlled in
Internal Control Module
(Page 5D- default mode. Recovers normal condition.
EEPROM Error
50) • TCM shifts gear to neutral.
P0715 (Page Input / Turbine Speed • When only clutch speed sensor is
5D-52) Sensor “A” Circuit malfunctioning.
– TCM substitutes VSS signal or
engine speed sensor signal for
clutch speed by calculation.
• When VSS, engine speed sensor
or APP sensor is malfunctioning.
Input / Turbine Speed Recovers normal condition.
P0716 (Page – TCM stops gear shift control.
Sensor “A” Circuit Range /
5D-52) – TCM controls gear shift to
Performance
neutral when vehicle is
stopping, starting or creeping.
– TCM substitutes engine speed
sensor signal or VSS signal for
clutch speed by calculation.
P0720 (Page Output Speed Sensor • When only VSS is Recovers normal condition or
5D-54) Circuit malfunctioning. ignition is set to “ON”.
– TCM stops gear shift control.
– TCM stops starting / creeping
control when gear is shifted
from D to R or R to D.
– TCM substitutes clutch speed
sensor signal or engine speed
sensor signal for vehicle speed
by calculation.
Output Speed Sensor • When clutch speed sensor,
P0721 (Page
Circuit Range / engine speed sensor or APP Recovers normal condition.
5D-54)
Performance sensor is malfunctioning.
– TCM stops gear shift control.
– TCM controls gear shift to
neutral when vehicle is
stopping, starting or creeping.
– TCM substitutes engine speed
sensor signal or clutch speed
sensor signal for vehicle speed
by calculation.
 Automated Manual Transaxle: 5D-30

DTC DTC name Fail-safe operation Fail-safe cancel condition

• TCM stops gear shift control.
• TCM releases clutch when
vehicle is stopping, starting or
creeping.
• TCM stops creep control.
• TCM stops cranking.
P0805 (Page Clutch Position Sensor • TCM stops engine if the following Recovers normal condition.
5D-56) Circuit conditions are met.
– Vehicle speed is lower than
specified value.
– Engine speed is lower than
specified value.
– Accelerator pedal is depressed
less than specified value.
P080A
Clutch Position Not TCM restricts gear shift control
(Page 5D- Recovers normal condition.
Learned except N, R and 1st gear.
58)
Transmission Fluid • TCM stops creep control.
P0840 (Page
Pressure Sensor / Switch • TCM shifts gear to neutral if the
5D-56)
“A” Circuit following conditions are met.
– Vehicle is stopped.
Transmission Fluid Recovers normal condition.
P0841 (Page Pressure Sensor / Switch – Accelerator pedal is released.
5D-56) “A” Circuit Range / – Gear is engaged.
Performance – Brake pedal is not depressed
for more than specified time.
• TCM stops gear shift control.
• TCM stops cranking.
P0904 (Page Gate Select Position
• TCM stops starting / creeping Recovers normal condition.
5D-57) Circuit
control when selector lever is
shifted from D to R or R to D.
P0914 (Page
Gear Shift Position Circuit TCM restricts gear shift control. Recovers normal condition.
5D-57)
• TCM stops gear shift control.
P0944 (Page Hydraulic Pressure Unit • TCM controls gear shift to neutral Oil pressure is higher than specified
5D-59) Loss of Pressure when vehicle is stopping, starting value.
or creeping.
TCM stops gear shift request to
P0945 (Page Hydraulic Pump Relay
gears other than neutral when oil Recovers normal condition.
5D-59) Circuit / Open
pressure is not enough.
P1702 (Page Internal Control Module • TCM stops gear shift control.
Recovers normal condition.
5D-50) Memory Check Sum Error • TCM stops cranking.
P1704 (Page Internal Control Module • TCM controls gear shift to neutral
Recovers normal condition.
5D-50) Memory EEPROM Error when vehicle is stopping.
Torque Request
P1706 (Page
Communication Error — —
5D-61)
From TCM
P1707 (Page Torque Reduction Error
— —
5D-61) From ECM
P1711 (Page TCM Power Input Low
TCM stops gear shift control. Recovers normal condition.
5D-46) Voltage
• TCM stops vehicle start control.
P1844 (Page
Grid Position Not Learned • TCM stops creep control. Recovers normal condition.
5D-62)
• TCM stops gear shift control.
5D-31 Automated Manual Transaxle:

DTC DTC name Fail-safe operation Fail-safe cancel condition

TCM turns OFF oil pump for a
P184A
specified period of time and turns
(Page 5D- Pump Off Failed Ignition is set to “ON”.
ON when oil pressure becomes
63)
lower than specified value.
• TCM stops gear shift control.
• TCM stops engine if the following
conditions are met.
P184B – Vehicle speed is lower than
Solenoid Driver “A” Circuit
(Page 5D- specified value. Recovers normal condition.
Range / Performance
64) – Engine speed is lower than
specified value.
– Accelerator pedal is depressed
less than specified value.
• TCM stops gear shift control.
• TCM stops engine if the following
conditions are met.
P184C Solenoid Driver “A” – Vehicle speed is lower than
Recovers normal condition or
(Page 5D- Feedback Signal Range / specified value.
ignition is set to “ON”.
64) Performance – Engine speed is lower than
specified value.
– Accelerator pedal is depressed
less than specified value.
P184D
Solenoid Driver “B” Circuit
(Page 5D- TCM stops gear shift control. Recovers normal condition.
Range / Performance
64)
• TCM stops gear shift control.
• TCM stops engine if the following
conditions are met.
P184E – Vehicle speed is lower than
TCM Internal Supply
(Page 5D- specified value. Recovers normal condition.
Voltage “B” Circuit
65) – Engine speed is lower than
specified value.
– Accelerator pedal is depressed
less than specified value.
P184F
TCM Internal Supply
(Page 5D- — —
Voltage “C” Circuit
65)
P1850 (Page Gear Shift Odd Actuator • TCM stops gear shift control.
5D-66) Circuit
Recovers normal condition.
P1851 (Page Gear Shift Even Actuator • TCM stops vehicle start after
5D-66) Circuit stopping vehicle.
 Automated Manual Transaxle: 5D-32

DTC DTC name Fail-safe operation Fail-safe cancel condition

• TCM stops gear shift control.
• TCM stops engine if the following
conditions are met.
– Vehicle speed is lower than
specified value.
– Engine speed is lower than
P1852 (Page specified value.
Sensor Power Supply “A” Recovers normal condition.
5D-67) – Accelerator pedal is depressed
less than specified value.
• TCM stops creep control.
• TCM stops cranking.
• TCM releases clutch when
vehicle is stopping, starting or
creeping.
• TCM stops gear shift control.
P1853 (Page • TCM stops creep control.
Sensor Power Supply “B” Recovers normal condition.
5D-67) • TCM stops vehicle start control.
• TCM stops cranking.
• TCM stops gear shift control.
• TCM stops engine if the following
conditions are met.
– Vehicle speed is lower than
P1854 (Page TCM Internal Supply
specified value. Recovers normal condition.
5D-65) Voltage “A” Low
– Engine speed is lower than
specified value.
– Accelerator pedal is depressed
less than specified value.
P1855 (Page TCM Internal Supply
— —
5D-65) Voltage “A” High
P185A
Clutch End Stroke Position
(Page 5D- — —
Self-tune
58)
P185B
(Page 5D- Clutch Stroke Self-tune TCM stops cranking. Recovers normal condition.
58)
P185C
Hydraulic Pump Relay
(Page 5D- — —
Circuit
67)
P185E • TCM stops engine.
TCM Safety Function
(Page 5D- • TCM stops gear shift control. Ignition is set to “OFF”.
Failure
68) • TCM disengages clutch.
P185F • TCM stops gear shift control.
TCM Safety Integrity
(Page 5D- • TCM disengages clutch. Ignition is set to “OFF”.
Function Failure
68) • TCM stops CAN communication.
P1884 (Page Reverse Lamp Control
— —
5D-69) Circuit
• TCM stops creep control.
P1885 (Page • When vehicle stops for specified Recovers normal condition.
Door Switch Circuit
5D-70) time without depressing brake
pedal, TCM shifts gear to neutral.
5D-33 Automated Manual Transaxle:

DTC DTC name Fail-safe operation Fail-safe cancel condition

• TCM stops gear shift control
except neutral.
P1886 (Page • TCM controls gear position to
Dual port RAM Check neutral after vehicle stopping. Recovers normal condition.
5D-71)
• TCM stops creep control.
• TCM stops cranking.
• TCM stops gear shift control.
• TCM stops engine if the following
conditions are met.
– Vehicle speed is lower than
P1888 (Page
Clutch Actuator Circuit specified value. Recovers normal condition.
5D-66)
– Engine speed is lower than
specified value.
– Accelerator pedal is depressed
less than specified value.
P1889 (Page Gate Select Actuator • TCM stops gear shift control.
Recovers normal condition.
5D-66) Circuit • TCM shifts gear to neutral.
P188A Transmission Range
(Page 5D- Sensor Circuit Fault Type
71) “A”
P188B Transmission Range
(Page 5D- Sensor Circuit Fault Type
71) “B”
P188C Transmission Range • TCM cancels manual gear shift. After recovering normal condition,
(Page 5D- Sensor Circuit Fault Type the following steps are performed.
• TCM controls gear position to
74) “C” neutral at vehicle low speed. 1. Ignition is set to “ON”.
P188D Transmission Range 2. Gear is shifted to R, N, D and M
(Page 5D- Sensor Circuit Fault Type • TCM stops creep control.
holding each gear position for
76) “D” • TCM stops vehicle start control. more than 1 second.
P188E Transmission Range
(Page 5D- Sensor Circuit Fault Type
76) “E”
P188F Transmission Range
(Page 5D- Sensor Circuit Fault Type
71) “F”
P1902 (Page Transmission Range
— —
5D-78) Sensor Supply Circuit
P1903 (Page Clutch Not Opening Before Gear is shifted by selector lever
TCM stops gear shift control.
5D-79) Gear Shifting normally.
• TCM controls gear shift to
P1904 (Page Clutch Closing During neutral.
Ignition is set to “ON”.
5D-79) Engage • TCM stops gear shift until gear is
shifted to neutral.
• TCM stops gear shift control.
• TCM stops engine if the following
conditions are met.
– Vehicle speed is lower than
P1905 (Page
Clutch Control Error specified value. Ignition is set to “ON”.
5D-81)
– Engine speed is lower than
specified value.
– Accelerator pedal is depressed
less than specified value.
P1906 (Page Gear Box Disengage Gear is shifted by selector lever
TCM stops gear shift control.
5D-82) Failed normally.
P1907 (Page
Gear Box Shift Failed — —
5D-82)
 Automated Manual Transaxle: 5D-34

DTC DTC name Fail-safe operation Fail-safe cancel condition

P1908 (Page
Gear Box Engage Failed — —
5D-82)
• TCM stops creep control.
P1909 (Page Gear Box Unintended • TCM shifts gear position to Ignition is set to “ON”.
5D-84) Gear Disengage neutral, and then gear shift to any
position becomes possible.
P190A
(Page 5D- Gear Box Shift Locked — —
82)
P190B • TCM stops gear shift control.
Gear Box Unintended
(Page 5D- • TCM releases clutch until ignition Ignition is set to “ON”.
Gear Engage
84) “OFF”.
P190C
(Page 5D- Gear shift Endless TCM stops gear shift control. Ignition is set to “OFF”.
85)
P190D
Clutch speed is lower than specified
(Page 5D- Clutch Overspeed TCM controls gear shift to neutral.
value.
86)
Oil pump temperature is lower than
P190E • TCM restricts oil pump operation. specified value for more than
(Page 5D- Pump Overheating
• TCM restricts gear shift. specified time, or ignition is set to
87)
“ON”.
P190F
(Page 5D- Accumulator Failed — —
87)
Oil pump temperature is lower than
P1980 (Page • TCM restricts gear shift.
System Misuse specified value, or ignition is set to
5D-88) • TCM restricts oil pump operation. “ON”.
P1981 (Page CAN Invalid Data of
TCM uses temporary value. Recovers normal condition.
5D-88) Engine Torque
Internal Control Module • TCM stops creep control.
P1982 (Page
EEPROM Error • TCM stops vehicle start control. Recovers normal condition.
5D-50)
(Application) • TCM stops gear shift control.
Internal Control Module • TCM stops engine.
P1983 (Page
Monitoring Processor • TCM stops gear shift control. Recovers normal condition.
5D-50)
Output Failure • TCM disengages clutch.
• TCM stops engine.
P1984 (Page TCM Safety Input
• TCM stops gear shift control. Ignition is set to “OFF”.
5D-68) Preprocessing Failure
• TCM disengages clutch.
P1985 (Page Torque Up Error From
— —
5D-61) ECM
Vehicle equipment
P1986 (Page
information self-learning • TCM stops cranking.
5D-89)
not completed Normal condition is recovered.
P1987 (Page Vehicle equipment • TCM uses temporary value.
5D-89) information not matched
• TCM restricts gear shift.
P2712 (Page Hydraulic Power Unit
• TCM shifts gear to neutral when Ignition is set to “ON”.
5D-90) Leakage
hydraulic pressure is at low.
P2789 (Page Clutch “A” Adaptive
— —
5D-90) Learning at Limit
5D-35 Automated Manual Transaxle:

DTC DTC name Fail-safe operation Fail-safe cancel condition

U0073(Page Control Module • TCM stops gear shift request to
5D-91) Communication Bus Off gears other than neutral.
• TCM controls gear shift to neutral
when vehicle stopping.
U0100(Page Lost Communication With
• TCM stops vehicle start control.
5D-91) ECM
• TCM stops creep control. Recovers normal condition.
• TCM stops cranking.
U0121
Lost Communication With
(Page 5D-
ABS/ESP® Control Module
91)
U0140(Page Lost Communication With
TCM uses temporary value.
5D-91) Body Control Module
U0155 Lost Communication With
(Page 5D- Instrument Panel Cluster Normal condition is recovered.
91) (IPC) Control Module

Scan Tool Data

AENJCA0A5404009
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 auto gear shift or actuator is not operating (in the condition) as
indicated by the scan tool.

NOTE
• If communication between SUZUKI scan tool and TCM is not possible, perform the following
checks:
– Check communication condition between PC and VCI using SUZUKI scan tool function.
– Check DLC power circuit and ground circuit.
– Check DLC cable. If necessary, check DLC cable by substituting a known-good DLC cable.
– Check CAN communication system. (“Control Module Communication Bus Off” is detected in any
control module.) (Page 10H-15)
– Check TCM power circuit and ground circuit. (Page 5D-91)
• The following scan tool data related to auto gear shift can be checked only by communicating with
TCM.

Normal condition /
Scan tool data Vehicle condition
Reference value
• Vehicle: Stop
0 rpm
Input Shaft Revolution (Page 5D- • Shift selector: R, D or M range
39) The same value as
Vehicle: Running
engine speed reading
• Vehicle: Stop
0 rpm
Output Shaft Revolution (Page 5D- • Shift selector: R, D or M range
39) • Vehicle: Running at 10 km/h (6 mile/h)
Approx. 100 rpm
• Shift selector: R range
Clutch Position Sensor (Page 5D- Ignition: “ON” 800 to 1500
39) Engine: Idle speed 100 to 500
Shift selector: R range 600 to 800
Select Position Sensor (Page 5D-
Shift selector: N range 600 to 800
39)
Shift selector: D or M range 200 to 400
Shift selector: R range 600 to 800
Shift Position Sensor (Page 5D-39) Shift selector: N range 400 to 600
Shift selector: D or M range 200 to 400
 Automated Manual Transaxle: 5D-36

Normal condition /
Scan tool data Vehicle condition
Reference value
Battery Voltage (Page 5D-39) Engine: Idle speed 13 to 15 V
• Shift selector: N range
4 to 6 MPa
Oil Pressure (Page 5D-39) • Brake pedal: Released
(40 to 60 bar)
• Accelerator pedal: Released
Clutch Solenoid Control Value Ignition: “ON” 0 mA
(Page 5D-39) Engine: Idle speed 264 to 794 mA
Ignition: “ON” 0 mA
Select Solenoid Control Value
Gear is in shift operation with vehicle stationary with
(Page 5D-39) 0 mA or more
ignition “ON”
Ignition: “ON” 0 mA
Shift Solenoid No.1 (Odd Side)
Gear is in shift operation with vehicle stationary with
Control Value (Page 5D-39) 0 mA or more
ignition “ON”
Ignition: “ON” 0 mA
Shift Solenoid No.2 (Even Side)
Gear is in shift operation with vehicle stationary with
Control Value (Page 5D-39) 0 mA or more
ignition “ON”
K10B model: 650 to 750
• Engine: Specified idle speed after warming up rpm
Engine Speed (Page 5D-39)
• Shift selector: N range K12M model: 600 to 750
rpm
• Engine: Stop
0 to 10%
• Accelerator pedal: Released
Throttle Position (Page 5D-39)
• Engine: Stop
90 to 100%
• Accelerator pedal: Fully depressed
• Engine: Stop
0 to 2%
Accel Effective Position (Page 5D- • Accelerator pedal: Released
39) • Engine: Stop
90 to 100%
• Accelerator pedal: Fully depressed
Approx. 80 to 100 °C
ECT (Page 5D-39) Engine: Specified idle speed after warming up
(176 to 212 °F)
Outside air temperature
Outside Air Temp (Page 5D-39) Engine: Cold and ignition “ON”
is displayed.
Barometric pressure is
Barometric Pressure (Page 5D-39) Engine: Cold and ignition “ON”
displayed.
The same value as
Vehicle Speed (Page 5D-39) Vehicle: Running
speedometer reading
• Ignition: “ON”
Closed
• Shift selector: N range
• Ignition: “ON” Slipping Before
• Shift selector: Being shifted from N to D Engaging
Clutch Control Status (Page 5D-39)
• Ignition: “ON”
Slipping After Engaging
• Shift selector: After completion of N to D shift
• Engine: Idle speed
Opened
• Shift selector: N range
5D-37 Automated Manual Transaxle:

Normal condition /
Scan tool data Vehicle condition
Reference value
Shift selector: Mid point of gear shift Shift in Progress
Shift selector: D range 1st
• Vehicle: Running at 18 km/h (11 mile/h)
2nd
• Shift selector: D range
• Vehicle: Running at 29 km/h (18 mile/h)
3rd
• Shift selector: D range
Gear Position (Page 5D-39)
• Vehicle: Running at 41 km/h (25 mile/h)
4th
• Shift selector: D range
• Vehicle: Running at 59 km/h (37 mile/h)
5th
• Shift selector: D range
Shift selector: R range R
Shift selector: N range N
Gear Position Indication
Shift selector: D range
off
• Shift selector: M range
1st
• Manual mode gear position: 1
• Shift selector: M range
2nd
• Manual mode gear position: 2
Manual Gear Position (Page 5D-39) • Shift selector: M range
3rd
• Manual mode gear position: 3
• Shift selector: M range
4th
• Manual mode gear position: 4
• Shift selector: M range
5th
• Manual mode gear position: 5
Estimated Clutch Temperature Estimated clutch temperature: Same as engine Approx. –40 to 350 °C (–
(Page 5D-39) coolant temperature after vehicle stopping 40 to 662 °F)
Ignition: “ON” Normal
K10B model:
Estimated clutch temperature: Higher than 200 °C
(392 °F)
Clutch High Temperature Control Hot Mode 1
K12M model:
Status (Page 5D-40)
Estimated clutch temperature: Higher than 240 °C
(464 °F)
Estimated clutch temperature: Higher than Hot
Hot Mode 2
Mode 1
Automatic Discrimination (ABS/ESP)
— Complete
(Page 5D-40)
ABS Equipped (Page 5D-40) — YES
ESP / ABS+Hill Hold Equipped
— NO
(Page 5D-40)
Automatic Discrimination (AEB)
— Complete
(Page 5D-40)
AEB Equipped (Page 5D-40) — NO
Automatic Discrimination (Push Start)
— Complete
(Page 5D-40)
Push Start System Equipped (Page
— NO
5D-40)
Lever Position Switch: M1 (Page Shift selector: R or N range ON
5D-40) Shift selector: D, M, + or – range OFF
Lever Position Switch: M2 (Page Shift selector: N, D, M, + or – range ON
5D-40) Shift selector: R range OFF
Lever Position Switch: M3 (Page Shift selector: M, + or – range ON
5D-40) Shift selector: R, N or D range OFF
Lever Position Switch: M4 (Page Shift selector: R, N, D, M or + range ON
5D-40) Shift selector: – range OFF
 Automated Manual Transaxle: 5D-38

Normal condition /
Scan tool data Vehicle condition
Reference value
Lever Position Switch: M5 (Page Shift selector: R, N, D, M or – range ON
5D-40) Shift selector: + range OFF
Lever Position Switch: H1 (Page Shift selector: R range ON
5D-40) Other than above condition OFF
Lever Position Switch: H2 (Page Shift selector: N range ON
5D-40) Other than above condition OFF
Lever Position Switch: H3 (Page Shift selector: D, M, + or – range ON
5D-40) Other than above condition OFF
Driv Door SW (Wire Harness) (Page Driver side front door: Open ON
5D-40) Driver side front door: Close OFF
Brake Pedal Switch No.1 (Page 5D- Brake pedal: Fully depressed ON
40) Brake pedal: Released OFF
Brake Pedal Switch No.2 (Page 5D- Brake pedal: Released ON
40) Brake pedal: Fully depressed OFF
Repeating gear shift operation with vehicle
Hydraulic Pump Active (Page 5D- ON
stationary with ignition “ON”
40)
Other than above condition OFF
Driver side front door: Open Open
Driv Door SW (CAN) (Page 5D-40)
Driver side front door: Close Close
Parking brake lever: Pulled ON
Parking Brake SW (Page 5D-40)
Parking brake lever: Released OFF
A/C compressor magnet clutch: Connected ON
A/C Comp Clutch (Page 5D-40)
A/C compressor magnet clutch: Released OFF
Fuel cut operating ON
Fuel Cut Active (Page 5D-41)
Fuel cut not operating OFF
Hill Hold Control Active (Page 5D-
— ON
41)
Transaxle Warning Light (Lighting) Engine: Running with faulty condition ON
(Page 5D-41) Engine: Running without faulty condition OFF
Transaxle Warning Light (Flashing) Clutch: Overheating ON
(Page 5D-41) Clutch: Normal condition OFF
Engine: Running with faulty condition ON
MIL Request (Page 5D-41)
Engine: Running without faulty condition OFF
• Engine: Running
• Shift selector: D or M range ON
• Brake pedal: Released
Creep Control Active (Page 5D-41) • Engine: Running
• Shift selector: D or M range OFF
• Brake pedal: Depressed
Ignition: “ON” OFF
Driver side front door: Open ON
Driv Door SW (Page 5D-41)
Driver side front door: Close OFF
Shift selector: D range Automatic
A/M State (Page 5D-41)
Shift selector: M range Manual
After completion of contact-point learning Complete
Contact Point Learning Complete
Before completion of contact-point learning (after
(Page 5D-41) Incomplete
reset of learning)
After completion of clutch close learning Complete
Clutch Close Learning Complete
Before completion of clutch close learning (after
(Page 5D-41) Incomplete
reset of learning)
After completion of clutch end stroke learning Complete
Clutch End Stroke Learning Complete
Before completion of clutch end stroke learning
(Page 5D-41) Incomplete
(after reset of learning)
After completion of clutch-stroke learning Complete
Clutch Stroke Check Complete
Before completion of clutch-stroke learning (after
(Page 5D-41) Incomplete
reset of learning)
5D-39 Automated Manual Transaxle:

Normal condition /
Scan tool data Vehicle condition
Reference value
After completion of grid learning Complete
Grid Learning Complete (Page 5D-
Before completion of grid learning (after reset of
41) Incomplete
learning)
Shift selector: Mid point of gear shift Shift in Progress
Shift selector: R range R
Transmission Gear Selector Position
Shift selector: N range N
(Page 5D-41)
Shift selector: D range D
Shift selector: M range M

Scan Tool Data Definitions: Throttle Position (%)

Input Shaft Revolution (rpm)
This parameter indicates input shaft speed detected by
clutch speed sensor.
Output Shaft Revolution (rpm)
This parameter indicates output shaft speed calculated
by multiplying input shaft speed and reduction gear ratio.
This parameter indicates throttle position sent from ECM
through CAN.
Accel Effective Position (Accelerator Effective
Position (%))
This parameter indicates accelerator pedal position sent
from ECM through CAN.

Clutch Position Sensor ECT (Engine Coolant Temperature, °C, °F)

This parameter indicates the states of clutch position This parameter indicates engine coolant temperature
sensor. sent from ECM through CAN.

Select Position Sensor Outside Air Temp (Outside Air Temperature, °C, °F)
This parameter indicates the states of select position This parameter indicates outside air temperature sent
sensor. from BCM through CAN.

Shift Position Sensor Barometric Pressure (kPa)

This parameter indicates the states of shift position This parameter indicates barometric pressure sent from
sensor. ECM through CAN.

Battery Voltage (V) Vehicle Speed (km/h)

This parameter indicates battery positive voltage This parameter indicates vehicle speed detected by
inputted to TCM. VSS.

Oil Pressure (MPa) Clutch Control Status

This parameter indicates oil pressure detected by
pressure sensor.
Clutch Solenoid Control Value (mA)
This parameter indicates control current value that TCM
outputs to clutch solenoid valve.
Select Solenoid Control Value (mA)
This parameter indicates control current value that TCM
outputs to select solenoid valve.
Shift Solenoid No.1 (Odd Side) Control Value (mA)
This parameter indicates control current value that TCM
outputs to shift solenoid valve 1.
Shift Solenoid No.2 (Even Side) Control Value (mA)
This parameter indicates control current value that TCM
outputs to shift solenoid valve 2.
Engine Speed (rpm)
This parameter indicates engine speed sent from ECM
through CAN.
This parameter indicates the states of clutch control.
Closed: Shift selector is in N with ignition “ON” and
engine stopped.
Slipping Before Engaging: Shift selector is being shifted
from N to D with ignition “ON”.
Slipping After Engaging: After completion of N to D shift
with ignition “ON”
Opened: Shift selector is in N with engine idling.
Gear Position
This parameter indicates shift position information in
drive mode.
Manual Gear Position
This parameter indicates shift position information in
manual mode.
Estimated Clutch Temperature (°C, °F)
This parameter indicates estimated clutch temperature
calculated by TCM.

Clutch High Temperature Control Status
This parameter indicates the states of clutch high
temperature control.
Normal: Estimated clutch temperature is less than 200
°C (392 °F) (K10B model) or 240 °C (464 °F) (K12M
model).
Hot Mode 1: Estimated clutch temperature is higher than
200 °C (392 °F) (K10B model) or 240 °C (464 °F) (K12M
model).
Hot Mode 2: Estimated clutch temperature is higher than
hot mode 1.
Automatic Discrimination (ABS/ESP)
This parameter is indicated all the time without change.
ABS Equipped
This parameter is indicated all the time without change.
ESP / ABS+Hill Hold Equipped
This parameter is indicated all the time without change.
Automatic Discrimination (AEB)
This parameter is indicated all the time without change.
AEB Equipped
This parameter is indicated all the time without change.
Automatic Discrimination (Push Start)
This parameter is indicated all the time without change.
Push Start System Equipped
This parameter is indicated all the time without change.
Lever Position Switch: M1 (ON/OFF)
This parameter indicates the states of R or N range
sensor in shift selector.
ON: Shift selector is in R or N.
OFF: Shift selector is in D, M, + or –.
Lever Position Switch: M2 (ON/OFF)
This parameter indicates the states of N, D, M, + or –
range sensor in shift selector.
ON: Shift selector is in N, D, M, + or –.
OFF: Shift selector is in R.
Lever Position Switch: M3 (ON/OFF)
This parameter indicates the states of M, + or – range
sensor in shift selector.
ON: Shift selector is in M, + or –.
OFF: Shift selector is in R, N or D.
Lever Position Switch: M4 (ON/OFF)
This parameter indicates the states of R, N, D, M or +
range sensor in shift selector.
ON: Shift selector is in R, N, D, M or +.
OFF: Shift selector is in –.
Lever Position Switch: M5 (ON/OFF)
This parameter indicates the states of R, N, D, M or –
range sensor in shift selector.
Automated Manual Transaxle: 5D-40
ON: Shift selector is in R, N, D, M or –.
OFF: Shift selector is in +.
Lever Position Switch: H1 (ON/OFF)
This parameter indicates the states of reverse sensor in
shift selector.
ON: Shift selector is in R.
OFF: Shift selector is in N, D, M, + or –.
Lever Position Switch: H2 (ON/OFF)
This parameter indicates the states of neutral sensor in
shift selector.
ON: Shift selector is in N.
OFF: Shift selector is in R, D, M, + or –.
Lever Position Switch: H3 (ON/OFF)
This parameter indicates the states of forward sensor in
shift selector.
ON: Shift selector is in D, M, + or –.
OFF: Shift selector is in R or N.
Driv Door SW (Wire Harness) (Driver’s Door Switch
Wiring Harness) (ON/OFF)
This parameter indicates driver’s door switch wiring
harness.
ON: Driver's door is open.
OFF: Driver's door is closed.
Brake Pedal Switch No.1 (ON/OFF)
This parameter indicates brake light switch inputted to
TCM.
ON: Brake light switch is ON. (Brake pedal depressed)
OFF: Brake light switch is OFF. (Brake pedal released)
Brake Pedal Switch No.2 (ON/OFF)
This parameter indicates brake switch inputted to TCM.
ON: Brake switch is ON. (Brake pedal released)
OFF: Brake switch is OFF. (Brake pedal depressed)
Hydraulic Pump Active (ON/OFF)
This parameter indicates the states of hydraulic pump.
ON: Hydraulic pump operating
OFF: Hydraulic pump not operating
Driv Door SW (CAN) (Driver’s Door Switch (CAN))
This parameter indicates driver’s door switch sent from
BCM through CAN.
Open: Driver's door is open.
Close: Driver's door is closed.
Parking Brake SW (Parking Brake Switch) (ON/OFF)
This parameter indicates parking brake switch sent from
BCM through CAN.
ON: Parking brake lever is pulled.
OFF: Parking brake lever is released.
A/C Comp Clutch (ON/OFF)
This parameter indicates air conditioner request
information received from ECM through CAN.
ON: A/C request signal is ON.
5D-41 Automated Manual Transaxle:

OFF: A/C request signal is OFF.
Fuel Cut Active (ON/OFF)
This parameter indicates the state of fuel cut signal from
ECM through CAN.
ON: Fuel injection is cut (output signal to injector is
stopped).
OFF: Fuel injection is not cut.
Hill Hold Control Active (ON/OFF)
This parameter indicates all the time without change.
Clutch End Stroke Learning Complete
This parameter indicates the states of clutch end stroke
learning.
Complete: Clutch end stroke learning is completed.
Incomplete: Clutch end stroke learning is not completed.
Clutch Stroke Check Complete
This parameter indicates the states of clutch stroke
check.
Complete: Clutch-stroke learning is completed.
Incomplete: Clutch-stroke learning is not completed.

Transaxle Warning Light (Lighting) (ON/OFF) Grid Learning Complete

This parameter indicates the states of auto gear shift This parameter indicates the states of grid learning.
warning light (lighting) output signal from TCM through Complete: Grid learning is completed.
CAN. Incomplete: Grid learning is not completed.
ON: Engine is running with faulty condition.
OFF: Engine is running in normal condition. Transmission Gear Selector Position
This parameter indicates shift position information.
Transaxle Warning Light (Flashing) (ON/OFF)
This parameter indicates the states of auto gear shift
warning light (flashing) output signal from TCM through
CAN.
ON: Clutch is overheating.
OFF: Clutch temperature is normal.

MIL Request (ON/OFF)

This parameter indicates the states of MIL output signal
from TCM through CAN.
ON: TCM requests combination meter to turn on MIL.
OFF: TCM does not request combination meter to turn
on MIL.

Creep Control Active (ON/OFF)

This parameter indicates the states of creep control.
ON: Creep control operating
OFF: Creep control not operating

Driv Door SW (Driver’s Door Switch) (ON/OFF)

This parameter indicates driver’s door switch inputted to
TCM.
ON: Driver's door is open.
OFF: Driver's door is closed.

A/M State (Automatic / Manual State)

This parameter indicates the gear shifting mode.
Automatic: Automatic gear shifting
Manual: Manual gear shifting

Contact Point Learning Complete

This parameter indicates the states of contact-point
learning.
Complete: Contact-point learning is completed.
Incomplete: Contact-point learning is not completed.

Clutch Close Learning Complete

This parameter indicates the states of clutch close
learning.
Complete: Clutch close learning is completed.
Incomplete: Clutch close learning is not completed.
 Automated Manual Transaxle: 5D-42

Auto Gear Shift Symptom Diagnosis

AENJCA0A5404010

Hydraulic Transaxle
Electrical system
system system

Diagnostic item

Starting motor control relay drive signal

Gear shift and select shaft assembly

Ambient temperature sensor
Driver side front door switch

Auto gear shift transaxle

Ignition “START” signal

Clutch position sensor

Select position sensor

Clutch solenoid valve

Shift solenoid valve 1
Shift solenoid valve 2
Select solenoid valve
Clutch speed sensor
Shift position sensor

Back up light signal

Brake light switch

Pressure sensor
Symptom

Clutch actuator
Engine system

Shift selector

Clutch lining
Valve body

Clutch link
Battery

TCM

VSS
Unable to start in D, M or R range
Poor startability and acceleration in D, M or R range
Poor vehicle run

Engine speed increases quickly in D, M or R range

Unable to switch to manual mode
No gear change in manual mode
Unable to creep
Engine stalls at vehicle stopping, creeping, starting
or low speed running
Engine speed increases (races) at gear change
points in D, M or R range
Poor gear
change

Unable to shift gear at vehicle stopping

Unable to change gear position at vehicle running
Engine stalls at deceleration in D, M or R range
Engine stalls when gear is shifted at vehicle running
Large starting shock in D, M or R range
Others Shock

Large shock at gear change

Back up light does not come on
Unable to start engine
IJCA0A540013-01

MIL Does Not Come ON with Ignition “ON” and Engine Stopped (but Engine Can Be Started)
AENJCA0A5404063
Refer to “MIL Does Not Come ON with Ignition “ON” and Engine Stopped (but Engine Can Be Started)” in Section 1A.
• K10B model: (Page 1A-45)
• K12M model: (Page 1A-169)

MIL Remains ON after Engine Starts

AENJCA0A5404064
Refer to “MIL Remains ON after Engine Starts” in Section 1A.
• K10B model: (Page 1A-45)
• K12M model: (Page 1A-169)

Auto Gear Shift Warning Light Does Not Come ON at Ignition “ON” and Engine Stopped
AENJCA0A5404011
Troubleshooting
Step Action Yes No
1 DTC check Go to troubleshooting Go to Step 2.
1) Check DTC related to CAN communication. for applicable DTC.

Is there CAN-DTC(s) detected?

2 Combination meter check Replace auto gear shift Replace combination
1) Check combination meter. (Page 9C-21) actuator unit and meter.
recheck DTC. (Page
Is check result OK? 5D-104)
5D-43 Automated Manual Transaxle:

Auto Gear Shift Warning Light Remains ON after Engine Starts

AENJCA0A5404012
Troubleshooting
Step Action Yes No
1 DTC check Go to troubleshooting Replace combination
1) Check DTC. for applicable DTC. meter and recheck
DTC. (Page 9C-25)
Is there any DTC(s)?
If auto gear shift
warning light still
remains ON, replace
auto gear shift actuator
unit and recheck DTC.
(Page 5D-104)

Starting Motor Control Relay Circuit Check

AENJCA0A5404013
Circuit Diagram

[B]
7
1
[A] 5 [A]
C15-19 RED
4 6

2 RED 8
C15-21 GRN A1
A2
GRN
YEL

B1
3

IJCA0A540014-01

[A]: Without keyless entry system 1. TCM 6. “IGN2” fuse

[B]: With keyless entry system 2. Starting motor control relay 7. “KEY2” fuse
A1: Starting motor control relay power supply 3. Starting motor 8. “ST” fuse
(switch side) circuit
A2: Starting motor control relay signal circuit 4. “ST SIG” fuse
B1: Starting motor power supply circuit 5. Ignition switch

Troubleshooting
Step Action Yes No
1 DTC check Go to troubleshooting Go to Step 2.
1) Check DTC. for applicable DTC.

Is there any DTC(s)?

2 Starting motor control relay power supply (switch side) Go to Step 3. Repair or replace
check defective wire harness.
1) With ignition “OFF”, remove starting motor control relay.
2) Check for proper terminal connection to starting motor
control relay connector.
3) If connection is OK, check that voltage between “A1” and
ground is battery voltage.

Is check result OK?

 Automated Manual Transaxle: 5D-44

Step Action Yes No

3 Starting motor control relay signal circuit check Go to Step 4. Repair or replace
1) Disconnect starting motor connector. defective wire harness.
2) Check for proper terminal connection to starting motor
connector.
3) If connection is OK, check the following points.
• Resistance of “A2” circuit: less than 1 Ω
• Resistance between “A2” circuit and ground: infinity

Is check result OK?

4 Starting motor control relay check Go to Step 5. Repair starting motor
1) Check starting motor control relay. (Page 5D-117) control relay.

Is check result OK?

5 Starting motor power supply circuit check Replace starting motor. Repair or replace
1) Disconnect starting motor cable. (Page 1I-5) (Page 1I-5) defective wire harness.
2) Check for proper terminal connection to starting motor
cable.
3) If connection is OK, check that voltage between “B1” and
ground is battery voltage.

Is check result OK?

DTC P0070
AENJCA0A5404014
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0070: Ambient Air Temperature Sensor Circuit • Outside air temperature sensor and/or its
TCM received abnormality of outside air temperature signal from circuit
BCM. • BCM
(1 D/C detection logic)
5D-45 Automated Manual Transaxle:

Circuit Diagram

A1 4 3 2

RED [A]:E05-1
[B]:E04-11
7 5 5 5
[A]:E05-7
WHT
[B]:E04-6

A2
1
6

RED C15-7
5
WHT C15-10

[C] C15

10 9 8 7 6 5 4 3 2 1

23 22 21 20 19 18 17 16 15 14 13 12 11 [a]

28 27 26 25 24

IJCA0A540015-03

[A]: Without keyless entry system A2: Outside air temperature sensor signal circuit 4. BCM
[B]: With keyless entry system 1. TCM 5. CAN driver
[C]: TCM connector (View: [a]) 2. ECM 6. To other control modules connected by CAN
A1: Outside air temperature power supply circuit 3. ABS control module 7. Outside air temperature

DTC Confirmation Procedure

NOTE
Check that the following conditions are met in this procedure.
• DTC U0073 or U0140 is not detected.
• 11 V < Battery voltage < 15 V

1) Set ignition “ON”.

DTC Troubleshooting
Step Action Yes No
1 Was “Auto Gear Shift System Check” performed? Go to Step 2. Go to “Auto Gear Shift
System Check” (Page
5D-18).
2 DTC check Go to troubleshooting Go to Step 3.
for CAN-DTC. (Page
Is there any CAN-DTC detected? 10H-7)
3 DTC check Go to troubleshooting End.
1) Check DTC in BCM. (Page 10B-13) for applicable DTC.

Is there any DTC(s) detected?

 Automated Manual Transaxle: 5D-46

DTC P0560 / P0562 / P1711

AENJCA0A5404015
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0560: System Voltage • TCM power supply circuit and/or
If any one of the following conditions is met. ground circuit
• Power supply voltage from battery to TCM is out of specified range. • Charging system
• Power supply voltage from ignition switch to TCM is out of specified range. • TCM incorporated in auto gear shift
(1 D/C detection logic) actuator unit
P0562: System Voltage Low
Power supply voltage from battery to TCM is lower than specified range.
(1 D/C detection logic)
P1711: TCM Power Input Low Voltage
TCM power supply voltage from battery is lower than specified value for
specified time.
(1 D/C detection logic)

Circuit Diagram

A1 2
C15-24 WHT
A2 3
C15-26 WHT
A3
[A]
4
C15-28 BRN 5

6 [B]
7

[C] C15

10 9 8 7 6 5 4 3 2 1

23 22 21 20 19 18 17 16 15 14 13 12 11 [a]

28 27 26 25 24

IJCA0A540016-01

[A]: Without keyless entry system A3: Ignition power supply circuit 5. To ignition switch
[B]: With keyless entry system 1. TCM 6. “IG1 SIG2” fuse
[C]: TCM connector (View: [a]) 2. “AMT PUMP” fuse 7. To IG11 relay
A1: Electric motor power supply circuit 3. “AMT1” fuse
A2: TCM power supply circuit 4. “IG1 SIG” fuse

DTC Confirmation Procedure

P0560

NOTE
Check that the following condition is met in this procedure.
• DTC P0562 is not detected.

1) Set ignition “ON”.

P0562 / P1711
1) Set ignition “ON”.
5D-47 Automated Manual Transaxle:

DTC Troubleshooting
Step Action Yes No
1 Was “Auto Gear Shift System Check” performed? Go to Step 2. Go to “Auto Gear Shift
System Check” (Page
5D-18).
2 TCM power supply and ground circuit check Go to Step 3. Repair TCM power
1) Check TCM power supply and ground circuits. (Page supply and/or ground
5D-91) circuit.

Is check result OK?

3 Charging system check Replace TCM and Repair or replace
1) Check that charging system is working properly. recheck DTC. (Page defective parts.
5D-113)
• K10B model: (Page 1J-5)
• K12M model: (Page 1J-23)

Is check result OK?

DTC P0572 / P0573

AENJCA0A5404016
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0572: Brake Switch “A” Circuit Low • Brake light switch and/or its circuit
There is no signal from brake light switch and brake switch • TCM incorporated in auto gear shift actuator unit
for more than specified time.
(1 D/C detection logic)
P0573: Brake Switch “A” Circuit High
Vehicle is driven more than specified operating range, but
brake light switch cannot be changed (stays ON).
(1 D/C detection logic)

Circuit Diagram

[A]
IG1 3
A1
4 B1
BRN 1
[B] 6 LT GRN C15-1
+BB WHT
A1 5
7 B2
BLU GRN C15-2
A2 2

[C] C15

10 9 8 7 6 5 4 3 2 1

23 22 21 20 19 18 17 16 15 14 13 12 11 [a]

28 27 26 25 24

IJCA0A540017-01

[A]: Without keyless entry system B1: Brake switch signal circuit 4. “IG1 SIG” fuse
[B]: With keyless entry system B2: Brake light switch signal circuit 5. “IG1 SIG2” fuse
[C]: TCM connector (View: [a]) 1. Brake light switch 6. To IG11 relay
A1: Brake switch power supply circuit 2. Brake light 7. “STOP” fuse
A2: Brake light switch power supply circuit 3. TCM
 Automated Manual Transaxle: 5D-48

DTC Confirmation Procedure

P0572

NOTE
Check that the following conditions are met in this procedure.
• 11 V < Battery voltage < 15 V
• 11 V < Ignition voltage < 15 V

1) Set ignition “ON”.

2) Depress and release brake pedal.

P0573

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

NOTE
• Limit the driving speed permissible in road conditions and regulations.
• Check that the following conditions are met in this procedure.
– DTC P0720 or P0721 is not detected.
– 11 V < Battery voltage < 15 V
– 11 V < Ignition voltage < 15 V

1) Start engine.
2) Drive vehicle at more than 40km/h (25 mile/h) continuously for more than 45 sec.
3) Stop vehicle continuously for more than 30 sec.
4) Repeat Step 2) – 3) 5 times.

DTC Troubleshooting
Step Action Yes No
1 Was “Auto Gear Shift System Check” performed? Go to Step 2. Go to “Auto Gear Shift
System Check” (Page
5D-18).
2 Brake light switch power supply circuit check Go to Step 3. Repair or replace
1) With ignition “OFF”, disconnect brake light switch defective wire harness.
connector.
2) Check for proper terminal connection to brake light
switch connector.
3) If connection is OK, set ignition “ON”.
4) Check that voltage between each of “A1” and “A2”
circuits and ground is battery voltage.

Is check result OK?

5D-49 Automated Manual Transaxle:

Step Action Yes No

3 Brake light switch signal circuit check Go to Step 4. Repair or replace
1) With ignition “OFF”, disconnect “C15” connector from defective wire harness.
TCM.
2) Check for proper terminal connection to “C15”
connector.
3) If connection is OK, check the following points.
• Resistance of “B1” and “B2” circuits: less than 1 Ω
• Resistance between each of “B1” and “B2” circuits
and ground: infinity
• Resistance between “B1” circuit terminal and other
terminal at brake light switch connector: infinity
• Resistance between “B2” circuit terminal and other
terminal at brake light switch connector: infinity
• Voltage of “B1” and “B2” circuits: approx. 0 V (When
ignition is “ON”)

Is check result OK?

4 Brake light switch check Replace TCM and Repair brake light
1) Check brake light switch. (Page 4A-11) recheck DTC. (Page switch. (Page 4A-12)
5D-113)
Is check result OK?

DTC P0602
AENJCA0A5404017
DTC Detecting Condition and Trouble Area

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

DTC detecting condition Trouble area

P0602: Control Module Programming Error • Reprogramming of TCM failure
TCM internal failure (data programming error) • TCM incorporated in auto gear shift actuator unit
(1 D/C detection logic but auto gear shift warning light
does not light up)

DTC Confirmation Procedure

1) Set ignition “ON”.

DTC Troubleshooting
Step Action Yes No
1 Was “Auto Gear Shift System Check” performed? Go to Step 2. Go to “Auto Gear Shift
System Check” (Page
5D-18).
2 DTC check Go to troubleshooting Go to Step 3.
for applicable DTC.
Is there any DTC(s) other than P0602?
3 Reprogramming operation procedure check and Go to Step 4. Check the operation
equipment preparation procedures and inspect
SUZUKI scan tool and
Is there a problem with reprogramming operation procedure, DLC.
SUZUKI scan tool or DLC?
4 TCM reprogramming Intermittent trouble. Replace TCM and
recheck DTC. (Page
Was reprogramming of TCM executed? 5D-113)
 Automated Manual Transaxle: 5D-50

DTC P0604 / P060A / P062F / P1702 / P1704 / P1982 / P1983

AENJCA0A5404018
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0604: Internal Control Module Random Access Memory (RAM) Error TCM incorporated in auto gear shift
TCM internal failure (RAM error) actuator unit
(1 D/C detection logic)
P060A: Internal Control Module Monitoring Processor Performance
TCM internal failure (SMP error)
(1 D/C detection logic)
P062F: Internal Control Module EEPROM Error
TCM internal failure (EEPROM error)
(1 D/C detection logic)
P1702: Internal Control Module Memory Check Sum Error
TCM internal failure (check sum error)
(1 D/C detection logic)
P1704: Internal Control Module Memory EEPROM Error
TCM internal failure (EEPROM memory error)
(1 D/C detection logic)
P1982: Internal Control Module EEPROM Error (Application)
TCM internal failure (EEPROM application error)
(1 D/C detection logic)
P1983: Internal Control Module Monitoring Processor Output Failure
TCM internal failure (monitoring processor output failure)
(1 D/C detection logic)

DTC Confirmation Procedure

P0604
1) Open driver side front door.

P060A / P062F / P1704 / P1982 / P1983

1) Set ignition “ON”.

P1702
1) Set ignition “OFF”.
2) Set ignition “ON”.

DTC Troubleshooting
Step Action Yes No
1 Is DTC P0604, P060A, P062F, P1702, P1704, P1982 or Replace TCM and End.
P1983 detected after performing “DTC Confirmation recheck DTC. (Page
Procedure”? 5D-113)

DTC P0615
AENJCA0A5404019
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0615: Starter Relay Circuit • Starting motor control relay and/or its circuit
Request to starting motor control relay and feedback • TCM incorporated in auto gear shift actuator unit
signal disagree.
(1 D/C detection logic)
5D-51 Automated Manual Transaxle:

Circuit Diagram

[B]
7
1
[A] 5 [A]
C15-19 RED
A1 4 6

A2 2 RED 8
C15-21 GRN

GRN
YEL

[C] C15

10 9 8 7 6 5 4 3 2 1

23 22 21 20 19 18 17 16 15 14 13 12 11 [a]

28 27 26 25 24

IJCA0A540018-01

[A]: Without keyless entry system 1. TCM 6. “IGN2” fuse

[B]: With keyless entry system 2. Starting motor control relay 7. “KEY2” fuse
[C]: TCM connector (View: [a]) 3. Starting motor 8. “ST” fuse
A1: Starting motor control relay power supply 4. “ST SIG” fuse
(coil side) circuit
A2: Starting motor control relay drive circuit 5. Ignition switch

DTC Confirmation Procedure

NOTE
Check that the following condition is met in this procedure.
• 11 V < Battery voltage < 15 V

1) Start engine, if possible.

DTC Troubleshooting
Step Action Yes No
1 Was “Auto Gear Shift System Check” performed? Go to Step 2. Go to “Auto Gear Shift
System Check” (Page
5D-18).
2 Starting motor control relay power supply (coil side) Go to Step 3. Repair or replace
check defective wire harness.
1) With ignition “OFF”, remove starting motor control relay.
2) Check for proper terminal connection to starting motor
control relay connector.
3) If connection is OK, set ignition “START”.
4) Check that voltage between “A1” and ground is battery
voltage.

Is check result OK?

 Automated Manual Transaxle: 5D-52

Step Action Yes No

3 Starting motor control relay drive circuit check Go to Step 4. Repair or replace
1) With ignition “OFF”, disconnect “C15” connector from defective wire harness.
TCM.
2) Check for proper terminal connection to “C15”
connector.
3) If connection is OK, check the following points.
• Resistance of “A2” circuit: less than 1 Ω
• Resistance between “A2” circuit and ground: infinity
• Resistance between “A2” circuit terminal and other
terminal at starting motor control relay connector:
infinity
• Voltage of “A2” circuit: approx. 0 V (When ignition is
“START”)

Is check result OK?

4 Starting motor control relay check Replace TCM and Repair starting motor
1) Check starting motor control relay. (Page 5D-117) recheck DTC. (Page control relay.
5D-113)
Is check result OK?

DTC P0715 / P0716

AENJCA0A5404020
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0715: Input / Turbine Speed Sensor “A” Circuit • Clutch speed sensor and/or its circuit
There is no clutch speed sensor signal for more than • Countershaft 2nd gear
specified time or clutch speed sensor signal is incorrect.
• TCM incorporated in auto gear shift actuator unit
(1 D/C detection logic)
P0716: Input / Turbine Speed Sensor “A” Circuit
Range / Performance
Clutch speed rises rapidly.
(1 D/C detection logic)

DTC Confirmation Procedure

P0715

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

NOTE
• Limit the driving speed permissible in road conditions and regulations.
• Check that the following conditions are met in this procedure.
– DTC P1852 is not detected.
– 11 V < Battery voltage < 15 V

1) Start engine and run it at idle speed for 1 min.

2) Drive vehicle at more than 20 km/h (12 mile/h) continuously for 1 min.
5D-53 Automated Manual Transaxle:

P0716

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

NOTE
• Limit the driving speed permissible in road conditions and regulations.
• Check that the following conditions are met in this procedure.
– DTC P1852 is not detected.
– 11 V < Battery voltage < 15 V

1) Start engine and drive vehicle at more than 40 km/h (25 mile/h) continuously for 1 min.

DTC Troubleshooting
Step Action Yes No
1 Was “Auto Gear Shift System Check” performed? Go to Step 2. Go to “Auto Gear Shift
System Check” (Page
5D-18).
2 Clutch speed sensor and countershaft 2nd gear check Replace auto TCM and Repair or replace
1) Check clutch speed sensor. (Page 5D-115) recheck DTC. (Page defective parts.
5D-113)
Is check result OK?
 Automated Manual Transaxle: 5D-54

DTC P0720 / P0721

AENJCA0A5404021
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0720: Output Speed Sensor Circuit • VSS and/or its circuit
There is no VSS signal for more than specified time or VSS • Speed sensor ring
signal is incorrect.
• TCM incorporated in auto gear shift actuator unit
(1 D/C detection logic)
P0721: Output Speed Sensor Circuit Range / Performance
VSS signal rises rapidly.
(1 D/C detection logic)

Circuit Diagram

A2 2 A1

C15-3 BEG BLU 3

GRY

A3
[A] C15

10 9 8 7 6 5 4 3 2 1

23 22 21 20 19 18 17 16 15 14 13 12 11 [a]

28 27 26 25 24

IJCA0A540019-01

[A]: TCM connector (View: [a]) A3: VSS ground circuit 3. To main relay
A1: VSS power supply circuit 1. TCM
A2: VSS signal circuit 2. VSS

DTC Confirmation Procedure

P0720

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

NOTE
• Limit the driving speed permissible in road conditions and regulations.
• Check that the following conditions are met in this procedure.
– DTC P1909 or U0073 is not detected.
– 11 V < Battery voltage < 15 V

1) Start engine and drive vehicle at more than 20 km/h (12 mile/h) continuously for 1 min.
5D-55 Automated Manual Transaxle:

P0721

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

NOTE
• Limit the driving speed permissible in road conditions and regulations.
• Check that the following condition is met in this procedure.
– 11 V < Battery voltage < 15 V

1) Start engine and drive vehicle at more than 40 km/h (25 mile/h) continuously for 45 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Auto Gear Shift System Check” performed? Go to Step 2. Go to “Auto Gear Shift
System Check” (Page
5D-18).
2 VSS power supply circuit check Go to Step 4. Go to Step 3.
1) With ignition “OFF”, disconnect VSS connector.
2) Check for proper terminal connection to VSS connector.
3) If connection is OK, set ignition “ON”.
4) Check that voltage between “A1” and “A3” is battery
voltage.

Is check result OK?

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

Is check result OK?

4 VSS signal circuit check Go to Step 5. Repair or replace
1) With ignition “OFF”, disconnect “C15” connector from defective wire harness.
TCM.
2) Check for proper terminal connection to “C15”
connector.
3) If connection is OK, check the following points.
• Resistance of “A2” circuit: less than 1 Ω
• Resistance between “A2” circuit and ground: infinity
• Resistance between “A2” circuit terminal and other
terminal at clutch speed sensor connector: infinity
• Voltage of “A2” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

5 VSS and speed sensor ring check Replace TCM and Repair or replace
1) Check VSS and speed sensor ring. recheck DTC. (Page defective parts.
5D-113)
• VSS: (Page 5D-116)
• Speed sensor ring: (Page 5D-144)

Is check result OK?

 Automated Manual Transaxle: 5D-56

DTC P0805
AENJCA0A5404022
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0805: Clutch Position Sensor Circuit • Clutch position sensor (auto gear shift
If any one of the following conditions is met. actuator unit) and/or its circuit
• Clutch position sensor signal is more than specified value for • TCM incorporated in auto gear shift actuator
specified time. unit
• Clutch position sensor signal is less than specified value for
specified time.
(1 D/C detection logic)

DTC Confirmation Procedure

NOTE
Check that the following conditions are met in this procedure.
• Limit the driving speed permissible in road conditions and regulations.
• DTC P1852 is not detected.
• 11 V < Battery voltage < 15 V

1) Set ignition “ON” for 1 min.

DTC Troubleshooting
Step Action Yes No
1 Was “Auto Gear Shift System Check” performed? Go to Step 2. Go to “Auto Gear Shift
System Check” (Page
5D-18).
2 DTC check Replace sensor (auto Intermittent trouble.
1) Perform the DTC confirmation procedure gear shift actuator unit)
and recheck DTC.
2) Check DTC. (Page 5D-21)
(Page 5D-104)
Is DTC P0805 detected?

DTC P0840 / P0841

AENJCA0A5404066
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0840: Transmission Fluid Pressure Sensor / Switch “A” Circuit • Pressure sensor (auto gear shift actuator
If any one of the following conditions is met. unit) and/or its circuit
• Pressure sensor signal is more than specified value. • TCM incorporated in auto gear shift actuator
• Pressure sensor signal is less than specified value. unit
(1 D/C detection logic)
P0841: Transmission Fluid Pressure Sensor / Switch “A” Circuit
Range / Performance
Pressure sensor signal rises rapidly.
(1 D/C detection logic)

DTC Confirmation Procedure

NOTE
Check that the following conditions are met in this procedure.
• DTC P1852 is not detected.
• 11 V < Battery voltage < 15 V

1) Set ignition “ON”.

5D-57 Automated Manual Transaxle:

DTC Troubleshooting
Step Action Yes No
1 Was “Auto Gear Shift System Check” performed? Go to Step 2. Go to “Auto Gear Shift
System Check” (Page
5D-18).
2 DTC check Replace auto gear shift End.
1) Perform the DTC confirmation procedure actuator unit and
recheck DTC. (Page
2) Check DTC. (Page 5D-21)
5D-104)
Is DTC(s) P0840 or P0841 detected?

P0904 / P0914
AENJCA0A5404067
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0904: Gate Select Position Circuit • Select position sensor (incorporated in TCM)
If any one of the following conditions is met. • TCM incorporated in auto gear shift actuator
• Select position sensor signal is more than specified value for unit
specified time.
• Select position sensor signal is less than specified value for
specified time.
(1 D/C detection logic)
P0914: Gear Shift Position Circuit • Shift position sensor (incorporated in TCM)
If any one of the following conditions is met. • TCM incorporated in auto gear shift actuator
• Shift position sensor signal is more than specified value for unit
specified time.
• Shift position sensor signal is less than specified value for
specified time.
(1 D/C detection logic)

DTC Confirmation Procedure

NOTE
Check that the following conditions are met in this procedure.
• Limit the driving speed permissible in road conditions and regulations.
• DTC P1853 is not detected.
• 11 V < Battery voltage < 15 V

1) Set ignition “ON” for 1 min.

DTC Troubleshooting
Step Action Yes No
1 Was “Auto Gear Shift System Check” performed? Go to Step 2. Go to “Auto Gear Shift
System Check” (Page
5D-18).
2 DTC check Replace sensor (auto End.
1) Perform the DTC confirmation procedure gear shift actuator unit)
and recheck DTC.
2) Check DTC. (Page 5D-21)
(Page 5D-104)
Is DTC P0904 or 0914 detected?
 Automated Manual Transaxle: 5D-58

DTC P080A / P185A / P185B

AENJCA0A5404023
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P080A: Clutch Position Not Learned • Clutch disc
Clutch-contact-point learning (recognition of clutch • Clutch cover
engaging point) is not completed.
• Flywheel
(1 D/C detection logic)
• Clutch release system
• TCM incorporated in auto gear shift actuator unit
P185A: Clutch End Stroke Position Self-tune
Clutch-end-stroke-position learning (recognition of clutch
stopper position) is not completed.
(1 D/C detection logic)
P185B: Clutch Stroke Self-tune
Clutch-stroke learning (recognition of distance between
clutch closed position and clutch stopper) is not possible.
(1 D/C detection logic)

DTC Confirmation Procedure

P080A / P185A
1) Set ignition “ON” for 1 min.

P185B

NOTE
Check that the following condition is met in this procedure.
• DTC P185A or P2789 is not detected.

1) Set ignition “ON” for 1 min.

DTC Troubleshooting
Step Action Yes No
1 Was “Auto Gear Shift System Check” performed? Go to Step 2. Go to “Auto Gear Shift
System Check” (Page
5D-18).
2 DTC check Go to troubleshooting Go to Step 3.
1) Perform the DTC confirmation procedure for applicable DTC.
2) Check DTC. (Page 5D-21)

Is DTC(s) P080A, P185A or P185B still detected?

3 Initialization for clutch system Go to Step 4. End.
1) Perform “Clutch Assembly Initialization” under “TCM and
Clutch Initialization” (Page 5D-96).
2) Check DTC. (Page 5D-21)

Is DTC P080A, P185A or P185B still detected?

4 Clutch rod check Go to Step 5. Replace defective parts.
1) Check clutch rod for proper installation and operation,
and for obstructions within its operating range.

Is check result OK?

5D-59 Automated Manual Transaxle:

Step Action Yes No

5 Clutch check Replace TCM and Repair or replace
1) Dismount auto gear shift unit. (Page 5D-117) recheck DTC. (Page defective parts.
5D-113)
2) Check the following parts.
• Clutch cover and clutch disc: (Page 5D-146)
• Clutch release system: (Page 5D-149)
• Flywheel:
– K10B model: (Page 1D-34)
– K12M model: (Page 1D-109)

Is check result OK?

DTC P0944
AENJCA0A5404024
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0944: Hydraulic Pressure Unit Loss of Pressure • Electric motor
Pressure sensor signal is less than specified value. • Auto gear shift actuator unit oil leakage
(1 D/C detection logic)
• TCM incorporated in auto gear shift actuator unit

DTC Confirmation Procedure

NOTE
Check that the following condition is met in this procedure.
• DTC P0840 or P0841 is not detected.

1) Set ignition “ON” for 2 min.

DTC Troubleshooting
Step Action Yes No
1 Was “Auto Gear Shift System Check” performed? Go to Step 2. Go to “Auto Gear Shift
System Check” (Page
5D-18).
2 Auto gear shift actuator unit oil leakage check Go to Step 3. Replace auto gear shift
1) Check auto gear shift actuator unit oil level and leakage. actuator unit and
(Page 5D-98) recheck DTC. (Page
5D-104)
Is check result OK?
3 DTC check Replace auto gear shift End.
1) Perform the DTC confirmation procedure actuator unit and
recheck DTC. (Page
2) Check DTC. (Page 5D-21)
5D-104)
Is DTC(s) P0944 detected?

DTC P0945
AENJCA0A5404025
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0945: Hydraulic Pump Relay Circuit / Open • Electric motor power supply circuit
Power supply voltage from battery to electric motor is • TCM incorporated in auto gear shift actuator unit
lower than specified value.
• “AMT PUMP” fuse
(1 D/C detection logic)
 Automated Manual Transaxle: 5D-60

Circuit Diagram

1
A2 A1
2
C15-24 WHT
3
C15-26 WHT

[A] 4
C15-28 BRN 5
[B] 6
7

[C] C15

10 9 8 7 6 5 4 3 2 1

23 22 21 20 19 18 17 16 15 14 13 12 11 [a]

28 27 26 25 24

IJCA0A540020-02

[A]: Without keyless entry system A2: Electric motor power supply circuit 2 4. “IG1 SIG” fuse
[B]: With keyless entry system 1. TCM 5. To ignition switch
[C]: TCM connector (View: [a]) 2. “AMT PUMP” fuse 6. “IG1 SIG2” fuse
A1: Electric motor power supply circuit 1 3. “AMT1” fuse 7. To IG11 relay

DTC Confirmation Procedure

1) Set ignition “ON”.

DTC Troubleshooting
Step Action Yes No
1 Was “Auto Gear Shift System Check” performed? Go to Step 2. Go to “Auto Gear Shift
System Check” (Page
5D-18).
2 “AMT PUMP” fuse check Go to Step 4. Go to Step 3.
1) Check “AMT PUMP” fuse for blowout.

Is check result OK?

3 Electric motor power supply circuit check 1 Replace “AMT PUMP” Repair or replace
1) Set ignition “ON”. fuse. defective wire harness.
2) Check that voltage between “A1” and ground is battery
voltage.

Is check result OK?

4 Electric motor power supply circuit check 2 Replace TCM and Repair or replace
1) With ignition “OFF”, disconnect “C15” connector from recheck DTC. (Page defective wire harness.
TCM. 5D-113)
2) Check for proper terminal connection to “C15”
connector.
3) If connection is OK, check the following points.
• Resistance of “A2” circuit: less than 1 Ω
• Resistance between “A2” circuit and ground: infinity
• Resistance between “A2” circuit terminal and other
terminal at “C15” connector: infinity
• Voltage of “A2” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

5D-61 Automated Manual Transaxle:

DTC P1706
AENJCA0A5404026
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P1706: Torque Request Communication Error From TCM TCM
ECM detects abnormality of CAN communication data from TCM.
(1 D/C detection logic but auto gear shift warning light does not light up)

DTC Confirmation Procedure

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

NOTE
• Limit the driving speed permissible in road conditions and regulations.
• Check that the following conditions are met in this procedure.
– DTC U0073 or U0100 is not detected.
– 11 V < Battery voltage < 15 V

1) Start engine and drive vehicle.

DTC Troubleshooting
Step Action Yes No
1 Was “Auto Gear Shift System Check” performed? Go to Step 2. Go to “Auto Gear Shift
System Check” (Page
5D-18).
2 DTC check Go to troubleshooting Replace TCM and
1) Perform the DTC confirmation procedure for applicable DTC. recheck DTC.“TCM
Removal and
2) Check DTC. (Page 5D-21)
Installation” (Page 5D-
Is other than DTC P1706 detected? 113)

DTC P1707 / P1985

AENJCA0A5404068
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P1707: Torque Reduction Error From ECM ECM
TCM detects a condition which is not acceptable for engine torque reduction
in ECM.
(1 D/C detection logic but auto gear shift warning light does not light up)
P1985: Torque Up Error From ECM
TCM detects a condition which is not acceptable for engine torque up in ECM.
(1 D/C detection logic but auto gear shift warning light does not light up)
 Automated Manual Transaxle: 5D-62

DTC Confirmation Procedure

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

NOTE
• Limit the driving speed permissible in road conditions and regulations.
• Check that the following conditions are met in this procedure.
– DTC U0073 or U0100 is not detected.
– 11 V < Battery voltage < 15 V

1) Start engine and drive vehicle.

DTC Troubleshooting
Step Action Yes No
1 Was “Auto Gear Shift System Check” performed? Go to Step 2. Go to “Auto Gear Shift
System Check” (Page
5D-18).
2 DTC check Go to troubleshooting Go to Step 3.
for CAN-DTC. (Page
Is there any CAN-DTC detected? 10H-7)
3 DTC check Go to troubleshooting END
1) Check DTC in ECM. for applicable DTC.
• K10B model: (Page 1A-22)
• K12M model: (Page 1A-140)

Is there any DTC(s) detected?

DTC P1844
AENJCA0A5404027
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P1844: Grid Position Not Learned • Shift rod and select piston (auto gear shift actuator unit)
Grid learning (recognition of proper gear engagement) is • Gear shift and select shaft assembly
not completed.
• Auto gear shift unit
(1 D/C detection logic)
• TCM incorporated in auto gear shift actuator unit

DTC Confirmation Procedure

1) Set ignition “ON”.

DTC Troubleshooting
Step Action Yes No
1 Was “Auto Gear Shift System Check” performed? Go to Step 2. Go to “Auto Gear Shift
System Check” (Page
5D-18).
2 DTC check Go to troubleshooting Go to Step 3.
1) Perform the DTC confirmation procedure for applicable DTC.
2) Check DTC. (Page 5D-21)

Is DTC(s) other thanP1844 detected?

5D-63 Automated Manual Transaxle:

Step Action Yes No

3 TCM learning Go to Step 4. End.
1) Perform “Shift Tower Initialization” under “TCM and
Clutch Initialization” (Page 5D-96).
2) Perform DTC confirmation procedure, after check DTC.
(Page 5D-21)

Is DTC P1844 detected?

4 DTC check Go to Step 5. End.
1) Move vehicle to rotate tires a half of a turn forward or
backward with tires in contact with ground.
2) Perform “Shift Tower Initialization” under “TCM and
Clutch Initialization” (Page 5D-96).
3) Perform DTC confirmation procedure, after check DTC.
(Page 5D-21)
4) Repeat Step 1) to 4).

Is DTC P1844 detected?

5 Auto gear shift unit mechanical parts check Replace TCM and Repair or replace
1) Dismount auto gear shift unit. (Page 5D-117) recheck DTC. (Page defective parts.
5D-113)
2) Check the following parts for proper operation.
• Auto gear shift actuator unit (engage piston and select
piston): (Page 5D-104)
• Gear shift and select shaft assembly: (Page 5D-
114)
• Gear shift shaft components: (Page 5D-140)

Is check result OK?

DTC P184A
AENJCA0A5404028
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P184A: Pump Off Failed • Electric motor (auto gear shift actuator unit)
Oil pump functions for more than specified time. • Accumulator (auto gear shift actuator unit)
(1 D/C detection logic)
• TCM incorporated in auto gear shift actuator unit

DTC Confirmation Procedure

NOTE
Check that the following condition is met in this procedure.
• DTC P0945 or P185C is not detected.

1) Set ignition “ON”.

DTC Troubleshooting
Step Action Yes No
1 Was “Auto Gear Shift System Check” performed? Go to Step 2. Go to “Auto Gear Shift
System Check” (Page
5D-18).
2 Is check result OK for auto gear shift actuator unit oil level Go to Step 3. Replace auto gear shift
and leakage? actuator unit and
recheck DTC. (Page
5D-104).
 Automated Manual Transaxle: 5D-64

Step Action Yes No

3 DTC check Replace auto gear shift End.
1) Perform the DTC confirmation procedure actuator unit and
recheck DTC. (Page
2) Check DTC. (Page 5D-21)
5D-104)
Is DTC(s) P184A detected?

DTC P184B / P184C / P184D

AENJCA0A5404029
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P184B: Solenoid Driver “A” Circuit Range/Performance TCM incorporated in auto gear shift actuator
Malfunction of solenoid driver “A” (driver for clutch solenoid valve and unit
shift solenoid valve 1) is detected.
(1 D/C detection logic)
P184C: Solenoid Driver “A” Feedback Signal Range/Performance
If any one of the following conditions is met.
• Electric current of clutch solenoid is higher than specified value for
specified time and feedback voltage is lower than specified value.
• Electric current of clutch solenoid is lower than specified value for
specified time and feedback voltage is higher than specified value.
(1 D/C detection logic)
P184D: Solenoid Driver “B” Circuit Range/Performance
Malfunction of solenoid driver “B” (driver for shift solenoid valve 2,
select solenoid valve and back up light relay) is detected.
(1 D/C detection logic)

DTC Confirmation Procedure

P184B / P184D

NOTE
Check that the following conditions are met in this procedure.
• DTC P184E is not detected.
• 11 V < Battery voltage < 15 V

1) Set ignition “ON” for 10 sec.

P184C

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

NOTE
• Limit the driving speed permissible in road conditions and regulations.
• Check that the following conditions are met in this procedure.
– DTC P184B, P184D, P184E, P1854 or P1888 is not detected.
– 11 V < Battery voltage < 15 V

1) Start engine and drive vehicle.

5D-65 Automated Manual Transaxle:

DTC Troubleshooting
Step Action Yes No
1 Was “Auto Gear Shift System Check” performed? Go to Step 2. Go to “Auto Gear Shift
System Check” (Page
5D-18).
2 DTC check Replace TCM and End.
1) Perform the DTC confirmation procedure recheck DTC. (Page
5D-113)
2) Check DTC. (Page 5D-21)

Is DTC P184B, P184C or P184D detected?

DTC P184E / P184F / P1854 / P1855

AENJCA0A5404030
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P184E: TCM Internal Supply Voltage “B” Circuit TCM incorporated in auto gear shift actuator
Power supply for sub-microcomputer is out of specified range. unit
(1 D/C detection logic)
P184F: TCM Internal Supply Voltage “C” Circuit
More than specified time has passed after power OFF (latch circuit
OFF), but TCM stays ON.
(1 D/C detection logic)
P1854: TCM Internal Supply Voltage “A” Low
Power supply voltage for solenoid drivers is lower than specified value.
(1 D/C detection logic)
P1855: TCM Internal Supply Voltage “A” High
More than specified time has passed after power load relay for
solenoid drivers is OFF, power supply voltage for solenoid drivers is
higher than specified value.
(1 D/C detection logic)

DTC Confirmation Procedure

P184E

NOTE
Check that the following condition is met in this procedure.
• 11 V < Battery voltage < 15 V

1) Set ignition “ON” for 10 sec.

P184F / P1855
1) Set ignition “ON”.
2) Set ignition “OFF”.

P1854

NOTE
Check that the following condition is met in this procedure.
• 10 V < Battery voltage or 10 V < ignition voltage

1) Set ignition “ON” for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Auto Gear Shift System Check” performed? Go to Step 2. Go to “Auto Gear Shift
System Check” (Page
5D-18).
 Automated Manual Transaxle: 5D-66

Step Action Yes No

2 DTC check Replace TCM and End.
1) Perform the DTC confirmation procedure recheck DTC. (Page
5D-113)
2) Check DTC. (Page 5D-21)

Is DTC P184E, P184F, P1854 or P1855 detected?

DTC P1850 / P1851 / P1888 / P1889

DTC Detecting Condition and Trouble Area
DTC detecting condition
P1850: Gear Shift Odd Actuator Circuit
Malfunction of shift solenoid valve 1 is detected.
(1 D/C detection logic)
P1851: Gear Shift Even Actuator Circuit
Malfunction of shift solenoid valve 2 is detected.
(1 D/C detection logic)
P1888: Clutch Actuator Circuit
Malfunction of clutch solenoid valve is detected.
(1 D/C detection logic)
P1889: Gate Select Actuator Circuit
Malfunction of select solenoid valve is detected.
(1 D/C detection logic)
AENJCA0A5404031
Trouble area
• Shift solenoid valve 1 (auto gear shift actuator unit)
• TCM incorporated in auto gear shift actuator unit
• Shift solenoid valve 2 (auto gear shift actuator unit)
• TCM incorporated in auto gear shift actuator unit
• Clutch solenoid valve (auto gear shift actuator unit)
• TCM incorporated in auto gear shift actuator unit
• Select solenoid valve (auto gear shift actuator unit)
• TCM incorporated in auto gear shift actuator unit

DTC Confirmation Procedure

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

NOTE
• Limit the driving speed permissible in road conditions and regulations.
• Check that the following conditions are met in this procedure.
– DTC P184B, P184C, P184D, P184E or P1854 is not detected.
– 11 V < Battery voltage < 15 V

1) Start engine and drive vehicle at more than 30 km/h (17 mile/h) continuously for more than 30 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Auto Gear Shift System Check” performed? Go to Step 2. Go to “Auto Gear Shift
System Check” (Page
5D-18).
2 DTC check Replace auto gear shift Replace TCM and
1) Perform the DTC confirmation procedure actuator unit and recheck DTC.(Page
recheck DTC. (Page 5D-113)
2) Check DTC. (Page 5D-21)
5D-104)
Is DTC(s) other than P1850, P1851, P1888 or P1889
detected?
5D-67 Automated Manual Transaxle:

DTC P1852 / P1853

AENJCA0A5404032
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P1852: Sensor Power Supply “A” TCM incorporated in auto gear shift actuator unit
If any one of the following conditions is met.
• Power supply voltage for pressure sensor, clutch position sensor
and clutch speed sensor is higher than specified value.
• Power supply voltage for pressure sensor, clutch position sensor
and clutch speed sensor is lower than specified value.
(1 D/C detection logic)
P1853: Sensor Power Supply “B”
If any one of the following conditions is met.
• Power supply voltage for shift position sensor and select position
sensor is higher than specified value.
• Power supply voltage for shift position sensor and select position
sensor is lower than specified value.
(1 D/C detection logic)

DTC Confirmation Procedure

NOTE
Check that the following condition is met in this procedure.
• 11 V < Battery voltage < 15 V

1) Set ignition “ON” for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Auto Gear Shift System Check” performed? Go to Step 2. Go to “Auto Gear Shift
System Check” (Page
5D-18).
2 DTC check Replace TCM and End.
1) Perform the DTC confirmation procedure recheck DTC. (Page
5D-113)
2) Check DTC. (Page 5D-21)

Is DTC P1852 or P1853 detected?

DTC P185C
AENJCA0A5404065
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P185C: Hydraulic Pump Relay Circuit • Electric motor and/or its circuit
If any one of the following conditions is met. • TCM incorporated in auto gear shift actuator unit
• Feedback electric current of electric motor is out of
specified range.
• Feedback voltage of electric motor is out of specified
range.
• Oil pressure is higher than specified value without
operation of oil pump. (1 D/C detection logic)
 Automated Manual Transaxle: 5D-68

DTC Confirmation Procedure

NOTE
Check that the following condition is met in this procedure.
• DTC P0840, P0841 and P1852 are not detected.
• 10 V < Battery voltage

1) Set ignition “ON”.

2) Select shift selector from N to D range.
3) Select shift selector from D to N range.
4) With ignition “ON”, leave shift selector for more than 1 minute without operation.
5) Repeat Step 2) – 4) more than 5 times continuously.

DTC Troubleshooting
Step Action Yes No
1 Was “Auto Gear Shift System Check” performed? Go to Step 2. Go to “Auto Gear Shift
System Check” (Page
5D-18).
2 DTC check Go to troubleshooting Replace TCM and
1) Perform the DTC confirmation procedure for applicable DTC. recheck DTC. (Page
5D-113)
2) Check DTC. (Page 5D-21)

Is DTC(s) other than P185A detected?

DTC P185E / P185F / P1984

AENJCA0A5404033
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P185E: TCM Safety Function Failure TCM incorporated in auto gear shift
TCM internal failure (safety function control error)(1 D/C detection logic) actuator unit
P185F: TCM Safety Integrity Function Failure
MMP failure is detected by SMP in TCM. (1 D/C detection logic)
P1984: TCM Safety Input Preprocessing Failure
TCM internal failure (safety input preprocessing control error)(1 D/C
detection logic)

DTC Confirmation Procedure

1) Set ignition “ON”.

DTC Troubleshooting
Step Action Yes No
1 Was “Auto Gear Shift System Check” performed? Go to Step 2. Go to “Auto Gear Shift
System Check” (Page
5D-18).
2 DTC check Go to troubleshooting Replace TCM and
1) Perform the DTC confirmation procedure for applicable DTC. recheck DTC.“TCM
Removal and
2) Check DTC. (Page 5D-21)
Installation” (Page 5D-
Is there other than DTC P185E, P185F or P1984 detected? 113)
5D-69 Automated Manual Transaxle:

DTC P1884
AENJCA0A5404035
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P1884: Reverse Lamp Control Circuit • Back up light relay and/or its circuit
Malfunction of back up light relay and its circuit (open, • TCM incorporated in auto gear shift actuator unit
shorted to power supply or shorted to ground) is detected.
(1 D/C detection logic)

Circuit Diagram

[A]
1 YEL RED
IG1
[B] 2
4 3
RED YEL

C15-25 PPL BLK

A1 A2

[C] C15

10 9 8 7 6 5 4 3 2 1

23 22 21 20 19 18 17 16 15 14 13 12 11 [a]

28 27 26 25 24

IJCA0A540021-01

[A]: Without keyless entry system A1: Back up light relay drive circuit 2. Back up light relay
[B]: With keyless entry system A2: Back up light relay ground circuit 3. “BACK” fuse
[C]: TCM connector (View: [a]) 1. TCM 4. Back up light

DTC Confirmation Procedure

NOTE
Check that the following conditions are met in this procedure.
• DTC P184D, P184E or P1854 is not detected.
• 11 V < Battery voltage < 15 V

1) Set ignition “ON”.

2) Select shift selector to R range.
3) Select shift selector to N range.

DTC Troubleshooting
Step Action Yes No
1 Was “Auto Gear Shift System Check” performed? Go to Step 2. Go to “Auto Gear Shift
System Check” (Page
5D-18).
2 Back up light relay drive circuit check Go to Step 4. Go to Step 3.
1) With ignition “OFF”, remove back up light relay.
2) Check for proper terminal connection to back up light
relay connector.
3) If connection is OK, set ignition “ON” and select shift
selector to R range.
4) Check that voltage between “A1” and “A2” is battery
voltage.

Is check result OK?

 Automated Manual Transaxle: 5D-70

Step Action Yes No

3 Back up light relay ground circuit check Repair or replace “A2” Repair or replace “A1”
1) Check that voltage between “A1” and ground is battery circuit. circuit.
voltage. If this DTC is detected
again, replace TCM and
Is check result OK? recheck DTC. “TCM
Removal and
Installation” (Page 5D-
113)
4 Back up light relay check End. Replace back up light
1) Check back up light relay. (Page 5D-117) relay.

Is check result OK?

DTC P1885
AENJCA0A5404036
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P1885: Door Switch Circuit • Driver side front door switch circuit
Driver side front door switch signal is not inputted for • TCM incorporated in auto gear shift actuator unit
specified time.
(1 D/C detection logic)

Circuit Diagram

1
A1
2
C15-23 BRN

[A] C15

10 9 8 7 6 5 4 3 2 1

23 22 21 20 19 18 17 16 15 14 13 12 11 [a]

28 27 26 25 24

IJCA0A540022-01

[A]: TCM connector (View: [a]) 1. TCM 3. BCM

A1: Driver side front door switch signal circuit 2. Driver side front door switch

DTC Confirmation Procedure

NOTE
Check that the following condition is met in this procedure.
• 11 V < Battery voltage < 15 V

1) Set ignition “ON”.

2) Open driver side front door and then close it.

DTC Troubleshooting
Step Action Yes No
1 Was “Auto Gear Shift System Check” performed? Go to Step 2. Go to “Auto Gear Shift
System Check” (Page
5D-18).
5D-71 Automated Manual Transaxle:

Step Action Yes No

2 Door switch signal circuit check Replace TCM and Repair or replace
1) With ignition “OFF”, disconnect “C15” connector from recheck DTC. “TCM defective wire harness.
TCM, “L02” connector from BCM and driver side front Removal and
door switch connector. Installation” (Page 5D-
113)
2) Check for proper terminal connection to “C15” connector
and driver side front door switch connector.
3) If connections are OK, check the following points.
• Resistance of “A1” circuit: less than 1 Ω
• Resistance between “A1” circuit and ground: infinity
• Resistance between “A1” circuit terminal and other
terminal at “C15” connector: infinity
• Voltage of “A1” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

DTC P1886
AENJCA0A5404037
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P1886: Dual Port RAM Check TCM incorporated in auto gear shift actuator unit
TCM internal failure (data integrity error)
(1 D/C detection logic)

DTC Confirmation Procedure

1) Set ignition “ON”.

DTC Troubleshooting
Step Action Yes No
1 Was “Auto Gear Shift System Check” performed? Go to Step 2. Go to “Auto Gear Shift
System Check” (Page
5D-18).
2 DTC check Replace TCM and End.
1) Perform the DTC confirmation procedure recheck DTC. “TCM
Removal and
2) Check DTC. (Page 5D-21)
Installation” (Page 5D-
Is DTC P1886 detected? 113)

DTC P188A / P188B / P188F

AENJCA0A5404038
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P188A: Transmission Range Sensor Circuit Fault Type “A” • Shift selector and/or its ground circuit
None of shift selector position sensor signals is inputted. • TCM incorporated in auto gear shift actuator unit
(1 D/C detection logic)
P188B: Transmission Range Sensor Circuit Fault Type “B”
None of M1, M2, M3, M4 and M5 sensor signals is inputted.
(1 D/C detection logic)
P188F: Transmission Range Sensor Circuit Fault Type “F”
Failure of shift selector position sensor signals except P188A,
P188B, P188C, P188D and P188E
(1 D/C detection logic)
 Automated Manual Transaxle: 5D-72

Circuit Diagram

+BB
A1
3 1
2
B1
WHT
BLK C15-11
D1
4 LT BLU C15-22
D2
5 LT GRN C15-20
D3
6 BLU C15-18
D4
7 PPL C15-16
D5
8 WHT C15-14

E1
9 RED C15-13
E2
10 GRN C15-9
E3
11 BRN C15-17
C1

GRY C15-4

C2
[A] C15

10 9 8 7 6 5 4 3 2 1

23 22 21 20 19 18 17 16 15 14 13 12 11 [a]

28 27 26 25 24

IJCA0A540023-01

[A]: TCM connector (View: [a]) D4: Lever position sensor M4 signal circuit 4. Hall sensor M1
A1: Shift selector power supply circuit D5: Lever position sensor M5 signal circuit 5. Hall sensor M2
B1: Shift selector drive circuit E1: Lever position sensor H1 signal circuit 6. Hall sensor M3
C1: Shift selector ground circuit 1 E2: Lever position sensor H2 signal circuit 7. Hall sensor M4
C2: Shift selector ground circuit 2 E3: Lever position sensor H3 signal circuit 8. Hall sensor M5
D1: Lever position sensor M1 signal circuit 1. TCM 9. Hall sensor H1
D2: Lever position sensor M2 signal circuit 2. Shift selector 10. Hall sensor H2
D3: Lever position sensor M3 signal circuit 3. “AMT2” fuse 11. Hall sensor H3

DTC Confirmation Procedure

NOTE
Check that the following condition is met in this procedure.
• 11 V < Battery voltage < 15 V

1) Set ignition “ON”.

2) Select shift selector to R, N, D, M, + and – range.
5D-73 Automated Manual Transaxle:

DTC Troubleshooting
Step Action Yes No
1 Was “Auto Gear Shift System Check” performed? Go to Step 2. Go to “Auto Gear Shift
System Check” (Page
5D-18).
2 Shift selector ground circuit check Go to Step 3. Repair or replace
1) With ignition “OFF”, disconnect “C15” connector from defective wire harness.
TCM and shift selector connector.
2) Check for proper terminal connection to “C15” connector
and shift selector connector.
3) If connections are OK, check the following points.
• Resistance of “C1” and “C2” circuits: less than 1 Ω
• Resistance between each of “C1” and “C2” circuits
and ground: infinity
• Resistance between “C1” circuit terminal and other
terminal at shift selector connector: infinity
• Resistance between “C2” circuit terminal and other
terminal at shift selector connector: infinity
• Voltage of “C1” and “C2” circuits: approx. 0 V (When
ignition is “ON”)

Is check result OK?

3 Shift selector check Replace TCM and Replace shift selector.
1) Check shift selector. (Page 5D-103) recheck DTC. “TCM (Page 5D-101)
Removal and
Is check result OK? Installation” (Page 5D-
113)
 Automated Manual Transaxle: 5D-74

DTC P188C
AENJCA0A5404039
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P188C: Transmission Range Sensor Circuit Fault Type “C” • Shift selector and/or its signal circuit
One of M1, M2, H1, H2 or H3 sensor signals is not inputted or • TCM incorporated in auto gear shift actuator unit
abnormal.
(1 D/C detection logic)

Circuit Diagram

+BB
A1
3 1
2
B1
WHT
BLK C15-11
D1
4 LT BLU C15-22
D2
5 LT GRN C15-20
D3
6 BLU C15-18
D4
7 PPL C15-16
D5
8 WHT C15-14

E1
9 RED C15-13
E2
10 GRN C15-9
E3
11 BRN C15-17
C1

GRY C15-4

C2
[A] C15

10 9 8 7 6 5 4 3 2 1

23 22 21 20 19 18 17 16 15 14 13 12 11 [a]

28 27 26 25 24

IJCA0A540023-01

[A]: TCM connector (View: [a]) D4: Lever position sensor M4 signal circuit 4. Hall sensor M1
A1: Shift selector power supply circuit D5: Lever position sensor M5 signal circuit 5. Hall sensor M2
B1: Shift selector drive circuit E1: Lever position sensor H1 signal circuit 6. Hall sensor M3
C1: Shift selector ground circuit 1 E2: Lever position sensor H2 signal circuit 7. Hall sensor M4
C2: Shift selector ground circuit 2 E3: Lever position sensor H3 signal circuit 8. Hall sensor M5
D1: Lever position sensor M1 signal circuit 1. TCM 9. Hall sensor H1
D2: Lever position sensor M2 signal circuit 2. Shift selector 10. Hall sensor H2
D3: Lever position sensor M3 signal circuit 3. “AMT2” fuse 11. Hall sensor H3

DTC Confirmation Procedure

NOTE
Check that the following condition is met in this procedure.
• 11 V < Battery voltage < 15 V

1) Set ignition “ON”.

2) Select shift selector to R, N, D, M, + and – range.
5D-75 Automated Manual Transaxle:

DTC Troubleshooting
Step Action Yes No
1 Was “Auto Gear Shift System Check” performed? Go to Step 2. Go to “Auto Gear Shift
System Check” (Page
5D-18).
2 Lever position sensor signal circuit check Go to Step 3. Repair or replace
1) With ignition “OFF”, disconnect “C15” connector from defective wire harness.
TCM and shift selector connector.
2) Check for proper terminal connection to “C15” connector
and shift selector connector.
3) If connections are OK, check the following points.
• Resistance of “D1”, “D2”, “E1”, “E2” and “E3” circuits:
less than 1 Ω
• Resistance between each of “D1”, “D2”, “E1”, “E2”
and “E3” circuits and ground: infinity
• Resistance between “D1” circuit terminal and other
terminal at shift selector connector: infinity
• Resistance between “D2” circuit terminal and other
terminal at shift selector connector: infinity
• Resistance between “E1” circuit terminal and other
terminal at shift selector connector: infinity
• Resistance between “E2” circuit terminal and other
terminal at shift selector connector: infinity
• Resistance between “E3” circuit terminal and other
terminal at shift selector connector: infinity
• Voltage of “D1”, “D2”, “E1”, “E2” and “E3” circuits:
approx. 0 V (When ignition is “ON”)

Is check result OK?

3 Shift selector check Replace TCM and Replace shift selector.
1) Check shift selector. (Page 5D-103) recheck DTC. “TCM (Page 5D-101)
Removal and
Is check result OK? Installation” (Page 5D-
113)
 Automated Manual Transaxle: 5D-76

DTC P188D / P188E

AENJCA0A5404040
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P188D: Transmission Range Sensor Circuit Fault Type “D” • Shift selector and/or its signal circuit
M3, M4 and M5 shift selector position sensor signals are not • TCM incorporated in auto gear shift actuator unit
inputted.
(1 D/C detection logic)
P188E: Transmission Range Sensor Circuit Fault Type “E”
One of M3, M4, M5 or H2 sensor signals is not inputted or
abnormal.
(1 D/C detection logic)

Circuit Diagram

+BB
A1
3 1
2
B1
WHT
BLK C15-11
D1
4 LT BLU C15-22
D2
5 LT GRN C15-20
D3
6 BLU C15-18
D4
7 PPL C15-16
D5
8 WHT C15-14

E1
9 RED C15-13
E2
10 GRN C15-9
E3
11 BRN C15-17
C1

GRY C15-4

C2
[A] C15

10 9 8 7 6 5 4 3 2 1

23 22 21 20 19 18 17 16 15 14 13 12 11 [a]

28 27 26 25 24

IJCA0A540023-01

[A]: TCM connector (View: [a]) D4: Lever position sensor M4 signal circuit 4. Hall sensor M1
A1: Shift selector power supply circuit D5: Lever position sensor M5 signal circuit 5. Hall sensor M2
B1: Shift selector drive circuit E1: Lever position sensor H1 signal circuit 6. Hall sensor M3
C1: Shift selector ground circuit 1 E2: Lever position sensor H2 signal circuit 7. Hall sensor M4
C2: Shift selector ground circuit 2 E3: Lever position sensor H3 signal circuit 8. Hall sensor M5
D1: Lever position sensor M1 signal circuit 1. TCM 9. Hall sensor H1
D2: Lever position sensor M2 signal circuit 2. Shift selector 10. Hall sensor H2
D3: Lever position sensor M3 signal circuit 3. “AMT2” fuse 11. Hall sensor H3
5D-77 Automated Manual Transaxle:

DTC Confirmation Procedure

NOTE
Check that the following condition is met in this procedure.
• 11 V < Battery voltage < 15 V

1) Set ignition “ON”.

2) Select shift selector to R, N, D, M, + and – range.

DTC Troubleshooting
Step Action Yes No
1 Was “Auto Gear Shift System Check” performed? Go to Step 2. Go to “Auto Gear Shift
System Check” (Page
5D-18).
2 Lever position sensor signal circuit check Go to Step 3. Repair or replace
1) With ignition “OFF”, disconnect “C15” connector from defective wire harness.
TCM and shift selector connector.
2) Check for proper terminal connection to “C15” connector
and shift selector connector.
3) If connections are OK, check the following points.
• Resistance of “D3”, “D4”, “D5” and “E2” circuits: less
than 1 Ω
• Resistance between each of “D3”, “D4”, “D5” and “E2”
circuits and ground: infinity
• Resistance between “D3” circuit terminal and other
terminal at shift selector connector: infinity
• Resistance between “D4” circuit terminal and other
terminal at shift selector connector: infinity
• Resistance between “D5” circuit terminal and other
terminal at shift selector connector: infinity
• Resistance between “E2” circuit terminal and other
terminal at shift selector connector: infinity
• Voltage of “D3”, “D4”, “D5” and “E2” circuits: approx. 0
V (When ignition is “ON”)

Is check result OK?

3 Shift selector check Replace TCM and Replace shift selector.
1) Check shift selector. (Page 5D-103) recheck DTC. “TCM (Page 5D-101)
Removal and
Is check result OK? Installation” (Page 5D-
113)
 Automated Manual Transaxle: 5D-78

DTC P1902
AENJCA0A5404041
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P1902: Transmission Range Sensor Supply Circuit • Shift selector power supply circuit and/or drive circuit
Request to shift selector power supply voltage and • Shift selector
feedback signal disagree.
• TCM incorporated in auto gear shift actuator unit
(1 D/C detection logic)
• “AMT2” fuse

Circuit Diagram

+BB
A1
3 1
2
B1
WHT
BLK C15-11
D1
4 LT BLU C15-22
D2
5 LT GRN C15-20
D3
6 BLU C15-18
D4
7 PPL C15-16
D5
8 WHT C15-14

E1
9 RED C15-13
E2
10 GRN C15-9
E3
11 BRN C15-17
C1

GRY C15-4

C2
[A] C15

10 9 8 7 6 5 4 3 2 1

23 22 21 20 19 18 17 16 15 14 13 12 11 [a]

28 27 26 25 24

IJCA0A540023-01

[A]: TCM connector (View: [a]) D4: Lever position sensor M4 signal circuit 4. Hall sensor M1
A1: Shift selector power supply circuit D5: Lever position sensor M5 signal circuit 5. Hall sensor M2
B1: Shift selector drive circuit E1: Lever position sensor H1 signal circuit 6. Hall sensor M3
C1: Shift selector ground circuit 1 E2: Lever position sensor H2 signal circuit 7. Hall sensor M4
C2: Shift selector ground circuit 2 E3: Lever position sensor H3 signal circuit 8. Hall sensor M5
D1: Lever position sensor M1 signal circuit 1. TCM 9. Hall sensor H1
D2: Lever position sensor M2 signal circuit 2. Shift selector 10. Hall sensor H2
D3: Lever position sensor M3 signal circuit 3. “AMT2” fuse 11. Hall sensor H3

DTC Confirmation Procedure

NOTE
Check that the following condition is met in this procedure.
• 11 V < Battery voltage < 15 V

1) Set ignition “ON”.

2) Select shift selector to R, N, D, M, + and – range.
5D-79 Automated Manual Transaxle:

DTC Troubleshooting
Step Action Yes No
1 Was “Auto Gear Shift System Check” performed? Go to Step 2. Go to “Auto Gear Shift
System Check” (Page
5D-18).
2 Shift selector power supply circuit check Go to Step 3. Repair or replace
1) With ignition “OFF”, disconnect shift selector connector. defective wire harness.
2) Check for proper terminal connection to shift selector
connector.
3) If connection is OK, set ignition “ON”.
4) Check that voltage between “A1” and ground is battery
voltage.

Is check result OK?

3 Shift selector drive circuit check Go to Step 4. Repair or replace
1) With ignition “OFF”, disconnect “C15” connector from defective wire harness.
TCM.
2) Check for proper terminal connection to “C15”
connector.
3) If connection is OK, check the following points.
• Resistance of “B1” circuit: less than 1 Ω
• Resistance between “B1” circuit and ground: infinity
• Resistance between “B1” circuit terminal and other
terminal at “C15” connector: infinity
• Voltage of “B1” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

4 Shift selector check Replace TCM and Replace shift selector.
1) Check shift selector. (Page 5D-103) recheck DTC. “TCM (Page 5D-101)
Removal and
Is check result OK? Installation” (Page 5D-
113)

DTC P1903 / P1904

AENJCA0A5404042
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P1903: Clutch Not Opening Before Gear Shifting • Clutch
Clutch is not released before gear shifting. • Clutch rod
(1 D/C detection logic)
• Clutch release system
P1904: Clutch Closing During Engage
Clutch is engaged during gear shifting. • Auto gear shift actuator fluid leakage (auto gear shift
(1 D/C detection logic) actuator unit)
• Auto gear shift actuator unit
• Valve body (auto gear shift actuator unit)
• TCM incorporated in auto gear shift actuator unit
 Automated Manual Transaxle: 5D-80

DTC Confirmation Procedure

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

NOTE
• Limit the driving speed permissible in road conditions and regulations.
• Check that the following condition is met in this procedure.
– DTC P0805 or P1852 is not detected.

1) Start engine.
2) Drive vehicle at more than 40 km/h (25 mile/h) continuously for more than 30 sec.
3) Stop vehicle.
4) Repeat Step 2) – 3) 3 times.

DTC Troubleshooting
Step Action Yes No
1 Was “Auto Gear Shift System Check” performed? Go to Step 2. Go to “Auto Gear Shift
System Check” (Page
5D-18).
2 DTC check Go to troubleshooting Go to Step 3.
1) Perform the DTC confirmation procedure for applicable DTC.
2) Check DTC. (Page 5D-21)

Is DTC(s) P0944, P184A or P185C detected?

3 Clutch rod check Go to Step 4. Repair or replace
1) Check clutch rod for proper installation and operation, defective parts.
and for obstructions within its operating range.

Is check result OK?

4 Clutch check Replace auto gear shift Repair or replace
1) Dismount auto gear shift unit. (Page 5D-117) actuator unit and defective parts.
recheck DTC. (Page
2) Check the following parts.
5D-104)
• Clutch cover and clutch disc: (Page 5D-146)
• Clutch release system: (Page 5D-149)
• Flywheel:
– K10B model: (Page 1D-34)
– K12M model: (Page 1D-109)

Is check result OK?

5D-81 Automated Manual Transaxle:

DTC P1905
AENJCA0A5404043
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P1905: Clutch Control Error • Clutch
If any one of the following conditions is met. • Clutch rod
• Clutch is engaged suddenly. • Clutch release system
• Clutch sticks at disengaged state. • Auto gear shift actuator fluid leakage (auto gear shift
(1 D/C detection logic) actuator unit)
• Valve body (auto gear shift actuator unit)
• TCM incorporated in auto gear shift actuator unit

DTC Confirmation Procedure

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

NOTE
• Limit the driving speed permissible in road conditions and regulations.
• Check that the following condition is met in this procedure.
– DTC P184B, P184C or P1888 is not detected.

1) Start engine.
2) Drive vehicle at more than 20 km/h (12 mile/h) continuously more than 10 sec.
3) Stop vehicle.
4) Repeat Step 2) – 3) 3 times.

DTC Troubleshooting
Step Action Yes No
1 Was “Auto Gear Shift System Check” performed? Go to Step 2. Go to “Auto Gear Shift
System Check” (Page
5D-18).
2 DTC check Go to troubleshooting Go to Step 3.
1) Perform the DTC confirmation procedure for applicable DTC.
2) Check DTC. (Page 5D-21)

Is DTC(s) P0944, P184A or P185C detected?

3 Clutch rod check Go to Step 4. Repair or replace
1) Check clutch rod for proper installation and operation, defective parts.
and for obstructions within its operating range.

Is check result OK?

 Automated Manual Transaxle: 5D-82

Step Action Yes No

4 Clutch check Replace auto gear shift Repair or replace
1) Dismount auto gear shift unit. (Page 5D-117) actuator unit and defective parts.
recheck DTC. (Page
2) Check the following parts.
5D-104)
• Clutch cover and clutch disc: (Page 5D-146)
• Clutch release system: (Page 5D-149)
• Flywheel:
– K10B model: (Page 1D-34)
– K12M model: (Page 1D-109)

Is check result OK?

DTC P1906 / P1907 / P1908 / P190A

AENJCA0A5404044
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P1906: Gear Box Disengage Failed • Gear shift and select shaft assembly
Gear is not disengaged. • Auto gear shift actuator unit
(1 D/C detection logic)
• Auto gear shift transaxle internal parts
P1907: Gear Box Shift Failed
Gear is shifted to unintended position. • TCM incorporated in auto gear shift actuator unit
(1 D/C detection logic) • Clutch disc
P1908: Gear Box Engage Failed • Clutch cover
Gear cannot be engaged. • Flywheel
(1 D/C detection logic)
P190A: Gear Box Shift Locked • Clutch release system
Gear shift is not completed.
(1 D/C detection logic)

DTC Confirmation Procedure

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

P1906 / P1908

NOTE
• Limit the driving speed permissible in road conditions and regulations.
• Check that the following condition is met in this procedure.
– DTC P0914 or P1853 is not detected.

1) Start engine.
2) Drive vehicle in D range and check that shift up functions properly from 1st to 5th.
3) Stop vehicle.
4) Repeat Step 2) – 3) 10 times.
5D-83 Automated Manual Transaxle:

P1907 / P190A

NOTE
• Limit the driving speed permissible in road conditions and regulations.
• Check that the following condition is met in this procedure.
– DTC P0904, P184B, P184C, P184D, P1850, P1851, P1853, P1888 or P1889 is not detected.

1) Start engine.
2) Drive vehicle in D range and check that shift up functions properly from 1st to 5th.
3) Stop vehicle.
4) Repeat Step 2) – 3) 10 times.

DTC Troubleshooting
Step Action Yes No
1 Was “Auto Gear Shift System Check” performed? Go to Step 2. Go to “Auto Gear Shift
System Check” (Page
5D-18).
2 DTC check Go to troubleshooting Go to Step 3.
1) Perform the DTC confirmation procedure for applicable DTC.
2) Check DTC. (Page 5D-21)

Is there any DTC(s) other than P1906, P1907, P1908 or

P190A?
3 Clutch system check Go to Step 4. Replace defective parts.
1) Check clutch disc, clutch cover, flywheel and clutch
release system.

Is check result OK?

4 Auto gear shift unit mechanical parts check Go to Step 4. Repair or replace
1) Dismount auto gear shift unit. (Page 5D-117) defective parts.
2) Check the following parts for proper operation.
• Auto gear shift actuator unit (engage piston and select
piston): (Page 5D-114)
• Gear shift and select shaft assembly: (Page 5D-
114)
• Input shaft (gear and synchronizer sleeve & hub
assembly): (Page 5D-130)
• Countershaft (gear and synchronizer sleeve & hub
assembly): (Page 5D-135)
• Gear shift shaft components: (Page 5D-140)

Is check result OK?

5 Initialization for clutch system Replace auto gear shift End.
1) Remount auto gear shift unit. (Page 5D-117) actuator unit and
recheck DTC. (Page
2) Perform “All Learning Value Initialization” and “Shift
5D-104)
Tower Initialization” under “TCM and Clutch Initialization”
(Page 5D-96).
3) Perform DTC confirmation procedure, after check DTC.
(Page 5D-21)

Is DTC P1906, P1907, P1908 or P190A detected?

 Automated Manual Transaxle: 5D-84

DTC P1909 / P190B

AENJCA0A5404046
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P1909: Gear Box Unintended Gear Disengage • Gear shift and select shaft assembly
Gear is disengaged without request of disengagement. • Auto gear shift actuator unit
(1 D/C detection logic)
• TCM
P190B: Gear Box Unintended Gear Engage
Gear is engaged without gear shift request.
(1 D/C detection logic)

DTC Confirmation Procedure

P1909

NOTE
Check that the following condition is met in this procedure.
• DTC P0914 or P1853 is not detected.

1) Start engine.
2) Select shift selector to D range.
3) Select shift selector to N range.
4) Repeat Step 2) – 3) 4 times.

P190B

NOTE
Check that the following conditions are met in this procedure.
• DTC P0904, P0914 or P1853 is not detected.
• 11 V < Battery voltage < 15 V

1) Set ignition “ON”.

2) Select shift selector to N range.

DTC Troubleshooting
Step Action Yes No
1 Was “Auto Gear Shift System Check” performed? Go to Step 2. Go to “Auto Gear Shift
System Check” (Page
5D-18).
2 DTC check Go to troubleshooting Go to Step 3.
1) Perform the DTC confirmation procedure for applicable DTC.
2) Check DTC. (Page 5D-21)

Is there any DTC(s) other than P1909 or P190B?

3 Gear shift and select shaft assembly check Replace auto gear shift Replace gear shift and
1) Remove auto gear shift actuator unit. (Page 5D-104) actuator unit and select shaft assembly.
recheck DTC. (Page
2) Check gear shift and select shaft assembly. (Page 5D-
5D-104)
114)

Is check result OK?

5D-85 Automated Manual Transaxle:

DTC P190C
AENJCA0A5404047
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P190C: Gear shift Endless • Clutch
Gear shift is not completed within specified time. • Clutch rod
(1 D/C detection logic)
• Clutch release system
• Flywheel
• Gear shift and select shaft assembly
• Auto gear shift actuator unit
• Auto gear shift transaxle internal parts
• TCM

DTC Confirmation Procedure

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

NOTE
Limit the driving speed permissible in road conditions and regulations.

1) Start engine.
2) Drive vehicle in M (manual) mode and check that shift up and shift down function properly from 1st to 5th.
3) Stop vehicle.
4) Repeat Step 1) – 2) 10 times.

DTC Troubleshooting
Step Action Yes No
1 Was “Auto Gear Shift System Check” performed? Go to Step 2. Go to “Auto Gear Shift
System Check” (Page
5D-18).
2 DTC check Go to troubleshooting Go to Step 3.
1) Perform the DTC confirmation procedure for applicable DTC.
2) Check DTC. (Page 5D-21)

Is there any DTC(s) other than P190C?

3 Clutch system check Go to Step 4. Replace defective parts.
1) Check clutch disc, clutch cover, flywheel and clutch
release system.

Is check result OK?

 Automated Manual Transaxle: 5D-86

Step Action Yes No

4 Auto gear shift unit mechanical parts check Replace auto gear shift Replace defective parts.
1) Dismount auto gear shift unit. (Page 5D-117) actuator unit and
recheck DTC. (Page
2) Check the following parts for proper operation.
5D-104)
• Auto gear shift actuator unit (engage piston and select
piston): (Page 5D-114)
• Gear shift and select shaft assembly: (Page 5D-
114)
• Input shaft (gear and synchronizer sleeve & hub
assembly): (Page 5D-130)
• Countershaft (gear and synchronizer sleeve & hub
assembly): (Page 5D-135)
• Gear shift shaft components: (Page 5D-140)

Is check result OK?

DTC P190D
AENJCA0A5404048
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P190D: Clutch Overspeed • Auto gear shift actuator unit
Clutch speed exceeds specified value while gear is engaged. • TCM incorporated in auto gear shift actuator unit
(1 D/C detection logic)

DTC Confirmation Procedure

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

NOTE
• Limit the driving speed permissible in road conditions and regulations.
• Check that the following condition is met in this procedure.
– DTC P0715, P0716 or P1852 is not detected.

1) Start engine and drive vehicle at 40 km/h (25 mile/h) or more.

DTC Troubleshooting
Step Action Yes No
1 Was “Auto Gear Shift System Check” performed? Go to Step 2. Go to “Auto Gear Shift
System Check” (Page
5D-18).
2 DTC check Replace auto gear shift Check for intermittent
1) Perform the DTC confirmation procedure actuator unit and trouble.(Page 00-13)
recheck DTC. (Page
2) Check DTC. (Page 5D-21)
5D-104)
Is there any DTC(s) other than P190D?
5D-87 Automated Manual Transaxle:

DTC P190E
AENJCA0A5404049
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P190E: Pump Overheating • Electric motor
Estimated oil pump temperature exceeds specified • TCM incorporated in auto gear shift actuator unit
value.(1 D/C detection logic)

DTC Confirmation Procedure

1) Set ignition “ON” for 1 min.
2) Select shift selector from N to D range.
3) Select shift selector from D to N range.
4) Repeat Step 2) - 3) more than 50 times.

DTC Troubleshooting
Step Action Yes No
1 Was “Auto Gear Shift System Check” performed? Go to Step 2. Go to “Auto Gear Shift
System Check” (Page
5D-18).
2 DTC check Replace auto gear shift End.
1) Perform the DTC confirmation procedure actuator unit and
recheck DTC. (Page
2) Check DTC. (Page 5D-21)
5D-104)
Is there any DTC(s) other than P190E?

DTC P190F
AENJCA0A5404050
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P190F: Accumulator Failed Auto gear shift actuator unit
Accumulated oil volume exceeds specified limit.
(1 D/C detection logic)

DTC Confirmation Procedure

NOTE
Check that the following condition is met in this procedure.
• 11 V < Battery voltage < 15 V

1) Set ignition “ON” for 1 min.

2) Select shift selector from N to D range.
3) Select shift selector from D to N range.
4) Repeat Step 2)- 3) more than 50 times.

DTC Troubleshooting
Step Action Yes No
1 Was “Auto Gear Shift System Check” performed? Go to Step 2. Go to “Auto Gear Shift
System Check” (Page
5D-18).
2 DTC check Replace auto gear shift End.
1) Perform the DTC confirmation procedure actuator unit and
recheck DTC. (Page
2) Check DTC. (Page 5D-21)
5D-104)
Is there any DTC(s) other than P190F?
 Automated Manual Transaxle: 5D-88

DTC P1980
AENJCA0A5404051
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P1980: System Misuse Excessive gear shift operation (misoperation)
If the following conditions are met.
• The number of gear shift exceeds specified value
during specified period of time.
• Oil pump temperature exceeds specified value.
(1 D/C detection logic but auto gear shift warning light
does not light up)

DTC Confirmation Procedure

1) Start engine.
2) Select shift selector from N to D range.
3) Select shift selector from D to N range.
4) Repeat Step 2) – 3) continuously very fast.

DTC Troubleshooting
Step Action Yes No
1 Was “Auto Gear Shift System Check” performed? Go to Step 2. Go to “Auto Gear Shift
System Check” (Page
5D-18).
2 DTC check Leave vehicle with End.
1) Perform the DTC confirmation procedure engine off and hood
opened to cool oil
2) Check DTC. (Page 5D-21)
pump.
Is DTC P1980 detected?

DTC P1981
AENJCA0A5404052
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P1981: CAN Invalid Data of Engine Torque ECM
Invalid data of engine torque value is inputted.
(1 D/C detection logic but auto gear shift warning light
does not light up)

DTC Confirmation Procedure

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

NOTE
• Limit the driving speed permissible in road conditions and regulations.
• Check that the following conditions are met in this procedure.
– DTC U0073 or U0100 is not detected.
– 11 V < Battery voltage < 15 V

1) Start engine and drive vehicle.

5D-89 Automated Manual Transaxle:

DTC Troubleshooting
Step Action Yes No
1 Was “Auto Gear Shift System Check” performed? Go to Step 2. Go to “Auto Gear Shift
System Check” (Page
5D-18).
2 DTC check Go to troubleshooting Go to Step 3.
for CAN-DTC. (Page
Is there any CAN-DTC detected? 10H-7)
3 DTC check for ECM Go to troubleshooting End.
1) Check DTC in ECM. for applicable DTC.
• K10B model: (Page 1A-22)
• K12M model: (Page 1A-140)

Is there any DTC(s) detected?

DTC P1986 / P1987

AENJCA0A5404061
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P1986: Vehicle Equipment Information Self-Learning Not Completed • CAN communication line
TCM does not complete vehicle equipment information self learning. • Combination meter
(1 D/C detection logic)
• BCM
P1987: Vehicle Equipment Information Not Matched
Vehicle equipment information does not match to vehicle equipment • TCM incorporated in auto gear shift
information self-learning results stored into TCM. actuator unit
(1 D/C detection logic)

DTC Confirmation Procedure

NOTE
Check that the following condition is met in this procedure.
• 11 V < Battery voltage < 15 V
• DTC U0073, U0100, U0140 or U0155 is not detected.

P1986
1) Set ignition “ON” for 1 min.
2) Set ignition “OFF” for 1 min.
3) Repeat Step 1) – 2) 5 times.

P1987
1) Set ignition “ON” for 1 min.

DTC Troubleshooting
Step Action Yes No
1 Was “Auto Gear Shift System Check” performed? Go to Step 2. Go to “Auto Gear Shift
System Check” (Page
5D-18).
2 CAN-DTC check Go to troubleshooting Go to Step 3.
for CAN-DTC. (Page
Is there any CAN-DTC detected? 10H-7)
3 Combination meter and BCM check Replace TCM and Replace combination
recheck DTC. “TCM meter and/or BCM and
Are specified combination meter and BCM installed? Removal and recheck DTC.
Installation” (Page 5D-
113)
 Automated Manual Transaxle: 5D-90

DTC P2712
AENJCA0A5404053
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P2712: Hydraulic Power Unit Leakage • Accumulator (auto gear shift actuator unit)
Oil pressure in the accumulator is lower than the specified value.(1 • TCM incorporated in auto gear shift actuator
D/C detection logic) unit

DTC Confirmation Procedure

1) Set ignition “ON”.

DTC Troubleshooting
Step Action Yes No
1 Was “Auto Gear Shift System Check” performed? Go to Step 2. Go to “Auto Gear Shift
System Check” (Page
5D-18).
2 DTC check Go to troubleshooting Replace auto gear shift
1) Perform the DTC confirmation procedure for applicable DTC. actuator unit and
recheck DTC. (Page
2) Check DTC. (Page 5D-21)
5D-104)
Is there any DTC(s) other than P2712?

DTC P2789
AENJCA0A5404054
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P2789: Clutch “A” Adaptive Learning at Limit • Clutch
If any one of the following conditions is met. • Clutch rod
• Clutch closed position is more than specified value. • Clutch release system
• Clutch closed position is less than specified value. • TCM incorporated in auto gear shift actuator unit
(1 D/C detection logic)

DTC Confirmation Procedure

NOTE
Check that the following condition is met in this procedure.
• DTC P0805, P184B, P184C or P1852 is not detected.

1) Set ignition “ON”.

DTC Troubleshooting
Step Action Yes No
1 Was “Auto Gear Shift System Check” performed? Go to Step 2. Go to “Auto Gear Shift
System Check” (Page
5D-18).
2 DTC check Go to troubleshooting Go to Step 3.
1) Perform the DTC confirmation procedure. for applicable DTC.
2) Check DTC. (Page 5D-21)

Is there any DTC(s) other than P2789?

3 Clutch rod check Go to Step 4. Repair or replace
1) Check clutch rod for proper installation and operation, defective parts.
and for obstructions within its operating range.

Is check result OK?

5D-91 Automated Manual Transaxle:

Step Action Yes No

4 Clutch check Replace auto gear shift Repair or replace
1) Dismount auto gear shift unit. (Page 5D-117) actuator unit and defective parts.
recheck DTC. (Page
2) Check the following parts.
5D-104)
• Clutch cover and clutch disc: (Page 5D-146)
• Clutch release system: (Page 5D-149)
• Flywheel:
– K10B model: (Page 1D-34)
– K12M model: (Page 1D-109)

Is check result OK?

DTC U0073
AENJCA0A5404055
Refer to “Troubleshooting for Communication Bus Off” in Section 10H (Page 10H-15).

DTC U0100
AENJCA0A5404056
Refer to “Troubleshooting for Lost Communication” in Section 10H (Page 10H-9).

DTC U0121
AENJCA0A5404057
Refer to “Troubleshooting for Lost Communication” in Section 10H (Page 10H-9).

DTC U0140
AENJCA0A5404058
Refer to “Troubleshooting for Lost Communication” in Section 10H (Page 10H-9).

DTC U0155
AENJCA0A5404062
Refer to “Troubleshooting for Lost Communication” in Section 10H (Page 10H-9).

TCM Power Supply and Ground Circuit Check

AENJCA0A5404059
Circuit Diagram

A1 2
C15-24 WHT
A2 3
C15-26 WHT
A3
[A]
4
C15-28 BRN 5

6 [B]
7

[C] C15

10 9 8 7 6 5 4 3 2 1

23 22 21 20 19 18 17 16 15 14 13 12 11 [a]

28 27 26 25 24

IJCA0A540016-01

[A]: Without keyless entry system A3: Ignition power supply circuit 5. To ignition switch
[B]: With keyless entry system 1. TCM 6. “IG1 SIG2” fuse
[C]: TCM connector (View: [a]) 2. “AMT PUMP” fuse 7. To IG11 relay
A1: Electric motor power supply circuit 3. “AMT1” fuse
A2: TCM power supply circuit 4. “IG1 SIG” fuse
 Automated Manual Transaxle: 5D-92

Troubleshooting
Step Action Yes No
1 TCM power supply circuit check Go to Step 2. Check that “AMT1” fuse
1) With ignition “OFF”, disconnect “C15” connector from has not blown. If check
TCM. result is OK, repair or
replace defective wire
2) Check that voltage between “A2” and ground is battery
harness.
voltage.

Is check result OK?

2 Electric motor power supply circuit check Go to Step 3. Check that “AMT
1) Check that voltage between “A1” and ground is battery PUMP” fuse has not
voltage. blown. If check result is
OK, repair or replace
Is check result OK? defective wire harness.
3 Ignition power supply circuit check Go to Step 4. Check that “IG1 SIG”
1) Set ignition “ON”. fuse (without keyless
entry system) or “IG1
2) Check that voltage between “A3” and ground is battery
SIG2” (with keyless
voltage.
entry system) has not
Is check result OK? blown. If check result is
OK, repair or replace
defective wire harness.
4 Auto gear shift actuator unit check TCM power supply and Tighten auto gear shift
1) Check auto gear shift actuator unit bolts for ground circuits are in actuator unit bolt to
looseness.(Page 5D-104) good condition. specified torque.
(Page 5D-104)
Is check result OK?

Inspection of TCM and Its Circuits

AENJCA0A5404060
TCM and its circuits can be checked at TCM wiring connectors by measuring voltage and pulse signal.

NOTICE
If you connect a voltmeter or an ohmmeter directly to the TCM terminals with the TCM connectors
disconnected, you can damage the TCM.
Never connect a voltmeter or an ohmmeter directly to any terminal on the TCM with the TCM
connectors disconnected.

Voltage and Signal Check

1) Check voltage and/or pulse signal at each terminal of connectors using voltmeter (1) and oscilloscope (2).
5D-93 Automated Manual Transaxle:

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 using voltmeter because it is pulse signal. Check it
using oscilloscope.

[A] C15

10 9 8 7 6 5 4 3 2 1

23 22 21 20 19 18 17 16 15 14 13 12 11 [a]

28 27 26 25 24

1 2

IDL70A540150-01

[A]: TCM connector “C15” (View: [A])

“C15” connector
Terminal Normal
Wire color Circuit Condition
No. voltage
10 to 14 V Brake pedal: Released
C15-1 LT GRN Brake switch signal circuit (normal close)
Approx. 0 V Brake pedal: Fully depressed
Brake light switch signal circuit (normal Approx. 0 V Brake pedal: Released
C15-2 GRN
open) 10 to 14 V Brake pedal: Fully depressed
Refer to reference waveform.
C15-3* BEG VSS signal circuit
“VSS signal” (Page 5D-95)
C15-4 GRY Shift selector ground circuit Approx. 0 V Constantly
C15-5 — — — —
C15-6 — — — —
Refer to reference waveform.
C15-7* RED CAN (high) communication circuit
“CAN communication signal” (Page 5D-95)
C15-8 — — — —
Ignition: “ON”
Approx. 0 V
Shift selector: N range
C15-9 GRN Lever position sensor H2 signal circuit Ignition: “ON”
10 to 14 V Shift selector: Other than N
range
Refer to reference waveform.
C15-10* WHT CAN (low) communication circuit
“CAN communication signal” (Page 5D-95)
Approx. 0 V Ignition: “ON”
C15-11 BLK Shift selector drive circuit
8V Other than above condition
C15-12 — — — —
Ignition: “ON”
Approx. 0 V
Shift selector: R range
C15-13 RED Lever position sensor H1 signal circuit Ignition: “ON”
10 to 14 V Shift selector: Other than R
range
Ignition: “ON”
10 to 14 V
C15-14 WHT Lever position sensor M5 signal circuit Shift selector: – range
Approx. 0 V Other than above condition
C15-15 — — — —
Ignition: “ON”
10 to 14 V
C15-16 PPL Lever position sensor M4 signal circuit Shift selector: + range
Approx. 0 V Other than above condition
 Automated Manual Transaxle: 5D-94

Terminal Normal
Wire color Circuit Condition
No. voltage
Ignition: “ON”
Approx. 0 V Shift selector: D, M, + or –
range
C15-17 BRN Lever position sensor H3 signal circuit
Ignition: “ON”
10 to 14 V Shift selector: Other than D, M,
+ or – range
Ignition: “ON”
Approx. 0 V
C15-18 BLU Lever position sensor M3 signal circuit Shift selector: M, + or – range
10 to 14 V Other than above condition
10 to 14 V Ignition: “START”
Approx. 0 V Other than above condition
C15-19 RED ST signal circuit Refer to reference waveform.
“Starting motor control relay signal” (Page 5D-
95)
Ignition: “ON”
10 to 14 V
C15-20 LT GRN Lever position sensor M2 signal circuit Shift selector: R range
Approx. 0 V Other than above condition
Approx. 0 V Ignition: “START”
Refer to reference waveform.
C15-21 GRN Starting motor control relay drive circuit
“Starting motor control relay signal” (Page 5D-
95)
Ignition: “ON”
10 to 14 V Shift selector: D, M, + or –
C15-22 LT BLU Lever position sensor M1 signal circuit
range
Approx. 0 V Other than above condition
10 to 14 V Driver side front door: Close
C15-23 BRN Driver side front door switch signal circuit
Approx. 0 V Driver side front door: Open
C15-24 WHT Electric motor power supply circuit 10 to 14 V Constantly
Ignition: “ON”
10 to 14 V Brake pedal: Depressed
C15-25 PPL Back up light relay drive circuit
Shift selector: R range
Approx. 0 V Other than above condition
C15-26 WHT TCM power supply circuit 10 to 14 V Constantly
C15-27 — — — —
10 to 14 V Ignition: “ON”
C15-28 BRN Ignition ON signal circuit
Approx. 0 V Other than above condition

Reference Waveform NOTE

Oscilloscope display
• Display includes the following types of
Shown below is typical waveform display provided using
data:
oscilloscope.

ICP70A110009-01

[A]: Waveform of channel 1 [C]: VOLT/DIV of each channel

[B]: Ground level of each channel [D]: TIME/DIV
5D-95 Automated Manual Transaxle:

• Waveform varies depending on ST signal (2)

measurement condition and vehicle spec. Channel Probe Terminal No.
+ C15-19
2
VSS signal – Ground
Channel Probe Terminal No.
Measurement condition
+ C15-3
1 • Ignition: → “ON” → “START”
– Ground

Measurement condition
Engine: Drive vehicle at 20 km/h (12 mile/h)

IJCA0A540024-01

3. Ignition: “ON”
4. Ignition: “START”
5. Starting motor control relay: “ON”
IDL70A540151-01

CAN communication signal

CAN (high) communication signal (1)

Channel Probe Terminal No.
+ C15-7
1
– Ground

CAN (low) communication signal (2)

Channel Probe Terminal No.
+ C15-10
2
– Ground

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

I8C50B111041-01

Starting motor control relay signal

Starting motor control relay drive signal (1)

Channel Probe Terminal No.
+ C15-21
1
– Ground
 Automated Manual Transaxle: 5D-96

Repair Instructions
TCM and Clutch Initialization e) Select “Show Auto Gear Shift Learning Result”
AENJCA0A5406001 function under “Utility” mode on Suzuki scan tool.
1) Select learning procedure in the following table.
f) Check that displayed values for following items
Replacement / Reinstallation Initialization on SUZUKI scan tool are within the specified
• Auto gear shift transaxle or range. Perform the following procedure if any
auto gear shift transaxle value is out of the specified range.
parts
Scan tool data Specified value
• Auto gear shift actuator unit All Learning Value Select stroke Hi-Lo More than 340
or Auto gear shift actuator Initialization Select stroke Hi-Mid More than 145
parts Select stroke Mid-Lo More than 170
• Dismount auto gear shift Shift stroke 1st-2nd More than 450
transaxle Shift stroke 3rd-4th More than 450
Gear shift and select shaft Shift stroke 5th-Reverse More than 450
Shift Tower Initialization
assembly Shift alignment 1st-3rd Less than 20
• Clutch Shift alignment 3th-5rd Less than 20
• Engine parts (after Clutch Assembly Shift alignment 1st-5th Less than 20
separation of auto gear shift Initialization Shift alignment 2nd-4th Less than 20
transaxle from engine) Shift alignment 4th-Reverse Less than 20
New auto gear shift transaxle Shift alignment 2nd-Reverse Less than 20
Clutch-contact-point
and new auto gear shift
learning Initialization i) Set ignition “OFF” and release parking brake.
actuator unit
ii) Move vehicle to rotate tires a half of a turn
2) Apply parking brake and select shift selector to N forward or backward with tires in contact with
range. ground.
3) Perform selected initialization procedure as follows. iii) Repeat Step c) to f).
All Learning Value Initialization: g) With engine idling, check that combination meter
a) Set ignition “OFF”. (information display) shows N, 1st or R
b) Connect SUZUKI scan tool to DLC (1). according to shift selector operation from N to D
or R, and check parameter of “Gear Position”
Special tool displayed on SUZUKI scan tool also shows the
(A): SUZUKI scan tool (SUZUKI SDT-II) same indication. (Page 5D-35)
Shift Tower Initialization:
a) Set ignition “OFF”.
b) Connect SUZUKI scan tool to DLC (1).
Special tool
(A): SUZUKI scan tool (SUZUKI SDT-II)
1

(A)
IJCA0A181004-01

c) Set ignition “ON”.

d) Select “All Learning Value Initialization” function
under “Utility” mode on SUZUKI scan tool, and
follow the instructions displayed on SUZUKI
(A)
scan tool.
IJCA0A181004-01
5D-97 Automated Manual Transaxle:

c) Set ignition “ON”.

d) Select “Shift Tower Initialization” function under
“Utility” mode on SUZUKI scan tool, and follow
the instructions displayed on SUZUKI scan tool.
e) Select “Show Auto Gear Shift Learning Result”
function under “Utility” mode on Suzuki scan tool. 1
f) Check that displayed values for following items
on SUZUKI scan tool are within the specified
range. Perform the following procedure if any
value is out of the specified range.
Scan tool data Specified value
Select stroke Hi-Lo More than 340
Select stroke Hi-Mid More than 145
Select stroke Mid-Lo More than 170
Shift stroke 1st-2nd More than 450
Shift stroke 3rd-4th More than 450
Shift stroke 5th-Reverse More than 450
Shift alignment 1st-3rd Less than 20 (A)
Shift alignment 3th-5rd Less than 20 IJCA0A181004-01
Shift alignment 1st-5th Less than 20 c) Set ignition “ON”.
Shift alignment 2nd-4th Less than 20
d) Select “Clutch Assembly Initialization” function
Shift alignment 4th-Reverse Less than 20
under “Utility” mode on SUZUKI scan tool, and
Shift alignment 2nd-Reverse Less than 20
follow the instructions displayed on SUZUKI
i) Set ignition “OFF” and release parking brake. scan tool.
ii) Move vehicle to rotate tires a half of a turn e) Check that DTC P080A, P185A or P185B is not
forward or backward with tires in contact with detected. (Page 5D-21)
ground. f) Check that release arm moves according to shift
iii) Repeat Step c) to f). selector operation of N to D or D to N, and check
parameter of “Clutch Control Status” displayed
g) With engine idling, check that combination meter on SUZUKI scan tool as well. (Page 5D-35)
(information display) shows N, 1st or R
according to shift selector operation from N to D g) Check that combination meter (information
or R, and check parameter of “Gear Position” display) shows N, 1st or R according to shift
displayed on SUZUKI scan tool also shows the selector operation of N to D or R, and check
same indication. (Page 5D-35) parameter of “Gear Position” displayed on
Clutch Assembly Initialization: SUZUKI scan tool as well. (Page 5D-35)
Clutch-contact-point Learning Initialization:
a) Set ignition “OFF”.
a) Start engine and run it for 20 sec.
b) Connect SUZUKI scan tool to DLC (1).
b) Set ignition “OFF” for 5 sec.
Special tool c) Set ignition “ON”.
(A): SUZUKI scan tool (SUZUKI SDT-II)
d) Check that DTC P080A or P185B is not
detected. (Page 5D-21)
e) Check that release arm moves according to shift
selector operation of N to D or D to N, and check
parameter of “Clutch Control Status” displayed
on SUZUKI scan tool as well. (Page 5D-35)
f) Check that combination meter (information
display) shows N, 1st or R according to shift
selector operation of N to D or R, and check
parameter of “Gear Position” displayed on
SUZUKI scan tool as well. (Page 5D-35)
 Automated Manual Transaxle: 5D-98

Auto Gear Shift Actuator Oil Level Check Auto Gear Shift Transaxle Oil Level Check
AENJCA0A5406037 AENJCA0A5406002
1) Set ignition “OFF”. 1) Hoist vehicle and remove left side splash cover.
2) Connect SUZUKI scan tool to DLC (1). 2) Check auto gear shift transaxle for oil leakage.
Repair leaky point, if any.
Special tool
(A): SUZUKI scan tool (Suzuki SDT-II) 3) Remove oil level / filler plug (1). Check oil
contamination and check that oil level (2) reaches
lower end of oil level / filler plug hole using special
tool.
If oil is excessively dirty or insufficient, change oil or
add specified oil up to plug hole. (Page 5D-99)
Special tool
1
(A): 09922M36310
4) Apply sealant to thread of level / filler plug, and then
tighten it to specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Oil level / filler plug (a): 21 N·m (2.1 kgf-m, 15.5
lbf-ft)

(A)
IJCA0A181004-01

3) Set ignition “ON”.

4) Select “Oil Discharge” function under “Utility” mode
on SUZUKI scan tool, and follow the instructions
displayed on SUZUKI scan tool. 1, (a), “A”
5) After completing “Oil Discharge”, set ignition “OFF”
and disconnect SUZUKI scan tool from DLC.
6) Check that auto gear shift actuator oil level in
reservoir (1) is between “MAX” mark (2) and “MIN”
IJCA0A540025-02
mark (3) on reservoir.
If the level is out of the specified range, replace auto
gear shift actuator unit.

1 2

2 (A)

IJW60P321037-01

5) Check auto gear shift transaxle oil for leakage.

3 6) Install left side splash cover.

IJCA0A540096-01
5D-99 Automated Manual Transaxle:

Auto Gear Shift Transaxle Oil Change Differential Side Oil Seal Replacement
AENJCA0A5406003 AENJCA0A5406004
1) Before changing oil, stop engine and hoist vehicle 1) Hoist vehicle and drain auto gear shift transaxle oil.
horizontally. (Page 5D-99)
2) Hoist vehicle and remove left side splash cover. 2) Remove front drive shaft assembly. (Page 3A-3)
3) Check oil leakage. If leakage exists, correct it. 3) Remove oil seal (1) using special tool.
4) Remove oil level / filler plug (1). Special tool
5) Remove drain plug (2) and drain oil. (A): 09913M50121
6) Apply sealant to thread of drain plug, and tighten it to
specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Oil drain plug (a): 21 N·m (2.1 kgf-m, 15.5 lbf-ft)
7) Add new specified oil until oil level reaches lower
end of oil filler plug hole. 1

Auto gear shift transaxle oil capacity

(A)
Reference: 1.5 liters (3.17/2.64 US/Imp. pt)
Auto gear shift transaxle oil specification
: SUZUKI GEAR OIL 75W 99000–22B27–036 IDL70A540003-01

Viscosity chart 4) Install new oil seal (1) to specified position using
special tool.
75W NOTE
C - 30 - 20 - 10 0 10 20 30 40
• When installing oil seal, face its spring
F - 22 -4 14 32 50 68 86 104
[a]
side inward.
IELA0B540015-02 • Check that oil seal is installed horizontally
[a]: Temperature to surface of case after installing oil seal.

8) Check oil level. (Page 5D-98) Special tool

9) Apply sealant to thread of oil level / filler plug, and (A): 09944M88220
then tighten it to specified torque. (B): 09924M74510

“A”: Sealant 99000–31260 (SUZUKI Bond Distance from case end face to left oil seal
No.1217G) “a”: 1.0 to 2.0 (0.04 to 0.07 in.)

Tightening torque Distance from case end face to right oil seal
Oil level / filler plug (b): 21 N·m (2.1 kgf-m, 15.5 “b”: –0.5 to 0.5 mm (–0.19 to 0.19 in.)
lbf-ft) 5) Apply grease to oil seal lip. Then, check drive shaft
where oil seal contacts and check its smoothness.
“A”: Grease 99000–25011 (SUZUKI Super
Grease A)

1, (b), “A”

2, (a), “A”

IJCA0A540026-01

10) Check auto gear shift for leakage.

11) Install left side splash cover.
 Automated Manual Transaxle: 5D-100

6) Install front drive shafts. (Page 3A-3)

1, “A”
7) Add auto gear shift transaxle oil. (Page 5D-99)

(B) (B)
(A) (A)

“b”
“a”
IJCA0A521010-01

Shift Selector Components

AENJCA0A5406005

9 5

8
7
6

10 (a)

IJCA0A540027-01

1. Shift selector knob 5. Lower select indicator 9. Shift selector

2. Upper select indicator 6. Shift selector illumination light assembly 10. Shift selector nut
3. Upper slide cover 7. Bulb : 13 Nm (1.3 kgf-m, 9.5 lbf-ft)
4. Lower slide cover 8. Bulb filter
5D-101 Automated Manual Transaxle:

Shift Selector Removal and Installation

AENJCA0A5406006
Removal
1) Shift selector to N range.
2) Disconnect negative (–) cable at battery.
3) Remove instrument panel lower cover. (Page 9C- 1, (a)
25).
4) Disconnect connectors (1) from shift selector and
wiring harness clamps (2).

1, (a)
IJCA0A540030-01

Shift Selector Disassembly and Reassembly

AENJCA0A5406007
Disassembly
1) Remove shift selector knob (1) by rotating it
1 counterclockwise.
2) Releasing claws (2), remove upper select indicator
(3).

2
3

2
IJCA0A540028-01

5) Remove shift selector nuts (1) and shift selector (2).

2

1
2

IJCA0A540031-01

3) Remove upper slide cover (1) and lower slide cover

(2).

IJCA0A540029-01

Installation
Reverse removal procedure noting the following point.
• Tighten shift selector nuts (1) to specified torque.
Tightening torque
Shift selector nut (a): 13 N·m (1.3 kgf-m, 9.5 lbf-ft)
 Automated Manual Transaxle: 5D-102

Installation
1
1) Install lower select indicator (1) and illumination light
2
assembly (2) as shown in figure.

IJCA0A540035-01

2) Install lower slide cover (2) to upper slide cover (1),

and then install them to shift selector (3).
IJCA0A540032-01

4) Disconnect illumination light socket (1) from lower 1

select indicator and remove illumination light
assembly (2). 2

1
3

2 [A]

[A]
IJCA0A540033-01

5) Releasing claws (1), remove lower select indicator

(2).

IJCA0A540036-01

[A]: Front side

1

2 3) Install upper select indicator (1).

4) Install shift selector knob (2) onto shift selector by
1
rotating it clockwise and set it in straight ahead
position.

IJCA0A540034-01
5D-103 Automated Manual Transaxle:

NOTICE Terminal No. (sensor)

Shift
Rotating shift selector knob beyond specified 1 2 6
position
range may damage the knob. (H1) (H2) (H3)
Do not rotate the knob excessively. – H H L

NOTE L: 0 V
H: 10 – 14 V
The torque value is for reference.

Tightening torque
Shift selector knob: 6.0 N·m (0.61 kgf-m, 4.5 lbf-
ft)

2
5 4 3 2 1
16 15 14 13 12 11 10 9 8 7 6

- +

IJCA0A540038-01

IJCA0A540037-01 Illumination Light

1) Remove instrument panel lower cover. (Page 9C-
Shift Selector Inspection 25)
AENJCA0A5406008
Position Sensor 2) Disconnect shift selector illumination light connector.
1) Remove instrument panel lower cover. (Page 9C- 3) Check continuity between terminal “1” and “2” of shift
25) selector illumination light connector.
If check result is not as specified, replace defective
2) Disconnect shift selector position sensor connector. part.
3) Check voltage between terminal “10” or “11” of shift
selector connector and each terminal of each shift
position, referring to the following table.
If check result is not as specified, replace shift
selector.
Terminal No. (sensor)
Shift
13 12 9 8 7
position
(M1) (M2) (M3) (M4) (M5)
R L H H L L
N L L H L L
D H L H L L 2 1
M H L L L L
+ H L L L H
– H L L H L

Terminal No. (sensor)

Shift
1 2 6
position
(H1) (H2) (H3)
R L H H
N H L H IJCA0A540039-01

D H H L
M H H L
+ H H L
 Automated Manual Transaxle: 5D-104

Auto Gear Shift Actuator Unit Removal and NOTICE

Installation
AENJCA0A5406009
NOTICE
Performing the following prohibited
operations will affect the original
performance of auto gear shift actuator unit.
• Do not disassemble the auto gear shift
actuator unit.
• Do not remove the motor.
• Regarding auto gear shift actuator unit
removal and installation, check specified
torque and do not use impact tool.
• Use care not to allow dust to enter auto
gear shift actuator unit.
• Do not place auto gear shift actuator unit
on its side or upside down.
• Do not give an impact to hydraulic unit.
Removal
1) Set ignition “OFF”.
2) Connect SUZUKI scan tool to DLC (1).
Special tool
(A): SUZUKI scan tool (SUZUKI SDT-II)
Even though pressurized oil cannot be
discharged due to malfunction of TCM or oil
pump and so on, auto gear shift actuator unit
can be removed from gear shift and select
shaft assembly. But failure to take the
following precautions can cause damage to
each part.
• If select piston of auto gear shift actuator
unit came off, replace auto gear shift
actuator unit with new one.
• If clutch cylinder gets stuck and clutch rod
cannot be removed from clutch release
fork, loosen bolts on mating face between
engine and transmission and make space
of clutch release fork to remove it.
• If auto gear shift actuator unit is removed
from gear shift and select shaft assembly
keeps gears engaged, move engage lever
on the top of gear shift and select shaft
assembly to N position before installing
auto gear shift actuator unit to gear shift
and select shaft assembly.
NOTE
Do not close driver side front door without
disconnecting negative (–) cable at battery
after completing “Oil Discharge”.

5) After completing “Oil Discharge”, set ignition “OFF”

and disconnect SUZUKI scan tool from DLC.
1
6) Select shift selector to N range.
7) Remove battery and battery tray.
• K10B model: (Page 1J-6)
• K12M model: (Page 1J-24)

(A)
IJCA0A181004-01

3) Set ignition “ON”.

4) Select “Oil Discharge” function under “Utility” mode
on SUZUKI scan tool, and follow the instructions
displayed on SUZUKI scan tool.
5D-105 Automated Manual Transaxle:

8) Disconnect harness clamp (1) from harness bracket 10) Disconnect auto gear shift actuator unit connector
and remove harness bracket bolts (2). turning the lock lever (2) counter clockwise while
releasing lock claw (1) by pushing it inward.
2

IGJA0A540040-02

1 11) Disconnect clutch rod (1) from clutch release arm

(2).

2
IJCA0A540040-02 2
9) Remove following parts, if necessary.
• Brake pipes (1): (Page 4A-13)

IJCA0A540042-01

IJCA0A540041-01

• Electric throttle body assembly

– K10B model: (Page 1D-8)
– K12M model: (Page 1D-84)
• EVAP canister purge valve
– K10B model: (Page 1B-3)
– K12M model: (Page 1B-11)
 Automated Manual Transaxle: 5D-106

12) Disconnect clutch speed sensor connector (1) and

actuator bracket bolts (2).

[a]

[a]
1
2
3

IJCA0A540043-01
13) Remove auto gear shift actuator unit bolt (1) and
nuts (2), and then remove transaxle hook (3), auto
gear shift actuator unit (4) and O-ring.
IJCA0A540044-01
14) Remove actuator harness (1) as follows, if
necessary:
• Pull the cap (2) and lock lever (3) in arrow
direction as shown in figure.
• Disconnect transmission control unit connector (4)
• Disconnect motor connector (5).

4 3

1
IK1K0A540060-01

• Disconnect clutch position sensor connector (1).

5D-107 Automated Manual Transaxle:

Installation

NOTICE
Auto gear shift actuator unit of supply part is
filled with oil and the breather cap (1) is
sealed using O-ring (2).
Without removal of the O-ring, the actuator
cannot operate properly while driving
affected by rise of internal pressure.
Remove the O-ring when installing the new
auto gear shift actuator unit.

1
IK1K0A540061-01

15) Remove clutch actuator anchor (1) as follows, if 1

necessary.
• Push the clutch actuator anchor out of the clutch
cable (2) in arrow direction as shown in figure.
• Push the clutch actuator anchor downwards
maintaining the anchor slit position vertically
IFP80A540043-01
upward and remove clutch actuator anchor.
Reverse removal procedure noting the following points.
• Install new clutch actuator boot (1) using special tool
(A) as shown in figure by running along the rim of
base plate (3), if necessary.
Special tool
(A): 09925M57610

1 2
IK1K0A540040-01 (A)

16) Remove the clutch actuator boot (1) if necessary.

IK1K0A540063-01

• Use new O-ring.

• Check that O-ring and gear shift and select shaft
assembly are free from foreign material such as dust
or oil.
1

IK1K0A540041-01
 Automated Manual Transaxle: 5D-108

• Check that shift rod (1) at the bottom of auto gear shift
actuator unit and engage lever (2) on the top of gear
shift and select shaft assembly are in N position “a” as
shown in figure.
• Apply grease to engage lever.
“A”: Grease 99000–25011 (SUZUKI Super Grease
A)
1 lbf-ft)
• Install transaxle hook (1) and tighten auto gear shift
actuator unit bolt (2), nuts (3) and actuator bracket
bolts (4) to specified torque.
Tightening torque
Auto gear shift actuator unit bolt (a): 23 N·m (2.3
kgf-m, 17.0 lbf-ft)
Auto gear shift actuator unit nut (b): 23 N·m (2.3
kgf-m, 17.0 lbf-ft)
Actuator bracket bolt (c): 23 N·m (2.3 kgf-m, 17.0

“a”

IJCA0A540045-01

2, (a)

“a”
2

“A”

IJCA0A540046-01

“a”: Approx. 10°

3, (b)
1

IJCA0A540047-01

4, (c)
IJCA0A540048-01

• Connect connector and fix wire harness with clamp

securely.
• Initialize auto gear shift actuator unit. (Page 5D-96)
5D-109 Automated Manual Transaxle:

Auto Gear Shift Oil Reservoir Tank Removal and 5) Remove the oil reservoir tank trap (1) along with O-
Installation ring using a special tool and put it on the container, if
AENJCA0A5406038 necessary.
Removal
1) Remove auto gear shift actuator unit and actuator Special tool
harness. (Page 5D-104) (A): 09925M57610
2) Mount auto gear shift actuator unit (1) on actuator
stand (A).
(A)
Special tool
(A): 09921M05520 1

(A)

IK1K0A540066-01

NOTICE
Remove oil reservoir tank trap (1) only if oil
trap color is black [A], if it is green [B] do not
open the trap as it will lead to damage of trap.

[A] 1

IK1K0A540064-01

3) Remove the oil reservoir tank breather cap and

clean it.
4) Clean oil reservoir tank cap (1) surface and remove 1
it. [B]

IK1K0A540067-01

6) Drain oil from auto gear shift oil reservoir tank.

IK1K0A540065-01
 Automated Manual Transaxle: 5D-110

7) Remove the oil reservoir tank (1) as follows.

a) Remove upper screws (2) from oil reservoir tank.
b) Remove bottom screw (3) from oil reservoir tank.
2
c) Remove oil reservoir tank by pulling in upward
direction as shown in figure.

2
1
1
IK1K0A540070-01

9) Clean the baseplate area properly and cover the

area with a cover cap (1) or the like.

2 1

IK1K0A540071-01

3
Installation
1) Install new O-ring (1) into the oil reservoir tank (2).

IK1K0A540068-01
1
d) Remove the O-ring (1) from oil reservoir tank
sitting area in base plate using a special tool.
2
Special tool
(A): 09925M57610

(A)

IK1K0A540072-01

2) Remove the cover cap or the like from the base

plate.
3) Install oil reservoir tank (1) as follows.
a) Install oil reservoir tank on the auto gear shift
actuator unit by moving it vertically towards the
1 mating surface as shown in figure.
b) Hand tighten upper screws (2).
c) Tighten lower screw (3) to specified torque.
Tightening torque
IK1K0A540069-01 Oil reservoir tank lower screw (a): 10 N·m (
8) Drain the oil from oil reservoir tank and base plate 1.0 kgf-m, 7.5 lbf-ft)
sitting area with syringe or the like. d) Tighten upper screws (2) to specified torque in
numerical order (“1” – “3”) as shown in figure.
Tightening torque
Oil reservoir tank upper screw (b): 10 N·m (
1.0 kgf-m, 7.5 lbf-ft)
5D-111 Automated Manual Transaxle:

Auto Gear Shift Electric Motor Removal and

Installation
2, “3”, (b) AENJCA0A5406039
1 Removal
1) Remove auto gear shift actuator unit and actuator
harness. (Page 5D-104)
2) Mount auto gear shift actuator unit (1) on actuator
stand (A) and clean actuator unit.

2, “2”, (b) Special tool

2, “1”, (b)
(A): 09921M05520

3, (a)

(A)

IK1K0A540073-01

4) Add new specified oil to oil reservoir tank.

: Oil 99000–24121–135 (Auto gear shift actuator
oil (550 ML))
Auto gear shift actuator oil capacity IK1K0A540064-01
Reference: 0.55 liters (1.16/0.96 US/Imp. pt) 3) Clean motor surface properly.
5) If removed, install oil trap and O-ring back into oil 4) Remove screws (1) and then remove auto gear shift
reservoir tank. electric motor (2) and sponge (3).
6) Install and tighten oil reservoir tank cap (1) to
specified torque and cover it with breather cap.
Tightening torque
Oil reservoir tank cap (a): 2 N·m (0.2 kgf-m, 1.5
lbf-ft)

1, (a)

IK1K0A540074-01

7) Install auto gear shift actuator unit and actuator

harness. (Page 5D-104)
 Automated Manual Transaxle: 5D-112

NOTE
Align oldham joint slot (2) with the axis
passing through the two fixing threaded
holes using a flat-bladed screw driver (3) as
2
shown in figure.

1
1

1
1

IK1K0A540078-01

2) Place new sponge (1) on base plate.

IK1K0A540075-01

5) Clean base plate surface (1) properly.

IK1K0A540079-01

3) Install auto gear shift electric motor as follows.

IK1K0A540076-01

6) Remove the oldham joint (1) using a plier.

IK1K0A540077-01

Installation
1) Place new oldham joint (1) on base plate.
5D-113 Automated Manual Transaxle:

NOTE TCM Removal and Installation

AENJCA0A5406040
Align auto gear shift electric motor shaft Removal
(1)with the axis passing through the two
1) Remove auto gear shift actuator unit and actuator
fixing holes by using hands as shown in
harness. (Page 5D-104)
figure.
2) Remove auto gear shift oil reservoir tank. (Page
5D-109)
3) Remove TCM fixing screws (1) in numerical order
(“1” – “4”) as shown in figure.

1, “4”
1, “1”
1

1
1, “2”
1, “3”

IK1K0A540082-01

4) Insert special tools (A) to screw holes.

NOTE
Insertion of special tools to two screw holes
IK1K0A540080-01 as a guide will guarantee right TCM
translation during the dismounting.
a) Ensure proper seating of auto gear shift electric
motor (1). Special tool
b) Firstly tighten new auto gear shift electric motor (A): 09932M97690
screws (2) by approximately 180° and then
tighten it to specified torque in numerical order
(“1” – “3”) as shown in figure.
Tightening torque (A)
Auto gear shift electric motor screw (a): 6
(A)
N·m (0.6 kgf-m, 4.5 lbf-ft)

1 IK1K0A540083-01

5) Remove the TCM from the valve body and unscrew

special tools.
2, “1”, (a)
2, “2”, (a) Installation
1) Clean the valve body face properly.
2) Insert special tools (A) to screw holes.
2, “3”, (a)
IK1K0A540081-01

4) Install auto gear shift actuator unit and actuator

harness. (Page 5D-104)
 Automated Manual Transaxle: 5D-114

NOTE Gear Shift and Select Shaft Assembly

Insertion of special tools to two screw holes Components
AENJCA0A5406010
as a guide will guarantee right TCM
translation during the mounting. (a)

Special tool
(A): 09932M97690

(A)

(A)

IK1K0A540083-01

3) Install the TCM (2) to the valve body and unscrew

special tools (A).
IJCA0A540050-01
4) Tighten new TCM mounting screws (1) to specified
1. Gear shift and select shaft assembly
torque in numerical order (“1” – “4”) as shown in
: 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
figure. : Do not reuse.
Tightening torque
TCM mounting screw (a): 6 N·m (0.6 kgf-m, 4.5 Gear Shift and Select Shaft Assembly Removal
lbf-ft) and Installation
AENJCA0A5406011
1, “4”, (a) Removal
1, “1”, (a)
1) Remove auto gear shift actuator unit. (Page 5D-
104)
2) Remove gear shift and select shaft assembly (1).

1, “2”, (a)
1, “3”, (a)
1

IK1K0A540084-01

5) Install auto gear shift oil reservoir tank. (Page 5D- IJCA0A540051-01
109)
6) Install auto gear shift actuator unit and actuator Installation
harness. (Page 5D-104) 1) Install gear shift and select shaft assembly to
transaxle left case as follows.
a) Clean mating surfaces of gear shift and select
shaft assembly and left case.
b) Apply specified amount of sealant to left case as
shown in figure.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
5D-115 Automated Manual Transaxle:

Sealant amount for transaxle left case

“a”: 1.5 mm (0.059 in.)

IJCA0A540053-01
“a”
“A”
“A” “a”
Installation
1) Apply oil to new O-ring, and then install it on clutch
IDL70A540029-01
speed sensor.
c) Install gear shift and select shaft assembly to left 2) Install clutch speed sensor (1) and tighten clutch
case. speed sensor bolt (2) to specified torque.
2) Tighten new gear shift and select shaft assembly Tightening torque
bolts (1) to specified torque. Clutch speed sensor bolt (a): 10 N·m (1.0 kgf-m,
7.5 lbf-ft)
NOTICE
The gear shift and select shaft assembly
bolts are pre-coated with adhesive. If the
bolts are reused, they may work loose. 2, (a)
Replace gear shift and select shaft assembly
bolts with new ones whenever they are
removed.

Tightening torque
1
Gear shift and select shaft assembly bolt (a): 23
N·m (2.3 kgf-m, 17.0 lbf-ft)

IJCA0A540054-01
1, (a)
3) Connect clutch speed sensor connector and lower
vehicle.

Clutch Speed Sensor Inspection

AENJCA0A5406013
1) Check the following points.
• Check that O-ring (1) is free from damage.

1, (a)

IJCA0A540052-01

3) Install auto gear shift actuator unit. (Page 5D-104)

4) Initialize gear shift and select shaft assembly.
(Page 5D-96)
1
Clutch Speed Sensor Removal and Installation
AENJCA0A5406012 IDL70A540033-01
Removal • Check that end face of sensor and countershaft
1) Hoist vehicle and disconnect clutch speed sensor 2nd gear teeth are free from any metal particles
connector (1). and damage.
2) Remove clutch speed sensor (2).
 Automated Manual Transaxle: 5D-116

IJCA0A540056-01

Installation
1) Apply oil to new O-ring, and then install it on VSS.
IJCA0A540055-01

2) Check clutch speed sensor as follows. 2) Install VSS (1) and tighten VSS bolt (2) to specified
If faulty condition is found, replace clutch speed torque.
sensor. Tightening torque
a) Connect battery (1) and ohmmeter (3) to clutch VSS bolt (a): 10 N·m (1.0 kgf-m, 7.5 lbf-ft)
speed sensor as shown in figure.
b) Check that clutch speed sensor resistance varies
as specified below by passing ferromagnetic
material (iron) (2) in front of clutch speed sensor.

NOTE 2, (a)
1
Keep approximately 1 mm (0.03 in.) gap “a”
between ferromagnetic material (iron) and
end face of clutch speed sensor.

Clutch speed sensor resistance

Resistance alternates between 220 Ω or
smaller (ON) and infinity (OFF)

IJCA0A540057-01
1 2 3 3) Connect VSS connector and lower vehicle.
“a”

3
VSS Inspection
AENJCA0A5406015
1) Check the following points.
• Check that O-ring (1) is free from damage.
2 1 • Check that end face of sensor and speed sensor
ring teeth are free from any metal particles and
IDL70A540034-01 damage.

VSS Removal and Installation

AENJCA0A5406014
Removal
1) Hoist vehicle and disconnect VSS connector (1). 1

2) Remove VSS (2).

IDL70A540037-01

2) Check VSS as follows.

5D-117 Automated Manual Transaxle:

If faulty condition is found, replace VSS.

a) Connect battery (1) and ohmmeter (3) to VSS as
shown in figure. 1 2 3

b) Check that VSS resistance varies as specified

3
below by passing ferromagnetic material (iron)
(2) at VSS’s side.

NOTE
“a”
Keep approximately 1 mm (0.03 in.) gap “a” 1
between ferromagnetic material (iron) and 2
end face of VSS. IDL70A540038-01

VSS resistance Starting Motor Control Relay and Back Up Light

Resistance alternates between 100 Ω or smaller Relay Inspection
(ON) and infinity (OFF) AENJCA0A5406016
Refer to “Control Relay Inspection” in Section 10B (Page
10B-51).

Auto Gear Shift Unit Components

AENJCA0A5406017

[A] [B] 1

(a)

(a)

(a) 2

(a)
(a)
(b) (a)
IJCA0A540058-01

[A]: Front view 1. Engine : 55 Nm (5.6 kgf-m, 40.5 lbf-ft)

[B]: Rear view 2. Auto gear shift and auto gear shift actuator unit : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)

Auto Gear Shift Unit Dismounting and 2) Select shift selector to N range, and remove battery
Remounting and battery tray.
AENJCA0A5406018
• K10B model: (Page 1J-6)
Dismounting
• K12M model: (Page 1J-24)
NOTE
If new auto gear shift transaxle and new auto
gear shift actuator unit are to be installed as a
set, start the dismounting procedure from
Step 2).

1) If auto gear shift actuator unit is removed after

dismounting auto gear shift, it is necessary to
perform “Oil Discharge” function under “Utility” mode
on SUZUKI scan tool before dismounting it referring
to “Auto Gear Shift Actuator Unit Removal and
Installation” (Page 5D-104) under Step 1) – 5).
 Automated Manual Transaxle: 5D-118

3) Remove harness bracket bolts (2). 8) Disconnect the following electric wires / connectors
and each clamp.
2 • Engine harness clamp (1)
• Auto gear shift actuator unit connector (2)
• VSS connector (3)

3
2 IGJA0A540056-01
IJCA0A540040-02

1. Clamp

4) Drain auto gear shift transaxle oil. (Page 5D-99)

2
5) Remove front drive shaft assembly. (Page 3A-3)
6) Remove starting motor. (Page 1I-5)
7) Disconnect ground cable (1) and ground cable
clamp.

IGJA0A540057-02
1 9) Loosen bolts and nut fastening engine and auto gear
shift unit.
10) Support engine assembly using shackle, engine
hook, chain hoist or the like.
IFRA0A521013-01
• K10B model: Refer to Step 30) of removal
procedure in “Engine Assembly Removal and
Installation”: K10B and Bi-Fuel CNG in Section 1D
(Page 1D-24).
• K12M model: Refer to Step 25) of removal
procedure in“Engine Assembly Removal and
Installation”: K12M in Section 1D (Page 1D-100).
11) Remove engine left mounting.
• K10B model: (Page 1D-23)
• K12M model: (Page 1D-99)
12) Support transaxle with transmission jack.
5D-119 Automated Manual Transaxle:

13) Remove bolts and nut fastening engine and • Add auto gear shift transaxle oil. (Page 5D-99)
transaxle, and then detach transaxle from engine. • Initialize auto gear shift.
– When removed or new auto gear shift transaxle is
Remounting
installed, refer to “All Learning Value Initialization:”
Reverse dismounting procedure noting the following
under “TCM and Clutch Initialization” (Page 5D-96).
points.
– When new auto gear shift transaxle and new auto
NOTICE gear shift actuator unit are installed as a set, refer
Failure to take proper precautions when to “Clutch-contact-point Learning Initialization:”
remounting the auto gear shift transaxle can under “TCM and Clutch Initialization” (Page 5D-96).
cause damage to parts. • Check function of engine, clutch and transaxle.
• When installing the transaxle, be careful • Check that there is no oil leakage at each connection.
not to let the drive shaft scratch the oil • Check front wheel alignment. (Page 2B-2)
seal.
Oil leakage may occur if the oil seal lip is
scratched by the drive shaft.
• Do not use a hammer when installing the
drive shaft joint into the differential gear.
Hitting the drive shaft joint with a hammer
will damage the joint.

• Tighten the following bolts and nut to specified torque.

– Transaxle to engine bolt and nut: (Page 5D-117)
– Engine left mounting bolt and nut
– K10B model: (Page 1D-23)
– K12M model: (Page 1D-99)
• For K10B model, touch terminal edge to rib on
transaxle case and tighten ground terminal bolt (1) to
specified torque.
For K12M model, position terminal parallel with rib on
transaxle case and tighten ground terminal bolt (1) to
specified torque.
Tightening torque
Ground terminal bolt (a): 25 N·m (2.5 kgf-m, 18.5
lbf-ft)

[A] [B]
1, (a) 1, (a)

IJCA0A540060-01

• Set each clamp for wiring securely.

 Automated Manual Transaxle: 5D-120

Auto Gear Shift Components

AENJCA0A5406019

(c)
(c)

30

22
31
(c)
4 A

29

28
(c)

19 27 1217G (b)

(a)
26
(a)
(a) 20

23 21
OIL

22
24 A
OIL

22
6
(c)
[B] (c)

33 25 1217G (b)
2 1217G
24 A 33 20
6

18
5 17
[A]
16
(a)

1 1217G
15
32
13

(c)
14
OIL

12 A 8 7
9

10
(a)
11
IJCA0A540061-02
5D-121 Automated Manual Transaxle:

[A]: K10B model 13. Countershaft right bearing 27. Oil level / filler plug
: Apply sealant 99000-31260 to
threads.
[B]: K12M model 14. Countershaft oil channel 28. Breather hose
1. Transaxle right case 15. Bearing stopper plate 29. Breather plug
: Apply sealant 99000-31260 to mating
surface of right case and left case.
2. Transaxle left case 16. Magnet 30. Transmission No.1 hook
: Apply sealant 99000-31260 to mating
surface of left case and gear shift and
select shaft assembly.
3. Auto gear shift actuator unit 17. Input shaft oil channel 31. Actuator bracket
4. Gear shift and select shaft assembly 18. Countershaft circlip 32. Gasket
: Apply grease 99000-25011 to engage
lever.
5. Input shaft and countershaft assembly 19. Oil gutter 33. Differential side bearing outer
: For details, refer to “Auto Gear Shift race
Transaxle Disassembly and Reassembly”
(Page 5D-121).
6. Differential assembly 20. Dowel pin : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
7. Reverse gear shaft 21. Clutch speed sensor : 21 Nm (2.1 kgf-m, 15.5 lbf-ft)
8. Washer 22. O-ring : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
9. Reverse idler gear 23. VSS : Apply transaxle oil.

10. Reverse gear shift lever 24. Oil seal : Do not reuse.
: Apply grease 99000-25011 to oil seal lip.
11. Reverse gear shift locating ball assembly 25. Oil drain plug
: Apply sealant 99000-31260 to threads.
12. Input shaft oil seal 26. Transaxle case plug
: Apply grease 99000-25011 to oil seal lip.

Auto Gear Shift Transaxle Disassembly and

Reassembly
AENJCA0A5406020

Disassembly
1) Remove auto gear shift actuator unit. (Page 5D-
104)
2) Remove gear shift and select shaft assembly.
(Page 5D-114)
3) Remove clutch speed sensor. (Page 5D-115)
4) Remove VSS. (Page 5D-116)
5) Remove reverse gear shaft bolt (1) with gasket.

1
IJCA0A540062-01

IDL70A540045-01

6) Remove transaxle case bolts (1).

 Automated Manual Transaxle: 5D-122

7) Remove transaxle case plug (1) with flat-bladed 9) Remove reverse gear shift lever bolts (1) and
screwdriver (2) or the like. reverse gear shift lever (2).
10) Remove reverse gear shaft (3), washer (4) and
reverse idler gear (5).
1

3
2

5
1

IDL70A540047-01
2
8) While expanding countershaft circlip (1) to unhook it
from bearing groove, remove transaxle left case (2) IDL70A540050-01
from right case using special tool. 11) Remove magnet from right case.
NOTE 12) Tapping input shaft end with plastic hammer, push it
out as assembly from case a little, and then take out
When removing transaxle left case, circlip
input shaft assembly (1), countershaft assembly (2),
comes out with left case and bearing remains
5th and reverse gear shift shaft (3), high speed gear
at countershaft side.
shift shaft (4) and low speed gear shift shaft (5).
Special tool
(A): 09912M34510 4
3
5

1
2
1 IDL70A540051-01

13) Remove differential assembly from transaxle right

IDL70A540048-01 case.

Reassembly
2
1) Install differential assembly into transaxle right case.
2) Join input shaft assembly (1), countershaft assembly
(A) (2), 5th and reverse gear shift shaft (3), high speed
gear shift shaft (4) and low speed gear shift shaft (5)
all together, and then install them into transaxle right
case (6) so as not to damage oil seal by input shaft
spline.

IJCA0A540063-01

3. Countershaft left bearing

5D-123 Automated Manual Transaxle:

NOTE NOTE
• Input shaft right bearing on shaft can be Position reverse gear shift lever (4) not to
installed into transaxle right case by touch outside diameter (5) of idler gear
tapping shaft with plastic hammer. sleeve.
• Check that countershaft is engaged with
final gear while installing.

4
4
5
6

3
1
2
IDL70A540052-01
2

3) Install special tool to transaxle right case.

Special tool
(A): 09922M28111
1
4) Install reverse gear shift lever (1).
5) Tighten new reverse gear shift lever bolts (2) to
specified torque while pushing reverse gear shift IGJA0A540070-01
lever in arrow direction. 7) Align matchmark (1) of reverse idler gear assembly
NOTICE with matchmark (2) of transaxle right case.

The reverse gear shift lever bolts are pre-

coated with adhesive. If these bolts are
reused, they may work loose.
Replace the reverse gear shift lever bolts with
new ones whenever they are removed.

Tightening torque
Reverse gear shift lever bolt (a): 10 N·m (1.0 kgf-
m, 7.5 lbf-ft)
1

(A)
1 IDL70A540054-01

8) Install magnet (1) to right case and input shaft oil

2, (a) channel (2) to input shaft.

IGJA0A540069-01

6) Install reverse idler gear (1), washer (2) and reverse

gear shaft (3).
 Automated Manual Transaxle: 5D-124

NOTICE
2
Fitting failure of circlip into bearing groove
causes noise or breakage of countershaft
related parts because of wrong positioning of
countershaft.
Fit circlip into bearing groove.

2
1

IDL70A540055-02

9) Clean mating surfaces of both right and left cases,

and apply sealant to transaxle right case (1) as
1
shown in figure.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Sealant amount for transaxle right case IDL70A540057-01
“a”: 1.5 mm (0.059 in.)
12) Tighten transaxle case bolts (1) to specified torque.

“a” Tightening torque

1
“a”
Transaxle case bolt (a): 23 N·m (2.3 kgf-m, 17.0
“A” lbf-ft)

“A”
IJCA0A540064-01

10) While expanding countershaft circlip (1) not to fit it

into bearing groove (2), install transaxle left case
onto right case, and install transaxle case bolts
temporarily.
11) Turn transaxle assembly upside down so that
countershaft bearing fits in left case and circlip fits in
bearing groove.

1, (a)
IJCA0A540065-01

13) Tighten new reverse gear shaft bolt (1) with new
gasket to specified torque.
5D-125 Automated Manual Transaxle:

NOTICE
The reverse gear shaft bolt is pre-coated with
adhesive. If the bolt is reused, it may work
loose. 1
Replace the reverse gear shaft bolt with new
one whenever it is removed.

Tightening torque
Reverse gear shaft bolt (a): 23 N·m (2.3 kgf-m,
17.0 lbf-ft)

IJCA0A540066-01

3) For K12M model, remove differential side bearing

1, (a)
outer race (1) and differential side shim using special
tool.
Special tool
(A): 09925M16510

IDL70A540059-01 (A)
14) Install new transaxle case plug (1) using special tool.
Special tool
(A): 09924M74590
(B): 09924M74510 1

(B)

(A)

1 IGJA0A520021-01

Reassembly
1) Install new circlip and oil gutter (1), if removed.

NOTE
IDL70A540060-02
When installing oil gutter, fit its claws into
15) Install VSS. (Page 5D-116) holes of transaxle left case securely.
16) Install clutch speed sensor. (Page 5D-115)
17) Install gear shift and select shaft assembly. (Page
5D-114)

Transaxle Left Case Disassembly and

Reassembly
AENJCA0A5406021

Disassembly
1) Remove differential side oil seal from transaxle left
case, if necessary. (Page 5D-99) 1

2) Remove circlip (1) and oil gutter (2), if necessary.

IJCA0A540067-01

2) Install new differential side oil seal to transaxle left

case, if removed. (Page 5D-99)
 Automated Manual Transaxle: 5D-126

3) For K12M model, calculate clearance for selection of

applicable differential side shim as follows. 1

a) Install differential side bearing outer race to

transaxle right case. (Page 5D-127)
b) Install differential assembly (2) to transaxle right
case (1).
c) Install differential side bearing outer race of
transaxle left case side (3) to differential
assembly.
d) Keep pushing differential side bearing outer race
with force of 35 N (3.6 kgf, 7.9 lbf) by hand and “b”
turn differential assembly 10 times or more.

3
1 2

IGJA0A520024-01

g) Calculate clearance “c” by the following formula.

Clearance “c” = Depth “b” – Distance “a”
• Depth “b”: mating surface of transaxle left case to
installation position of differential side bearing
outer race
• Distance “a”: mating surface of transaxle right
case to differential side bearing outer race

IGJA0A520022-01 “c”
e) Measure distance “a” from mating surface of
transaxle right case (1) to differential side
“b” “a”
bearing outer race (2).

“a” 2

1
IGJA0A520025-01

4) Select shim closest to calculated clearance “c” from

the following available sizes.

Available shim thickness

IGJA0A520023-01
Clearance “c” Applicable shim
f) Measure depth “b” from mating surface of 0.491 – 0.530 mm
transaxle left case (1) to installation position of 0.66 mm (0.0260 in.)
(0.01934 – 0.02086 in.)
differential side bearing outer race. 0.531 – 0.570 mm
0.70 mm (0.0276 in.)
(0.02091 – 0.02244 in.)
0.571 – 0.610 mm
0.74 mm (0.0291 in.)
(0.02249 – 0.02401 in.)
0.611 – 0.650 mm
0.78 mm (0.0307 in.)
(0.02406 – 0.02559 in.)
0.651 – 0.690 mm
0.82 mm (0.0323 in.)
(0.02563 – 0.02716 in.)
0.691 – 0.730 mm
0.86 mm (0.0339 in.)
(0.02721 – 0.02874 in.)
0.731 – 0.770 mm
0.90 mm (0.0354 in.)
(0.02878 – 0.03031 in.)
5D-127 Automated Manual Transaxle:

0.771 – 0.810 mm
0.94 mm (0.0370 in.)
(0.03036 – 0.03188 in.)
(A)
0.811 – 0.850 mm
0.98 mm (0.0386 in.)
(0.03193 – 0.03346 in.)
0.851 – 0.890 mm
1.02 mm (0.0402 in.)
(0.03351 – 0.03503 in.)
0.891 – 0.930 mm
1.06 mm (0.0417 in.)
(0.03508 – 0.03661 in.) 1
0.931 – 0.970 mm
1.10 mm (0.0433 in.)
(0.03666 – 0.03818 in.)
0.971 – 1.010 mm
1.14 mm (0.0449 in.)
(0.03823 – 0.03976 in.)
1.011 – 1.050 mm
1.18 mm (0.0465 in.)
(0.03981 – 0.04133 in.)
1.051 – 1.090 mm
1.22 mm (0.0480 in.)
(0.04138 – 0.04291 in.) IGJA0A520028-01

1.091 – 1.130 mm
1.26 mm (0.0496 in.)
(0.04296 – 0.04448 in.) Transaxle Right Case Disassembly and
1.131 – 1.170 mm Reassembly
1.30 mm (0.0512 in.) AENJCA0A5406022
(0.04453 – 0.04606 in.)
1.171 – 1.210 mm
1.34 mm (0.0528 in.) Disassembly
(0.04611 – 0.04763 in.)
1.211 – 1.250mm 1) Remove differential side oil seal from transaxle right
1.38 mm (0.0543 in.) case, if necessary. (Page 5D-99)
(0.04768 – 0.04921 in.)
1.251 – 1.290 mm 2) Remove input shaft oil seal (1) using special tool, if
1.42 mm (0.0559 in.)
(0.04926 – 0.05078 in.) necessary.

5) Install differential side shim (1). Special tool

(A): 09913M50121
1
(A)

IGJA0A520027-01 IDL70A540063-02

6) Install differential side bearing outer race (1) using 3) Remove bearing stopper plate (1), countershaft right
special tool. bearing (2) and oil channel (3), using special tool, if
necessary.
Special tool
(A): 09913M85210 Special tool
(A): 09930M30104
(B): 09941M64511
 Automated Manual Transaxle: 5D-128

Reassembly
(A)
1) For K12M model, install differential side bearing
outer race (1) using special tool, if removed.
Special tool
(B) (A): 09913M85210

2 (A)

IGJA0A520030-01

2) Install new input shaft oil seal (1) facing its spring
IJCA0A540095-01 side upward up to bottom of transaxle right case
4) Remove reverse gear shift locating ball assembly hole, if removed. Use special tool and hammer for
(1), if necessary. installation and apply grease to oil seal lip.
“A”: Grease 99000–25011 (SUZUKI Super
Grease A)
1 Special tool
(A): 09926M37610M003
(B): 09913M80113

(B)

(A)

IDL70A540065-02

5) For K12M model, remove differential side bearing

outer race (1) using special tool, if necessary.
Special tool
(A): 09925M16510 1, “A”

IDL70A540066-03

3) Install countershaft oil channel (1) and new

(A) countershaft right bearing (2), using special tool, if
removed.

NOTE
Install countershaft oil channel aligning its
ridge (3) with ridge (4) of transaxle right case.
1

Special tool
(A): 09913M70123

IGJA0A520029-01
5D-129 Automated Manual Transaxle:

(A)

1 4

IJCA0A540069-01

4) Install bearing stopper plate (1) and tighten new

bearing stopper plate bolt (2) to specified torque.

NOTICE
The bearing stopper plate bolt is pre-coated
with adhesive. If the bolt is reused, it may
work loose.
Replace the bearing stopper plate bolt with
new one whenever it is removed.

Tightening torque
Bearing stopper plate bolt (a): 10 N·m (1.0 kgf-
m, 7.5 lbf-ft)

1 2, (a)
IDL70A540068-01

5) Install reverse gear shift locating ball assembly, if

removed.
6) Install new differential side oil seal to transaxle right
case, if removed. (Page 5D-99)
 Automated Manual Transaxle: 5D-130

Input Shaft Components

AENJCA0A5406023

8
6

OIL
3
7

17
1
4

OIL
OIL

2
15

OIL
12
16

11 14

13
9
OIL

3
OIL

10
OIL

IJCA0A540070-01

1. Input shaft 8. Circlip 15. 5th gear synchronizer key

2. Input shaft right bearing 9. 4th gear synchronizer ring 16. 5th gear synchronizer hub plate
3. Needle bearing 10. Input shaft 4th gear 17. Input shaft left bearing
4. Input shaft 3rd gear 11. Input shaft 5th gear spacer : Apply transaxle oil.

5. 3rd gear synchronizer ring 12. Input shaft 5th gear : Do not reuse.
6. High speed synchronizer sleeve & hub 13. 5th gear synchronizer ring
7. High speed synchronizer key 14. 5th gear synchronizer sleeve & hub

Input Shaft Disassembly and Reassembly

AENJCA0A5406024

Disassembly
5
! CAUTION 1
2
Using an inappropriate hydraulic press or 4
bearing puller could cause personal injury.
Use the hydraulic press and bearing puller
which are capable of safely bearing a load of
at least 5 tons (11,000 lbs).
3 3
NOTICE IDL70A540070-01

Supporting the gear on the concave side of 5. Metal stick

the bearing puller can cause damage to the

gear.
Support the gear on the flat side of the
bearing puller.

1) Remove input shaft right bearing (2) and left bearing

(4) from input shaft (1) using bearing puller (3) and
hydraulic press.
5D-131 Automated Manual Transaxle:

2) Remove circlip (1) using snap ring pliers (2). c) Remove 5th gear spacer (1) using bearing puller
(2) and hydraulic press.

2
IDL70A540071-01

3) Remove 5th gear synchronizer hub plate.

4) Remove 5th gear synchronizer sleeve & hub
assembly (1), 5th gear synchronizer ring and 5th
gear (2) from input shaft (3) using bearing puller and
IDL70A540074-01
hydraulic press.
7) Remove 4th gear, 4th gear synchronizer ring and 4th
gear needle bearing from input shaft.
4
1 8) Remove circlip (1) using snap ring pliers (2).
3

2
2

1
IDL70A540072-02

4. Metal stick

5) Remove 5th gear needle bearing from input shaft.

6) Remove 5th gear spacer according to the following
procedure.
IDL70A540075-02
a) Engage high speed synchronizer sleeve with 4th
gear. 9) Remove high speed synchronizer sleeve & hub
assembly (1) and 3rd gear (2) from input shaft (4)
b) Push down input shaft (1) a little using bearing
using bearing puller (3) and hydraulic press.
puller (2) and hydraulic press.

1 2

IDL70A540076-01

10) Remove 3rd gear needle bearing from input shaft.

11) Disassemble synchronizer sleeve & hub assembly.
IJCA0A540071-01
 Automated Manual Transaxle: 5D-132

Reassembly 4) Install right bearing (1) to input shaft (2) using special
1) Clean all components thoroughly, check them for tool and hydraulic press.
any abnormality and replace them with new ones if Special tool
necessary. (A): 09913M80113
2) Check clearance “a” between synchronizer ring (2)
and gear (1) and replace with new one, if necessary.
Also, check gear teeth for damage.
(A)
Clearance “a” between synchronizer ring and
gear (3rd, 4th and 5th) 1
Standard: 0.40 – 1.10 mm (0.016 – 0.043 in.)
Service limit: 0.40 mm (0.016 in.)

IJCA0A540072-01

5) Install 3rd gear needle bearing and apply transaxle

oil to it, and then install 3rd gear (1) and 3rd gear
synchronizer ring (2) to input shaft.
6) Install high speed hub (3) with long flange downward
using special tool and hydraulic press.

NOTE
• Inside diameter of high speed
synchronizer hub is larger than that of 5th
gear synchronizer hub.
IDL70A540077-01 • While press-fitting high speed
3) To ensure lubrication of input shaft (1), blow air into synchronizer hub, check that synchronizer
oil holes (2) as shown in figure and check that they ring key protrusions (4) are aligned with
are free from any obstruction. key slots (5) on hub.
• Check free rotation of 3rd gear after press-
fitting hub.
2

Special tool
1 (A): 09913M84510

(A)

2
[b] 3
IDL70A540078-02
[a]

2
5

1
4

IJCA0A540074-01

[a]: 3rd gear side [b]: Long flange

5D-133 Automated Manual Transaxle:

7) Fit high speed synchronizer sleeve (1) to hub (2) and
3 keys (3) as shown in figure.
NOTE
• No specific direction is assigned to high
speed synchronizer sleeve or each key.
• When fitting synchronizer hub into sleeve,
raise the sleeve and check that the hub
comes off with the self-weight.
NOTE
• Inside diameter of 5th gear synchronizer
hub is smaller than that of high speed
synchronizer hub.
• While press-fitting hub, check that
synchronizer ring key protrusions (2) are
aligned with key slots (3) in hub.
• Check free rotation of 5th gear after press-
fitting hub.

Synchronizer key installation position Special tool

(A): 09913M80113

(A)
2
1
[a]
1

1 2
IJCA0A540073-01

[a]: 5th gear side

2
IDL70A540080-03 13) Fit 5th gear synchronizer sleeve (1) to hub (2) and 3
8) Install new circlip. keys (3) as shown in figure.
9) Install 4th gear needle bearing (2) and apply NOTE
transaxle oil to it, and then install synchronizer ring
(4) and 4th gear (3). • No specific direction is assigned to each
key.
10) Install 5th gear spacer (1) using special tool and
hydraulic press. • When fitting sleeve to hub, raise the hub
and check that the sleeve comes off with
Special tool the self-weight.
(A): 09913M84510

Synchronizer key installation position

(A)

2 1
3
3
4

1
IDL70A540082-01

11) Install 5th gear needle bearing and apply transaxle

oil to it, and then install 5th gear and synchronizer
ring.
12) Install 5th gear synchronizer hub (1) using special
1
tool and hydraulic press.

2
IELA0B540025-01
 Automated Manual Transaxle: 5D-134

14) Install 5th gear synchronizer hub plate.

15) Select new circlip (1) that makes thrust clearance “a”
of 5th gear synchronizer hub plate 0.1 mm (0.004 in)
or less and install it.
Available circlip thickness
Clearance “b” Circlip thickness
2.000 – 2.049 mm
2.00 mm (0.0787 in.)
(0.0787 – 0.0806 in.)
2.050 – 2.099 mm
2.05 mm (0.0807 in.)
(0.0807 – 0.0826 in.)
2.100 – 2.149 mm
2.10 mm (0.0827 in.)
(0.0827 – 0.0846 in.)
2.150 – 2.199 mm
2.15 mm (0.0846 in.)
(0.0846 – 0.0865 in.)
2.200 – 2.249 mm
2.20 mm (0.0866 in.)
(0.0866 – 0.0885 in.)
2.250 – 2.300 mm
2.25 mm (0.0886 in.)
(0.0886 – 0.0905 in.)

“a” “b”

IDL70A540085-01

16) Press-fit left bearing (1) using special tool and

hydraulic press.
Special tool
(A): 09944M66060

(A)

IDL70A540086-01
5D-135 Automated Manual Transaxle:

Countershaft Components
AENJCA0A5406025

OIL
7

6
9
4

OIL
8

OIL
2
15
5

3 14 1
1

OIL
13

1
12

OIL
7
10

11
1
IJCA0A540075-01

1. Circlip 7. Needle bearing 13. Countershaft 1st gear

2. Countershaft left bearing 8. Countershaft 2nd gear 14. Countershaft
3. Countershaft 5th gear 9. 2nd gear synchronizer ring 15. Countershaft right bearing inner race
4. Countershaft 4th gear 10. Low speed synchronizer key : Apply transaxle oil.

5. Countershaft 3rd and 4th gear spacer 11. Low speed synchronizer sleeve & hub : Do not reuse.
6. Countershaft 3rd gear 12. 1st gear synchronizer ring

Countershaft Disassembly and Reassembly

AENJCA0A5406026

Disassembly
2

! CAUTION
Using an inappropriate hydraulic press or
bearing puller could cause personal injury.
Use the hydraulic press and bearing puller 1
which are capable of safely bearing a load of
at least 5 tons (11,000 lbs).

NOTICE IDL70A540088-02

Supporting the gear on the concave side of

the bearing puller can cause damage to the
gear.
Support the gear on the flat side of the
bearing puller.

1) Remove circlip (1) using snap ring pliers (2).

 Automated Manual Transaxle: 5D-136

2) Remove left bearing (1) using bearing puller (2) and 7) Remove 2nd gear needle bearing and 2nd gear
hydraulic press. synchronizer ring.
8) Remove circlip (1) using snap ring pliers (2).

1
3
1
2
2

IDL70A540089-01 IDL70A540093-02

3. Metal stick
9) Apply bearing puller (3) to 1st gear (2) and remove
low speed synchronizer sleeve & hub assembly (1),
3) Remove circlip (1) using snap ring pliers (2). 1st gear synchronizer ring and 1st gear using
hydraulic press.

2
1

1 2

IDL70A540090-02
4) Apply bearing puller (3) to 4th gear (2) and remove
5th gear (1) together with 4th gear using hydraulic
press.
IDL70A540094-01
10) Remove 1st gear needle bearing.
11) Remove circlip (1) using snap ring pliers (2).

IDL70A540095-02

IDL70A540091-01

5) Remove 3rd and 4th gear spacer.

6) Apply bearing puller (3) to 2nd gear (2) and remove
3rd gear (1) together with 2nd gear using hydraulic
press.

1
2

IDL70A540092-01
5D-137 Automated Manual Transaxle:

12) Grind portion “a” of right bearing inner race (1) using
grinder (2) as shown.

NOTICE
The shaft (3) will be damaged if the bearing is
ground too much.
Limit the grinding to a minimum necessary
amount.

2
3

“a”
1
3
1
IDL70A540077-01

3) To ensure lubrication of countershaft (1), blow air

IDL70A540096-01 into oil holes (2) as shown in figure and check that
13) Break the thinnest portion of bearing inner race (2) they are free from any obstruction.
with a chisel (1) and remove bearing inner race.
1
2

IDL70A540099-02

4) Install right bearing inner race (1) using special tool

2 and hydraulic press.
IDL70A540097-01

Special tool
Reassembly (A): 09913M80113
1) Clean all components thoroughly, check them for
any abnormality and replace them with new ones if
(A)
necessary.
2) Check clearance “a” between synchronizer ring (2) 1
and gear (1) and replace with new one, if necessary.
Also, check gear teeth for damage.
Clearance “a” between synchronizer ring and
gear (1st and 2nd)
Standard: 0.40 – 1.10 mm (0.016 – 0.043 in.)
Service limit: 0.40 mm (0.016 in.)
IDL70A540098-01

5) Install new circlip.

6) Install 1st gear needle bearing and apply transaxle
oil to it, and then install 1st gear (1) and 1st gear
synchronizer ring to countershaft.
7) Install low speed hub (2) using special tool and
hydraulic press.
 Automated Manual Transaxle: 5D-138

NOTE 11) Install 3rd gear (1) using special tool and hydraulic
press.
• No specific direction is assigned to each
key. Special tool
• While press-fitting low speed synchronizer (A): 09925M18011
hub, check that synchronizer ring key
protrusions (3) are aligned with key slots (A)
(4) on hub.
• Check free rotation of 1st gear after press- 1
fitting hub.

Special tool [b]

(A): 09940M51710

(A)
[a]

4
2
IDL70A540102-01

3 [a]: 2nd gear side [b]: Long flange

12) Install 3rd and 4th gear spacer (1) and then install
1 4th gear (2) using special tool and hydraulic press.
IJCA0A540077-01 Special tool
8) Fit low speed synchronizer sleeve (1) to hub (2) and (A): 09925M18011
3 keys (3) as shown in figure.
(A)
NOTE
2
• No specific direction is assigned to each
key.
• When fitting sleeve to hub, raise the hub 1
and check that the sleeve comes off with [b]
the self-weight.
[a]

3 IDL70A540103-01

[a]: 3rd and 4th gear spacer side [b]: Long flange

2
13) Install 5th gear (1) using special tool and hydraulic
1
press.
Special tool
(A): 09925M18011

1
(A)

[a]
1

2
IJCA0A540076-01
[b]
[a]: 1st gear side
[a]

9) Install new circlip.

10) Install 2nd gear needle bearing and apply transaxle
oil to it, and then install 2nd gear synchronizer ring
and 2nd gear to countershaft. IDL70A540104-01

[a]: 4th gear side [b]: Long flange

5D-139 Automated Manual Transaxle:

14) Select new circlip (1) that makes thrust clearance “a”
of 5th gear 0.1 mm (0.004 in) or less and install it.
Available circlip thickness
Clearance “b” Circlip thickness
2.150 – 2.199 mm
2.15 mm (0.0846 in.)
(0.0846 – 0.0865 in.)
2.200 – 2.249 mm
2.20 mm (0.0866 in.)
(0.0866 – 0.0885 in.)
2.250 – 2.299 mm
2.25 mm (0.0886 in.)
(0.0886 – 0.0905 in.)
2.300 – 2.349 mm
2.30 mm (0.0906 in.)
(0.0906 – 0.0924 in.)
2.350 – 2.399 mm
2.35 mm (0.0925 in.)
(0.0925 – 0.0944 in.)
2.400 – 2.450 mm
2.40 mm (0.0945 in.)
(0.0945 – 0.0964 in.)

“a” “b”

IDL70A540105-01

2. Countershaft 4. 4th gear

3. 5th gear

15) Install left bearing (1) using special tool and

hydraulic press.
Special tool
(A): 09913M80113

(A)
[b]

[a]

IDL70A540106-01

[a]: 5th gear side [b]: Gloves

16) Install new circlip.

 Automated Manual Transaxle: 5D-140

Gear Shift Shaft Components

AENJCA0A5406027

5 (a)

4
IJCA0A540078-02

1. Low speed gear shift shaft
2. High speed gear shift shaft
3. 5th and reverse gear shift shaft
4. Reverse gear shift lever : Do not reuse.
5. Reverse gear shift lever bolt
: For tightening procedure, refer to “Auto Gear
Shift Transaxle Disassembly and Reassembly”
(Page 5D-121).
: 10 Nm (1.0 kgf-m, 7.5 lbf-ft)

Gear Shift Shaft and Fork Inspection

AENJCA0A5406028
1) Using feeler gauge, check clearance between fork
(1) and sleeve (2) and replace those parts if it
exceeds specified value.
Clearance “a” between fork and sleeve
Service limit: 0.40 mm (0.016 in.)

I2RH01520068-01

2) Insert each gear shift shaft into case and check that
it moves smoothly. If not, correct burns or dents with
oilstone, reamer or the like.
5D-141 Automated Manual Transaxle:

Differential Components
AENJCA0A5406029

OIL
4

OIL
5
2 3
[B]
OIL

1
[A]

12 2

OIL
1

OIL
3 11
OIL

9
4
OIL

[A]
5
OIL

[B]
8
7

10
OIL

6 (a)
IJCA0A540079-01

[A]: K10B model 5. Side gear washer 11. Differential pinion shaft
: For adjustment of differential thrust play, refer
to “Differential Disassembly and Reassembly”
(Page 5D-141).
[B]: K12M model 6. Differential side bearing 12. Differential pinion shaft pin
: For installation depth, refer to “Differential
Disassembly and Reassembly” (Page 5D-
141).
1. Differential pinion washer 7. Speed sensor ring : 100 Nm (10.2 kgf-m, 74.0 lbf-ft)
2. Differential pinion 8. Final gear : Apply transaxle oil.

3. Differential side gear 9. Differential case : Do not reuse.

4. Spring washer 10. Final gear bolt

Differential Disassembly and Reassembly

AENJCA0A5406030

NOTE
The following procedure is shown using
figures of K12M model (taper roller bearing
type). However, for K10B model (ball bearing (A)
type), the same manner and special tools can
be applied for disassembly and reassembly.

Disassembly 1

1) Support differential case with soft jawed vise and

remove final gear bolts, and then remove final gear.
2) Remove left side bearing (1) using special tool, 2
bearing puller (2) and hydraulic press.
Special tool
(A): 09913M75821

IFKA0Q540126-01
 Automated Manual Transaxle: 5D-142

3) Remove right side bearing (1) and speed sensor ring 6) Remove differential pinions (1), differential pinion
(2) using special tool, bearing puller (3) and washers (2), side gears (3), spring washers (4) and
hydraulic press. Support speed sensor ring on the side gear washers (5) (if equipped) from differential
flat side of the bearing puller. case (6).
Special tool 5
(A): 09913M75821
4

3
2

(A)

2
4
1 6
5
IJCA0A540080-01

Reassembly
2
If abnormalities of component parts are found during
3 visual check before/after disassembly, prepare replacing
parts and proceed to reassembly. Check that all parts
are clean.
1) Install side gear washers (1) (if equipped), spring
IFKA0Q540127-01
washers (2), side gears (3), differential pinion
4) Remove differential pinion shaft pin using special washers (4) and differential pinions (5) to differential
tool and hammer. case (6).
Special tool 2) Install pinion shaft (7) to differential case.
(A): 09922M85811
6
3

(A)

1 2

4 4

5
5

1 2
3
IJCA0A540081-01
IJCA0A521046-01
3) Measure thrust play of differential side gear (1) at
5) Remove pinion shaft (1) from differential case (2). each side as follows.
If measured value is out of specification, select
2
suitable side gear washer (2) from the following
1
available sizes, install it and check again.
Special tool
(A): 09900M20607
(B): 09900M20701
a) Hold differential assembly with soft jawed vise
and apply dial gauge to side gear as shown in
figure.
IFKA0Q540129-01
b) Move side gear up and down by hand and read
dial gauge.
5D-143 Automated Manual Transaxle:

Differential side gear thrust play

0.03 – 0.31 mm (0.0012 – 0.0122 in.)
(A)

(A)
[A]
“a”

(B)
3 1
2

1 4
IFKA0Q540131-01

5) Install speed sensor ring (1) using special tool and

hydraulic press as shown in figure.

1
Special tool
3 (A): 09913M75510
(B): 09944M77030
[B]

(A)
(A)
3

(B)

4 (B)
1

1
2
3

1
IJCA0A540082-01

[A]: Right side 3. Differential case

IJCA0A540084-01
[B]: Left side 4. Spring washer
6) Install right side bearing (1) using special tool and
Available side gear washer thickness hydraulic press.
Thickness mm (in.) Thickness mm (in.) Special tool
0.60 mm (0.0236 in.) 0.85 mm (0.0335 in.) (A): 09913M76010
0.65 mm (0.0256 in.) 0.90 mm (0.0354 in.)
0.70 mm (0.0276 in.) 0.95 mm (0.0374 in.) (A)

0.75 mm (0.0295 in.) 1.00 mm (0.0394 in.)

0.80 mm (0.0315 in.) 1.05 mm (0.0413 in.)
1

4) Install new differential pinion shaft pin (1) from left

side until depth “a” becomes 4.7 – 5.7 mm (0.19 –
0.22 in.) as shown using special tool.
Special tool
(A): 09922M85811

IJCA0A540085-01

7) Install left side bearing (1) using special tool and

hydraulic press.
Special tool
(A): 09913M76010
(B): 09913M85230
 Automated Manual Transaxle: 5D-144

(A)

(B)

IJCA0A540086-01 IJCA0A540088-02

8) Support differential case with soft jawed vise and

install final gear (1), and then tighten new final gear
bolts to specified torque.

NOTICE
The bolts may loosen during operation of the
differential if any bolts other than the
specified ones are installed.
Use only the specified new bolts.

Tightening torque
Final gear bolt (a): 100 N·m (10.2 kgf-m, 74.0 lbf-
ft)

(a)

IJCA0A540087-01

Speed Sensor Ring Inspection

AENJCA0A5406036
Check speed sensor ring for crack and damage.
If any defect is found, replace speed sensor ring.
5D-145 Automated Manual Transaxle:

Clutch Cover and Clutch Disc Components

AENJCA0A5406031

(a)
8

1 A

2 A
9
5

4 A

10 (a)

6
7
IJCA0A540089-01

1. Clutch release shaft seal 7. Clutch disc

: Apply grease 99000-25011 to seal lip.
2. Clutch release shaft No.2 bushing 8. Release arm
: Apply grease 99000-25011 to bushing inside. : For installation, refer to “Clutch Release System Component Removal and
Installation” (Page 5D-147).
3. Release shaft 9. Pin
: Apply grease 99000-25011 to the end of release shaft arm.
4. Clutch release shaft No.1 bushing 10. Clutch cover bolt
: Apply grease 99000-25011 to bushing inside. : For tightening order, refer to “Clutch Cover and Clutch Disc Removal and
Installation” (Page 5D-145)
5. Release bearing : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
6. Clutch cover : Do not reuse.

Clutch Cover and Clutch Disc Removal and

1
Installation
AENJCA0A5406032

NOTE
Do not remove auto gear shift actuator unit
from auto gear shift when removing or
installing the clutch related parts.

Removal
1) Dismount auto gear shift unit. (Page 5D-117)
1
2) Hold flywheel with special tool and remove clutch 1
cover bolts (1), clutch cover (2) and clutch disc. I9P60A531018-01

Special tool Installation

(A): 09924M17811
NOTE
Before assembling, check that flywheel
surface and pressure plate surface have
been cleaned and dried thoroughly.

1) Hold flywheel with special tool (A).

 Automated Manual Transaxle: 5D-146

2) Align clutch disc with crankshaft center using special Clutch Cover and Clutch Disc Inspection
tool (B) and install clutch cover (1). AENJCA0A5406033

3) Install and tighten clutch cover bolts using the
following procedure.
a) Tighten 3 bolts (3) by hand.
b) Tighten other 3 bolts (4) evenly and gradually to
5.0 Nm (0.51 kgf-m, 4.0 lbf-ft).
c) Fully tighten all bolts evenly and gradually to
specified torque in numerical order (“1” – “6”)
starting from bolt nearby strut plate rivet (2).
NOTE
For centering of clutch disc spline, tighten
clutch cover bolts while pushing clutch disc
with special tool.
Clutch Disc
At clutch cover side of clutch disc, measure depth “a” of
rivet head depression, i.e. distance between rivet head
and facing surface.
If depression is found to have reached service limit at
any of rivet holes, replace clutch disc.
Rivet head depth
Standard: 0.9 – 1.5 mm (0.0354 – 0.0591 in.)
Limit: 0.5 mm (0.0197 in.)

Special tool
(A): 09924M17811
(B): 09923M36320
Tightening torque I4RS0B540166-03
Clutch cover bolt* (a): 5.0 Nm → 23 Nm
(0.51 kgf-m → 2.3 kgf-m, 4.0 lbf-ft → 17.0 lbf- Clutch Cover
ft) Check clutch cover as follows.
Clutch cover bolt (b): 23 N·m (2.3 kgf-m, 17.0 1) Check diaphragm spring (1) for abnormal wear or
lbf-ft) damage.
4, “4”, (a)
2) Check pressure plate (2) for wear or heat spots.
3) Replace clutch cover if defective.
3, “2”, (b) Do not disassemble it into diaphragm spring and
1 pressure plate.

3, “1”, (b)
(B)

4, “5”, (a)
2

(A)

4, “6”, (a) I3RM0A530015-01

3, “3”, (b)
I9P60A531019-02

4) Join auto gear shift unit with engine. (Page 5D-

117)

NOTE
When inserting transaxle input shaft to clutch
disc, turn crankshaft little by little to match
the splines.

5) Initialize clutch system. (Page 5D-96)

5D-147 Automated Manual Transaxle:

Clutch Release System Component Removal

and Installation
AENJCA0A5406034

1
Removal
1) Remove release arm (1) by loosening its bolt (2).
2) Remove release bearing (3) by turning release shaft
(4).

IDL70A540121-02
2 4) Remove release shaft.
5) Remove clutch release shaft No.1 bushing as
follows, if necessary.
a) Install tap (M16 X 1.5) (1) to clutch release shaft
No.1 bushing (2).

3
IJCA0A540090-01

3) Remove clutch release shaft No.2 bushing and

release shaft seal as follows.
a) Drive out clutch release shaft No.2 bushing and
release shaft seal (1) together using special tool
and hammer, and remove release shaft seal. 2 1

Special tool
(A): 09922M46010 IDL70A540122-01

b) Connect special tools to tap (1) and pull out No.1

bushing.
Special tool
(B): 09923M46030
(C): 09930M30104
1

(A)

IDL70A540120-01

b) Pry out clutch release shaft No.2 bushing (1)

using pliers.
1 (B) (C) (C)

IDL70A540123-01
 Automated Manual Transaxle: 5D-148

Installation
1) Press-fit a new No.1 bushing (1) using special tool,
suitable bar (2) and hammer, and then apply grease
to bushing inside. 1, “A”

“A”: Grease 99000–25011 (SUZUKI Super

Grease A)
Special tool
(A): 09923M46030

(A)

1, “A” (A) 2

IJCA0A540091-01

2) Install release shaft.

3) Apply grease to No.2 bushing (1) inside and press-fit
it using the same special tool used for removal.
IJCA0A540093-01
“A”: Grease 99000–25011 (SUZUKI Super
6) Apply grease to release shaft (2), and then set
Grease A)
release bearing (1).
Special tool
“A”: Grease 99000–25011 (SUZUKI Super
(A): 09922M46010
Grease A)

(A) 1, “A”

“A”

“A”

IJCA0A540092-01 1

4) Apply grease to release shaft seal (1) lip, and then IDL70A540125-01
install it using special tool facing its lip downward
7) Set release arm (1) to release shaft (2) aligning
(inside) until it is flush with case surface.
punch mark (4) of release arm with groove (3) of
“A”: Grease 99000–25011 (SUZUKI Super release shaft. Then tighten release arm bolt to
Grease A) specified torque.
Special tool Tightening torque
(A): 09925M98221 Release arm bolt (a): 23 N·m (2.3 kgf-m, 17.0 lbf-
ft)
5) Caulk right case at three points (2) as follows.
5D-149 Automated Manual Transaxle:

Clutch Release Shaft and Bushing

Check clutch release shaft and bushings for the
following points.
• Deflection or damage of shaft and its pin.
3
• Smooth rotation of the shaft.
• Wear, noise of bushings.
4 If any abnormality is found, replace the parts.
2

(a) 1

IDL70A540126-01

Clutch Release System Component Inspection

AENJCA0A5406035

Clutch Release Bearing

Check clutch release bearing (1) for smooth rotation. If
abnormality is found, replace it.

NOTICE
IJCA0A540094-01
If the release bearing is washed, the grease
contained within the release bearing may
wash away, causing the bearing to seize up.
Do not wash the release bearing.

I7V20A531009-01

Specifications
Tightening Torque Specifications
AENJCA0A5407001
NOTE
For fastener(s) with * (asterisk) below, refer to the specified procedure in “Repair Instructions”.

Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Oil level / filler plug (Page 5D-98) /
21 2.1 15.5
(Page 5D-99)
Oil drain plug 21 2.1 15.5 (Page 5D-99)
Shift selector nut 13 1.3 9.5 (Page 5D-101)
Shift selector knob 6.0 0.61 4.5 (Page 5D-103)
Auto gear shift actuator unit bolt 23 2.3 17.0 (Page 5D-108)
Auto gear shift actuator unit nut 23 2.3 17.0 (Page 5D-108)
Actuator bracket bolt 23 2.3 17.0 (Page 5D-108)
Oil reservoir tank lower screw 10 1.0 7.5 (Page 5D-110)
Oil reservoir tank upper screw 10 1.0 7.5 (Page 5D-110)
 Automated Manual Transaxle: 5D-150

Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Oil reservoir tank cap 2 0.2 1.5 (Page 5D-111)
Auto gear shift electric motor screw 6 0.6 4.5 (Page 5D-113)
TCM mounting screw 6 0.6 4.5 (Page 5D-114)
Gear shift and select shaft assembly bolt 23 2.3 17.0 (Page 5D-115)
Clutch speed sensor bolt 10 1.0 7.5 (Page 5D-115)
VSS bolt 10 1.0 7.5 (Page 5D-116)
Ground terminal bolt 25 2.5 18.5 (Page 5D-119)
Reverse gear shift lever bolt 10 1.0 7.5 (Page 5D-123)
Transaxle case bolt 23 2.3 17.0 (Page 5D-124)
Reverse gear shaft bolt 23 2.3 17.0 (Page 5D-125)
Bearing stopper plate bolt 10 1.0 7.5 (Page 5D-129)
Final gear bolt 100 10.2 74.0 (Page 5D-144)
Clutch cover bolt* 5.0 Nm → 23 Nm (0.51 kgf-m → 2.3 kgf- (Page 5D-146)
m, 4.0 lbf-ft → 17.0 lbf-ft)
Clutch cover bolt 23 2.3 17.0 (Page 5D-146)
Release arm bolt 23 2.3 17.0 (Page 5D-148)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Shift Selector Components” (Page 5D-100)
“Gear Shift and Select Shaft Assembly Components” (Page 5D-114)
“Auto Gear Shift Unit Components” (Page 5D-117)
“Auto Gear Shift Components” (Page 5D-120)
“Gear Shift Shaft Components” (Page 5D-140)
“Differential Components” (Page 5D-141)
“Clutch Cover and Clutch Disc Components” (Page 5D-145)
“Fasteners Information” in Section 0A (Page 0A-6)

Special Tools and Equipment

Recommended Service Material
AENJCA0A5408001
Material SUZUKI recommended product or Specification Note
Grease SUZUKI Super Grease A P/No.: 99000–25011 (Page 5D-99) / (Page
5D-108) / (Page 5D-128) /
(Page 5D-148) / (Page
5D-148) / (Page 5D-148) /
(Page 5D-148)
Oil Auto gear shift actuator oil (550 ML) P/No.: 99000–24121– (Page 5D-111)
135
Sealant SUZUKI Bond No.1217G P/No.: 99000–31260 (Page 5D-98) / (Page
5D-99) / (Page 5D-99) /
(Page 5D-114) / (Page
5D-124)

NOTE
Required service material(s) is also described in:
“Auto Gear Shift Components” (Page 5D-120)
“Input Shaft Components” (Page 5D-130)
“Countershaft Components” (Page 5D-135)
“Differential Components” (Page 5D-141)
“Clutch Cover and Clutch Disc Components” (Page 5D-145)

Special Tool
AENJCA0A5408002
5D-151 Automated Manual Transaxle:

09900M20607 09900M20701
Dial gauge Magnetic stand
(Page 5D-142) (Page 5D-142)

09912M34510 09913M50121
Case separator Oil seal remover
(Page 5D-122) (Page 5D-99) /
(Page 5D-127)

09913M70123 09913M75510
Bearing installer Bearing installer
(Page 5D-128) (Page 5D-143)

09913M75821 09913M76010
Bearing installer attachment Bearing installer
(Page 5D-141) / (Page 5D-143) /
(Page 5D-142) (Page 5D-143)

09913M80113 09913M84510
Bearing installer Bearing installer
(Page 5D-128) / (Page 5D-132) /
(Page 5D-132) / (Page 5D-133)
(Page 5D-133) /
(Page 5D-137) /
(Page 5D-139)
09913M85210 09913M85230
Bearing installer Bearing remover tool
(Page 5D-127) / (Page 5D-143)
(Page 5D-128)

09921M05520 09922M28111
Actuator stand Reverse gear shift lever
positioner
(Page 5D-109) / (Page 5D-123)
(Page 5D-111)

09922M36310 09922M46010
Oil level gauge Clutch bushing remover
(Page 5D-98) (Page 5D-147) /
(Page 5D-148)
 Automated Manual Transaxle: 5D-152

09922M85811 09923M36320
Spring pin remover (4.5 mm) Clutch center guide (15 mm)
(Page 5D-142) / (Page 5D-146)
(Page 5D-143)

09923M46030 09924M17811
Joint pipe Flywheel holder
(Page 5D-147) / (Page 5D-145) /
(Page 5D-148) (Page 5D-146)

09924M74510 09924M74590
Bearing and oil seal handle Input shaft oil seal installer
attachment
(Page 5D-99) / (Page 5D-125)
(Page 5D-125)

09925M16510 09925M18011
Oil seal installer Transmission gear, bush
and bearing installer
(Page 5D-125) / (Page 5D-138) /
(Page 5D-128) (Page 5D-138) /
(Page 5D-138)

09925M57610 09925M98221
Rubber boot installer Bearing installer
(Page 5D-107) / (Page 5D-148)
(Page 5D-109) /
(Page 5D-110)

09926M37610M003 09930M30104
Bearing remover attachment Sliding shaft
(Page 5D-128) (Page 5D-127) /
(Page 5D-147)

09932M97690 09940M51710
Guide Bearing installer
(Page 5D-113) / (Page 5D-138)
(Page 5D-114)

09941M64511 09944M66060
Bearing and oil seal remover Bearing installer
(30 mm min.)
(Page 5D-127) (Page 5D-134)
5D-153 Automated Manual Transaxle:

09944M77030 09944M88220
Bearing / cover installer Oil seal installer
support
(Page 5D-143) (Page 5D-99)

SUZUKI scan tool (SUZUKI

SDT-II)
—
(Page 5D-21) /
(Page 5D-21) /
(Page 5D-96) /
(Page 5D-96) /
(Page 5D-97) /
(Page 5D-98) /
(Page 5D-104)

Section 6
Steering
CONTENTS
Precautions .................................................6-1
Precautions............................................................. 6-1
Precautions for Steering ....................................... 6-1
Steering General Diagnosis.................... 6A-1
Precautions...........................................................6A-1
Precautions for Steering General Diagnosis ....... 6A-1
Diagnostic Information and Procedures............6A-1
Steering Symptom Diagnosis.............................. 6A-1
Steering Wheel and Column................... 6B-1
Precautions...........................................................6B-1
Precautions for Steering Wheel and Column ...... 6B-1
General Description .............................................6B-1
Steering Wheel and Column Construction .......... 6B-1
Diagnostic Information and Procedures............6B-1
Checking Steering Column for Accident
Damage ............................................................ 6B-1
Repair Instructions ..............................................6B-2
Steering Wheel and Column Components.......... 6B-2
Steering Wheel Removal and Installation ........... 6B-3
Contact Coil Assembly Removal and
Installation ......................................................... 6B-4
Centering of Contact Coil Assembly ................... 6B-6
Contact Coil Assembly Inspection....................... 6B-6
Steering Column Removal and Installation ......... 6B-7
Steering Shaft Joint On-Vehicle Inspection ........ 6B-8
Steering Column Inspection ................................ 6B-8
Steering Lower Shaft Inspection ......................... 6B-9
Steering Lock Removal and Installation.............. 6B-9
Steering Lock Disassembly and Reassembly ... 6B-10
Steering Lock Inspection................................... 6B-11
Ignition Switch Removal and Installation........... 6B-11
Ignition Switch Inspection ................................. 6B-12
Steering Lower Shaft Removal and
Installation ....................................................... 6B-12
Steering Gear Case Assembly Components .... 6B-14
Tie-Rod End Boot On-Vehicle Inspection ......... 6B-15
Tie-Rod End Removal and Installation.............. 6B-15
Tie-Rod End Inspection .................................... 6B-16
Steering Gear Case Assembly Removal and
Installation ....................................................... 6B-16
Steering Rack Boot Inspection.......................... 6B-17
Tie-Rod / Rack Boot Removal and Installation .. 6B-17
Table of Contents 6- i
Pinion Shaft Rotation Torque Inspection...........6B-18
Pinion Shaft Rotation Torque Adjustment .........6B-19
Specifications .....................................................6B-20
Tightening Torque Specifications......................6B-20
Special Tools and Equipment ...........................6B-21
Recommended Service Material .......................6B-21
Special Tool ......................................................6B-21
Power Assisted Steering System........... 6C-1
Precautions...........................................................6C-1
Precautions for Diagnosing Trouble....................6C-1
General Description .............................................6C-1
P/S System Description ......................................6C-1
Description of EPS System Component
Function ............................................................6C-1
P/S Control Module Input / Output Diagram........6C-4
OBD System Description ....................................6C-5
Schematic and Routing Diagram ........................6C-6 6
P/S System Circuit Diagram................................6C-6
Component Location ...........................................6C-8
Power Steering Control System Component
Location.............................................................6C-8
Diagnostic Information and Procedures ............6C-9
P/S System Check ..............................................6C-9
Electric Power Steering Warning Light Check ..6C-11
DTC Check........................................................6C-12
DTC Clearance .................................................6C-12
DTC Table.........................................................6C-13
Fail-Safe Table..................................................6C-14
Scan Tool Data .................................................6C-15
Visual Inspection ...............................................6C-16
P/S System Symptom Diagnosis ......................6C-16
Electric Power Steering Warning Light Does
Not Come ON with Ignition “ON” before
Engine Starts...................................................6C-17
Electric Power Steering Warning Light
Remains ON Steady after Engine Starts.........6C-19
DTC C1111 / C1113 / C1114 / C1115 ..............6C-19
DTC C1141 / C1142 / C1143 / C1145 ..............6C-21
DTC C1152 / C1154..........................................6C-22
DTC C1153 .......................................................6C-23
DTC C1155 / C1157..........................................6C-24
DTC C1160 .......................................................6C-25
DTC C1161 / C1162 / C1166 ............................6C-26
6-ii Table of Contents
DTC U0073 .......................................................6C-27
DTC U0100 .......................................................6C-27
P/S Control Module Power Supply and
Ground Circuit Check......................................6C-27
Inspection of P/S Control Module and Its
Circuits ............................................................6C-28
Steering Wheel Play Check ..............................6C-31
Steering Force Check .......................................6C-31
Repair Instructions ............................................6C-32
P/S Control Module Removal and Installation...6C-32
Torque Sensor and Its Circuit Inspection ..........6C-32
P/S Motor and Its Circuit Inspection ..................6C-33
Specifications .....................................................6C-34
Tightening Torque Specifications......................6C-34
Special Tools and Equipment ...........................6C-34
Special Tool ......................................................6C-34
 Precautions: 6-1

Precautions
Steering

Precautions
Precautions for Steering
AENJCA0A6000001
General Precautions
Refer to “General Precautions” in Section 00 (Page 00-1).

Precautions for Electrical Circuit Service

Refer to “Precautions for Electrical Circuit Service” in Section 00 (Page 00-3).

Caution for Fastener

Refer to “Caution for Fastener” in Section 00 (Page 00-6).

Warning for Airbag

Refer to “Warning for Airbag” in Section 00 (Page 00-7).

Warning for Vehicle Equipped with Supplemental Restraint (Airbag) System

Refer to “Warning for Vehicle Equipped with Supplemental Restraint (Airbag) System” in Section 00 (Page 00-7).

Reassembling Note for Wiring Harness

Observe “Reassembling Note for Wiring Harness” in Section 9A (Page 9A-132) whenever installing wiring harness.
Otherwise, electrical trouble may occur.

Warning for P/S System

Refer to “Warning for P/S System” in Section 00 (Page 00-7).
6A-1 Steering General Diagnosis:
Steering General Diagnosis
Steering
Precautions
Precautions for Steering General Diagnosis
Since the problems in steering involve several systems, such possibilities should be fully considered when diagnosing
a complaint. To avoid being misled by an unclear symptom, always perform the road test first. Proceed with the
following preliminary inspection and correct defects if any.
1) Check tires for proper pressure and uneven wear.
2) Hoist vehicle and check steering system for loose or damaged parts.
3) Spin front wheels. Check for out-of-round tires, out-of-balance tires, bent rims, loose and/or rough wheel bearings.
Diagnostic Information and Procedures
Steering Symptom Diagnosis
Condition Possible cause
Hard steering Insufficient tire pressure
Binding tie-rod end ball joint
Binding suspension arm ball joint
Binding steering column
Improper tooth contact between rack
and pinion
Malfunction of power steering system
Disturbed front wheel alignment
Too much play in steering Loose or rattle steering wheel
Worn wheel bearing(s)
Loose steering gear case bolt
Worn joint of steering column
Worn tie-rod end or tie-rod ball joint
Worn suspension arm joint
Improper tooth contact between rack
and pinion
Faulty steering gear case assembly
AENJCA0A6100001
AENJCA0A6104001
Correction / Reference Item
Adjust tire pressure.
Replace tie-rod end. (Page 6B-15)
Replace suspension arm. (Page 2B-10)
Replace steering column assembly. (Page
6B-7)
Check pinion shaft rotation torque or replace
steering gear case assembly.
• Pinion shaft rotation torque: (Page 6B-18)
• Steering gear case assembly: (Page 6B-
16)
Check and correct. (Page 6C-9)
Check and adjust front wheel alignment.
(Page 2B-2)
Check steering wheel play. (Page 6C-31)
Replace wheel bearing(s). (Page 3A-10)
Tighten steering gear case bolt. (Page 6B-
16)
Replace steering column assembly. (Page
6B-7)
Replace tie-rod end or tie-rod.
• Tie-rod end: (Page 6B-15)
• Tie-rod: (Page 6B-17)
Replace suspension arm. (Page 2B-10)
Check pinion shaft rotation torque or replace
steering gear case assembly.
• Pinion shaft rotation torque: (Page 6B-18)
• Steering gear case assembly: (Page 6B-
16)
Replace steering gear case assembly. (Page
6B-16)

Condition Possible cause
Poor return ability Insufficient tire pressure
Binding tie-rod end ball joint
Binding suspension arm joint
Binding steering column
Improper tooth contact between rack
and pinion
Malfunction of power steering system
Faulty steering gear case assembly
Disturbed front wheel alignment
Steering noise (Rattle or Broken or damaged wheel bearing(s)
chuckle) Worn tie-rod end or tie-rod ball joint Replace tie-rod end or tie-rod.
Loose steering gear case bolt
Improper tooth contact between rack
and pinion
Faulty steering column
Faulty steering gear case assembly
Wander or poor steering Mismatched tire or uneven tire pressure Replace or adjust tire pressure. (Page 2D-3)
stability Loose suspension arm joint and tie-rod Replace suspension arm or tie-rod end.
end
Faulty front strut assembly or mounting Replace front strut assembly or repair
Broken or sagging coil spring
Loose stabilizer bar
Improper tooth contact between rack
and pinion
Malfunction of power steering system
Faulty steering gear case assembly
Disturbed front wheel alignment
Steering General Diagnosis: 6A-2
Correction / Reference Item
Adjust tire pressure.
Replace tie-rod end. (Page 6B-15)
Replace suspension arm. (Page 2B-10)
Replace steering column. (Page 6B-7)
Check pinion shaft rotation torque or replace
steering gear case assembly.
• Pinion shaft rotation torque: (Page 6B-18)
• Steering gear case assembly: (Page 6B-
16)
Check and correct. (Page 6C-9)
Replace steering gear case assembly. (Page
6B-16)
Check and adjust front wheel alignment.
(Page 2B-2)
Replace wheel bearing(s). (Page 3A-10)
• Tie-rod end: (Page 6B-15)
• Tie-rod: (Page 6B-17)
Tighten steering gear case bolt. (Page 6B-
16)
Check pinion shaft rotation torque or replace
steering gear case assembly.
• Pinion shaft rotation torque: (Page 6B-18)
• Steering gear case assembly: (Page 6B-
16)
Replace steering column assembly. (Page
6B-7)
Replace steering gear case assembly. (Page
6B-16)
• Suspension arm: (Page 2B-10)
• Tie-rod end: (Page 6B-15)
mounting. (Page 2B-6)
Replace coil spring. (Page 2B-8)
Tighten or replace stabilizer bar or bushing.
(Page 2B-15)
Check pinion shaft rotation torque or replace
steering gear case assembly.
• Pinion shaft rotation torque: (Page 6B-18)
• Steering gear case assembly: (Page 6B-
16)
Check and correct. (Page 6C-9)
Replace steering gear case assembly. (Page
6B-16)
Check and adjust front wheel alignment.
(Page 2B-2)
6A-3 Steering General Diagnosis:

Condition Possible cause Correction / Reference Item

Erratic steering when Uneven tire pressure Adjust tire pressure.
braking Worn wheel bearing(s) Replace wheel bearing(s). (Page 3A-10)
Brakes not working in unison Check and repair brake system. (Page 4A-2)
Front brake disc stained with brake fluid Clean and check brake disc and caliper.
• Brake disc: (Page 4B-4)
• Brake caliper: (Page 4B-10)
Warped brake disc Replace brake disc. (Page 4B-4)
Badly worn brake pad Replace brake pad. (Page 4B-2)
Broken or sagging coil spring Replace coil spring. (Page 2B-8)
Faulty front strut assembly (shock Replace front strut assembly (shock absorber).
absorber) (Page 2B-8)
Disturbed front wheel alignment Check and adjust front wheel alignment.
(Page 2B-2)
Steering lock does not Faulty steering lock (ignition switch Check steering lock. (Page 6B-11)
operate (not locked or model) / auto steering lock (keyless
released) push start model)
 Steering Wheel and Column: 6B-1

Steering Wheel and Column

Steering

Precautions
Precautions for Steering Wheel and Column
AENJCA0A6200001
For service precautions, refer to “Precautions for Handling and Storage of Airbag System Components” in Section 8B
(Page 8B-1).

General Description
Steering Wheel and Column Construction
AENJCA0A6201001
• The steering column is 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:
– Two types of steering column, tilt type and non-tilt type are provided. The tilt type steering column is provided with
a tilt adjustment mechanism. This mechanism allows step-less adjustment of the whole steering column in up-
and-down directions.
– The steering column incorporates a steering lock to help prevent theft. The ignition switch is installed on the
steering column together with the steering lock.
When servicing the steering column, it is important that only the specified fasteners be used and they are tightened
exactly to the specified torques to keep the collapsible steering column and other features fully workable. It is also
important to carefully handle the steering column during and after its removal from the vehicle, such as preventing the
use of a steering wheel puller and avoiding hammering the end of the steering shaft, leaning the removed steering
column assembly against the wall or any other object, or dropping the assembly. These precautions should be
observed to prevent the capsules that keep the designed length and position of the steering column from being
loosened.
• The steering wheel has the driver airbag (inflator) module of the supplemental restraint (airbag) system installed at
the center. During service operations on the steering wheel, the airbag (inflator) module should be handled carefully
while observing all instructions in “Precautions for Airbag System Service” in Section 8B (Page 8B-1) to prevent
accidental deployment.

Diagnostic Information and Procedures

Checking Steering Column for Accident Damage
AENJCA0A6204001
Refer to “Steering Column Inspection” (Page 6B-8).
6B-2 Steering Wheel and Column:

Repair Instructions
Steering Wheel and Column Components
AENJCA0A6206001

11 (b)

8
6

5 12 (b)

(a)

10 (c)

9 (c)
2

13 16

4
14

15
IJCA0A620001-01
 Steering Wheel and Column: 6B-3

1. Driver airbag (inflator) module
2. Steering wheel
3. Steering column upper cover
4. Steering column lower cover
5. Contact coil assembly
: Center contact coil cable assembly.
(Page 6B-6)
6. Steering column
7. Steering lower shaft
8. Steering column assembly 15. Ignition switch cylinder
9. Steering column nut 16. Steering joint cover
: For tightening order, refer to “Steering
Column Removal and Installation” (Page
6B-7).
10. Steering column lower bolt : 33 Nm (3.4 kgf-m, 24.5 lbf-ft)
: For tightening order, refer to “Steering
Column Removal and Installation” (Page
6B-7).
11. Steering column joint bolt : 35 Nm (3.6 kgf-m, 26.0 lbf-ft)
: For tightening order, refer to “Steering
Lower Shaft Removal and Installation”
(Page 6B-12).
12. Steering lower shaft joint bolt : 14 Nm (1.4 kgf-m, 10.5 lbf-ft)
: For tightening order, refer to “Steering
Lower Shaft Removal and Installation”
(Page 6B-12).
13. Ignition switch : Do not reuse.
14. Steering lock

Steering Wheel Removal and Installation Special tool

AENJCA0A6206002 (A): 09944M36011
NOTICE
• The coil in the contact coil assembly will
break if the contact coil is turned too
much.
Do not turn contact coil more than about
two and a half turns in either direction from
the neutral position.
• The impact energy absorbing function of
the steering column assembly may be (A)

impaired if the steering column assembly IFRA0A620002-01

receives an excessively large force.

Be careful not to strongly impact the
steering column assembly when removing
and installing steering wheel.

Removal
1) Park vehicle on a level surface, apply parking brake,
set steering wheel in straight ahead position and set
ignition “OFF”.
2) Disconnect negative (–) cable at battery.
3) Disable airbag system. (Page 8B-56)
4) Remove driver airbag (inflator) module from steering
wheel. (Page 8B-59)
5) Disconnect steering switch connector (if equipped).
6) Remove steering shaft nut and then make alignment
marks (1) across steering wheel and shaft for correct
reinstallation.

I4RS0A620005-01

7) Remove steering wheel using special tool.

6B-4 Steering Wheel and Column:

Installation Contact Coil Assembly Removal and

Installation
NOTICE AENJCA0A6206003

If the operations in Step 1) – 3) are omitted or NOTICE

not performed as instructed, the contact coil
assembly will break when the steering wheel
is turned.
Perform Step 1) – 3) exactly as instructed.
1) Check that vehicle's front wheels are at straight
ahead position.
Removal
2) If contact coil is turned after removing steering
wheel, center contact coil assembly. (Page 6B-6)
3) Install steering wheel to steering shaft with 2 grooves
(1) in contact coil assembly fitted on 2 lugs (2) on
back side of steering wheel, while aligning marks (3)
on steering wheel and steering shaft each other.
4) Tighten steering shaft nut (4) to specified torque.
The coil in the contact coil assembly will
break if the contact coil is turned too much.
Do not turn the contact coil more than about
two and a half turns in either direction from
the neutral position.
1) Remove steering wheel from steering column.
(Page 6B-3)
2) Remove standard screw (1), and then detach
steering column lower cover (2).
3) Remove tapping screws (3), and then detach
steering column upper cover (4).

Tightening torque 4
Steering shaft nut (a): 33 N·m (3.4 kgf-m, 24.5 3
lbf-ft)

4,(a)

1
2
I9P60A620004-02

4) Disconnect contact coil assembly connector (1) as

follows.
1
I9P60A620003-01
a) Release locking slider (2) by sliding it in arrow
direction “1”.
5) Connect steering switch connector (if equipped).
b) After unlocking, disconnect contact coil
6) Install driver airbag (inflator) module to steering
assembly connector by pulling it in arrow
wheel. (Page 8B-59)
direction “2”.
7) Connect negative (–) cable at battery. Without steering switch
8) Enable airbag system. (Page 8B-57)

“1”
2

“2” 1

IFKA0P620009-01
 Steering Wheel and Column: 6B-5

With steering switch Installation

1) Check that vehicle’s front wheels are in straight
ahead position.
2) Install contact coil assembly (1) to lighting switch
3 securely.

NOTE
New contact coil assembly is supplied with
“2” contact coil set and held at its center position
1
with a lock pin (2). Remove this lock pin after
installing contact coil assembly to lighting
“1”
2 switch.
IFKA0P620010-01

3: Contact coil assembly

5) Disconnect horn connector (1).

I9P60A620008-01

3) Connect contact coil assembly connector (1) and

1
horn connector (2) to contact coil assembly (3)
securely. Check that contact coil assembly connector
is locked.

I8C50A620010-01

6) Release claws (2) and remove contact coil assembly 3

(1).

2
1
1

IBP80A620007-01

I9P60A620007-02
6B-6 Steering Wheel and Column:

4) Install steering column upper cover (4) with tapping
screws (3).
5) Install steering column lower cover (2) with standard
screw (1).
NOTICE
Lead wires will be damaged if they get
pinched when you install the covers.
Check that there is no wire caught between
the covers before securing the covers.
4) From the position of Step 3), turn contact coil
assembly clockwise to place connector at top
position within one rotation.
5) Turn rotation part (2) two turns clockwise to place
connector (1) at top position. Check that triangle
mark (4) on rotation part is aligned with that on
stationary part (3) and flat cable (6) is visible in hole
(5) as shown in figure.
6

5
4 1
3

2
2

1
I9P60A620004-02

6) Install steering wheel to steering column. (Page

6B-3) 4

Centering of Contact Coil Assembly

AENJCA0A6206004
3
1) Remove steering wheel. (Page 6B-3) IDL10A620003-01
2) Check that ignition is “OFF”.
3) Turn contact coil counterclockwise slowly with a light Contact Coil Assembly Inspection
AENJCA0A6206005
force till contact coil will not turn any further.
Refer to “Contact Coil and Its Circuit Check” in Section
NOTE 8B (Page 8B-52).
Contact coil can turn about 5 turns at
maximum, that is, if it is at the center
position, it can turn about two and a half
turns both clockwise and counterclockwise.

IDL10A620002-01
 Steering Wheel and Column: 6B-7

Steering Column Removal and Installation 6) Disconnect both key reminder switch connector (1)
AENJCA0A6206006 and ignition switch connector (2).
NOTICE 7) Detach steering column harness clamps (3).
The steering column assembly can be easily 8) Remove steering column nuts (4) and steering
damaged during and after removal. column lower bolt (5).
To avoid damaging the steering column
assembly, take the following precautions
when removing it and when setting it down
after removal:
3
• Do not release tilt lever with steering
column nuts loosened or steering column 2
removed from vehicle. Doing so may
increase operating force for tilt motion. 1

• The impact energy absorbing function of

the steering column assembly may be
impaired if the steering column assembly 4 4
receives an excessively large force.
Be careful not to strongly impact the 3
steering column assembly when removing
and installing it. 5

• Never drop the steering column assembly

on its end. This could collapse the steering
shaft or loosen capsules that maintain the
IJCA0A620003-01
design length of the column.
• Do not lean the steering column assembly 9) Remove steering column.
against something. This could cause it to
bend or deform. Installation
• Do not loosen the steering column nuts NOTICE
when the steering lower shaft is still
Tightening the fasteners in the wrong order
installed. This could cause damage to the
may cause damage to the steering shaft joint
shaft joint bearing.
of steering column.
Tighten the steering column nuts in the order
Removal
given before installing the steering lower
1) Remove contact coil assembly. (Page 6B-4) shaft.
2) Remove immobilizer control module from steering
lock. (Page 10C-16) 1) Check that vehicle’s front wheels are in straight
3) Remove lighting switch and wiper switch. ahead position.
• Lighting switch: (Page 9B-10) 2) Install steering column.
• Wiper switch: (Page 9D-9) 3) Tighten steering column lower bolt (1) to specified
torque.
4) Remove steering lower shaft. (Page 6B-12)
4) Install steering column nuts (2) to specified torque.
5) Disconnect P/S control module connector (1).
Tightening torque
Steering column lower bolt (a): 14 N·m (1.4 kgf-
m, 10.5 lbf-ft)
Steering column nut (b): 14 N·m (1.4 kgf-m, 10.5
lbf-ft)
5) Check that tilt functions operate smoothly when the
lever is released, and the functions are securely
fixed when lever is locked.

IJCA0A620002-01
6B-8 Steering Wheel and Column:

6) Connect both key reminder switch connector (3) and
ignition switch connector (4).
7) Attach steering column harness clamps (5) in place.
Steering Shaft Joint On-Vehicle Inspection
AENJCA0A6206007
Check steering shaft joint for wear, breakage and any
other damage. Replace steering column assembly with
new one if defective.

2, (b) 2, (b)

I9P60A620041-01
1, (a)

Steering Column Inspection

AENJCA0A6206008

IJCA0A620004-01 NOTE
8) Connect P/S control module connector (1). Steering column assembly should be
checked if vehicle was involved in an
accident and steering column assembly was
exposed to impact or airbag deployed.

Perform the following checks if damage to steering

column assembly is suspected. If check result is not OK,
replace steering column assembly with new one.
• Check that two capsules (1) are attached to steering
column bracket securely.

1
1

IJCA0A620002-01

9) Install steering lower shaft. (Page 6B-12)

10) Install lighting switch and wiper switch.
• Lighting switch: (Page 9B-10)
• Wiper switch: (Page 9D-9) IFRA0A620004-01

11) Install immobilizer control module to steering lock. • Check steering column assembly for looseness in
(Page 10C-16) arrow directions [a] and [b] in figure with tilt lever
12) Install contact coil assembly. (Page 6B-4) locked.
13) Enable airbag system. (Page 8B-57)

[a]

[b]

IFRA0A620005-01
 Steering Wheel and Column: 6B-9

• Check that distances “a”, “b” and “c” shown in figure Steering Lock Removal and Installation
are as specified. AENJCA0A6206010
Removal
Power steering column length
“a”: 423.0 ± 1.5 mm (16.65 ± 0.059 in.) ! WARNING
“b”: 225.0 ± 1.5 mm (8.858 ± 0.059 in.)
Steering lock is made of magnesium.
“c”: 110.5 ± 1.3 mm (4.350 ± 0.051 in.)
Drilling, cutting or filing the steering lock
“a”
may spark to ignite magnesium powder,
causing a fire or burn.
Do not perform drilling, cutting or filing
magnesium powder on the steering lock.

NOTICE
Failure to take the following precautions
when removing or installing the steering lock
can cause failure of the steering lock.
• Do not drop or otherwise expose the
steering lock to large shock. Any steering
lock that has received large shock should
be replaced.
• Keep the steering column and/or the
steering lock free of oil, water, dust or
other foreign materials.

1) Remove steering column (1). (Page 6B-7)

2) Hold steering column using vise.
“b”
3) Loosen steering lock bolt(s) (2) using chisel, and
then remove steering lock (3) from steering column.

“c”

3
1
IFRA0A620006-01

Steering Lower Shaft Inspection

AENJCA0A6206009
• Adjust distance “a” between yoke centers of steering
lower shaft bearing to 295.5 mm (11.63 in.).
• Then check that steering lower shaft retracts by 20 2
IJCA0A620006-01
mm (0.78 in.) and extends by 10 mm (0.39 in.) from
distance “a”.

[a]

[b]

1
1
“a”
IAP70A620006-01

[a]: Retracts by 20 mm (0.78 in.) 1. Yoke

[b]: Extends by 10 mm (0.39 in.)

• Check steering lower shaft for smooth rotation.

6B-10 Steering Wheel and Column:

Installation 4) Install steering column. (Page 6B-7)

1) Align oblong hole (2) in steering shaft (3) with center 5) Set ignition to “ACC” or “ON” and check that steering
of hole (1) in steering column. shaft rotates smoothly. Then set ignition to “LOCK”
Turn ignition key to “LOCK” position and pull it out, (“OFF”) (and pull out key) and check that steering
and then align lug of steering lock with hole in wheel is locked.
steering shaft. 6) If ignition switch cylinder has been replaced, register
ignition key transponder code in BCM after
completing installation. (Page 9F-13)
7) Check steering column and torque sensor after
installation. If faulty condition is found, replace
3 steering column.
• Steering column: (Page 6B-8)
1 • Torque sensor: (Page 6C-32)

2
Steering Lock Disassembly and Reassembly
AENJCA0A6206011

NOTE
Ignition switch and ignition switch cylinder
can be replaced without removing steering
IFRA0A620008-01
lock.
2) Install steering lock to steering shaft with key When removing steering lock, refer to
cylinder (1) toward steering wheel. “Steering Lock Removal and Installation”
(Page 6B-9).
[a] Disassembly
1) Remove ignition switch (1). (Page 6B-11)
2) Turn ignition key to “ACC”, and then push lock button
(4) on ignition switch cylinder using a rod (2) of about
2 mm (0.08 in) in diameter inserted through hole (3).
3) Pull out ignition switch cylinder (5) from steering lock
1 (6).

1
IJCA0A620007-01
6
[a]: Steering wheel side

3) Tighten new steering lock bolts (1) until head of each

bolt is broken off.

1
3
4

IJCA0A620009-01

Reassembly
Reverse removal procedure noting the following points.
• Turn ignition key to “ACC”, and then insert ignition
switch cylinder into steering lock securely.
IJCA0A620008-01 • If ignition switch cylinder has been replaced, register
ignition key transponder code in BCM after completing
installation. (Page 10B-46)
 Steering Wheel and Column: 6B-11

Steering Lock Inspection Ignition Switch Removal and Installation

AENJCA0A6206012 AENJCA0A6206014
Key Reminder Switch Inspection Removal
1) Disconnect key reminder switch connector (1) from 1) Disconnect negative (–) cable at battery.
steering lock (2). 2) Remove steering column upper cover and lower
2) Check continuity between terminals of key reminder cover. (Page 6B-4)
switch connector. 3) Check that ignition key is removed.
If check result is not as specified, replace steering
4) Disconnect connector from ignition switch.
lock.
5) Remove ignition switch (2) from steering lock while
pushing claws (1) in arrow direction.
2

2
[C]
2 1
1

1
IJCA0A620010-01

Key reminder switch continuity

1
[A]
1 2
[B]
IJCA0A620012-01
[C]

[D] Installation
I9P60A620034-02
Reverse removal procedure.
[A]: Terminal [C]: Key inserted
[B]: Condition [D]: Key pulled out

Steering Lock Inspection

1) Insert ignition key (1).
2) Check lock shaft (2) for operation as follows.
a) Lock shaft moves in arrow direction “1”, when
turning ignition key to “ACC” or “ON”.
b) Lock shaft moves in arrow direction “2”, when
turning ignition key to “LOCK” and pulling out
ignition key.
If faulty condition is found, replace steering lock.

“1” “2”

2 1

IJCA0A620011-01
6B-12 Steering Wheel and Column:

Ignition Switch Inspection Steering Lower Shaft Removal and Installation

AENJCA0A6206015 AENJCA0A6206016
• Check for continuity between terminals at each switch
NOTICE
position. If check result is not as specified, replace
ignition switch (1). If the steering wheel is turned with the
steering lower shaft removed, the neutral
setting of the contact coil may be disturbed.
If it is turned in either direction more than
about two and a half turns, the contact coil
will break.
Never turn the steering wheel with the
steering lower shaft removed.
3 2 1
6 5 4
Removal
1 1) Turn steering wheel so that vehicle’s front wheels
are at straight ahead position.
2) Set ignition “LOCK” and remove key.
IJCA0A620013-01
3) Remove steering joint cover. (Page 6B-2)
4) Make matchmarks (1) on the following parts for
Ignition switch continuity
correct reinstallation.
Terminal • Steering lower shaft joint (2) and steering column
1 2 3 4 5 6 (3)
Position
LOCK • Steering lower shaft joint and pinion shaft (4)
ACC
NOTE
ON Turn steering wheel a little for removal of
steering lower shaft joint bolt.
START
5) Remove steering column joint bolt (6) and steering
I9P60A620038-01 lower shaft joint bolt (5).
6) Remove steering lower shaft.

6
1
2

5 4

I9P60A620039-01
 Steering Wheel and Column: 6B-13

Installation

NOTICE
The steering lower shaft joint bolts are pre-
coated with friction stabilizer. If the bolts are
reused, they may work loose.
Never reuse the steering lower shaft joint
bolts.

1) Check that vehicle’s front wheels are in straight

ahead position.
2) Fit joint part of steering lower shaft (1) onto steering
column (2) and pinion shaft (3) while aligning
matchmarks (4).

NOTE
Turn steering wheel a little for installation of
steering lower shaft joint bolt (pinion shaft
side).

3) Tighten new steering column joint bolt and new

steering lower shaft joint bolt to specified torque in
numerical order (“1” through “2”) as shown in figure.
Tightening torque
Steering lower shaft joint bolt* (a): 35 N·m (3.6
kgf-m, 26.0 lbf-ft)
Steering column joint bolt* (b): 35 N·m (3.6 kgf-
m, 26.0 lbf-ft)

“2”, (b)

1
2

3
“1”, (a)
IJHB0A620002-01

4) Install steering joint cover. (Page 6B-2)

6B-14 Steering Wheel and Column:

Steering Gear Case Assembly Components

AENJCA0A6206017

(c)

10

9
11 (d) (c)

8 (a)

(a)

1
5
7

6
E

3 (b)

4 2

E
2

3 (b) 5

[f]
(a) 9
4
8 (a)

6
7
IJCA0A620014-01

[f]: Forward 6. Rack boot clip : 45 Nm (4.6 kgf-m, 33.5 lbf-ft)
1. Steering gear case 7. Tie-rod end : 84 Nm (8.6 kgf-m, 62.0 lbf-ft)
2. Tie-rod lock washer 8. Tie-rod end nut : 80 Nm (8.2 kgf-m, 59.0 lbf-ft)
: For removing and installing procedure of
tie-rod lock washer, refer to “Tie-Rod / Rack
Boot Removal and Installation” (Page 6B-
17).
3. Tie-rod 9. Clip : 69 Nm (7.0 kgf-m, 51.0 lbf-ft)
4. Band 10. Steering gear cover : Apply grease 99000-25050 to tie-rod,
referring to “Tie-Rod / Rack Boot Removal
and Installation” (Page 6B-17).
5. Boot 11. Steering rack damper screw lock nut : Do not reuse.
 Steering Wheel and Column: 6B-15

Tie-Rod End Boot On-Vehicle Inspection 3) Disconnect tie-rod end (1) from steering knuckle (2)
AENJCA0A6206018 using special tool.
Check boot for crack and damage.
Replace tie-rod end, if defective. Special tool
(A): 09913M65210

(A)

I9P60A630016-01

4) To facilitate adjustment after installation, make mark

(1) of tie-rod end lock nut (2) position on tie-rod end
thread. Then, loosen lock nut and remove tie-rod
IFRA0A620012-01 end (3) from tie-rod (4).

Tie-Rod End Removal and Installation

AENJCA0A6206019

Removal
1) Hoist vehicle, and then remove front wheel. (Page 2
2D-3)
2) Remove clip (2) and tie-rod end nut (1) from tie-rod
end.

1 4

IDAA0A630014-01

Installation
1) Install tie-rod end lock nut (2) and tie-rod end (3) to
tie-rod (4). Align lock nut with mark (1) on tie-rod
thread.
2

2
IFRA0A620013-01

1 4

IDAA0A630014-01
6B-16 Steering Wheel and Column:

2) Connect tie-rod end to steering knuckle. Tighten tie- Steering Gear Case Assembly Removal and
rod end nut (1) to specified torque. Installation
AENJCA0A6206021
Tightening torque
Tie-rod end nut (a): 45 N·m (4.6 kgf-m, 33.5 lbf- NOTICE
ft) Failure to take proper precautions before
3) Install new clip (2). starting the procedure below can result in
damage to the contact coil of the airbag
system.
Before starting the procedure below, set the
front wheels in straight ahead position and
then lock the steering wheel by removing
ignition key at “LOCK” position.

Removal
1) Remove front suspension frame with steering gear
case assembly. (Page 2B-15)
2) Remove steering gear cover (1) after detaching its
2
claws (3) from gear case.
3) Remove steering gear case bolts (4), and then
remove steering gear case assembly (2) from front
1, (a)
suspension frame.

IFRA0A620014-01 1
4) Install front wheel. (Page 2D-3)
5) Check for toe. (Page 2B-2)
6) After checking that toe is as specified, tighten tie-rod 3 2
end lock nut to specified torque.
Tightening torque
Tie-rod end lock nut: 45 N·m (4.6 kgf-m, 33.5 lbf- 1
2
ft)

Tie-Rod End Inspection

AENJCA0A6206020
• Check tie-rod end ball joint for play.
• Check tie-rod ball joint for play.
If result of either inspection is not OK, replace with
new one. 4 4
IJCA0A620015-01

Installation

NOTICE
The steering gear case bolts are pre-coated
with friction stabilizer. If these bolts are
reused, they may work loose.
I9P60A630019-01
Never reuse the steering gear case bolts.

1) Mount steering gear case assembly (1) to front

suspension frame.
 Steering Wheel and Column: 6B-17

2) Install new steering gear case bolts (2) to specified Tie-Rod / Rack Boot Removal and Installation
torques. AENJCA0A6206023

Tightening torque Removal

Steering gear case bolt (a): 80 N·m (8.2 kgf-m, 1) Remove steering gear case assembly. (Page 6B-
59.0 lbf-ft) 16)
3) Align grooves (3) in steering gear case and steering 2) Remove tie-rod end. (Page 6B-15)
gear cover (4) with each other. 3) Remove band (2) and rack boot clip (1).
4) Install new steering gear cover to steering gear case. 4) Remove boot (3) from tie-rod.
NOTICE
Once steering gear cover use, the packing
part transforms. If this cover is reused, water
may enter into gearbox.
Never reuse the steering gear cover.

2
3 1 3

IDAA0A630019-01
1
5) Unbend bent parts of tie-rod lock washer (1).
4
6) Hold steering rack end (4) using vise (2) with suitable
1
spacers (3) as shown and remove tie-rod (5) from
steering rack (6).

4 3

2, (a) 2, (a) “b”

IJCA0A620016-01

5) Install front suspension frame with steering gear “a”

case assembly. (Page 2B-15)

Steering Rack Boot Inspection

AENJCA0A6206022
Check the steering rack boot for the following points.
Repair or replace steering rack boot if defective.
• Check steering rack boot (3) for deformation, 5
deterioration or crack.
2
• Check steering rack boot clip (1) and band (2) for
fitting. 1
6

IDL10A630030-01

“a”: 5 mm (0.20 in.) “b”: 10 mm (0.39 in.) or more

1
I9P60A630026-02
6B-18 Steering Wheel and Column:

Installation 4) Fasten new band (1) using special tool, and install
1) Install tie-rod (1) and new tie-rod lock washer (3) to rack boot clip (2).
rack (2), and then tighten tie-rod to specified torque. Special tool
Tightening torque (A): 09943M55010
Tie-rod (a): 84 N·m (8.2 kgf-m, 62.0 lbf-ft)
1

2
(A)

1, (a) I9P60A630031-01

5) Install tie-rod end. (Page 6B-15)

2
6) Install steering gear case assembly. (Page 6B-16)
3

IDL10A630025-01 Pinion Shaft Rotation Torque Inspection

AENJCA0A6206025
2) Bend lock washer (1) at 2 places as shown in figure.
1) Remove steering gear case assembly. (Page 6B-
16)
2) Remove steering rack boots. (Page 6B-17)
3) Check pinion shaft rotation torque with rack position
1
centered using special tool.
Check that rack as a whole moves smoothly.
If check result is not as specified, adjust pinion shaft
rotation torque.
Special tool
(A): 09944M16810

I9P60A630029-02
Rotation torque specification
0.68 – 1.38 Nm (0.07 – 0.14 kgf-m, 0.5 – 1.0 lbf-ft)
3) Apply grease to section “A” of tie-rod indicated in
figure. Position boot properly in grooves of steering
gear case and tie-rod.
Check that boot is free from twist and dent.
“A”: Grease 99000–25050 (SUZUKI Super
(A)
Grease E)

IHSE0A620011-01
“A”

IDAA0A630021-01
 Steering Wheel and Column: 6B-19

Pinion Shaft Rotation Torque Adjustment
AENJCA0A6206026
1) Remove steering gear case assembly. (Page 6B-
16)
2) Remove steering rack boots. (Page 6B-17)
3) Set steering rack position in center of steering rack
stroke.
4) Using special tool, remove rack damper screw lock
nut (1).
Special tool
(A): 09941M75450
5) Tighten or loosen rack damper screw (2) to adjust
pinion shaft rotation torque to specified torque using
special tool. (Page 6B-18)
6) Apply sealant “A” to rack damper screw.
“A”: Sealant 99000–31110 (SUZUKI Bond
No.1215)
7) Using special tool, tighten rack damper screw lock
nut while holding rack damper screw.
Tightening torque
Rack damper screw lock nut (b): 69 N·m (7.0
kgf-m, 51.0 lbf-ft)
NOTE
When tightening rack damper screw lock nut
with torque wrench connected to arm portion
of special tool, reading value is smaller than
the nut torque. Reading value should be
calculated using the formula below.
Formula for reading value of torque wrench.
M = T x L / (L + “a”)
• M: Reading value using the special tool
• T: Specified torque
• L: Torque wrench length
• “a”: Dimension of special tool (45 mm (1.7 in.))

L
1, (a)

2, “A”
(A)

“a”

(A)

IJCA0A620017-02

8) Recheck pinion shaft rotation torque is as specified.

(Page 6B-18)
9) Install steering rack boots. (Page 6B-17)
10) Install steering gear case assembly. (Page 6B-16)
6B-20 Steering Wheel and Column:

Specifications
Tightening Torque Specifications
AENJCA0A6207001
NOTE
For fastener(s) with * (asterisk) below, refer to the specified procedure in “Repair Instructions”.

Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Steering shaft nut 33 3.4 24.5 (Page 6B-4)
Steering column lower bolt 14 1.4 10.5 (Page 6B-7)
Steering column nut 14 1.4 10.5 (Page 6B-7)
Steering lower shaft joint bolt* 35 3.6 26.0 (Page 6B-13)
Steering column joint bolt* 35 3.6 26.0 (Page 6B-13)
Tie-rod end nut 45 4.6 33.5 (Page 6B-16)
Tie-rod end lock nut 45 4.6 33.5 (Page 6B-16)
Steering gear case bolt 80 8.2 59.0 (Page 6B-17)
Tie-rod 84 8.2 62.0 (Page 6B-18)
Rack damper screw lock nut 69 7.0 51.0 (Page 6B-19)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Steering Wheel and Column Components” (Page 6B-2)
“Steering Gear Case Assembly Components” (Page 6B-14)
“Fasteners Information” in Section 0A (Page 0A-6)
 Steering Wheel and Column: 6B-21

Special Tools and Equipment

Recommended Service Material
AENJCA0A6208001
Material SUZUKI recommended product or Specification Note
Grease SUZUKI Super Grease E P/No.: 99000–25050 (Page 6B-18)
Sealant SUZUKI Bond No.1215 P/No.: 99000–31110 (Page 6B-19)

NOTE
Required service material(s) is also described in:
“Steering Gear Case Assembly Components” (Page 6B-14)

Special Tool
AENJCA0A6208002
09913M65210 09941M75450
Tie-rod end remover Rack damper lock nut
wrench
(Page 6B-15) (Page 6B-19)

09943M55010 09944M16810
Boot clamp pliers Pinion torque checking
socket
(Page 6B-18) (Page 6B-18)

09944M36011
Steering wheel remover
(Page 6B-3)
6C-1 Power Assisted Steering System:

Power Assisted Steering System

Steering

Precautions
Precautions for Diagnosing Trouble
AENJCA0A6300001
! WARNING
If you do not select a suitable route and take proper precautions when performing a road test, an
accident can occur.
• Select a level road with no traffic to minimize the risk of accident.
• Perform the test extremely carefully.
• Perform the road test using 2 persons, a driver and an assistant.

NOTE
Limit the driving speed permissible in road conditions and regulations.

• Before using scan tool, read its Operator’s Manual to know how to use it.
• After completion of repair, clear DTC and confirm that no DTC is stored in P/S control module. (Page 6C-12)

General Description
P/S System Description
AENJCA0A6301001
Power steering system employs an electronic power steering (EPS) system that is a column assist type.
EPS system consists of P/S control module and steering column assembly (including P/S motor and torque sensor).
The controllability of assisting steering force is optimized in all vehicle speed ranges.
For location of EPS system components, refer to “Power Steering Control System Component Location” (Page 6C-8).

Description of EPS System Component Function

AENJCA0A6301002
EPS system components Function
Steering Torque sensor Using two circuits (i.e. main and sub circuits), torque sensor outputs voltages
column proportional to steering input torque and direction to P/S control module.
assembly P/S motor P/S motor produces steering assist torques that correspond to electric current from
P/S control module.
P/S control module • P/S control module controls P/S motor drive current by determining its amount
and direction of assistance based on voltage signal from torque sensor, vehicle
speed and other data which are received via CAN communication.
• P/S control module judges whether engine is running or not using engine speed
signal from CAN.
ECM ECM transmits “Vehicle speed signal” and “Engine speed signal” to P/S control
module through CAN communication.
Electric power steering Refer to “OBD System Description” (Page 6C-5) for operation of the electric power
warning light steering warning light.
 Power Assisted Steering System: 6C-2

Steering Column Assembly

Steering column assembly mainly consists of torque sensor shaft (input shaft) from steering wheel, worm wheel shaft
(output shaft) to steering gear case, torsion bar connecting the input and output shafts, torque sensor and P/S motor.

Torque sensor
Torque sensor adopts a hall IC-aided torque sensing system and consists of stationary magnet on input shaft,
stationary yoke on output shaft and stationary magnetic flux focusing ring (including hall IC) in torque sensor housing.
The magnet provides magnetic flux, the yoke adjusts the magnetic flux and the torque sensor detects fluctuation of
magnetic flux in the magnetic flux focusing ring. Further, the magnetic flux focusing ring consists of dual circuit, hall IC
1 and hall IC 2. This enables the P/S control module to compute steering assist torque corresponding to steering
wheel handling force based on signal from hall IC 1 (main signal). And hall IC 2 (sub signal) is used to check if hall IC
1 (main signal) is normal.

Torque sensing principle

1) At neutral point of the steering wheel (with no handling force applied), each tooth of yoke is positioned at
intermediate point between S and N poles. Therefore, magnetic flux does not pass through hall IC in this state.
2) When handling force is applied to steering wheel (input shaft) against sensor shaft (output shaft), which is
stationary with road friction, torsion occurs in torsion bar and a phase deviation relative to the torsion angle is
generated between yoke teeth and magnet.
3) Upon generation of the relative phase deviation between yoke teeth and magnet, each tooth of yoke is positioned
on S or N pole. Therefore, magnetic flux passes through yoke, magnetic flux focusing ring and hall IC.
4) Magnetic flux which passes through hall IC varies according to the steering direction and, density of the magnetic
flux varies according to the steering wheel handling force (steering torque). Hall IC converts the detected variation
of the magnetic flux on its direction and density to electrical signal and outputs to P/S control module.
5) Output voltage of hall IC 1 (main torque sensor) and hall IC 2 (sub torque sensor) is 2.5 V at steering wheel neutral
point. In this position, P/S control module computes steering handling torque at zero. However, when steering
wheel is rotated with handling force, P/S control module controls the steering based on signal from hall IC 1 (main
torque sensor) according to the level of the handling force. When output voltage of hall IC 1 (main torque sensor)
exceeds 2.5 V, P/S control module assists the steering to the right. On the other hand, when the voltage is below
2.5 V, the control module assists the steering to the left.
6C-3 Power Assisted Steering System:

[A] [B] [C]

1
4 3 2

6
6

8
5
7

7 4 7 7
9 9 9

5V 5V 5V
S N S N S S N S N S S N S N S
10 10 10
8 5 8 8

[D] [E] [F]

13
14
[G]
V

10 9

11 12 2.5V
15
1 [A] [H] [C]

4
IJCA0A630001-01

[A]: Left side steering 1. Magnet 9. Main signal

[B]: Neutral point 2. N pole 10. Sub signal
[C]: Right side steering 3. S pole 11. Sensor shaft (output shaft)
[D]: Pass of magnetic flux to hall IC upper side 4. Magnetic flux focusing ring 12. Torsion bar
[E]: No pass of magnetic flux to hall IC 5. Yoke teeth 13. Yoke
[F]: Pass of magnetic flux to hall IC lower side 6. Magnetic flux 14. Torque sensor housing
[G]: Torque sensor output characteristics 7. Hall IC1 15. Input shaft
[H]: Steering wheel neutral point (steering wheel 8. Hall IC2
handling torque)
 Power Assisted Steering System: 6C-4

Handling of steering when P/S system stops

The system has a fail-safe function, which works as
manual steering without power assist when engine is 2
stopped or power steering system is malfunctioning.
When steering wheel is rotated by hand under these “a”
conditions, torsion bar (1) is twisted but steering assist is
not available without supply of electricity. Therefore, 1
steering torque sensor shaft (input shaft) (2) in steering 3
column bumps against manual stopper (4) in worm 4
wheel shaft (output shaft) (3) and torque sensor shaft IDMAKPF60003-01
(input shaft) rotates worm wheel shaft (output shaft) “a”: Maximum torsional angle of torsion bar
directly.

P/S Control Module

P/S control module determines basic assist power based on steering assist control and improves feeling of the
steering by using steering return control and steering converging control. Further, the P/S control module controls
motor current to harmonize target current with actual current in accordance with computing result of each control and
maximum current limit control.
And, the P/S control module communicates with ECM and combination meter through CAN communication.

P/S Control Module Input / Output Diagram

AENJCA0A6301003

P/S control module

Torque sensor Steering

assist control

Motor angular speed

(detected value) Steering
return control

Electric current of motor

(measured value) Steering Motor electric
P/S motor
converging control current control

Maximum
electric current
limit control
ECM
Vehicle speed information CAN
CAN communication
Engine speed information function Combination meter
CAN
Warning light request (P/S)

Fail-safe control

IJCA0A630002-01
6C-5 Power Assisted Steering System:

Control item Control function

Electric current value to assist steering is determined based on steering torque
Steering assist control information from torque sensor and vehicle speed information through CAN
communication. This is basic control of P/S system.
Friction in steering system affects return feeling of the steering wheel especially at low
Steering return control speed of the vehicle. The compensation current assists the motor rotation in steering
return direction and improves return feeling of the steering wheel.
At high speed running, steering damping performance becomes worse. Therefore, the
Steering converging control
compensation current is supplied for improvement of vehicle high speed stability.
If the steering wheel is kept at fully turned position with engine running, maximum current
Maximum electric current for full steering assist is continuously being supplied to P/S motor causing the motor and
limit control P/S control module to overheat. To prevent this, the control module reduces the current
gradually when the maximum current is supplied for specified time continuously.
P/S control module is equipped with fail-safe relay in its power supply circuit. When the
system is operating normally, the relay is “ON” and the control module can supply electric
Fail-safe control power to P/S motor. However, once any malfunction is detected by self-diagnosis in P/S
control system, the relay is set to “OFF” and the power supply is cut off to stop the power
assist system.

OBD System Description

AENJCA0A6301004 [A]
The P/S control module has an on-board self-diagnostic
function which detects a malfunction in this system.
Have full understanding of “OBD System Description”
and each item in “Precautions for Diagnosing Trouble”
(Page 6C-1), before executing diagnosis according to
“P/S System Check” (Page 6C-9).
The P/S control module performs on-board diagnosis
1
(self-diagnosis) on the system and operates the electric
power steering warning light (1) as follows.
• The electric power steering warning light turns on
when the ignition is “ON” (but the engine at stop) [B]
regardless of the condition of the P/S control system.
This is only to check if the electric power steering
warning light operates properly.
• When the engine is started, on-board diagnosis (self-
diagnosis) is performed and the electric power
steering warning light turns off if no trouble is found.
IJCA0A630003-01
• When the P/S control module detects a trouble, the
electric power steering warning light comes on to [A]: Without tachometer [B]: With tachometer

warn the driver of the trouble. At the same time, a

DTC is stored in the module.
 Power Assisted Steering System: 6C-6

Schematic and Routing Diagram

P/S System Circuit Diagram
AENJCA0A6302001

12V
3
9
12V
10
11 GRN G10-1 6

12V E61-1 RED

4
[A] 5V
E61-2 BLK
12
14 G10-2
17 BLK

16

[B]
13
5V
15 8
17 BRN G10-8
16

2 E11-2 RED
BRN 18
19
RED G10-5 5V
20 5 5
WHT G10-4 E11-5 WHT
BLK

RED WHT 5V

E11-4 YEL
21

E11-3 BLK

IJCA0A630004-01

[A]: With keyless entry system 7. P/S motor 15. “IG1 SIG” fuse
[B]: Without keyless entry system 8. Torque sensor 16. “MTR” fuse
1. P/S control module 9. Relay box 17. To ignition power supply
2. CPU 10. “P/S” fuse 18. Combination meter
3. Fail-safe relay 11. To continuous power supply 19. Electric power steering warning light
4. Power supply circuit 12. J/B 20. Meter driver
5. CAN driver 13. Individual circuit fuse box 21. To other control modules by CAN
6. Steering column assembly 14. “IG1 SIG2” fuse
6C-7 Power Assisted Steering System:

Terminal Arrangement of P/S Control Module Connector (Viewed from Harness Side)

NOTE
For circuit name and terminal voltage, refer to“Inspection of P/S Control Module and Its Circuits”
(Page 6C-28).

[A] E61
[A] G10

[A] E11
[a]
1
2 1
5 4 3 2 1 2 1

4 3 8 7 6 5 4 3

IJCA0A630005-01

[A]: P/S control module connector (View: [a]) 1. P/S control module
 Power Assisted Steering System: 6C-8

Component Location
Power Steering Control System Component Location
AENJCA0A6303001

[C] [D]
1
[A] 6

8
7
5

2
7
9
[B] 1

12

10

3
11

13

IJCA0A630006-01

[A]: Without tachometer 3. “P/S” fuse 9. “IG1 SIG” fuse

[B]: With tachometer 4. Relay box 10. Steering column assembly
[C]: With keyless entry system 5. J/B 11. P/S control module
[D]: Without keyless entry system 6. Individual circuit fuse box 12. P/S motor
1. Combination meter 7. “MTR” fuse 13. Steering gear case assembly
2. Electric power steering warning light 8. “IG1 SIG2” fuse
6C-9 Power Assisted Steering System:

Diagnostic Information and Procedures

P/S System Check
AENJCA0A6304001
! WARNING
If you do not select a suitable route and take proper precautions when performing a road test, an
accident can occur.
• Select a level road with no traffic to minimize the risk of accident.
• Perform the test extremely carefully.
• Perform the road test using 2 persons, a driver and an assistant.

NOTE
Limit the driving speed permissible in road conditions and regulations.

Refer to the following items for the details of each step.

Step Action Yes No
1 Customer complaint analysis Go to Step 2. Perform customer
1) Perform customer complaint analysis. (Page 6C-10) complaint analysis.

Was customer complaint analysis performed?

2 DTC check, record and clearance Print DTC or write it Go to Step 4.
1) Check for DTC (including pending DTC). (Page 6C-11) down and clear it
referring to “DTC
Is there any DTC? Clearance” (Page 6C-
12), and then go to Step
3.
3 Visual inspection Repair or replace Go to Step 5.
1) Perform visual inspection. (Page 6C-11) defective part, and then
go to Step 11.
Is there any faulty condition?
4 Visual inspection Repair or replace Go to Step 8.
1) Perform visual inspection. (Page 6C-11) defective part, and then
go to Step 11.
Is there any faulty condition?
5 Trouble symptom confirmation Go to Step 6. Go to Step 7.
1) Check trouble symptom. (Page 6C-11)

Is trouble symptom identified?

6 Rechecking and record of DTC Go to Step 9. Go to Step 8.
1) Recheck for DTC. (Page 6C-11)

Is there any DTC(s)?

7 Rechecking and record of DTC Go to Step 9. Go to Step 10.
1) Recheck for DTC. (Page 6C-11)

Is there any DTC(s)?

8 Steering symptom diagnosis and P/S system symptom Go to Step 11. Check and repair
diagnosis defective part, and then
1) Check and repair. (Page 6C-11) go to Step 10.
• Steering symptom diagnosis: (Page 6A-1)
• P/S system symptom diagnosis: (Page 6C-16)

Are check and repair complete?

9 Troubleshooting for DTC Go to Step 11. Check and repair
1) Check and repair. (Page 6C-11) defective part, and then
go to Step 11.
Are check and repair complete?
 Power Assisted Steering System: 6C-10

Step Action Yes No

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

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 a questionnaire form shown below will facilitate collecting information for proper analysis and diagnosis.
Check if the problem described in “Customer questionnaire” occurs actually in the vehicle if necessary.
(This step should be performed with the customer if possible.)

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

Customer questionnaire form (Example)

IAP70A630004-01
6C-11 Power Assisted Steering System:

Step 2: DTC Check, Record and Clearance Electric Power Steering Warning Light Check
Check DTC (current and pending DTC) referring to “DTC AENJCA0A6304002

Check” (Page 6C-12).
If DTC is indicated, print or write down the DTC and then
clear the DTC referring to “DTC Clearance” (Page 6C-
12).
Step 3 and 4: Visual Inspection
Visually check electric power steering warning light for
proper operation, connectors for proper condition and
each part condition referring to “Visual Inspection” (Page
6C-16).
Step 5: Trouble Symptom Confirmation
Based on “Step 1: Customer Complaint Analysis” (Page
6C-10) and “Step 2: DTC Check, Record and Clearance”
(Page 6C-11), check trouble symptoms. Also, check
trouble symptoms by performing test drive and turning
steering wheel fully to right and left with vehicle stopped.
1) Set ignition “ON” (without running engine) and check
if the electric power steering warning light (1) comes
on. If the electric power steering warning light does
not come on, go to “Electric Power Steering Warning
Light Does Not Come ON with Ignition “ON” before
Engine Starts” (Page 6C-17) of the diagnostic flows.
2) Start engine and check if the electric power steering
warning light turns OFF. If electric power steering
warning light remains ON and no DTC is stored in P/
S control module, go to “Electric Power Steering
Warning Light Remains ON Steady after Engine
Starts” (Page 6C-19) for troubleshooting.
[A]

Step 6 and 7: Rechecking and Record of DTC

Refer to “DTC Check” (Page 6C-12) for checking
procedure. 1

Step 8: Steering Symptom Diagnosis and P/S

System Symptom Diagnosis
Perform basic steering system check first. (Page 6A-1) [B]
Near the end of flow, check the parts of the system
suspected as a possible cause referring to “P/S System
Symptom Diagnosis” (Page 6C-16) and based on
symptoms appearing on the vehicle (symptoms obtained
through steps of customer complaint analysis, trouble
symptom confirmation and/or basic P/S system check).
Repair or replace faulty parts. IJCA0A630003-01

[A]: Without tachometer [B]: With tachometer

Step 9: Troubleshooting for DTC
Perform applicable DTC troubleshooting and repair or
replace faulty parts.

Step 10: Intermittent Problems Check

Check parts that are prone to cause intermittent problem
(e.g. wire harness, connector, etc.), referring to
“Intermittent Connection and Poor Contact Inspection” in
Section 00 (Page 00-13) and related circuit of DTC
recorded in Step 2.

Step 11: Final Confirmation Test

Check that the problem symptom has disappeared and
the P/S system is free from any abnormal conditions. If
what has been repaired is related to the DTC, clear the
DTC once, perform DTC confirmation procedure and
check that no DTC is indicated.

DTC Check
AENJCA0A6304003
1) Set ignition “OFF”.
2) Connect SUZUKI scan tool to DLC (1).
Special tool
(A): SUZUKI scan tool (Suzuki SDT-II)
3) Set ignition “ON”.
4) Read DTC according to instructions displayed on
SUZUKI scan tool and print it or write it down. Refer
to Operator's Manual of SUZUKI scan tool for further
details.
NOTE
If communication between SUZUKI scan tool
and P/S control module is not possible,
perform the following checks:
• Check communication condition between
PC and VCI (2) using SUZUKI scan tool
function.
• Check DLC power circuit and ground
circuit.
• Check DLC cable. If necessary, check DLC
cable by substituting a known-good DLC
cable.
• Check CAN communication system.
(“Control Module Communication Bus Off”
is detected in any control module.) (Page
10H-15)
• Check P/S control module power circuit
and ground circuit. (Page 6C-27)
1 1
2 2
(A)
IJCA0A111011-01
5) After completing the check, set ignition “OFF” and
disconnect SUZUKI scan tool from DLC.
Power Assisted Steering System: 6C-12
DTC Clearance
AENJCA0A6304004
1) Set ignition “OFF”.
2) Connect SUZUKI scan tool to DLC (1).
Special tool
(A): SUZUKI scan tool (Suzuki SDT-II)
3) Set ignition “ON”.
4) Clear DTC according to instructions displayed on
SUZUKI scan tool and print it or write it down. Refer
to Operator's Manual of SUZUKI scan tool for further
details.
NOTE
If communication between SUZUKI scan tool
and P/S control module is not possible,
perform the following checks:
• Check communication condition between
PC and VCI (2) using SUZUKI scan tool
function.
• Check DLC power circuit and ground
circuit.
• Check DLC cable. If necessary, check DLC
cable by substituting a known-good DLC
cable.
• Check CAN communication system.
(“Control Module Communication Bus Off”
is detected in any control module.) (Page
10H-15)
• Check P/S control module power circuit
and ground circuit. (Page 6C-27)
(A)
IJCA0A111011-01
5) After completing DTC clearance, set ignition “OFF”
and disconnect SUZUKI scan tool from DLC.
6C-13 Power Assisted Steering System:

DTC Table
AENJCA0A6304005
NOTE
• If you do not perform the “P/S System Check” (Page 6C-9) before starting the DTC diagnosis, the
diagnosis will show a false result.
Perform “P/S System Check” (Page 6C-9) before starting the diagnosis.
• *D/C (Driving Cycle) is a duration from engine start to the following engine shutoff.
– 1 D/C: When a malfunction is detected in 1st driving cycle, DTC is detected as current DTC.

Electric power
DTC DTC name DTC detecting condition *D/C steering
warning light
Voltage of torque sensor signal (main) circuit is
C1111 Torque Sensor (Main)
higher than specified value (4.7 V) or lower than 1 Lights up
(Page 6C-19) Circuit Malfunction
specified value (0.3 V) for more than specified time.
Torque Sensor (Main Voltage difference between torque sensor signal
C1113
and Sub) Signal (main) circuit and torque sensor signal (sub) circuit 1 Lights up
(Page 6C-19)
Difference remains too large for more than specified time.
Torque Sensor Power Power supply voltage (5 V) for torque sensor circuit
C1114
Supply (5 V) Circuit is higher than specified value (5.5 V) or lower than 1 Lights up
(Page 6C-19)
Malfunction specified value (4.5 V) for more than specified time.
Voltage of torque sensor signal (sub) circuit is
C1115 Torque Sensor (Sub)
higher than specified value (4.7 V) or lower than 1 Lights up
(Page 6C-19) Circuit Malfunction
specified value (0.3 V) for more than specified time.
Measured motor drive circuit voltage is higher than
C1141 P/S Motor Circuit
normal voltage by 0.3 V or more, or motor drive 1 Lights up
(Page 6C-21) Voltage Malfunction
circuit is defective.
C1142 P/S Motor Circuit Measured motor drive current is more than target
1 Lights up
(Page 6C-21) Current Malfunction 1 value by 10 A or more.
C1143 P/S Motor Circuit
Measured motor drive current is more than 45 A. 1 Lights up
(Page 6C-21) Current Too Big
C1145 P/S Motor Circuit Target motor drive current is more than measured
1 Lights up
(Page 6C-21) Current Malfunction 2 motor drive current.
Fail-Safe Relay Measured voltage at fail-safe relay contact is higher
C1152
Malfunction (Melting than 5.5 V even though fail-safe relay off is 1 Lights up
(Page 6C-22)
Stuck) commanded.
Measured voltage of fail-safe relay contact is lower
C1153 Power Supply Voltage than 9 V even if engine speed is more than 600 rpm
1 Lights up
(Page 6C-23) Too Low or Too High and fail-safe relay on is commanded, or voltage at
fail-safe relay contact is too high.
Measured voltage at fail-safe relay contact is lower
C1154 Fail-Safe Relay
than 4 V even though fail-safe relay on is 1 Lights up
(Page 6C-22) Malfunction (Contact)
commanded.
C1155 P/S Control Module
P/S control module internal failure. 1 Lights up
(Page 6C-24) Internal Failure
C1157 P/S motor relay is on even though P/S motor relay
Motor Relay Malfunction 1 Lights up
(Page 6C-24) off is commanded after engine start.
C1160 Assist Map Signal
Assist map data is not set in P/S control module. 1 Lights up
(Page 6C-25) Failure
C1161 CAN Invalid Data from
Invalid vehicle speed data is received from ECM. 1 Lights up
(Page 6C-26) Vehicle Speed
C1162 CAN Invalid Data from
Invalid engine speed data is received from ECM. 1 Lights up
(Page 6C-26) Engine Speed
C1166 Reliability Defect Of Invalid data about vehicle speed reliability is
1 Lights up
(Page 6C-26) Vehicle Speed Data received from ECM.
U0073 Control Module Transmitting and receiving error of P/S control
1 Off
(Page 6C-27) Communication Bus Off module is detected for specified time continuously.
U0100 Lost Communication CAN communication data from ECM cannot be
1 Lights up
(Page 6C-27) With ECM received.
 Power Assisted Steering System: 6C-14

Fail-Safe Table
AENJCA0A6304006
When any of the following DTCs is detected, P/S control module enters fail-safe mode as long as malfunction
continues to exist but that mode is canceled when the following cancel conditions are met.
DTC Fail-safe operation Fail-safe operation cancel condition
C1111 (Page
6C-19)
C1113 (Page
6C-19)
C1114 (Page
6C-19)
C1115 (Page
6C-19)
C1141 (Page P/S motor and fail-safe relay turned off. Ignition is set to “OFF”.
6C-21)
C1142 (Page
6C-21)
C1143 (Page
6C-21)
C1145 (Page
6C-21)
C1152 (Page
6C-22)
If one of the following conditions is met:
C1153 (Page P/S motor turned off or assist value is decreased • Voltage at fail-safe relay contact is higher than
6C-23) to minimum. 10 V or lower than 17.5 V.
• Ignition is set to “OFF”.
C1154 (Page Recovery from malfunction or ignition is set to
P/S motor turned off.
6C-22) “OFF”.
C1155 (Page P/S motor turned off or P/S motor and fail-safe Recovery from malfunction or ignition is set to
6C-24) relay turned off. “OFF”.
C1157 (Page
P/S motor and fail-safe relay turned off. Ignition is set to “OFF”.
6C-24)
C1160 (Page
Default assist map is applied. Setting of correct assist map.
6C-25)
C1161 (Page
Assist value is decreased to minimum.
6C-26)
C1162 (Page
Assist is stopped.
6C-26)
Normal data is received or ignition is set to “OFF”.
C1166 (Page
Assist value is decreased to minimum.
6C-26)
U0100 (Page Assist is stopped or assist value is decreased to
6C-27) minimum.
6C-15 Power Assisted Steering System:

Scan Tool Data

AENJCA0A6304007

NOTE
• If communication between SUZUKI scan tool and P/S control module is not possible, perform the
following checks:
– Check communication condition between PC and VCI using SUZUKI scan tool function.
– Check DLC power circuit and ground circuit
– Check DLC cable. If necessary, check DLC cable by substituting a known-good DLC cable.
– Check CAN communication system. (“Control Module Communication Bus Off” is detected in any
control module) (Page 10H-15)
– Check P/S control module power circuit and ground circuit. (Page 6C-27)
• *1: Turn steering wheel fully and hold it with force applied.
• *2: The voltage and current of motor decrease gradually after few seconds when steering wheel is
turned.

Normal condition /
Scan tool data Vehicle condition
Reference value
Battery Voltage Approx. 12 to 14 V Engine running at idle speed
Sensor Power Supply Approx. 5 V Engine running at idle speed
Engine running at idle speed
–0.8 to 0.8Nm
Steering wheel at neutral
Engine running at idle speed
Sensor (Main) Torque 8.0 to 12.0 Nm
Vehicle stationary and steering wheel turned fully to right *1
Engine running at idle speed
–8.0 to –12.0 Nm
Vehicle stationary and steering wheel turned fully to left *1
Engine running at idle speed
Approx. ±0 Nm
Steering wheel at neutral
Engine running at idle speed
Sensor (Sub) Torque –8.0 to –12.0 Nm
Vehicle stationary and steering wheel turned fully to right *1
Engine running at idle speed
8.0 to 12.0 Nm
Vehicle stationary and steering wheel turned fully to left *1
Engine running at idle speed
–8.0 to 0.8 Nm
Steering wheel at neutral
Engine running at idle speed
Control Torque Approx. 7.8 Nm
Vehicle stationary and steering wheel turned fully to right *1
Engine running at idle speed
Approx. –7.8 Nm
Vehicle stationary and steering wheel turned fully to left *1
Engine running at idle speed
0.0 A
Steering wheel at neutral
Target Motor Current Engine running at idle speed
Approx. 40 A Vehicle stationary and steering wheel turned fully to right or left
*1, *2
Engine running at idle speed
0.0 A
Steering wheel at neutral
Measured MOT Current Engine running at idle speed
Approx. 40 A Vehicle stationary and steering wheel turned fully to right or left
*1, *2
Drive vehicle at 40 km/h using chassis dynamometer or while
Vehicle Speed Approx. 40 km/h
checking speedometer
0 rpm Set ignition “ON”
Engine Speed
Specified idle speed Engine running at idle speed after warming up
ON Set ignition “ON”
IGN Switch Status
OFF Other than above condition
ON Current flowing to P/S control module power supply
System Power Status
OFF Other than above condition
ON Power steering system operates normally
Fail Safe Relay / FET
OFF Performing fail-safe operation
 Power Assisted Steering System: 6C-16

Normal condition /
Scan tool data
Reference value
Motor Drive Voltage (+)
Motor Drive Voltage (–)
Vehicle condition
Engine running at idle speed
Approx. 1.0 V
Steering wheel at neutral
Engine running at idle speed
Approx. 8.5 V
Vehicle stationary and steering wheel turned fully to right *1, *2
Engine running at idle speed
Approx. 0.1 V
Vehicle stationary and steering wheel turned fully to left *1, *2
Engine running at idle speed
Approx. 1.0 V
Steering wheel at neutral
Engine running at idle speed
Approx. 0.1 V
Vehicle stationary and steering wheel turned fully to right *1, *2
Engine running at idle speed
Approx. 8.5 V
Vehicle stationary and steering wheel turned fully to left *1, *2

Visual Inspection
AENJCA0A6304008
Visually check the following parts and systems.
Inspection item Referring section
• K10B and bi-fuel CNG model: “Battery Description”: K10B
Fluid level, leakage and Bi-Fuel CNG in Section 1J (Page 1J-2)
Battery
indicator • K12M model: “Battery Description”: K12M in Section 1J (Page
1J-20)
Connectors of electric wire “Intermittent Connection and Poor Contact Inspection” in Section
Disconnection, friction
harness 00 (Page 00-13)
Fuses Blowout
Electric power steering
Operation “Electric Power Steering Warning Light Check” (Page 6C-11)
warning light
Other parts that can be checked visually

P/S System Symptom Diagnosis

AENJCA0A6304009
This section describes trouble diagnosis of the P/S system parts whose troubles are not indicated using SUZUKI scan
tool. When no malfunction is indicated by SUZUKI scan tool and steering basic parts as described in “Steering
Symptom Diagnosis” in Section 6A (Page 6A-1) are all in good condition, check the following power steering system
parts which may be possible causes for each trouble symptom of steering.

NOTE
Perform “Steering Force Check” (Page 6C-31) and “Front Wheel Alignment Inspection and
Adjustment” in Section 2B (Page 2B-2) before diagnosis.

Condition Possible cause Correction / Reference Item

Steering wheel feels Improper installation of steering wheel
heavy Poor performance of torque sensor
Poor performance of P/S motor
Malfunction of steering gear case
assembly
Vehicle speed data provided through
CAN communication
Steering wheel feels Malfunction of steering gear case
heavy momentarily when assembly
turning it to left or right
Poor recovery from turns Poor performance of torque sensor
Malfunction of steering gear case
assembly
Vehicle pulls to one side Poor performance of torque sensor
during straight driving Malfunction of steering gear case
assembly
Abnormal noise Malfunction of P/S motor (built in
steering column assembly)
Install steering wheel correctly. (Page 6B-3)
Check torque sensor. (Page 6C-32)
Check P/S motor. (Page 6C-33)
Replace steering gear case assembly. (Page
6B-16)
Check vehicle speed data. (Page 6C-15)
Replace steering gear case assembly. (Page
6B-16)
Check torque sensor. (Page 6C-32)
Replace steering gear case assembly. (Page
6B-16)
Check torque sensor. (Page 6C-32)
Replace steering gear case assembly. (Page
6B-16)
Replace steering column. (Page 6B-7)
6C-17 Power Assisted Steering System:

Electric Power Steering Warning Light Does Not Come ON with Ignition “ON” before Engine Starts
AENJCA0A6304010
Circuit Diagram

[C] 2
4
1
8

[D] 3 6

5
1 BRN G10-8
A1
8

BRN 9
G241-3 7
10

G241-21 RED G10-5

11 12 12
A2 G241-9 WHT G10-4

BLK G241-5
BLK G10-2

[A]
[B]
[a]

12 11 10 9 8 7 6 5 4 3 2 1
2 1
24 23 22 21 20 19 18 17 16 15 14 13
8 7 6 5 4 3

IJCA0A630007-01

[A]: P/S control module connector “G10” (View: [a]) 1. To ignition power supply 7. CPU
[B]: Combination meter connector “G240” (View: [a]) 2. J/B 8. “MTR” fuse
[C]: With keyless entry system 3. Individual circuit fuse box 9. Combination meter
[D]: Without keyless entry system 4. “IG1 SIG2” fuse 10. Electric power steering warning light
A1: Combination meter power supply circuit 5. “IG1 SIG” fuse 11. Meter driver
A2: Combination meter ground circuit 6. P/S control module / motor assembly 12. CAN driver
 Power Assisted Steering System: 6C-18

Troubleshooting
Step Action Yes No
1 Electric power steering warning light check Go to Step 2. Go to Step 4.
1) Set ignition “ON”.

Do other warning lights come ON?

2 DTC check Refer to “CAN DTC Go to Step 3.
1) Connect scan tool to DLC with ignition “OFF”. (Lost Communication
and Communication
2) When ignition is “ON”, check DTC.
Bus Off) Table” in
Is DTC U0073 detected? Section 10H (Page 10H-
7).
3 Combination meter check Replace P/S control End.
1) Replace combination meter. (Page 9C-25) module. (Page 6C-32)
2) Set ignition “ON”.

Does electric power steering warning light stay OFF?

4 Fuse check Go to Step 5. Replace fuse and check
for short circuit to
Is circuit fuse for combination meter in good condition? ground.
5 CAN communication circuit check Go to Step 6. Repair or replace.
1) Check CAN communication circuit between combination
meter and P/S control module. (Page 10H-9)

Is CAN communication circuit in good condition?

6 Combination meter power supply circuit check Replace combination Go to Step 7.
1) Remove combination meter with ignition “OFF”. (Page meter and recheck.
9C-25)
2) Check for proper connection to combination meter
connector.
3) If check result is OK, set ignition “ON”.
4) Check voltage between “G241-3” terminal and “G241-5”
terminal is battery voltage.

Is check result OK?

7 Combination meter ground circuit check Repair or replace “A1” Repair or replace “A2”
1) Set ignition “OFF”. circuit. circuit.
2) Check resistance between “G241-5” terminal and
ground is 1 Ω or less.

Is check result OK?

6C-19 Power Assisted Steering System:

Electric Power Steering Warning Light Remains ON Steady after Engine Starts
AENJCA0A6304011
Troubleshooting
Step Action Yes No
1 DTC check Go to troubleshooting Go to Step 2.
1) Start engine and recheck DTC of P/S control module. for applicable DTC.

Is DTC(s) detected?
2 P/S control module check Replace combination End.
1) Replace P/S control module. (Page 6C-32) meter. (Page 9C-25)
2) Set ignition “ON”.

Does electric power steering warning light stay ON?

DTC C1111 / C1113 / C1114 / C1115

AENJCA0A6304012
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C1111: Torque Sensor (Main) Circuit Malfunction • Torque sensor (steering column assembly)
Voltage of torque sensor signal (main) circuit is higher than • Torque sensor circuit / connector
specified value (4.7 V) or lower than specified value (0.3 V) for
• P/S control module
more than specified time.
C1113: Torque Sensor (Main and Sub) Signal Difference
Voltage difference between torque sensor signal (main) circuit
and torque sensor signal (sub) circuit remains too large for
more than specified time.
C1114: Torque Sensor Power Supply (5 V) Circuit
Malfunction
Power supply voltage (5 V) for torque sensor circuit is higher
than specified value (5.5 V) or lower than specified value (4.5
V) for more than specified time.
C1115: Torque Sensor (Sub) Circuit Malfunction
Voltage of torque sensor signal (sub) circuit is higher than
specified value (4.7 V) or lower than specified value (0.3 V) for
more than specified time.

Circuit Diagram

5V

A1

RED E11-2
A2 5V
2
WHT E11-5
A3

YEL E11-4 5V
A4

BLK E11-3

[A]
[a]

5 4 3 2 1

IJCA0A630008-01

[A]: Torque sensor connector “E11” (View [a]) A3: Torque sensor signal (sub) circuit 2. CPU
A1: 5 V power supply circuit for torque sensor A4: Ground circuit for torque sensor 3. Torque sensor
A2: Torque sensor signal (main) circuit 1. P/S control module
 Power Assisted Steering System: 6C-20

DTC Confirmation Procedure

Upon completion of initial check, turn steering wheel in both directions fully with vehicle stopped, and then handle
steering while driving.

DTC Troubleshooting
Step Action Yes No
1 Was “P/S System Check” performed? Go to Step 2. Go to “P/S System
Check” (Page 6C-9).
2 Torque sensor circuit wire check Go to Step 3. Repair or replace
1) Check for proper connection to torque sensor connector. defective wire harness.
2) Visually check circuit between torque sensor connector
and torque sensor for open circuit and short to ground.

Is check result OK?

3 Torque sensor power supply circuit check Go to Step 4. Replace P/S control
1) Start engine. module. (Page 6C-32)
2) Measure voltage between torque sensor connector
terminal “E11-2” and ground is approx. 5 V.

Is check result OK?

4 Torque sensor ground circuit check Go to Step 5. Replace P/S control
1) Measure voltage between torque sensor connector module. (Page 6C-32)
terminals “E11-2” and “E11-3” is approx. 5 V.

Is check result OK?

5 Torque sensor check Replace P/S control Replace torque sensor
1) Check torque sensor. (Page 6C-32) module. (Page 6C-32) (steering column
assembly). (Page 6B-
Is check result OK? 7)
6C-21 Power Assisted Steering System:

DTC C1141 / C1142 / C1143 / C1145

AENJCA0A6304014
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C1141: P/S Motor Circuit Voltage Malfunction • P/S motor (steering column assembly)
Measured motor drive circuit voltage is higher than normal voltage by 0.3 • P/S control module
V or more, or motor drive circuit is defective.
C1142: P/S Motor Circuit Current Malfunction 1
Measured motor drive current is more than target value by 10 A or more.
C1143: P/S Motor Circuit Current Too Big
Measured motor drive current is more than 45 A.
C1145: P/S Motor Circuit Current Malfunction 2
Target motor drive current is more than measured motor drive current.

Circuit Diagram

3 12V

A1

RED E61-1
2
BLK E61-2

A2

[A]

[a]
2 1

4 3

IJCA0A630009-01

[A]: P/S motor connector “E61” (View: [a]) A2: P/S motor output 2 circuit 2. CPU
A1: P/S motor output 1 circuit 1. P/S control module 3. P/S motor

DTC Confirmation Procedure

1) Start engine.
2) Turn steering wheel fully in both directions.

DTC Troubleshooting
Step Action Yes No
1 Was “P/S System Check” performed? Go to Step 2. Go to “P/S System
Check” (Page 6C-9) and
recheck DTC.
2 P/S motor drive circuit wire check Go to Step 3. Repair or replace
1) Check for proper connection to P/S motor connector. defective wire harness.
2) Visually check circuit between P/S motor connector and
P/S motor for open circuit and short to ground.

Is check result OK?

3 P/S motor circuit check Replace P/S control Replace P/S motor as
1) Check for P/S motor. (Page 6C-33) module and recheck steering column
DTC. (Page 6C-32) assembly. (Page 6B-
Is check result OK? 7)
 Power Assisted Steering System: 6C-22

DTC C1152 / C1154

AENJCA0A6304015
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C1152: Fail-Safe Relay Malfunction (Melting Stuck) P/S control module
Measured voltage at fail-safe relay contact is higher than
5.5 V even though fail-safe relay off is commanded.
C1154: Fail-Safe Relay Malfunction (Contact)
Measured voltage at fail-safe relay contact is lower than 4
V even though fail-safe relay on is commanded.

Circuit Diagram

A2 12V
6
2 A1
BLK G10-2
3
1 GRN G10-1 5

[A]

[a]
2 1

8 7 6 5 4 3

IJCA0A630010-01

[A]: P/S control module connector “G10” (View: [a]) 2. Relay box 6. Fail-safe relay
A1: P/S control module power supply circuit 3. “P/S” fuse 7. To power supply circuit
A2: P/S control module ground circuit 4. P/S control module
1. To continuous power supply 5. CPU

DTC Confirmation Procedure

1) Set ignition “ON”.
2) Start engine.

DTC Troubleshooting
Step Action Yes No
1 Was “P/S System Check” performed? Go to Step 2. Go to “P/S System
Check” (Page 6C-9) and
recheck DTC.
2 P/S control module power supply and ground circuit Replace P/S control Repair or replace
check module and recheck defective wire harness.
1) Check P/S control module power supply and ground DTC. (Page 6C-32)
circuits. (Page 6C-27)

Is check result OK?

6C-23 Power Assisted Steering System:

DTC C1153
AENJCA0A6304016
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C1153: Power Supply Voltage Too Low or Too High • Charging system
Measured voltage of fail-safe relay contact is lower than 9 V even if • P/S control module
engine speed is more than 600 rpm and fail-safe relay on is
commanded, or voltage at fail-safe relay contact is too high.

Circuit Diagram

3
5 A1
6
7 GRN G10-1 2

[a] [A]

2 1

8 7 6 5 4 3

IJCA0A630011-01

[A]: P/S control module connector “G10” (View [a]) 2. CPU 5. Relay box
A1: P/S control module power supply circuit 3. Fail-safe relay 6. “P/S” fuse
1. P/S control module 4. To power supply circuit 7. To continuous power supply

DTC Confirmation Procedure

Run engine at idle speed for more than 5 seconds.

DTC Troubleshooting
Step Action Yes No
1 Was “P/S System Check” performed? Go to Step 2. Go to “P/S System
Check” (Page 6C-9) and
recheck DTC.
2 P/S control module power supply voltage check Replace P/S control Go to Step 3.
1) With ignition “OFF”, disconnect P/S control module module and recheck
connector. DTC. (Page 6C-32)
2) Set ignition “ON”, measure voltage between P/S control
module connector terminal “G10-1” and ground.

Is voltage approx. 12 V?
3 P/S control module power supply circuit check Check charging system. Repair or replace “A1”
1) Set ignition “OFF”. • K10B and Bi-fuel circuit.
2) Check “A1” circuit for resistance. CNG model: (Page
1J-5)
Is resistance 1 Ω or less?
• K12M model:
(Page 1J-23)
 Power Assisted Steering System: 6C-24

DTC C1155 / C1157

AENJCA0A6304026
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C1155: P/S Control Module Internal Failure • P/S control module power supply circuit
P/S control module internal failure. • P/S control module ground circuit
C1157: Motor Relay Malfunction
• P/S control module
P/S motor relay is on even though P/S motor relay off is
commanded after engine start.

Circuit Diagram

A3 12V
11
3 A1
BLK G10-2
4
1 GRN G10-1

12
[B]
5 A2
10
7
2 BRN G10-8

[C]
6
8
2

[A]

[a]
2 1

8 7 6 5 4 3

IJCA0A630012-01

[A]: P/S control module connector “G10” (View: [a]) 1. To continuous power supply 7. “IG1 SIG2” fuse
[B]: With keyless entry system 2. To ignition power supply 8. “IG1 SIG” fuse
[C]: Without keyless entry system 3. Relay box 9. P/S control module
A1: P/S control module power supply circuit 4. “P/S” fuse 10. CPU
A2: Ignition power supply circuit 5. J/B 11. Fail-safe relay
A3: P/S control module ground circuit 6. Individual circuit fuse box 12. To power supply circuit

DTC Confirmation Procedure

C1155
1) Set ignition “ON”.
2) Start engine and set engine speed at 3,000 rpm or more.

C1157
1) Start engine.
6C-25 Power Assisted Steering System:

DTC Troubleshooting
Step Action Yes No
1 Was “P/S System Check” performed? Go to Step 2. Go to “P/S System
Check” (Page 6C-9) and
recheck.
2 DTC recheck Go to Step 3. Check for intermittent
1) Clear DTC. (Page 6C-12) trouble. (Page 00-13)
2) Set ignition “OFF”.
3) Perform “DTC Confirmation Procedure” and check DTC.
(Page 6C-12)

DTC C1155 or C1157 still detected?

3 P/S control module power supply and ground circuit Replace P/S control Repair or replace
check module and recheck defective wire harness.
1) Check P/S control module power supply and ground DTC. (Page 6C-32)
circuits. (Page 6C-27)

Is check result OK?

DTC C1160
AENJCA0A6304017
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C1160: Assist Map Signal Failure P/S control module
Assist map data is not set in P/S control module.

Circuit Diagram

A3 12V
11
3 A1
BLK G10-2
4
1 GRN G10-1

12
[B]
5 A2
10
7
2 BRN G10-8

[C]
6
8
2

[A]

[a]
2 1

8 7 6 5 4 3

IJCA0A630013-01

[A]: P/S control module connector “G10” (View: [a]) 1. To continuous power supply 7. “IG1 SIG2” fuse
[B]: With keyless entry system 2. To ignition power supply 8. “IG1 SIG” fuse
[C]: Without keyless entry system 3. Relay box 9. P/S control module
A1: P/S control module power supply circuit 4. “P/S” fuse 10. CPU
A2: Ignition power supply circuit 5. J/B 11. Fail-safe relay
A3: P/S control module ground circuit 6. Individual circuit fuse box 12. To power supply circuit
 Power Assisted Steering System: 6C-26

DTC Confirmation Procedure

1) Set ignition “ON”.
2) Set ignition “OFF”.
3) Set ignition “ON”.

DTC Troubleshooting
Step Action Yes No
1 Was “P/S System Check” performed? Go Step 2. Go to “P/S System
Check” (Page 6C-9) and
recheck DTC.
2 P/S control module power supply and ground circuit Replace P/S control Repair or replace
check module and recheck defective wire harness.
1) Check P/S control module power supply and ground DTC. (Page 6C-32)
circuits. (Page 6C-27)

Is check result OK?

DTC C1161 / C1162 / C1166

AENJCA0A6304018
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C1161: CAN Invalid Data from Vehicle Speed • CAN communication circuit
Invalid vehicle speed data is received from ECM. • ECM
C1162: CAN Invalid Data from Engine Speed
• P/S control module
Invalid engine speed data is received from ECM.
C1166: Reliability Defect Of Vehicle Speed Data
Invalid data about vehicle speed reliability is received from ECM.

DTC Confirmation Procedure

C1161 / C1166
Refer to “DTC Confirmation Procedure” for DTC P0500 Vehicle Speed Sensor “A”.
• K10B and bi-fuel CNG model: (Page 1A-84)
• K12M model: (Page 1A-223)

C1162
Refer to “DTC Confirmation Procedure” for DTC P0335 Crankshaft Position Sensor “A” Circuit.
• K10B and bi-fuel CNG model: (Page 1A-73)
• K12M model: (Page 1A-208)

DTC Troubleshooting
Step Action Yes No
1 Was “P/S System Check” performed? Go to Step 2. Go to “P/S System
Check” (Page 6C-9) and
recheck DTC.
2 DTC check Go to troubleshooting Replace P/S control
1) Check ECM for DTC. for applicable DTC. module and recheck
(ECM-related faulty) DTC. (Page 6C-32)
• K10B model: (Page 1A-22)
• K12M model: (Page 1A-140)
• Bi-fuel CNG model: (Page 1A-293)

Is DTC(s) detected?
6C-27 Power Assisted Steering System:

DTC U0073
AENJCA0A6304019
Refer to “Troubleshooting for Communication Bus Off” in Section 10H (Page 10H-15).

DTC U0100
AENJCA0A6304020
Refer to “Troubleshooting for Lost Communication” in Section 10H (Page 10H-9).

P/S Control Module Power Supply and Ground Circuit Check

AENJCA0A6304022
Circuit Diagram

A3 12V
11
3 A1
BLK G10-2
4
1 GRN G10-1

12
[B]
5 A2
10
7
2 BRN G10-8

[C]
6
8
2

[A]

[a]
2 1

8 7 6 5 4 3

IJCA0A630012-01

[A]: P/S control module connector “G10” (View: [a]) 1. To continuous power supply 7. “IG1 SIG2” fuse
[B]: With keyless entry system 2. To ignition power supply 8. “IG1 SIG” fuse
[C]: Without keyless entry system 3. Relay box 9. P/S control module
A1: P/S control module power supply circuit 4. “P/S” fuse 10. CPU
A2: Ignition power supply circuit 5. J/B 11. Fail-safe relay
A3: P/S control module ground circuit 6. Individual circuit fuse box 12. To power supply circuit

Troubleshooting
Step Action Yes No
1 Circuit fuse check Go to Step 2. Replace fuse(s) and
1) Check that ignition is “OFF”. check for short to
ground in circuits
2) Disconnect “G10” connector.
connected to fuse(s).
3) Check for proper connection to “G10-1”, “G10-2” and
“G10-8” terminals.
4) If connections are OK, check “P/S” fuse and “IG1 SIG2”
or “IG1 SIG” fuse for blowing.

Is check result OK?

2 P/S control module power supply circuit check Go to Step 3. “A1” circuit is open.
1) Check voltage between “G10-1” terminal and ground.

Is voltage 10 – 14 V?
 Power Assisted Steering System: 6C-28

Step Action Yes No

3 Ignition power supply circuit check Go to Step 4. “A2” circuit is open.
1) Set ignition “ON”.
2) Check voltage between “G10-8” terminal and ground.

Is voltage 10 – 14 V?
4 P/S control module ground circuit check P/S control module “A3” circuit is open or
1) Set ignition “OFF”. power supply and too high in resistance.
ground circuits are in
2) Check for proper connection to “G10-2” terminal.
good condition.
3) Check resistance between “G10-2” terminal and ground.

Is resistance 1 Ω or less?

Inspection of P/S Control Module and Its Circuits

AENJCA0A6304023
P/S control module (1) and its circuits can be checked at P/S control module wiring connectors by measuring voltage
and resistance.

NOTICE
If you connect a voltmeter or an ohmmeter directly to the P/S control module with the P/S control
module connectors disconnected, the P/S control module will be damaged.
Never connect a voltmeter or an ohmmeter directly to any terminal on the P/S control module with the
P/S control module connectors disconnected.

[A]

5 4 3 2 1

[B] [C]

2 1
2 1 [a]
8 7 6 5 4 3 1
4 3

IJCA0A630014-01

[A]: Torque sensor connector “E11” (View: [a]) [B]: P/S motor connector “E61” (View: [a]) [C]: P/S control module connector “G10” (View: [a])
6C-29 Power Assisted Steering System:

Voltage Check
1) Remove steering column lower cover. (Page 6B-2)
2) Measure voltage at each terminal with connectors connected to the P/S control module.

NOTE
• As each terminal voltage is affected by the battery voltage, check that the battery voltage is 12 V or
more when ignition is “ON”.
• *1: Turn steering wheel fully and hold it with force applied.

“E11” connector
Terminal Circuit Wire color Normal voltage Condition
E11-1 — — — —
Torque sensor 5 V power supply
E11-2 RED Approx. 5 V Ignition “ON”
circuit
E11-3 Torque sensor ground circuit BLK 0V Ignition in any position
Engine: Idle speed
Approx. 2.5 V
Steering wheel at neutral
Engine: Idle speed
Approx. 1.2 V Vehicle stationary and steering
E11-4 Torque sensor (Sub) signal circuit YEL
wheel turned fully to right *1
Engine: Idle speed
Approx. 3.8 V Vehicle stationary and steering
wheel turned fully to left *1
Engine: Idle speed
Approx. 2.5 V
Steering wheel at neutral
Engine: Idle speed
Approx. 3.8 V Vehicle stationary and steering
E11-5 Torque sensor (Main) signal circuit WHT
wheel turned fully to right *1
Engine: Idle speed
Approx. 1.2 V Vehicle stationary and steering
wheel turned fully to left *1

“E61” connector
Terminal Circuit Wire color Normal voltage Condition
P/S motor drive circuit (steering Refer to oscilloscope display.
E61-1 RED
wheel turn right) “P/S motor signal” (Page 6C-30)
P/S motor drive circuit (steering Refer to oscilloscope display.
E61-2 BLK
wheel turn left) “P/S motor signal” (Page 6C-30)
E61-3 — — — —
E61-4 — — — —

“G10” connector
Terminal Circuit Wire color Normal voltage Condition
P/S control module power supply
G10-1 GRN Approx. 12 V Ignition in any position
circuit
G10-2 P/S control module ground circuit BLK 0V Ignition in any position
G10-3 — — — —
Refer to oscilloscope display.
G10-4* CAN (Low) communication circuit WHT
“CAN communication signal” (Page 6C-31)
Refer to oscilloscope display.
G10-5* CAN (High) communication circuit RED
“CAN communication signal” (Page 6C-31)
G10-6 — — — —
G10-7 — — — —
G10-8 Ignition power supply circuit BRN Approx. 12 V Ignition “ON”
 Power Assisted Steering System: 6C-30

Reference Waveform Measurement condition

Oscilloscope display • Engine is idling and steering wheel is turned to left or
Shown below is typical waveform display provided by right at turning speed of 90°/sec.
oscilloscope.

NOTE Steering wheel is turned to left

• Display includes the following types of

data:

IJW60A630016-01

Steering wheel is turned to right

I8T401111066-01

[A]: Waveform of channel 1 [C]: VOLT/DIV of each channel

[B]: Ground level of each channel [D]: TIME/DIV

• Waveform varies depending on

measurement condition and vehicle spec.

P/S motor signal

Channel Probe Terminal No. IJW60A630017-01
+ E61-1
1 [A]: 12V ON 1. P/S motor signal No.1
– Ground [B]: GND ON 2. P/S motor signal No.2
+ E61-2 [C]: 1 duty cycle
2
– Ground

Measurement condition
• Engine is idling and steering wheel is in the center
position.

IJW60A630015-01

1. P/S motor signal No.1 2. P/S motor signal No.2

6C-31 Power Assisted Steering System:

Measurement condition Steering Wheel Play Check

• Engine is idling and steering wheel is kept fully turned
• Check steering wheel for looseness or rattle by
to left or right.
Steering wheel is turned to left
• Check steering wheel for play, holding vehicle in
IJW60A630018-01
Steering wheel is turned to right
AENJCA0A6304024
moving it in axial and lateral directions.
If check result is not OK, repair or replace steering
wheel.
straight ahead position on the ground with engine
stopped.
If steering wheel play is not as specified, check the
following components and replace any of them if
defective.
– Tie-rod end and tie-rod ball joint for wear
– Suspension arm joint for wear
– Steering shaft joint for wear
– Steering pinion or rack gear for wear or breakage
– Each part for looseness
Steering wheel play “a”
: 0 – 30 mm (0.00 – 1.18 in.)

“a”

I8C50A630015-02
IJW60A630019-01

[A]: 12V ON 1. P/S motor signal No.1 Steering Force Check

[B]: GND ON 2. P/S motor signal No.2 AENJCA0A6304025
1) Place vehicle on level road and set steering wheel at
CAN communication signal straight ahead position.
Channel Probe Terminal No. 2) Check that tire inflation pressure is as specified
+ G10-5 referring to the “Tire Placard”.
CH1
– Ground 3) Start engine.
+ G10-4 4) With engine idling, measure steering force using
CH2
– Ground spring balance (1).
Measurement condition Steering force
• Ignition mode: “ON” : 30 N (3.1 kgf, 6.7 lbf) or less

1
I8C50A630016-01

IAW101630008-01

[a]: CH1 1. CAN communication signal

[b]: CH2
 Power Assisted Steering System: 6C-32

Repair Instructions
P/S Control Module Removal and Installation
AENJCA0A6306002
Removal
1) Disconnect negative (–) cable at battery.
2) Remove steering column. (Page 6B-7)
3) Disconnect P/S motor connector (1) and torque
1
sensor connector (2) from P/S control module (3).
4) Remove P/S control module screws (4) from
steering column assembly.
5) Remove P/S control module.

2
(A)
4 IJCA0A111011-01
3
2. VCI

2) Start engine and select “Sensor (Main) Torque” and

1 “Sensor (Sub) Torque” in “Data list” mode on
IJCA0A630018-01
SUZUKI scan tool.
Installation 3) Check each of “Sensor (Main) Torque” and “Sensor
Reverse removal procedure noting the following point. (Sub) Torque” changes linearly as specified in the
following graph.
• Tighten P/S control module screws (1) to specified
torque. [A]
[F] [N∙m]
Tightening torque
P/S control module screw (a): 3.0 N·m (0.31 kgf- 8.0 to 12.0
m, 2.5 lbf-ft)
0

-12.0 to - 8.0

[H] [E] [H]

[C] [D]
[B]
[G] [N∙m]

1, (a)
8.0 to 12.0

-12.0 to - 8.0

IJCA0A630019-01
[H] [E] [H]

Torque Sensor and Its Circuit Inspection [C] [D]

AENJCA0A6306001 IGJA0A630017-02
Using SUZUKI Scan Tool
[A]: Main signal
1) Connect SUZUKI scan tool to DLC (1). [B]: Sub signal
[C]: Steering force at left turn
Special tool
[D]: Steering force at right turn
(A): SUZUKI scan tool (Suzuki SDT-II)
[E]: Steering wheel at straight ahead position
[F]: “Sensor (Main) Torque” in “Data List” displayed on scan tool
[G]: “Sensor (Sub) Torque” in “Data List” displayed on scan tool
[H]: Turn steering wheel fully and hold it with force applied.
6C-33 Power Assisted Steering System:

4) If check result is not as specified, repair or replace 3) Check voltage changes linearly in main signal and
any of the following items. sub signal as specified in the following graph.
• Torque sensor harness and connector
[A]
• Torque sensor (steering column assembly) [F] [V]

• P/S control module

Approx. 3.8 V

Using Voltmeter Approx. 2.5 V

1) Remove steering column lower cover. (Page 6B-2)

Approx. 1.2 V
2) Start engine and measure voltage between terminals
“E11-3” – “E11-4” and “E11-3” – “E11-5” at torque [H] [E] [H]
sensor connector (1) connected to P/S control
module (2). [C] [D]
[B]
[G] [V]
2

Approx. 3.8 V

Approx. 2.5 V

Approx. 1.2 V
1

[H] [E] [H]

[C] [D]
IDL10A630032-01

[A] [A]: Main signal

[B]: Sub signal
[C]: Steering force at left turn
5 4 3 2 1
[D]: Steering force at right turn
[E]: Steering wheel at straight ahead position
[a]
[F]: “Sensor (Main) Torque” measured voltage by volt meter
[G]: “Sensor (Sub) Torque” measured voltage by volt meter
[H]: Turn steering wheel fully and hold it with force applied.
IJCA0A630015-01

[A]: Torque sensor connector “E11” (View: [a])

4) If check result is not as specified, repair or replace
any of the following items.
• Torque sensor harness and connector
• Torque sensor (steering column assembly)
• P/S control module

P/S Motor and Its Circuit Inspection

AENJCA0A6306003
1) With ignition “OFF”, disconnect P/S motor connector
from P/S control module.
2) Check resistance between terminals “E61-1” and
“E61-2” of P/S motor connector.
If check result is not as specified, replace steering
column assembly.
Motor circuit resistance
Between “E61-1” and “E61-2”: Approx. 1 Ω
 Power Assisted Steering System: 6C-34

3) Check continuity between terminal “E61-1” of P/S Motor current at hoisted vehicle
motor connector and ground. When steering When steering
If check result is not as specified, replace steering wheel is at wheel is kept fully
column assembly. Condition
straight position: turned left or
Motor circuit resistance [A] right: [B]
“E61-1” and ground: No continuity Motor current Approx. 0 A Approx. 40 A

[A]
[A]

2 1

4 3

[a]

IJCA0A630016-01

[A]: P/S motor connector “E61” (View: [a])

[B]

4) Hoist vehicle.
5) With ignition “OFF”, connect P/S motor connector (3)
to P/S control module (4). 4
1 2
6) Using ammeter (2), check that P/S motor current (1)
with engine idling is as indicated below. If check 3
result is not as specified, check P/S control module E61-1
and its circuit. (Page 6C-28)
If P/S control module and its circuit check result is
OK, replace steering column assembly.
E61-2

IJCA0A630017-01

Specifications
Tightening Torque Specifications
AENJCA0A6307001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
P/S control module screw 3.0 0.31 2.5 (Page 6C-32)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Fasteners Information” in Section 0A (Page 0A-6)

Special Tools and Equipment

Special Tool
AENJCA0A6308001
SUZUKI scan tool (Suzuki
SDT-II)
—
(Page 6C-12) /
(Page 6C-12) /
(Page 6C-32)
6C-35 Power Assisted Steering System:

Section 7
HVAC
CONTENTS
Precautions .................................................7-1
Precautions............................................................. 7-1
Precautions for HVAC ........................................... 7-1
A/C System Caution.............................................. 7-1
Precautions for Servicing A/C System .................. 7-1
HVAC System........................................... 7B-1
General Description .............................................7B-1
HVAC System Description .................................. 7B-1
Sub-Cool A/C System Description ...................... 7B-3
Compressor Drive Belt Description ..................... 7B-3
A/C Operation Description .................................. 7B-4
Schematic and Routing Diagram........................7B-6
Manual A/C Electronic Control Input / Output
Block Diagram................................................... 7B-6
Manual A/C System Circuit Diagram................... 7B-7
Component Location ...........................................7B-9
Manual A/C Control System Component
Location ............................................................ 7B-9
Diagnostic Information and Procedures..........7B-11
A/C System Performance Inspection ................ 7B-11
Trouble Diagnosis for Abnormal Pressure ........ 7B-17
A/C System Symptom Diagnosis ...................... 7B-20
Abnormal Noise Symptom Diagnosis of
HVAC System ................................................. 7B-22
Air Conditioning System Check......................... 7B-24
Visual Inspection ............................................... 7B-26
Inspection of HVAC Control Unit and Its
Circuit.............................................................. 7B-26
Inspection of A/C System Circuits at ECM........ 7B-27
Repair Instructions ............................................7B-28
Operation Procedure for Refrigerant Charge .... 7B-28
A/C System Components.................................. 7B-34
Radiator Cooling Fan Removal and
Installation ....................................................... 7B-35
Radiator Cooling Fan Inspection....................... 7B-35
Condenser Assembly On-Vehicle Inspection.... 7B-35
Condenser Assembly Removal and
Installation ....................................................... 7B-35
HVAC Unit Components ................................... 7B-37
HVAC Unit Removal and Installation ................ 7B-38
Blower Motor Removal and Installation............. 7B-39
Table of Contents 7- i
Blower Motor Inspection....................................7B-40
Blower Motor Resistor Removal and
Installation .......................................................7B-40
Blower Motor Resistor Inspection .....................7B-40
Evaporator Removal and Installation ................7B-40
Evaporator Inspection .......................................7B-41
Evaporator Temperature Sensor Removal
and Installation ................................................7B-41
Evaporator Temperature Sensor Inspection .....7B-42
Heater Core Removal and Installation ..............7B-42
Expansion Valve Removal and Installation .......7B-43
Expansion Valve Inspection ..............................7B-44
HVAC Control Unit Components.......................7B-44
HVAC Control Unit Removal and Installation....7B-45
Blower Speed Selector Inspection ....................7B-47
A/C Refrigerant Pressure Sensor and Its
Circuit Inspection.............................................7B-47
A/C Refrigerant Pressure Sensor Removal
and Installation ................................................7B-48
Center Ventilation Louver Removal and
Installation .......................................................7B-48
Side Ventilation Louver Removal and
Installation .......................................................7B-48 7
HVAC Air Filter Removal and Installation .........7B-49
HVAC Air Filter Inspection ................................7B-49
A/C Switch Inspection .......................................7B-50
HVAC System Relay Inspection........................7B-50
Compressor Drive Belt Inspection.....................7B-50
Compressor Drive Belt Removal and
Installation .......................................................7B-51
Compressor Assembly Removal and
Installation .......................................................7B-52
Compressor Assembly Components.................7B-54
Magnet Clutch Inspection..................................7B-54
Magnet Clutch Removal and Installation...........7B-55
Relief Valve Inspection......................................7B-56
Relief Valve Removal and Installation...............7B-57
Specifications .....................................................7B-58
Tightening Torque Specifications......................7B-58
Special Tools and Equipment ...........................7B-58
Recommended Service Material .......................7B-58
Special Tool ......................................................7B-58
7-1 Precautions:
Precautions
HVAC
Precautions
Precautions for HVAC
AENJCA0A7000001
General Precautions
Refer to “General Precautions” in Section 00 (Page 00-
1).
Precautions for Electrical Circuit Service
Refer to “Precautions for Electrical Circuit Service” in
Section 00 (Page 00-3).
Caution for Fastener
Refer to “Caution for Fastener” in Section 00 (Page 00-
6).
Warning for Airbag
Refer to “Warning for Airbag” in Section 00 (Page 00-7).
Reassembling Note for Wiring Harness
Observe “Reassembling Note for Wiring Harness” in
Section 9A (Page 9A-132) whenever installing wiring
harness.
Otherwise, electrical trouble may occur.
Precautions for Ignition Mode
Refer to “Ignition Modes and Ignition Switch Positions” in
Section 0A (Page 0A-6).
A/C System Caution
AENJCA0A7000002
NOTICE
The A/C system of this vehicle uses HFC-
134a (R-134a) refrigerant. The compressor oil
and parts used in the system are also made
of materials compatible with this refrigerant.
If this system is serviced using compressor
oils or parts that are not appropriate for HFC-
134a (R-134a) refrigerant, refrigerant leakage
and damage or other faulty conditions will
occur in the A/C system. This will also cause
damage to or faulty operation of the servicing
equipment.
Use only HFC-134a (R-134a) refrigerant and
also use only the specified compressor oil
and replacement parts.
Precautions for Servicing A/C System
AENJCA0A7000003
Handling HFC-134a (R-134a) Refrigerant and
Specified Compressor Oil
! WARNING
• If HFC-134a (R-134a) is exposed to high
temperatures, it turns into a poisonous
gas.
Take the following precautions to prevent
health problems caused by HFC-134a (R-
134a) gas.
– Do not handle refrigerant in or near any
area where welding or steam cleaning is
performed.
– Keep refrigerant in a cold and dark
place. Avoid storing it under direct
sunlight, in a place close to fire or inside
a vehicle.
– If HFC-134a (R-134a) is burned, avoid
breathing fumes.
• Contact of liquid HFC-134a (R-134a)
refrigerant with skin and eyes will cause
frostbite. The refrigerant cools the surface
coming in contact with it to a temperature
much lower than the freezing point of
water.
Avoid contact with HFC-134a (R-134a)
refrigerant and wear goggles and gloves
whenever handling the refrigerant. Should
the refrigerant happen to contact your
eyes or skin, immediately take action as
described below to prevent aggravating
the condition:
– In the event of eye contact, do not touch
the eye with your hand. Instead, pour
fresh cold water over the eye to raise
gradually the temperature. After
washing the eye thoroughly with water,
receive medical attention as soon as
possible.
– If liquid HFC-134a (R-134a) contacts
your skin, wash the affected area
thoroughly with water. Since the skin
may have been frostbitten, receive
medical attention.
 Precautions: 7-2

NOTICE
• Do not discharge HFC-134a (R-134a)
refrigerant into atmosphere.
• The specified compressor oil for HFC-134a
(R-134a) is highly hygroscopic. Keep
internal parts of air conditioning free from
moisture and dirt. When disconnecting any
line from system, install a blind plug or cap
to the fitting immediately.
• If pipes or hoses are replaced, replenish
compressor with specified amount of
compressor oil from suction side referring
to “Replenishing Compressor Oil” in
“Operation Procedure for Refrigerant
Charge” in Section 7B (Page 7B-28).

Handling A/C Cycle Parts and Tooling

NOTE
• Route drain hose so that drained water
does not adhere to vehicle components.
• When connecting hoses and pipes, apply a
few drops of compressor oil (refrigerant
oil) to O-ring.
• Replace O-ring with new one, once hoses,
pipes or parts are disconnected.
• For locations of high pressure service
valve and low pressure service valve, refer
to “A/C System Components” in Section
7B (Page 7B-34).
• Check local governmental regulations
regarding working with refrigerator
systems and its tooling.

Refrigerant Recovery
When discharging refrigerant out of A/C system, always
recover it using refrigerant recovery and recycling
equipment because discharging HFC-134a (R-134a)
refrigerant into atmosphere would cause adverse effect
to environment. For the method, refer to “Recovery” in
“Operation Procedure for Refrigerant Charge” in Section
7B (Page 7B-28).

Refrigerant Charge
After performing compressor oil replenishment and
evacuation, charge the A/C system with a proper amount
of refrigerant referring to “Charge” in “Operation
Procedure for Refrigerant Charge” in Section 7B (Page
7B-28).
7B-1 HVAC System:

HVAC System
HVAC

General Description
HVAC System Description
AENJCA0A7201001
• This HVAC system is a manually controlled air conditioning type.
• Settings of air flow mode, temperature control and air inlet mode are possible using air flow selector, temperature
selector and air intake selector respectively. When these selectors are set in desired positions, the corresponding
cables move air flow control door, temperature control door and air intake door accordingly.
• Air flow rate can be adjusted by blower speed selector. Four positions are available: LO, ML, MH and HI.
• Rear defogger switch (if equipped) is located on the HVAC control unit.
• 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” (Page 7B-4) for details.
• The ECM circuits related to the A/C system also control evaporator temperature depending on the data from
evaporator temperature sensor. Refer to “A/C Operation Description” (Page 7B-4) for details. On the other hand,
compressor can adjust the flow rate of refrigerant, monitoring the A/C refrigerant pressure mechanically. This also
helps to keep the evaporator temperature at an optimum level.
• The A/C system uses an A/C refrigerant pressure sensor that is capable of detecting linear changes in refrigerant
pressure.
• HVAC unit incorporates blower motor unit, heater core unit and evaporator unit. The HVAC unit also incorporates an
air filter.
• Each side ventilator has a shutter mechanism.
• The condenser is a sub-cool type. It is integral with the receiver / dryer and mounted on the vehicle body in a
floating manner.
• For further information on manual A/C system, refer to “Manual A/C Control System Component Location” (Page
7B-9), “A/C System Components” (Page 7B-34) and “Manual A/C Electronic Control Input / Output Block Diagram”
(Page 7B-6).
 HVAC System: 7B-2

HVAC System Construction

9
12

10

9
23 22

18
1

19

21

13
14

17 11 11
16
15
20

8
6

4
2
7
5
: [A]
3
: [B]

: [C]

IJCA0A720067-01

[A]: Air flow 7. Liquid hose 16. Air intake door

[B]: Refrigerant flow 8. Expansion valve 17. Temperature control door
[C]: Engine coolant flow 9. Side ventilation air 18. Air flow control door
1. HVAC unit 10. Center ventilation air 19. Heater core
2. Compressor 11. Front foot air 20. HVAC air filter
3. Condenser assembly 12. Defroster air 21. Engine
4. Receiver / dryer 13. Fresh air 22. Radiator
5. Discharge hose 14. Recirculation air 23. Reservoir
6. Suction hose 15. Evaporator
7B-3 HVAC System:

Sub-Cool A/C System Description

AENJCA0A7201002
In the sub-cool A/C system (condenser incorporating receiver / dryer), the inside of the condenser is divided into the
condensation part and the sub-cooler part, and the receiver / dryer is located between these parts. In the receiver /
dryer, the refrigerant is separated into vapor refrigerant and liquid refrigerant. Only the liquid refrigerant is delivered to
the sub-cooler part of the condenser. The refrigerant is supercooled by the sub-cooler part of the condenser.

IFRA0A721002-01

[A]: Liquid 4. Receiver/dryer 10. Desiccant

[B]: Vapor 5. Refrigerant pressure sensor 11. Filter
[C]: Superheated vapor 6. Expansion valve 12. Vapor refrigerant
1. Compressor 7. Evaporator 13. Liquid refrigerant
2. Magnet clutch 8. Condensation part
3. Condenser 9. Sub-cooler part

Compressor Drive Belt Description

AENJCA0A7201003
The compressor drive belt is a stretch-type belt. It stretches itself to maintain the belt tension. Therefore, a tension
pulley, which is used to adjust the belt tension, or components for adjusting the clearance between the crankshaft
pulley and the magnet clutch pulley are not necessary. When removing or installing the stretch-type belt, use the
special tool to prevent the belt from being damaged.
 HVAC System: 7B-4

A/C Operation Description

AENJCA0A7201004
Upon receiving A/C switch ON signal from HVAC control unit, ECM control A/C compressor relay and radiator
(condenser) cooling fan relay as described in the table below.
The A/C switch ON signal is sent from the HVAC control unit to BCM. Then it is transmitted to ECM as A/C request
signal through CAN. For CAN communication system, refer to “Communication System Description” in Section 10H
(Page 10H-1).
Input sensor
Control item Description
(or signal)
A/C compressor Evaporator Evaporator ECM controls compressor by turning A/C compressor relay ON/
relay control temperature temperature OFF according to request signal from BCM. BCM sends the signal
sensor based on the signal from evaporator temperature sensor to
prevent evaporator from freezing.
Control during CKP sensor ECM stops compressor by turning A/C compressor relay OFF
low engine (engine rpm) according to signal from CKP sensor (engine rpm) to prevent
speed engine from stalling while engine speed is low.
Control during ECM stops compressor by turning A/C compressor relay OFF
high engine according to signal from CKP sensor (engine rpm) to prevent
speed compressor from over-revolution while engine speed is high.
Control at ECM stops compressor temporarily by turning A/C compressor
engine start relay OFF according to signals from CKP sensor (engine rpm)
and others to stabilize engine idling speed immediately after
engine start.
Control at A/C refrigerant • ECM stops compressor by turning A/C compressor relay OFF
abnormal pressure sensor according to signal from A/C refrigerant pressure sensor to
refrigerant protect system when refrigerant pressure is abnormal.
pressure • ECM stops compressor by turning A/C compressor relay OFF
when A/C refrigerant pressure sensor malfunctions.
Control during APP sensor and • ECM stops compressor temporarily by turning A/C compressor
acceleration wheel speed relay OFF according to signal from APP sensor to provide
sensor enough acceleration while accelerator pedal is fully depressed
regardless of vehicle speed.
• ECM stops compressor temporarily by turning A/C compressor
relay OFF according to signal from throttle position sensor to
provide enough acceleration when accelerator pedal is
depressed more than specification while vehicle speed is low.
Control at high ECT sensor • ECM stops compressor by turning A/C compressor relay OFF
engine coolant according to signal from ECT sensor to prevent overheating
temperature when engine coolant temperature is higher than specified level.
• ECM stops compressor by turning A/C compressor relay OFF
when ECT sensor malfunctions.
7B-5 HVAC System:

Input sensor
Control item Description
(or signal)
Radiator (condenser) cooling fan A/C refrigerant K10B and bi-fuel CNG model:
relay control pressure sensor ECM drives radiator cooling fan under the following conditions by
and wheel turning radiator cooling fan relay ON according to signals from A/
speed sensor C refrigerant pressure sensor and wheel speed sensor when A/C
compressor relay is ON.
• Vehicle speed is less than specified value.
• Vehicle speed is more than specified value and refrigerant
pressure more than specified value.
• Wheel speed sensor malfunction is not detected.
K12M model:
ECM drives radiator cooling fan in low or high speed mode under
the following conditions by turning radiator cooling fan relays
No.1, No.2 and No.3 ON/OFF according to signals from A/C
refrigerant pressure sensor and wheel speed sensor when A/C
compressor relay is ON.
• Low speed mode (Radiator cooling fan relay No.1 ON)
– Vehicle speed is less than specified value.
– Vehicle speed is more than specified value and refrigerant
pressure more than specified value.
– Wheel speed sensor malfunction is not detected.
• High speed mode (Radiator cooling fan relays No.1, No.2 and
No.3 ON)
– Refrigerant pressure more than specified value.
 HVAC System: 7B-6

Schematic and Routing Diagram

Manual A/C Electronic Control Input / Output Block Diagram
AENJCA0A7202001

Input sensor (or signal) Control module Output actuator (or signal)

ECM (A/C control area)

A/C refrigerant
pressure sensor A/C compressor relay A/C compressor relay
control
Accelerator pedal
position sensor Compressor
Radiator (condenser)
ECT sensor cooling fan relay control

Radiator cooling fan relay

CKP sensor

Wheel speed sensor Radiator cooling fan

ABS control module

Evaporator temperature
sensor

BCM

HVAC control unit

Blower motor
A/C switch

Blower speed selector Blower motor resistor

CAN communication
IJCA0A720001-01
7B-7 HVAC System:

Manual A/C System Circuit Diagram

AENJCA0A7202002

[A] 1

18
27
35
26
18

[B] 36

18

2
3

17 4

[C]
5

28
[D]
5
19

6
9 G155-5 GRN

7 G155-4 YEL
G155-3 29
BLK 20
G155-1 PPL

G155-6 G155-2 BLK/YEL

8
LT GRN 21
10 G154-1 G154-7 BLU
22 31
YEL G154-11 12V 5V
11 32

12
23
LT BLU G154- 2 G154-12 BLK
13
24 33 34
14

G154-8 BRN
15
30
12V 25
BLK G154-3 G154-9 RED
16

33 34
IJCA0A720002-01

[A]: With keyless entry system
[B]: Without keyless entry system
[C]: K10B and bi-fuel CNG model
[D]: K12M model
1. J/B
2. Relay box
3. Blower motor relay
4. Main relay
5. Radiator cooling fan relay No.1
6. Radiator cooling fan relay No.2
7. Radiator cooling fan relay No.3
8. A/C compressor relay
9. Radiator cooling fan motor
10. Compressor
HVAC System: 7B-8
11. ECM 25. Illumination light
12. APP sensor (main) 26. Rear defogger (if equipped)
13. APP sensor (sub) 27. Rear defogger relay (if equipped)
14. ECT sensor 28. Blower motor
15. A/C refrigerant pressure sensor 29. Blower motor resistor
16. CKP sensor 30. To J/B or lighting switch
17. To continuous power supply 31. BCM
18. To ignition power supply 32. Evaporator temperature sensor
19. HVAC control unit 33. CAN driver
20. Blower speed selector 34. To other control module and DLC connected by CAN
21. A/C switch 35. To BCM
22. “A/C” indicator light 36. Individual circuit fuse box
23. Rear defogger indicator light (if equipped)
24. Rear defogger switch (if equipped)
7B-9 HVAC System:

Component Location
Manual A/C Control System Component Location
AENJCA0A7203001

6 7 8
9
5

1
3

10

2 4

11

13

12

IJCA0A720003-01
 HVAC System: 7B-10

3 24

21
17 16 15
14
18

19

20
23 22

IJCA0A720004-01

1. BCM 9. Temperature selector 17. Radiator cooling fan relay No.2 (K12M model)
2. Rear defogger relay (if equipped) 10. Air intake selector 18. Radiator cooling fan relay No.3 (K12M model)
3. HVAC unit 11. Blower motor 19. Main relay
4. HVAC control unit 12. Blower motor resistor 20. Compressor
5. Air flow selector 13. Evaporator temperature sensor 21. Condenser assembly
6. Rear defogger switch (if equipped) 14. A/C compressor relay 22. Radiator cooling fan
7. Blower speed selector 15. Blower motor relay 23. A/C refrigerant pressure sensor
8. A/C switch 16. Radiator cooling fan relay No.1 24. ECM
7B-11 HVAC System:

Diagnostic Information and Procedures

A/C System Performance Inspection
AENJCA0A7204001
1) Check that vehicle and environmental conditions are as follows.
• Vehicle is put indoors.
• Ambient temperature is within 25 – 45 °C (77 – 113 °F).
• Relative humidity is within 30 – 70%.
• There is no wind indoors.
• HVAC unit is normal.
• Blower motor is normal.
• There is no air leakage from air ducts.
• Condenser fins are clean.
• HVAC air filter is not clogged with dirt and dust.
• Battery voltage is about 12 V or more (battery in good condition).
• Radiator cooling fan operates normally.
2) Check that high pressure valve (1) and low pressure valve (2) of manifold gauge are firmly closed.
3) Connect high pressure charging hose (3) to high pressure service valve (4) and low pressure charging hose (5) to
low pressure service valve (6).

NOTE
For locations of high pressure service valve and low pressure service valve, refer to “A/C System
Components” (Page 7B-34).

2 1

5
3

IELA0A722038-01

4) Warm up engine to normal operating temperature and keep it at specified idle speed.
5) Turn A/C switch ON, and then set blower speed selector to maximum speed position, temperature selector to
maximum cold position, air flow selector to face position, air intake selector to recirculation mode and side
ventilation louvers to open position. (Check that compressor and radiator cooling fan are working.)
6) Wait for ten minutes to stabilize A/C operation.
7) Open all door windows, front doors and hood.
 HVAC System: 7B-12

8) Put about 20 mm (0.79 in.) of dry-bulb thermometer (1) in front of center ventilation louver (2). Put wet-and-dry-
bulb thermometer (3) near air inlet of HVAC unit.

3
ICN10P720004-01

9) Check for each pressure of low side and high side if it is within shaded range in the cooling inspection graph. If
each gauge reading is out of specified pressure, correct defective part referring to the following table.
When diagnosing troubles of abnormal pressure on the low side and high side more specifically, refer to “Trouble
Diagnosis for Abnormal Pressure” (Page 7B-17).

NOTE
• If radiator fan changes speed between Low and High while checking the pressure, wait for another
ten minutes to stabilize A/C operation.
• Cooling inspection graph shows a measurement value under relative humidity of 30 – 70%. Outlet
air temperature has a decreasing tendency when the humidity is 30% and an increasing tendency
when the humidity is 70%.
• Outlet air temperature may vary according to relative humidity under the same conditions of inlet air
temperature, low pressure value and high pressure value.
7B-13 HVAC System:

Cooling inspection graph (High and low pressure gauge)

[A]
psi kPa kgf/cm2 %
355.6 2500 25
341.4 2400 24
327.1 2300 23
70
312.9 2200 22
298.7 2100 21
284.4 2000 20
270.2 1900 19
256.0 1800 18 30
“f”
241.7 1700 17
227.5 1600 16 [e]
213.3 1500 15
199.1 1400 14
184.9 1300 13
“g ”
170.6 1200 12 [d ]
[a] 151.4 1100 11
142.2 1000 10
128.0 900 9
113.8 800 8
99.5 700 7
85.3 600 6 70
71.1 500 5 “h ”
30
56.9 400 4 [e]
42.7 300 3
[b] “i”
28.4 200 2
14.2 100 1
0
25 30 35 40 45°C
77 86 95 104 113°F
[c ]
IJCA0A720005-01

[B]
psi kPa kgf/cm2 %
355.6 2500 25
341.4 2400 24
327.1 2300 23 70
312.9 2200 22
298.7 2100 21
284.4 2000 20
270.2 1900 19 30
256.0 1800 18
“f”
241.7 1700 17
227.5 1600 16
[e]
213.3 1500 15
199.1 1400 14
184.9 1300 13
“g ”
170.6 1200 12 [d ]
[a] 151.4 1100 11
142.2 1000 10
128.0 900 9
113.8 800 8
99.5 700 7
85.3 600 6 70
71.1 500 5 “h ”
56.9 400 4 [e] 30

[b] 42.7 300 3

“i”
28.4 200 2
14.2 100 1
0
25 30 35 40 45°C
77 86 95 104 113°F
[c ]
IJCA0A720007-01
 HVAC System: 7B-14

[A]: K10B and bi-fuel CNG model [b]: Pressure on low pressure gauge [e]: Acceptable range
[B]: K12M model [c]: Ambient temperature
[a]: Pressure on high pressure gauge [d]: Humidity

Measuring result and cooling inspection graph, normal example is shown (ambient temperature at 30 °C
(86 °F))
K10B and bi-fuel CNG model K12M model
1180 – 1520 kPa 1100 – 1470 kPa
Pressure on high pressure gauge (HI) (12.0 – 15.5 kgf/cm2) (11.2 – 15.0 kgf/cm2)
(171 – 220 psi) (159 – 213 psi)
270 – 390 kPa 280 – 390 kPa
Pressure on low pressure gauge (LO) (2.8 – 4.0 kgf/cm2) (2.9 – 4.0 kgf/cm2)
(39.1 – 56.5 psi) (40.6 – 56.5 psi)

High pressure gauge

Condition Possible cause Correction
Pressure is higher than Refrigerant overcharged Recharge.
acceptable range Expansion valve frozen or clogged Check expansion valve.
(“f” area) Clogged refrigerant passage of high pressure side Clean or replace.
Radiator cooling fan malfunction (insufficient cooling Check radiator cooling fan.
of condenser)
Dirty or bent condenser fins (insufficient cooling of Clean or repair.
condenser)
Compressor malfunction (insufficient oil etc.) Check compressor.
Engine overheat Check engine cooling system.
• K10B and bi-fuel CNG model:
(Page 1F-4)
• K12M model: (Page 1F-21)
Pressure is lower than Insufficient refrigerant (insufficient charge or leakage) Check for leakage, repair if necessary
acceptable range and recharge.
(“g” area) Expansion valve malfunction (valve opens too wide) Check expansion valve.
Compressor malfunction (insufficient compression) Check compressor.

Low pressure gauge

Condition
Pressure is higher than
acceptable range
(“h” area)
Pressure is lower than
acceptable range
(“i” area)
Possible cause Correction
Expansion valve malfunction (valve opens too wide) Check expansion valve.
Compressor malfunction (insufficient compression) Check compressor.
Insufficient refrigerant (insufficient charge or leakage) Check for leakage, repair if necessary
and recharge.
Expansion valve malfunction (valve opens too narrow) Check expansion valve.
Clogged refrigerant passage (crashed pipe) Repair or replace.
7B-15 HVAC System:

10) Check correlation between inlet port temperature and outlet port temperature using the graph. For example, if
temperature near air inlet of HVAC unit is 35 °C (95 °F) and the one at air outlet of center ventilation louver is 22 °C
(71.6 °F), their crossing point is within acceptable range as shown in the graph. In this case, cooling performance
is satisfactory and proper.
11) If crossing point is out of acceptable range, diagnose trouble referring to the following table.
Cooling inspection graph (Thermometer at center ventilation louver)

[A]
°F °C %
100.4 38
70
98.6 37
96.8 36
95.0 35
93.2 34
91.4 33
89.6 32
87.8 31 [c]
86.0 30
84.2 29
82.4 28
80.6 27
78.8 26 “f” 30
77.0 25
75.2 24 [d ]
[a] 73.4 23
71.6 22 [e]
69.8 21
68.0 20
66.2 19
64.4 18
62.6 17
60.8 16 “g”
59.0 15
57.2 14
55.4 13
53.6 12
51.8 11
50.0 10
48.2 9
25 30 35 40 45°C
77 86 95 104 113°F
[b ]
IJCA0A720008-01
 HVAC System: 7B-16

[B]
°F °C %
100.4 38
98.6 37 70
96.8 36
95.0 35
93.2 34
91.4 33 [c]
89.6 32
87.8 31
86.0 30
84.2 29
82.4 28
80.6 27
78.8 26 “f”
77.0 25
[d ]
75.2 24
30
[a] 73.4 23
71.6 22 [e]
69.8 21
68.0 20
66.2 19
64.4 18 “g”
62.6 17
60.8 16
59.0 15
57.2 14
55.4 13
53.6 12
51.8 11
50.0 10
48.2 9
25 30 35 40 45°C
77 86 95 104 113°F
[b ]
IJCA0A720009-01

[A]: K10B and bi-fuel CNG model [b]: Temperature near air inlet of HVAC unit [e]: Crossing point
[B]: K12M model [c]: Humidity
[a]: Temperature at outlet of center ventilation louver [d]: Acceptable range

Thermometer at center ventilation louver

Condition Possible cause Correction
Crossing point is higher Insufficient or excessive charge of refrigerant Check refrigerant pressure.
than acceptable range (“f” Dirty or bent evaporator fins Clean or repair.
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
Compressor malfunction Check compressor.
Crossing point is lower Insufficient air volume from center ventilation Check blower motor and fan.
than acceptable range louver (heater blower malfunction)
(“g” area) Compressor malfunction Check compressor.

12) After completion of repair, check the system performance again.

7B-17 HVAC System:

Trouble Diagnosis for Abnormal Pressure

AENJCA0A7204002
K10B and Bi-Fuel CNG Model

NOTE
Normal pressure for high pressure gauge (HI) and low pressure gauge (LO) in the following table are
those measured when the ambient temperature is about 30 °C (86 °F). As normal pressure for both
gauges vary depending on the ambient temperature, perform the following steps before starting
diagnosis of troubles.
1. Measure the ambient temperature and using that temperature, read the normal high and low
pressure from the graph given in Step 9 of “A/C System Performance Inspection” (Page 7B-11).
2. Use these values in place of the normal pressure in the following table.

Condition
Manifold gauge (kPa (kgf/cm2) (psi)) Possible cause Correction
Detail
LO HI
270 – 390 (2.8 – 4.0) 1180 – 1520 (12.0 – Normal condition
— —
(39.1 – 56.5) 15.5) (171 – 220)
Negative pressure 500 – 600 LO gauge reads Dust particles Replace expansion
(5.1 – 6.1) negative pressure, while accumulate or water valve.
(72.6 – 87.0) HI gauge reads droplets are frozen Replace condenser
extremely low pressure. inside expansion assembly.
Presence of frost around valve, preventing Evacuate A/C system
tubing to and from refrigerant from and recharge system
condenser assembly and flowing. with fresh refrigerant.
expansion valve.
Normal condition: Normal condition: During A/C operation, Expansion valve is Replace expansion
270 – 390 (2.8 – 4.0) 1180 – 1520 (12.0 – LO gauge sometimes frozen due to moisture valve.
(39.1 – 56.5) 15.5) (171 – 220) indicates negative in system, temporarily Replace condenser
↑↓ ↑↓ pressure, and shutting off assembly.
Abnormal condition: Abnormal condition: sometimes normal refrigeration cycle. Evacuate A/C system
Negative pressure 700 – 1000 (7.2 – pressure. Also HI gauge and recharge system
10.2) (102 – 145) reading fluctuates with fresh refrigerant.
between abnormal and
normal pressures.
50 – 150 700 – 1000 Both LO and HI gauge Insufficient refrigerant Using leak detector,
(0.5 – 1.5) (7.2 – 10.2) indicate low readings. in system check for leakage and
(7.26 – 21.7) (102 – 145) Output air is slightly cold.(refrigerant leakage). repair if necessary.
Recharge system with
refrigerant to
specified amount.
If pressure reading is
almost 0 when
manifold gauges are
attached, check for
any leakage, repair
them, and evacuate
system.
400 – 600 Pressure on LO gauge is Internal leakage in Check compressor
(4.1 – 6.1) high. compressor. and repair or replace
(58.1 – 87.0) Pressure on HI gauge is if necessary.
low.
Both pressures become
equal right after A/C is
turned OFF.
 HVAC System: 7B-18

Condition
Manifold gauge (kPa (kgf/cm2) (psi)) Possible cause Correction
Detail
LO HI
400 – 450 2000 – 2500 (20.4 – High pressure reading Overcharged A/C Adjust refrigerant to
(4.1 – 4.6) 25.5) (290 – 362) on both LO and HI system. specified amount.
(58.1 – 65.2) gauges. Faulty radiator cooling Clean condenser.
operation.
Faulty radiator cooling Check and repair
fan operation. radiator cooling fan.
High pressure reading Presence of air in A/C Replace condenser.
on both LO and HI system Check quantity of
gauges. (improperly compressor oil and
Low pressure tubing is evacuated). presence of
not cold when touched. contaminants in oil.
Evacuate system and
recharge system with
fresh refrigerant.
450 – 550 (4.6 – 5.6) High pressure reading Faulty expansion Replace expansion
(65.3 – 79.7) on both LO and HI valve. valve.
gauges. Refrigerant flow is not
Large amount of frost or regulated properly.
dew on low pressure
tubing.

K12M Model

NOTE
Normal pressure for pressure gauge (HI) and low pressure gauge (LO) in the following table are those
measured when the ambient temperature is about 30 °C (86 °F). As normal pressure for both gauges
vary depending on the ambient temperature, perform the following steps before starting diagnosis of
troubles.
1. Measure the ambient temperature and using that temperature, read the normal high and low
pressure from the graph given in Step 9 of “A/C System Performance Inspection” (Page 7B-11).
2. Use these values in place of the normal pressure in the following table.

Condition
Manifold gauge (kPa (kgf/cm2) (psi)) Possible cause Correction
Detail
LO HI
280 – 390 (2.9 – 4.0) 1100 – 1470 (11.2 – Normal condition
— —
(40.6 – 56.5) 15.0) (159 – 213)
Negative pressure 500 – 600 LO gauge reads Dust particles Replace expansion
(5.1 – 6.1) negative pressure, while accumulate or water valve.
(72.6 – 87.0) HI gauge reads droplets are frozen Replace condenser
extremely low pressure. inside expansion assembly.
Presence of frost around valve, preventing Evacuate A/C system
tubing to and from refrigerant from and recharge system
condenser assembly flowing. with fresh refrigerant.
and expansion valve.
Normal condition: Normal condition: During A/C operation, Expansion valve is Replace expansion
280 – 390 (2.9 – 4.0) 1100 – 1470 (11.2 – LO gauge sometimes frozen due to moisture valve.
(40.6 – 56.5) 15.0) (159 – 213) indicates negative in system, temporarily Replace condenser
↑↓ ↑↓ pressure, and shutting off assembly.
Abnormal condition: Abnormal condition: sometimes normal refrigeration cycle. Evacuate A/C system
Negative pressure 700 – 1000 (7.2 – pressure. Also HI gauge and recharge system
10.2) (102 – 145) reading fluctuates with fresh refrigerant.
between abnormal and
normal pressures.
7B-19 HVAC System:

Condition
Manifold gauge (kPa (kgf/cm2) (psi)) Possible cause Correction
Detail
LO HI
50 – 150 700 – 1000 Both LO and HI gauge Insufficient refrigerant Using leak detector,
(0.5 – 1.5) (7.2 – 10.2) indicate low readings. in system check for leakage and
(7.26 – 21.7) (102 – 145) Output air is slightly cold. (refrigerant leakage). repair if necessary.
Recharge system with
refrigerant to specified
amount.
If pressure readings
are almost 0 when
manifold gauges are
attached, check for
any leakage, repair
them, and evacuate
system.
400 – 600 Pressure on LO gauge is Internal leakage in Check compressor
(4.1 – 6.1) high. compressor. and repair or replace
(58.1 – 87.0) Pressure on HI gauge is if necessary.
low.
Both pressures become
equal right after A/C is
turned OFF.
400 – 450 2000 – 2500 (20.4 – High pressure reading Overcharged A/C Adjust refrigerant to
(4.1 – 4.6) 25.5) (290 – 362) on both LO and HI system. specified amount.
(58.1 – 65.2) gauges. Faulty radiator cooling Clean condenser.
operation.
Faulty radiator cooling Check and repair
fan operation. radiator cooling fan.
High pressure reading Presence of air in A/C Replace condenser.
on both LO and HI system Check quantity of
gauges. (improperly compressor oil and
Low pressure tubing is evacuated). presence of
not cold when touched. contaminants in oil.
Evacuate system and
recharge system with
fresh refrigerant.
450 – 550 (4.6 – 5.6) High pressure reading Faulty expansion Replace expansion
(65.3 – 79.7) on both LO and HI valve. valve.
gauges. Refrigerant flow is not
Large amount of frost or regulated properly.
dew on low pressure
tubing.
 HVAC System: 7B-20

A/C System Symptom Diagnosis

AENJCA0A7204003

Condition Possible cause Correction / Reference Item

Blower motor does not Blown fuse Check related fuses, and then check for short
operate circuit to ground.
Faulty blower motor relay Check blower motor relay. (Page 7B-50)
Faulty blower motor resistor Check blower motor resistor. (Page 7B-40)
Faulty blower speed selector Check blower speed selector. (Page 7B-47)
Faulty blower motor Check blower motor. (Page 7B-40)
Foreign material is present Remove foreign material.
Faulty wiring or grounding Repair wiring.
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 Leaky or clogged air ducts Repair air ducts.
Broken air flow control door assembly Repair air flow control door assembly.
Air intake door does not Broken or bent air intake control cable Check air intake control cable.
change even if air intake Faulty air intake selector Check air intake selector.
mode is changed Incorrect installation of air intake control Check position of cable and adjust it if
cable necessary.
Broken air intake door assembly Repair air intake control door assembly.
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.
Clogged air ducts Repair air ducts.
Faulty thermostat Check thermostat.
• K10B and bi-fuel CNG model: (Page 1F-
11)
• K12M model: (Page 1F-29)
Faulty ECT sensor Check ECT sensor.
• K10B and bi-fuel CNG model: (Page 1C-
11)
• K12M model: (Page 1C-28)
Leaky or clogged heater hoses Replace heater hoses.
Broken temperature control door Repair temperature control door assembly.
assembly
Leaky or clogged heater core Replace heater core.
7B-21 HVAC System:

Condition Possible cause Correction / Reference Item

No cool air comes out Blown fuse Check related fuses, and then check for short
(Compressor does not circuit to ground.
operate) Faulty A/C compressor relay Check A/C compressor relay. (Page 7B-50)
Faulty A/C switch Check A/C switch. (Page 7B-50)
Faulty blower speed selector Check blower speed selector. (Page 7B-47)
Faulty BCM Check BCM. (Page 10B-36)
Faulty ECM and its circuit Check ECM. (Page 7B-27)
Faulty magnet clutch Check magnet clutch. (Page 7B-54)
Loose or broken compressor drive belt Check compressor drive belt. (Page 7B-50)
Faulty compressor Check compressor.
Faulty ECT sensor Check ECT sensor.
• K10B and bi-fuel CNG model: (Page 1C-
11)
• K12M model: (Page 1C-28)
No refrigerant Check amount of refrigerant and system for
leakage.
Recover refrigerant, evacuate and charge A/C
system. (Page 7B-28)
Faulty A/C refrigerant pressure sensor Check A/C refrigerant pressure sensor.
(Page 7B-47)
Faulty evaporator temperature sensor Check evaporator temperature sensor.
(Page 7B-42)
Faulty HVAC control unit Check HVAC control unit. (Page 7B-26)
Faulty wiring or grounding Repair wiring.
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 radiator cooling fan relay Check radiator cooling fan relay. (Page 7B-
50)
Faulty radiator cooling fan motor Check radiator cooling fan motor.
• K10B and bi-fuel CNG model: (Page 1F-
12)
• K12M model: (Page 1F-31)
Faulty ECM and its circuit Check ECM. (Page 7B-27)
Faulty wiring or grounding Repair wiring.
Cool air does not come Faulty blower motor Check blower motor. (Page 7B-40)
out or insufficient cooling Air leakage from HVAC unit or air duct Repair HVAC unit or air duct.
(compressor in normal Loose or broken compressor drive belt Check compressor drive belt. (Page 7B-50)
operation) Faulty magnet clutch Check magnet clutch. (Page 7B-54)
Faulty compressor Check compressor.
Faulty expansion valve Check expansion valve. (Page 7B-44)
Faulty heater and ventilation system Check HVAC unit.
Insufficient or excessive charge of Check amount of refrigerant and system for
refrigerant leakage.
Excessive compressor oil in A/C system Drain excessive compressor oil from A/C
system circuit and compressor.
Clogged condenser Check condenser. (Page 7B-35)
Clogged or frosted evaporator Check evaporator and evaporator temperature
sensor.
• Evaporator: (Page 7B-41)
• Evaporator temperature sensor: (Page
7B-42)
Faulty evaporator temperature sensor Check evaporator temperature sensor.
(Page 7B-42)
Air in A/C system Replace condenser, and then evacuate and
charge A/C system with refrigerant. (Page
7B-28)
 HVAC System: 7B-22

Condition Possible cause Correction / Reference Item

Cool air does not come Faulty magnet clutch
out intermittently Excessive amount of refrigerant
Faulty expansion valve
Faulty evaporator temperature sensor
Excessive moisture in A/C system
Faulty wiring connection
Cool air comes out only at Loose compressor drive belt
high speed Faulty compressor
Clogged condenser
Insufficient charge of refrigerant
Air in A/C system
Cool air does not come Excessive amount of refrigerant
out only at high speed Frosted evaporator
Insufficient cool air flow Faulty blower motor
Air leakage from HVAC unit or air duct
Clogged or frosted evaporator
Faulty wiring or grounding
Check magnet clutch. (Page 7B-54)
Check the amount of refrigerant.
Check expansion valve. (Page 7B-44)
Check evaporator temperature sensor.
(Page 7B-42)
Replace condenser, and then evacuate and
charge A/C system. (Page 7B-28)
Repair wiring.
Check compressor drive belt. (Page 7B-50)
Check compressor.
Check condenser. (Page 7B-35)
Check amount of refrigerant and system for
leakage.
Replace condenser, and then evacuate and
charge A/C system with refrigerant. (Page
7B-28)
Check amount of refrigerant.
Check evaporator and evaporator temperature
sensor.
• Evaporator: (Page 7B-41)
• Evaporator temperature sensor: (Page
7B-42)
Check blower motor. (Page 7B-40)
Repair HVAC unit or air duct.
Check evaporator and evaporator temperature
sensor.
• Evaporator: (Page 7B-41)
• Evaporator temperature sensor: (Page
7B-42)
Repair wiring.

Abnormal Noise Symptom Diagnosis of HVAC System

Abnormal Noise from Compressor
Condition
During compressor
operation, a rumbling
noise is heard as to
engine speed increases
Loud noise is heard at
certain rpm, irrespective
of greatness of speed in
Loud rattle is heard at low
engine rpm
Possible cause
Inadequate clearance in scroll area
Loose or faulty compressor drive belt
Loose compressor mounting bolts
Loose compressor armature plate bolt
AENJCA0A7204004
Correction / Reference Item
Replace compressor. (Page 7B-52)
Check compressor drive belt. (Page 7B-50)
Retighten mounting bolts. (Page 7B-52)
Replace compressor if it has operated in
rattling condition for a long time.
Retighten armature plate bolt. (Page 7B-55)

Abnormal Noise from Magnet Clutch

Condition
Rumbling noise is heard
when compressor is not
in operation
Chattering noise is heard
when compressor is in
operation
Possible cause Correction / Reference Item
Worn or damaged bearings Replace magnet clutch assembly. (Page 7B-
55)
Faulty magnet clutch clearance Adjust magnet clutch clearance. (Page 7B-
(excessive clearance) 55)
Worn magnet clutch friction surface Replace magnet clutch assembly. (Page 7B-
55)
Compressor oil leakage from shaft seal, Replace compressor body assembly. (Page
contaminating friction surface 7B-52)
7B-23 HVAC System:

Abnormal Noise from Tubing

Condition Possible cause Correction / Reference Item
Droning noise is heard Faulty tubing clamps Reposition clamps or increase number of
from inside of the vehicle, clamps.
but not particularly Resonance caused by pulsation from Attach a silencer to tubing, or modify its
noticeable in engine variations in refrigerant pressure position and length.
compartment

Abnormal Noise from Condenser Assembly

Condition Possible cause Correction / Reference Item
Considerable vibration in Resonance from condenser assembly Firmly insert a silencer between condenser
condenser assembly bracket and body assembly bracket and body.

Abnormal Noise from Crankshaft Pulley

Condition Possible cause Correction / Reference Item
Large rattling noise is Loosen crankshaft pulley bolt Retighten bolt.
heard at idle or sudden • K10B and bi-fuel CNG model: (Page 1D-
acceleration 30)
• K12M model: (Page 1D-104)

Abnormal Noise from Tension Pulley

Condition Possible cause Correction / Reference Item
Clattering noise is heard Worn or damaged bearing Replace tension pulley.
from pulley
Pulley cranks upon Cracked or loose bracket Replace or retighten bracket.
contact

Abnormal Noise from Evaporator

Condition Possible cause
Whistling sound is heard Depending on the combination of the
from evaporator interior / exterior temperatures, engine
rpm and refrigerant pressure, the
refrigerant flowing out of the expansion
valve may generate whistling sound.
Correction / Reference Item
Slightly decreasing amount of refrigerant may
stop this noise.
Check expansion valve and replace it if faulty.
(Page 7B-44)

Abnormal Noise from Blower Motor

Condition Possible cause Correction / Reference Item
Blower motor emits a Worn or damaged motor brushes or Replace blower motor. (Page 7B-39)
chirping sound in commutator
proportion to its speed of
rotation
Fluttering noise or large Leaves or other debris introduced from Remove debris and check that screen at fresh
droning noise is heard fresh air inlet to blower motor air inlet is intact.
from blower motor
 HVAC System: 7B-24

Air Conditioning System Check

AENJCA0A7204005

Step Action Yes No

1 Customer complaint analysis Go to Step 2. Perform customer
1) Perform “Step 1: Customer Complaint Analysis” (Page complaint analysis.
7B-25).

Was customer complaint analysis performed?

2 Visual inspection Repair or replace Go to Step 3.
1) Perform “Step 2: Visual Inspection” (Page 7B-25). defective part.

Is there any faulty condition?

3 A/C system performance inspection Repair or replace Go to Step 4.
1) Perform “Step 3: A/C System Performance Inspection” defective part, and then
(Page 7B-25). go to Step 6.

Is there any faulty condition?

4 A/C system symptom diagnosis Repair or replace Go to Step 5.
1) Check and repair A/C system. (Page 7B-25) defective part, and then
go to Step 6.
Is there any faulty condition?
5 Check for intermittent problem Repair or replace Go to Step 6.
1) Check for intermittent problems. (Page 7B-25) defective part, and then
go to Step 6.
Is there any faulty condition?
6 Final confirmation test Go to Step 3. End.
1) Perform “Step 6: Final Confirmation Test” (Page 7B-25).

Is there any malfunction?

7B-25 HVAC System:

Step 1: Customer Complaint Analysis

Talk to customer, and then record details of the problem.

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

Customer questionnaire form (Example)

Abnormal noise while compressor is working: from compressor /

from condenser fan motor
Chattering from compressor:

Compressor does not work:

Vehicle at stop & compressor is working:

No DTC / DTC ( )
No DTC / DTC ( )
IFRA0A721054-03

Step 2: Visual Inspection Step 5: Check for Intermittent Problem

As a preliminary step, perform visual check of the items
that support proper function of the air conditioning
system referring to “Visual Inspection” (Page 7B-26).
Step 3: A/C System Performance Inspection
Check A/C system suspected to be a possible cause
referring to “A/C System Performance Inspection” (Page
7B-11).
Check parts that are prone to cause intermittent problem
(e.g. wire harness, connector, etc.), referring to
“Intermittent Connection and Poor Contact Inspection” in
Section 00 (Page 00-13).
Step 6: Final Confirmation Test
Check that trouble symptom has disappeared and A/C
system is free from abnormal conditions.

Step 4: A/C System Symptom Diagnosis

Check any part or system suspected to be a possible
cause referring to “A/C System Symptom Diagnosis”
(Page 7B-20).
 HVAC System: 7B-26

Visual Inspection
AENJCA0A7204006
Inspection item Referring section
• K10B and bi-fuel CNG model: “Battery Description”: K10B and
Bi-Fuel CNG in Section 1J (Page 1J-2)
• Battery – Fluid level and corrosion of terminals
• K12M model: “Battery Description”: K12M in Section 1J (Page
1J-20)
• Connectors of electric wire harness – “Intermittent Connection and Poor Contact Inspection” in Section 00
Disconnection and friction (Page 00-13)
“Intermittent Connection and Poor Contact Inspection” in Section 00
• Fuses – Blowout
(Page 00-13)
• Parts – Installation and damage —
• Other parts that can be checked visually —

Inspection of HVAC Control Unit and Its Circuit

AENJCA0A7204007
HVAC control unit and its circuits can be checked at HVAC control unit connectors by measuring voltage.

NOTICE
If you connect a voltmeter or an ohmmeter directly to the HVAC control unit with the HVAC control unit
connector disconnected, you can damage the HVAC control unit.
Never connect a voltmeter or an ohmmeter directly to any terminal on the HVAC control unit with the
HVAC control unit connector disconnected.

Voltage Check
1) Remove HVAC control unit. (Page 7B-45)
2) Connect “G154” connector and “G155” connector.
3) Check voltage at each terminal.

NOTE
As each terminal voltage is affected by the battery voltage, check that battery voltage is 11 V or more
with ignition “ON”.

2
1 G154 G155

[a] 6 5 4 3 2 1 3 2 1
12 11 10 9 8 7 6 5 4
IGSB0A722009-01

1. HVAC control unit 2. HVAC control unit connector (View: [a])

“G154” connector
Terminal Wire color Circuit Normal voltage Condition
A/C switch: OFF
or
A/C switch: ON
0–1V
and
G154-1 LT GRN Ground for A/C switch
Blower speed selector: any position other
than OFF
A/C switch: ON
10 – 14 V
Blower speed selector: OFF
Rear defogger: OFF (Rear defogger
0–1V
indicator: OFF)
G154-2 LT BLU Rear defogger indicator light
Rear defogger: ON (Rear defogger
10 – 14 V
indicator: ON)
G154-3 BLK Ground for illumination Below 0.5 V —
7B-27 HVAC System:

Terminal Wire color Circuit Normal voltage Condition

A/C switch: ON
and
0–1V
G154-7 BLU A/C switch signal Blower speed selector: any position other
than OFF
10 – 14 V A/C switch: OFF
Refer to “Inspection of BCM and Its Circuits (with Keyless
G154-8 BRN Rear defogger switch signal
Entry System)” in Section 10B (Page 10B-36).
0–1V Lighting switch: “OFF” position
G154-9 RED Illumination switch
10 – 14 V Lighting switch: “ON” position
0–1V Ignition: “OFF”
G154-11 YEL Ignition power supply
10 – 14 V Ignition: “ON”
G154-12 BLK Ground for HVAC control unit Below 0.5 V —

“G155” connector
Terminal Wire color Circuit Normal voltage Condition
10 – 14 V Blower speed selector: OFF position
G155-1 PPL Blower speed selector (3rd) Blower speed selector: 3rd and 4th
0–1V
positions
10 – 14 V Blower speed selector: OFF position
G155-2 BLK/YEL Blower speed selector (4th)
0–1V Blower speed selector: 4th position
Ground for blower speed
G155-3 BLK Below 0.5 V —
selector
10 – 14 V Blower speed selector: OFF position
G155-4 YEL Blower speed selector (2nd) Blower speed selector: at each of 2nd to
0–1V
4th positions
10 – 14 V Blower speed selector: OFF position
G155-5 GRN Blower speed selector (1st) Blower speed selector: other than above
0–1V
condition
A/C switch: OFF
or
A/C switch: ON
0–1V
and
G155-6 LT GRN Ground for A/C switch Blower speed selector: any position other
than OFF
A/C switch: ON
10 – 14 V and
Blower speed selector: OFF position

Inspection of A/C System Circuits at ECM

AENJCA0A7204008
Check the voltage related to A/C system at ECM terminals.
• K10B model: (Page 1A-103)
• K12M model: (Page 1A-254)
• Bi-fuel CNG model: (Page 1A-347)
 HVAC System: 7B-28

Repair Instructions
Operation Procedure for Refrigerant Charge
AENJCA0A7206001
NOTE
• For locations of high pressure service valve and low pressure service valve, refer to “A/C System
Components” (Page 7B-34).
• Check local governmental regulations regarding working with refrigerator systems and its tooling.
• When handling recovery and recycling equipment, follow the instruction manual for the equipment.

Start evacuation.
15 minutes (below -100 kPa)
Stop evacuation. Check and repair connections.
Wait for 10 minutes
If gauge shows
Check A/C system for abnormal conditions
pressure tightness.

Recharge A/C system with Recharge system with specified value

refrigerant. of refrigerant.

Check A/C system for refrigerant

leakage and amount of refrigerant
charged.

Performance test
IDAA0A722014-04

Recovery Replenishing Compressor Oil

When discharging refrigerant out of A/C system, always
recover it using refrigerant recovery and recycling
equipment because discharging refrigerant HFC-134a
(R-134a) into atmosphere would cause adverse effect to
environment.
It is necessary to replenish compressor with specified
amount of compressor oil from compressor suction side
hole (1) before evacuating system and charging it with
refrigerant.

NOTE
After recovering refrigerant from system,
measure the amount of removed compressor
oil to determine the amount of compressor
oil for replenishment.

IJCA0A720010-01

When charging refrigerant only

When charging refrigerant without replacing any
component, replenish compressor with compressor oil of
the same amount measured when recovering
refrigerant. If lost oil is not measured, add 30 cm3 (30 ml,
1.02 US.oz, 1.05 Imp.oz) of oil.

IELA0A722040-01
7B-29 HVAC System:
When replacing compressor
NOTICE
Use of a compressor oil other than the
specified oil is inappropriate for the
components of the A/C system and may
cause problems with operation of the
system.
Use only the specified compressor oil or
equivalent.
Compressor oil is sealed in each new compressor by the
amount required for A/C system. Therefore, when using
a new compressor, drain the calculated amount of oil
from it.
“C” = “A” – “B”
• “C”: Amount of oil to be drained
• “A”: Amount of oil in a new compressor
• “B”: Amount of oil in removed compressor
NOTE
Compressor assembly supplied from factory
is filled up with the following amount of oil.
Compressor oil 95590–58D30 (Compressor oil (ND-
OIL8))
Amount of oil in compressor
80 – 90 cm3 (80 – 90 ml, 2.71 – 3.04 US.oz, 2.82 – 3.17
Imp.oz)
1 2
"C"
"A"
"B"
I7V20A720017-01
1. New compressor 2. Removed compressor
When replacing other parts
Replenish compressor with the following amount of oil.
Amount of compressor oil to be replenished
Evaporator and expansion valve: 15 cm3 (15 ml, 0.51
US.oz, 0.53 Imp.oz)
Condenser (with receiver/dryer): 10 cm3 (10 ml, 0.34
US.oz, 0.35 Imp.oz)
Hoses: 5 cm3 (5 ml, 0.17 US.oz, 0.18 Imp.oz) each
Pipes: 5 cm3 (5 ml, 0.17 US.oz, 0.18 Imp.oz) each
Evacuation
NOTICE
Attempting to evacuate the A/C system when
refrigerant remains in the system will
damage the vacuum pump.
Do not evacuate the A/C system before
completely recovering the refrigerant from
the system.
NOTE
If A/C system circuit is opened (exposed) to
atmosphere, system must be evacuated
using a vacuum pump. The A/C system
should be fitted with manifold gauge set, and
should be evacuated for approximately 15
minutes.
1) Connect high pressure charging hose (1) and low
pressure charging hose (2) of manifold gauge set (3)
as follows:
High pressure charging hose → High pressure
charging valve (4) on discharge hose
Low pressure charging hose → Low pressure
charging valve (5) on suction hose
2) Attach center charging hose (6) of manifold gauge
set to vacuum pump (7).
3) Operate vacuum pump, and then open discharge
side valve (HI) (8) of manifold gauge set.
If there is no blockage in the system, there will be an
indication on high pressure gauge (9).
When this occurs, open the other side valve (LO)
(10) of the gauge set.
4) Approximately 10 minutes later, low pressure gauge
(11) should show negative pressure lower than –100
kPa (–1.0 kgf/cm2, –750 mmHg, –14.5 psi),
indicating that no leakage exists.
NOTE
• If the system does not show negative
pressure below –100 kPa (–1.0 kgf/cm2, –
750 mmHg, –14.5 psi), close both valves,
stop vacuum pump and watch change in
reading of low pressure gauge.
• Increase in gauge reading suggests of
leakage. In this case, repair the system
before continuing its evacuation.
• If the gauge shows a stable reading
(suggesting no leakage), continue
evacuation.
 HVAC System: 7B-30

5) Carry out evacuation for a total of at least 15 Checking A/C System for Pressure Leakage
minutes. After completing the evacuation, close manifold gauge
6) Continue evacuation until lower pressure gauge high pressure valve and low pressure valve and wait for
indicates negative pressure lower than –100 kPa (– 10 minutes. Check that low pressure gauge reading has
1.0 kgf/cm2, –750 mmHg, –14.5 psi), and then close not changed.
both valves.
NOTE
7) Stop vacuum pump. Disconnect center charging
If gauge reading moves closer to “0”, there is
hose from pump inlet. Now, the system is ready for
leakage somewhere. Check the tubing
charging refrigerant.
connections and make necessary
3 corrections.
11 Then, evacuate system once again and check
9
that there is no leakage.
10 8

Charge

! WARNING
1
2 There is a risk of personal injury or health
problems if the A/C system is charged with
refrigerant incorrectly or if refrigerant
5 containers are improperly handled.
7 6
Take the following precautions to reduce the
4 risk of injury or health problems.
• Perform the refrigerant charge operation
with the engine stopped. Charge the high-
pressure side first and then the low-
pressure side. If you do not, the refrigerant
may flow backward and cause the hose or
refrigerant container to burst.
IELA0A722034-02
• Install the tap valve carefully following the
instructions on the refrigerant container to
prevent contact with the refrigerant.
• Empty the refrigerant container before
discarding it to prevent possible health
problems and other dangerous
consequences.
• Never expose the refrigerant container to a
heat higher than 40 °C (104 °F). Liquid
refrigerant will turn into a toxic gas.
7B-31 HVAC System:
NOTICE
Failure to take proper precautions when
charging the A/C system can result in
charging the system with the incorrect
amount of refrigerant and can lead to poor
system operation or damage to system
components.
• Since the A/C system has no sight glass,
first recover refrigerant and evacuate the
system, and then fill the system with the
specified amount of refrigerant.
• Charge the system only when the
compressor is not hot to assure that you
have used the correct amount of
refrigerant.
• Check the pressure gauges before and
during charging to assure that there is the
correct amount of refrigerant in the
system.
• Do not turn the refrigerant container
upside down during charging. Doing so
will cause liquid refrigerant to enter the
compressor and damage it.
NOTE
The A/C system contains HFC-134a (R-134a).
Described here is a method for charging the
A/C system with refrigerant from the
refrigerant service container.
When charging the system with the
refrigerant recovered using the refrigerant
recycling equipment, follow the procedure
described in the equipment manufacturer’s
instruction manual.
Perform initial charge through high pressure side with
the engine stopped.
Next, charge the system with refrigerant as follows from
low pressure side with engine running.
1) Check if hoses are routed properly after evacuating
system.
2) Connect low charging hose (1) and high charging
hose (2) of manifold gauge set (3) in position. Then,
open refrigerant container valve (4) to purge
charging line.
3) Open high pressure side valve (5) to charge system
with refrigerant.
4) After a while, open low pressure side valve (6) and
close high pressure side valve.
! WARNING
If the high-pressure side valve is not closed
securely, the refrigerant may flow backwards
and cause the hose or refrigerant container
to burst, possibly resulting in a personal
injury.
Close the high-pressure side valve securely.
5) Start engine and keep engine speed at 1500 r/min,
and then operate A/C system.
6) Charge A/C system with vapor refrigerant. At this
time, refrigerant container should be held upright.
3
6 5
4
1
2
IELA0A722041-01
 HVAC System: 7B-32

7) When refrigerant container (1) is emptied, use the 8) After the system is charged with specified amount of
following procedure to replace it with a new refrigerant or when low pressure gauge (1) and high
refrigerant container. pressure gauge (2) have indicated the following
a) Close low pressure valve. specified values, close low pressure side valve (3)
on manifold gauge set (4).
b) Replace empty container with a refrigerant
container which has been charged with Specified amount of refrigerant
refrigerant. When using refrigerant container tap 390 ± 20 g (13.7 ± 0.705 oz)
valve (2), use the following procedure for
Low pressure side and high pressure side
replacement.
example (K10B and bi-fuel CNG model)
i) Turn handle of tap valve counterclockwise to
Gauges should read as follows when ambient
retract needle (3), and then remove
temperature is 30 °C (86 °F).
refrigerant container tap valve by loosening
1180 – 1520 kPa
its plate nut (4). Pressure on high
(12.0 – 15.5 kgf/cm2)
ii) Install refrigerant container tap valve to new pressure gauge
(171 – 220 psi)
refrigerant container. 270 – 390 kPa
Pressure on low pressure
(2.8 – 4.0 kgf/cm2)
gauge
(31.9 – 56.5 psi)

Low pressures side and high pressure side

example (K12M model)
Gauges should read as follows when ambient
temperature is 30 °C (86 °F).
1100 – 1470 kPa
Pressure on high
(11.2 – 15.0 kgf/cm2)
pressure gauge
(159 – 213 psi)
280 – 390 kPa
Pressure on low pressure
I2RH01720018-01 (2.9 – 4.0 kgf/cm2)
c) Purge any air from center charging hose. gauge
(40.6 – 56.5 psi)
When using refrigerant container tap valve, use
the following procedure to purge air.
4
i) Fully tighten refrigerant container tap valve
1 2
(1), and then loosen (open) plate nut (2)
slightly. 3
ii) Open low pressure side valve (3) of manifold
gauge set (4) a little.
iii) As soon as refrigerant comes out with a
“hiss” through a clearance between
refrigerant container and tap valve, tighten
plate nut as well as low pressure side valve.
iv) Turn handle of tap valve clockwise so that its
needle is screwed into the new container to
make a hole for refrigerant flow.

IELA0A722042-01

I2RH01720019-01
7B-33 HVAC System:
Removal of Manifold Gauge Set
! WARNING
If the manifold gauge set is removed
carelessly, refrigerant under pressure may
spray out of the high-pressure side of the A/C
system. The refrigerant could contact your
eyes or skin, causing injury.
Remove the manifold gauge set carefully,
following the instructions provided below.
For A/C system charged with specified amount of
refrigerant, remove manifold gauge set as follows:
1) Close low pressure side valve of manifold gauge set.
(high pressure side valve has already been closed
during charging process.)
2) Close refrigerant container valve.
3) Stop engine.
4) Using shop rag, remove charging hoses from service
valves. Perform this operation quickly.
5) Put caps on service valves.
Checking A/C System for Refrigerant Leakage
Whenever refrigerant leakage is suspected in the
system or any service operation has been performed
which may result in malfunction of lines and connections,
it is important to perform check for leakage.
Common sense should be used during refrigerant
leakage test, since the need and extent of any such test
will, in general, depend upon the nature of a complaint
and the type of a service performed on the system.
Liquid leak detector
! WARNING
If the refrigerant is exposed to a fire, it turns
to a poisonous gas (phosgene).
Do not inhale the gas that is produced if
refrigerant is exposed to a fire.
There is a number of fittings and places throughout the
A/C system where liquid leak detector solution may be
used to pinpoint refrigerant leakage.
By applying the solution to the area in question with a
swab, bubbles will form within seconds if there is
leakage.
For connections in such confined areas, as those around
evaporator and condenser, electronic (refrigerant) leak
detector (1) is more practical for determining leakage.
IDAA0A722074-01
 HVAC System: 7B-34

A/C System Components

AENJCA0A7206002

(b)

(b)

12

OIL
7
(a)

10 (a) 9
OIL

7
5 11
8

(a) 3

(a)
OIL

OIL

OIL
7 7
a

2
13 (c)

4
(a)

13 (c)
IJCA0A720011-02

1. HVAC unit 7. O-ring 13. Condenser bolt

: Apply compressor oil. : For tightening procedure of condenser
bolt, refer to “Condenser Assembly
Removal and Installation” (Page 7B-
35).
2. Compressor 8. Liquid hose : 11 Nm (1.1 kgf-m, 8.5 lbf-ft)
3. Condenser with receiver / dryer 9. Expansion valve : 4.5 Nm (0.46 kgf-m, 3.5 lbf-ft)
4. Compressor mounting bolt 10. A/C refrigerant pressure sensor : 5.0 Nm (0.51 kgf-m, 4.0 lbf-ft)
: For tightening procedure of compressor
mounting bolt, refer to “Compressor Assembly
Removal and Installation” (Page 7B-52).
5. Discharge hose 11. High pressure charging valve : Do not reuse.
6. Suction hose 12. Low pressure charging valve
7B-35 HVAC System:

Radiator Cooling Fan Removal and Installation 4) Remove discharge hose bolt (1) and liquid hose bolt
AENJCA0A7206003 (2).
Refer to “Radiator Cooling Fan Assembly Removal and
Installation”: K10B and Bi-Fuel CNG in Section 1F (Page 5) Disconnect discharge hose (3) and liquid hose (4)
1F-13) or “Radiator Cooling Fan Assembly Removal and from condenser assembly (5).
Installation”: K12M in Section 1F (Page 1F-31).
1 5

Radiator Cooling Fan Inspection

AENJCA0A7206004
Refer to “Radiator Cooling Fan Assembly On-Vehicle
3
Inspection”: K10B and Bi-Fuel CNG in Section 1F (Page
1F-12) or “Radiator Cooling Fan Assembly On-Vehicle
Inspection”: K12M in Section 1F (Page 1F-30).

Condenser Assembly On-Vehicle Inspection

AENJCA0A7206005
Check the following items. 4
• Condenser fins for clogging. 2
If clogged, wash condenser with water and dry it with
compressed air.
IJCA0A720012-01
• Condenser fins for leakage and breakage.
If any defects are found, repair or replace condenser. 6) Remove condenser bolts (1) and then remove
condenser assembly (2).
• Condenser fittings for leakage.
If any defects are found, repair or replace condenser.

Condenser Assembly Removal and Installation

AENJCA0A7206006
NOTICE
Condenser and radiator fins can easily be
bent during removal of the condenser 1
assembly.
1
Remove the condenser assembly carefully
not to damage the condenser and radiator
fins. If any of them is bent, straighten it using
a flat-bladed screwdriver or pliers.

Removal
2
1) Recover refrigerant from A/C system referring to IJCA0A720013-01
“Recovery” in “Operation Procedure for Refrigerant
Charge” (Page 7B-28).

NOTE
Measure the amount of removed compressor
oil to determine how much compressor oil is
required for replenishment.

2) Hoist vehicle.
3) Remove front bumper. (Page 9H-3)
 HVAC System: 7B-36

Installation
Reverse removal procedure noting the following points.
• Apply compressor oil to new O-rings of discharge
hose and liquid hose.
: Compressor oil 95590–58D30 (Compressor oil
(ND-OIL8))
• Replenish compressor with specified amount of
compressor oil from compressor suction side referring
to “Replenishing Compressor Oil” in “Operation
Procedure for Refrigerant Charge” (Page 7B-28).
• Tighten condenser bolts in numerical order (“1” – “4”)
to specified torque.
Tightening torque
Condenser bolt (a): 5.0 N·m (0.51 kgf-m, 4.0 lbf-ft)

“3”, (a)

“4”, (a)

“2”, (a)

“1”, (a)

IJCA0A720066-01

• Evacuate and charge A/C system referring to

“Evacuation” and “Charge” in “Operation Procedure
for Refrigerant Charge” (Page 7B-28).
7B-37 HVAC System:

HVAC Unit Components

AENJCA0A7206007

9
1
9

17 21
10 24

16

20

22 4
22

24 3

14
13
12
23
24 5

11

18
OIL

19
6

15
(a)

7
[A]

IJCA0A720015-01

[A]: Forward 9. Packing 18. Blower motor resistor

1. Fresh air inlet duct 10. Air flow control door assembly 19. O-ring
: Apply compressor oil.
2. Air intake case 11. Heater core 20. Air intake control door assembly
3. Air filter 12. Evaporator 21. Air intake control lever
: For installation, refer to “HVAC Air Filter
Removal and Installation” (Page 7B-49).
4. Filter cover 13. Evaporator temperature sensor 22. Air flow control lever
5. Blower upper case 14. Cover 23. Temperature control lever
6. Blower lower case 15. Expansion valve 24. Cable clamp
7. Blower motor 16. Temperature control door assembly : 3.5 Nm (0.36 kgf-m, 2.5 lbf-ft)
 HVAC System: 7B-38

8. Heater case 17. Foot duct : Do not reuse.

HVAC Unit Removal and Installation 8) Remove drain hose (1), if necessary.
AENJCA0A7206008

Removal
1) Disable airbag system. (Page 8B-56)
2) Recover refrigerant from A/C system using recovery
and recycling equipment referring to “Recovery” in
“Operation Procedure for Refrigerant Charge” (Page
7B-28).
1
3) Drain engine coolant.
• K10B and bi-fuel CNG model: (Page 1F-9)
• K12B model: (Page 1F-27)
4) Remove cowl top garnish. (Page 9H-13)
5) Disconnect heater hoses (1) from HVAC unit.

IJCA0A720017-01

IJCA0A720016-01 9) Remove HVAC unit (1) from vehicle by removing

6) Remove suction hose bolt (1), and then remove nuts (2).
liquid hose and suction hose from expansion valve NOTE
(2).
When removing HVAC unit, be careful not to
spill engine coolant and compressor oil on
1 vehicle floor.

2
IFRA0A721013-01 2
7) Remove instrument panel from vehicle body.
(Page 9C-25)

2
IJCA0A720018-01
7B-39 HVAC System:

Installation • Install new packing (1) to installation hole uniformly.

Reverse removal procedure noting the following points.
• Replenish compressor with specified amount of
compressor oil from compressor suction side referring
to “Replenishing Compressor Oil” in “Operation
Procedure for Refrigerant Charge” (Page 7B-28). 1
• Install drain hose (1) as follows.
– Align groove (2) of drain hose with protrusion (3) of
HVAC unit (4).
– Fit hose grommet (5) to dash panel hole so that
IDAA0A722036-01
lower lip of the grommet is positioned under the
panel. • Tighten the HVAC unit mounting nuts to specified
torques. (Page 7B-34)
• Evacuate and charge A/C system referring to
“Evacuation” and “Charge” in “Operation Procedure
for Refrigerant Charge” (Page 7B-28).
3 • Refill cooling system with coolant.
2
– K10B and bi-fuel CNG model: (Page 1F-9)
– K12M model: (Page 1F-27)
1
• Adjust control cables. (Page 7B-45)

Blower Motor Removal and Installation

AENJCA0A7206009
Removal
1) Disconnect negative (–) cable at battery.
2) Disconnect connector and clamp from blower motor
(1).
3) Remove screws (2).
4 4) Remove blower motor from HVAC unit.

2
2

1
6 2
IJCA0A720020-01

Installation
IJCA0A720019-01
Reverse removal procedure.
6. Vehicle downward
 HVAC System: 7B-40

Blower Motor Inspection Blower Motor Resistor Removal and Installation

AENJCA0A7206010
• Check resistance between two blower motor terminals
as shown.
If there is no continuity, replace blower motor.
AENJCA0A7206011
Removal
1) Disconnect negative (–) cable at battery.
2) Disconnect connector from blower motor resistor.
3) Release lock (1) by pushing it in arrow direction and
remove blower motor resistor (2) upward.

1
2

I9P60A721013-01

• Check blower motor for operation and current.

a. Put blower motor (1) in a soft jawed vise.
b. Connect battery to blower motor as shown. IJCA0A720021-01

c. Check if blower motor operates smoothly without

noise. Installation
Reverse removal procedure.
d. Check that the ammeter indicates specified
current when the voltage is applied for 1 min.
If check result is not as specified, replace blower Blower Motor Resistor Inspection
AENJCA0A7206012
motor. Measure terminal-to-terminal resistance. If check result
Blower motor specified current at 12 V is not as specified, replace blower motor resistor.
16 A maximum at 20 – 25 °C (68 – 77 °F) Blower motor resistor resistance
Resistance at 20 – 25 °C
Terminals
(68 – 77 °F)
1
“3” (H) – “1” (MH) Approx. 0.47 Ω
“1” (MH) – “4” (ML) Approx. 1.09 Ω
“4” (ML) – “2” (L) Approx. 3.49 Ω

3
“2” “1”
1
I9P60A721039-01

4
“4” “3”

2
IDAA0A721011-01

Evaporator Removal and Installation

AENJCA0A7206041

NOTICE
Evaporator fins can easily be bent during
removal of the evaporator.
Remove the evaporator carefully not to
damage the evaporator fins. If any of them is
bent, straighten it using a flat-bladed
screwdriver or pliers.
7B-41 HVAC System:

Removal 6) Remove cover (1), and then remove evaporator (2)

1) Remove HVAC unit. (Page 7B-38) from blower upper case (3).
2) Remove expansion valve. (Page 7B-43)
3) Remove screw (1) and claws (2), and then remove
foot duct (3) from HVAC unit.

2
2

2
1 3
IJCA0A720024-01

7) Remove evaporator temperature sensor, if

necessary. (Page 7B-41)

Installation
3 1 Reverse removal procedure.
IJCA0A720022-01

4) Disconnect evaporator temperature sensor clamp

(1).
5) Remove screw (2) and claws (3), and then remove
blower lower case (4) from blower upper case.
1 dry it with compressed air.
Evaporator Inspection
AENJCA0A7206013
Check the following items.
• Evaporator fins for clogging
If clogged, wash evaporator fins with water, and then
• Evaporator fins for leakage and breakage
If evaporator fins are leaky or broken, repair or
replace evaporator.
• Evaporator fittings for leakage
If evaporator fittings are leaky, repair or replace
evaporator.

Evaporator Temperature Sensor Removal and

Installation
AENJCA0A7206043
Removal
1) Remove evaporator. (Page 7B-40)

3 3 4

IJCA0A720023-01
 HVAC System: 7B-42

2) Remove evaporator temperature sensor (1) from

evaporator (2).

I7RW01721018-01 k 10 1
9
Installation 8
Reverse removal procedure noting the following point.
7
• Install evaporator temperature sensor (1) onto
6
evaporator (2) as shown.
[A] 5
4

3
2

1
5
1 0 5 10 15 20 25 30 (°C)
32 41 50 59 68 77 86 (°F)
[B]
IJCA0A720025-01

[A]: Resistance [B]: Temperature

7
Heater Core Removal and Installation
6 AENJCA0A7206042

NOTICE
2 Heater core fins can easily be bent during
3
removal of the heater core.
4
IJCA0A720068-01
Remove the heater core carefully not to
damage the heater core fins. If any of them is
3. Sensor part fixed to 5th fin from the right
bent, straighten it using a flat-bladed
4. Holding part fixed to 26th fin from the right
5. Pipe fitting
screwdriver or pliers.
6. 37 mm (1.4 in.)
7. 70 mm (2.7 in.)
Removal
1) Remove HVAC unit. (Page 7B-38)
Evaporator Temperature Sensor Inspection 2) Remove expansion valve. (Page 7B-43)
AENJCA0A7206015
Check resistance between terminals of evaporator 3) Remove screw (1) and claws (2), and then remove
temperature sensor. foot duct (3) from HVAC unit.
If check result is not as specified, replace evaporator
2
assembly (1).
2
Evaporator temperature sensor resistance
0 °C (32 °F): 6.7 – 6.9 kΩ
25 °C (77 °F): 2.0 – 2.2 kΩ

3 1
IJCA0A720026-01
7B-43 HVAC System:

4) Remove screws (1) and claws (2), and then remove Expansion Valve Removal and Installation
heater case (3) and air intake case (4) from HVAC AENJCA0A7206016

unit.
Removal
5) Disconnect evaporator temperature sensor clamp
(5). 1) Recover refrigerant from A/C system using recovery
and recycling equipment referring to “Recovery” in
6) Remove screw (6) and claws (7), and then remove “Operation Procedure for Refrigerant Charge” (Page
blower lower case (8) from blower upper case. 7B-28).
2) Remove suction hose bolt (1), and then remove
1 liquid hose and suction hose from expansion valve
5
(2).
3) Remove expansion valve bolts (3) and remove
expansion valve.
1

1
3
4
3

2
2
IFRA0A721020-01

2
Installation
Reverse removal procedure noting the following points.
8 • Apply compressor oil to O-rings of expansion valve
7 7
and pipes.
: Compressor oil 95590–58D30 (Compressor oil
(ND-OIL8))
• Tighten expansion valve bolts (1) and suction hose
bolt (2) to specified torque.
Tightening torque
Expansion valve bolt (a): 3.5 N·m (0.36 kgf-m, 2.5
6
lbf-ft)
IJCA0A720027-01
Suction hose bolt (b): 11 N·m (1.1 kgf-m, 8.5 lbf-
7) Remove heater core (1) from blower upper case (2). ft)

1 2, (b)

1, (a)

2 IFRA0A721021-01
IJCA0A720028-01
• Evacuate and charge A/C system referring to
“Evacuation” and “Charge” in “Operation Procedure
Installation
for Refrigerant Charge” (Page 7B-28).
Reverse removal procedure.
 HVAC System: 7B-44

Expansion Valve Inspection Refer to “A/C System Performance Inspection” (Page

AENJCA0A7206017 7B-11).

HVAC Control Unit Components

AENJCA0A7206018

3
9
2

6
8
IJCA0A720029-01

1. HVAC control unit 4. Temperature control cable 7. Blower speed selector knob
2. Air intake control cable 5. Air flow selector 8. Air intake selector knob
3. Air flow control cable 6. Temperature selector knob 9. Bulb
7B-45 HVAC System:

HVAC Control Unit Removal and Installation 4) Remove instrument panel shift garnish from
AENJCA0A7206019 instrument panel. (Page 9C-25)
Removal 5) Inserting an interior trim remover (2) or the like,
release the lower hooks in arrow direction “1”.
1) Disconnect negative (–) cable at battery.
6) Remove HVAC control unit (1) by pulling it in arrow
2) Remove glove box.
direction “2”.
3) Disconnect air intake control cable (1), temperature
control cable (2) and air flow control cable (3) from A B
A
HVAC unit.

1
1

B
A B
A B
A A
B
A A
“1” “2” “1”

A A

IJCA0A720031-01

7) Disconnect HVAC control unit connectors.

Installation
3 Reverse removal procedure noting the following points.
• Connect air intake control cable, temperature control
cable and air flow control cable of HVAC control unit
to corresponding links of HVAC unit as follows:
a. Set air flow selector (1), air intake selector (2) and
temperature selector (3) to the position as shown
2 in figure.

IJCA0A720030-01 1 3

2
IJCA0A720032-01
 HVAC System: 7B-46

b. Move air intake control lever (1), temperature e. Fix air intake control inner cable (1) to pin of air
control lever (2) and air flow control lever (3) fully intake control lever.
in arrow direction. f. Fix air intake outer cable (2) to cable lock clamp
(3).

1
1

2
IJCA0A720035-01

3
NOTE
After installing control cables, check that
control levers move smoothly and stop at
proper position.

• Check that air flow outlet changes correctly as air flow

2 selector is changed.
• Check that outlet temperature changes correctly as
temperature selector is changed.
IJCA0A720033-01
• Check that air intake changes correctly as air intake
c. Position air flow control cable above temperature selector is changed.
control cable, fix temperature control inner cable
(1) to pin of temperature control lever and air flow
control inner cable (2) to pin of air flow control
lever.
d. Fix each outer cable (3) to each cable lock clamp
(4).

4
3
2

4
3
IJCA0A720034-01
7B-47 HVAC System:

Blower Speed Selector Inspection A/C Refrigerant Pressure Sensor and Its Circuit
AENJCA0A7206020
Check blower speed selector for terminal-to-terminal
Inspection
AENJCA0A7206021
continuity. If check result is not as specified, replace 1) Disconnect negative (–) cable at battery.
HVAC control unit.
2) Disconnect A/C refrigerant pressure sensor
connector.
Terminal
3 6 5 4 1 2 3) Connect negative (–) cable at battery.
Position
4) Set ignition “ON”.
OFF
5) Check that voltage between “BEG” wire terminal and
1
“LT GRN” wire terminal of A/C refrigerant pressure
2 sensor connector is 4.75 V to 5.25 V.
3 If check result is not as specified, check A/C
refrigerant pressure sensor circuit.
4
6) Set ignition “OFF”.
IJCA0A720036-01
7) Disconnect negative (–) cable at battery.
8) Connect A/C refrigerant pressure sensor connector.
3 2 1
9) Connect negative (–) cable at battery.
6 5 4 10) Connect manifold gauge set to charging valves.
11) Check A/C refrigerant pressure sensor voltage of
ECM connector.
• K10B model: (Page 1A-103)
• K12M model: (Page 1A-254)
• Bi-Fuel CNG model: (Page 1A-347)
If voltage is not as specified, replace A/C refrigerant
pressure sensor.
A/C refrigerant pressure sensor voltage
specifications (A/C refrigerant pressure measured
by manifold gauge)

5 (V)
3
4 5.0
1
2 4.0
6

IJCA0A720037-01
3.0
[A]
2.0

1.0

0.5 1.0 1.5 2.0 2.5 3.0 3.5 (MPa)

[B]
IAW101720062-02

[A]: Voltage [B]: Pressure on high pressure gauge

 HVAC System: 7B-48

A/C Refrigerant Pressure Sensor Removal and Center Ventilation Louver Removal and
Installation Installation
AENJCA0A7206022 AENJCA0A7206027
Removal Removal
1) Recover refrigerant from A/C system using recovery 1) Protect instrument panel sticking masking tape (1)
and recycling equipment referring to “Recovery” in as shown in figure.
“Operation Procedure for Refrigerant Charge” (Page 2) Inserting an interior trim remover (2) or the like,
7B-28). release the lower hooks in arrow direction “1”.
2) Disconnect negative (–) cable at battery. 3) Remove center ventilation louver (3) by pulling it in
3) Disconnect A/C refrigerant pressure sensor arrow direction “2”.
connector.
4) While holding liquid hose (1) using backup wrench, A B
A C
A

remove A/C refrigerant pressure sensor (2).

3 C
A A
1
2 “2”
B
A
B
A “1”

1 B
A
A 2

IJCA0A720038-01 IJCA0A720040-01

Installation Installation
Reverse removal procedure noting the following points. Reverse removal procedure.
• Apply compressor oil to new O-ring of A/C refrigerant
pressure sensor. Side Ventilation Louver Removal and
: Compressor oil 95590–58D30 (Compressor oil Installation
AENJCA0A7206028
(ND-OIL8)) Removal
• Tighten A/C refrigerant pressure sensor (1) to 1) Protect instrument panel sticking masking tape (1)
specified torque. as shown in figure.
Tightening torque 2) Inserting an interior trim remover (2) or the like,
A/C refrigerant pressure sensor (a): 11 N·m (1.1 release the lower hooks in arrow direction “1”.
kgf-m, 8.5 lbf-ft) 3) Remove side ventilation louver (3) by pulling it in
arrow direction “2”.

“2”
1, (a)
3
A A
“1”
1
A

IJCA0A720039-01

• Evacuate and charge A/C system referring to

“Evacuation” and “Charge” in “Operation Procedure
for Refrigerant Charge” (Page 7B-28). IJCA0A720041-01
7B-49 HVAC System:

Installation Installation
Reverse removal procedure noting the following point. Reverse removal procedure noting the following points.
• Fit claw (2) on side ventilation louver (1) into cutout (3) • Position air filter (1) directing its arrow mark (2)
on instrument panel. upward.
• Hook claw (3) of filter cover onto HVAC unit, and while
3 placing air filter edge onto receiving rail (4) of filter
[A]
cover to prevent rail from digging into air filter, install
filter cover.

2 2

IJCA0A720042-01 1

HVAC Air Filter Removal and Installation

AENJCA0A7206029
Removal
1) Remove glove box.
3
2) Remove filter cover (2) from HVAC unit. 1

3) Remove air filter (1) from HVAC unit.

4
IJCA0A720045-01

1 HVAC Air Filter Inspection

AENJCA0A7206030
Check that filter is not excessively dirty, damaged or oily.
Clean filter with compressed air from its air outlet side.
2

IJCA0A720043-02

UP

IDL10A721045-01
 HVAC System: 7B-50

A/C Switch Inspection Compressor Drive Belt Inspection

AENJCA0A7206031 AENJCA0A7206033
Check A/C switch for terminal-to-terminal continuity. If 1) Check compressor drive belt (1) for wear, cracks,
check result is not as specified, replace HVAC control deformation and contamination. If any defect is
unit. found, replace the belt with new one. (Page 7B-51)
NOTE 2) Start engine and stop it after 2 or 3 seconds to
stabilize compressor drive belt tension.
To perform measurement with A/C switch to
“ON”, use diode range of circuit tester. 3) Hoist vehicle and remove right side front wheel.
(Page 2D-3)
4) Remove right side splash cover.
A/C switch continuity
5) Check compressor drive belt tension by tension
Terminal meter following the instructions mentioned in the
1 7 11 tension meter manual. If compressor drive belt
Position
tension is not as specified, replace the belt with new
OFF one.
Compressor drive belt tension
ON
Standard: 454 – 834 N (46.3 – 85.0 kgf or 102.1 –
IEFA0A722029-01
187.5 lbf)
Limit: 200 N (20.4 kgf or 45.0 lbf)
Recommended belt tension meter specification
Gates Corporation “508” or equivalent
6 5 4 3 2 1
12 11 10 9 8 7
Setting value for belt tension meter “508”
MASS 57.0
WIDTH 1.0
K10B and bi-fuel CNG model 181.8
SPAN
K12M model 181.9

NOTE
• For using general belt tension meter (other
than Gates Corporation “508”) refer to the
following belt specification values.
– Length: 719 mm
– Weight: 41 g
– Distance between the contact points of
7
belt and pulley: 181.8 mm (K10B and bi-
11 1 fuel CNG model) / 181.9 mm (K12M
model)
IJCA0A720047-01
• For the setting of the belt tension meter,
follow the operation manual of belt tension
HVAC System Relay Inspection meter.
AENJCA0A7206032
A/C Compressor Relay
Refer to “Control Relay Inspection” in Section 10B (Page
1
10B-51).

Blower Motor Relay

Refer to “Control Relay Inspection” in Section 10B (Page
10B-51).

2 3
IDP60A722010-01

2. Crankshaft pulley 3. Magnet clutch pulley

7B-51 HVAC System:

Compressor Drive Belt Removal and 4) Turn crankshaft pulley (1) clockwise until special tool
Installation is held between crankshaft pulley and compressor
AENJCA0A7206034 drive belt (2).
Removal
1) Hoist vehicle and remove right side front wheel.
(Page 2D-3)
2) Remove right side splash cover.
3) Place special tool between crankshaft pulley (1) and
compressor drive belt (2) as shown in figure.
Special tool
(A): 09991M07450

(A)

1 2
IJCA0A720049-01

5) Lift special tool 90° in arrow direction “1”.

6) While holding special tool in position, turn crankshaft
pulley (1) clockwise, and then remove compressor
drive belt (2).

2
1

IJCA0A720048-01
1
2

“1”

IJCA0A720050-01

Installation
1) Fit ribs of compressor drive belt (2) into grooves of
magnet clutch pulley (1).
2) Install compressor drive belt and special tool to
crankshaft pulley (3) as shown in figure.
Special tool
(A): 09991M07460
 HVAC System: 7B-52

NOTICE 3) Turn crankshaft pulley (1) clockwise until ribs of

Installing compressor drive belt using compressor drive belt (2) fit into grooves of
special tool without its protective cover crankshaft pulley and magnet clutch pulley (3)
attached may cause damage to crankshaft completely.
pulley or peeling of its surface coating.
1
Always use special tool with its protective
cover (4) attached. If designated protective
cover is not available, cut PVC (soft polyvinyl
chloride) hose to specified dimension as
shown below and attach it to special tool.
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.) 3
• Thickness “d”: 1.5 mm (0.059 in.)
2
IJCA0A720052-01

4) Turn crankshaft clockwise 720° and check that all

ribs of belt fit into grooves of pulleys.
(A)
5) Check compressor drive belt tension. (Page 7B-
50)
6) Install right side splash cover.
“d”
7) Install right side front wheel. (Page 2D-3)
4
“b”
“c”
Compressor Assembly Removal and
Installation
“a” AENJCA0A7206035
Removal
IFL10B721018-01
1) Recover refrigerant from A/C system using recovery
and recycling equipment referring to “Recovery” in
“Operation Procedure for Refrigerant Charge” (Page
(A) 3 7B-28).
2) Disconnect negative (–) cable at battery.
3) Remove compressor drive belt. (Page 7B-51)
4) Disconnect magnet clutch lead wire connector (1).

(A)

2 1

4
IJCA0A720051-01

IJCA0A720053-01
7B-53 HVAC System:

5) Disconnect discharge hose (1) and suction hose (2) Installation

from compressor (3). Reverse removal procedure noting the following points.
• If compressor is replaced, replenish A/C system with
NOTE
new compressor oil referring to “Replenishing
Cap open fittings immediately to keep Compressor Oil” in “Operation Procedure for
moisture out of the system. Refrigerant Charge” (Page 7B-28).
6) Remove compressor mounting bolts (4), and then • Apply compressor oil to new O-rings of discharge
remove compressor. hose and suction hose.
: Compressor oil 95590–58D30 (Compressor oil
4 (ND-OIL8))
1
• Tighten compressor mounting bolts in numerical order
(“1” – “3”) to specified torque as shown in figure.
2 • Tighten discharge hose bolt (1) and suction hose bolt
3
(2) to specified torque.
Tightening torque
Compressor mounting bolt (a): 25 N·m (2.5 kgf-
m, 18.5 lbf-ft)
4
Discharge hose bolt (b): 11 N·m (1.1 kgf-m, 8.5
lbf-ft)
Suction hose bolt (c): 11 N·m (1.1 kgf-m, 8.5 lbf-ft)
4 “1”, (a)
IJCA0A720054-01

1, (b)
2, (c)

“2”, (a)

“3”, (a)
IJCA0A720055-01

• Check compressor drive belt tension. (Page 7B-50)

• Evacuate and charge A/C system referring to
“Evacuation” and “Charge” in “Operation Procedure
for Refrigerant Charge” (Page 7B-28).
 HVAC System: 7B-54

Compressor Assembly Components

AENJCA0A7206036

4 (b)
5

OIL
3

(a)

IJCA0A720056-01

1. Clutch set 4. Screw : 13 Nm (1.3 kgf-m, 9.5 lbf-ft)

2. Clip set 5. Relief valve set : Do not reuse.
O-ring: Apply compressor oil.
3. Bracket : 18 Nm (1.8 kgf-m, 13.5 lbf-ft)

Magnet Clutch Inspection

AENJCA0A7206037
• Check armature plate for wear and magnet clutch
pulley for oil soak respectively.
1
• Check magnet clutch pulley bearing for noise, wear
and grease leakage.
• Using ohmmeter (1), measure resistance of magnet
clutch coil.
If check result is not as specified, replace magnet
clutch assembly.
Magnet clutch coil resistance
Approx. 4.1 Ω (at 20 °C (68 °F)) IJCA0A720057-01
7B-55 HVAC System:

Magnet Clutch Removal and Installation

AENJCA0A7206038
Removal 2

1) Remove compressor from vehicle. (Page 7B-52)

2) Fix armature plate (1) with special tool and remove 3
armature plate bolt (2).
Special tool
(A): 09991M06310
3) Remove armature plate.

2
1
IJCA0A720059-01
(A)

Installation
1) Install magnet clutch coil (1) by fitting protrusion (2)
of magnet clutch coil onto hole (3) in compressor.
1

2
1

IJCA0A720058-01

4) Remove shim(s).
3
5) Remove snap ring (1) using snap ring pliers.
6) Remove magnet clutch pulley (2) using puller.

IGSB0A722034-01
1
2) Install new snap ring (1), directing the plane side
downward using snap ring pliers, and then install
2 magnet clutch lead wire screw (2).

1
1

IFKA0P721047-02

7) Remove snap ring (2) using snap ring pliers.

8) Remove magnet clutch lead wire screw (1).
9) Remove magnet clutch coil (3) from compressor.

2
IJCA0A720060-01
 HVAC System: 7B-56

3) Install magnet clutch pulley (1). e) Disconnect battery negative (–) terminal from
4) Install new snap ring (2), directing the plane side compressor body assembly. (At this point,
downward using snap ring pliers. armature plate and magnet clutch pulley are not
in contact.)
2 f) Read stroke of armature plate from dial gauge by
performing Step d) – e) repeatedly. (Stroke of
2
armature plate indicates clearance between
armature plate and magnet clutch pulley.)

NOTE
1 Three shims in different thickness are
included in clip set of supply parts. Using the
three pieces at the maximum, adjust the
clearance.

Standard clearance between armature plate

and magnet clutch pulley
“a”: 0.30 – 0.65 mm (0.0118 – 0.0255 in.)
IGSB0A722036-01

5) Install the same amount of removing shim(s). 4

1
6) Install armature plate (1) and then tighten armature “a”
plate bolt (2) to specified torque.
Special tool
(A): 09991M06310
Tightening torque 2
Armature plate bolt (a): 18 N·m (1.8 kgf-m, 13.5
lbf-ft)

2, (a)
3

(A)

IJCA0A720062-01
1

Relief Valve Inspection

AENJCA0A7206039
1) Check relief valve for refrigerant leakage using leak
detector (1).
If there is refrigerant leakage, replace relief valve.
IJCA0A720061-01

7) Check clearance between armature plate (1) and

magnet clutch pulley (2) as follows. If clearance is
out of specified range, adjust it by putting shim(s) on
compressor.
a) Put compressor in a soft jawed vise (3).
b) Set dial gauge (4) on armature plate, and then
adjust its pointer at 0.
1
c) Connect battery positive (+) terminal to magnet
clutch coil lead wire.
d) Connect battery negative (–) terminal to
compressor body assembly. (At this point,
armature plate and magnet clutch pulley are kept
in contact.)
IJCA0A720063-01
7B-57 HVAC System:

Relief Valve Removal and Installation Installation

AENJCA0A7206040
Removal
1) Recover refrigerant from A/C system using recovery
and recycling equipment referring to “Recovery” in
“Operation Procedure for Refrigerant Charge” (Page
7B-28).
2) Remove relief valve (1) from compressor.
Reverse removal procedure noting the following points.
• Use new O-ring.
• Apply compressor oil to O-ring.
: Compressor oil 95590–58D30 (Compressor oil
(ND-OIL8))
• Tighten relief valve (1) to specified torque.
Tightening torque
Relief valve (a): 13 N·m (1.3 kgf-m, 9.5 lbf-ft)

1, (a)

IJCA0A720064-01

IJCA0A720065-01

• Evacuate and charge A/C system referring to

“Evacuation” and “Charge” in “Operation Procedure
for Refrigerant Charge” (Page 7B-28).
 HVAC System: 7B-58

Specifications
Tightening Torque Specifications
AENJCA0A7207001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Condenser bolt 5.0 0.51 4.0 (Page 7B-36)
Expansion valve bolt 3.5 0.36 2.5 (Page 7B-43)
Suction hose bolt (Page 7B-43) /
11 1.1 8.5
(Page 7B-53)
A/C refrigerant pressure sensor 11 1.1 8.5 (Page 7B-48)
Compressor mounting bolt 25 2.5 18.5 (Page 7B-53)
Discharge hose bolt 11 1.1 8.5 (Page 7B-53)
Armature plate bolt 18 1.8 13.5 (Page 7B-56)
Relief valve 13 1.3 9.5 (Page 7B-57)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“A/C System Components” (Page 7B-34)
“HVAC Unit Components” (Page 7B-37)
“Compressor Assembly Components” (Page 7B-54)
“Fasteners Information” in Section 0A (Page 0A-6)

Special Tools and Equipment

Recommended Service Material
AENJCA0A7208001
Material SUZUKI recommended product or Specification Note
Compressor oil Compressor oil (ND-OIL8) P/No.: 95590–58D30 (Page 7B-29) / (Page
7B-36) / (Page 7B-43) /
(Page 7B-48) / (Page
7B-53) / (Page 7B-57)

NOTE
Required service material(s) is also described in:
“A/C System Components” (Page 7B-34)
“HVAC Unit Components” (Page 7B-37)
“Compressor Assembly Components” (Page 7B-54)

Special Tool
AENJCA0A7208002
09991M06310 09991M07450
Armature plate holder Low modulus belt remover
(Page 7B-55) / (Page 7B-51)
(Page 7B-56)

09991M07460
Low modulus belt installer
(Page 7B-51)
7B-59 HVAC System:

Section 8
Restraint
CONTENTS
Precautions .................................................8-1
Precautions............................................................. 8-1
Precautions for Restraint ...................................... 8-1
Seat Belts ................................................. 8A-1
Precautions...........................................................8A-1
Precautions for Service and Diagnosis of Seat
Belt.................................................................... 8A-1
General Description .............................................8A-2
Seat Belt Construction ........................................ 8A-2
Diagnostic Information and Procedures............8A-3
Repair and Inspection Required after
Accident (4-Channel Airbag System) ................ 8A-3
Repair Instructions ..............................................8A-4
Front Seat Belt Components............................... 8A-4
Front Seat Belt Assembly Removal and
Installation ......................................................... 8A-5
Front Seat Belt Assembly Inspection .................. 8A-6
Front Seat Belt Buckle Inspection ....................... 8A-7
Passenger Seat Belt Reminder Sensor
Inspection.......................................................... 8A-7
Rear Seat Belt Components ............................... 8A-8
Rear Side Seat Belt Assembly Removal and
Installation ......................................................... 8A-8
Rear Center Seat Belt Removal and
Installation ......................................................... 8A-9
Rear Seat Belt Assembly Inspection................... 8A-9
Rear Seat Belt Buckle Inspection ....................... 8A-9
Specifications.......................................................8A-9
Tightening Torque Specifications........................ 8A-9
Air Bag System ........................................ 8B-1
Precautions...........................................................8B-1
Precautions for Airbag System Service............... 8B-1
Precautions for Handling and Storage of
Airbag System Components ............................. 8B-1
Precautions for Disposal of Airbag and Seat
Belt Pretensioner .............................................. 8B-3
General Description .............................................8B-4
Airbag System Construction ............................... 8B-4
Schematic and Routing Diagram........................8B-5
Airbag System Input / Output Diagram ............... 8B-5
Airbag System Circuit Diagram ........................... 8B-6
Component Location ...........................................8B-8
Table of Contents 8- i
Airbag System Component, Wiring and
Connector Location ...........................................8B-8
Diagnostic Information and Procedures ............8B-9
Airbag Diagnostic System Check........................8B-9
Visual Inspection .................................................8B-9
“AIRBAG” Warning Light Check........................8B-10
Self-Diagnosis Function ....................................8B-10
DTC Check........................................................8B-11
DTC Clearance .................................................8B-11
DTC Table.........................................................8B-12
Scan Tool Data .................................................8B-13
“AIRBAG” Warning Light Comes ON Steady ....8B-14
“AIRBAG” Warning Light Does Not Come ON ..8B-16
DTC B1001-00 ..................................................8B-18
DTC B1002-00 ..................................................8B-18
DTC B1003-04 ..................................................8B-19
DTC B1004-17 ..................................................8B-20
DTC B1004-18 ..................................................8B-21
DTC B1032-00 / B1035-00................................8B-22
DTC B1060-14 ..................................................8B-23
DTC B1060-15 ..................................................8B-24
DTC B1060-1A..................................................8B-26
DTC B1060-1B..................................................8B-28
DTC B1062-14 ..................................................8B-30
DTC B1062-15 ..................................................8B-31
DTC B1062-1A..................................................8B-32
DTC B1062-1B..................................................8B-35
8
DTC B1064-14 / B1065-14................................8B-37
DTC B1064-15 / B1065-15................................8B-39
DTC B1064-1A / B1065-1A...............................8B-41
DTC B1064-1B / B1065-1B...............................8B-43
DTC B1090-01 / B1090-95................................8B-45
DTC B1090-87 ..................................................8B-46
DTC U0073-88 ..................................................8B-49
SDM Power Supply and Ground Circuit
Check ..............................................................8B-50
Contact Coil and Its Circuit Check ....................8B-52
Repair and Inspection Required after
Accident ..........................................................8B-54
Repair Instructions ............................................8B-56
Disabling Airbag System ...................................8B-56
Enabling Airbag System....................................8B-57
Release of Shorting Bar ....................................8B-57
SDM Removal and Installation..........................8B-57
SDM Inspection.................................................8B-58
8-ii Table of Contents
Driver Airbag (Inflator) Module Removal and
Installation ....................................................... 8B-59
Driver Airbag (Inflator) Module Inspection.........8B-60
Passenger Airbag (Inflator) Module Removal
and Installation (4-Channel Airbag System).... 8B-61
Passenger Airbag (Inflator) Module
Inspection (4-Channel Airbag System) ...........8B-62
Seat Belt Pretensioner Components (4-
Channel Airbag System) ................................. 8B-62
Seat Belt Pretensioner Removal and
Installation (4-Channel Airbag System)...........8B-62
Seat Belt Pretensioner Inspection (4-Channel
Airbag System) ...............................................8B-63
Forward Impact Sensor Removal and
Installation .......................................................8B-63
Forward Impact Sensor Inspection ...................8B-64
Passenger Airbag (Inflator) Module Repair
Harness Installation.........................................8B-64
Airbag (Inflator) Module and Seat Belt
Pretensioner Disposal .....................................8B-64
Deployed Airbag (Inflator) Module and
Activated Seat Belt Pretensioner Disposal......8B-71
Specifications .....................................................8B-71
Tightening Torque Specifications......................8B-71
Special Tools and Equipment ...........................8B-72
Use of Special Tools .........................................8B-72
Special Tool ......................................................8B-72
 Precautions: 8-1

Precautions
Restraint

Precautions
Precautions for Restraint
AENJCA0A8000001
General Precautions
Refer to “General Precautions” in Section 00 (Page 00-1).

Precautions for Electrical Circuit Service

Refer to “Precautions for Electrical Circuit Service” in Section 00 (Page 00-3).

Caution for Fastener

Refer to “Caution for Fastener” in Section 00 (Page 00-6).

Warning for Airbag

Refer to “Warning for Airbag” in Section 00 (Page 00-7).

Warning for Vehicle Equipped with Supplemental Restraint (Airbag) System

Refer to “Warning for Vehicle Equipped with Supplemental Restraint (Airbag) System” in Section 00 (Page 00-7).

Reassembling Note for Wiring Harness

Observe “Reassembling Note for Wiring Harness” in Section 9A (Page 9A-132) whenever installing wiring harness.
Otherwise, electrical trouble may occur.
8A-1 Seat Belts:

Seat Belts
Restraint

Precautions
Precautions for Service and Diagnosis of Seat Belt
AENJCA0A8100001
! WARNING

• If a seat belt is combined with any buckle that is not originally paired with the belt, the latch plate of
the belt may not fully engage with the buckle and thus may not lock reliably when the belt is
fastened.
Always replace the seat belt and buckle as a set. SUZUKI only supplies the buckle and seat belt
assembly packaged together as a set.
• For 4-channel airbag system, a seat belt pretensioner that has been activated can no longer protect
the seat belt wearer.
Replace any seat belt whose pretensioner has been activated with a new seat belt and buckle set.

Before servicing or replacing seat belt assembly, refer to the following precautions.
• Check if tongue plate and buckle are normal.
• Keep sharp edges and damaging objects away from webbing.
• Never bend or damage buckle and tongue plate.
• Do not bleach or dye webbing. (Use only mild soap and lukewarm water to clean it.)
• When installing a seat belt anchor bolt, first tighten it by hand to prevent cross-threading and then tighten to
specified torque.
• Do not attempt any repair on seat belt assembly. If any fault is found, replace the seat belt as an assembly.
• Keep belts dry and clean at all times.
• Any defective part must be replaced with a new one.
• Replace seat belt assembly whose webbing is cut or damaged.
• Do not put anything into trim panel opening which seat belt webbing passes through.
• For 4-channel airbag system, after an accident, whether the seat belt pretensioner has activated or not, perform
checks and repairs described on “Repair and Inspection Required after Accident” in Section 8B (Page 8B-54).
 Seat Belts: 8A-2

General Description
Seat Belt Construction
AENJCA0A8101001

[A] 13 [B]

12

7
3 5

6
11

4
9
8
10
9
IJCA0A810001-02

[A]: Without tachometer
[B]: With tachometer
1. Driver front seat belt assembly (with ELR)
2. Driver front seat belt retractor (1-channel airbag system)
or seat belt pretensioner (4-channel airbag system)
3. Passenger front seat belt assembly (with ELR)
4. Passenger front seat belt retractor (1-
channel airbag system) or seat belt
pretensioner (4-channel airbag system)
5. Front seat belt buckle
6. Passenger seat belt reminder sensor
7. Right-side rear seat belt assembly (with
ELR)
8. Left-side rear seat belt assembly (with ELR)
9. Rear seat belt buckle
10. Rear center seat belt assembly
11. Rear center seat belt buckle
12. Combination meter
13. Front seat belt reminder light

Seat Belt Assembly with ELR

Seat belt assembly with emergency locking retractor (ELR) is designed so that it locks immediately (to prevent the
webbing from being pulled out of the retractor any further) when any of the following items is detected as exceeding
each set value:
• Speed at which the webbing is pulled out of the retractor
• Acceleration or deceleration of vehicle speed
• Inclination
8A-3 Seat Belts:

Seat Belt Assembly with ELR and Pretensioner (4-Channel Airbag System)
The seat belt assembly with ELR and a pretensioner has a pretensioner mechanism which operates in linkage with the
airbag in addition to the described ELR.
The pretensioner is incorporated in retractor and controlled by SDM as one of airbag system components. It will be
activated at the same time as the driver and passenger airbag (inflator) module, when an impact at the front of vehicle
exceeds the specified value.
When servicing front seat belt assembly, observe all WARNINGs and CAUTIONs and “Precautions for Airbag System
Service” in Section 8B (Page 8B-1).

Seat Belt Reminder

If driver or passenger seat belt is unfastened under the following conditions, seat belt reminder light and warning
buzzer inform that driver or passenger seat belt is unfastened. Seat belt reminder light is located in combination meter.
Warning buzzer is located inside combination meter. These reminder light and warning buzzer operate as follows:
• Seat belt reminder light comes on if driver or passenger seat belt is unfastened when ignition is “ON”.
• If vehicle runs with seat belt unfastened and the speed exceeds 15 km/h (9 mile/h), warning buzzer operates for
approximately 95 seconds and the corresponding seat belt reminder light flashes synchronously with buzzer. When
warning buzzer stops operating, the corresponding seat belt reminder light stays ON.
• While vehicle is running at more than 15 km/h (9 mile/h) and if driver or passenger seat belt is unfastened, warning
buzzer operates for approximately 95 seconds and the corresponding seat belt reminder light flashes
synchronously with buzzer. When warning buzzer stops operating, the corresponding seat belt reminder light stays
ON.

Diagnostic Information and Procedures

Repair and Inspection Required after Accident (4-Channel Airbag System)
AENJCA0A8104001
After an accident, whether the seat belt pretensioner has activated or not, perform checks and repairs referring to
“Repair and Inspection Required after Accident” in Section 8B (Page 8B-54).
 Seat Belts: 8A-4

Repair Instructions
Front Seat Belt Components
AENJCA0A8106001
NOTE
The figure shows the driver’s seat belt. The tightening torque for the passenger’s seat belt is the same.

3, “2” (a)

3, “1” (a)

3, “3” (a) (a)

IJCA0A810002-01

1. Seat belt assembly 3. Front seat belt bolt

: Tightening order: “1” – “3”
2. Buckle : 43 Nm (4.4 kgf-m, 32.0 lbf-ft)
: Tighten buckle nut and then check that buckle can be moved backward and forward.
8A-5 Seat Belts:

Front Seat Belt Assembly Removal and Installation

Installation Reverse removal procedure noting the following points.
AENJCA0A8106002
• Fit claw (2) on seat belt pretensioner (retractor) (1)
! WARNING into cutout (3) on body panel.

Failure to take proper precautions when

servicing retractor or seat belt pretensioner
may result in personal injury.
1
• Do not disassemble or repair seat belt
3
components. If any abnormalities are
found, replace the seat belt components
with a new replacement set.
• Before servicing the seat belt, read
“Precautions for Service and Diagnosis of
Seat Belt” (Page 8A-1) and follow all the
2
instructions provided.
IJCA0A810011-01
Removal • Tighten bolts of front seat belt assembly in numerical
NOTE order to specified torque. (Page 8A-4)
For 4-channel airbag system, refer to “Repair • For 4-channel airbag system, connect connector (2) to
and Inspection Required after Accident” in seat belt pretensioner (1) as follows.
Section 8B (Page 8B-54) before replacing an a. Connect connector to seat belt pretensioner with
activated pretensioner. lock button (3) released.
b. Press lock button to lock connector securely.
1) For 4-channel airbag system, disable airbag system.
(Page 8B-56) “1” “2” 3
2) Remove center pillar lower trim. (Page 9H-25)
3) For 4-channel airbag system, disconnect connector
(1) from seat belt pretensioner (2) as shown in
figure.
2
a) Release lock button (3).
b) Disconnect connector with lock released.

“2” “1” 3

1
1

IJCA0A810012-01

• For 4-channel airbag system, enable airbag system.

(Page 8B-57)

IJCA0A810010-01

4) Remove bolts of front seat belt assembly.

5) Remove front seat belt assembly.

Front Seat Belt Assembly Inspection
AENJCA0A8106003
! WARNING
For 4-channel airbag system, failure to take
proper precautions when servicing seat belt
components or attempting to disassemble or
repair the seat belt pretensioner may cause
personal injury.
• Never measure the resistance of a seat belt
pretensioner with a tester. Electric current
from the tester may trigger activation of
the seat belt pretensioner.
IJHA0A810008-01
• When placing a live seat belt pretensioner
on a workbench or other flat surface,
check that the pretensioner’s exhaust hole
side faces (1) upward.
• Do not put anything on the exhaust hole
side of a live seat belt pretensioner. Also
avoid placing one live seat belt
pretensioner on top of another.
IJHA0A810016-01
Seat Belts: 8A-6
NOTICE
For 4-channel airbag system, if a seat belt
pretensioner is dropped, it may not work
normally.
If a seat belt pretensioner is dropped, replace
both the seat belt and buckle with a new
replacement set.
Seat belts and attaching parts can affect the vital
components and systems of vehicle.
Therefore, they should be checked carefully and
replaced with genuine parts only.
Webbing
Check that webbing is not damaged.
Seat Belt Pretensioner (Retractor)
1) Check the following points.
• Let the seat belt retract fully to check its smooth
retraction.
• Retractor should lock webbing when pulled
quickly.
• Retractor should lock its webbing when tilted
forward and backward, leftward and rightward.
2) Replace seat belt assembly with new one if any of
the following symptom is found.
• Pretensioner has activated. (4-channel airbag
system)
• There is a crack in seat belt pretensioner
(retractor) (2).
• Seat belt pretensioner (retractor) is damaged or a
strong impact (e.g. dropping) was applied to it.
2
I9P60A810008-01
1. Webbing
8A-7 Seat Belts:

Front Seat Belt Buckle Inspection Seat belt buckle switch continuity
AENJCA0A8106004
Belt Latch
Terminal
1 2
• Check that tongue plate (2) is latched securely. Seat belt status

• Check that lock is released by pressing release button Unlatched

(3) when tongue plate is latched to buckle (1). Latched

I9P60A810010-01

2 Passenger Seat Belt Reminder Sensor

Inspection
AENJCA0A8106010
3
1) Disconnect seat belt buckle switch connector (4) and
floor harness connector (5).

1
I8T201810005-01

Seat Belt Buckle Switch

1) Disconnect seat belt buckle switch connector (4). 7
2) Check continuity between seat belt buckle switch
connector terminals “1” and “2”. 1 2

2 1

1
4

6
5
4

3
2
1 2

[A] 7

1 4 IJHA0A810010-01

3 1. Seat belt buckle switch

2. Passenger seat belt reminder sensor
3. BCM
6. Passenger seat belt reminder sensor connector (buckle side)
[B] 1 7. Passenger seat belt reminder sensor connector (floor harness side)

4
2) Check continuity between terminal “1” of passenger
2
seat belt reminder sensor connector (buckle side)
3
and terminal “1” of passenger seat belt reminder
sensor connector (floor harness side).
Passenger seat belt reminder sensor continuity
IJHA0A810009-01 Continuity exists
[A]: Driver seat 2. Passenger seat belt reminder
sensor
[B]: Passenger seat 3. BCM
1. Seat belt buckle switch
 Seat Belts: 8A-8

3) Check resistance between terminal “2” of passenger Rear Side Seat Belt Assembly Removal and
seat belt reminder sensor connector (buckle side) Installation
and terminal “2” of passenger seat belt reminder AENJCA0A8106006

sensor connector (floor harness side).

Removal
Passenger seat belt reminder sensor resistance 1) Remove rear seat assembly. (Page 9G-16)
Terminal Seat status Resistance
2) Remove rear quarter lower front trim, lower rear trim
Occupied Less than 100Ω
“2” – “2” and upper trim. (Page 9H-25)
Not occupied More than 1MΩ
3) Remove bolts and then remove rear side seat belt
assembly.
Passenger seat belt Passenger seat belt
Terminal
reminder sensor connector reminder sensor connector Installation
(buckle side) (floor harness side)
Reverse removal procedure noting the following points.
Seat status 1 2 1 2
• Fit claw (2) on rear seat belt assembly (1) into hole (3)
on body panel.
Occupied

Not occupied
IAP70A810005-01
3

Rear Seat Belt Components

AENJCA0A8106005
NOTE
The figure shows right-side rear seat belt and
2
rear center seat belt. Left-side rear seat belt
is the same as the right-side rear seat belt.

5, “2” (a)

1 5, “1 ” (a)
1

IJCA0A810007-01

• Tighten bolts of rear side seat belt in numerical order

to specified torque. (Page 8A-8)
• Do not step on vehicle bead (2) when installing anchor
plate (1).
2
3
5, “3” (a) 4 (a) 1

(a) IJCA0A810008-01

(a)
IJCA0A810006-02

1. Rear side seat belt assembly 4. Rear center seat belt buckle
2. Rear center seat belt 5. Rear side seat belt bolt
: Tightening order: “1” – “3”
3. Rear side seat belt buckle : 43 Nm (4.4 kgf-m, 32.0 lbf-ft)
8A-9 Seat Belts:

Rear Center Seat Belt Removal and Installation Rear Seat Belt Assembly Inspection
AENJCA0A8106007 AENJCA0A8106008
Seat belts and attaching parts can affect the vital
Removal components and systems of vehicle.
1) Remove rear seat cushion assembly. (Page 9G- Therefore, they should be checked carefully and
12) replaced with genuine parts only.
2) Remove bolts and then remove rear center seat belt.
Webbing
Check that webbing is not damaged.
Installation
Reverse removal procedure noting the following points.
Retractor (Rear Side Seat Belt)
• Tighten bolts of rear center seat belt to specified
• Check that retractor locks webbing when pulled
torque. (Page 8A-8)
quickly.
• Do not step on vehicle bead (2) when installing anchor
• Check that retractor locks its webbing when tilted
plate (1).
forward and backward, leftward and rightward.
1
Rear Seat Belt Buckle Inspection
AENJCA0A8106009
Refer to “Front Seat Belt Buckle Inspection” (Page 8A-
7).
2

IJCA0A810009-01

Specifications
Tightening Torque Specifications
AENJCA0A8107001
Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Front Seat Belt Components” (Page 8A-4)
“Rear Seat Belt Components” (Page 8A-8)
“Fasteners Information” in Section 0A (Page 0A-6)
 Air Bag System: 8B-1

Air Bag System

Restraint

Precautions
Precautions for Airbag System Service Precautions for Handling and Storage of Airbag
AENJCA0A8200001
System Components
! WARNING AENJCA0A8200002
! WARNING
• Performing service operations on or
around airbag system components or Measuring the resistance of any airbag
wiring without temporarily deactivating the (inflator) module (driver or passenger) or any
airbag system may result in accidental seat belt pretensioner (driver or passenger
activation of the airbag system. This could pretensioner) with a tester is dangerous, as
cause injury or the need for extra repairs to the electric current from the tester may
the airbag system. trigger the airbag or pretensioner.
Temporarily deactivate the airbag system Never measure the resistance of an airbag
before performing service operations on or (inflator) module or seat belt pretensioner.
around airbag system components. Follow
the procedures described in “Disabling
Airbag System” (Page 8B-56).
• If the driver’s and front passenger’s seats
are modified or accessories such as seat
covers or cushions are attached to or put
on the seats, the airbag system will not
work properly, which increases the risk of
personal injury.
Do not modify the front seats and avoid
adding anything to them such as seat
covers or cushions.
• If you disconnect the connector from the
airbag (inflator) module with a screwdriver IJHA0A820001-01
or the like, static electricity may trigger
deployment of the airbag, which could When checking each wiring harness, use special tool (A)
result in personal injury. referring to “Use of Special Tools” (Page 8B-72).
Never insert a screwdriver or the like
between the airbag (inflator) module and Special tool
the connector. (A): 09932M76010

• When storing airbag system components, select a

place where the ambient temperature is below 65 °C
(149 °F).
• When applying paint around the airbag system related
parts, be careful that the harness or connector will not
be exposed to the paint mist.
(A)

(A)

IJHA0A820002-01
8B-2 Air Bag System:

SDM Live (Undeployed) Airbag (Inflator) Module

! WARNING
• If the SDM is not rigidly attached to the
vehicle, it could accidentally cause the
airbags to deploy when the airbag system
is powered, possibly causing personal
injury.
Always check that the SDM is rigidly
attached to the vehicle before supplying
power to the airbag system.
• The SDM that has been involved in an
accident severe enough to cause
deployment of airbags is not guaranteed to
provide its original performance.
Never use an SDM that has been involved
in an airbag deployment accident. Refer to
“Airbag Diagnostic System Check” (Page
8B-9) for the SDM check procedure.
• Never disassemble SDM.
• When storing SDM, select a place where neither high
temperature nor high humidity is anticipated and oil,
water and dust are kept off.
Special care is necessary when handling and storing live
(undeployed) airbag (inflator) modules. Accidental
deployment of airbag (inflator) module could throw itself
or objects around it in the air.
IBP80A820001-01
Live (Inactivated) Seat Belt Pretensioner
! WARNING
Failure to take proper precautions when
handling and storing a live (non-activated)
seat belt pretensioner can result in personal
injury due to accidental activation of the
pretensioner.
• Handle or store a live seat belt
pretensioner in a place with an ambient
temperature below 65 °C (149 °F), without
high humidity and away from electric noise
sources.
• Never carry a live seat belt pretensioner by
holding the belt webbing.
• When placing a live seat belt pretensioner
on a workbench or other flat surface,
check that the pretensioner’s exhaust hole
side faces (1) upward.
• Do not put anything on the exhaust hole
side of a live seat belt pretensioner. Also
avoid placing one live seat belt
pretensioner on top of another.

1
I9W10P821061-01

• If SDM has been dropped, replace it with new one.

• If SDM installation part of floor is damaged, repair it
completely before reinstallation.
• All SDM and mounting bracket fasteners must be
carefully torqued and the arrow on SDM must point
toward the front of the vehicle to ensure proper
operation of the airbag system.

IJHA0A810016-01
 Air Bag System: 8B-3

Special care is necessary when handling and storing a Precautions for Disposal of Airbag and Seat
live (inactivated) pretensioner. Accidental activation of Belt Pretensioner
pretensioner will cause high pressure gas to blow off AENJCA0A8200003

from the exhaust hole and retract the webbing (1) quickly When disposal is necessary, deploy / activate the airbag
into the retractor assembly (2). These actions may throw and seat belt pretensioner. (Page 8B-64)
the pretensioner itself or objects around it in the air.

2
I9P60A820003-01

Deployed Airbag (Inflator) Module and Activated

Seat Belt Pretensioner
Refer to “Deployed Airbag (Inflator) Module and
Activated Seat Belt Pretensioner Disposal” (Page 8B-
71).

Airbag Wire Harness and Connector

Airbag wire harness is included in main harness (1),
instrument panel harness (2) and floor harness (3).
Airbag wire harness can be identified easily as the
connector side wire harness is covered with a yellow
protection tube or tape. Be careful when handling it.
• If damaged harness, connector or terminal is found on
an airbag wire harness, replace the harness.
• When installing the airbag wire harness, be careful so
that it is not caught or does not interfere with other
parts.
• Check that airbag system grounding point (4) is clean
and ground terminal is securely fastened for optimum
metal-to-metal contact. Poor grounding can cause
intermittent problems that are difficult to diagnose.

2
1

IJCA0A820001-01
8B-4 Air Bag System:

General Description
Airbag System Construction The airbag system is designed to activate only in severe
AENJCA0A8201001 frontal collisions. It is not designed to activate in rear
There are two types of airbag system in this model, 1-
impacts, side impacts, rollovers, or minor frontal
channel airbag system and 4-channel airbag system,
collisions; it would offer no protection in these types of
depending on vehicle specification.
accidents.
Main Components of 1-Channel Airbag System
• Driver airbag (inflator) module
• Forward impact sensor
• SDM

Main Components of 4-Channel Airbag System

IDL10A820003-01
• Driver and passenger airbag (inflator) modules
• Driver and passenger seat belt pretensioners
• Forward impact sensor
• SDM
To supplement protection offered by seat belts, the
airbag system includes the following airbags: front
airbag for driver seat and front airbag for passenger seat
(4-channel airbag system).
For 4-channel airbag system, in addition to these
airbags, 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 airbag (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 airbag
2. Passenger airbag (4-channel airbag system)
3. Seat belt pretensioner (4-channel airbag system)
 Air Bag System: 8B-5

Schematic and Routing Diagram

Airbag System Input / Output Diagram
AENJCA0A8202001

INPUT SDM OUTPUT

Driver airbag
Battery voltage DC / DC converter Safing power driver

Passenger airbag
Front airbag (4-channel airbag system)
Back up capacitor and
seat belt
pretensioner
X-Y G sensor Driver seat belt pretensioner
deployment
(Longitudinal / (4-channel airbag system)
driver
lateral acceleration)
Main CPU Passenger seat belt pretensioner
Forward impact sensor (4-channel airbag system)

BCM
(With keyless entry system)

Combination meter

IJCA0A820002-02
8B-6 Air Bag System:

Airbag System Circuit Diagram

AENJCA0A8202002

5
11
YEL/BLK YEL/BLK G11-12
10 G11-21 YEL
GRN GRN G11-13
[E40] G11-22 GRY
[E381] [G333]
[G346] [S171] [S121] 12
BLU G11-11
16

L1
[C]
[G211]
[A] 1 G11-24 YEL YEL
L2
2
L3 G11-23 PPL PPL
BRN [G372] [G373] [G259]
3 7 13
[G241] L4
8
9 RED G11-26 L04-3 YEL
6 6
WHT G11-25 L04-4 GRY
BLK [L283] 14
RED G11-10
4 L04-6 YEL

[B] 1 L04-5 PPL

[L285] 15
17
[A]
3
G11-9 PPL
4
[L01] 20

: 18 G11-16 BLK
: 19

IJCA0A820003-02

[A]: With keyless entry system 6. CAN Driver 14. Driver seat belt pretensioner
[B]: Without keyless entry system 7. Combination meter 15. Passenger seat belt pretensioner
[C]: 4-channel airbag system 8. CPU (Combination meter) 16. DLC
1. Ignition power supply 9. “AIRBAG” warning light 17. Individual circuit fuse box
2. J/B 10. Forward impact sensor 18. Shorting bar
3. “MTR” fuse 11. Contact coil assembly 19. Connection detection pin
4. “A/B” fuse 12. Driver airbag (inflator) module 20. BCM
5. SDM 13. Passenger airbag (inflator) module
 Air Bag System: 8B-7

Terminal arrangement of SDM connector

[B]
[A]
1 2 3 4 5 6
[a]
L3 L4 1 2 7 8 9 10 11 L1 L2 12 13 14 15
3 4 5 6
16 17 18 19 20 21 22 23 24 25 26
IJHA0A820005-01

[A]: SDM connector “L04” (View: [a]) [B]: SDM connector “G11” (View: [a])

“L04” connector
Terminal Circuit Terminal Circuit
L04-1 — L04-4 Driver front seat belt pretensioner (–)
L04-2 — L04-5 Passenger front seat belt pretensioner (–)
L04-3 Driver front seat belt pretensioner (+) L04-6 Passenger front seat belt pretensioner (+)

“G11” connector
Terminal Circuit Terminal Circuit
G11-1 — G11-14 —
G11-2 — G11-15 —
G11-3 — G11-16 Ground
G11-4 — G11-17 —
G11-5 — G11-18 —
G11-6 — G11-19 —
G11-7 — G11-20 —
G11-8 — G11-21 Driver airbag (inflator) module (+)
G11-9 Airbag deployed signal G11-22 Driver airbag (inflator) module (–)
G11-10 Power supply G11-23 Passenger airbag (inflator) module (–)
G11-11 DLC G11-24 Passenger airbag (inflator) module (+)
G11-12 Forward impact sensor (+) G11-25 CAN (Lo)
G11-13 Forward impact sensor (–) G11-26 CAN (Hi)
8B-8 Air Bag System:

Component Location
Airbag System Component, Wiring and Connector Location
AENJCA0A8203001

[F] [G]
[D] 1 [E]
10

5 “G373”
5 “G259”
3 “G372”
“G241”
“E381”
2 6 [C]
“G333”

[a]

“L285”
“E40”
4

“S121”
[B] “L04”

“G346” [A]
“S171”
“G11” 8

“L283”
4

[B] [a]

IJCA0A820009-02

[A]: Main harness [G]: Without keyless entry system 6. Contact coil assembly
[B]: Floor harness 1. “AIRBAG” warning light 7. Forward impact sensor
[C]: Instrument panel harness 2. Driver airbag (inflator) module 8. SDM
[D]: Without tachometer 3. Passenger airbag (inflator) module (4-channel airbag system) 9. J/B
[E]: With tachometer 4. Retractor pretensioner (4-channel airbag system) 10. Individual circuit fuse box
[F]: With keyless entry system 5. “A/B” fuse
 Air Bag System: 8B-9

Diagnostic Information and Procedures

Airbag Diagnostic System Check
AENJCA0A8204001
Referring to “Precautions for Airbag System Service” (Page 8B-1), check airbag system according to the following
procedure.
Step Action Yes No
1 DTC check Go to applicable DTC Go to Step 2.
1) Check DTC referring to “DTC Check” (Page 8B-11). diagnosis flow, and go
to Step 5.
2) Clear DTC referring to “DTC Clearance” (Page 8B-11).

Is there any DTC(s) when rechecking?

2 Visual inspection Repair faulty part or Go to Step 3.
1) Perform visual inspection referring to “Visual Inspection” replace it, and go to
(Page 8B-9). Step 5.

Is there any faulty condition?

3 Impact sign check Check faulty Go to Step 4.
1) Check vehicle for evidence of impact. connections and
replace them according
Are there any signs of impact? to “Repair and
Inspection Required
after Accident” (Page
8B-54), and go to Step
5.
4 Intermittent problem check Repair faulty part or Go to Step 5.
1) Check intermittent problems referring to “Intermittent replace it, and go to
Connection and Poor Contact Inspection” in Section 00 Step 5.
(Page 00-13).

Is there any faulty condition?

5 Final confirmation test Return to Step 1. End.
1) Check that problematic symptom has gone and airbag
system is free from any abnormal conditions. If what has
been repaired is related to DTC, clear DTC once and
check that no DTC is indicated.

Does malfunction recur?

Visual Inspection
AENJCA0A8204002
Visually check the following parts and systems.
Inspection item Reference
• K10B and bi-fuel CNG model: “Battery Description”: K10B
and Bi-Fuel CNG in Section 1J (Page 1J-2).
Battery Fluid level, leakage
• K12M model: “Battery Description”: K12M in Section 1J
(Page 1J-20).
Connectors of electric wire “Intermittent Connection and Poor Contact Inspection” in
Disconnection, friction
harness Section 00 (Page 00-13)
Fuses Burning
“Airbag System Component, Wiring and Connector Location”
Airbag system component Installation, damage
(Page 8B-8)
Other parts that can be checked visually
8B-10 Air Bag System:

“AIRBAG” Warning Light Check Self-Diagnosis Function

AENJCA0A8204003
1) Set ignition “ON”.
2) Check that “AIRBAG” warning light (1) is on for 6
seconds. If “AIRBAG” warning light is not on, refer to
““AIRBAG” Warning Light Does Not Come ON”
(Page 8B-16). If “AIRBAG” warning light is kept ON
and no DTC is detected in SDM, refer to ““AIRBAG”
Warning Light Comes ON Steady” (Page 8B-14).
[A]
AENJCA0A8204004
SDM also has self-diagnosis function that memorizes
DTC when an error is detected. After understanding the
following descriptions, perform troubleshooting referring
to “Airbag Diagnostic System Check” (Page 8B-9) when
an error is detected.
• SDM always monitors system while ignition is “ON”. If
an error is detected, it notifies driver of error by turning
on “AIRBAG” warning light (1) and detected error is
stored in SDM memory as DTC.
• “AIRBAG” warning light turns on for about 6 seconds
when ignition is “ON” to indicate that it operates
properly and turns off if no error is found in airbag
system.

[A]

[B]

[B]
IJCA0A820010-01

[A]: Without tachometer [B]: With tachometer

IJCA0A820010-01

[A]: Without tachometer [B]: With tachometer


DTC Check
AENJCA0A8204005
1) Set ignition “OFF”.
2) Connect SUZUKI scan tool to DLC (1).
Special tool
(A): SUZUKI scan tool (Suzuki SDT-II)
3) Set ignition “ON”.
4) Read DTC according to instructions displayed on
SUZUKI scan tool and print it or write it down. Refer
to Operator's Manual of SUZUKI scan tool for further
details.
NOTE
If communication between SUZUKI scan tool
and SDM is not possible, perform the
following checks:
• Check communication condition between
PC and VCI (2) using SUZUKI scan tool
function.
• Check DLC power circuit and ground
circuit.
• Check DLC cable. If necessary, check DLC
cable by substituting a known-good DLC
cable.
• Check CAN communication system.
(“Control Module Communication Bus Off”
is detected in any control module.) (Page
10H-15)
• Check SDM power circuit and ground
circuit. (Page 8B-50)
(A)
IJCA0A111011-01
5) After completing the check, set ignition “OFF” and
disconnect SUZUKI scan tool from DLC.
Air Bag System: 8B-11
DTC Clearance
AENJCA0A8204006
1) Set ignition “OFF”.
2) Connect SUZUKI scan tool to DLC (1).
Special tool
(A): SUZUKI scan tool (Suzuki SDT-II)
3) Set ignition “ON”.
4) Clear DTC according to instructions displayed on
SUZUKI scan tool. Refer to Operator's Manual of
SUZUKI scan tool for further details.
NOTE
• If communication between SUZUKI scan
tool and SDM is not possible, perform the
following checks:
– Check communication condition
between PC and VCI (2) using SUZUKI
scan tool function.
– Check DLC power circuit and ground
circuit.
– Check DLC cable. If necessary, check
DLC cable by substituting a known-good
DLC cable.
– Check CAN communication system.
(“Control Module Communication Bus
Off” is detected in any control module.)
(Page 10H-15)
– Check SDM power circuit and ground
circuit. (Page 8B-50)
• If DTC B1003-04, B1032-00 or B1035-00 is
stored in SDM, it is not possible to clear
DTC.
2
(A)
IJCA0A111011-01
5) After completing DTC clearance, set ignition “OFF”
and disconnect SUZUKI scan tool from DLC.
8B-12 Air Bag System:

DTC Table
AENJCA0A8204007
DTC DTC name DTC detecting condition
B1001-00 (Page 8B-
SDM Wrong Assembly SDM has inconsistent ID code.
18)
B1002-00 (Page 8B-
Intermittent Connection of SDM Connector Faulty connection of SDM connector.
18)
B1003-04 (Page 8B- Malfunctioning SDM internal circuit, G sensor,
SDM Internal Failure
19) memory or CPU.
B1004-17 (Page 8B- Power supply voltage is more than specified
Power Source Voltage Too High
20) range.
B1004-18 (Page 8B- Power supply voltage is less than specified
Power Source Voltage Too Low
21) range.
B1032-00 (Page 8B- Deployment of front airbag has been recorded in
Front Airbag Deployment Record
22) SDM.
B1035-00 (Page 8B- Activation of seat belt pretensioner has been
Seat Belt Pretensioner Activation Record
22) recorded in SDM.
B1060-14 (Page 8B- Driver Airbag (1st Stage) Circuit Shorted to Driver airbag (inflator) module circuit has been
23) Ground shorted to ground.
B1060-15 (Page 8B- Driver Airbag (1st Stage) Circuit Shorted to Driver airbag (inflator) module circuit has been
24) Power Supply shorted to power supply.
B1060-1A (Page 8B- Driver Airbag (1st Stage) Circuit Low Driver airbag (inflator) module circuit resistance
26) Resistance is less than specified range.
B1060-1B (Page 8B- Driver Airbag (1st Stage) Circuit High Driver airbag (inflator) module circuit resistance
28) Resistance is more than specified range.
B1062-14 (Page 8B- Passenger Airbag (1st Stage) Circuit Passenger airbag (inflator) module circuit has
30) Shorted to Ground been shorted to ground.
B1062-15 (Page 8B- Passenger Airbag (1st Stage) Circuit Passenger airbag (inflator) module circuit has
31) Shorted to Power Supply been shorted to power supply.
B1062-1A (Page 8B- Passenger Airbag (1st Stage) Circuit Low Passenger airbag (inflator) module circuit
32) Resistance resistance is less than specified range.
B1062-1B (Page 8B- Passenger Airbag (1st Stage) Circuit High Passenger airbag (inflator) module circuit
35) Resistance resistance is more than specified range.
B1064-14 (Page 8B- Driver Seat Belt Pretensioner Circuit Driver seat belt pretensioner circuit has been
37) Shorted to Ground shorted to ground.
B1064-15 (Page 8B- Driver Seat Belt Pretensioner Circuit Driver seat belt pretensioner circuit has been
39) Shorted to Power Supply shorted to power supply.
B1064-1A (Page 8B- Driver Seat Belt Pretensioner Circuit Low Driver seat belt pretensioner circuit resistance is
41) Resistance less than specified range.
B1064-1B (Page 8B- Driver Seat Belt Pretensioner Circuit High Driver seat belt pretensioner circuit resistance is
43) Resistance more than specified range.
B1065-14 (Page 8B- Passenger Seat Belt Pretensioner Circuit Passenger seat belt pretensioner circuit has
37) Shorted to Ground been shorted to ground.
B1065-15 (Page 8B- Passenger Seat Belt Pretensioner Circuit Passenger seat belt pretensioner circuit has
39) Shorted to Power Supply been shorted to power supply.
B1065-1A (Page 8B- Passenger Seat Belt Pretensioner Circuit Passenger seat belt pretensioner circuit
41) Low Resistance resistance is less than specified range.
B1065-1B (Page 8B- Passenger Seat Belt Pretensioner Circuit Passenger seat belt pretensioner circuit
43) High Resistance resistance is more than specified range.
B1090-01 (Page 8B- Driver Forward Impact Sensor No
Forward impact sensor failure.
45) Response
B1090-87 (Page 8B- Driver Forward Impact Sensor Forward impact sensor has communicated with
46) Communication Data Invalid no response or invalid data.
B1090-95 (Page 8B- Driver Forward Impact Sensor Forward impact sensor has communicated with
45) Communication Data Inconsistent inconsistent ID code.
U0073-88 (Page 8B- Transmitting and receiving error of SDM for
Control Module Communication Bus Off
49) specified time continuously.
 Air Bag System: 8B-13

Scan Tool Data

AENJCA0A8204008

NOTE
If communication between SUZUKI scan tool and SDM 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-15)
• Check SDM power circuit and ground circuit. (Page 8B-50)

Scan tool data Normal condition / Reference value

System ID (Page 8B-13) 1ch / 4ch
Battery Voltage (Page 8B-13) 10 – 14 V
Backup Volt (Page 8B-13) 27.0 – 33.0 V
Driver Airbag Initiator Resistance (Page 8B-13) 1.0 – 4.5 Ω
Passenger Airbag Initiator Resistance (Page 8B-13) 1.0 – 3.8 Ω
Driver-Side Seat Belt Pretensioner Initiator Resistance (Page 8B-13) 1.0 – 3.8 Ω
Passenger-Side Seat Belt Pretensioner Initiator Resistance (Page 8B-
1.0 – 3.8 Ω
13)

Scan Tool Data Definition Passenger Airbag Initiator Resistance (Ω)

System ID (1ch / 4ch) This parameter indicates resistance of passenger airbag
This parameter indicates number of initiator circuits. initiator circuit.

Battery Voltage (V) Drive-Side Seat Belt Pretensioner Initiator

Power supply voltage is an analog input signal read by
SDM.
Backup Volt (V)
This parameter indicates capacity of backup capacitor
installed to maintain ignition current (as much as
possible) even when power supply to SDM that ignites
inflator is shut off.
Resistance (Ω)
This parameter indicates resistance of driver seat belt
pretensioner initiator circuit.
Passenger Side Seat Belt Pretensioner Initiator
Resistance (Ω)
This parameter indicates resistance of passenger seat
belt pretensioner initiator circuit.

Driver Airbag Initiator Resistance (Ω)

This parameter indicates resistance of driver airbag
initiator circuit.
8B-14 Air Bag System:

“AIRBAG” Warning Light Comes ON Steady

AENJCA0A8204009
Circuit Diagram

[A]
3 6 2
4
1 BRN G241-3
7
BLK G241-5
G241-22 RED G11-26
8 8
G241-10 WHT G11-25

5
RED G11-10

BLK G11-16

[B] 9

4
1

[D]
[C]

[a] 1 2 3 4 5 6
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24 7 8 9 10 11 L1 L2 12 13 14 15

16 17 18 19 20 21 22 23 24 25 26
IJCA0A820004-01

[A]: With keyless entry system 2. SDM 7. CPU (Combination meter)

[B]: Without keyless entry system 3. J/B 8. CAN driver
[C]: “G241” connector (View: [a]) 4. “MTR” fuse 9. Individual circuit fuse box
[D]: “G11” connector (View: [a]) 5. “A/B” fuse
1. Ignition power supply 6. Combination meter

Troubleshooting
Step Action Yes No
1 SDM connector check Go to Step 2. Connect connector
1) Check for proper connection to SDM connector. securely.

Is connection in good condition?

2 DTC check Go to applicable DTC Go to Step 3.
1) Perform “DTC Check” (Page 8B-11). troubleshooting.

Is there any DTC(s)?

3 SDM power supply and ground circuit check Go to Step 4. Repair SDM power
1) Check SDM power supply circuit and ground circuit. supply and ground
(Page 8B-50) circuits.

Is check result OK?

4 CAN communication circuit check Go to Step 5. Repair defective wire
1) Check CAN communication circuit between SDM and harness.
combination meter.

Is check result OK?

 Air Bag System: 8B-15

Step Action Yes No

5 Combination meter check Replace SDM and End.
1) Replace combination meter. (Page 9C-25) recheck “AIRBAG”
warning light operation.
2) Set ignition “ON”.
(Page 8B-57)
Does “AIRBAG” warning light stay on?

NOTE
Upon completion of inspection and repair work, perform the following items.
• Reconnect all airbag system components and check that all components are properly mounted.
• Repeat “Airbag Diagnostic System Check” (Page 8B-9) to check that the trouble has been solved.
8B-16 Air Bag System:

“AIRBAG” Warning Light Does Not Come ON

AENJCA0A8204010
Circuit Diagram

[A]
3 6 2
4
1 BRN G241-3
7
BLK G241-5
G241-22 RED G11-26
8 8
G241-10 WHT G11-25

5
RED G11-10

BLK G11-16

[B] 9

4
1

[D]
[C]

[a] 1 2 3 4 5 6
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24 7 8 9 10 11 L1 L2 12 13 14 15

16 17 18 19 20 21 22 23 24 25 26
IJCA0A820004-01

[A]: With keyless entry system 2. SDM 7. CPU (Combination meter)

[B]: Without keyless entry system 3. J/B 8. CAN driver
[C]: “G241” connector (View: [a]) 4. “MTR” fuse 9. Individual circuit fuse box
[D]: “G11” connector (View: [a]) 5. “A/B” fuse
1. Ignition power supply 6. Combination meter

Troubleshooting
Step Action Yes No
1 Warning light check Go to Step 2. Go to Step 3.
1) Set ignition “ON”.

Do other indicator lights come ON?

2 DTC check Go to “Troubleshooting Replace SDM and
1) Check that ignition is “OFF”. for Communication Bus recheck DTC. (Page
Off” in Section 10H 8B-57)
2) Connect scan tool to DLC.
(Page 10H-15).
3) Set ignition “ON”.
4) Check DTC. (Page 8B-11)

Is DTC U0073-88 detected?

3 Fuse check Go to Step 4. Replace “MTR” fuse
and check for short
Is “MTR” fuse for combination meter in good condition? circuit to ground.
4 CAN communication circuit check Go to Step 5. Repair defective wire
1) Check CAN communication circuit between SDM and harness.
combination meter.

Is check result OK?

 Air Bag System: 8B-17

Step Action Yes No

5 Combination meter power supply circuit check Go to Step 6. Repair defective wire
1) Check that ignition is “OFF”. harness.
2) Remove combination meter. (Page 9C-25)
3) Check for proper connection to “G241” connector.
4) If OK, set ignition “ON”.
5) Measure voltage between “G241-3” terminal and
ground.
Special tool
(A): 09932M76010

[G241] (A)

1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24

IJCA0A820011-01

Is it 10 – 14 V?
6 Combination meter ground circuit check Replace combination Repair defective wire
1) Measure resistance between “G241-5” terminal and meter and recheck harness.
ground. “AIRBAG” warning light
operation. (Page 9C-
Special tool 25)
(A): 09932M76010

[G241] (A)

1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24

IJCA0A820012-01

Is resistance less than 1 Ω?

NOTE
Upon completion of inspection and repair work, perform the following items.
• Reconnect all airbag system components and check that all components are properly mounted.
• Repeat “Airbag Diagnostic System Check” (Page 8B-9) to check that the trouble has been solved.
8B-18 Air Bag System:

DTC B1001-00
AENJCA0A8204011
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
B1001-00: SDM Wrong Assembly SDM
SDM has inconsistent ID code.

DTC Troubleshooting
Step Action Yes No
1 Was “Airbag Diagnostic System Check” performed? Go to Step 2. Go to “Airbag
Diagnostic System
Check” (Page 8B-9).
2 Airbag system type check Replace SDM and Change SDM with the
1) Identify SDM’s channel number of airbag, judging from recheck DTC. (Page one compatible with
SDM part number. 8B-57) vehicle airbag
specification.
2) Identify vehicle’s channel number of airbag, judging from
modules or pretensioners installed in vehicle.

Is SDM applicable to vehicle specification?

NOTE
Upon completion of inspection and repair work, perform the following items.
• Reconnect all airbag system components and check that all components are properly mounted.
• Clear DTCs, referring to “DTC Clearance” (Page 8B-11) if any DTC is detected.
• Repeat “Airbag Diagnostic System Check” (Page 8B-9) to check that the trouble has been solved.

DTC B1002-00
AENJCA0A8204012
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
B1002-00: Intermittent Connection of SDM Connector • SDM connector
Faulty connection of SDM connector. • SDM

DTC Troubleshooting
Step Action Yes No
1 Was “Airbag Diagnostic System Check” performed? Go to Step 2. Go to “Airbag
Diagnostic System
Check” (Page 8B-9).
2 SDM connector check Replace SDM and Check intermittent
1) Check proper connection of SDM connector and recheck DTC. (Page trouble. (Page 00-13)
“Connection detection pin” of SDM connector. 8B-57)

Is check result OK?

NOTE
Upon completion of inspection and repair work, perform the following items.
• Reconnect all airbag system components and check that all components are properly mounted.
• Clear DTCs, referring to “DTC Clearance” (Page 8B-11) if any DTC is detected.
• Repeat “Airbag Diagnostic System Check” (Page 8B-9) to check that the trouble has been solved.
 Air Bag System: 8B-19

DTC B1003-04
AENJCA0A8204013
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
B1003-04: SDM Internal Failure SDM
Malfunctioning SDM internal circuit, G sensor, memory or CPU.

DTC Troubleshooting
Step Action Yes No
1 Was “Airbag Diagnostic System Check” performed? Go to Step 2. Go to “Airbag
Diagnostic System
Check” (Page 8B-9).
2 DTC check Replace SDM and Check intermittent
1) Clear DTC. (Page 8B-11) recheck DTC. (Page trouble. (Page 00-13)
8B-57)
2) Check that ignition is “OFF”.
3) Set ignition “ON”.
4) Check DTC. (Page 8B-11)

Is DTC B1003-04 still detected?

NOTE
Upon completion of inspection and repair work, perform the following items.
• Reconnect all airbag system components and check that all components are properly mounted.
• Clear DTCs, referring to “DTC Clearance” (Page 8B-11) if any DTC is detected.
• Repeat “Airbag Diagnostic System Check” (Page 8B-9) to check that the trouble has been solved.
8B-20 Air Bag System:

DTC B1004-17
AENJCA0A8204014
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
B1004-17: Power Source Voltage Too High • Charging system
Power supply voltage is more than specified range. • SDM

Circuit Diagram

[A] 3
5

2
1 RED G11-10

BLK G11-16

[B] 6

2
1

[C]

1 2 3 4 5 6
:4 [a]
7 8 9 10 11 L1 L2 12 13 14 15

16 17 18 19 20 21 22 23 24 25 26
IJCA0A820005-01

[A]: With keyless entry system 1. Ignition power supply 4. Instrument panel harness
[B]: Without keyless entry system 2. “A/B” fuse 5. J/B
[C]: “G11” connector (View: [a]) 3. SDM 6. Individual circuit fuse box

DTC Troubleshooting
Step Action Yes No
1 Was “Airbag Diagnostic System Check” performed? Go to Step 2. Go to “Airbag
Diagnostic System
Check” (Page 8B-9).
2 SDM power voltage check Go to Step 3. Check charging system
1) Check that ignition is “OFF”. and repair wiring.
2) Disconnect “G11” connector. (Page 8B-57) • K10B and bi-fuel
CNG model: (Page
3) Start engine and set engine speed at 3000 rpm or more.
1J-5)
4) Measure voltage between “G11-10” terminal and ground.
• K12M model:
Special tool (Page 1J-23)
(A): 09932M76010

[G11]
(A)
1 2 3 4 5 6

7 8 9 10 11 L1 L2 12 13 14 15

16 17 18 19 20 21 22 23 24 25 26

IJHA0A820009-01

Is voltage 15 V or less?
 Air Bag System: 8B-21

Step Action Yes No

3 DTC check Replace SDM and Intermittent trouble.
1) Check that ignition is “OFF”. recheck DTC. (Page Check for intermittent
8B-57) trouble. (Page 00-13)
2) Connect “G11” connector. (Page 8B-57)
3) Set ignition “ON”.
4) Check DTC. (Page 8B-11)

Is DTC B1004-17 detected?

NOTE
Upon completion of inspection and repair work, perform the following items.
• Reconnect all airbag system components and check that all components are properly mounted.
• Clear DTCs, referring to “DTC Clearance” (Page 8B-11) if any DTC is detected.
• Repeat “Airbag Diagnostic System Check” (Page 8B-9) to check that the trouble has been solved.

DTC B1004-18
AENJCA0A8204015
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
B1004-18: Power Source Voltage Too Low • Charging system
Power supply voltage is less than specified range. • SDM

Circuit Diagram

[A] 3
5

2
1 RED G11-10

BLK G11-16

[B] 6

2
1

[C]

1 2 3 4 5 6
:4 [a]
7 8 9 10 11 L1 L2 12 13 14 15

16 17 18 19 20 21 22 23 24 25 26
IJCA0A820005-01

[A]: With keyless entry system 1. Ignition power supply 4. Instrument panel harness
[B]: Without keyless entry system 2. “A/B” fuse 5. J/B
[C]: “G11” connector (View: [a]) 3. SDM 6. Individual circuit fuse box
8B-22 Air Bag System:

DTC Troubleshooting
Step Action Yes No
1 Was “Airbag Diagnostic System Check” performed? Go to Step 2. Go to “Airbag
Diagnostic System
Check” (Page 8B-9).
2 SDM power supply circuit and ground circuit check Go to Step 3. Repair or replace
1) Check SDM power supply circuit and ground circuit. defective part.
(Page 8B-50)

Is check result OK?

3 DTC check Replace SDM and Intermittent trouble.
1) Check that ignition is “OFF”. recheck DTC. (Page Check for intermittent
8B-57) trouble. (Page 00-13)
2) Connect “G11” connector.
3) Set ignition “ON”.
4) Check DTC. (Page 8B-11)

Is DTC B1004-18 detected?

NOTE
Upon completion of inspection and repair work, perform the following items.
• Reconnect all airbag system components and check that all components are properly mounted.
• Clear DTCs, referring to “DTC Clearance” (Page 8B-11) if any DTC is detected.
• Repeat “Airbag Diagnostic System Check” (Page 8B-9) to check that the trouble has been solved.

DTC B1032-00 / B1035-00

AENJCA0A8204016
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
B1032-00: Front Airbag Deployment Record If this DTC has been recorded even though airbag or
Deployment of front airbag has been recorded in SDM. pretensioner has not been deployed
B1035-00: Seat Belt Pretensioner Activation Record • SDM
Activation of seat belt pretensioner has been recorded in SDM.
• Driver and/or passenger airbag (inflator) module
• Driver and/or passenger seat belt pretensioner
• Those initiator circuits

NOTE
If DTC B1032-00 or B1035-00 is stored in SDM, it is not possible to clear DTC.

DTC Troubleshooting
Step Action Yes No
1 Was “Airbag Diagnostic System Check” performed? Replace SDM. (Page Go to “Airbag
8B-57) Diagnostic System
Check” (Page 8B-9).

NOTE
Upon completion of inspection and repair work, perform the following items.
• Reconnect all airbag system components and check that all components are properly mounted.
• Repeat “Airbag Diagnostic System Check” (Page 8B-9) to check that the trouble has been solved.
 Air Bag System: 8B-23

DTC B1060-14
AENJCA0A8204017
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
B1060-14: Driver Airbag (1st Stage) Circuit Shorted to Ground • Driver airbag (inflator) module circuit
Driver airbag (inflator) module circuit has been shorted to ground. • Contact coil assembly
• SDM

Circuit Diagram

3
[S121] [S171] [G346]
A1
1 2

YEL G11-21
A2

GRY G11-22

[A] [B] [C]

:4 1 2 1 2
[a] 1 2 3 4 5 6
:5 7 8 9 10 11 L1 L2 12 13 14 15

16 17 18 19 20 21 22 23 24 25 26
IJCA0A820006-01

[A]: “S121” connector (View: [a]) A2: Driver airbag (inflator) module deployment 4. Shorting bar
signal ground circuit
[B]: “G346” connector (View: [a]) 1. Driver airbag (inflator) module 5. Instrument panel harness
[C]: “G11” connector (View: [a]) 2. Contact coil assembly
A1: Driver airbag (inflator) module deployment 3. SDM
signal output circuit

DTC Troubleshooting
Step Action Yes No
1 Was “Airbag Diagnostic System Check” performed? Go to Step 2. Go to “Airbag
Diagnostic System
Check” (Page 8B-9).
2 Driver airbag (inflator) module circuit check Go to Step 3. Replace instrument
1) Check that ignition is “OFF”. panel harness.
2) Disconnect “G346” connector. (Page 6B-4)
3) Disconnect “G11” connector. (Page 8B-57)
4) Release shorting bar in SDM connector. (Page 8B-57)
5) Check the following point.
• Resistance between each of “A1” and “A2” circuits
and ground: infinity
Special tool
: 09932M76010

Is check result OK?

8B-24 Air Bag System:

Step Action Yes No

3 Contact coil circuit check Replace SDM and Replace contact coil.
1) Connect “G346” connector. recheck DTC. (Page (Page 6B-4)
8B-57)
2) Remove driver airbag (inflator) module from steering
wheel. (Page 8B-59)
3) Release shorting bar in SDM connector. (Page 8B-57)
4) Check the following point.
• Resistance between each of “A1” and “A2” circuits
and ground: infinity
Special tool
: 09932M76010

Is check result OK?

NOTE
Upon completion of inspection and repair work, perform the following items.
• Reconnect all airbag system components and check that all components are properly mounted.
• Clear DTCs, referring to “DTC Clearance” (Page 8B-11) if any DTC is detected.
• Repeat “Airbag Diagnostic System Check” (Page 8B-9) to check that the trouble has been solved.

DTC B1060-15
AENJCA0A8204018
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
B1060-15: Driver Airbag (1st Stage) Circuit Shorted to Power Supply • Driver airbag (inflator) module circuit
Driver airbag (inflator) module circuit has been shorted to power supply. • Contact coil assembly
• SDM

Circuit Diagram

3
[S121] [S171] [G346]
A1
1 2

YEL G11-21
A2

GRY G11-22

[A] [B] [C]

:4 1 2 1 2
[a] 1 2 3 4 5 6
:5 7 8 9 10 11 L1 L2 12 13 14 15

16 17 18 19 20 21 22 23 24 25 26
IJCA0A820006-01

[A]: “S121” connector (View: [a]) A2: Driver airbag (inflator) module deployment 4. Shorting bar
signal ground circuit
[B]: “G346” connector (View: [a]) 1. Driver airbag (inflator) module 5. Instrument panel harness
[C]: “G11” connector (View: [a]) 2. Contact coil assembly
A1: Driver airbag (inflator) module deployment 3. SDM
signal output circuit
 Air Bag System: 8B-25

DTC Troubleshooting
Step Action Yes No
1 Was “Airbag Diagnostic System Check” performed? Go to Step 2. Go to “Airbag
Diagnostic System
Check” (Page 8B-9).
2 Driver airbag (inflator) module circuit check Go to Step 3. Replace instrument
1) Check that ignition is “OFF”. panel harness.
2) Disconnect “G346” connector. (Page 6B-4)
3) Disconnect “G11” connector. (Page 8B-57)
4) Release shorting bar in SDM connector. (Page 8B-57)
5) Set ignition “ON”.
6) Check the following point.
• Voltage between each of “A1” and “A2” circuits and
ground: 0 V
Special tool
: 09932M76010

Is check result OK?

3 Contact coil circuit check Replace SDM and Replace contact coil
1) Check that ignition is “OFF”. recheck DTC. (Page assembly. (Page 6B-
8B-57) 4)
2) Connect “G346” connector.
3) Remove driver airbag (inflator) module from steering
wheel. (Page 8B-59)
4) Release shorting bar in SDM connector. (Page 8B-57)
5) Set ignition “ON”.
6) Check the following point.
• Voltage between each of “A1” and “A2” circuits and
ground: 0 V
Special tool
: 09932M76010

Is check result OK?

NOTE
Upon completion of inspection and repair work, perform the following items.
• Reconnect all airbag system components and check that all components are properly mounted.
• Clear DTCs, referring to “DTC Clearance” (Page 8B-11) if any DTC is detected.
• Repeat “Airbag Diagnostic System Check” (Page 8B-9) to check that the trouble has been solved.
8B-26 Air Bag System:

DTC B1060-1A
AENJCA0A8204019
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
B1060-1A: Driver Airbag (1st Stage) Circuit Low Resistance • Driver airbag (inflator) module circuit
Driver airbag (inflator) module circuit resistance is less than • Contact coil assembly
specified range.
• Driver airbag (inflator) module
• SDM

Circuit Diagram

3
[S121] [S171] [G346]
A1
1 2

YEL G11-21
A2

GRY G11-22

[A] [B] [C]

:4 1 2 1 2
[a] 1 2 3 4 5 6
:5 7 8 9 10 11 L1 L2 12 13 14 15

16 17 18 19 20 21 22 23 24 25 26
IJCA0A820006-01

[A]: “S121” connector (View: [a]) A2: Driver airbag (inflator) module deployment 4. Shorting bar
signal ground circuit
[B]: “G346” connector (View: [a]) 1. Driver airbag (inflator) module 5. Instrument panel harness
[C]: “G11” connector (View: [a]) 2. Contact coil assembly
A1: Driver airbag (inflator) module deployment 3. SDM
signal output circuit

DTC Troubleshooting
Step Action Yes No
1 Was “Airbag Diagnostic System Check” performed? Go to Step 2. Go to “Airbag
Diagnostic System
Check” (Page 8B-9).
 Air Bag System: 8B-27

Step Action Yes No

2 Driver airbag (inflator) module check Go to Step 3. Go to Step 4.
1) Check that ignition is “OFF”.
2) Disconnect “G346” connector. (Page 6B-4)
3) Connect “BASE OF COLUMN” harness (1) of special
tools (A) and (B) to “G346” connector.
Special tool
(A): 09932M75011
(B): 09932M78340

[G346]

1
(B)
(A)
IJCA0A820013-01

4) Set ignition “ON”.

5) Check DTC. (Page 8B-11)

Is DTC B1060-1A detected?

3 Driver airbag (inflator) module circuit check Replace SDM and Replace instrument
1) Set ignition “OFF”. recheck DTC. (Page panel harness.
8B-57)
2) Disconnect “G11” connector. (Page 8B-57)
3) Release shorting bar in SDM connector. (Page 8B-57)
4) Check the following point.
• Resistance between “G11-21” and “G11-22”
terminals: infinity
Special tool
: 09932M76010

Is check result OK?

4 Contact coil circuit check Replace driver airbag Replace contact coil
1) Check contact coil circuit. (Page 8B-52) (inflator) module. assembly. (Page 6B-
(Page 8B-59) 4)
Is check result OK?

NOTE
Upon completion of inspection and repair work, perform the following items.
• Reconnect all airbag system components and check that all components are properly mounted.
• Clear DTCs, referring to “DTC Clearance” (Page 8B-11) if any DTC is detected.
• Repeat “Airbag Diagnostic System Check” (Page 8B-9) to check that the trouble has been solved.
8B-28 Air Bag System:

DTC B1060-1B
AENJCA0A8204020
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
B1060-1B: Driver Airbag (1st Stage) Circuit High Resistance • Driver airbag (inflator) module circuit
Driver airbag (inflator) module circuit resistance is more than • Contact coil assembly
specified range.
• Driver airbag (inflator) module
• SDM

Circuit Diagram

3
[S121] [S171] [G346]
A1
1 2

YEL G11-21
A2

GRY G11-22

[A] [B] [C]

:4 1 2 1 2
[a] 1 2 3 4 5 6
:5 7 8 9 10 11 L1 L2 12 13 14 15

16 17 18 19 20 21 22 23 24 25 26
IJCA0A820006-01

[A]: “S121” connector (View: [a]) A2: Driver airbag (inflator) module deployment 4. Shorting bar
signal ground circuit
[B]: “G346” connector (View: [a]) 1. Driver airbag (inflator) module 5. Instrument panel harness
[C]: “G11” connector (View: [a]) 2. Contact coil assembly
A1: Driver airbag (inflator) module deployment 3. SDM
signal output circuit

DTC Troubleshooting
Step Action Yes No
1 Was “Airbag Diagnostic System Check” performed? Go to Step 2. Go to “Airbag
Diagnostic System
Check” (Page 8B-9).
 Air Bag System: 8B-29

Step Action Yes No

2 Driver airbag (inflator) module check Go to Step 3. Go to Step 4.
1) Check that ignition is “OFF”.
2) Check for proper connection to “G346” connector.
3) Disconnect “G346” connector. (Page 6B-4)
4) Connect “BASE OF COLUMN” harness (1) of special
tools (A) and (B) to “G346” connector.
Special tool
(A): 09932M75011
(B): 09932M78340

[G346]

1
(B)
(A)
IJCA0A820013-01

5) Set ignition “ON”.

6) Check DTC. (Page 8B-11)

Is DTC B1060-1B detected?

3 Driver airbag (inflator) module circuit check Replace SDM with new Replace instrument
1) Set ignition “OFF”. one. (Page 8B-57) panel harness.
2) Check for proper connection to “G11” connector.
3) Disconnect “G11” connector. (Page 8B-57)
4) Release shorting bar in SDM connector. (Page 8B-57)
5) Check the following point.
• Resistance of “A1” and “A2” circuits: 1 Ω or less
Special tool
: 09932M76010

Is check result OK?

4 Contact coil circuit check Replace driver airbag Replace contact coil
1) Check contact coil circuit. (Page 8B-52) (inflator) module. assembly. (Page 6B-
(Page 8B-59) 4)
Is check result OK?

NOTE
Upon completion of inspection and repair work, perform the following items.
• Reconnect all airbag system components and check that all components are properly mounted.
• Clear DTCs, referring to “DTC Clearance” (Page 8B-11) if any DTC is detected.
• Repeat “Airbag Diagnostic System Check” (Page 8B-9) to check that the trouble has been solved.
8B-30 Air Bag System:

DTC B1062-14
AENJCA0A8204021
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
B1062-14: Passenger Airbag (1st Stage) Circuit • Passenger airbag (inflator) module circuit
Shorted to Ground • SDM
Passenger airbag (inflator) module circuit has been
shorted to ground.

Circuit Diagram

2
[G259] [G373] [G372]
A1 A3
1

YEL YEL G11-24

A2 A4

PPL PPL G11-23

[A] [B] [C]

:3
[a] 1 2 1 2
:4 1 2 3 4 5 6

7 8 9 10 11 L1 L2 12 13 14 15
:5
16 17 18 19 20 21 22 23 24 25 26
IJCA0A820007-01

[A]: “G259” connector (View: [a])
[B]: “G372” connector (View: [a])
[C]: “G11” connector (View: [a])
A1: Passenger airbag (inflator) module
deployment signal output circuit
A2: Passenger airbag (inflator) module 2. SDM
deployment signal ground circuit
A3: Passenger airbag (inflator) module 3. Shorting bar
deployment signal output circuit
A4: Passenger airbag (inflator) module 4. Instrument panel harness
deployment signal ground circuit
1. Passenger airbag (inflator) module 5. Passenger airbag (inflator) module harness

DTC Troubleshooting
Step Action Yes No
1 Was “Airbag Diagnostic System Check” performed? Go to Step 2. Go to “Airbag
Diagnostic System
Check” (Page 8B-9).
2 Passenger airbag (inflator) module circuit check Replace SDM and Go to Step 3.
1) Check that ignition is “OFF”. recheck DTC. (Page
8B-57)
2) Disconnect “G259” connector. (Page 8B-61)
3) Disconnect “G11” connector. (Page 8B-57)
4) Release shorting bar in SDM connector. (Page 8B-57)
5) Check the following point.
• Resistance between each of “A3” and “A4” circuits
and ground: infinity
Special tool
: 09932M76010

Is check result OK?

 Air Bag System: 8B-31

Step Action Yes No

3 Passenger airbag (inflator) module circuit check Replace passenger Replace instrument
1) Disconnect “G372” connector. airbag (inflator) module panel harness.
harness.
2) Release shorting bar in SDM connector. (Page 8B-57)
3) Check the following point.
• Resistance between each of “A3” and “A4” circuits
and ground: infinity
Special tool
: 09932M76010

Is check result OK?

NOTE
Upon completion of inspection and repair work, perform the following items.
• Reconnect all airbag system components and check that all components are properly mounted.
• Clear DTCs, referring to “DTC Clearance” (Page 8B-11) if any DTC is detected.
• Repeat “Airbag Diagnostic System Check” (Page 8B-9) to check that the trouble has been solved.

DTC B1062-15
AENJCA0A8204022
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
B1062-15: Passenger Airbag (1st Stage) Circuit • Passenger airbag (inflator) module circuit
Shorted to Power Supply • SDM
Passenger airbag (inflator) module circuit has been
shorted to power supply.

Circuit Diagram

2
[G259] [G373] [G372]
A1 A3
1

YEL YEL G11-24

A2 A4

PPL PPL G11-23

[A] [B] [C]

:3
[a] 1 2 1 2
:4 1 2 3 4 5 6

7 8 9 10 11 L1 L2 12 13 14 15
:5
16 17 18 19 20 21 22 23 24 25 26
IJCA0A820007-01

[A]: “G259” connector (View: [a])
[B]: “G372” connector (View: [a])
[C]: “G11” connector (View: [a])
A1: Passenger airbag (inflator) module
deployment signal output circuit
A2: Passenger airbag (inflator) module 2. SDM
deployment signal ground circuit
A3: Passenger airbag (inflator) module 3. Shorting bar
deployment signal output circuit
A4: Passenger airbag (inflator) module 4. Instrument panel harness
deployment signal ground circuit
1. Passenger airbag (inflator) module 5. Passenger airbag (inflator) module harness
8B-32 Air Bag System:

DTC Troubleshooting
Step Action Yes No
1 Was “Airbag Diagnostic System Check” performed? Go to Step 2. Go to “Airbag
Diagnostic System
Check” (Page 8B-9).
2 Passenger airbag (inflator) module circuit check Replace SDM and Go to Step 3.
1) Check that ignition is “OFF”. recheck DTC. (Page
8B-57)
2) Disconnect “G259” connector. (Page 8B-61)
3) Disconnect “G11” connector. (Page 8B-57)
4) Release shorting bar in SDM connector. (Page 8B-57)
5) Set ignition “ON”.
6) Check the following point.
• Voltage between each of “A3” and “A4” circuits and
ground: 0 V
Special tool
: 09932M76010

Is check result OK?

3 Passenger airbag (inflator) module circuit check Replace passenger Replace instrument
1) Check that ignition is “OFF”. airbag (inflator) module panel harness.
harness.
2) Disconnect “G372” connector.
3) Release shorting bar in SDM connector. (Page 8B-57)
4) Set ignition “ON”.
5) Check the following point.
• Voltage between each of “A3” and “A4” circuits and
ground: 0 V
Special tool
: 09932M76010

Is check result OK?

NOTE
Upon completion of inspection and repair work, perform the following items.
• Reconnect all airbag system components and check that all components are properly mounted.
• Clear DTCs, referring to “DTC Clearance” (Page 8B-11) if any DTC is detected.
• Repeat “Airbag Diagnostic System Check” (Page 8B-9) to check that the trouble has been solved.

DTC B1062-1A
AENJCA0A8204023
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
B1062-1A: Passenger Airbag (1st Stage) Circuit Low • Passenger airbag (inflator) module circuit
Resistance • Passenger airbag (inflator) module
Passenger airbag (inflator) module circuit resistance is
• SDM
less than specified range.
 Air Bag System: 8B-33

Circuit Diagram

2
[G259] [G373] [G372]
A1 A3
1

YEL YEL G11-24

A2 A4

PPL PPL G11-23

[A] [B] [C]

:3
[a] 1 2 1 2
:4 1 2 3 4 5 6

7 8 9 10 11 L1 L2 12 13 14 15
:5
16 17 18 19 20 21 22 23 24 25 26
IJCA0A820007-01

[A]: “G259” connector (View: [a])
[B]: “G372” connector (View: [a])
[C]: “G11” connector (View: [a])
A1: Passenger airbag (inflator) module
deployment signal output circuit
A2: Passenger airbag (inflator) module 2. SDM
deployment signal ground circuit
A3: Passenger airbag (inflator) module 3. Shorting bar
deployment signal output circuit
A4: Passenger airbag (inflator) module 4. Instrument panel harness
deployment signal ground circuit
1. Passenger airbag (inflator) module 5. Passenger airbag (inflator) module harness

DTC Troubleshooting
Step Action Yes No
1 Was “Airbag Diagnostic System Check” performed? Go to Step 2. Go to “Airbag
Diagnostic System
Check” (Page 8B-9).
2 Passenger airbag (inflator) module check Go to Step 3. Replace passenger
1) Check that ignition is “OFF”. airbag (inflator) module.
(Page 8B-61)
2) Disconnect “G259” connector. (Page 8B-61)
3) Connect “STEERING WHEEL” harness (1) of special
tool (A), (B) and (C) to “G259” connector.
Special tool
(A): 09932M76010
(B): 09932M78310
(C): 09932M75011

(B)

(A) [G259]

(C)

IJCA0A820014-01

4) Set ignition “ON”.

5) Check DTC. (Page 8B-11)

Is DTC B1062-1A detected?

8B-34 Air Bag System:

Step Action Yes No

3 Passenger airbag (inflator) module circuit check Replace SDM and Go to Step 4.
1) Set ignition “OFF”. recheck DTC. (Page
8B-57)
2) Disconnect “G11” connector. (Page 8B-57)
3) Release shorting bar in SDM connector. (Page 8B-57)
4) Check the following point.
• Resistance between “G11-23” and “G11-24”
terminals: infinity
Special tool
: 09932M76010

Is check result OK?

4 Passenger airbag (inflator) module circuit check Replace passenger Replace instrument
1) Disconnect “G372” connector. airbag (inflator) module panel harness.
harness.
2) Release shorting bar in SDM connector. (Page 8B-57)
3) Check the following point.
• Resistance between “G11-23” and “G11-24”
terminals: infinity
Special tool
: 09932M76010

Is check result OK?

NOTE
Upon completion of inspection and repair work, perform the following items.
• Reconnect all airbag system components and check that all components are properly mounted.
• Clear DTCs, referring to “DTC Clearance” (Page 8B-11) if any DTC is detected.
• Repeat “Airbag Diagnostic System Check” (Page 8B-9) to check that the trouble has been solved.
 Air Bag System: 8B-35

DTC B1062-1B
AENJCA0A8204024
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
B1062-1B: Passenger Airbag (1st Stage) Circuit High • Passenger airbag (inflator) module circuit
Resistance • Passenger airbag (inflator) module
Passenger airbag (inflator) module circuit resistance is
• SDM
more than specified range.

Circuit Diagram

2
[G259] [G373] [G372]
A1 A3
1

YEL YEL G11-24

A2 A4

PPL PPL G11-23

[A] [B] [C]

:3
[a] 1 2 1 2
:4 1 2 3 4 5 6

7 8 9 10 11 L1 L2 12 13 14 15
:5
16 17 18 19 20 21 22 23 24 25 26
IJCA0A820007-01

[A]: “G259” connector (View: [a])
[B]: “G372” connector (View: [a])
[C]: “G11” connector (View: [a])
A1: Passenger airbag (inflator) module
deployment signal output circuit
A2: Passenger airbag (inflator) module 2. SDM
deployment signal ground circuit
A3: Passenger airbag (inflator) module 3. Shorting bar
deployment signal output circuit
A4: Passenger airbag (inflator) module 4. Instrument panel harness
deployment signal ground circuit
1. Passenger airbag (inflator) module 5. Passenger airbag (inflator) module harness

DTC Troubleshooting
Step Action Yes No
1 Was “Airbag Diagnostic System Check” performed? Go to Step 2. Go to “Airbag
Diagnostic System
Check” (Page 8B-9).
8B-36 Air Bag System:

Step Action Yes No

2 Passenger airbag (inflator) module check Go to Step 3. Replace passenger
1) Check that ignition is “OFF”. airbag (inflator) module.
(Page 8B-61)
2) Check for proper connection to “G259” connector.
3) Disconnect “G259” connector. (Page 8B-61)
4) Connect “STEERING WHEEL” harness (1) of special
tool (A), (B) and (C) to “G259” connector.
Special tool
(A): 09932M76010
(B): 09932M78310
(C): 09932M75011

(B)

(A) [G259]

(C)

IJCA0A820014-01

5) Set ignition “ON”.

6) Check DTC. (Page 8B-11)

Is DTC B1062-1B detected?

3 Passenger airbag (inflator) module circuit check Replace SDM and Go to Step 4.
1) Set ignition “OFF”. recheck DTC. (Page
8B-57)
2) Check for proper connection to “G11” connector.
3) Disconnect “G11” connector. (Page 8B-57)
4) Release shorting bar in SDM connector. (Page 8B-57)
5) Check the following points.
• Resistance between “G11-24” and “G259-1”
terminals: 1 Ω or less
• Resistance between “G11-23” and “G259-2”
terminals: 1 Ω or less
Special tool
: 09932M76010

Is check result OK?

4 Passenger airbag (inflator) module circuit check Replace passenger Replace instrument
1) Check for proper connection to “G372” connector. airbag (inflator) module panel harness.
harness.
2) Disconnect “G372” connector.
3) Release shorting bar in SDM connector. (Page 8B-57)
4) Check the following point.
• Resistance of “A3” and “A4” circuits: 1 Ω or less
Special tool
: 09932M76010

Is check result OK?

 Air Bag System: 8B-37

NOTE
Upon completion of inspection and repair work, perform the following items.
• Reconnect all airbag system components and check that all components are properly mounted.
• Clear DTCs, referring to “DTC Clearance” (Page 8B-11) if any DTC is detected.
• Repeat “Airbag Diagnostic System Check” (Page 8B-9) to check that the trouble has been solved.

DTC B1064-14 / B1065-14

AENJCA0A8204025
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
B1064-14: Driver Seat Belt Pretensioner Circuit Shorted to Ground • Driver / passenger seat belt
Driver seat belt pretensioner circuit has been shorted to ground. pretensioner circuit
B1065-14: 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 L04-3
A2

GRY L04-4

[L285]

2 B1

YEL L04-6
B2

PPL L04-5

[A] [B]

:4 [a]
L3 L4 1 2
1 2
:5 3 4 5 6

IJHA0A820014-01

[A]: “L283” / “L285” connector (View: [a]) 1. Driver seat belt pretensioner
[B]: “L04” connector (View: [a]) 2. Passenger seat belt pretensioner
A1: Driver seat belt pretensioner operation signal output circuit 3. SDM
A2: Driver seat belt pretensioner operation signal ground circuit 4. Shorting bar
B1: Passenger seat belt pretensioner operation signal output circuit 5. Floor harness
B2: Passenger seat belt pretensioner operation signal ground circuit
8B-38 Air Bag System:

DTC Troubleshooting
Step Action Yes No
1 Was “Airbag Diagnostic System Check” performed? Go to Step 2. Go to “Airbag
Diagnostic System
Check” (Page 8B-9).
2 Seat belt pretensioner circuit check Replace SDM and Replace floor harness.
1) Check that ignition is “OFF”. recheck DTC. (Page
8B-57)
2) Disconnect “L283” or “L285” connector. (Page 8B-62)
3) Disconnect “L04” connector. (Page 8B-57)
4) Release shorting bar in SDM connector. (Page 8B-57)
5) Check the following points.
• Resistance between each of “A1” and “A2” circuits
and ground (DTC B1064-14): infinity
• Resistance between each of “B1” and “B2” circuits
and ground (DTC B1065-14): infinity
Special tool
: 09932M76010

Is check result OK?

NOTE
Upon completion of inspection and repair work, perform the following items.
• Reconnect all airbag system components and check that all components are properly mounted.
• Clear DTCs, referring to “DTC Clearance” (Page 8B-11) if any DTC is detected.
• Repeat “Airbag Diagnostic System Check” (Page 8B-9) to check that the trouble has been solved.
 Air Bag System: 8B-39

DTC B1064-15 / B1065-15

AENJCA0A8204026
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
B1064-15: Driver Seat Belt Pretensioner Circuit Shorted to Power • Driver / passenger seat belt
Supply pretensioner circuit
Driver seat belt pretensioner circuit has been shorted to power supply. • SDM
B1065-15: 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 L04-3
A2

GRY L04-4

[L285]

2 B1

YEL L04-6
B2

PPL L04-5

[A] [B]

:4 [a]
L3 L4 1 2
1 2
:5 3 4 5 6

IJHA0A820014-01

[A]: “L283” / “L285” connector (View: [a]) 1. Driver seat belt pretensioner
[B]: “L04” connector (View: [a]) 2. Passenger seat belt pretensioner
A1: Driver seat belt pretensioner operation signal output circuit 3. SDM
A2: Driver seat belt pretensioner operation signal ground circuit 4. Shorting bar
B1: Passenger seat belt pretensioner operation signal output circuit 5. Floor harness
B2: Passenger seat belt pretensioner operation signal ground circuit
8B-40 Air Bag System:

DTC Troubleshooting
Step Action Yes No
1 Was “Airbag Diagnostic System Check” performed? Go to Step 2. Go to “Airbag
Diagnostic System
Check” (Page 8B-9).
2 Seat belt pretensioner circuit check Replace SDM and Replace floor harness.
1) Check that ignition is “OFF”. recheck DTC. (Page
8B-57)
2) Disconnect “L283” or “L285” connector. (Page 8B-62)
3) Disconnect “L04” connector. (Page 8B-57)
4) Release shorting bar in SDM connector. (Page 8B-57)
5) Set ignition “ON”.
6) Check the following points.
• Voltage between each of “A1” and “A2” circuits and
ground (DTC B1064-15): 0 V
• Voltage between each of “B1” and “B2” circuits and
ground (DTC B1065-15): 0 V
Special tool
: 09932M76010

Is check result OK?

NOTE
Upon completion of inspection and repair work, perform the following items.
• Reconnect all airbag system components and check that all components are properly mounted.
• Clear DTCs, referring to “DTC Clearance” (Page 8B-11) if any DTC is detected.
• Repeat “Airbag Diagnostic System Check” (Page 8B-9) to check that the trouble has been solved.
 Air Bag System: 8B-41

DTC B1064-1A / B1065-1A

AENJCA0A8204027
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
B1064-1A: Driver Seat Belt Pretensioner Circuit Low • Driver / passenger seat belt pretensioner circuit
Resistance • Driver / passenger seat belt pretensioner
Driver seat belt pretensioner circuit resistance is less than
• SDM
specified range.
B1065-1A: 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 L04-3
A2

GRY L04-4

[L285]

2 B1

YEL L04-6
B2

PPL L04-5

[A] [B]

:4 [a]
L3 L4 1 2
1 2
:5 3 4 5 6

IJHA0A820014-01

[A]: “L283” / “L285” connector (View: [a]) 1. Driver seat belt pretensioner
[B]: “L04” connector (View: [a]) 2. Passenger seat belt pretensioner
A1: Driver seat belt pretensioner operation signal output circuit 3. SDM
A2: Driver seat belt pretensioner operation signal ground circuit 4. Shorting bar
B1: Passenger seat belt pretensioner operation signal output circuit 5. Floor harness
B2: Passenger seat belt pretensioner operation signal ground circuit
8B-42 Air Bag System:

DTC Troubleshooting
Step Action Yes No
1 Was “Airbag Diagnostic System Check” performed? Go to Step 2. Go to “Airbag
Diagnostic System
Check” (Page 8B-9).
2 Seat belt pretensioner check Go to Step 3. Replace seat belt
1) Check that ignition is “OFF”. pretensioner. (Page
8A-5)
2) Disconnect “L283” or “L285” connector. (Page 8B-62)
3) Connect “STEERING WHEEL” harness (1) of special
tool (A), (B) and (C) to “L283” or “L285” connector.
Special tool
(A): 09932M76010
(B): 09932M78310
(C): 09932M75011

[L283], [L285]
(A)

(C)

1
(B)

IJCA0A820015-01

4) Set ignition “ON”.

5) Check DTC. (Page 8B-11)

Is DTC B1064-1A or B1065-1A detected?

3 Seat belt pretensioner circuit check Replace SDM and Replace floor harness.
1) Set ignition “OFF”. recheck DTC. (Page
8B-57)
2) Disconnect “L04” connector. (Page 8B-57)
3) Release shorting bar in SDM connector. (Page 8B-57)
4) Check the following points.
• Resistance between “L04-3” and “L04-4” terminals
(DTC B1064-1A): infinity
• Resistance between “L04-5” and “L04-6” terminals
(DTC B1065-1A): infinity
Special tool
: 09932M76010

Is check result OK?

NOTE
Upon completion of inspection and repair work, perform the following items.
• Reconnect all airbag system components and check that all components are properly mounted.
• Clear DTCs, referring to “DTC Clearance” (Page 8B-11) if any DTC is detected.
• Repeat “Airbag Diagnostic System Check” (Page 8B-9) to check that the trouble has been solved.
 Air Bag System: 8B-43

DTC B1064-1B / B1065-1B

AENJCA0A8204028
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
B1064-1B: Driver Seat Belt Pretensioner Circuit High • Driver / passenger seat belt pretensioner circuit
Resistance • Driver / passenger seat belt pretensioner
Driver seat belt pretensioner circuit resistance is more
• SDM
than specified range.
B1065-1B: 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 L04-3
A2

GRY L04-4

[L285]

2 B1

YEL L04-6
B2

PPL L04-5

[A] [B]

:4 [a]
L3 L4 1 2
1 2
:5 3 4 5 6

IJHA0A820014-01

[A]: “L283” / “L285” connector (View: [a]) 1. Driver seat belt pretensioner
[B]: “L04” connector (View: [a]) 2. Passenger seat belt pretensioner
A1: Driver seat belt pretensioner operation signal output circuit 3. SDM
A2: Driver seat belt pretensioner operation signal ground circuit 4. Shorting bar
B1: Passenger seat belt pretensioner operation signal output circuit 5. Floor harness
B2: Passenger seat belt pretensioner operation signal ground circuit
8B-44 Air Bag System:

DTC Troubleshooting
Step Action Yes No
1 Was “Airbag Diagnostic System Check” performed? Go to Step 2. Go to “Airbag
Diagnostic System
Check” (Page 8B-9).
2 Seat belt pretensioner check Go to Step 3. Replace seat belt
1) Check that ignition is “OFF”. pretensioner. (Page
8A-5)
2) Check for proper connection to “L283” or “L285”
connector.
3) Disconnect “L283” or “L285” connector. (Page 8B-62)
4) Connect “STEERING WHEEL” harness (1) of special
tool (A), (B) and (C) to “L283” or “L285” connector.
Special tool
(A): 09932M76010
(B): 09932M78310
(C): 09932M75011

[L283], [L285]
(A)

(C)

1
(B)

IJCA0A820015-01

5) Set ignition “ON”.

6) Check DTC. (Page 8B-11)

Is DTC B1064-1B or B1065-1B detected?

3 Seat belt pretensioner circuit check Replace SDM and Replace floor harness.
1) Set ignition “OFF”. recheck DTC. (Page
8B-57)
2) Check for proper connection to “L04” connector.
3) Disconnect “L04” connector. (Page 8B-57)
4) Release shorting bar in SDM connector. (Page 8B-57)
5) Check the following points.
• Resistance of “A1” and “A2” circuits (DTC B1064-1B):
1 Ω or less
• Resistance of “B1” and “B2” circuits (DTC B1065-1B):
1 Ω or less
Special tool
: 09932M76010

Is check result OK?

NOTE
Upon completion of inspection and repair work, perform the following items.
• Reconnect all airbag system components and check that all components are properly mounted.
• Clear DTCs, referring to “DTC Clearance” (Page 8B-11) if any DTC is detected.
• Repeat “Airbag Diagnostic System Check” (Page 8B-9) to check that the trouble has been solved.
 Air Bag System: 8B-45

DTC B1090-01 / B1090-95

AENJCA0A8204029
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
B1090-01: Driver Forward Impact Sensor No Response • Forward impact sensor
Forward impact sensor failure. • Forward impact sensor circuit
B1090-95: Driver Forward Impact Sensor Communication Data
• SDM
Inconsistent
Forward impact sensor has communicated with inconsistent ID code.

DTC Troubleshooting
Step Action Yes No
1 Was “Airbag Diagnostic System Check” performed? Go to Step 2. Go to “Airbag
Diagnostic System
Check” (Page 8B-9).
2 DTC check Go to applicable DTC Go to Step 3.
1) Check if DTC B1090-87 is detected. (Page 8B-11) troubleshooting.

Is DTC B1090-87 detected?

3 Forward impact sensor check Replace SDM and End.
1) Check that ignition is “OFF”. recheck DTC. (Page
8B-57)
2) Replace forward impact sensor. (Page 8B-63)
3) Set ignition “ON”.
4) Check DTC. (Page 8B-11)

Is DTC detected?

NOTE
Upon completion of inspection and repair work, perform the following items.
• Reconnect all airbag system components and check that all components are properly mounted.
• Clear DTCs, referring to “DTC Clearance” (Page 8B-11) if any DTC is detected.
• Repeat “Airbag Diagnostic System Check” (Page 8B-9) to check that the trouble has been solved.
8B-46 Air Bag System:

DTC B1090-87
AENJCA0A8204030
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
B1090-87: Driver Forward Impact Sensor Communication Data Invalid • Forward impact sensor
Forward impact sensor has communicated with no response or invalid data. • Forward impact sensor circuit
• SDM

Circuit Diagram

[E40] [E381] [G333] 2

A1 A3
1

YEL/BLK YEL/BLK G11-12

A2 A4

GRN GRN G11-13

[A] [B] [D]

:3

:4 [a] 1 2 1 2 3 4 5 6
3 2 1 7 6 5 4
8
15 14 13 12 11 10 9 7 8 9 10 11 L1 L2 12 13 14 15

16 17 18 19 20 21 22 23 24 25 26
[C]

4 5 6 7 1 2 3
8
9 10 11 12 13 14 15
IJCA0A820042-01

[A]: “E40” connector (View: [a]) A1: Forward impact sensor signal output circuit 1. Forward impact sensor
[B]: “E381” connector (View: [a]) A2: Forward impact sensor signal ground circuit 2. SDM
[C]: “G333” connector (View: [a]) A3: Forward impact sensor signal output circuit 3. Instrument panel harness
[D]: “G11” connector (View: [a]) A4: Forward impact sensor signal ground circuit 4. Main harness

DTC Troubleshooting
Step Action Yes No
1 Was “Airbag Diagnostic System Check” performed? Go to Step 2. Go to “Airbag
Diagnostic System
Check” (Page 8B-9).
 Air Bag System: 8B-47

Step Action Yes No

2 Forward impact sensor circuit check Go to Step 3. Replace instrument
1) Check that ignition is “OFF”. panel harness.
2) Disconnect “G11” connector. (Page 8B-57)
3) Disconnect “G333” connector.
4) Check the following point.
• Resistance of “A3” and “A4” circuits: 1 Ω or less
Special tool
(A): 09932M76010

[G333]

4 5 6 7 1 2 3
8 (A)
9 10 11 12 13 14 15

[G11]

1 2 3 4 5 6

7 8 9 10 11 L1 L2 12 13 14 15

16 17 18 19 20 21 22 23 24 25 26
IJCA0A820043-01

Is check result OK?

3 Forward impact sensor circuit check Go to Step 4. Replace instrument
1) Check the following point. panel harness.
• Resistance between “G11-12” and “G11-13”
terminals: infinity
Special tool
(A): 09932M76010

(A)

[G11]

1 2 3 4 5 6

7 8 9 10 11 L1 L2 12 13 14 15

16 17 18 19 20 21 22 23 24 25 26
IJHA0A820018-01

Is check result OK?

4 Forward impact sensor circuit check Go to Step 5. Replace instrument
1) Check the following point. panel harness.
• Resistance between each of “A3” and “A4” circuits
and ground: infinity
Special tool
(A): 09932M76010

[G11]
(A)

1 2 3 4 5 6

7 8 9 10 11 L1 L2 12 13 14 15

16 17 18 19 20 21 22 23 24 25 26
IJHA0A820019-01

Is check result OK?

8B-48 Air Bag System:

Step Action Yes No

5 Forward impact sensor circuit check Go to Step 6. Replace instrument
1) Set ignition “ON”. panel harness.
2) Check the following point.
• Voltage between each of “A3” and “A4” circuits and
ground: 0 V
Special tool
(A): 09932M76010

[G11]
(A)
1 2 3 4 5 6

7 8 9 10 11 L1 L2 12 13 14 15

16 17 18 19 20 21 22 23 24 25 26

IJHA0A820009-01

Is check result OK?

6 Forward impact sensor circuit check Go to Step 7. Replace main harness.
1) Set ignition “OFF”.
2) Disconnect “E40” connector. (Page 8B-63)
3) Check the following point.
• Resistance of “A1” and “A2” circuits: 1 Ω or less
Special tool
(A): 09932M76010

[E382]

3 2 1 7 6 5 4
8
15 14 13 12 11 10 9

[E40] (A)

1 2

IJHA0A820020-01

Is check result OK?

7 Forward impact sensor circuit check Go to Step 8. Replace main harness.
1) Check the following point.
• Resistance between “E40-1” and “E40-2” terminals:
infinity
Special tool
(A): 09932M76010

(A)
[E40]

1 2

IDL10A820037-01

Is check result OK?

 Air Bag System: 8B-49

Step Action Yes No

8 Forward impact sensor circuit check Go to Step 9. Replace main harness.
1) Check the following point.
• Resistance between each of “A1” and “A2” circuits
and ground: infinity
Special tool
(A): 09932M76010

(A)
[E40]

1 2

IDL10A820038-01

Is check result OK?

9 Forward impact sensor circuit check Go to Step 10. Replace main harness.
1) Set ignition “ON”.
2) Check the following point.
• Voltage between each of “A1” and “A2” circuits and
ground: 0 V
Special tool
(A): 09932M76010

(A)
[E40]

1 2

IDL10A820039-01

Is check result OK?

10 Forward impact sensor check Replace SDM and End.
1) Check that ignition is “OFF”. recheck DTC. (Page
8B-57)
2) Replace forward impact sensor. (Page 8B-63)
3) Set ignition “ON”.
4) Check DTC. (Page 8B-11)

Is DTC detected?

NOTE
Upon completion of inspection and repair work, perform the following items.
• Reconnect all airbag system components and check that all components are properly mounted.
• Clear DTCs, referring to “DTC Clearance” (Page 8B-11) if any DTC is detected.
• Repeat “Airbag Diagnostic System Check” (Page 8B-9) to check that the trouble has been solved.

DTC U0073-88
AENJCA0A8204031
Refer to “Troubleshooting for Communication Bus Off” in Section 10H (Page 10H-15).
8B-50 Air Bag System:

SDM Power Supply and Ground Circuit Check

AENJCA0A8204032
Circuit Diagram

[A] 3
5

2
1 RED G11-10

BLK G11-16

[B] 6

2
1

[C]

1 2 3 4 5 6
:4 [a]
7 8 9 10 11 L1 L2 12 13 14 15

16 17 18 19 20 21 22 23 24 25 26
IJCA0A820005-01

[A]: With keyless entry system 1. Ignition power supply 4. Instrument panel harness
[B]: Without keyless entry system 2. “A/B” fuse 5. J/B
[C]: “G11” connector (View: [a]) 3. SDM 6. Individual circuit fuse box
 Air Bag System: 8B-51

Troubleshooting
Step Action Yes No
1 Battery voltage check Go to Step 2. Check charging system
1) Check battery voltage. and repair it.
• K10B and bi-fuel
Is voltage in 10 – 14 V?
CNG model: (Page
1J-5)
• K12M model:
(Page 1J-23)
2 SDM connection check Go to Step 3. Check for intermittent
1) Check for proper connection to SDM connector. trouble. (Page 00-13)
If OK, replace SDM and
Is it connected securely?
recheck connection.
(Page 8B-57)
3 Fuse check Go to Step 4. Replace instrument
1) Check that ignition is “OFF”. panel harness and then
replace “A/B” fuse.
2) Check “A/B” fuse.

Is “A/B” fuse in good condition?

4 Power circuit check Go to Step 5. Replace instrument
1) Disconnect “G11” connector. (Page 8B-57) panel harness.
2) Set ignition “ON”.
3) Measure voltage between “G11-10” terminal and ground.
Special tool
(A): 09932M76010

[G11]
(A)
1 2 3 4 5 6

7 8 9 10 11 L1 L2 12 13 14 15

16 17 18 19 20 21 22 23 24 25 26

IJHA0A820009-01

Is voltage in 10 – 14 V?
5 Ground circuit check SDM power supply Replace instrument
1) Set ignition “OFF”. circuit and ground circuit panel harness.
are in good condition.
2) Measure resistance between “G11-16” terminal and
ground.
Special tool
(A): 09932M76010

[G11]
(A)

1 2 3 4 5 6

7 8 9 10 11 L1 L2 12 13 14 15

16 17 18 19 20 21 22 23 24 25 26
IJHA0A820019-01

Is resistance 1 Ω or less?
8B-52 Air Bag System:

Contact Coil and Its Circuit Check

AENJCA0A8204033
Circuit Diagram

3
[S121] [S171] [G346]
A1
1 2

YEL G11-21
A2

GRY G11-22

[A] [B] [C]

:4 1 2 1 2
[a] 1 2 3 4 5 6
:5 7 8 9 10 11 L1 L2 12 13 14 15

16 17 18 19 20 21 22 23 24 25 26
IJCA0A820006-01

[A]: “S121” connector (View: [a]) A2: Driver airbag (inflator) module deployment 4. Shorting bar
signal ground circuit
[B]: “G346” connector (View: [a]) 1. Driver airbag (inflator) module 5. Instrument panel harness
[C]: “G11” connector (View: [a]) 2. Contact coil assembly
A1: Driver airbag (inflator) module deployment 3. SDM
signal output circuit

Troubleshooting
Step Action Yes No
1 Driver airbag (inflator) module circuit check Go to Step 2. Check for defective wire
1) Remove driver airbag (inflator) module from steering harness. If check result
wheel. (Page 8B-59) is OK, replace contact
coil assembly. (Page
2) Disconnect “G11” connector. (Page 8B-57)
6B-4)
3) Release shorting bar in SDM connector. (Page 8B-57)
4) Check the following point.
• Resistance between “G11-21” and “G11-22”
terminals: infinity
Special tool
: 09932M76010

Is check result OK?

 Air Bag System: 8B-53

Step Action Yes No

2 Contact coil circuit (driver airbag (inflator) module Go to Step 3. Replace contact coil
circuit) check assembly. (Page 6B-
1) Remove contact coil assembly. (Page 6B-4) 4)
2) Check the following points.
• Resistance between “S121-1” and “S171-2” terminals:
1 Ω or less
• Resistance between “S121-2” and “S171-1” terminals:
1 Ω or less
Special tool
(A): 09932M76010

[S171]

2 1

(A)

[S121]

1 2

IJCA0A820016-01

Is check result OK?

3 Contact coil circuit check Contact coil and its Replace contact coil
1) Measure resistance between each terminal of contact circuit are in good assembly. (Page 6B-
coil and other terminals. condition. 4)

Is each measured resistance infinite?

8B-54 Air Bag System:

Repair and Inspection Required after Accident Accident with or without Deployment / Activation –
AENJCA0A8204034 Component Inspections
! WARNING Check the following airbag system components after any
crash, whether airbag system was activated or not. If
Failure to properly check and repair a vehicle
any faulty condition is found in the following checks,
that has been involved in an accident can
replace faulty component.
result in unsafe operating conditions.
• Steering column and steering lower shaft
• For any vehicle that was involved in an
accident, check all airbag system – Check for length, damage and bend according to
components including the electrical “Steering Column Inspection” in Section 6B (Page
harness and the areas where they are 6B-8).
mounted, even if the airbag system was • Steering column bracket
not activated. Any components deformed – Check for damage and bend according to “Steering
or otherwise damaged must be replaced. Column Inspection” in Section 6B (Page 6B-8).
• Never use airbag system parts from • Steering wheel and driver airbag (inflator) module
another vehicle model.
– Check airbag (inflator) module for damage and
• Do not repair the following parts. installation condition.
Replace any of them that are found faulty.
– Check trim cover (pad surface) for crack.
– Driver / passenger airbag (inflator)
– Check wire harness and connector for damage and
modules
tightness.
– Driver / passenger seat belt
pretensioners
– Forward impact sensor
– SDM
– Contact coil
– Airbag wire harnesses (in main harness,
instrument panel harness and floor
harness) and passenger airbag harness
• Perform all repairs in a manner which
assures that the vehicle’s original
configuration is restored.
• The SDM that has been involved in an IJCA0A820017-01
accident severe enough to cause • Contact coil assembly
deployment of airbags is not guaranteed to
provide its original performance. – Check wire harness and connectors for damage
and tightness.
• Never use an SDM that has been involved
in an airbag deployment accident. – Check contact coil case for damage.
– Check contact coil circuit referring to “Contact Coil
Accident with Deployment / Activation – Component and Its Circuit Check” (Page 8B-52).
Replacement
Replace the following components when driver and
passenger airbags are deployed.
• Driver and passenger airbag (inflator) modules
• Driver / passenger seat belt pretensioners
• SDM
• Forward impact sensor
• Instrument panel

I9P60A820041-01
 Air Bag System: 8B-55

• Instrument panel member and reinforcement
– Check for any distortion, bend, crack and other
damage.
– Check instrument panel for crack and deformation.
• Passenger airbag (inflator) module
– Check for dents, crack, damage and installation
condition.
– Check harness and connector for damage and
tightness.
• Airbag wire harnesses and connectors
– Check for damage, deformation and poor
connections.
Refer to “Intermittent Connection and Poor Contact
Inspection” in Section 00 (Page 00-13).
– Check wire harnesses for tightness.
2
1

IJCA0A820001-01

1. Main harness 3. Floor harness

2. Instrument panel harness 4. Grounding point

• Forward impact sensor

– Check sensor (1) and right-side front side member
(2) for damage, bend and rust.
– Check connector (3) and lead wire (4) of forward
impact sensor for scorch, melt and damage.

IJCA0A820018-01

• SDM
– Check for external damage such as deformation,
scratch, crack and peeled paint.
– Check SDM for deformation which prevents its
proper installation (gap between SDM and SDM
4 3
plate, etc.).
1
– Check connector or lead wire of SDM for scorch, IJCA0A820021-01

melt or damage.
– Check SDM connector and terminals for tightness.
– Check DTC and follow referring corresponding
diagnostic flow if any DTC is found.

IJCA0A820019-01
8B-56 Air Bag System:

• Seat belt pretensioner • Seat belts and mounting points

– Check for dents, crack, damage and installation – Refer to “Front Seat Belt Components” in Section
condition. 8A (Page 8A-4).
– Check harness and connector for damage and • “AIRBAG” warning light
tightness. – Perform “Airbag Diagnostic System Check” (Page
8B-9) after vehicle is completely repaired.

2
I9P60A820003-01

1. Webbing 2. Retractor assembly

Repair Instructions
Disabling Airbag System
AENJCA0A8206001
When servicing airbag system, related parts and working around airbag (inflator) module, disable airbag (inflator)
modules as follows.
Servicing item Disabling procedure
• When disconnecting or connecting airbag system
connectors.
• When removing or installing airbag system Disconnect negative (–) cable at battery. (Page 8B-56)
components.
• When servicing airbag system, related parts or working
around airbag (inflator) module with ignition “OFF”.
• When servicing airbag system, related parts or working
Remove “A/B” fuse. (Page 8B-56)
around airbag (inflator) module with ignition “ON”.
• When performing electric welding.
Disconnect negative (–) cable at battery, and remove all
• When there is a possibility that airbag system or related airbag (inflator) modules, forward impact sensor and
parts would be heated up to 90 °C (194 °F) and more SDM. (Page 8B-56)
by electric welding or paint baking process.

Disabling Procedure (Disconnecting Negative (–) 1) Set ignition “OFF”.

Battery Cable)
1) Set front wheels in straight ahead position.
2) Set ignition “OFF”.
3) Disconnect negative (–) cable at battery.
4) Wait for at least 90 seconds after performing Step 3).
Disabling Procedure (Removing “A/B” Fuse)
NOTE
“AIRBAG” warning light will light if “A/B”
fuse is disconnected, but this is normal and
DTC for airbag system will not be detected.
2) Remove “A/B” fuse.
3) Wait for at least 90 seconds after performing Step 2).
4) Start working and set ignition “ON”.
Disabling Procedure (Disconnecting Negative (–)
Battery Cable and Removing All Airbag (Inflator)
Module)
1) Set front wheels in straight ahead position.
2) Set ignition “OFF”.
3) Disconnect negative (–) cable at battery.
4) Wait for at least 90 seconds after performing Step 3).
5) Remove all airbag (inflator) modules.
 Air Bag System: 8B-57

Enabling Airbag System 4) Set ignition “ON”.

AENJCA0A8206002
5) Check if “AIRBAG” warning light turns on for about 6
1) Check that removed components are installed and/
seconds and then comes off.
or disconnected connectors are connected properly.
6) Perform “Airbag Diagnostic System Check” (Page
2) Check that ignition is “OFF”.
8B-9) if defective.
3) Connect negative (–) cable at battery and/or install
“A/B” fuse.

Release of Shorting Bar

AENJCA0A8206017
Release shorting bar in SDM connector inserting release tool.

NOTE
• To prevent accidental deployment of airbag during inspection, shorting bars are set in SDM
connector (such as G11, L04, etc.). Therefore, before checking wiring harness connected to SDM for
short to power supply, short to ground, short between two lines, release of corresponding shorting
bar using special tool is necessary.
• As an example, two connectors are shown in figure. When checking wiring harness related to DTC,
it is necessary to release proper shorting bar referring to corresponding circuit diagram.

Special tool
(A): 09932M76010

[G11] [L04]

(A)
(A)

IGSB0A821061-01

SDM Removal and Installation

AENJCA0A8206003
A
! WARNING
1
If the SDM is handled roughly when
performing the service operations described
below, there is a risk of personal injury due to A
accidental activation of the airbag system.
Read “Precautions for Airbag System
A
Service” (Page 8B-1) before starting the A
operations described below and follow all of
the instructions provided.
A
Removal
IJCA0A820022-01
1) Disable airbag system. (Page 8B-56)
5) Disconnect SDM connectors (1).
2) Remove instrument panel lower cover. (Page 9C-
25) 6) Remove SDM (2).
3) Turn over floor carpet.
4) Remove clips and then remove SDM cover (1).
8B-58 Air Bag System:

SDM Inspection
2 AENJCA0A8206004

NOTICE
The SDM may not function properly if you do
not handle it carefully.
• Do not connect any type of tester to the
SDM.

1
IJCA0A820023-01

Installation
Reverse removal procedure noting the following points.
• Check that none of the following faulty conditions
exists.
– Bend, scratch, deformation on mating surface of
vehicle body where SDM is mounted
– Foreign material or rust on mating surface of
vehicle body where SDM is mounted
• Tighten SDM bolts (1) to specified torque.
Tightening torque
SDM bolt (a): 9.0 N·m (0.92 kgf-m, 7.0 lbf-ft)
1, (a)
1, (a)
I9W10P821002-01
• Never repair or disassemble the SDM.
• Replace the SDM if it has been dropped.
If any faulty condition is found in the following checks,
replace the SDM with new one.
• Check airbag module is deployed or pretensioner is
activated.
• Check SDM for dents, crack or deformation.
• Check SDM connector for damage, crack or lock
mechanism.
• Check SDM terminal for bend, corrosion or rust.
• Check DTC B1003-04, B1032-00 or B1035-00 is
stored in SDM.

IJCA0A820024-01

• Enable airbag system. (Page 8B-57)

 Air Bag System: 8B-59

Driver Airbag (Inflator) Module Removal and Removal

Installation 1) Set steering wheel in straight ahead position.
AENJCA0A8206005
2) Disable airbag system. (Page 8B-56)
! WARNING
3) Release driver airbag (inflator) module locks as
Failure to take proper precautions when follows.
performing service on the driver airbag a) Turn steering wheel (1) counterclockwise 90°,
(inflator) module can result in personal injury insert a 6 mm diameter pin (3) into service hole
or non-activation of the airbag in the event of (2) to push lock plate (4) into steering wheel
a collision. center and release right side lock.
• Never disassemble or repair an airbag
(inflator) module. If any abnormal
condition is found, replace the module
with a new one.
• Carefully read “Precautions for Airbag
System Service” (Page 8B-1), “Precautions 1
for Handling and Storage of Airbag System
Components” (Page 8B-1) and
“Precautions for Disposal of Airbag and
Seat Belt Pretensioner” (Page 8B-3) and 3
follow all of the instructions provided.

NOTICE
An airbag (inflator) module that has been
dropped may not operate correctly. 2
Never use an airbag (inflator) module that
has been dropped. Replace the module with a 4

new one.

NOTE
Refer to “Repair and Inspection Required
after Accident” (Page 8B-54) before replacing
“a”
deployed airbag.

1
IJCA0A820025-01

a: 90°
8B-60 Air Bag System:

b) Turn steering wheel (1) clockwise 180° and
release left side lock in the same manner as in
Step a).
c) Set steering wheel in straight ahead position and
release lower side lock in the same manner as in
Step a).
1
6) Remove driver airbag (inflator) module from steering
wheel.
Installation
Reverse removal procedure noting the following points.
• Lock connector for driver airbag (inflator) module
securely.
• Insert two upper pins (1) of driver airbag (inflator)
module first, and then bottom pin (2).

IJCA0A820027-01

• Enable airbag system. (Page 8B-57)

Driver Airbag (Inflator) Module Inspection

2 AENJCA0A8206006

! WARNING
3 Failure to take proper precautions when
checking the driver airbag (inflator) module
1 can result in personal injury due to
accidental deployment of the airbag.
IJCA0A820026-01
Never measure the resistance of the airbag
2. Service hole 4. Lock plate (inflator) module.
3. 6 mm diameter pin

4) Disconnect horn connector (1).

5) Disconnect driver airbag (inflator) module connector
(2) as shown in figure.
a) Release lock button (3) by pulling it in arrow
direction “1”.
b) Disconnect connector with lock released by
pulling it in arrow direction “2”.

I9P60A820053-01

“1” “2” Check airbag (inflator) module and if any of the following
conditions is found, replace airbag (inflator) module or
steering wheel with new one.
• Airbag being deployed.
• Airbag (inflator) module is damaged or a strong
impact was applied to it.
3 2
• Connector being damaged.
1 • Airbag (inflator) module bracket of steering wheel
IJCA0A820044-01
being deformed or damaged.
 Air Bag System: 8B-61

• Unable to install new airbag (inflator) module Removal

smoothly (Clearance (1) between steering wheel and
airbag (inflator) module is uneven).
1 follows.
1) Disable airbag system. (Page 8B-56)
2) Remove glove box.
3) Disconnect passenger airbag (inflator) module
connector (1) from instrument panel harness as
a) Release locking slider (2) by sliding it in arrow
direction “1”.
b) Disconnect passenger airbag (inflator) module
connector by pulling it in arrow direction “2”.

2 “1”

“2”
IA1J0P821055-01

1
Passenger Airbag (Inflator) Module Removal
and Installation (4-Channel Airbag System)
AENJCA0A8206007
! WARNING
Failure to take proper precautions when
performing service on the passenger airbag
(inflator) module can result in personal injury
or non-activation of the airbag in the event of
a collision.
• Never disassemble or repair an airbag IJCA0A820028-01

(inflator) module. If any abnormal
condition is found, replace the module
with a new one.
• Carefully read “Precautions for Airbag
System Service” (Page 8B-1), “Precautions
for Handling and Storage of Airbag System
Components” (Page 8B-1) and
“Precautions for Disposal of Airbag and
Seat Belt Pretensioner” (Page 8B-3) and
follow all of the instructions provided.
4) Disconnect clamps (1) from instrument panel.
5) Remove passenger airbag (inflator) module bolts (2)
and screws (3).
6) Release tabs (4), and then remove passenger airbag
(inflator) module from instrument panel.
4

4
NOTICE
An airbag (inflator) module that has been 4
dropped may not operate correctly.
Never use an airbag (inflator) module that
has been dropped. Replace the module with a
new one.
4
NOTE
Refer to “Repair and Inspection Required
after Accident” (Page 8B-54) before replacing
a deployed airbag. 1

2
2
1

IJCA0A820040-01
8B-62 Air Bag System:

7) Disconnect passenger airbag (inflator) module • Enable airbag system. (Page 8B-57)
connector (1) as shown in figure.
a) Release lock button (2) by pulling it in arrow Passenger Airbag (Inflator) Module Inspection
direction “1”. (4-Channel Airbag System)
AENJCA0A8206008
b) Disconnect connector with lock released by
pulling it in arrow direction “2”. ! WARNING
Failure to take proper precautions when
2 “1” checking the passenger airbag (inflator)
“2”
module can result in personal injury due to
accidental deployment of the airbag.
1 Never measure the resistance of the airbag
(inflator) module.

IJCA0A820039-01

Installation
Reverse removal procedure noting the following points.
• Fit tabs (1) of passenger airbag (inflator) module (2) to
instrument panel securely.
• Lock connector for passenger airbag (inflator) module
securely.
I9P60A820062-01
• Tighten passenger airbag (inflator) module screws (3).
• Tighten passenger airbag (inflator) module bolts to Check airbag (inflator) module and if any of the following
specified torque. conditions is found, replace airbag (inflator) module with
Tightening torque new one.
Passenger airbag (inflator) module bolt (a): 23 • Airbag being deployed.
N·m (2.3 kgf-m, 17.0 lbf-ft) • Airbag (inflator) module is damaged or a strong
impact was applied to it.
1
• Connector being damaged.
• Bend or deformation of airbag (inflator) module
bracket.
1
Seat Belt Pretensioner Components (4-Channel
1
Airbag System)
AENJCA0A8206009
Refer to “Front Seat Belt Components” in Section 8A
(Page 8A-4).

1
Seat Belt Pretensioner Removal and Installation
(4-Channel Airbag System)
AENJCA0A8206010
Refer to “Front Seat Belt Assembly Removal and
2 Installation” in Section 8A (Page 8A-5).
3
3

(a)
(a)

IJCA0A820041-01
 Air Bag System: 8B-63

Seat Belt Pretensioner Inspection (4-Channel Removal

Airbag System)
AENJCA0A8206011
! WARNING
Failure to take proper precautions when
checking the seat belt pretensioner can
result in personal injury due to accidental
activate of the seat belt pretensioner.
Never measure the resistance of the seat belt
pretensioner.
1) Disable airbag system. (Page 8B-56)
2) Remove front bumper. (Page 9H-3)
3) Remove right-side headlight unit. (Page 9B-5)
4) Disconnect forward impact sensor connector as
follows.
a) Release locking slider (1) by sliding it in arrow
direction “1”.
b) Disconnect forward impact sensor connector (2)
by pulling it in arrow direction “2”.
5) Remove forward impact sensor bolt (3) and remove
forward impact sensor (4) from front side member
(5).

1 3

5
“1”

IJHA0A810008-01

“2”
Check seat belt assembly (retractor pretensioner) and if
any of the following conditions is found, replace seat belt
assembly (retractor pretensioner) with new one. 2 4
IJCA0A820032-01
• Pretensioner being activated.
Installation
NOTE
1) Check that none of the following faulty conditions
As retractor pretensioner is controlled with exists.
driver and passenger airbag, you should
judge that pretensioner has been activated if • Bend, deformation or rust on front side member
airbag has deployed. • Foreign material on sensor
2) Align mounting pin (1) to mounting hole (2) of vehicle
• Retractor pretensioner is damaged or a strong impact to install forward impact sensor (3).
was applied to it.
3) Tighten forward impact sensor bolt to specified
• Connector being damaged. torque.
Tightening torque
Forward Impact Sensor Removal and
Forward impact sensor bolt (a): 9.0 N·m (0.92
Installation kgf-m, 7.0 lbf-ft)
AENJCA0A8206012
! WARNING
Failure to take proper precautions when
handling the airbag system sensor can result
in personal injury due to non-deployed
airbag system in the event of an accident or
accidental airbag deployment. 2
• Never impact or shake the sensor.
Otherwise, proper operation of the sensor
cannot be assured.
(a)
• Always tighten the mounting bolt to
specified torque when installing the 3

sensor. Otherwise, proper operation of the 1

sensor cannot be assured. IJCA0A820033-01
8B-64 Air Bag System:

4) Connect forward impact sensor connector securely. ! WARNING

5) Install right-side headlight unit. (Page 9B-5)
Failure to take proper precautions when
6) Install front bumper. (Page 9H-3)
deploying an airbag (inflator) module and/or
7) Enable airbag system. (Page 8B-57) activating a seat belt pretensioner can result
in severe personal injury.
Forward Impact Sensor Inspection Take all of the following precautions when
AENJCA0A8206013
deploying an airbag (inflator) module and/or
Check forward impact sensor and if any of the following
activating a seat belt pretensioner:
conditions are found, replace it with new one.
• Strictly follow the procedure described in
• Driver airbag or passenger airbag has deployed.
this section.
• Check sensor for dents, cracks or deformation.
• Read “Precautions for Airbag System
• Check sensor connectors (sensor side and harness Service” (Page 8B-1) and follow all of the
side) and sensor connector lock mechanism for instructions provided.
damage or crack.
• Only one person should perform this work
• Check connector terminals for bend, corrosion or rust. to avoid accidental deployment/activation.
• Perform this work in a well-ventilated area
Passenger Airbag (Inflator) Module Repair as smoke is produced when the airbag
Harness Installation (inflator) module / pretensioner is
AENJCA0A8206014
For replacement of passenger airbag (inflator) module activated.
harness, refer to “Passenger Airbag (Inflator) Module • Wear safety glasses throughout the
Inspection (4-Channel Airbag System)” (Page 8B-62) disposal procedure from the very
and the following point. beginning. The airbag (inflator) module /
• After replacing passenger airbag (inflator) module seat belt pretensioner will immediately be
harness, check that no DTC is detected in SDM with activated when a 12-volt battery is
ignition “ON”. connected.
• Wear suitable ear protection when
Airbag (Inflator) Module and Seat Belt activating an airbag (inflator) module / seat
belt pretensioner. Also, advise persons in
Pretensioner Disposal
AENJCA0A8206015 nearby areas to wear suitable ear
! WARNING protection.
• Do not activate two or more airbag
If live airbag (inflator) modules or seat belt (inflator) modules, seat belt pretensioners,
pretensioners are disposed of without being or a combination of two at the same time.
deployed/activated beforehand using the
• Never connect the deployment harness to
proper procedure, there is a risk of personal
any 12-volt battery before connecting it to
injury and health problems from contact with
the airbag (inflator) module or seat belt
the harmful substances that may come out if
pretensioner. The deployment harness
the deployment container seal is broken.
must remain shorted and not be connected
Before disposing of any live airbag (inflator)
to a 12-volt battery until preparation for
modules or seat belt pretensioners, deploy/
activation of the airbag (inflator) module /
activate them using the specified procedure.
seat belt pretensioner is completed.
Never dispose of any live ones through
ordinary refuse disposal channels. • Never disconnect banana plug (1) till
deployment harness (A) is connected to
Airbag (inflator) module / seat belt pretensioner can be vehicle battery as static may cause
deployed / activated inside or outside the vehicle. accidental deployment of airbag.
Deployment / Activation method depends upon final
disposition of vehicle. Review the following instructions
to determine which method will work best in a given
situation.
Deployment / Activation Outside the Vehicle: When you
intend to return vehicle to service, deploy airbag (inflator)
module(s) and/or activate seat belt pretensioner(s)
outside the vehicle.
Deployment / Activation Inside the Vehicle: When
vehicle will be destroyed or salvaged for component
parts, deploy airbag module(s) and/or activate seat belt
pretensioner(s) installed on vehicle.
 Air Bag System: 8B-65

• Check that there is no open, short or 3) Connect deployment harness (A) and adapter cable
damage in deployment harness and (B) to driver airbag (inflator) module.
adapter cable of special tool.
Special tool
Special tool (A): 09932M75032
(A): 09932M75032 (B): 09932M76510

(A)

1
I8G001821052-01

Deployment / Activation Outside the Vehicle

Removal
Remove airbag (inflator) module or seat belt 1 (B)
pretensioner from vehicle.
(A)
• Driver airbag (inflator) module: (Page 8B-59)
I9P60A820084-01
• Passenger airbag (inflator) module (4-channel airbag 1. Banana plug
system): (Page 8B-61)
• Seat belt pretensioner (4-channel airbag system): Passenger airbag (inflator) module (4-channel airbag
(Page 8A-5) system)
1) Turn deployment surface upward and tighten to
Setting deployment fixture (A) to specified torque using
Driver airbag (inflator) module passenger airbag (inflator) module bolt.
1) Clear space (3) on ground about 185 cm (6.1 ft) in
diameter where driver airbag (inflator) module (1) is Special tool
set for deployment. Paved and outdoor location (A): 09932M75041
where there is no activity is preferred. If outdoor Tightening torque
location is not available, use space on shop floor Passenger airbag (inflator) module bolt (a): 23
where there is no activity and sufficient ventilation is N·m (2.3 kgf-m, 17.0 lbf-ft)
provided.
Check that no loose or flammable object exists [a]
within deployment area.
2) Place driver airbag (inflator) module with its vinyl trim 1
cover facing up (2) on ground in Step 1).

2 (a)

1 (A)

IJCA0A820034-01

[a]: Airbag deployment direction

1. Passenger airbag (inflator) module

I9P60A820083-01
8B-66 Air Bag System:

2) Connect deployment harness (A) and adapter cable 4) Tie seat belt pretensioner with wire harness (1) to
(B) to passenger airbag (inflator) module. tire at least 3 times as shown.
Special tool Wire harness section
(A): 09932M75032 1.25 mm2 (0.0019 in.2 or more)
(B): 09932M76510

(A)
(B)
1
1
IFRA0A820061-01

5) Connect deployment harness (A) and adapter cable

(B) to seat belt pretensioner.
IJCA0A820035-01

1. Banana plug Special tool

(A): 09932M75032
Retractor pretensioner (4-channel airbag system) (B): 09932M76510
1) Cut webbing (1) at tongue plate stopper (2) of seat (B)
belt pretensioner (3) side as shown.
2) Remove tongue plate (4) and shoulder anchor (5)
from webbing.
(A)

3
5
4
1 2

1
IFRA0A820062-01

1. Banana plug

IFRA0A820059-01

3) Hold seat belt pretensioner (1) vertically, tie webbing

(2) tightly at 10 cm (3.9 in.) from cutting edge as
shown.

2 “a”

IFRA0A820060-01

“a”: 10 cm (3.9 in.)

 Air Bag System: 8B-67

6) Pile 3 tires (2) and wheel-installed tire (1) on top of ! WARNING

tire with seat belt pretensioner, and tie them with
wire harness (3) as shown. Failure to take proper precautions when
handling a deployed airbag and/or activated
Special tool
seat belt pretensioner may result in a fire,
(A): 09932M75032
personal injury or health problems.
(B): 09932M76510
• Wait for at least 30 minutes before
touching any metal surface of an activated
1 airbag (inflator) module / seat belt
pretensioner.
• Leave airbag (inflator) module / seat belt
3 pretensioner for 30 minutes or more after
deployment / activation to prevent
2 accident due to remaining heat. After
checking that airbag (inflator) module /
seat belt pretensioner has got cold,
dispose of it.
(B)
• Do not place an activated airbag (inflator)
module / seat belt pretensioner near any
1 flammable objects because it is hot
enough to start a fire.
• Do not pour water, oil, etc. over an airbag
(inflator) module / seat belt pretensioner
(A) immediately after its activation.
4
• Follow all of the procedures described in
this section.
IFRA0A820063-01

4. Banana plug
7) Drape blanket over those tires.
Deployment
1) Clear space (4) on ground about 185 cm (6.1 ft) in
diameter where airbag (inflator) module or seat belt
pretensioner is set for deployment. Paved and
outdoor location where there is no activity is
preferred. If outdoor location is not available, use
space on shop floor where there is no activity and
sufficient ventilation is provided.
Check that no loose or flammable object exists
within deployment area.
2) Stretch deployment harness (A) from airbag (inflator)
module or seat belt pretensioner to its full length 10
m (33 ft).
Special tool
(A): 09932M75032
(B): 09932M76510
3) Place 12 V vehicle battery (1) near the shorted end
of deployment harness (A).
4) Check that area around airbag (inflator) module or
seat belt pretensioner is clear of all people and loose
or flammable objects.
5) Separate two banana plugs (2) on deployment
harness.
6) Connect deployment harness to 12 V vehicle battery.
NOTE
• When airbag (inflator) module deploys and
seat belt pretensioner activates, rapid gas
expansion will create substantial report.
Wear suitable ear protection. Notify all
people in immediate area that you intend
to deploy airbag (inflator) module or
activate seat belt pretensioner and suitable
ear protection should be worn.
• When driver airbag (inflator) module
deploys, driver airbag (inflator) module
may jump about 30 cm (1.0 ft) vertically.
This is normal reaction to force of rapid
gas expansion inside of drive airbag
(inflator) module.
• After airbag (inflator) module has been
deployed, surface of airbag (inflator) may
contain powdery residue. This powder
consists primarily of cornstarch (used to
lubricate bag (inflator) as it inflates) and
by-products of chemical reaction.
8B-68 Air Bag System:

7) Put on safety glasses (1) and pair of shop gloves (2)

to protect your eyes and hands from possible
4 irritation and heat when handling deployed airbag
(inflator) module or activated seat belt pretensioner.
8) Dispose of deployed airbag (inflator) module or
activated seat belt pretensioner through normal
(A) (B)
refuse channels after it has cooled for at least 30
minutes and tightly seal airbag (inflator) module or
“a”
seat belt pretensioner in strong vinyl bag.
2 4
1

1
2
(A)

(B)

“a”
3
2
1
4

I8T201821025-01
(B)
9) Wash your hands with mild soap and water.
(A)
Deployment / Activation Inside the Vehicle
1) Place vehicle on safe place and fully close all
“a” windows.

2 ! CAUTION
1