2022 K12N Baleno 99500M55T00-74E-V1

00
TABLE OF CONTENTS
Precautions............................................................... 00-i Transmission / Transaxle .......................................... 5-i

Precautions ............................................................ 00-1 Precautions .............................................................. 5-1 1
Manual Transmission/Transaxle ............................5B-1
General Information ................................................... 0-i Clutch .....................................................................5C-1
General Information ............................................... 0A-1 Automated Manual Transaxle ................................5D-1
Maintenance and Lubrication ................................. 0B-1
Steering ....................................................................... 6-i 2
Engine ......................................................................... 1-i Precautions .............................................................. 6-1
Precautions .............................................................. 1-1 Steering General Diagnosis ...................................6A-1
Engine General Information and Diagnosis ........... 1A-1 Steering Wheel and Column ..................................6B-1
Aux. Emission Control Devices .............................. 1B-1 Power Assisted Steering System ...........................6C-1
Engine Electrical Devices.......................................1C-1 3
Engine Mechanical.................................................1D-1 HVAC ........................................................................... 7-i
Engine Lubrication System .................................... 1E-1 Precautions .............................................................. 7-1
Engine Cooling System.......................................... 1F-1 HVAC System ........................................................7B-1
Fuel System ...........................................................1G-1
Restraint...................................................................... 8-i 4
Ignition System.......................................................1H-1
Starting System....................................................... 1I-1 Precautions .............................................................. 8-1
Charging System.....................................................1J-1 Seat Belts...............................................................8A-1
Exhaust System ..................................................... 1K-1 Air Bag System ......................................................8B-1
Suspension................................................................. 2-i Body, Cab and Accessories ...................................... 9-i 5

Precautions .............................................................. 2-1 Precautions .............................................................. 9-1
Suspension General Diagnosis.............................. 2A-1 Wiring Systems ......................................................9A-1
Front Suspension ................................................... 2B-1 Lighting Systems....................................................9B-1
Rear Suspension....................................................2C-1 Instrumentation / Driver Info. / Horn .......................9C-1
Wheels and Tires ...................................................2D-1 Wipers / Washers ...................................................9D-1 6
Glass / Windows / Mirrors ......................................9E-1
Driveline / Axle ........................................................... 3-i Security and Locks................................................. 9F-1
Precautions .............................................................. 3-1 Seats ..................................................................... 9G-1
Drive Shaft / Axle ................................................... 3A-1 Exterior Trim / Interior Trim ....................................9H-1
Hood / Fenders / Doors.......................................... 9J-1 7
Brakes ......................................................................... 4-i Body Structure .......................................................9K-1
Precautions .............................................................. 4-1 Paint / Coatings ...................................................... 9L-1
Brake Control System and Diagnosis .................... 4A-1 Audio Visual / Navigation ...................................... 9O-1
Front Brakes........................................................... 4B-1
Rear Brakes ...........................................................4C-1 Control Systems....................................................... 10-i 8
Parking Brake.........................................................4D-1 Precautions ............................................................ 10-1
ABS ........................................................................ 4E-1 Cruise Control System .........................................10A-1
Electronic Stability Program ................................... 4F-1 Body Electrical Control System ............................10B-1
Immobilizer Control System .................................10C-1
Keyless Start System ...........................................10E-1 9
Communication System .......................................10H-1
Engine Auto Stop Start System............................. 10I-1
10
Table of Contents 00- i
Section 00
00
Precautions
CONTENTS
Precautions ...............................................00-1 Precautions for Vehicle Equipped with ESP®

Precautions........................................................... 00-1 System .............................................................. 00-7
General Precautions ........................................... 00-1 Warning for Air Bag............................................. 00-7
Precautions for Electrical Circuit Service ............ 00-3 Warning for Vehicle Equipped with
Precautions for Electrical System Work .............. 00-5 Supplemental Restraint (Air Bag) System......... 00-7
Caution for Fastener ........................................... 00-6 Precautions for Installing Mobile
Warning for ENG A-STOP System ..................... 00-6 Communication Equipment ............................. 00-10
Precautions for Catalytic Converter .................... 00-6 Caution for Vehicles Equipped with DCM ......... 00-10
Caution for Suspension....................................... 00-6 Repair Instructions ............................................ 00-11
Warning for Wheel and Tire ................................ 00-6 Electrical Circuit Inspection Procedure ............. 00-11
Warning for Brake ............................................... 00-7 Intermittent Connection and Poor Contact
Warning for P/S System...................................... 00-7 Inspection........................................................ 00-13
00-1 Precautions:
Precautions
Precautions
Precautions
General Precautions • Do not swallow any service materials.
AENNTA0E0000001 (01(01) 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. • When washing the vehicle or cleaning the engine
• If the service work being performed compartment, do not allow water to contact the engine
requires running the engine, check that the opening and electrical components (including
parking brake is fully set, block drive electronic parts such as ECU, sensors, etc.).
wheels and the transaxle is in “Neutral” or Otherwise poor engine starting and electrical device
“N” range. malfunction might be caused.
Also keep hands, hair, clothing, tools, etc. • Before starting any service work, cover fenders, seats
away from the fan and belts while the and any other parts that are likely to get scratched or
engine is running. stained during servicing. Also, be aware that what you
• When running the engine indoors, provide wear (e.g. buttons) may cause damage to the
a means to force exhaust gases outdoors. vehicle’s finish.
• 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-
ventilated area.
• 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
I2RH01010025-01
oil. Prolonged contact with used engine oil
has been proven to cause skin cancer in • When performing service to electrical parts that does
laboratory animals. Brief contact with used not require use of battery power, disconnect negative
oil may irritate the skin. To minimize (–) cable at battery.
exposure to used engine oil, wear a long- • Before disconnecting the negative (–) cable at the
sleeve shirt and moisture-proof gloves battery or after connecting the cable to the battery,
(such as dish washing gloves) when perform the procedure, referring to “Precautions for
changing engine oil. If engine oil contacts Electrical System Work”.
your skin, wash thoroughly with soap and • When removing the battery, disconnect the negative
water. Launder any clothing or rags if wet (–) cable first and then the positive (+) cable. When
with oil. Recycle or properly dispose of reconnecting the battery, connect the positive (+)
used oil and filters. cable first and then the negative (–) cable. Reinstall
• Whenever handling service materials, wear the terminal cover.
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.
Precautions: 00-2
Special tool
(A): 09917MXXXXX
(B): 09916MXXXXX
I2RH01010027-01
• When removing parts that are to be reused, keep

them arranged in an orderly manner so that they can
I2RH01010031-01
be reinstalled in the proper order and into the correct
positions. • After servicing any system that is concerned with fuel,
oil, coolant, vacuum, exhaust gases or brakes, check
all related lines for leakage.
I5RW0A000002-01
• Do not reuse oil seals, gaskets, packing, O-rings, lock

washers, split pins, self-locking nuts, and other
specified parts, but use new ones. Also, before I2RH01010033-01
installing new gaskets, packing, etc., remove any
• Never disconnect any of the fuel lines between fuel
residual material from the mating surfaces.
pump and injectors without first releasing the fuel
pressure, or fuel can be sprayed out under pressure.
• When performing any work that produces a heat
exceeding 80 °C (176 °F) in the vicinity of the
electrical parts, remove the heat-sensitive electrical
part(s) beforehand.
IDL10A000002-01
• 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
I2RH01010034-01
No.XXXXX)
• Do not expose connectors and electrical parts to
“A” water, which will cause trouble to electrical systems.
I5RS0B150012-01
• Use special tools when instructed.

00-3 Precautions:
I2RH01010040-01
I2RH01010035-01
• When connecting male and female connectors, also
• Do not handle electrical components (computers, hold connectors and put them together until they lock
relays, etc.) in a rough manner or drop them. securely (a click is heard).
I2RH01010041-01
I2RH01010036-01
• When installing a wiring harness, secure it with
clamps so that no slack is left.
Precautions for Electrical Circuit Service
AENNTA0E0000002 (01(01)
• When replacing a fuse, use a fuse of the specified
capacity. Use of a fuse with a larger capacity will
cause a damage to electrical parts and a fire.
I2RH01010042-01
• When installing vehicle parts, check that they do not

interfere with any wiring harness and they do not
catch any wiring harness under them.
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. I2RH01010043-01
– Ignition power supply: Set ignition “OFF”. • Protect the part of harness which may touch any edge
• When disconnecting connectors, never pull on the by wrapping it with tape or the like.
wiring harness. Unlock the connector lock first and
then pull the male and female connectors apart by
holding them.
Precautions: 00-4
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).
I2RH01010044-01
• Be careful not to touch the electrical terminals of parts

which use microcomputers (e.g. electronic control unit
such as ECM, P/S control module, etc.) and sensors
(e.g. temperature sensor, pressure sensor, speed
sensor, angle sensor, yaw rate / g sensor, etc. ).
The static electricity from your body can damage
these parts. 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.
IMTA0A000001-01 IAW101000003-01
• When reverse voltage or overvoltage is input, sensor • When checking connection of terminals, check male
or actuator (1) may be damaged. terminals for bend, female terminals for excessive
Do not input reverse voltage or overvoltage to sensor opening, and both for locking (looseness), corrosion,
or actuator. dust, etc.
• Before measuring voltage at each terminal, check that
battery voltage is 12 V or more. Terminal voltage
1 1 check at low battery voltage will lead to erroneous
results.
5V
2 2
12V 12V
IMTA0A000002-01
• Never connect any tester (voltmeter, ohmmeter or

whatever) to terminals of an electronic control unit
I2RH01010048-01
when its connector is disconnected. Doing so may
cause damage to the electronic control unit. • For the details of the names and installation positions
• Never connect an ohmmeter to an electronic control of relays and circuit fuses described in this manual,
unit with its connector connected to it. Doing so may refer to:
cause damage to electronic control unit and sensors. – “Fuses and the Protected Parts” in Section 9A
• Use only the specified voltmeter / ohmmeter. – “J/B Connector Layout” in Section 9A
Otherwise, accurate measurements may not be
obtained or personal injury may result. Where no Wire Color
• On some connectors, some different circuits use the
same wire color.
00-5 Precautions:
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
Precautions for Electrical System Work

AENNTA0E0000003 (01(01)
Disconnect the negative cable from the battery before
[b] performing electrical work such as disconnecting the
connector.
[a] ! CAUTION
IAP70P000003-01
• If aluminum wire of lavender (LVN) color comes in If the electrical system is operated without
direct contact with copper wire, it may result in non- removing the negative cable of the battery,
continuity, heat generation or vehicle fire hazard due parts, harnesses, connectors, etc. may be
to corrosion. Never let aluminum wire come in direct burned due to a short circuit in the electrical
contact with copper wire. system. Always disconnect the negative
cable from the battery before performing any
• Never attempt to repair aluminum wire. In case of
electrical work.
defect in aluminum wire, replace defective wiring
harness completely.
NOTE
Terminal Number • Disconnecting negative cable of the
With some connectors, the numbers are molded into the battery may erase DTC, audio memory, and
connector. However, the numbers may not mean the other data stored in some controllers.
terminal numbers which represent the terminal position Before disconnecting the negative cable
described in this manual. from the battery, perform the following
Do not refer to the numbers on the connector for the operations:.
terminal numbers.
– Check the DTC for each controller.
Twist Pair Wire Harness – Keep notes to restore audio memory,
etc.
NOTE – Record displayed contents of the clock,
For locations where twist pair wire harness audio system, etc. before disconnecting
are used, refer to “System Circuit Diagram” to be able to restore the original settings
in Section 9A. after connecting the cable.
• A twist (1) in the twist pair wire harnesses except

around the connectors (2) should be within 100 mm
(3.9 in.). Excessively-loose lines can be affected by
electric noise.
Precautions: 00-6
– Perform electric throttle control system ! WARNING

calibration referring to “Electric Throttle
Control System Calibration” in Section There is a risk of personal injury due to the
1C after reconnecting the negative (–) accidental engine starting if the service work
cable at the battery. is performed while the ENG A-STOP OFF
– For power window model, perform switch turns off, i.e. the ENG A-STOP
power window system initialization warning light does not light.
referring to “Power Window System Turn on the ENG A-STOP OFF switch and
Initialization / Reset (Driver Side Only)” check that the ENG A-STOP warning light
in Section 9E after reconnecting the lights before the service work, except when
negative (–) cable at the battery. the service manual instructs to turn it off.
• Connect the negative cable of the battery
only when the diagnosis or the inspection Precautions for Catalytic Converter
procedure requires negative cable AENNTA0E0000006 (01(01)
connection such as ignition ON. If there is As this vehicle equipped with a catalytic converter, use
an instruction to turn off the ignition, be only unleaded gasoline and be careful not to let a large
sure to disconnect the negative cable of amount of unburned gasoline enter the converter, or it
the battery after turning off the ignition. can be damaged.
• To disconnect the negative cable of the • Conduct a spark jump test only when necessary to the
battery, perform the following procedure:. shortest possible time without opening the throttle.
1) Turn off the ignition. • Conduct engine compression checks within the
2) Disconnect the negative cable from the shortest possible time.
battery. • Avoid any situations which can result in engine misfire
• If you are connecting a negative cable to (e.g. starting the engine when the fuel tank is nearly
the battery, perform the following empty.)
procedure:.
1) Connect the negative cable securely to Caution for Suspension
the battery. AENNTA0E0000007 (01(01)
2) Tighten the battery cable nut with the ! CAUTION
specified torque. “Battery Removal and
Failure to use proper suspension fasteners
Installation” in Section 1J
or to perform proper maintenance / repair of
suspension components can cause unsafe
Caution for Fastener operating conditions.
AENNTA0E0000004 (01(01)
NOTICE • Replace suspension fasteners only with
fasteners having the same part number or
Failure to use correct fasteners or to properly their equivalent. Do not use replacement
use fasteners can cause parts or system parts of lesser quality or substitute design.
damage.
• Observe the specified torque for each
• When fasteners are removed, always fastener to assure proper retention of
reinstall them at the locations from which components.
they were removed.
• Never repair any suspension part using
• All fasteners must be replaced with heating, quenching, or straightening.
fasteners having the same part number. If a Instead, replace the part with a new one.
fastener of the correct part number is not
available, a fastener of the same size
having equal or higher strength may be Warning for Wheel and Tire
AENNTA0E0000008 (01(01)
used.
• This manual identifies and indicates
! WARNING
special conditions for all non-reusable Failure to use proper wheel fasteners or to
fasteners and fasteners requiring the use perform proper maintenance / repair of
of thread-locking compound. Follow all wheels can cause unsafe operating
instructions, including torque. conditions.
• Replace wheel fasteners only with
Warning for ENG A-STOP System fasteners having the same part number or
AENNTA0E0000005 (01(01) their equivalent. Do not use replacement
parts of lesser quality or substitute design.
00-7 Precautions:
• Tighten wheel fasteners to specified ESP® Control Module

torque to assure proper retention of • When ESP® control module is removed / installed, do
wheels. not use an impact wrench, as shock it generates may
• Never repair any wheel by welding. damage the sensors in the ESP® control module.
Excessive heat caused by welding may After performing any of the following
damage the wheel. operations,calibrate the steering angle sensor
referring to “Sensor Calibration” in Section 4F.
– Replacement of steering angle sensor
Warning for Brake
AENNTA0E0000009 (01(01) – Replacement of ESP® control module
! WARNING
Warning for Air Bag
Failure to use proper brake fasteners or to AENNTA0E0000012 (01(01)
perform proper maintenance / repair of brake ! WARNING
components can cause unsafe operating
conditions. Failure to take proper precautions when
• Replace brake fasteners only with performing service on or around the air bag
fasteners having the same part number or system components or wiring could cause
their equivalent. Do not use replacement accidental activation of the air bag system or
parts of lesser quality or substitute design. render the system inoperative. Either of
these may lead to personal injury.
• Observe the specified torque when
tightening brake fasteners to assure • Only an authorized SUZUKI dealer should
proper retention of brake parts. perform service on or around the air bag
system components or wiring. Refer to
• Never repair any part by welding.
“Air Bag System Component, Wiring and
Excessive heat caused by welding may
Connector Location”: 4-Channel in Section
damage brake components.
8B or “Air Bag System Component, Wiring
and Connector Location”: 8-Channel in
Warning for P/S System Section 8B to check whether you are
AENNTA0E0000010 (01(01) performing service on or near the air bag
! WARNING system components or wiring.
• Read and understand all “WARNING”s and
Failure to use proper steering gear fasteners
“Precautions for Air Bag System Service”:
or to perform proper maintenance / repair of
4-Channel in Section 8B or “Precautions
steering components can cause unsafe
for Air Bag System Service”: 8-Channel in
operating conditions.
Section 8B before performing service on or
• Replace steering gear fasteners only with around the air bag system components or
fasteners having the same part number or wiring.
their equivalent. Do not use replacement
• All service work must be started at least 90
parts of lesser quality or substitute design.
seconds after the ignition has been set
• Observe the specified torque for each “OFF” and the negative (–) cable has been
fastener to assure proper retention of disconnected from the battery. Otherwise,
components. the air bag system may be activated by
reserve energy stored in the Sensing and
Diagnostic Module (SDM).
Precautions for Vehicle Equipped with ESP®
System
AENNTA0E0000011 (01(01)
• When testing an ESP® system equipped vehicle with Warning for Vehicle Equipped with
any of the following or similar equipment by rotating Supplemental Restraint (Air Bag) System
AENNTA0E0000013 (01(01)
wheels (tires) under vehicle stop condition, deactivate
ESP® system referring to “Test with Speedometer ! WARNING
Tester or Other Equipment” in Section 4F. Failure to follow the proper procedures when
– 2 or 4-wheel chassis dynamometer servicing (removing, reinstalling and
– Speedometer tester checking) any of air bag system components
– Brake tester could result in personal injury due to
accidental air bag activation, damage to
components, or non-activation of the air bag
system in the event of a collision.
Precautions: 00-8
• 4-channel air bag model: (Air Bag System

Component, Wiring and Connector
Location): 4-Channel in Section 8B
• 8-channel air bag model: (Air Bag System
Component, Wiring and Connector
Location): 8-Channel in Section 8B
When servicing any of the air bag
components, take the following precautions:
• Follow the procedures described in
“Precautions for Air Bag System Service”:
4-Channel in Section 8B or “Precautions
for Air Bag System Service”: 8-Channel in
Section 8B.
• If the air bag system and another vehicle IAP70P821001-01
system both require repair, repairing the
other system prior to the air bag system
may increase the chance of unintended Servicing and Handling
activation of the air bag system and
! WARNING
possible personal injury. SUZUKI
recommends that the air bag system be Failure to take proper precautions when
repaired first. servicing and handling air bag (inflator)
• Modifying any parts supporting or modules can cause accidental triggering of
surrounding the air bag system the inflator, which can result in severe
components can adversely affect the personal injury.
performance of the system and lead to • Always disconnect the “A/B” fuse and air
personal injury. bag (inflator) modules from the initiator
Do not modify the steering wheel, circuit when instructed in any service
dashboard or any other parts that are near procedure.
the air bag system components. • Handle and store a live (non-deployed) air
• High temperatures over 93 °C (200 °F) may bag (inflator) module in a dry place where
activate the air bag system or damage its the ambient temperature is below 65 °C
components. (150 °F), and there are no electric noise
Before performing paint baking or other sources.
operations that involve high temperatures, • Always carry a live air bag (inflator)
remove the air bag system components module with the air bag’s opening pointing
from the vehicle and place them in an area away from you. Doing so will help reduce
away from the area where such operations the chance of injury in case of an
are to be performed. accidental deployment of the air bag.
• Never carry a live air bag (inflator) module
by its wires or connector.
Diagnosis
• Always place a live air bag (inflator)
• When troubleshooting the air bag system, follow “Air
module on a bench or other surface with
Bag Diagnostic System Check”: 4-Channel in Section
the bag side facing up to keep it away from
8B or “Air Bag Diagnostic System Check”: 8-Channel
the surface.
in Section 8B. Bypassing these procedures may result
in extended diagnostic time, incorrect diagnosis, and • Do not place anything including another
incorrect replacement of parts. air bag (inflator) module on top of an air
bag (inflator) module. Allowing for a free
• Never use electrical test equipment other than that
space above the module is essential to
specified.
minimize the risk of personal injury in the
! WARNING event of accidental deployment of the air
bag (inflator) module.
Measuring the resistance of any air bag • Never dispose of any live air bag (inflator)
(inflator) module or any seat belt module. Before disposing of any live air
pretensioner with a tester is dangerous, as bag (inflator) module, deploy it according
the electric current from the tester may to the applicable procedure described in
trigger the air bag or pretensioner. “Air Bag (Inflator) Module and Seat Belt
Never measure the resistance of an air bag Pretensioner Disposal”: 4-Channel in
(inflator) module or seat belt pretensioner.
00-9 Precautions:
Section 8B or “Air Bag (Inflator) Module • Never power the air bag system when the
and Seat Belt Pretensioner Disposal”: 8- SDM is not rigidly attached to the vehicle.
Channel in Section 8B. Unless all fasteners of the SDM mounting
• The air bag (inflator) module is very hot bracket are firmly tightened and the arrow
immediately after deployment. Wait for at points toward the front of the vehicle, the
least half an hour to let it cool down before SDM could be accidentally activated when
proceeding to the next step. the air bag system is powered, possibly
causing the air bags to deploy.
• After deployment of an air bag (inflator)
module, there will be a powdery substance
remaining on its surface. This substance ! WARNING
consists primarily of cornstarch that is
Driver and Passenger Seat Belt
used to lubricate the bag as it inflates and
Pretensioners
by-products of a chemical reaction. Like
with many other service procedures, wear
servicing and handling the seat belt
gloves and safety glasses to protect the
pretensioners can cause accidental
skin and eyes when handling a deployed
triggering of the pretensioners, which can
air bag (inflator) module.
result in severe personal injury.
[A] • Always disconnect the “A/B” fuse and air
bag (inflator) modules 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
[B]
(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
:[C]
IBP80A000002-01 similar surface. Any objects on top of the
pretensioner can increase the risk of
[A]: Always carry air bag (inflator) module with trim cover (air bag opening)
away from body. personal injury in the event of accidental
[B]: Always place air bag (inflator) module on workbench with trim cover activation.
(air bag opening) up, away from loose objects.
[C]: Air bag deployment direction
• Never dispose of a live pretensioner.
Before disposing of a live pretensioner,
activate it according to the applicable
procedure described in “Air Bag (Inflator)
! WARNING Module and Seat Belt Pretensioner
SDM Disposal”: 4-Channel in Section 8B or “Air
Failure to take proper precautions when Bag (Inflator) Module and Seat Belt
servicing and handling the Sensing and Pretensioner Disposal”: 8-Channel in
Diagnostic Module (SDM) can cause Section 8B.
accidental triggering of the inflator, which • The seat belt pretensioner is very hot
can result in severe personal injury. immediately after activation. Wait for at
• Always disconnect the “A/B” fuse and air least half an hour to let it cool down before
bag (inflator) modules from the initiator proceeding to the next step.
circuit when instructed in any service • Like with many other service procedures,
procedure. wear gloves and safety glasses when
• Handle and store an SDM in a dry place handling pretensioners to protect the skin
where the ambient temperature is below 65 and eyes.
°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.
Precautions: 00-10
NOTICE • Never expose the air bag system

Failure to take proper precautions when components to extremely hot air (i.e.,
servicing the air bag and seat belt placing the vehicle in an oven to dry it after
pretensioner systems may cause faulty painting).
operation or damage to components of the • WARNING / CAUTION labels are affixed to
systems. every air bag system component. Follow
• After any accident, even if it was not the instructions provided on them.
severe enough to cause deployment of the • After completing repairs on any air bag
air bags, check the air bag system and system component, perform the
other related components according to the procedures in “Air Bag Diagnostic System
instructions under “Repair and Inspection Check”: 4-Channel in Section 8B or “Air
Required after Accident”: 4-Channel in Bag Diagnostic System Check”: 8-Channel
Section 8B or “Repair and Inspection in Section 8B.
Required after Accident”: 8-Channel in
Section 8B.
• If any air bag system component is Precautions for Installing Mobile
impacted during service on other Communication Equipment
AENNTA0E0000014 (01(01)
components, remove the air bag system When installing mobile communication equipment such
component before continuing the service. as CB (citizen band) radio or cellular telephone, observe
• Carefully handle the following components the following precautions.
not to drop or otherwise impact them: the Failure to follow these cautions may adversely affect
air bag (inflator) modules; the seat belt electronic control system.
pretensioners; the forward sensor; and the • Keep the antenna as far away as possible from the
SDM. If any of these components receives vehicle’s electronic control unit.
an impact, never disassemble and repair it
• Keep the antenna feeder more than 20 cm (7.9 in.)
but replace it with new one.
away from any electronic control unit and its wire
• If any of the following components gets harnesses.
contaminated with such materials as
• Do not run the antenna feeder parallel with other wire
grease, cleaning solvents, oil or water,
harnesses.
wipe it clean with a dry cloth: the air bag
(inflator) modules and the seat belt • Check that the antenna and feeder are correctly
pretensioners. adjusted.
• The air bag harness is part of the main
harness, instrument panel harness and Caution for Vehicles Equipped with DCM
AENNTA0E0000015 (01(01)
floor harness. For easy identification, the When the DTC indicates a warning or performs an
connector-side of each air bag harness inspection/repair detected by DTC, false warning light
wire is covered with a yellow protection notification might be sent from DCM to SUZUKI
tube and each connector is yellow in color. CONNECT APP of user.
Handle the air bag harness wires and Before performing maintenance or repairing a vehicle
connectors very carefully. equipped with DCM, perform the following procedure so
• When an open wire or damaged connector that Suzuki Support will not misrecognize the DTC
/ terminal is found in the air bag harness, output.
replace the entire harness rather than • In accordance with the Suzuki scan tool diagnostic
replacing only the damaged wire or software instruction manual, select the system
connector/terminal. "Telematic System" and the utility name
• Apply power to the air bag system only "Communication Function Pause" on the utility screen
when all its components are connected or and press the "Start" button.
a diagnostic procedure requires it. Doing • Switch "Communication Function Pause [OFF]"
otherwise will set a DTC. displayed on the screen to [ON].
• Never use air bag system components After the vehicle has been repaired, the following
from another vehicle. operations must be carried out:.
• When doing any electric welding, • In accordance with the Suzuki scan tool diagnostic
temporarily disable the air bag system software instruction manual, select the system
referring to “Disabling Air Bag System”: 4- "Telematic System" and the utility name
Channel in Section 8B or “Disabling Air "Communication Function Pause" on the utility screen
Bag System”: 8-Channel in Section 8B. and press the "Start" button.
00-11 Precautions:
• Switch "Communication Function Pause [ON]" NOTE

displayed on the screen to [OFF]. If the Suzuki scan tool cannot be used,
disconnect the negative cable from the
battery when performing maintenance or
repair work in order to ensure that
communication with DCM is stopped.
Repair Instructions
Electrical Circuit Inspection Procedure
AENNTA0E0006001 (08(03)
While there are various electrical circuit inspection
methods, the following describes the general methods
using an ohmmeter and a voltmeter to check open and
short circuits.
Open Circuit Check

Possible causes for the open circuit are as listed below. I2RH01010050-01
As defects in connectors or terminals are most often the
1. Check contact tension by inserting and removing just once.
causes, they need to be checked particularly and
carefully.
4) Perform continuity test or voltage check using the
• Loose connection of connector
following procedure, to check the wire harness for
• Poor contact of terminal (caused by dirt, corrosion or open circuit and poor connection at its terminals.
rust on it, poor contact tension, entry of foreign object,
etc.)
• Open wire harness
When checking circuits including an electronic control
unit such as ECM, TCM, etc., it is important to carefully
perform check, starting with items which are easiest to
check.
I2RH01010051-01
1) Disconnect negative (–) cable at battery.
1. Looseness of crimping 3. Thin wire (single strand of wire)
2) Check connectors at both ends of the circuit being 2. Open
checked for loose connection. Also check lock
condition of connectors if equipped with connector Continuity Test
locks. 1) Measure resistance between connector terminals at
both ends of the circuit under test (between “A-1”
and “C-1” in the figure). If no continuity is indicated
(infinity or over limit), it means that the circuit is open
between terminals “A-1” and “C-1”.
I2RH01010049-01
3) Using a male terminal for test use, check terminals

on both ends of the circuit being checked for contact
tension of female terminals. Check each terminal
visually for cause of poor contact (dirt, corrosion,
rust, entry of foreign object, etc.). At the same time,
check that each terminal is held and locked in I2RH01010052-01
connector fully. 2) Disconnect the connector included in the circuit
(connector-B in the figure) and measure resistance
between terminals “A-1” and “B-1”.
Precautions: 00-12
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
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.
I5RH01000005-01
a) If measurements are taken as shown in figure
and results are as listed below, it means that the
Short Circuit Check (Wire Harness to Ground)
circuit is open between terminals “B-1” and “A-1”.
Voltage between
2) Disconnect connectors at both ends of the circuit to
“C-1” and ground: Approx. 5 V
be checked.
“B-1” and ground: Approx. 5 V
“A-1” and ground: 0 V NOTE
b) If measurements are as listed below, it means If the circuit to be checked is connected to
that there is an abnormally high resistance other parts (1), disconnect all connections to
causing the indicated voltage drop in the circuit these parts.
between terminals “A-1” and “B-1”. This is essential to having correct check
Voltage between results.
“C-1” and ground: Approx. 5 V
3) Measure resistance between the terminal at one end
“B-1” and ground: Approx. 5 V
of the circuit (“A-1” terminal in the figure) and
“A-1” and ground: Approx. 3 V
ground. If continuity is indicated, it means that the
circuit is shorted to ground between terminals “A-1”
and “C-1”.
00-13 Precautions:
• Damaged connector body, terminals exposed to

moisture and dirt, misalignment of terminals on
component or connector and mating connector.
I2RH01010057-02
• Improperly formed or damaged terminals.

Check each connector terminal in circuit with problem
for good contact tension using a corresponding test
terminal.
If contact tension is not enough, correct terminal
shape to increase contact tension or replace harness.
I5RH01000006-01
4) Disconnect the connector included in circuit

(connector-B) and measure resistance between “A-
1” and ground. If continuity is indicated, the circuit is
shorted to ground between terminals “A-1” and “B-
1”.
I5RH01000007-01
1. Check contact tension by inserting and removing just once.

2. Check each terminal for bend and proper alignment.
• Poor connection of terminal and wire.

I2RH01010056-01 Check each wire harness in circuit with problem for
1. To other parts poor connection by shaking it by hand lightly. If any
abnormal condition is found, repair or replace
Intermittent Connection and Poor Contact harness.
Inspection
AENNTA0E0006002 (08(03)
Most intermittent connections are caused by faulty
electrical connections or wiring, although a sticking relay
or solenoid can occasionally be a cause. When checking
connections, perform check of suspect circuit for:
• Poor mating of connector halves, or terminals not fully
seated in the connector body (backed out).
• Dirt or corrosion on the terminals. The terminals must
be clean and free of any foreign material which could I2RH01010059-01
impede proper terminal contact. However, cleaning
• Damaged wire insulation, causing intermittent short
the terminal with a sand paper or the like is prohibited.
circuit to other wiring or parts.
Precautions: 00-14
• 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
0
CONTENTS
General Information ................................ 0A-1 Fuel Tank, Cap Gasket and Fuel Line
General Description .............................................0A-1 Inspection..........................................................0B-4
Abbreviations ...................................................... 0A-1 Fuel Filter Replacement ......................................0B-4
ISO-to-SUZUKI Term .......................................... 0A-2 PCV Valve Inspection .........................................0B-4
Symbols .............................................................. 0A-4 Fuel Evaporative Emission Control System
Wire Color / Connector Color Symbols ............... 0A-5 Inspection..........................................................0B-4
Ignition Modes and Ignition Switch Positions ...... 0A-5 Brake Disc and Pad Inspection ...........................0B-4
Fasteners Information ......................................... 0A-5 Brake Drum and Shoe Inspection .......................0B-4
Vehicle Lifting Points........................................... 0A-7 Brake Hose and Pipe Inspection.........................0B-4
Vehicle Identification Number ........................... 0A-10 Brake Fluid Replacement....................................0B-5
Identification Plate............................................. 0A-10 Brake Pedal Inspection (M/T Model)...................0B-5
Engine Identification Number ............................ 0A-10 Brake Lever and Cable Inspection ......................0B-5
SUZUKI Scan Tool (Suzuki SDT-II) General Clutch Pedal Inspection (M/T Model) ..................0B-5
Description ...................................................... 0A-10 Clutch Fluid Inspection (M/T Model) ...................0B-5
Component Location .........................................0A-12 Clutch Fluid Replacement (M/T Model)...............0B-5
Warning, Caution and Information Location...... 0A-12 Tire Inspection.....................................................0B-5
Wheel Disc Inspection.........................................0B-6
Diagnostic Information and Procedures..........0A-14
Wheel Bearing Inspection ...................................0B-6
Suzuki SDT-II Connection and Disconnection .. 0A-14
Drive Shaft (Axle) Boot Inspection ......................0B-6
Special Tools and Equipment ...........................0A-15 Suspension System Inspection ...........................0B-6
Special Tool ...................................................... 0A-15 Steering System Inspection ................................0B-6
Manual Transaxle Oil Inspection (M/T Model) ....0B-7
Maintenance and Lubrication................. 0B-1 Manual Transaxle Oil Replacement (M/T
Scheduled Maintenance ......................................0B-1 Model) ...............................................................0B-7
Maintenance Schedule under Normal Driving Auto Gear Shift Actuator Oil Inspection (AGS
Conditions ......................................................... 0B-1 Model) ...............................................................0B-7
Repair Instructions ..............................................0B-3 Auto Gear Shift Oil Inspection (AGS Model) .......0B-7
Accessory Drive Belt Inspection.......................... 0B-3 Auto Gear Shift Oil Replacement (AGS
Accessory Drive Belt Replacement..................... 0B-3 Model) ...............................................................0B-7
Engine Oil and Filter Change .............................. 0B-3 All Latches, Hinges and Locks Inspection...........0B-7
Engine Coolant Change ...................................... 0B-3 HVAC Air Filter Inspection ..................................0B-7
Exhaust System Inspection................................. 0B-3 HVAC Air Filter Replacement..............................0B-8
Spark Plug Replacement .................................... 0B-4 Final Inspection for Maintenance Service ...........0B-8
Air Cleaner Filter Inspection................................ 0B-4 Special Tools and Equipment .............................0B-9
Air Cleaner Filter Replacement ........................... 0B-4 Recommended Fluids and Lubricants.................0B-9
0A-1 General Information:
General Information
General Information
General Description
Abbreviations EGT: Exhaust Gas Temperature
AENNTA0E0101001 (01(02) 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 HUD: Head-Up Display
BCM: Body electrical Control Module I:
BTDC: Before Top Dead Center IAC: Idle Air Control
B+: Battery Positive Voltage IAT: Intake Air Temperature
BB+: Battery Positive Voltage for Backup IMRC: Intake Manifold Runner Control
C: IMT: Intake Manifold Tuning
CAN: Controller Area Network ISC: Idle Speed Control
CKP: Crankshaft Position ISG: Integrated Starter Generator
CMP: Camshaft Position ISO: International Organization for Standardization
CO: Carbon Monoxide J:
CO2: Carbon Dioxide JIS: Japanese Industrial Standards
CPP: Clutch Pedal Position J/B: Junction Block
CPU: Central Processing Unit J/C: Junction Connector
CVT: Continuously Variable Transmission, L:
Continuously Variable Transaxle L: Left
D: LCD: Liquid Crystal Display
DC: Direct Current LED: Light Emitting Diode
D/C: Driving Cycle LHD: Left Hand Drive vehicle
DCM: Data Communication Module LIN: Local Interconnect Network
DLC: Data Link Connector LO: Low
DOHC: Double Over Head Camshaft LSD: Limited Slip Differential
DOJ: Double Offset Joint LSPV: Load Sensing Proportioning Valve
DOT: Department of Transportation M:
DPF®: Diesel Particulate Filter MAF: Mass Air Flow
DRL: Daytime Running Light
MAP: Manifold Absolute Pressure
DSBS: Dual Sensor Brake Support
Max: Maximum
DTC: Diagnostic Trouble Code (Diagnostic Code)
MFI: Multiport Fuel Injection
E:
Min: Minimum
EBD: Electronic Brake Force Distribution
MIL: Malfunction Indicator Lamp (“CHECK ENGINE”
ECM: Engine Control Module
Light or “SERVICE ENGINE SOON” Light)
ECT: Engine Coolant Temperature
M/T: Manual Transmission, Manual Transaxle
ECU: Electronic Control Unit
N:
EEPROM: Electrically Erasable Programmable Read
NOx: Nitrogen Oxides
Only Memory
O:
EFE Heater: Early Fuel Evaporation Heater
OBD: On-Board Diagnostic system
EGR: Exhaust Gas Recirculation
General Information: 0A-2
OCM: Occupant Classification Module TCC: Torque Converter Clutch

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 Matter 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:
ISO-to-SUZUKI Term
AENNTA0E0101002 (01(02)
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
ISO term
SUZUKI term
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
ISO term
SUZUKI term
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
Symbols
AENNTA0E0101003 (01(02)
Symbol Definition Symbol Definition
Tightening torque Apply SILICONE SEALANT
99000-31120
Apply oil (engine, transmission, transfer, Apply SEALING COMPOUND 366E
differential) 99000-31090
Apply fluid (brake, power steering or Apply THREAD LOCK 1322
automatic transmission fluid) 99000-32150
Apply ECSTAR GREASE A Apply THREAD LOCK 1333B
99000-25480 99000-32020
Apply ECSTAR GREASE C Apply THREAD LOCK 1342
99000-25490 99000-32050
Apply ECSTAR SUPER GREASE E Do not reuse
99000-25450
Apply ECSTAR GREASE H Note on reassembly
99000-25510
Apply SUZUKI SUPER GREASE I Alert
99000-25210
Apply SUZUKI BOND NO. 1215 Do not touch electricity
99000-31110
Symbol Definition Symbol Definition

Apply SUZUKI BOND NO. 1207F Do not repair or disassemble
99000-31250
Apply SUZUKI BOND NO. 1217G Refer to service manual or owner’s
99000-31260 manual
Apply SUZUKI BOND NO. 1216B Holding position with hands
99000-31230
Apply SUZUKI BOND NO. 1207B Inserting position of resin remover
99000-31140
Wire Color / Connector Color Symbols

AENNTA0E0101004 (01(02)
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
Metric Fasteners
Ignition Modes and Ignition Switch Positions Most of the fasteners used for this vehicle are JIS-
AENNTA0E0101005 (01(02) defined and ISO-defined metric fasteners. When
In this manual, each ignition switch position (models with replacing any fasteners, it is most important that
a conventional ignition switch system) and the replacement fasteners are of the correct diameter,
corresponding ignition mode (models with a keyless thread pitch and strength.
push start system) are indicated using the following
unified word / acronym preceded by “ignition”: START, NOTICE
ON, ACC or OFF (e.g. “ignition ON”) unless there is Combining male and female fasteners with
need to express it otherwise. different thread pitches will damage both
fasteners.
Fasteners Information It is important to note that, even when the
AENNTA0E0101006 (01(02)
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 head of each bolt. Some metric nuts have a inscribed
correct thread pitch and then, screw it in or number, 6 or 8 on their end surfaces. Figure shows
on the mating fastener by hand. If the different strength markings.
fastener is too tight to turn by hand, its When replacing metric fasteners, use bolts and nuts of
thread pitch may be different from that of the the same strength class as or higher class than the
mating fastener. original bolts and nuts. It is also important to select
replacement fasteners of the correct diameter and
JIS-to-ISO main fasteners comparison table thread pitch. Correct replacement bolts and nuts are
Nominal diameter available as SUZUKI spare parts.
M6 M8 M10 M12 M14 Metric bolts and nuts: Strength class numbers or marks
Thread pitch 1.0 1.25 1.25 1.25 1.5 (The larger the number, the greater the strength).
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
Fastener Strength Identification I5RH01010001-01

Most commonly used strength classes of metric 1. Nut strength identification
fasteners are 4T, 6.8, 7T and 8.8. Strength class is
indicated by a number or radial line(s) embossed on the
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
Thread diameter (Nominal diameter) (mm)

Strength Unit
4 5 6 8 10 12 14 16 18
Fastener of strength class equivalent to Nm 2.4 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
Vehicle Lifting Points

AENNTA0E0101007 (01(02)
! 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
When Using Frame Contact Hoist
[A] [B]
2 2
[F]
1
1
3
[a] “a”
IMTA0A010001-01
[A]: Front side [a]: Wheel center 2. Support position for frame contact hoist and safety stand
[B]: Rear side “a”: Approx. 900 – 940 mm (Approx. 35.5 – 3. Gravity center position without load in vehicle
37.0 in.)
[F]: Vehicle front 1. Floor jack position
When Using Floor Jack Front
! WARNING
Improperly raising only the front or rear of
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
1
safety stands. It is extremely dangerous to
IMTA0A010003-01
do any work on the vehicle supported by a
jack alone.
Rear
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.) 2
IMTA0A010004-01
Length “l”: above 900 mm (above 35.4 in.)
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
supported. Then check that vehicle body does not slide
on safety stands and the vehicle is held stable.
Front
“l”
“h”
I4RS0A010002-01
1
In raising front or rear vehicle end off the floor by jacking, IMTA0A010005-01
put the jack against front suspension frame (1) or rear
towing hook (2).
Rear
1
IMTA0A010006-02
Vehicle Identification Number

AENNTA0E0101008 (02(01)
The number (1) is inscribed on the right dash side of 2
front panel in engine compartment.
3
IMTA0A010008-01
Engine Identification Number

AENNTA0E0101010 (02(01)
The engine identification number is inscribed on cylinder
block.
1
IMTA0A010007-02
Identification Plate
AENNTA0E0101009 (02(01)
Identification plate (1) is installed at the center pillar
lower side on the left side body panel.
The identification plate has the following information:
• VIN (2)
• Engine type (3) IFRA0B010003-01
SUZUKI Scan Tool (Suzuki SDT-II) General Description

AENNTA0E0101011 (03(01)
Suzuki SDT-II Description
SUZUKI scan tool (1) is a diagnostic tester carrying out two-way communications with ECUs (Electronic Control Units)
(2) – (4).
9 6
7
10
8
2 3 4
IK4J0A010010-01
5. Vehicle 7. Serial communication line 9. Two-way communications (Communication speed 10.4 kbps)
6. DLC 8. CAN communication line 10. Two-way communications (Communication speed 500 kbps)
For communication between ECU on vehicle and SUZUKI scan tool, CAN (controller area network) and serial
transmission are adopted. These communication systems conform to ISO (International Organization for
Standardization).
NOTE
Depending on vehicle specifications and equipment, serial communication line (7) may not be
equipped.
Suzuki SDT-II Function
NOTE
• For details of SUZUKI scan tool function, refer to the instruction manual.
• DTCs shown on SUZUKI scan tool conform to SAE (Society of Automotive Engineers).
Software function Contents

Vehicle Health Possible to display and save DTC of each system, software ID and software version
information.
Communication Bus Check Possible to detect malfunction related to CAN bus.
DTC Possible to display, save and clear current, history and undetermined codes, and
freeze frame data.
Data List Possible to display and save ECU data.
Active Test Possible to operate actuators forcedly.
Utility Possible to configure initial setting, change configuration and actuate various
operations necessary for ECU.
Data Recorder VCI (Vehicle Communication Interface) itself can save ECU data.
Diagnosis Report Possible to display, print and save DTC list of each system and ECU data.
Operation Log Possible to display history of various diagnostic data saved while diagnosing.
DLC Description
[a]
[A] G211
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
IA1J0P010012-01
[A]: G211 connector (View: [a])
Terminal No. Symbol Function

G211-4 CGND Chassis ground
G211-5 SGND Signal ground
G211-6 CANH CAN (high) communication
G211-7 SDL Serial communication (if equipped)
G211-14 CANL CAN (low) communication
G211-16 BAT B + (Continuous battery power)
Component Location
Warning, Caution and Information Location
AENNTA0E0103001 (04(01)
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.
IMTA0A010012-02
1. Battery label 4. Steering shaft joint cover label

2. Radiator cap label 5. Jack label
3. Engine cooling fan label 6. Compact spare tire label
[A]
1 2
3
4 6
8
IMTA0A010013-03
1. Air bag label on driver air bag (inflator) module 4. Air bag label on side-air bag (inflator) module 7. Pretensioner label on seat belt retractor
2. Air bag label on contact coil assembly 5. Air bag label on curtain air bag (inflator) 8. Side/Curtain air bag label on pillar (both
module right and left sides)
3. Air bag label on passenger air bag (inflator) module 6. Air bag label on SDM 9. Air bag label on sun visor
Diagnostic Information and Procedures

Suzuki SDT-II Connection and Disconnection NOTE
AENNTA0E0104001 (06(01)
If communication between SUZUKI scan tool
1) Set ignition “OFF”.
and ECU is not possible, perform the
2) Connect SUZUKI scan tool to DLC (1). following checks:
Special tool • Check communication condition between
(A): SUZUKI scan tool (Suzuki SDT-II) PC and VCI (2) using SUZUKI scan tool
function.
3) Set ignition “ON”.
• Check DLC power circuit and ground
4) Start SUZUKI scan tool and perform necessary
circuit.
operations.
• Check DLC cable. If necessary, check DLC
cable by substituting a known-good DLC
cable.
• Check CAN communication system.

(“Control Module Communication Bus Off” (A)
is detected in any ECU.) (Troubleshooting

for Communication Bus Off): CAN in 2
Section 10H
• Check ECU power circuit and ground
circuit.
• Current DTCs cannot be cleared as long as
current trouble is present.
• Solve the trouble and check that the
system is normal condition referring to
“Fail-safe cancel condition”. Clear DTCs 1
after changing current DTCs to history IMTA0A010010-01
DTCs.
5) After completing the check, set ignition “OFF” and
disconnect SUZUKI scan tool from DLC.
Special Tools and Equipment

Special Tool
AENNTA0E0108001 (11(s)
SUZUKI scan tool (Suzuki
SDT-II)
—
(L0A001)
Maintenance and Lubrication: 0B-1
Maintenance and Lubrication

General Information
Scheduled Maintenance
Maintenance Schedule under Normal Driving Conditions
AENNTA0E0205001 (07(01)
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 (Wear) (I: (Accessory Drive
Belt Inspection), R: (Accessory Drive Belt — — I I I I I I I R
Replacement))
Engine coolant (level, leakage) (R: (Engine
I I I R I R I R I R
Coolant Change))
Engine oil, engine oil filter and drain plug gasket
I I R R R R R R R R
(R: (Engine Oil and Filter Change))
Cooling system hoses and connections (Leakage
I I I I I I I I I I
and Damage)
Engine mounting and manifold fixing (Loose
— — I — I — I — I —
Damage)
Exhaust system (noise, leakage, etc.) (I: (Exhaust
— I — I — I — I — I
System Inspection))
Positive crank case ventilation system(Hoses,
— I — I — I — I — I
Connections and Valve) (PCV Valve Inspection)
Ignition
Ignition wire (Damage, Deterioration) — — — I — I — I — I
Spark plug (R: (Spark Plug Replacement)) Replace every 100,000km or 84 months whichever comes first
Fuel
Air cleaner filter element (R: (Air Paved road Clean every 5,000 KM. Replace after every 40,000 KM
Cleaner Filter Replacement), Dusty Clean every 2,500 KM or as required. Replace after every 40,000
I: (Air Cleaner Filter Inspection)) condition KM
Fuel tank cap, fuel lines and connections (Leakage
and Damage) (I: (Fuel Tank, Cap Gasket and Fuel — I — — — I — — — I
Line Inspection))
I I I I I I I I I I
Fuel filter (leakage) (R: (Fuel Filter Replacement))
Replace every 100,000 KM or 120 months whichever comes first
Clutch and Transmission
Clutch pedal (play) (I: (Clutch Pedal Inspection (M/
I I I I I I I I I I
T Model)))
Clutch Fluid (I: (Clutch Fluid Inspection (M/T
Model)), R: (Clutch Fluid Replacement (M/T I I I R I R I R I R
Model)))
Clutch slipping (Dragging or Excess Damage) I I I I I I I I I I
Manual / Auto Gear Shift (AGS) - Transmission oil
(level, leakage) (I: (Manual Transaxle Oil
I I I I I I I I I I
Inspection (M/T Model))/ (Auto Gear Shift Oil
Inspection (AGS Model)))
Gear shifter (Operation) (I: (Final Inspection for
I I I I I I I I I I
Maintenance Service))
Auto gear shift actuator oil (level, leakage) (I: (Auto
I I I I I I I I I I
Gear Shift Actuator Oil Inspection (AGS Model)))
Drive Shaft
Drive shaft noise (I: (Drive Shaft (Axle) Boot
I I I I I I I I I I
Inspection))
0B-2 Maintenance and Lubrication:
km (x 1,000) 1 5 10 20 30 40 50 60 70 80
Interval
months 1 6 12 24 36 48 60 72 84 96
Drive shaft boots (damage) (I: (Drive Shaft (Axle)
— I I I I I I I I I
Boot Inspection))
Brake
Brake fluid (level, leakage) (R: (Brake Fluid
I I I R I R I R I R
Replacement))
Brake pedal (pedal - carpet clearance) 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
(Brake Lever and Cable Inspection))
Brake discs and pads (wear) (I: (Brake Disc and
Pad Inspection))
Brake drums and shoes (wear) (I: (Brake Drum
— — I I I I I I I I
and Shoe Inspection))
Master cylinder, wheel cylinder, caliper piston(Fluid
leakage, Boot/Seal damage) (I: (Brake Hose and I I I I I I I I I I
Pipe Inspection))
Brake hoses and pipes (fluid leakage, damage) (I:
I I I I I I I I I I
(Brake Hose and Pipe Inspection))
Wheel
Tires (air pressure, abnormal wear, crack and
I I&O I&O I&O I&O I&O I&O I&O I&O I&O
rotation) (I: (Tire Inspection))
Wheels (damage) (I: (Wheel Disc Inspection)) 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
(Wheel Bearing Inspection))
Front / Rear Suspension
Suspension strut (Oil leakage, Damage) (I:
I I I I I I I I I I
(Suspension System Inspection))
Suspension arms / Knuckle support and Torsion
rods (Loose, Damage) (I: (Suspension System — I I I I I I I I I
Inspection))
Rear spring (Damage) (I: (Suspension System
I I I I I I I I I I
Inspection))
Shock absorbers (Oil leakage, Damage) (I:
I I I I I I I I I I
(Suspension System Inspection))
All bolts and nuts (Loose) (I: (Suspension System
— T T T T T T T T T
Inspection))
Steering
Steering wheel (Play, Loose) (I: (Steering System
I I I I I I I I I I
Inspection))
All rods and arms (Loose, Damage, Wear) I I I I I I I I I I
Tilt / Telescopic (if equipped) steering (Operation)
I I I I I I I I I I
(I: (Steering System Inspection))
Electrical
Battery - Electrolyte (Level, Leakage) and voltage I I I I I I I I I I
Wiring harness connection (Loose, Damage) — I I I I I I I I I
Lighting system (Operation, Stains, Damage) I I I I I I I I I I
Wiper (Operation) I I I I I I I I I I
Horn (Operation) I I I I I I I I I I
USB (if equipped), USB charger (if equipped) and
accessory socket(Operation)
Body
All chassis bolts and nuts (Tighten) — I T T T T T T T T
All latches, hinges and locks (function) (I: (All
I I&L I&L I&L I&L I&L I&L I&L I&L I&L
Latches, Hinges and Locks Inspection))
Road Test
Operation of Brakes, gear shifting and
I I I I I I I I I I
speedometer
Body and chassis noise I I I I I I I I I I
Air Conditioner
km (x 1,000) 1 5 10 20 30 40 50 60 70 80
Interval
months 1 6 12 24 36 48 60 72 84 96
Check belt tension I I I I I I I I I I
Tighten compressor mounting bolt — T T T T T T T T T
All hose joint (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 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 (I: (HVAC Air Filter
I I I I R I I R I I
Inspection), R: (HVAC Air Filter Replacement))
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
Repair Instructions
Accessory Drive Belt Inspection • Change engine coolant with new one.
AENNTA0E0206001 (08(03)
– Draining: (Cooling System Draining) in Section 1F
! WARNING
– Refilling: (Cooling System Refilling) in Section 1F
There is a risk of personal injury if the service
work described below is performed while the Exhaust System Inspection
engine is running. AENNTA0E0206005 (08(03)
Check that the ENGINE IS NOT RUNNING ! CAUTION
before performing the service work
Exhaust system components may be hot
described below.
enough to cause burns.
Check that all exhaust system components
• Check belt for tension, crack, cuts, deformation, wear have cooled before performing any service
and contamination. If any defect is found, replace belt. work on the exhaust system.
Check belt for tension.
– Water pump / generator drive belt: (Accessory When carrying out periodic maintenance, or the vehicle
Drive Belt Inspection) in Section 1J is hoisted for other service, check exhaust system as
– Compressor drive belt: (Compressor Drive Belt follows:
Inspection) in Section 7B • Check rubber mountings for damage, deterioration
and dislocation.
Accessory Drive Belt Replacement • Check exhaust system for leakage, loose
AENNTA0E0206002 (08(01)
connections, dents and damages.
• Replace accessory drive belt with new one. If bolts or nuts are loose, tighten them to specification.
– Water pump / generator drive belt: (Accessory • Check nearby body areas for damaged, missing or ill-
Drive Belt Removal and Installation) in Section 1J placed parts, open seams, holes, loose connections
– Compressor drive belt: (Compressor Drive Belt or other defects which could permit exhaust fumes to
Removal and Installation) in Section 7B seep into the vehicle.
• Check that exhaust system components have enough
Engine Oil and Filter Change clearance from the underbody to avoid overheating
AENNTA0E0206003 (08(01)
Change engine oil and filter.(Engine Oil and Filter and possible damage to floor carpet. (Exhaust System
Change) in Section 1E Components) in Section 1K
• Any defects should be fixed at once.
Engine Coolant Change
AENNTA0E0206004 (08(01)
Spark Plug Replacement

AENNTA0E0206006 (08(01)
Replace spark plugs with new ones. (Spark Plug
Removal and Installation) in Section 1H
2
Air Cleaner Filter Inspection
AENNTA0E0206007 (08(03)
1) Remove air cleaner filter. (Air Cleaner Filter Removal
1
and Installation) in Section 1D
2) Check that filter is not excessively dirty, damaged or IDAA0A020001-01
oily. Clean filter with compressed air from air outlet • Replace any damaged or deteriorated parts.
side of filter. There should be no sign of fuel leakage or moisture at
NOTICE any fuel connection. (Fuel System Components) in
Section 1G
Air cleaner filter may get damaged if below
conditions are not maintained.
Fuel Filter Replacement
• Compressed air pressure: Less than 200 AENNTA0E0206010 (08(01)
kPa (2.04 kgf/cm2, 29.0 psi, 2.0 bar) Replace fuel filter. (Fuel Pump Assembly Removal and
• Distance of nozzle from air cleaner filter: Installation) in Section 1G
More than 100 mm (3.94 in.)
• Compressed air quality: Dry
PCV Valve Inspection
AENNTA0E0206011 (08(03)
Ensure that above conditions are maintained Check PCV valve and hose.
while cleaning air cleaner filter. • PCV valve: (PCV Hose Inspection) in Section 1B
• PCV hose: (EVAP Connection Hose Inspection) in
Section 1B
Fuel Evaporative Emission Control System

Inspection
AENNTA0E0206012 (08(03)
Check EVAP canister and fuel vapor hose.
• EVAP canister: (EVAP Canister Removal and
Installation) in Section 1B
• EVAP connection hose: (EVAP Canister Inspection) in
IAW101020005-01 Section 1B
3) Install air cleaner filter. (Air Cleaner Filter Removal
and Installation) in Section 1D Brake Disc and Pad Inspection
AENNTA0E0206013 (08(03)
1) Check lining thickness of outside and inside pads.
Air Cleaner Filter Replacement
AENNTA0E0206008 (08(01) (Front Brake Pad On-Vehicle Inspection) in Section
Replace air cleaner filter with new one. (Air Cleaner 4B
Filter Removal and Installation) in Section 1D Use scale if necessary.
2) Check brake discs for excessive wear, damage and
Fuel Tank, Cap Gasket and Fuel Line Inspection deflection. (Front Brake Disc Inspection) in Section
AENNTA0E0206009 (08(03)
4B
• Check fuel tank, fuel filler cap (1) and fuel lines for Replace parts if necessary.
loose connection, deterioration or damage which
could cause leakage. Check that all clamps are
Brake Drum and Shoe Inspection
secure. AENNTA0E0206014 (08(03)
• Check fuel filler cap gasket (2) for an even filler neck Check rear brake drums and brake linings for excessive
imprint or any damage. wear and damage, while wheels and drums are
removed. At the same time, check wheel cylinders for
leakage. Replace these parts if necessary. (Rear Brake
Drum and Shoe Inspection) in Section 4C
Brake Hose and Pipe Inspection

AENNTA0E0206015 (08(03)
Perform this inspection where there is enough light and
use a mirror if necessary.
• Check brake hoses and pipes for improper Clutch Pedal Inspection (M/T Model)
connections, leakage, crack, chafing and other AENNTA0E0206019 (08(03)
Check clutch pedal travel. (Clutch Pedal Inspection) in
damage. (Brake Flexible Hose and Pipe Inspection) in
Section 5C
Section 4A
• Check that hoses and pipes are clear of sharp edges
and moving parts.
Clutch Fluid Inspection (M/T Model)
AENNTA0E0206020 (08(03)
Repair or replace any of these parts if necessary. 1) Check clutch system for sign of fluid leakage. Repair
NOTICE leaky point if any.
2) Check reservoir for fluid level. If fluid is lower than
Air in the brake system will cause poor
minimum level of reservoir, refill reservoir with
braking performance and can lead to an
specified brake fluid indicated on reservoir cap.
accident.
(Clutch Fluid Level Inspection) in Section 5C
After servicing the brake system, completely
bleed all air out of the system.
Clutch Fluid Replacement (M/T Model)
AENNTA0E0206021 (08(01)
Brake Fluid Replacement NOTICE
AENNTA0E0206016 (08(01)
Clutch fluid is supplied from brake fluid
Change brake fluid as follows.
reservoir.
Drain existing fluid from brake system completely, fill
system with specified fluid and carry out air bleeding Change clutch fluid as follows. Drain existing fluid from
operation. clutch system completely, fill system with specified fluid
For air bleeding procedure, refer to “Air Bleeding of and carry out air bleeding operation. For air bleeding
Brake System” in Section 4A. procedure, refer to “Air Bleeding of Clutch System” in
Section 5C.
Brake Pedal Inspection (M/T Model)
AENNTA0E0206017 (08(03)
Check brake pedal travel. Tire Inspection
AENNTA0E0206022 (08(03)
For checking procedure, refer to “Excessive Pedal
Travel Inspection” in Section 4A. 1) Check tires for uneven or excessive wear, or
damage. If faulty condition is found, replace tire.
Refer to “Tire Inspection” in Section 2D for details.
Brake Lever and Cable Inspection
AENNTA0E0206018 (08(03)
1) Check brake cables for damage and smooth
movement. (Parking Brake Components) in Section
4D
Replace deteriorated cable(s).
2) Check tooth tip of each brake lever ratchet notch for
damage or wear. If any damage or wear is found,
replace parking brake lever.
3) Check parking brake lever for proper operation and
stroke, and adjust it if necessary.
• Check: (Parking Brake Inspection) in Section 4D I2RH01020022-01
• Adjust: (Parking Brake Adjustment) in Section 4D 1. Wear indicator
2) Check inflation pressure of each tire and adjust

pressure to specification if necessary.
NOTE
• Tire inflation pressure should be checked
when tires are cool.
• The tire inflation pressure will change due
to changes in atmospheric pressure,
temperature or tire temperature when
driving.
For details of tire inflation pressure, refer
IDL10A020003-01 to “Tire Description” in Section 2D.
• Specified tire inflation pressure is
indicated on the “Tire Placard”.
Front
3) Rotate tires. For details, refer to “Tire Rotation” in
Section 2D.
Wheel Disc Inspection

AENNTA0E0206023 (08(03)
Check each wheel disc for dents, distortion and crack.
Badly damaged wheel disc must be replaced.
Wheel Bearing Inspection

AENNTA0E0206024 (08(03)
1) Check front wheel bearings for wear, damage and
abnormal noise. For details, refer to “Front Wheel
Bearing Check”: Front in Section 3A.
2) Check rear wheel bearings for wear, damage and
abnormal noise. For details, refer to “Rear Wheel
Bearing Check”: Rear in Section 3A.
IGSD0A210001-01
Rear
IDL10A020004-01
Drive Shaft (Axle) Boot Inspection

AENNTA0E0206025 (08(03)
Check drive shaft boots (wheel side and differential side)
for leakage, detachment, tear or other damage.
Replace defective parts if necessary.
IFRA0A210002-01
• Check dust covers of front suspension arm ball joints

for leakage, detachment, tear or any other damage.
IDAA0A020002-01 For checking procedure, refer to Steps 1) to 10) of
“Joint” under “Suspension Arm Check” in Section 2B.
Suspension System Inspection
AENNTA0E0206026 (08(03)
• Check front strut assemblies and rear shock
absorbers for sign of oil leakage, dents or any other
damage on sleeves. Also check anchor ends for
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.
IAW101020014-01
Repair or replace defective parts, if any.
Steering System Inspection

AENNTA0E0206027 (08(03)
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.)
Change transaxle oil with new specified one. (Manual

Transaxle Oil Change) in Section 5B
Auto Gear Shift Actuator Oil Inspection (AGS

Model)
AENNTA0E0206030 (08(03)
1) Check parts around AGS actuator for oil leakage.
2) Check AGS actuator oil level.(Auto Gear Shift
Actuator Oil Level Check) in Section 5D
I2RH01020026-01
2) Check bolts and nuts for tightness and retighten Auto Gear Shift Oil Inspection (AGS Model)
them if necessary. Repair or replace defective parts. AENNTA0E0206031 (08(03)
3) Check steering linkage for looseness and damage. Check transaxle oil for leakage, contamination and level.
Repair or replace defective parts. (Auto Gear Shift Transaxle Oil Level Check) in Section
5D
4) Check boots (1) and (2) of steering linkage and
steering gear case for damage (leakage,
detachment, tear, etc.). Replace defective steering Auto Gear Shift Oil Replacement (AGS Model)
AENNTA0E0206032 (08(01)
rack boot(s) or tie-rod end(s) with new one(s). Change auto gear shift oil with new specified oil.(Auto
If any dent is found on steering gear case boots, Gear Shift Transaxle Oil Change) in Section 5D
correct it to original shape by turning steering wheel
to the right or left as far as it stops and holding it for a All Latches, Hinges and Locks Inspection
few seconds. AENNTA0E0206033 (08(03)
5) Check universal joints (3) of steering shaft for Door

abnormal noise and damage. If abnormal noise or Check that each door opens and closes smoothly and
damage is detected, replace defective part with new locks securely when closed.
one. If any malfunction is found, lubricate hinges and latch or
repair door lock system.
I2RH01020033-01
1 2 1 Trunk Lid
IFRA0A020001-01 Check that trunk Lid opens and closes smoothly and
6) Check that steering wheel can be turned fully to the locks securely when closed.
right and left. Repair or replace defective parts, if If any malfunction is found, adjust trunk Lid latch striker.
any.
7) Check that steering wheel can be turned fully to the Hood
right and left with smaller force when engine is Check that secondary latch operates properly (check
running at idle speed than when it is stopped. Repair that secondary latch keeps hood from opening all the
power steering system if it provides no assistance. way when hood release handle inside vehicle is pulled.)
Also check that hood opens and closes smoothly and
8) Check wheel alignment referring to “Front Wheel
properly and hood locks securely when closed.
Alignment Inspection and Adjustment” in Section 2B.
If any malfunction is found, lubricate hinges and latch, or
repair hood lock system.
Manual Transaxle Oil Inspection (M/T Model)
AENNTA0E0206028 (08(03)
Check transaxle oil for leakage, contamination and level. HVAC Air Filter Inspection
AENNTA0E0206034 (08(03)
(Manual Transaxle Oil Level Check) in Section 5B
Check HVAC air filter for dirt and dust. If air filter is dirty,
clean or replace it with new one. (HVAC Air Filter
Manual Transaxle Oil Replacement (M/T Model) Inspection) in Section 7B
AENNTA0E0206029 (08(01)
HVAC Air Filter Replacement When performing the engine start check as
AENNTA0E0206035 (08(01) described below, take the following
Replace HVAC air filter with new one. (HVAC Air Filter
precautions:
Removal and Installation) in Section 7B
• Provide adequate space around the
vehicle.
Final Inspection for Maintenance Service
AENNTA0E0206036 (08(03) • Firmly apply both the parking brake and
! WARNING the foot brake.
• Do not use the accelerator pedal.
If you do not select a suitable route and take
proper precautions when performing a road • Set ignition “OFF” immediately if the
test, an accident can occur. engine starts.
Select a level road with no traffic to minimize
the risk of an accident, and perform the test On manual transaxle vehicles, place the gear shift lever
extremely carefully. in “Neutral,” depress clutch pedal halfway and try to
start.
Seat Starting motor should crank only when clutch pedal is
Check that each front seat slides smoothly and locks fully depressed.
securely at any position. Also check that reclining On AGS vehicles, try to start the engine in each select
mechanism of each front seat allows the seatback to be lever position. The starting motor should crank only
locked at any angle. when brake pedal is depressed in N range.
Seat Belt Exhaust System Check

Check seat belt systems including webbing, buckles, Check for leakage, crack or loose supports.
latch plates, retractors and anchors for damage or wear.
Check that each seat belt locks securely. If “REPLACE Clutch (M/T Model)
BELT” label on seat belt is visible, replace belt. Check for the following points:
• Clutch is completely released when clutch pedal is
Battery Check depressed.
Battery terminal check • No slipping clutch occurs when releasing pedal and
Check battery terminals for looseness, corrosion or accelerating.
damage. • Clutch itself is free from any abnormal conditions.
Battery electrolyte level check Gear Shift or Select Lever

• If battery is equipped with electrolyte level check lines Check gear shift or select lever for smooth movement to
on the case, check that the electrolyte level of all all positions and for good and correct response of
battery cells is between the upper and lower level transaxle in any position.
lines. Also check that shift indicator (if equipped) indicates
• If battery is equipped with built-in indicator, check position correctly according to select lever position.
battery condition by the indicator.
• If battery is not equipped with check lines and built-in Brake
indicator, it is not necessary to perform electrolyte Foot brake
level check. Check the following points:
• Brake pedal has proper travel.
Accelerator Pedal Operation • Brakes work properly.
Check that accelerator pedal operates smoothly without • Brakes do not generate abnormal noise.
getting caught by or interfering any other part.
• Vehicle does not pull to one side when brakes are
Engine Start applied.
Check the engine starts readily. • Brakes do not drag.
! WARNING Parking brake

Check that lever stroke is proper.
If you do not take proper precautions when
performing the engine start check as ! WARNING
described below, the vehicle could move
without warning causing personal injury and/ If you do not take proper precautions when
or property damage. 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, • Check that engine is free from abnormal noise and
take the following precautions: abnormal vibration.
• Check that there is nothing on the way
ahead. Body, Wheel and Power Train Components
Check that body, wheels and power train components
• Apply the foot brake quickly if the vehicle
are free from any abnormal conditions such as abnormal
moves.
noise and vibration.
Check that parking brake is fully effective when the
Meter and Gauge
vehicle is stopped on a slope by pulling parking brake
Check that speedometer, odometer, fuel gauge,
lever all the way.
temperature gauge, etc. operate accurately.
Steering
Light
• Check that steering wheel is not instable and has no Check that all lights operate properly.
abnormally large resistance to turn.
• Check that vehicle does not wander or pull to one Windshield Defroster
side. Periodically check that air comes out from defroster
outlet when operating heater or air conditioning.
Engine Set mode control lever to defroster position and fan
• Check that speed changes responsively to switch lever to highest position for this check.
accelerator positions.

Recommended Fluids and Lubricants
AENNTA0E0208001 (11(01)
Engine oil Refer to “Engine Oil and Filter Change” in Section 1E
Engine coolant “Anti-freeze/Anti-corrosion coolant”
(Ethylene glycol base coolant)
Brake fluid Refer to reservoir cap of brake master cylinder.
Manual transaxle oil (M/T model) Refer to “Manual Transaxle Oil Change” in Section 5B
Auto gear shift oil (AGS model) Refer to “Auto Gear Shift Transaxle Oil Change” in Section 5D
Door hinges Engine oil or water resistant chassis grease
Hood latch assembly Engine oil or water resistant chassis grease
Key lock cylinder Spray lubricant
Section 1
Engine
CONTENTS
Precautions .................................................1-1 MIL Does Not Come ON with Ignition “ON”

Precautions............................................................. 1-1 and Engine Stopped (but Engine Can Be
Precautions for Engine.......................................... 1-1 Started) ...........................................................1A-80
MIL Remains ON after Engine Starts................1A-80
Engine General Information and DTC P0010 / P0013 / P2088 / P2089 / P2090
Diagnosis ................................................. 1A-1 / P2091............................................................1A-80
DTC P0011 / P0014 ..........................................1A-82
General Description .............................................1A-1
DTC P0016 / P0017 ..........................................1A-85
Statement on Cleanliness and Care ................... 1A-1
DTC P0030 / P0031 / P0032.............................1A-90
Engine Diagnosis General Description ............... 1A-1
DTC P0036 / P0037 / P0038.............................1A-91
OBD System Description .................................... 1A-1
DTC P0102 / P0103 ..........................................1A-93
DLC Description .................................................. 1A-3
DTC P0107 / P0108 ..........................................1A-95
Engine and Emission Control System
DTC P0112 / P0113 ..........................................1A-97
Description ........................................................ 1A-4
DTC P0116 .......................................................1A-99
EGR Valve System Description .......................... 1A-4
DTC P0117 / P0118 ........................................1A-100
Air Intake System Description ............................. 1A-4
DTC P0122 / P0123 ........................................1A-102
Description of Electric Throttle Control
DTC P0130 .....................................................1A-104
System Calibration ............................................ 1A-4
DTC P0131 / P0132 ........................................1A-106
Electric Throttle Control System Description....... 1A-5
DTC P0133 .....................................................1A-108
Generator Control System Description ............... 1A-5
DTC P0134 .....................................................1A-110
Electronic Control System Description................ 1A-6
DTC P0137 / P0138 / P0140...........................1A-113
Engine and Emission Control Input / Output
DTC P0139 / P2271 ........................................1A-115
Table ................................................................. 1A-8
DTC P0171 / P0172 ........................................1A-118
Schematic and Routing Diagram......................1A-12 DTC P0197 / P0198 ........................................1A-121
Engine and Emission Control System DTC P0201 / P0202 / P0203 / P0204 / P0261
Diagram .......................................................... 1A-12 / P0262 / P0264 / P0265 / P0267 / P0268 /
Engine and Emission Control System Flow P0270 / P0271 / P21CF / P21D0 / P21D1 /
Diagram .......................................................... 1A-14 P21D2 / P21DB / P21DC / P21DE / P21DF /
Electronic Control System Circuit Diagram ....... 1A-16 P21E0 / P21E1 / P21E2 / P21E3 ..................1A-122
Component Location .........................................1A-17 DTC P0222 / P0223 ........................................1A-126
Electronic Control System Component DTC P0300 / P0301 / P0302 / P0303 / P0304 1A-128
Location .......................................................... 1A-17 DTC P0327 / P0328 ........................................1A-131
Diagnostic Information and Procedures..........1A-19 DTC P0335 / P0336 ........................................1A-132
Engine and Emission Control System Check.... 1A-19 DTC P0340 / P0365 ........................................1A-134
MIL Check ......................................................... 1A-23 DTC P0351 / P0352 / P0353 / P0354 / P2300
DTC Check ....................................................... 1A-23 / P2301 / P2303 / P2304 / P2306 / P2307 /
DTC Clearance ................................................. 1A-24 P2309 / P2310 ..............................................1A-136
DTC Table......................................................... 1A-24 DTC P0400 .....................................................1A-139
Fail-Safe Table.................................................. 1A-36 DTC P0403 .....................................................1A-141
Scan Tool Data ................................................. 1A-54 DTC P0420 .....................................................1A-143
Visual Inspection ............................................... 1A-72 DTC P0443 / P0458 / P0459...........................1A-145
Engine Basic Inspection.................................... 1A-72 DTC P0480 / P0691 / P0692...........................1A-147
Engine Symptom Diagnosis .............................. 1A-74 DTC P0481 / P0693 / P0694...........................1A-149
DTC P0500 .....................................................1A-151
DTC P0504 .....................................................1A-152
1-ii Table of Contents
DTC P0515 ..................................................... 1A-154 EGR Pipe Removal and Installation..................1B-15

DTC P0530 ..................................................... 1A-156 EGR Pipe Inspection.........................................1B-15
DTC P0560 / P0562 / P0563........................... 1A-158 Specifications .....................................................1B-15
DTC P0571 ..................................................... 1A-159 Tightening Torque Specifications......................1B-15
DTC P0602 ..................................................... 1A-160 Special Tools and Equipment ...........................1B-16
DTC P0606 ..................................................... 1A-161 Special Tool ......................................................1B-16
DTC P060A / P060B / P060D / P0611 /
P061A / P061B / P061C / P061D / P061F / Engine Electrical Devices ....................... 1C-1
P062B / P062D / P06D1 / P160B / P161A / Precautions...........................................................1C-1
P161B / P161C ............................................. 1A-162 Precaution for Engine Electrical devices.............1C-1
DTC P0645 / P0646 / P0647........................... 1A-165 Precautions for Replacing ECM ..........................1C-1
DTC P0703 ..................................................... 1A-166 Precaution for MAF Sensor with IAT Sensor ......1C-1
DTC P0A5A..................................................... 1A-168 Precaution for Electric Throttle Body
DTC P1660 ..................................................... 1A-170 Assembly...........................................................1C-1
DTC P1693 ..................................................... 1A-172 Precaution for Accelerator Pedal Assembly
DTC P2100 ..................................................... 1A-173 (Incorporating APP Sensor) ..............................1C-1
DTC P2101 / P2119 ........................................ 1A-174 General Description .............................................1C-1
DTC P2122 / P2123 ........................................ 1A-176 Engine Electrical Devices Description.................1C-1
DTC P2127 / P2128 ........................................ 1A-178
Component Location ...........................................1C-3
DTC P2135 ..................................................... 1A-180
Electric Control System Component Location.....1C-3
DTC P2138 ..................................................... 1A-182
DTC P2176 ..................................................... 1A-183 Repair Instructions ..............................................1C-3
DTC P2226 / P2227 ........................................ 1A-185 ECM Removal and Installation ............................1C-3
DTC U0073 ..................................................... 1A-186 Procedure after ECM Replacement ....................1C-5
DTC U0101 / U0121 / U0131 / U0140 / U0155 1A-186 Electric Throttle Body Assembly On-Vehicle
DTC U2001 ..................................................... 1A-186 Inspection..........................................................1C-5
DTC U2021 ..................................................... 1A-187 Electric Throttle Control System Calibration .......1C-6
Inspection of ECM and Its Circuits .................. 1A-188 ECM Learning Procedure of Engine Torque .......1C-7
ECM Power Supply and Ground Circuit APP Sensor On-Vehicle Inspection ....................1C-7
Check ............................................................ 1A-202 Accelerator Pedal Assembly (Incorporating
APP Sensor) Removal and Installation .............1C-7
Repair Instructions ..........................................1A-206
APP Sensor Inspection .......................................1C-8
Idle Speed Inspection......................................1A-206
MAP Sensor Removal and Installation................1C-8
Aux. Emission Control Devices ............. 1B-1 MAP Sensor Inspection.......................................1C-9
Oil Temperature Sensor On-Vehicle
Precautions...........................................................1B-1
Inspection........................................................1C-10
Precautions for EVAP system inspection............ 1B-1
Oil Temperature Sensor Removal and
General Description .............................................1B-1 Installation .......................................................1C-10
EGR (Exhaust Gas Recirculation) System Oil Temperature Sensor Inspection ..................1C-10
Description ........................................................ 1B-1 ECT Sensor Removal and Installation ..............1C-11
Diagnostic Information and Procedures............1B-2 ECT Sensor Inspection .....................................1C-11
EVAP Canister Purge System Inspection ........... 1B-2 HO2S On-Vehicle Inspection ............................1C-12
EGR Valve System Inspection ............................ 1B-3 HO2S Removal and Installation ........................1C-12
Repair Instructions ..............................................1B-3 CMP Sensor On- Vehicle Inspection.................1C-13
EVAP System Components ................................ 1B-3 CMP Sensor Removal and Installation .............1C-14
EVAP Canister Purge Valve Removal and CKP Sensor Removal and Installation ..............1C-14
Installation ......................................................... 1B-4 CKP Sensor Inspection .....................................1C-15
EVAP Canister Purge Valve Inspection .............. 1B-5 Knock Sensor On-Vehicle Inspection................1C-15
EVAP Canister Removal and Installation............ 1B-6 Knock Sensor Removal and Installation ...........1C-16
EVAP Canister Inspection................................... 1B-7 Engine and Emission Control System Relay
EVAP Connection Hose Inspection..................... 1B-7 Inspection........................................................1C-16
PCV Hose Inspection ..........................................1B-7 MAF Sensor with IAT Sensor On-Vehicle
PCV Valve Removal and Installation .................. 1B-7 Inspection........................................................1C-16
PCV Valve Inspection ......................................... 1B-8 MAF Sensor with IAT Sensor Removal and
Fuel EVAP Valve Inspection ............................... 1B-8 Installation .......................................................1C-16
EGR System Components .................................. 1B-9 MAF Sensor with IAT Sensor Inspection ..........1C-17
EGR Valve Removal and Installation ................ 1B-10 OCV Inspection .................................................1C-18
EGR Valve Inspection ....................................... 1B-12 Electric Load Current Sensor with Battery
EGR Cooler Removal and Installation .............. 1B-12 Temperature Sensor On-Vehicle Inspection ...1C-19
EGR Cooler Inspection ..................................... 1B-15
Table of Contents 1-iii
Electric Load Current Sensor with Battery Valve and Valve Guide Inspection ....................1D-42
Temperature Sensor Removal and Cylinder Head Inspection ..................................1D-44
Installation.......................................................1C-20 Cylinder Head Bolt Inspection...........................1D-45
Specifications.....................................................1C-20 Valve Spring Inspection ....................................1D-45
Tightening Torque Specifications......................1C-20 Piston, Piston Ring and Connecting Rod
Special Tools and Equipment ...........................1C-21 Components....................................................1D-46
Special Tool ......................................................1C-21 Piston, Piston Ring and Connecting Rod
Removal and Installation.................................1D-47
Engine Mechanical .................................. 1D-1 Piston, Piston Ring and Connecting Rod
General Description .............................................1D-1 Disassembly and Reassembly ........................1D-49
Engine Construction Description.........................1D-1 Cylinder, Piston and Piston Ring Inspection .....1D-50
VVT System Description .....................................1D-2 Piston Pin and Connecting Rod Inspection.......1D-52
Diagnostic Information and Procedures............1D-4 Connecting Rod Bolt Inspection........................1D-53
Compression Check............................................1D-4 Crankshaft Pin and Connecting Rod Bearing
Engine Vacuum Check .......................................1D-5 Inspection........................................................1D-53
Main Bearing, Crankshaft and Cylinder Block
Repair Instructions ..............................................1D-6
Components....................................................1D-56
Air Cleaner Components.....................................1D-6
Main Bearing, Crankshaft and Cylinder Block
Air Cleaner Filter Removal and Installation.........1D-7
Removal and Installation.................................1D-58
Air Cleaner Filter Inspection and Cleaning..........1D-7
Engine Rear Oil Seal Removal and
Air Cleaner Assembly Removal and
Installation .......................................................1D-63
Installation.........................................................1D-7
Crankshaft Inspection .......................................1D-64
Electric Throttle Body and Intake Manifold
Main Bearing Inspection....................................1D-65
Components......................................................1D-8
Main Bearing Cap Bolt Inspection.....................1D-69
Electric Throttle Body On-Vehicle Inspection......1D-9
Cylinder Block Inspection..................................1D-69
Electric Throttle Body Assembly Removal and
Sensor Plate Inspection ....................................1D-69
Installation.........................................................1D-9
Piston Cooling Jet Inspection............................1D-69
Electric Throttle Body Cleaning.........................1D-10
Intake Manifold Removal and Installation .........1D-10 Specifications.....................................................1D-69
Cylinder Head Cover Components ...................1D-12 Tightening Torque Specifications......................1D-70
Cylinder Head Cover Removal and Special Tools and Equipment ...........................1D-71
Installation.......................................................1D-12 Recommended Service Material .......................1D-71
Engine Mounting Components..........................1D-14 Special Tool ......................................................1D-71
Engine Left Mounting Removal and
Installation.......................................................1D-14
Engine Lubrication System .................... 1E-1
Engine Right Mounting Removal and General Description .............................................1E-1
Installation.......................................................1D-15 Engine Lubrication Description ...........................1E-1
Engine Assembly Removal and Installation ......1D-16 Diagnostic Information and Procedures ............1E-2
Timing Chain Cover Components .....................1D-19 Oil Pressure Check .............................................1E-2
Crankshaft Pulley Removal and Installation......1D-20 Repair Instructions ..............................................1E-3
Crankshaft Front Oil Seal Removal and Engine Oil and Filter Change ..............................1E-3
Installation.......................................................1D-22 Oil Pressure Switch Removal and Installation ....1E-5
Timing Chain Cover Removal and Installation ..1D-22 Oil Pressure Switch On-Vehicle Inspection.........1E-6
Timing Chain Cover Inspection .........................1D-25 Oil Pan and Oil Pump Strainer Components.......1E-6
OCV Removal and Installation ..........................1D-25 Oil Pan and Oil Pump Strainer Removal and
Flywheel Removal and Installation....................1D-25 Installation .........................................................1E-7
Flywheel Inspection ..........................................1D-26 Oil Pump Assembly Components .....................1E-10
Timing Chain and Chain Tensioner Oil Pump Assembly Removal and Installation ..1E-10
Components....................................................1D-27 Oil Pump Assembly Disassembly and
Timing Chain and Chain Tensioner Removal Reassembly ....................................................1E-10
and Installation................................................1D-27 Oil Pump Inspection ..........................................1E-11
Timing Chain and Chain Tensioner Inspection ..1D-30 Specifications.....................................................1E-12
Camshaft Components .....................................1D-30 Tightening Torque Specifications......................1E-12
Camshaft Removal and Installation ..................1D-31 Special Tools and Equipment ...........................1E-13
Camshaft Inspection .........................................1D-33 Recommended Service Material .......................1E-13
Valve and Cylinder Head Components .............1D-36 Special Tool ......................................................1E-13
Valve and Cylinder Head Removal and
Installation.......................................................1D-36 Engine Cooling System ...........................1F-1
Valve Rocker Arm Inspection............................1D-39 Precautions........................................................... 1F-1
Cylinder Head Disassembly and Reassembly ..1D-39 Precautions for Cooling System.......................... 1F-1
1-iv Table of Contents
General Description ............................................. 1F-1 Repair Instructions ........................................... 1G-12

Cooling System Description ................................ 1F-1 Fuel System Components................................ 1G-12
Coolant Description............................................. 1F-1 Fuel Hose Disconnection and Reconnection ... 1G-13
Cooling Fan Operation Description ..................... 1F-1 Fuel Pressure Relief Procedure ....................... 1G-16
Schematic and Routing Diagram........................ 1F-2 Fuel Leakage Check Procedure....................... 1G-16
Coolant Circulation.............................................. 1F-2 Fuel Line On-Vehicle Inspection ...................... 1G-16
Radiator Cooling Fan Control System Circuit Fuel Pipe Removal and Installation.................. 1G-17
Diagram ............................................................ 1F-3 Fuel Injector On-Vehicle Inspection ................. 1G-18
Diagnostic Information and Procedures............ 1F-3 Fuel Injector Removal and Installation ............. 1G-19
Engine Cooling Symptom Diagnosis................... 1F-3 Fuel Injector Inspection .................................... 1G-21
Radiator Cooling Fan System Check .................. 1F-4 Fuel Filler Cap Inspection ................................ 1G-23
Repair Instructions .............................................. 1F-8 Fuel Tank Removal and Installation................. 1G-23
Cooling System Components.............................. 1F-8 Fuel Tank Inspection........................................ 1G-25
Coolant Level Check ........................................... 1F-9 Fuel Tank Flushing Procedure ......................... 1G-25
Engine Cooling System Inspection ..................... 1F-9 Fuel Pump On-Vehicle Inspection.................... 1G-26
Cooling System Draining..................................... 1F-9 Fuel Pump Assembly Removal and
Cooling System Refilling ................................... 1F-10 Installation ...................................................... 1G-26
Cooling System Hose Removal and Fuel Pump Inspection ...................................... 1G-28
Installation ....................................................... 1F-10 Fuel Level Sensor Removal and Installation.... 1G-28
Water Inlet Pipe Removal and Installation ........ 1F-11 Fuel Level Sensor Inspection........................... 1G-28
Thermostat Removal and Installation................ 1F-12 Specifications .................................................... 1G-29
Thermostat Inspection....................................... 1F-12 Tightening Torque Specifications..................... 1G-29
Thermostat Case Removal and Installation ...... 1F-13 Special Tools and Equipment .......................... 1G-29
Radiator Cooling Fan Assembly On-Vehicle Special Tool ..................................................... 1G-29
Inspection........................................................ 1F-14
Radiator Cooling Fan Relay Inspection............. 1F-15 Ignition System........................................ 1H-1
Radiator Cooling Fan Assembly Removal and General Description .............................................1H-1
Installation ....................................................... 1F-15 Ignition System Construction ..............................1H-1
Radiator Cooling Fan Disassembly and Schematic and Routing Diagram ........................1H-1
Reassembly .................................................... 1F-15 Ignition System Circuit Diagram ..........................1H-1
Radiator On-Vehicle Inspection and Cleaning .. 1F-16 Component Location ...........................................1H-2
Radiator Removal and Installation .................... 1F-16 Ignition System Component Location .................1H-2
Water Pump Removal and Installation.............. 1F-17 Diagnostic Information and Procedures ............1H-2
Water Pump Inspection..................................... 1F-18 Ignition System Check ........................................1H-3
Specifications..................................................... 1F-18 Ignition Spark Test ..............................................1H-5
Tightening Torque Specifications...................... 1F-18 Repair Instructions ..............................................1H-5
Special Tools and Equipment ........................... 1F-18 Spark Plug Removal and Installation ..................1H-5
Recommended Service Material ....................... 1F-18 Spark Plug Inspection .........................................1H-6
Ignition Coil Assembly Removal and
Fuel System ............................................. 1G-1 Installation .........................................................1H-6
Precautions.......................................................... 1G-1 Ignition Coil Assembly Inspection .......................1H-6
Precautions for Fuel System Service ................. 1G-1 Ignition Timing Inspection ...................................1H-6
General Description ............................................ 1G-1 Specifications .......................................................1H-7
Fuel System Description .................................... 1G-1 Tightening Torque Specifications........................1H-7
Fuel Delivery System Description ...................... 1G-1 Special Tools and Equipment .............................1H-7
Fuel Pump Description....................................... 1G-2 Special Tool ........................................................1H-7
DUALJET System Description ........................... 1G-2
Schematic and Routing Diagram....................... 1G-2 Starting System .........................................1I-1
Fuel Delivery System Diagram........................... 1G-2 Precautions............................................................ 1I-1
Fuel Injector Control System Circuit Diagram .... 1G-2 Precautions for Replacing Starting Motor ............ 1I-1
Fuel Pump Control System Circuit Diagram ...... 1G-3 General Description .............................................. 1I-1
Diagnostic Information and Procedures........... 1G-4 Cranking System Description ............................... 1I-1
Fuel System Inspection...................................... 1G-4 Schematic and Routing Diagram ......................... 1I-1
Power Balance Test ........................................... 1G-5 Cranking System Circuit Diagram ........................ 1I-1
Fuel Injector Circuit Check ................................. 1G-5 Diagnostic Information and Procedures ............. 1I-2
Fuel Pump and Its Circuit Check........................ 1G-7 Cranking System Symptom Diagnosis................. 1I-2
Fuel Pressure Check........................................ 1G-10
Repair Instructions ............................................... 1I-4
Fuel Pressure Basic Check.............................. 1G-11
Starting Motor Control Relay Inspection .............. 1I-4
Fuel Cut Operation Inspection ......................... 1G-11
Table of Contents 1-v
Starting Motor Removal and Installation .............. 1I-4 Accessory Drive Belt Auto Tensioner
Starting Motor Components ................................. 1I-4 Removal and Installation................................. 1J-10
Starting Motor Disassembly and Reassembly ..... 1I-5 Accessory Drive Belt Auto Tensioner
Starting Motor Inspection ..................................... 1I-8 Inspection........................................................ 1J-10
Specifications...................................................... 1I-12 Generator Components..................................... 1J-10
Cranking System Specifications......................... 1I-12 Generator Disassembly and Reassembly......... 1J-11
Tightening Torque Specifications....................... 1I-13 Generator Inspection......................................... 1J-14
Special Tools and Equipment ............................ 1I-13 Specifications..................................................... 1J-15
Recommended Service Material ........................ 1I-13 Charging System Specifications ....................... 1J-15
Tightening Torque Specifications...................... 1J-16
Charging System ......................................1J-1 Special Tools and Equipment ........................... 1J-16
Precautions........................................................... 1J-1 Special Tool ...................................................... 1J-16
Precautions for Handling Battery .........................1J-1
Precautions for Replacing Battery .......................1J-2 Exhaust System ....................................... 1K-1
General Description ............................................. 1J-2 Precautions...........................................................1K-1
Battery Description...............................................1J-2 Precautions .........................................................1K-1
Generator Description ..........................................1J-2 General Description .............................................1K-1
Diagnostic Information and Procedures............ 1J-3 Exhaust System Description ...............................1K-1
Battery Inspection ................................................1J-3 Diagnostic Information and Procedures ............1K-1
Generator Symptom Diagnosis ............................1J-4 Exhaust System Check .......................................1K-1
Generator Test .....................................................1J-5 Repair Instructions ..............................................1K-1
Repair Instructions .............................................. 1J-6 Exhaust System Components.............................1K-1
Jump-Starting in Case of Emergency ..................1J-6 Exhaust Manifold Removal and Installation ........1K-2
Battery Removal and Installation .........................1J-6 Exhaust Manifold Inspection ...............................1K-3
Accessory Drive Belt Inspection...........................1J-7 Exhaust Pipe and Muffler Removal and
Accessory Drive Belt Removal and Installation .........................................................1K-4
Installation..........................................................1J-7 Specifications.......................................................1K-4
Generator Removal and Installation ....................1J-9 Tightening Torque Specifications........................1K-4
1-1 Precautions:
Precautions
Engine
Precautions
Precautions for Engine
AENNTA0E1000001 (01(01)
Warning for Air Bag
Refer to “Warning for Air Bag” in Section 00.
Precautions for Catalytic Converter

Refer to “Precautions for Catalytic Converter” in Section
00.

Refer to “Precautions for Electrical Circuit Service” in IYSQ01110001-01
Section 00.
Precautions for Diagnosing Trouble
Reassembling Note for Wiring Harness • Diagnostic information stored in ECM memory can be
Observe “Reassembling Note for Wiring Harness” in cleared as well as checked using SUZUKI scan tool or
Section 9A whenever installing wiring harness. CAN communication OBD-II generic scan tool. Before
Otherwise, electrical trouble may occur. using scan tool, read its Operator’s Manual to know
how to use it.
Precautions for Fuel System Service
• Priorities for diagnosing troubles:
Refer to “Precautions for Fuel System Service” in
If two or more DTCs are stored, perform DTC
Section 1G.
troubleshooting for these DTCs beginning with the
DTC detected earliest and follow the instructions
Precautions for Engine Service
available in the troubleshooting procedure.
• When raising or supporting engine, do not use a jack If no instructions are available, troubleshoot DTCs
under oil pan. Due to small clearance between oil pan according to the following priorities.
and oil pump strainer, jacking against oil pan may
a. DTCs other than DTC P0171 / P0172 (Fuel
cause it to be bent against strainer resulting in
system too lean/too rich) and DTC P0300 / P0301
damaged oil pick-up unit.
/ P0302 / P0303 / P0304 (Misfire detected)
• It should be kept in mind, while working on engine,
b. DTC P0171 / P0172 (Fuel system too lean/too
that 12-volt electrical system involves danger of
rich)
violent and damaging short circuits. When performing
any work where electrical terminals could be c. DTC P0300 / P0301 / P0302 / P0303 / P0304
grounded, ground cable of the battery should be (Misfire detected)
disconnected at battery. • Read “Precautions for Electrical Circuit Service” in
• Any time the air cleaner, throttle body or intake Section 00 before inspection and observe what is
manifold is removed, the intake opening should be written there.
covered. This will protect against accidental entrance • Communication of ECM and other control module are
of foreign material which could follow intake passage established via CAN. (For more detail of CAN
into cylinder and cause extensive damage when communication for ECM, refer to “Communication
engine is started. System Description”: CAN in Section 10H.)
• When disconnecting connectors, do not pull wire • Before performing troubleshooting, read the
harness but hold connector itself. With lock type “Precautions for ECM Circuit Inspection”.
connector, unlock before disconnection. Attempt to • Upon completion of inspection and repair work,
disconnect connector without unlocking may result in perform “DTC Confirmation Procedure” and check
damage to connector. When connecting lock type that the trouble has been repaired.
connector, insert it till clicking sound is heard and
connect it securely. 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.
Precautions: 1-2
– APP sensor, MAF sensor with IAT sensor, MAP • A large amount of electric load is applied.
sensor, electric load current sensor with battery • One of the following DTCs is detected.
temperature sensor, A/C refrigerant pressure
– U2001: LIN Lost Communication With Generator
sensor and TP sensor are in good condition and
none of their power circuits is shorted to ground. – U2021: LIN Invalid Data from ECM to Generator
• Before ECM replacement, perform “Procedure for
Caution for Vehicles Equipped with DCM
saving data before ECM replacement” under “Saving /
Refer to “Caution for Vehicles Equipped with DCM” in
Writing of Starter Drive Count” in Section 10I.
Section 00.
• After ECM replacement, perform “Procedure after
ECM Replacement” in Section 1C.
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.
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. (Electric Throttle Control
System Calibration) in Section 1C
• 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.
1A-1 Engine General Information and Diagnosis:
Engine General Information and Diagnosis

Engine
General Description
Statement on Cleanliness and Care • When ECM detects a malfunction which gives an
AENNTA0E1101001 (03(01) adverse effect to vehicle emission while the engine is
An automobile engine is a combination of many
running, ECM makes the MIL in the meter cluster of
machined, honed, polished and lapped surfaces with
the instrument panel turn ON or blink (blinking only
tolerances that are of the order of thousands of a
when detecting a misfire which can cause damage to
millimeter (ten thousandths of an inch).
the catalyst) and stores the malfunction area in its
Accordingly, when any internal engine parts are
memory. (If ECM detects a malfunction only in the first
serviced, cleanliness and care are important.
driving cycle (refer to “Driving Cycle”) but does not
It should be understood that proper cleaning and
detect the same malfunction in the next 2 consecutive
protection of machined surfaces and friction areas is part
driving cycles, ECM does not turn on MIL although it
of the repair procedure. This is considered standard
retains the associated DTC in its memory.)
shop practice even if not specifically stated.
• For some malfunctions, ECM adopts the 3 driving
• A liberal coating of engine oil should be applied to
cycle detection logic to prevent erroneous detection.
friction areas during assembly to protect and lubricate
(For more details, refer to “3 Driving Cycle Detection
the surfaces on initial operation.
Logic”.)
• Whenever valve train components, pistons, piston With this logic, MIL is turned on when the same
rings, connecting rods, rod bearings, and crankshaft malfunction is detected for 3 consecutive driving
journal bearings are removed for service, they should cycles.
be retained in order.
• When a malfunction is detected, engine and driving
At the time of installation, they should be installed in
conditions at the moment the malfunction was
the original locations and with the same mating
detected are stored in ECM memory as freeze frame
surfaces as when removed.
data. (For the details, refer to description on “Freeze
• Battery cables should be disconnected before any frame data clearance”.)
major work is performed on the engine.
• Not only SUZUKI scan tool (2) but also CAN
Failure to disconnect cables may result in damage to
communication OBD-II generic scan tool can
wire harness or other electrical parts.
communicate with ECM via DLC (3). (Diagnostic
• The four cylinders of the engine are identified by information can be accessed using a scan tool.)
numbers; No.1, No.2, No.3 and No.4 counted from
crankshaft pulley side to flywheel side.
1
Engine Diagnosis General Description

AENNTA0E1101002 (03(01)
The engine and emission control system in this vehicle
are controlled by ECM. ECM 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, have full
understanding of the outline of “OBD System
Description” and each item in “Precautions for
Diagnosing Trouble” under “Precautions for Engine” in
Section 1 and execute diagnosis according to “Engine IMTA0A110001-02
and Emission Control System Check”.

There is a close relationship between the engine 2
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”.
OBD System Description

AENNTA0E1101003 (03(01)
ECM in this vehicle has the following functions.
• When ignition is “ON” with the engine at a stop, MIL 3
(1) turns ON to check the circuit of the MIL. IMTA0A110002-01
Engine General Information and Diagnosis: 1A-2
Warm-Up Cycle – The sensor that the output voltage

A “warm-up cycle” means keeping the engine operating increases according to the opening
after the start until the coolant temperature rises by at angle, it displays 80%.
least 22 °C (40 °F) and reaches a minimum temperature – The sensor that the output voltage
of 71 °C (160 °F). decreases according to the opening
angle, it displays 20%.
Driving Cycle
• Relative TP indicates value calculated by
A “Driving Cycle” is a duration from an engine startup to
formula ((output voltage – output voltage
the following engine shutoff.
at closed throttle position) / power supply
voltage).
3 Driving Cycle Detection Logic
When power supply voltage is 5.0 V and
The malfunction detected in the first driving cycle is
output voltage at closed throttle position is
stored in ECM memory (in the form of pending DTC) but
1.0 V, freeze frame data is displayed as
MIL does not light at this time. ECM causes the MIL to
follows.
light up when it detects third time the same malfunction
in the next two driving cycle. – At closed throttle position (output
voltage = 1.0 V), it displays 0%.
Pending DTC – At wide open throttle position (output
“Pending DTC” is relevant to those DTCs to which the “3 voltage = 4.0 V), it displays 60%.
driving cycle detection logic” is applied. If such DTC’s However, for systems where the output is
are detected temporarily during the first and two of three inversely proportional to the input voltage, it
consecutive driving cycles, the DTC is called pending displays 100% minus above-mentioned
DTC. formula.
Freeze Frame Data

Freeze frame data (For example)
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. IDAA0A111039-01
When power supply voltage is 5.0 V and

output voltage is 4.0 V, freeze frame data is
displayed as follows.
Details of Freeze Frame Data

ECM has 4 freeze frames from 0 to 3 where freeze frame data can be stored.
Frame 0 is a special frame limited for freeze frame data that MIL turns on.
Frames 1 to 3 are assigned to store DTCs in detected order whether MIL turns on or not.
ECM stores 3 sets 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.
However, there is an order of priority on these freeze frame data of MIL turning on and P0300 – P0304 (Misfire
Detected), P0171 (System Too Lean Bank 1) and P0172 (System Too Rich Bank 1) have higher priority than the
others. Therefore, if one of the other DTCs is stored in the flame 0, that DTC will be replaced with an above priority
DTC at the time it is detected.
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. In this situation, when a malfunction stored in frame 0 to 3 is resolved, the next DTC becomes
accessible.
Frame 0 Frame 1 Frame 2 Frame 3
Freeze frame 1st freeze frame 2nd freeze frame 3rd freeze frame
data data data data
1 No DTC
2 P0530 P0530 data
DTC 3 P0480 P0530 data P0480 data
detection
order 4 P0443 P0443 data P0530 data P0480 data P0443 data
5 P0171 P0171 data P0530 data P0480 data P0443 data
6 P0112 P0171 data P0530 data P0480 data P0443 data
IBP50A110001-02
—: No freeze frame data
Freeze frame data clearance

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

The system readiness test is performed for the purpose DTC related to monitoring item
item
of checking that each of the exhaust-emission-related O2 Sensor P0133 P2271 P0139
systems fulfills the conditions that allow ECM to detect a EGR and/or
malfunction if it occurs and to set the corresponding P0400 P0011 P0014
VVT System
DTC.
The test is carried out by monitoring the specific items DLC Description
(components) using a scan tool (SUZUKI scan tool or AENNTA0E1101004 (03(01)
CAN communication OBD-II generic scan tool). When DLC (1) is in compliance with SAE J1962 in the shape of
the test shows that the conditions pre-established for the connector and pin assignment.
tested system are met, ECM performs an on-board OBD CAN High line (6) and Low line (3) (CAN line of ISO
diagnosis of the system, changes the status of the 15765-4) are used for SUZUKI scan tool (Suzuki SDT-II)
system readiness test from “Incomplete” to “Complete”, (7) or CAN communication OBD-II generic scan tool to
and causes the “Complete” status to be displayed on the communicate with ECM and other control modules.
scan tool.
The “Complete” status is maintained until DTC clearance 2 3
operation is performed using the scan tool. 16 15 14 13 12 11 10 9
NOTE 8 7 6 5 4 3 2 1
• The system readiness test status may 6 5

change from “Complete” to “Incomplete” if 1 4
any of the following service operations is
7
performed.
– Disconnection of battery negative (–)
cable
– Disconnection of ECM connectors
– Removal of ECM ground cable
• The items (components) indicated in the
table below are monitored in the system
readiness test to check the readiness for
detecting the DTCs listed beside each
monitoring item.
1
• The “Complete” or “Incomplete” status
IMTA0A110003-01
identified through the system readiness
test does NOT mean the “Normal” or 2. B + (Continuous battery power)
“Abnormal” result of on-board diagnosis. 4. ECM ground (Signal ground)
5. Ground (Chassis ground)
Monitoring item of system readiness test table

Monitoring
DTC related to monitoring item
item
Catalyst P0420 — —
Engine and Emission Control System Emission control system includes EGR, EVAP and PCV
Description systems.
AENNTA0E1101005 (03(01)
The engine and emission control system is divided into 4
major sub-systems: air intake system, fuel delivery
EGR Valve System Description
AENNTA0E1101006 (03(01)
system, electronic control system and emission control • EGR valve system recirculates water cooled EGR gas
system. to combustion chamber to control the combustion
Air intake system includes air cleaner, throttle body and temperature low for effective engine output reducing
intake manifold. knocking, pre-ignition, piston pumping loss and NOx.
Fuel delivery system includes fuel pump, delivery pipe,
• EGR valve is operated by a stepper motor and
etc.
controlled by ECM in response to the driving
Electronic control system includes ECM, various sensors
condition.
and controlled devices.
Air Intake System Description

AENNTA0E1101007 (03(01)
The main components of the air intake system are air cleaner (1), air cleaner outlet hose (2), electric throttle body
assembly (3) (for the details, refer to “Electric Throttle Control System Description”.) 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 assembly 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”.)
3
6
IMTA0A110036-01
Description of Electric Throttle Control System position data in ECM. When such data is registered in
Calibration ECM, it is saved in RAM (memory) of ECM and used as
AENNTA0E1101008 (03(01) the base data for controlling the throttle valve. This data
ECM calculates controlled opening of the throttle valve is cleared, when any of the works described in
on the basis of the completely closed throttle valve “Precautions for Electric Throttle Control System
position of the electric throttle control system. The Calibration” under “Precautions for Engine” in Section 1
completely closed position data is saved in memory of is performed.
ECM. However, the completely closed position of the Also, after replacement of the electric throttle body
throttle valve of the electric throttle control system (signal assembly and/or accelerator pedal assembly
voltage from throttle position sensor when throttle is (incorporating APP sensor), the completely closed
completely closed) differs one from the other depending position data in memory of ECM must be cleared once
on individual differences of the throttle valve and throttle and a new one must be registered. Otherwise, ECM
position sensor. As such individual differences must be cannot judge the completely closed position properly.
taken into account for controlling the throttle valve, it is
necessary to register the completely closed throttle valve
For the procedure to register such data, refer to “Electric engine is started during this registration process, such
Throttle Control System Calibration” in Section 1C. (After symptom as “longer cranking time” or “slow rise of
the completely closed position data is cleared from ECM, engine speed immediately after start-up” may occur.
for the first time only, the throttle valve opens and closes However, setting ignition “OFF” once and then restarting
for about 60 sec. after ignition is “ON”, for registration of the engine will register the position to ECM correctly.)
the completely closed throttle valve position. If the
Electric Throttle Control System Description

AENNTA0E1101009 (03(01)
The electric throttle control system consists of the following:
• Electric throttle body incorporating the throttle valve, throttle actuator and TP sensors (main/sub)
• Accelerator pedal assembly incorporating APP sensors (main/sub)
• ECM
Operation Description
ECM (5) detects depressed extent of the accelerator pedal based on the signal voltage of the APP sensor (1). Using
that data and engine operation condition, ECM calculates the optimum throttle valve opening. On the other hand, it
detects the throttle valve opening based on the signal voltage of the TP sensor (3) in the electric throttle body (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
Generator Control System Description

AENNTA0E1101010 (03(01)
Generator control system consists of a generator (1), electric load current sensor with battery temperature sensor (2)
and ECM (3).
ECM controls generated electricity (adjusting voltage of IC regulator (4)) so that it is suitable for the engine and electric
load conditions. To prevent drop in idling speed that would result from quick increase in electric load and consequent
increase in engine load, ECM performs a control so that the generator output increases gradually. In the case of a
temporary increase in electricity generation demand while driving, ECM performs a control to limit operation of the
generator and thus limits increase in load on the engine to maintain the engine performance whenever necessary
(during acceleration, for example).
Operation
• ECM optimally controls the generator output voltage by changing the excitation current and regulated voltage based
on the following information.
– Engine condition (ECT, engine speed, TP, APP, IAT, electric load current sensor voltage, battery temperature
sensor voltage, etc.) (5)
– LIN communication signal from generator (field duty signal, generator temperature signal and generator
diagnosis signal)
– CAN communication signal (BCM, ABS/ESP® control module, P/S control module, etc)
• Field coil (6) control duty which indicates the operation rate of the field coil.
• The signal to the “LIN” terminal of the generator adjusts the regulating voltage of the IC regulator, which in turn
controls the duty ratio of the field coil and thus the output voltage (“B” terminal output) of the generator.
• The generating condition of the generator is controlled to the optimum level using the electric load current sensor
which detects the electrical load condition (current consumption) linearly even when a sudden electrical load
variation occurs and thus the engine load is reduced.
• For more information on the generator output voltage, refer to “Charging System Specifications” in Section 1J.
1
B
10
3
LIN
4
9 5 7
2
IMTA0A110037-01
7. Battery 9. CAN driver

8. Combination meter 10. To other control modules and sensors connected by CAN
Electronic Control System Description Further, fuel cut is controlled in response to the driving
AENNTA0E1101011 (03(01) conditions.
NOTE
For details of cruise control system and ENG Engine start injection control
A-STOP system, refer to the following items. • Fuel injection timing
• Cruise control system: (Cruise Control The injection timing is decided corresponding to
System Construction) in Section 10A coolant temperature and fuel is injected in sequential
• ENG A-STOP system: (ENG A-STOP order synchronizing with crankshaft position sensor
System Description) in Section 10I signal.
• Fuel injection time (volume)
Fuel Injection Control System For engine start, the injection time is decided adding
The system controls fuel to be supplied into cylinder corrective factors such as intake air temperature,
adjusting injection timing and injection time (volume) battery voltage, engine speed (cranking speed) and
optimally. atmospheric pressure to the basic injection time.
Fuel injection timing and time (volume) are decided by And, the lower the coolant temperature, the longer the
engine start injection control for the engine starting and injection time for good startability.
after start injection control during the normal driving.
After start injection control Throttle Valve Control

• Fuel injection timing Receiving dual voltage signals, main and sub, from APP
sensor, a target throttle opening is calculated and to
– For programed finishing time of injection, start
bring the throttle opening closer to the target, throttle
timing of injection is calculated and fuel is injected
actuator is activated. Further, the system executes the
sequentially under normal condition.
following controls in response to the vehicle conditions.
– When fuel cut is finished and normal injection
restarts or when accelerating rapidly, fuel is injected Engine start control
into all cylinders simultaneously for a short time For engine start, throttle opening is set up according to
without synchronizing with crankshaft position coolant temperature to increase intake air for good
sensor signal. startability. And, the lower the coolant temperature, the
• Fuel injection time (volume) wider the throttle opening for the same purpose.
The basic injection time is decided based on intake air
volume and engine speed, and using this basic Idling control
injection time, optimum injection time is adjusted to fit Basic throttle opening is set up according to information
driving conditions taking information from each of coolant temperature, engine oil temperature, shift
sensor. position and A/C switch and, adding corrective factors, a
target throttle opening is determined.
Fuel cut control
• Engine speed fuel cut Normal condition control
To prevent engine overspeed, this fuel cut is operated Adding information of accelerator pedal position, engine
at engine speed 6,400 rpm or higher. load, etc. to basic throttle opening, a target throttle
opening is determined. If actual throttle opening differs
NOTE from the target, ECM adjusts the throttle opening to bring
Engine speed in fuel cut condition shown it closer to the target.
here is reference value as a guide line.
Deceleration control
• Deceleration fuel cut At the time of deceleration, the system opens throttle
To restrain hydrocarbon (HC) emissions and improve valve at specified degree to increase intake air and
fuel economy, this fuel cut is operated during prevents engine speed from excessive falling.
deceleration in specified conditions.
• Other Maximum vehicle speed limitation control
ECM operates a fuel cut based on the following The vehicle speed is limited by limiting the throttle valve
signals and performs an automatic stop of the engine. opening when the vehicle speed is 180 km/h (112
(For more details of execution condition, refer to “ENG mile/h) or higher.
A-STOP System Description” in Section 10I.)
Maximum engine speed limitation control
– Input signal of each sensor
To prevent engine overspeed, throttle opening is
– Information signal of each control module via CAN restricted in the following conditions.
communication
• When vehicle is running: Engine speed is 6,300 rpm
or more.
Ignition Timing Control
Corresponding to vehicle running conditions, ignition • When vehicle is stopped:
timing is controlled optimally. There are three control – Engine speed is 5,000 rpm or more.
modes to determine ignition timing, i.e. engine start – Engine speed is 2,800 rpm or more after engine
ignition control mode, normal driving condition ignition speed is 3,200 rpm or more for 150 sec.
control mode and ignition timing inspection mode. And, continuously.
the following control is performed based on CAN
communication signals from ESP® control module, NOTE
stereo camera and sonar control module. Each value in limitation control shown here is
reference value as a guide line.
Torque down control
To reduce engine torque by controlling ignition timing in
Torque down control (ESP® model)
torque down control. For more details, refer to “Torque
When the ESP® control module determines that the
down control (ESP® model)”in “Throttle Valve Control”.
engine torque down is necessary at the time of
executing TCS control and stability control, ESP® control
module transmits a torque down request to ECM. At this
time, ECM controls the throttle valve opening and the
ignition timing to reduce the engine torque.
Fail-safe control Main Relay Control

When malfunction of throttle control circuit is detected, • Corresponding to “ON” or “OFF” of ignition mode, the
ECM cuts off current to throttle actuator. As a result, main relay is controlled for startup or stop of EPI
throttle valve opening is fixed at a default angle or, system.
movable maximum opening of throttle valve is restricted
• The main relay has a self-shutoff function which
to a degree equivalent to the default angle. However,
supplies power source to internal circuit in ECM for
minimum vehicle running is ensured by control of fuel
specified time until the system stops after ignition
injection and ignition timing.
“OFF”, and a countercurrent prevention function
which refrains battery from supplying reverse current
HO2S Heater Control
caused by erroneous battery reverse connection.
To quicken startup or maintain activation of HO2S, the
system controls HO2S heater using duty cycle pulse
A/C Compressor Control
signal.
Based on the following signals, the system controls ON/
OFF of A/C compressor relay.
EVAP Purge Control
Corresponding to vehicle running conditions, the system • Refrigerant pressure sensor
controls ON/OFF of canister purge VSV to suck in fuel • Each sensor signal depending on the vehicle running
vapor absorbed in canister and feeds it into intake condition
manifold together with air-fuel mixture to burn. This • Information from A/C switch and brake booster sensor
function restrains the fuel vapor to be released to through CAN communication
atmosphere.
EGR Control
VVT Control To optimally control the opening of an EGR valve
The system controls OCV for optimum valve timing in according to an engine load, an engine rotation speed,
response to engine speed, volume of intake air, degree etc. In this way, EGR control system reduces knocking,
of throttle opening and coolant temperature etc. The pre-ignition, piston pumping loss and NOx. When the
valve timing is brought closer to the engine command by engine is started, EGR valve is fully closed to perform
feedback control detecting actual advance angle of the initialization control.
valve.
CAN Communication System
Radiator Cooling Fan Control Using this system, ECM transmits / receives data and
Based on the following signals, the system controls information with each control module.
radiator fan speed to LO, HI or stop using radiator fan
relays No.1, No.2 and No.3. Brake Override System
• Engine speed When ECM recognizes that both the accelerator pedal
• Vehicle speed and the brake pedal have been depressed while driving,
ECM limits throttle valve opening to suppress engine
• Coolant temperature
power and prioritizes brake operation.
• Refrigerant pressure
• Information of A/C switch and vehicle speed through NOTE
CAN communication • The system may not operate depending in
the following vehicle conditions.
Fuel Pump Control
– Depressing amount of accelerator pedal
The system operates or stops fuel pump controlling fuel
and brake pedal
pump relay.
ON conditions of fuel pump relay: – Vehicle speed
• For specified time after ignition “ON”. • The system restricts throttle valve opening
mainly. Therefore, ignition timing control
• While CKP sensor signal is being inputted to ECM
and VVT control are affected by this
with engine running.
system.
• When engine is stopped by engine auto stop control,
fuel pump ON condition is met for specified time.
Engine and Emission Control Input / Output Table

AENNTA0E1101012 (03(01)
Function Output Input

• Ignition “ON” signal
• Ignition “ST” signal
• ECT sensor
• CKP sensor
• Intake CMP sensor
• Exhaust CMP sensor
• TP sensor
• APP sensor
Injection control Fuel injector • MAF sensor
• IAT sensor
• MAP sensor
• HO2S
• Barometric pressure sensor
• Battery voltage
• Brake light switch
• BCM (A/C switch status signal)
• TCM (transmission shift position signal) (AGS model)
Fuel injector • Ignition “ON” signal
Immobilizer control
Ignition coil assembly • BCM
• ECT sensor
• CKP sensor
• Intake CMP sensor
• Exhaust CMP sensor
• TP sensor
• APP sensor
Ignition control Ignition coil assembly • MAF sensor
• IAT sensor
• MAP sensor
• Knock sensor
• Battery voltage
• TCM (transmission shift position signal and torque request
signal) (AGS model)

• ECT sensor
• CKP sensor
• TP sensor
• APP sensor
• MAF sensor
Idle speed control Throttle actuator
• IAT sensor
• MAP sensor
• Oil temperature sensor
• TCM (transmission shift position signal and torque request
signal) (AGS model)
• ECT sensor
• CKP sensor
• TP sensor
• APP sensor
Throttle valve control Throttle actuator • MAF sensor
• IAT sensor
• TCM (engine speed limit request signal and torque request
signal) (AGS model)
• ECT sensor
• CKP sensor
• TP sensor
HO2S heater control HO2S
• MAF sensor
• IAT sensor
• HO2S
• Battery voltage
• ECT sensor
• CKP sensor
• TP sensor
EVAP canister purge
EVAP purge control • MAF sensor
valve
• IAT sensor
• TCM (transmission shift position signal) (AGS model)

• ECT sensor
• CKP sensor
Intake OCV • Intake CMP sensor
VVT control
Exhaust OCV • Exhaust CMP sensor
• MAF sensor
• TP sensor
• Brake light switch
• ECT sensor
• CKP sensor
• TP sensor
• MAP sensor
A/C compressor control A/C compressor relay
• APP sensor
• A/C refrigerant pressure sensor
• BCM (A/C switch status signal and evaporator temperature
signal)
• Brake booster switch
• ECT sensor
Radiator cooling fan Radiator cooling fan • CKP sensor
control relay • A/C refrigerant pressure sensor
• ABS/ESP® control module (wheel speed signal)
Fuel pump control Fuel pump relay
• CKP sensor
Main relay control Main relay
• CKP sensor
• ECT sensor
• CKP sensor
EGR control EGR valve • APP sensor
• IAT sensor
• MAP sensor
• BCM (outside air temperature signal)

• ECT sensor
• CKP sensor
• APP sensor
• IAT sensor
• TP sensor
Generator control Generator
• Electric load current sensor
• Battery temperature sensor
• BCM (electric load signal)
• P/S control module (EPS control current signal)
• ABS/ESP® control module (wheel speed signal and motor
control active signal)
• Generator (LIN communication signal)
Schematic and Routing Diagram

Engine and Emission Control System Diagram
AENNTA0E1102001 (10(01)
17
2
3 [E]
18
4
19
5 [C]
20
6
8 21
10 22 [A]
43
11
23 [B]
12 24
44
[C]
13
[F]
14 25
26 27
[D] 15
15
[D] [C]
16
28
29
30
31
33
32
34
35 36
37
39
40
38
41
42
IMTA0A110004-04
[A]: Ignition switch model 12. Generator 29. Electric load current sensor
[B]: Keyless push start model 13. Neutral position switch 30. MAF sensor with IAT sensor
[C]: M/T model 14. Brake booster switch 31. TP sensor
[D]: AGS model 15. TCM 32. Throttle actuator
[E]: Cruise control model 16. To other control modules and sensors connected by CAN 33. Ignition coil assembly
[F]: ABS model 17. Accelerator pedal assembly (incorporating APP sensor) 34. MAP sensor
1. Intake CMP sensor 18. Brake switch 35. EVAP canister purge valve
2. Exhaust CMP sensor 19. Brake light switch 36. Fuel injector
3. CKP sensor 20. CPP No.2 switch 37. ECT sensor
4. A/C refrigerant pressure sensor 21. Main relay 38. Knock sensor
5. Fuel pump relay 22. Ignition switch 39. Oil temperature sensor
6. Radiator cooling fan relay No.1 23. IG11 relay 40. EGR valve
7. Radiator cooling fan relay No.2 24. BCM 41. HO2S-1
8. Radiator cooling fan relay No.3 25. Starting motor control relay 42. HO2S-2
9. A/C compressor relay 26. CPP No.1 switch 43. ECM
10. Intake OCV 27. Starting motor 44. Barometric pressure sensor
11. Exhaust OCV 28. Battery temperature sensor
Engine and Emission Control System Flow Diagram

AENNTA0E1102002 (10(03)
*: If equipped CAN communication line Air Vapor
Exhaust gas Fuel
EGR
valve
Electric Throttle Intake manifold
Air cleaner Engine Exhaust Three-way Exhaust
body assembly
MAP manifold catalyst pipe
IAT MAF Throttle TP Ignition
sensor CMP CKP Knock
sensor sensor actuator sensor coil OCV
sensor sensor sensor assembly HO2S-1 HO2S-2
Fuel
Check injector
valve
EVAP canister
ECT
purge valve Vapor control Fuel sensor
valve pump
EVAP Fuel tank
Fuel
canister pump
relay
Heater Heater
control control
ECM Barometric pressure sensor
TCM* Generator
A/C Knock CPP No.1 Brake light Main relay

· BCM Radiator
refrigerant sensor switch* / switch /
· ABS/ESP® control module cooling fan
pressure CPP No.2 Brake
· P/S control module relay
sensor switch* switch*
· SDM
· Lighting and turn signal switch
· Headlight auto leveling control module A/C
Electric load APP Oil Brake Newtral
· Combination meter current sensor sensor temperature booster position compressor
· 360 view camera control module sensor switch* switch* relay
· Central gateway control module Battery
temperature
· DLC
sensor
IMTA0A110005-04
Electronic Control System Circuit Diagram

AENNTA0E1102003 (10(01)
1
2 32
BRN E01-20 C01-51 LT GRN
3 33
PNK E01-16 C01-54 BRN M
BLU E01-19 C01-13 RED
BLK E01-6 34
C01-26 GRN
4 YEL E01-3 35
C01-16 WHT
WHT E01-5 C01-15 BLK
+B +B
5 C01-17 BLK 9
PPL C01-30 36
C01-31 PNK
C01-36 BRN 37
C01-11 WHT 38
6 39
YEL C01-40 C01-23 GRY
C01-10 RED 40
C01-32 BEG 41
7 42
PNK C01-39 C01-12 GRN
GRY 43
C01-24 LT GRN
8 9 44
+B RED C01-6 C01-48 GRN
GRN C01-7 C01-45 GRY
PPL C01-49 C01-46 YEL
C01-47 WHT
LT GRN C01-55 45
9 C01-41 GRY
10
YEL C01-8 46
C01-42 GRN
BRN C01-19
47
RED C01-52 C01-43 WHT
BEG C01-56 48
11 E01-24 RED
49 +BB
LT GRN C01-9 BLK P PNK
YEL C01-22 50
BEG C01-29 E01-2 LT GRN
LT BLU C01-14
12 53
BRN C01-27 L+ 51
E01-27 GRN 52
13 M H+
BLU C01-20
L-
GRY C01-4 H-
14 54
BLU C01-21 E01-41 GRY
WHT C01-5 GRY
15
WHT C01-25 71 55
BLU C01-37 56
[E] C01-44 YEL
LT GRN E01-8
16 57
C01-33 GRN
58
18 LT BLU E01-4
BLU E01-48 C01-34 PNK
17 19 59
PNK E01-47
YEL E01-22 C01-35 BEG
60
[C] 20 E01-49 PNK
PPL E01-42
E01-56 BLU
[F] 21 12V E01-55 BLU IG11
PNK E01-12
5V E01-1 WHT
IG2 [A]
IG11 [C] 22
PNK E01-40 IG1 61
+BB YEL E01-7
23 ST
24 BLU E01-44 62 [B]
[E]
25 LT BLU E01-18 IG2
26 64 63
27 GRY E01-14
RED E01-33 E01-31 PNK
BLU E01-9
E01-17 GRN
PPL E01-37 65 66
28
GRN E01-34 E01-36 BRN 67
69
29 BLU C01-1 68
30
E01-11 GRY
[D] [C] 70
[D] WHT C01-2
30
RED C01-3 E01-43 LT GRN
WHT E01-29 C01-50 BLK
31 72 C01-53 BLK
RED E01-28
: 73 : 74 : 12V : 5V
IMTA0A110006-07
[A]: Ignition switch model 22. Neutral position switch 49. Fuel pump
[B]: Keyless push start model 23. Brake light switch with brake switch 50. Radiator cooling fan relay No.1
[C]: M/T model 24. Brake switch 51. Radiator cooling fan relay No.2
[D]: AGS model 25. Brake light switch 52. Radiator cooling fan
[E]: Cruise control model 26. Brake light 53. Radiator cooling fan relay No.3
[F]: ABS model 27. A/C refrigerant pressure sensor 54. A/C compressor relay
1. ECM 28. DC/DC converter 55. A/C compressor
2. Accelerator pedal assembly (incorporating 29. Generator 56. Ignition coil assembly No.1
APP sensor)
3. APP sensor (main) 30. TCM 57. Ignition coil assembly No.2
4. APP sensor (sub) 31. To other control modules and sensors connected 58. Ignition coil assembly No.3
by CAN
5. Intake CMP sensor 32. Electric throttle body assembly 59. Ignition coil assembly No.4
6. Exhaust CMP sensor 33. Throttle actuator 60. Main relay
7. CKP sensor 34. TP sensor (main) 61. Ignition switch
8. HO2S-1 35. TP sensor (sub) 62. IG11 relay
9. Shield wire 36. Fuel injector No.1-1 63. IG2 relay
10. HO2S-2 37. Fuel injector No.1-2 64. BCM
11. MAF sensor with IAT sensor 38. Fuel injector No.2-1 65. Starting motor control relay
12. MAP sensor 39. Fuel injector No.2-2 66. Main fuse box
13. ECT sensor 40. Fuel injector No.3-1 67. ST2 relay
14. Oil temperature sensor 41. Fuel injector No.3-2 68. CPP No.1 switch
15. Knock sensor 42. Fuel injector No.4-1 69. Starting motor
16. Cruise control switch 43. Fuel injector No.4-2 70. Battery
17. Electric load current sensor with battery 44. EGR valve 71. Barometric pressure sensor
temperature sensor
18. Electric load current sensor 45. EVAP canister purge valve 72. CAN driver
19. Battery temperature sensor 46. Intake OCV 73. Engine Ground
20. CPP No.2 switch 47. Exhaust OCV 74. Body ground
21. Brake booster switch 48. Fuel pump relay
Terminal Arrangement of ECM Connector
NOTE
For circuit names and terminal voltages, refer to “Inspection of ECM and Its Circuits”.
[A] C01 E01
[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49
IMTA0A110007-01
[A]: ECM connector (View: [a])
Component Location
Electronic Control System Component Location
AENNTA0E1103001 (04(01)
Overall View
[1]
[1]
[a]
[A], 1
3
[B], 5 [A], 2
[4] [3]
7 [2]
4
[3]
[b]
[h]
[c]
[g]
[d] [e] [f]
IMTA0A110008-06
Information sensors Control devices Others

1. CPP No.2 switch [a]: MIL [1]: Combination meter
2. CPP No.1 switch [b]: Radiator cooling fan relay No.2 [2]: DLC
3. Brake light switch with brake switch [c]: Main relay [3]: Individual circuit fuse box No.1
4. Accelerator pedal assembly (incorporating APP sensor) [d]: Fuel pump relay [4]: ECM
5. Brake booster switch [e]: Radiator cooling fan relay No.1 [A]: M/T model
6. A/C refrigerant pressure sensor [f]: Starting motor control relay [B]: ABS model
7. Electric load current sensor with battery temperature [g]: Radiator cooling fan relay No.3
sensor
[h]: A/C compressor relay
Engine Vicinity View
[g]
4 8, [d]
[a]
[h]
[b]
6 10
[e]
1 [c]
11
[f]
3
IMTA0A110009-01
Information sensors Control devices

1. Oil temperature sensor [a]: Exhaust OCV
2. HO2S-1 [b]: EVAP canister purge valve
3. HO2S-2 [c]: EGR valve
4. MAF sensor with IAT sensor [d]: Electric throttle body assembly
5. Intake CMP sensor [e]: Fuel injector
6. ECT sensor [f]: Generator
7. Exhaust CMP sensor [g]: Ignition coil assembly
8. TP sensor [h]: Intake OCV
9. MAP sensor
10. Knock sensor
11. CKP sensor

Engine and Emission Control System Check
AENNTA0E1104001 (06(01)
Refer to the following items for the details of each step.
Step 1 Customer complaint analysis

1) Perform customer complaint analysis. (Step 1: Customer Complaint Analysis)
Was customer complaint analysis performed?
Yes Go to Step 2.
No Perform customer complaint analysis.
Step 2 DTC / freeze frame data check, record and clearance

1) Check for DTCs (including pending DTCs). (Step 2: DTC / Freeze Frame Data Check, Record and
Clearance)
Is there any DTC(s) / freeze frame data?

Yes Print DTCs and freeze frame data or write them down and clear them referring to “DTC Clearance”,
and go to Step 3.
No Go to Step 4.
Step 3 Visual inspection

1) Perform visual inspection. (Steps 3 and 4: Visual Inspection)
Is there any faulty condition?
Yes Repair or replace defective part, and then go to Step 11.

No Go to Step 5.

1) Perform visual inspection. (Steps 3 and 4: Visual Inspection)

No Go to Step 8.
Step 5 Trouble symptom confirmation

1) Check trouble symptom. (Step 5: Trouble Symptom Confirmation)
Is trouble symptom identified?
Yes Go to Step 6.
No Go to Step 7.
Step 6 Rechecking and recording DTC / freeze frame data

1) Recheck for DTC and freeze frame data. (Steps 6 and 7: Rechecking and Record in DTC / Freeze Frame
Data)
Is there any DTC(s)?
Yes Go to Step 9.
No Go to Step 8.
Step 7 Rechecking and recording DTC / freeze frame data

1) Recheck for DTC and freeze frame data. (Steps 6 and 7: Rechecking and Record in DTC / Freeze Frame
Data)
Yes Go to Step 9.
No Go to Step 10.
Step 8 Engine basic inspection and engine symptom diagnosis

1) Check and repair. (Step 8: Engine Basic Inspection and Engine Symptom Diagnosis)
Are check and repair complete?
Yes Go to Step 11.

No Check and repair defective part(s), and go to Step 11.
Step 9 Troubleshooting for DTC

1) Check and repair according to applicable DTC troubleshooting. (Step 9: Troubleshooting for DTC)

Yes Go to Step 11.

No Check and repair defective part(s), and go to Step 11.
Step 10 Intermittent problem check

1) Check for intermittent problems. (Step 10: Intermittent Problems Check)
Yes Repair or replace defective part(s), and go to Step 11.

No Go to Step 11.
Step 11 Final confirmation test

1) Clear DTC if any.
2) Perform final confirmation test. (Step 11: Final Confirmation Test)
Is there any problem symptom, DTC or abnormal condition?
Yes Go to Step 6.
No End.
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
Step 2: DTC / Freeze Frame Data Check, Record and 4) Perform “ECM Learning Procedure of Engine
Clearance Torque” in Section 1C.
1) Check DTC (including pending DTC). (DTC Check)
Steps 3 and 4: Visual Inspection
2) If DTC is detected, print it and freeze frame data or
As a preliminary step, perform visual check of the items
write them down, and then clear DTC. (DTC
that support proper function of the engine. (Visual
Clearance)
Inspection)
3) Perform “Electric Throttle Control System
Calibration” in Section 1C.
Step 5: Trouble Symptom Confirmation If MIL remains ON and no DTC is stored in ECM, go
If there is no DTC in Step 2: to “MIL Remains ON after Engine Starts” for
Based on information obtained in “Step 1: Customer troubleshooting.
Complaint Analysis” and “Step 2: DTC / Freeze Frame
Data Check, Record and Clearance”, check trouble
1
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” for checking procedure.
Step 8: Engine Basic Inspection and Engine IMTA0A110001-02

Symptom Diagnosis
1) Perform basic engine inspection. (Engine Basic DTC Check
Inspection) AENNTA0E1104003 (06(01)
2) If there is no faulty part found in inspection 1) Connect SUZUKI scan tool or CAN communication
procedure of “Engine basic inspection”, perform OBD-II generic scan tool to DLC. (Suzuki SDT-II
“Engine Symptom Diagnosis” based on symptom Connection and Disconnection) in Section 0A
found in vehicle checking in the following steps. 2) Set ignition “ON”.
• Customer complaint analysis 3) Read DTC, pending DTC and freeze frame data
• Trouble symptom confirmation according to instructions displayed on SUZUKI scan
tool and print them or write them down. Refer to
Step 9: Troubleshooting for DTC Operator's Manual of SUZUKI scan tool for further
Perform applicable DTC troubleshooting and repair or details.
replace faulty parts. NOTE
Step 10: Intermittent Problems Check • A communication error may occur due to
If there is no DTC in Step 2: temporary overlap of communication load.
Check for intermittent problem. (Intermittent Connection If communication error occurs, wait about
and Poor Contact Inspection) in Section 00 10 seconds and try the operation again.
• If communication between SUZUKI scan
If there is any DTC in Step 2: tool and ECM is not possible, perform the
Check parts related to detected DTC (e.g. wire harness, following checks:
connector, etc.). – Check communication condition
between PC and VCI using SUZUKI scan
Step 11: Final Confirmation Test tool function.
Check that the problem symptom has gone and engine
is free from any abnormal conditions. If what has been – Check DLC power circuit and ground
repaired is related to DTC, clear DTC once, perform circuit.
DTC confirmation procedure and check that no DTC is – Check CAN communication circuit and
indicated. connectors between DLC and central
gateway control module. (Refer to
MIL Check “Diagnosis flow: [a]” in
AENNTA0E1104002 (06(01) “Troubleshooting” of “Troubleshooting
1) Set ignition “ON” (with engine at stop) and check that for Lost Communication”.)
MIL (1) lights. (Troubleshooting for Lost
If MIL does not light up but engine can be started, go Communication): CAN in Section 10H
to “MIL Does Not Come ON with Ignition “ON” and – Check DLC cable. If necessary, check
Engine Stopped (but Engine Can Be Started)” for DLC cable by substituting a known-good
troubleshooting. DLC cable.
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”.
2) Start engine and check that MIL turns OFF.
– Check CAN communication system. – Check communication condition

(“Control Module Communication Bus between PC and VCI using SUZUKI scan
Off” is detected in any control module.) tool function.
(Troubleshooting for Communication – Check DLC power circuit and ground
Bus Off): CAN in Section 10H circuit.
– Check central gateway control module – Check CAN communication circuit and
power supply circuit and ground circuit. connectors between DLC and central
(Inspection of Central Gateway Control gateway control module. (Refer to
Module and Its Circuits): CAN (Central “Diagnosis flow: [a]” in
Gateway) in Section 10H “Troubleshooting” of “Troubleshooting
– Check ECM power circuit and ground for Lost Communication”.)
circuit. (ECM Power Supply and Ground (Troubleshooting for Lost
Circuit Check) Communication): CAN in Section 10H
– Check DLC cable. If necessary, check
4) Disconnect SUZUKI scan tool from DLC. (Suzuki DLC cable by substituting a known-good
SDT-II Connection and Disconnection) in Section 0A DLC cable.
– Check CAN communication system.
DTC Clearance (“Control Module Communication Bus
AENNTA0E1104004 (06(01)
1) Connect SUZUKI scan tool or CAN communication Off” is detected in any control module.)
OBD-II generic scan tool to DLC. (Suzuki SDT-II (Troubleshooting for Communication
Connection and Disconnection) in Section 0A Bus Off): CAN in Section 10H
2) Set ignition “ON”. – Check central gateway control module
power supply circuit and ground circuit.
3) Clear DTC and pending DTC according to (Inspection of Central Gateway Control
instructions displayed on SUZUKI scan tool and print Module and Its Circuits): CAN (Central
them or write them down. Refer to Operator's Gateway) in Section 10H
Manual of SUZUKI scan tool for further details.
– Check ECM power circuit and ground
NOTE circuit. (ECM Power Supply and Ground
Circuit Check)
• A communication error may occur due to
temporary overlap of communication load.
4) Perform “Electric Throttle Control System
If communication error occurs, wait about
Calibration” in Section 1C.
10 seconds and try the operation again.
5) Perform “ECM Learning Procedure of Engine
Torque” in Section 1C.
tool and ECM is not possible, perform the
following checks: 6) Disconnect SUZUKI scan tool from DLC. (Suzuki
SDT-II Connection and Disconnection) in Section 0A
DTC Table
AENNTA0E1104005 (06(01)
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”.
• 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”.
• For “Light up / off” (MIL operation) with asterisk (*) in this table, its operation is different depending
on detecting condition.
For details of operation, refer to each “DTC Detecting Condition and Trouble Area”.
• *1: Ignition switch model
• *2: Keyless push start model
DTC
DTC DTC name detection MIL
logic
C1371 (DTC Table) in Section
ENG A-STOP ESP® Control Module Performance 1 D/C Off
10I
C1372 (DTC Table) in Section Invalid Data Received From ENG A-STOP Control Module to
1 D/C Off
10I ABS / ESP® Control Module
C1373 (DTC Table) in Section Invalid Data Received From ENG A-STOP Control Module to
1 D/C Off
10I ABS / ESP® Control Module
*P0010 (DTC P0010 / P0013 /
P2088 / P2089 / P2090 / “A” Camshaft Position Actuator Circuit / Open Bank 1 3 D/C Lights up
P2091)
“A” Camshaft Position -Timing Over - Advanced or System
*P0011 (DTC P0011 / P0014) 3 D/C Lights up
Performance Bank 1
*P0013 (DTC P0010 / P0013 /
P2088 / P2089 / P2090 / “B” Camshaft Position Actuator Circuit / Open 3 D/C Lights up
P2091)
“B” Camshaft Position - Timing Over - Advanced or System
Performance
Crankshaft Position - Camshaft Position Correlation Bank 1
Sensor A
Crankshaft Position - Camshaft Position Correlation Bank 1
Sensor B
*P0030 (DTC P0030 / P0031 /
HO2S Heater Control Circuit Bank 1 Sensor 1 3 D/C Lights up
P0032)
*P0031 (DTC P0030 / P0031 /
HO2S Heater Control Circuit Low Bank 1 Sensor 1 3 D/C Lights up
P0032)
*P0032 (DTC P0030 / P0031 /
HO2S Heater Control Circuit High Bank 1 Sensor 1 3 D/C Lights up
P0032)
*P0036 (DTC P0036 / P0037 /
HO2S Heater Control Circuit Bank 1 Sensor 2 3 D/C Lights up
P0038)
*P0037 (DTC P0036 / P0037 /
HO2S Heater Control Circuit Low Bank 1 Sensor 2 3 D/C Lights up
P0038)
*P0038 (DTC P0036 / P0037 /
HO2S Heater Control Circuit High Bank 1 Sensor 2 3 D/C Lights up
P0038)
*P0102 (DTC P0102 / P0103) Mass or Volume Air Flow “A” Circuit Low 3 D/C Lights up
*P0103 (DTC P0102 / P0103) Mass or Volume Air Flow “A” Circuit High 3 D/C Lights up
*P0107 (DTC P0107 / P0108) Manifold Absolute Pressure/Barometric Pressure Circuit Low 3 D/C Lights up
*P0108 (DTC P0107 / P0108) Manifold Absolute Pressure/Barometric Pressure Circuit High 3 D/C Lights up
*P0112 (DTC P0112 / P0113) Intake Air Temperature Sensor 1 Circuit Low Bank 1 3 D/C Lights up
*P0113 (DTC P0112 / P0113) Intake Air Temperature Sensor 1 Circuit High Bank 1 3 D/C Lights up
Engine Coolant Temperature Sensor 1 Circuit Range/
*P0116 (DTC P0116) 3 D/C Lights up
Performance
*P0117 (DTC P0117 / P0118) Engine Coolant Temperature Sensor 1 Circuit Low 3 D/C Lights up
*P0118 (DTC P0117 / P0118) Engine Coolant Temperature Sensor 1 Circuit High 3 D/C Lights up
*P0122 (DTC P0122 / P0123) Throttle/Pedal Position Sensor/Switch “A” Circuit Low 1 D/C Lights up
*P0123 (DTC P0122 / P0123) Throttle/Pedal Position Sensor/Switch “A” Circuit High 1 D/C Lights up
*P0130 (DTC P0130) O2 Sensor Circuit Bank 1 Sensor 1 3 D/C Lights up
*P0131 (DTC P0131 / P0132) O2 Sensor Circuit Low Voltage Bank 1 Sensor 1 3 D/C Lights up
*P0132 (DTC P0131 / P0132) O2 Sensor Circuit High Voltage Bank 1 Sensor 1 3 D/C Lights up
*P0133 (DTC P0133) O2 Sensor Circuit Slow Response Bank 1 Sensor 1 3 D/C Lights up
*P0134 (DTC P0134) O2 Sensor Circuit No Activity Detected Bank 1 Sensor 1 3 D/C Lights up
*P0137 (DTC P0137 / P0138 /
O2 Sensor Circuit Low Voltage Bank 1 Sensor 2 3 D/C Lights up
P0140)
*P0138 (DTC P0137 / P0138 /
O2 Sensor Circuit High Voltage Bank 1 Sensor 2 3 D/C Lights up
P0140)
*P0139 (DTC P0139 / P2271) O2 Sensor Circuit Slow Response Bank 1 Sensor 2 3 D/C Lights up
*P0140 (DTC P0137 / P0138 /
O2 Sensor Circuit No Activity Detected Bank 1 Sensor 2 3 D/C Lights up
P0140)
*P0171 (DTC P0171 / P0172) System Too Lean Bank 1 3 D/C Lights up
DTC
logic
*P0172 (DTC P0171 / P0172) System Too Rich Bank 1 3 D/C Lights up
*P0197 (DTC P0197 / P0198) Engine Oil Temperature Sensor Circuit Low 3 D/C Off
*P0198 (DTC P0197 / P0198) Engine Oil Temperature Sensor Circuit High 3 D/C Off
*P0201 (DTC P0201 / P0202 /
P0203 / P0204 / P0261 /
P0262 / P0264 / P0265 /
P0267 / P0268 / P0270 /
P0271 / P21CF / P21D0 / Injector Circuit/Open - Cylinder 1 (Injector No.1-1) 3 D/C Lights up
P21D1 / P21D2 / P21DB /
P21DC / P21DE / P21DF /
P21E0 / P21E1 / P21E2 /
P21E3)
*P0202 (DTC P0201 / P0202 /
P0203 / P0204 / P0261 /
P0262 / P0264 / P0265 /
P0267 / P0268 / P0270 /
P21D1 / P21D2 / P21DB /
P21DC / P21DE / P21DF /
P21E0 / P21E1 / P21E2 /
P21E3)
*P0203 (DTC P0201 / P0202 /
P0203 / P0204 / P0261 /
P0262 / P0264 / P0265 /
P0267 / P0268 / P0270 /
P21D1 / P21D2 / P21DB /
P21DC / P21DE / P21DF /
P21E0 / P21E1 / P21E2 /
P21E3)
*P0204 (DTC P0201 / P0202 /
P0203 / P0204 / P0261 /
P0262 / P0264 / P0265 /
P0267 / P0268 / P0270 /
P21D1 / P21D2 / P21DB /
P21DC / P21DE / P21DF /
P21E0 / P21E1 / P21E2 /
P21E3)
*P0222 (DTC P0222 / P0223) Throttle/Pedal Position Sensor/Switch “B” Circuit Low 1 D/C Lights up
*P0223 (DTC P0222 / P0223) Throttle/Pedal Position Sensor/Switch “B” Circuit High 1 D/C Lights up
*P0261 (DTC P0201 / P0202 /
P0203 / P0204 / P0261 /
P0262 / P0264 / P0265 /
P0267 / P0268 / P0270 /
P0271 / P21CF / P21D0 / Cylinder 1 Injector Circuit Low (Injector No.1-1) 3 D/C Lights up
P21D1 / P21D2 / P21DB /
P21DC / P21DE / P21DF /
P21E0 / P21E1 / P21E2 /
P21E3)
DTC
logic
*P0262 (DTC P0201 / P0202 /
P0203 / P0204 / P0261 /
P0262 / P0264 / P0265 /
P0267 / P0268 / P0270 /
P0271 / P21CF / P21D0 / Cylinder 1 Injector Circuit High (Injector No.1-1) 3 D/C Lights up
P21D1 / P21D2 / P21DB /
P21DC / P21DE / P21DF /
P21E0 / P21E1 / P21E2 /
P21E3)
*P0264 (DTC P0201 / P0202 /
P0203 / P0204 / P0261 /
P0262 / P0264 / P0265 /
P0267 / P0268 / P0270 /
P21D1 / P21D2 / P21DB /
P21DC / P21DE / P21DF /
P21E0 / P21E1 / P21E2 /
P21E3)
*P0265 (DTC P0201 / P0202 /
P0203 / P0204 / P0261 /
P0262 / P0264 / P0265 /
P0267 / P0268 / P0270 /
P21D1 / P21D2 / P21DB /
P21DC / P21DE / P21DF /
P21E0 / P21E1 / P21E2 /
P21E3)
*P0267 (DTC P0201 / P0202 /
P0203 / P0204 / P0261 /
P0262 / P0264 / P0265 /
P0267 / P0268 / P0270 /
P21D1 / P21D2 / P21DB /
P21DC / P21DE / P21DF /
P21E0 / P21E1 / P21E2 /
P21E3)
*P0268 (DTC P0201 / P0202 /
P0203 / P0204 / P0261 /
P0262 / P0264 / P0265 /
P0267 / P0268 / P0270 /
P21D1 / P21D2 / P21DB /
P21DC / P21DE / P21DF /
P21E0 / P21E1 / P21E2 /
P21E3)
*P0270 (DTC P0201 / P0202 /
P0203 / P0204 / P0261 /
P0262 / P0264 / P0265 /
P0267 / P0268 / P0270 /
P21D1 / P21D2 / P21DB /
P21DC / P21DE / P21DF /
P21E0 / P21E1 / P21E2 /
P21E3)
DTC
logic
*P0271 (DTC P0201 / P0202 /
P0203 / P0204 / P0261 /
P0262 / P0264 / P0265 /
P0267 / P0268 / P0270 /
P21D1 / P21D2 / P21DB /
P21DC / P21DE / P21DF /
P21E0 / P21E1 / P21E2 /
P21E3)
*P0300 (DTC P0300 / P0301 /
Random/Multiple Cylinder Misfire Detected 3 D/C Lights up
P0302 / P0303 / P0304)
*P0301 (DTC P0300 / P0301 /
Cylinder 1 Misfire Detected 3 D/C Lights up
P0302 / P0303 / P0304)
*P0302 (DTC P0300 / P0301 /
P0302 / P0303 / P0304)
*P0303 (DTC P0300 / P0301 /
P0302 / P0303 / P0304)
*P0304 (DTC P0300 / P0301 /
P0302 / P0303 / P0304)
*P0327 (DTC P0327 / P0328) Knock Sensor 1 Circuit Low Bank 1 or Single Sensor 3 D/C Lights up
*P0328 (DTC P0327 / P0328) Knock Sensor 1 Circuit High Bank 1 or Single Sensor 3 D/C Lights up
*P0335 (DTC P0335 / P0336) Crankshaft Position Sensor “A” Circuit 3 D/C Lights up
*P0336 (DTC P0335 / P0336) Crankshaft Position Sensor “A” Circuit Range/Performance 3 D/C Lights up
*P0340 (DTC P0340 / P0365) Camshaft Position Sensor “A” Circuit Bank 1 or Single Sensor 3 D/C Lights up
*P0351 (DTC P0351 / P0352 /
P0353 / P0354 / P2300 /
P2301 / P2303 / P2304 / Ignition Coil “A” Primary / Secondary Circuit 3 D/C Lights up
P2306 / P2307 / P2309 /
P2310)
*P0352 (DTC P0351 / P0352 /
P0353 / P0354 / P2300 /
P2301 / P2303 / P2304 / Ignition Coil “B” Primary / Secondary Circuit 3 D/C Lights up
P2306 / P2307 / P2309 /
P2310)
*P0353 (DTC P0351 / P0352 /
P0353 / P0354 / P2300 /
P2301 / P2303 / P2304 / Ignition Coil “C” Primary / Secondary Circuit 3 D/C Lights up
P2306 / P2307 / P2309 /
P2310)
*P0354 (DTC P0351 / P0352 /
P0353 / P0354 / P2300 /
P2301 / P2303 / P2304 / Ignition Coil “D” Primary / Secondary Circuit 3 D/C Lights up
P2306 / P2307 / P2309 /
P2310)
*P0365 (DTC P0340 / P0365) Camshaft Position Sensor “B” Circuit 3 D/C Lights up
*P0400 (DTC P0400) Exhaust Gas Recirculation “A” Flow 3 D/C Lights up
*P0403 (DTC P0403) Exhaust Gas Recirculation “A” Control Circuit 3 D/C Lights up
*P0420 (DTC P0420) Catalyst System Efficiency Below Threshold Bank 1 3 D/C Lights up
*P0443 (DTC P0443 / P0458 /
Evaporative Emission System Purge Control Valve Circuit 3 D/C Lights up
P0459)
*P0458 (DTC P0443 / P0458 /
Evaporative Emission System Purge Control Valve Circuit Low 3 D/C Lights up
P0459)
*P0459 (DTC P0443 / P0458 /
Evaporative Emission System Purge Control Valve Circuit High 3 D/C Lights up
P0459)
*P0480 (DTC P0480 / P0691 /
Fan 1 Control Circuit 3 D/C Off
P0692)
DTC
logic
*P0481 (DTC P0481 / P0693 /
Fan 2 Control Circuit 3 D/C Off
P0694)
*P0500 (DTC P0500) Vehicle Speed Sensor “A” 3 D/C Lights up
*P0504 (DTC P0504) Brake Switch “A”/”B” Correlation 3 D/C Off
P0515 (DTC P0515) Battery Temperature Sensor Circuit 3 D/C Off
*P0530 (DTC P0530) A/C Refrigerant Pressure Sensor “A” Circuit 3 D/C Off
*P0555 (DTC Table) in Section
Brake Booster Pressure Sensor Circuit 1 D/C Off
10I
*P0560 (DTC P0560 / P0562 /
System Voltage 3 D/C Lights up
P0563)
*P0562 (DTC P0560 / P0562 /
System Voltage Low 3 D/C Lights up
P0563)
*P0563 (DTC P0560 / P0562 /
System Voltage High 3 D/C Lights up
P0563)
*P0571 (DTC P0571) Brake Switch “A” Circuit 1 D/C Lights up
Cruise Control Input Circuit 1 D/C Off
10A
*P0602 (DTC P0602) Control Module Programming Error 1 D/C Off
*P0606 (DTC P0606) Control Module Processor 3 D/C Lights up
*P060A (DTC P060A / P060B /
P060D / P0611 / P061A /
P061B / P061C / P061D /
Internal Control Module Monitoring Processor Performance 1 D/C Lights up
P061F / P062B / P062D /
P06D1 / P160B / P161A /
P161B / P161C)
*P060B (DTC P060A / P060B /
P060D / P0611 / P061A /
P061B / P061C / P061D /
Internal Control Module A/D Processing Performance 1 D/C Lights up
P061F / P062B / P062D /
P06D1 / P160B / P161A /
P161B / P161C)
*P060D (DTC P060A / P060B /
P060D / P0611 / P061A /
P061B / P061C / P061D / Internal Control Module Accelerator Pedal Position
1 D/C Lights up
P061F / P062B / P062D / Performance
P06D1 / P160B / P161A /
P161B / P161C)
*P0611 (DTC P060A / P060B /
P060D / P0611 / P061A /
P061B / P061C / P061D /
Fuel Injector Control Module Performance 1 D/C Lights up
P061F / P062B / P062D /
P06D1 / P160B / P161A /
P161B / P161C)
*P061A (DTC P060A / P060B /
P060D / P0611 / P061A /
P061B / P061C / P061D /
Internal Control Module Torque Performance 1 D/C Lights up
P061F / P062B / P062D /
P06D1 / P160B / P161A /
P161B / P161C)
*P061B (DTC P060A / P060B /
P060D / P0611 / P061A /
P061B / P061C / P061D /
Internal Control Module Torque Calculation Performance 1 D/C Lights up
P061F / P062B / P062D /
P06D1 / P160B / P161A /
P161B / P161C)
DTC
logic
*P061C (DTC P060A / P060B /
P060D / P0611 / P061A /
P061B / P061C / P061D /
Internal Control Module Engine RPM Performance 1 D/C Lights up
P061F / P062B / P062D /
P06D1 / P160B / P161A /
P161B / P161C)
*P061D (DTC P060A / P060B /
P060D / P0611 / P061A /
P061B / P061C / P061D /
Internal Control Module Engine Air Mass Performance 1 D/C Lights up
P061F / P062B / P062D /
P06D1 / P160B / P161A /
P161B / P161C)
*P061F (DTC P060A / P060B /
P060D / P0611 / P061A /
P061B / P061C / P061D / Internal Control Module Throttle Actuator Controller
1 D/C Lights up
P061F / P062B / P062D / Performance
P06D1 / P160B / P161A /
P161B / P161C)
*P062B (DTC P060A / P060B /
P060D / P0611 / P061A /
P061B / P061C / P061D /
Internal Control Module Fuel Injector Control Performance 1 D/C Lights up
P061F / P062B / P062D /
P06D1 / P160B / P161A /
P161B / P161C)
*P062D (DTC P060A / P060B /
P060D / P0611 / P061A /
P061B / P061C / P061D /
Fuel Injector Driver Circuit Performance Bank 1 1 D/C Lights up
P061F / P062B / P062D /
P06D1 / P160B / P161A /
P161B / P161C)
*P0645 (DTC P0645 / P0646 /
A/C Clutch Relay Control Circuit 3 D/C Off
P0647)
*P0646 (DTC P0645 / P0646 /
A/C Clutch Relay Control Circuit Low 3 D/C Off
P0647)
*P0647 (DTC P0645 / P0646 /
A/C Clutch Relay Control Circuit High 3 D/C Off
P0647)
Speed Control Lamp Control Circuit 1 D/C Off
10A
*P0691 (DTC P0480 / P0691 /
Fan 1 Control Circuit Low 3 D/C Off
P0692)
*P0692 (DTC P0480 / P0691 /
Fan 1 Control Circuit High 3 D/C Off
P0692)
*P0693 (DTC P0481 / P0693 /
Fan 2 Control Circuit Low 3 D/C Off
P0694)
*P0694 (DTC P0481 / P0693 /
Fan 2 Control Circuit High 3 D/C Off
P0694)
*P06D1 (DTC P060A / P060B /
P060D / P0611 / P061A /
P061B / P061C / P061D /
Internal Control Module Ignition Coil Control Performance 1 D/C Lights up
P061F / P062B / P062D /
P06D1 / P160B / P161A /
P161B / P161C)
*P0703 (DTC P0703) Brake Switch “B” Circuit 1 D/C Lights up
*P081D (DTC Table) in Section
Neutral Input Circuit 1 D/C Off
10I
*P083F (DTC Table) in Section
Clutch Pedal Switch “A” / “B” Correlation 1 D/C Off
10I
DTC
logic
P0A5A (DTC P0A5A) Generator Current Sensor Circuit Range / Performance 3 D/C Off
ENG A-STOP Starter Relay Circuit Low 1 D/C Off
10I
ENG A-STOP Starter Relay Circuit High 1 D/C Off
10I
ENG A-STOP Starter Performance 1 D/C Off
10I
ENG A-STOP Starter Active Counter Not Set 1 D/C Off
10I
P1321 (DTC Table) in Section
ENG A-STOP Battery Current Sensor “A” Circuit Low 1 D/C Off
10I
ENG A-STOP Battery Current Sensor “A” Circuit High 1 D/C Off
10I
ENG A-STOP Battery Temperature Sensor Circuit Low 1 D/C Off
10I
ENG A-STOP Battery Temperature Sensor Circuit High 1 D/C Off
10I
*P1330 (DTC Table) in Section 1 D/C Off
ENG A-STOP DC-DC Converter “A” Performance
10I 3 D/C Off
ENG A-STOP DC-DC Converter “A” Malfunction 3 D/C Off
10I
*P1350 (DTC Table) in Section ENG A-STOP DC-DC Converter “A” Over Temperature Short
3 D/C Off
10I Time
ENG A-STOP DC-DC Converter “A” Over Temperature 3 D/C Off
10I
*P1353 (DTC Table) in Section ENG A-STOP DC-DC Converter “A” Output Circuit Short to
3 D/C Off
10I Ground
ENG A-STOP Battery Performance 1 D/C Off
10I
P13A0 (DTC Table) in Section
ENG A-STOP OFF Switch Circuit 1 D/C Off
10I
P160B (DTC P060A / P060B /
P060D / P0611 / P061A /
P061B / P061C / P061D /
Internal Control Module A/D Converter Performance 1 D/C Lights up
P061F / P062B / P062D /
P06D1 / P160B / P161A /
P161B / P161C)
P1610(*1) (DTC Table):
Ignition Switch Model in
Section 10C
Immobilizer ID and/or Password Not Registered 1 D/C Off
Keyless Push Start Model in
Section 10C
P1611(*1) (DTC Table): Ignition
Switch Model in Section 10C
P1611(*2) (DTC Table): Password Not Matched 1 D/C Off
Section 10C
P161A (DTC P060A / P060B /
P060D / P0611 / P061A /
P061B / P061C / P061D /
Internal Control Module Ignition Timing 1 D/C Lights up
P061F / P062B / P062D /
P06D1 / P160B / P161A /
P161B / P161C)
DTC
logic
P161B (DTC P060A / P060B /
P060D / P0611 / P061A /
P061B / P061C / P061D / Internal Control Module Comparison of Lambda and Operation
1 D/C Lights up
P061F / P062B / P062D / Mode
P06D1 / P160B / P161A /
P161B / P161C)
P161C (DTC P060A / P060B /
P060D / P0611 / P061A /
P061B / P061C / P061D /
Internal Control Module Engine Mixture Check 1 D/C Lights up
P061F / P062B / P062D /
P06D1 / P160B / P161A /
P161B / P161C)
Section 10C
EEPROM Reading / Writing Error 1 D/C Off
Section 10C
Section 10C
Immobilizer Communication Line Error 1 D/C Off
Section 10C
Section 10C
Immobilizer ID Mismatched 1 D/C Off
Section 10C
Section 10C
ID Code Communication Error 1 D/C Off
Section 10C
Section 10C
ID Code Incorrectness 1 D/C Off
Section 10C
*P1660 (DTC P1660) Abnormal Refrigerant Pressure (High Pressure) 1 D/C Off
P1693 (DTC P1693) Equipment Information Mismatched 1 D/C Off
*P2088 (DTC P0010 / P0013 /
P2088 / P2089 / P2090 / “A” Camshaft Position Actuator Control Circuit Low Bank 1 3 D/C Lights up
P2091)
*P2089 (DTC P0010 / P0013 /
P2088 / P2089 / P2090 / “A” Camshaft Position Actuator Control Circuit High Bank 1 3 D/C Lights up
P2091)
*P2090 (DTC P0010 / P0013 /
P2088 / P2089 / P2090 / “B” Camshaft Position Actuator Control Circuit Low 3 D/C Lights up
P2091)
*P2091 (DTC P0010 / P0013 /
P2088 / P2089 / P2090 / “B” Camshaft Position Actuator Control Circuit High 3 D/C Lights up
P2091)
*P2100 (DTC P2100) Throttle Actuator “A” Control Motor Circuit/Open 1 D/C Lights up
DTC
logic
*P2101 (DTC P2101 / P2119) Throttle Actuator “A” Control Motor Circuit Range/Performance 1 D/C Lights up
*P2119 (DTC P2101 / P2119) Throttle Actuator Control Throttle Body Range / Performance 1 D/C Lights up
*P2122 (DTC P2122 / P2123) Throttle / Pedal Position Sensor / Switch “D” Circuit Low 1 D/C Lights up
*P2123 (DTC P2122 / P2123) Throttle / Pedal Position Sensor / Switch “D” Circuit High 1 D/C Lights up
*P2127 (DTC P2127 / P2128) Throttle / Pedal Position Sensor / Switch “E” Circuit Low 1 D/C Lights up
*P2128 (DTC P2127 / P2128) Throttle / Pedal Position Sensor / Switch “E” Circuit High 1 D/C Lights up
Throttle / Pedal Position Sensor / Switch “A”/”B” Voltage
Correlation
Throttle / Pedal Position Sensor / Switch “D”/”E” Voltage
Correlation
*P2176 (DTC P2176) Throttle Actuator Control System – Idle Position Not Learned 1 D/C Lights up
P21CF (DTC P0201 / P0202 /
P0203 / P0204 / P0261 /
P0262 / P0264 / P0265 /
P0267 / P0268 / P0270 /
P0271 / P21CF / P21D0 / Cylinder 1-2 Injector Circuit Low (Injector No.1-2) 3 D/C Lights up
P21D1 / P21D2 / P21DB /
P21DC / P21DE / P21DF /
P21E0 / P21E1 / P21E2 /
P21E3)
P21D0 (DTC P0201 / P0202 /
P0203 / P0204 / P0261 /
P0262 / P0264 / P0265 /
P0267 / P0268 / P0270 /
P21D1 / P21D2 / P21DB /
P21DC / P21DE / P21DF /
P21E0 / P21E1 / P21E2 /
P21E3)
P21D1 (DTC P0201 / P0202 /
P0203 / P0204 / P0261 /
P0262 / P0264 / P0265 /
P0267 / P0268 / P0270 /
P21D1 / P21D2 / P21DB /
P21DC / P21DE / P21DF /
P21E0 / P21E1 / P21E2 /
P21E3)
P21D2 (DTC P0201 / P0202 /
P0203 / P0204 / P0261 /
P0262 / P0264 / P0265 /
P0267 / P0268 / P0270 /
P0271 / P21CF / P21D0 / Injector Circuit / Open – Cylinder 4 (Injector No.4-2) 3 D/C Lights up
P21D1 / P21D2 / P21DB /
P21DC / P21DE / P21DF /
P21E0 / P21E1 / P21E2 /
P21E3)
P21DB (DTC P0201 / P0202 /
P0203 / P0204 / P0261 /
P0262 / P0264 / P0265 /
P0267 / P0268 / P0270 /
P0271 / P21CF / P21D0 / Cylinder1 Injector Circuit Low (Injector No.1-2) 3 D/C Lights up
P21D1 / P21D2 / P21DB /
P21DC / P21DE / P21DF /
P21E0 / P21E1 / P21E2 /
P21E3)
DTC
logic
P21DC (DTC P0201 / P0202 /
P0203 / P0204 / P0261 /
P0262 / P0264 / P0265 /
P0267 / P0268 / P0270 /
P0271 / P21CF / P21D0 / Cylinder 1-2 Injector Circuit High (Injector No.1-2) 3 D/C Lights up
P21D1 / P21D2 / P21DB /
P21DC / P21DE / P21DF /
P21E0 / P21E1 / P21E2 /
P21E3)
P21DE (DTC P0201 / P0202 /
P0203 / P0204 / P0261 /
P0262 / P0264 / P0265 /
P0267 / P0268 / P0270 /
P21D1 / P21D2 / P21DB /
P21DC / P21DE / P21DF /
P21E0 / P21E1 / P21E2 /
P21E3)
P21DF (DTC P0201 / P0202 /
P0203 / P0204 / P0261 /
P0262 / P0264 / P0265 /
P0267 / P0268 / P0270 /
P21D1 / P21D2 / P21DB /
P21DC / P21DE / P21DF /
P21E0 / P21E1 / P21E2 /
P21E3)
P21E0 (DTC P0201 / P0202 /
P0203 / P0204 / P0261 /
P0262 / P0264 / P0265 /
P0267 / P0268 / P0270 /
P21D1 / P21D2 / P21DB /
P21DC / P21DE / P21DF /
P21E0 / P21E1 / P21E2 /
P21E3)
P21E1 (DTC P0201 / P0202 /
P0203 / P0204 / P0261 /
P0262 / P0264 / P0265 /
P0267 / P0268 / P0270 /
P21D1 / P21D2 / P21DB /
P21DC / P21DE / P21DF /
P21E0 / P21E1 / P21E2 /
P21E3)
P21E2 (DTC P0201 / P0202 /
P0203 / P0204 / P0261 /
P0262 / P0264 / P0265 /
P0267 / P0268 / P0270 /
P21D1 / P21D2 / P21DB /
P21DC / P21DE / P21DF /
P21E0 / P21E1 / P21E2 /
P21E3)
DTC
logic
P21E3(DTC P0201 / P0202 /
P0203 / P0204 / P0261 /
P0262 / P0264 / P0265 /
P0267 / P0268 / P0270 /
P21D1 / P21D2 / P21DB /
P21DC / P21DE / P21DF /
P21E0 / P21E1 / P21E2 /
P21E3)
*P2226 (DTC P2226 / P2227) Barometric Pressure Sensor “A” Circuit 3 D/C Lights up
*P2227 (DTC P2226 / P2227) Barometric Pressure Sensor “A” Circuit Range/Performance 3 D/C Lights up
*P2271 (DTC P0139 / P2271) O2 Sensor Signal Biased/Stuck Rich Bank 1 Sensor 2 3 D/C Lights up
*P2300 (DTC P0351 / P0352 /
P0353 / P0354 / P2300 /
P2301 / P2303 / P2304 / Ignition Coil “A” Primary Control Circuit Low 3 D/C Lights up
P2306 / P2307 / P2309 /
P2310)
*P2301 (DTC P0351 / P0352 /
P0353 / P0354 / P2300 /
P2301 / P2303 / P2304 / Ignition Coil “A” Primary Control Circuit High 3 D/C Lights up
P2306 / P2307 / P2309 /
P2310)
*P2303 (DTC P0351 / P0352 /
P0353 / P0354 / P2300 /
P2301 / P2303 / P2304 / Ignition Coil “B” Primary Control Circuit Low 3 D/C Lights up
P2306 / P2307 / P2309 /
P2310)
*P2304 (DTC P0351 / P0352 /
P0353 / P0354 / P2300 /
P2301 / P2303 / P2304 / Ignition Coil “B” Primary Control Circuit High 3 D/C Lights up
P2306 / P2307 / P2309 /
P2310)
*P2306 (DTC P0351 / P0352 /
P0353 / P0354 / P2300 /
P2301 / P2303 / P2304 / Ignition Coil “C” Primary Control Circuit Low 3 D/C Lights up
P2306 / P2307 / P2309 /
P2310)
*P2307 (DTC P0351 / P0352 /
P0353 / P0354 / P2300 /
P2301 / P2303 / P2304 / Ignition Coil “C” Primary Control Circuit High 3 D/C Lights up
P2306 / P2307 / P2309 /
P2310)
*P2309 (DTC P0351 / P0352 /
P0353 / P0354 / P2300 /
P2301 / P2303 / P2304 / Ignition Coil “D” Primary Control Circuit Low 3 D/C Lights up
P2306 / P2307 / P2309 /
P2310)
*P2310 (DTC P0351 / P0352 /
P0353 / P0354 / P2300 /
P2301 / P2303 / P2304 / Ignition Coil “D” Primary Control Circuit High 3 D/C Lights up
P2306 / P2307 / P2309 /
P2310)
*P254F (DTC Table) in Section
Engine Hood Switch Circuit 1 D/C Off
10I
*U0073 (DTC U0073) Control Module Communication Bus Off 1 D/C Off
*U0101 (DTC U0101 / U0121 /
Lost Communication with TCM 1 D/C Lights up
U0131 / U0140 / U0155)
DTC
logic
*U0121 (DTC U0101 / U0121 /
Lost Communication With ABS/ESP® Control Module 1 D/C Lights up
U0131 / U0140 / U0155)
*U0131 (DTC U0101 / U0121 /
Lost Communication With Power Steering Control Module 1 D/C Off
U0131 / U0140 / U0155)
*U0140 (DTC U0101 / U0121 /
Lost Communication With Body Control Module 1 D/C Off
U0131 / U0140 / U0155)
*U0155 (DTC U0101 / U0121 / Lost Communication With Instrument Panel Cluster (IPC)
1 D/C Off
U0131 / U0140 / U0155) Control Module
*U2001 (DTC U2001) LIN Lost Communication With Generator 1 D/C Off
*U2021 (DTC U2021) LIN Invalid Data from ECM to Generator 1 D/C Off
Fail-Safe Table
AENNTA0E1104006 (06(01)
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
C1371 (DTC
ENG A-STOP ESP® Control Module
C1371) in
Performance
Section 10I
C1372 (DTC Invalid Data Received From ENG A-
C1372 / C1373) STOP Control Module to ABS / ESP® Refer to “Fail-Safe Table” in Section 10I.
in Section 10I Control Module
C1373 (DTC Invalid Data Received From ENG A-
C1372 / C1373) STOP Control Module to ABS / ESP®
in Section 10I Control Module
P0010 (DTC
P0010 / P0013 / “A” Camshaft Position Actuator Circuit/
P2088 / P2089 / Open Bank 1
P2090 / P2091) ECM stops intake VVT actuator control.
“A” Camshaft Position - Timing Over -
P0011 (DTC
Advanced or System Performance Bank
P0011 / P0014)
1
P0013 (DTC
P0010 / P0013 / “B” Camshaft Position Actuator Circuit /
P2088 / P2089 / Open
ECM stops exhaust VVT control.
P2090 / P2091)
P0014 (DTC “B” Camshaft Position - Timing Over -
P0011 / P0014) Advanced or System Performance
P0016 (DTC Crankshaft Position - Camshaft Position
ECM stops intake VVT actuator control.
P0016 / P0017) Correlation Bank 1 Sensor A
P0017 (DTC Crankshaft Position - Camshaft Position
ECM stops exhaust VVT actuator control.
P0016 / P0017) Correlation Bank 1 Sensor B

P0030 (DTC
HO2S Heater Control Circuit Bank 1
P0030 / P0031 /
Sensor 1
P0032)
P0031 (DTC
HO2S Heater Control Circuit Low Bank 1
P0030 / P0031 /
Sensor 1
P0032)
P0032 (DTC
HO2S Heater Control Circuit High Bank 1
P0030 / P0031 /
Sensor 1
P0032)
ECM stops A/F feedback (closed loop) control.
P0036 (DTC
HO2S Heater Control Circuit Bank 1
P0036 / P0037 /
Sensor 2
P0038)
P0037 (DTC
HO2S Heater Control Circuit Low Bank 1
P0036 / P0037 /
Sensor 2
P0038)
P0038 (DTC
HO2S Heater Control Circuit High Bank 1
P0036 / P0037 /
Sensor 2
P0038)
P0102 (DTC
Mass or Volume Air Flow Circuit Low ECM calculates MAF value from MAP sensor signal. If
P0102 / P0103)
MAP sensor error is also present, ECM calculates MAF
P0103 (DTC
Mass or Volume Air Flow Circuit High value from TP sensor signal.
P0102 / P0103)
P0107 (DTC Manifold Absolute Pressure / Barometric
P0107 / P0108) Pressure Circuit Low
ECM calculates MAP value from TP sensor signal.
P0108 (DTC Manifold Absolute Pressure / Barometric
P0107 / P0108) Pressure Circuit High
P0112 (DTC Intake Air Temperature Sensor 1 Circuit
P0112 / P0113) Low Bank 1 ECM controls actuators assuming that intake air
P0113 (DTC Intake Air Temperature Sensor 1 Circuit temperature is 20 °C (68 °F).
P0112 / P0113) High Bank 1
P0116 (DTC Engine Coolant Temperature Sensor 1
P0116) Circuit Range / Performance
P0117 (DTC Engine Coolant Temperature Sensor 1 • ECM calculates ECT value from engine load.
P0117 / P0118) Circuit Low • ECM operates radiator cooling fan. (high speed)
P0118 (DTC Engine Coolant Temperature Sensor 1
P0117 / P0118) Circuit High
P0122 (DTC Throttle / Pedal Position Sensor / Switch
P0122 / P0123) “A” Circuit Low
ECM decreases engine torque.
P0122 / P0123) “A” Circuit High
P0130 (DTC
O2 Sensor Circuit Bank 1 Sensor 1
P0130)
P0131 (DTC O2 Sensor Circuit Low Voltage Bank 1
P0131 / P0132) Sensor 1
P0132 (DTC O2 Sensor Circuit High Voltage Bank 1
P0131 / P0132) Sensor 1
P0133 (DTC O2 Sensor Circuit Slow Response Bank
--
P0133) 1 Sensor 1
P0134 (DTC O2 Sensor Circuit No Activity Detected
P0134) Bank 1 Sensor 1

P0137 (DTC
O2 Sensor Circuit Low Voltage Bank 1
P0137 / P0138 /
Sensor 2
P0140)
P0138 (DTC
O2 Sensor Circuit High Voltage Bank 1
P0137 / P0138 /
Sensor 2
P0140) --
P0139 (DTC O2 Sensor Circuit Slow Response Bank1
P0139 / P2271) Sensor2
P0140 (DTC
O2 Sensor Circuit No Activity Detected
P0137 / P0138 /
Bank 1 Sensor 2
P0140)
P0171 (DTC
System Too Lean Bank 1
P0171 / P0172)
--
P0172 (DTC
System Too Rich Bank 1
P0171 / P0172)
P0197 (DTC Engine Oil Temperature Sensor Circuit
P0197 / P0198) Low
--
P0198 (DTC Engine Oil Temperature Sensor Circuit
P0197 / P0198) High
P0201 (DTC
P0201 / P0202 /
P0203 / P0204 /
P0261 / P0262 /
P0264 / P0265 /
P0267 / P0268 /
P0270 / P0271 / Injector Circuit/Open - Cylinder 1 (Injector • ECM stops fuel injector No.1 control.
P21CF / P21D0 No.1-1) • ECM stops A/F feedback (closed loop) control.
/ P21D1 / P21D2
/ P21DB /
P21DC / P21DE
/ P21DF / P21E0
/ P21E1 / P21E2
/ P21E3)
P0202 (DTC
P0201 / P0202 /
P0203 / P0204 /
P0261 / P0262 /
P0264 / P0265 /
P0267 / P0268 /
P0270 / P0271 / Injector Circuit/Open - Cylinder 2 (Injector • ECM stops fuel injector No. 2 control.
/ P21D1 / P21D2
/ P21DB /
P21DC / P21DE
/ P21DF / P21E0
/ P21E1 / P21E2
/ P21E3)

P0203 (DTC
P0201 / P0202 /
P0203 / P0204 /
P0261 / P0262 /
P0264 / P0265 /
P0267 / P0268 /
/ P21D1 / P21D2
/ P21DB /
P21DC / P21DE
/ P21DF / P21E0
/ P21E1 / P21E2
/ P21E3)
P0204 (DTC
P0201 / P0202 /
P0203 / P0204 /
P0261 / P0262 /
P0264 / P0265 /
P0267 / P0268 /
/ P21D1 / P21D2
/ P21DB /
P21DC / P21DE
/ P21DF / P21E0
/ P21E1 / P21E2
/ P21E3)
P0222 / P0223) “B” Circuit Low
P0222 / P0223) “B” Circuit High

P0261 (DTC
P0201 / P0202 /
P0203 / P0204 /
P0261 / P0262 /
P0264 / P0265 /
P0267 / P0268 /
P0270 / P0271 / Cylinder 1 Injector Circuit Low (Injector
P21CF / P21D0 No.1-1)
/ P21D1 / P21D2
/ P21DB /
P21DC / P21DE
/ P21DF / P21E0
/ P21E1 / P21E2
/ P21E3) • ECM stops fuel injector No.1 control.
P0262 (DTC • ECM stops A/F feedback (closed loop) control.
P0201 / P0202 /
P0203 / P0204 /
P0261 / P0262 /
P0264 / P0265 /
P0267 / P0268 /
P0270 / P0271 / Cylinder 1 Injector Circuit High (Injector
P21CF / P21D0 No.1-1)
/ P21D1 / P21D2
/ P21DB /
P21DC / P21DE
/ P21DF / P21E0
/ P21E1 / P21E2
/ P21E3)
P0264 (DTC
P0201 / P0202 /
P0203 / P0204 /
P0261 / P0262 /
P0264 / P0265 /
P0267 / P0268 /
P21CF / P21D0 No.2-1)
/ P21D1 / P21D2
/ P21DB /
P21DC / P21DE
/ P21DF / P21E0
/ P21E1 / P21E2
/ P21E3) • ECM stops fuel injector No. 2 control.
P0201 / P0202 /
P0203 / P0204 /
P0261 / P0262 /
P0264 / P0265 /
P0267 / P0268 /
P21CF / P21D0 No.2-1)
/ P21D1 / P21D2
/ P21DB /
P21DC / P21DE
/ P21DF / P21E0
/ P21E1 / P21E2
/ P21E3)

P0267 (DTC
P0201 / P0202 /
P0203 / P0204 /
P0261 / P0262 /
P0264 / P0265 /
P0267 / P0268 /
P21CF / P21D0 No.3-1)
/ P21D1 / P21D2
/ P21DB /
P21DC / P21DE
/ P21DF / P21E0
/ P21E1 / P21E2
P0201 / P0202 /
P0203 / P0204 /
P0261 / P0262 /
P0264 / P0265 /
P0267 / P0268 /
P21CF / P21D0 No.3-1)
/ P21D1 / P21D2
/ P21DB /
P21DC / P21DE
/ P21DF / P21E0
/ P21E1 / P21E2
/ P21E3)
P0270 (DTC
P0201 / P0202 /
P0203 / P0204 /
P0261 / P0262 /
P0264 / P0265 /
P0267 / P0268 /
P21CF / P21D0 No.4-1)
/ P21D1 / P21D2
/ P21DB /
P21DC / P21DE
/ P21DF / P21E0
/ P21E1 / P21E2
P0201 / P0202 /
P0203 / P0204 /
P0261 / P0262 /
P0264 / P0265 /
P0267 / P0268 /
P21CF / P21D0 No.4-1)
/ P21D1 / P21D2
/ P21DB /
P21DC / P21DE
/ P21DF / P21E0
/ P21E1 / P21E2
/ P21E3)

P0300 (DTC
P0300 / P0301 / Random / Multiple Cylinder Misfire
--
P0302 / P0303 / Detected
P0304)
P0301 (DTC
P0300 / P0301 / ECM stops fuel injector No.1 control for catalyst
Cylinder 1 Misfire Detected
P0302 / P0303 / damaging levels of misfire.
P0304)
P0302 (DTC
P0304)
P0303 (DTC
P0304)
P0304 (DTC
P0304)
P0327 (DTC Knock Sensor 1 Circuit Low Bank 1 or
P0327 / P0328) Single Sensor
ECM retards ignition timing.
P0328 (DTC Knock Sensor 1 Circuit High Bank 1 or
P0327 / P0328) Single Sensor
P0335 (DTC
Crankshaft Position Sensor “A” Circuit
P0335 / P0336)
ECM calculates CKP signal from CMP sensor signal.
P0336 (DTC Crankshaft Position Sensor “A” Circuit
P0335 / P0336) Range / Performance
P0340 (DTC Camshaft Position Sensor “A” Circuit
P0340 / P0365) Bank 1 or Single Sensor
P0351 (DTC
P0351 / P0352 /
P0353 / P0354 /
Ignition Coil “A” Primary / Secondary
P2300 / P2301 /
Circuit
P2303 / P2304 /
P2306 / P2307 /
P2309 / P2310)
P0352 (DTC
P0351 / P0352 /
P0353 / P0354 /
Ignition Coil “B” Primary / Secondary
P2300 / P2301 /
Circuit
P2303 / P2304 /
P2306 / P2307 /
P2309 / P2310)
—
P0353 (DTC
P0351 / P0352 /
P0353 / P0354 /
Ignition Coil “C” Primary / Secondary
P2300 / P2301 /
Circuit
P2303 / P2304 /
P2306 / P2307 /
P2309 / P2310)
P0354 (DTC
P0351 / P0352 /
P0353 / P0354 /
Ignition Coil “D” Primary / Secondary
P2300 / P2301 /
Circuit
P2303 / P2304 /
P2306 / P2307 /
P2309 / P2310)

P0365 (DTC
Camshaft Position Sensor “B” Circuit ECM stops exhaust VVT actuator control.
P0340 / P0365)
P0400 (DTC
Exhaust Gas Recirculation “A” Flow ECM stops EGR control.
P0400)
P0403 (DTC Exhaust Gas Recirculation “A” Control
ECM controls EGR valve to closed position.
P0403) Circuit
P0420 (DTC Catalyst System Efficiency Below
—
P0420) Threshold Bank 1
P0443 (DTC
Evaporative Emission System Purge
P0443 / P0458 /
Control Valve Circuit
P0459)
P0458 (DTC • ECM stops EVAP canister purge valve control.
P0443 / P0458 /
Control Valve Circuit Low • ECM stops A/F feedback (closed loop) control.
P0459)
P0459 (DTC
P0443 / P0458 /
Control Valve Circuit High
P0459)
P0480 (DTC
P0480 / P0691 / Fan 1 Control Circuit
P0692)
—
P0481 (DTC
P0481 / P0693 / Fan 2 Control Circuit
P0694)
P0500 (DTC ECM controls actuators assuming that vehicle speed is 0
Vehicle Speed Sensor “A”
P0500) km/h (0 mile/h).
P0504 (DTC
Brake Switch “A”/”B” Correlation Refer to “Fail-Safe Table” in Section 10A.
P0504)
P0515 (DTC
Battery Temperature Sensor Circuit ECM stops generator control.
P0515)
P0530 (DTC A/C Refrigerant Pressure Sensor “A”
ECM stops A/C compressor relay control.
P0530) Circuit
P0555 Brake Booster Pressure Sensor Circuit Refer to “Fail-Safe Table” in Section 10I.
P0560 (DTC
P0560 / P0562 / System Voltage ECM limits throttle control and fuel injection.
P0563)
P0562 (DTC
P0560 / P0562 / System Voltage Low
P0563)
—
P0563 (DTC
P0560 / P0562 / System Voltage High
P0563)
P0571 (DTC
Brake Switch “A” Circuit Refer to “Fail-Safe Table” in Section 10A.
P0571)
P0575 Cruise Control Input Circuit Refer to “Fail-Safe Table” in Section 10A.
P0602 (DTC
Control Module Programming Error —
P0602)
P0606 (DTC
Control Module Processor —
P0606)

P060A (DTC
P060A / P060B /
P060D / P0611 /
P061A / P061B /
Internal Control Module Monitoring
P061C / P061D /
Processor Performance
P061F / P062B /
P062D / P06D1 /
P160B / P161A /
P161B / P161C)
P060B (DTC
P060A / P060B /
P060D / P0611 /
P061A / P061B /
Internal Control Module A/D Processing
P061C / P061D /
Performance
P061F / P062B /
P062D / P06D1 /
P160B / P161A /
P161B / P161C) • ECM cuts off fuel at specified engine speed.
P060D (DTC • ECM decreases engine torque.
P060A / P060B /
P060D / P0611 /
P061A / P061B /
Internal Control Module Accelerator
P061C / P061D /
Pedal Position Performance
P061F / P062B /
P062D / P06D1 /
P160B / P161A /
P161B / P161C)
P0611 (DTC
P060A / P060B /
P060D / P0611 /
P061A / P061B /
Fuel Injector Control Module
P061C / P061D /
Performance
P061F / P062B /
P062D / P06D1 /
P160B / P161A /
P161B / P161C)

P061A (DTC
P060A / P060B /
P060D / P0611 /
P061A / P061B /
Internal Control Module Torque
P061C / P061D /
Performance
P061F / P062B /
P062D / P06D1 /
P160B / P161A /
P161B / P161C)
P061B (DTC
P060A / P060B /
P060D / P0611 /
P061A / P061B /
Internal Control Module Torque
P061C / P061D /
Calculation Performance
P061F / P062B /
P062D / P06D1 /
P160B / P161A /
P061C (DTC • ECM decreases engine torque.
P060A / P060B /
P060D / P0611 /
P061A / P061B /
Internal Control Module Engine RPM
P061C / P061D /
Performance
P061F / P062B /
P062D / P06D1 /
P160B / P161A /
P161B / P161C)
P061D (DTC
P060A / P060B /
P060D / P0611 /
P061A / P061B /
Internal Control Module Engine Air Mass
P061C / P061D /
Performance
P061F / P062B /
P062D / P06D1 /
P160B / P161A /
P161B / P161C)

P061F (DTC
P060A / P060B /
P060D / P0611 /
P061A / P061B /
Internal Control Module Throttle Actuator
P061C / P061D /
Controller Performance
P061F / P062B /
P062D / P06D1 /
P160B / P161A /
P161B / P161C)
P062B (DTC
P060A / P060B /
P060D / P0611 /
P061A / P061B / • ECM cuts off fuel at specified engine speed.
Internal Control Module Fuel Injector
P061C / P061D /
Control Performance • ECM decreases engine torque.
P061F / P062B /
P062D / P06D1 /
P160B / P161A /
P161B / P161C)
P062D (DTC
P060A / P060B /
P060D / P0611 /
P061A / P061B /
Fuel Injector Driver Circuit Performance
P061C / P061D /
(Bank1)
P061F / P062B /
P062D / P06D1 /
P160B / P161A /
P161B / P161C)
P0645 (DTC
P0645 / P0646 / A/C Clutch Relay Control Circuit
P0647)
P0646 (DTC
P0645 / P0646 / A/C Clutch Relay Control Circuit Low —
P0647)
P0647 (DTC
P0645 / P0646 / A/C Clutch Relay Control Circuit High
P0647)
P0649 Speed Control Lamp Control Circuit Refer to “Fail-Safe Table” in Section 10A.
P0691 (DTC
P0480 / P0691 / Fan 1 Control Circuit Low
P0692)
P0692 (DTC
P0480 / P0691 / Fan 1 Control Circuit High
P0692)
—
P0693 (DTC
P0481 / P0693 / Fan 2Control Circuit Low
P0694)
P0694 (DTC
P0481 / P0693 / Fan 2 Control Circuit High
P0694)
P06D1 (DTC
P060A / P060B /
P060D / P0611 /
P061A / P061B / • ECM cuts off fuel at specified engine speed.
Internal Control Module Ignition Coil
P061C / P061D /
Control Performance • ECM decreases engine torque.
P061F / P062B /
P062D / P06D1 /
P160B / P161A /
P161B / P161C)

P0703 (DTC
Brake Switch “B” Circuit Refer to “Fail-Safe Table” in Section 10A.
P0703)
P081D (DTC
P081D) in Neutral Input Circuit
Section 10I
Refer to “Fail-Safe Table” in Section 10I.
P083F (DTC
P083F) in Clutch Pedal Switch “A” / “B” Correlation
Section 10I
P0A5A (DTC Generator Current Sensor Circuit Range /
ECM stops generator control.
P0A5A) Performance
P1311 (DTC
P1311 / P1312) ENG A-STOP Starter Relay Circuit Low
in Section 10I
P1312 (DTC
P1311 / P1312) ENG A-STOP Starter Relay Circuit High
in Section 10I
P1313 (DTC
P1313) in ENG A-STOP Starter Performance
Section 10I
P1314 (DTC
ENG A-STOP Starter Active Counter Not
P1314) in
Set
Section 10I
P1321 (DTC
ENG A-STOP Battery Current Sensor “A”
P1321 / P1322)
Circuit Low
in Section 10I
P1322 (DTC
ENG A-STOP Battery Current Sensor “A”
P1321 / P1322)
Circuit High
in Section 10I
P1326 (DTC
ENG A-STOP Battery Temperature
P1326 / P1327)
Sensor Circuit Low
in Section 10I
P1327 (DTC
ENG A-STOP Battery Temperature
P1326 / P1327) Refer to “Fail-Safe Table” in Section 10I.
Sensor Circuit High
in Section 10I
P1330 (DTC
ENG A-STOP DC-DC Converter “A”
P1330 / P1353)
Performance
in Section 10I
P1334 (DTC
P1334) in
Malfunction
Section 10I
P1350 (DTC
ENG A-STOP DC-DC Converter “A” Over
P1350 / P1351)
Temperature Short Time
in Section 10I
P1351 (DTC
ENG A-STOP DC-DC Converter “A” Over
P1350 / P1351)
Temperature
in Section 10I
P1353 (DTC
P1330 / P1353)
Output Circuit Short to Ground
in Section 10I
P1360 (DTC
P1360) in ENG A-STOP Battery Performance
Section 10I
P13A0 (DTC
P13A0) in ENG A-STOP OFF Switch Circuit
Section 10I

P160B (DTC
P060A / P060B /
P060D / P0611 /
P061A / P061B /
P061C / P061D / Control Module Performance
P061F / P062B /
P062D / P06D1 /
P160B / P161A /
P161B / P161C)
P161A (DTC
P060A / P060B /
P060D / P0611 /
P061A / P061B /
P061C / P061D / Internal Control Module Ignition Timing
P061F / P062B /
P062D / P06D1 /
P160B / P161A /
P161B (DTC • ECM decreases engine torque.
P060A / P060B /
P060D / P0611 /
P061A / P061B /
Internal Control Module Comparison of
P061C / P061D /
Lambda and Operation Mode
P061F / P062B /
P062D / P06D1 /
P160B / P161A /
P161B / P161C)
P161C (DTC
P060A / P060B /
P060D / P0611 /
P061A / P061B /
Internal Control Module Engine Mixture
P061C / P061D /
Check
P061F / P062B /
P062D / P06D1 /
P160B / P161A /
P161B / P161C)
P1660 (DTC Abnormal Refrigerant Pressure (High
ECM stops A/C compressor relay control.
P1660) Pressure)
P1693 (DTC
Equipment Information Mismatched —
P1693)
P2088 (DTC
P0010 / P0013 / “A” Camshaft Position Actuator Control
P2088 / P2089 / Circuit Low Bank 1
P2090 / P2091)
P2089 (DTC
P0010 / P0013 / “A” Camshaft Position Actuator Control
P2088 / P2089 / Circuit High Bank 1
P2090 / P2091)
P2090 (DTC
P0010 / P0013 / “B” Camshaft Position Actuator Control
P2088 / P2089 / Circuit Low
P2090 / P2091)
ECM stops exhaust VVT actuator control.
P2091 (DTC
P0010 / P0013 / “B” Camshaft Position Actuator Control
P2088 / P2089 / Circuit High
P2090 / P2091)

P2100 (DTC Throttle Actuator “A” Control Motor Circuit
P2100) / Open
P2101 (DTC Throttle Actuator “A” Control Motor Circuit
ECM performs fuel cut at specified engine speed.
P2119 (DTC Throttle Actuator Control Throttle Body
P2122 (DTC Throttle / Pedal Position Sensor/Switch
P2122 / P2123) “D” Circuit Low
P2122 / P2123) “D” Circuit High
P2127 / P2128) “E” Circuit Low
P2127 / P2128) “E” Circuit High
P2135) “A” / “B” Voltage Correlation
P2138) “D” / “E” Voltage Correlation
P2176 (DTC Throttle Actuator Control System – Idle
ECM cuts off fuel at specified engine speed.
P2176) Position Not Learned
P21CF (DTC
P0201 / P0202 /
P0203 / P0204 /
P0261 / P0262 /
P0264 / P0265 /
P0267 / P0268 /
P0270 / P0271 / Cylinder 1-2 Injector Circuit Low (Injector • ECM stops fuel injection of No.1 cylinder.
/ P21D1 / P21D2
/ P21DB /
P21DC / P21DE
/ P21DF / P21E0
/ P21E1 / P21E2
/ P21E3)
P21D0 (DTC
P0201 / P0202 /
P0203 / P0204 /
P0261 / P0262 /
P0264 / P0265 /
P0267 / P0268 /
/ P21D1 / P21D2
/ P21DB /
P21DC / P21DE
/ P21DF / P21E0
/ P21E1 / P21E2
/ P21E3)

P21D1 (DTC
P0201 / P0202 /
P0203 / P0204 /
P0261 / P0262 /
P0264 / P0265 /
P0267 / P0268 /
/ P21D1 / P21D2
/ P21DB /
P21DC / P21DE
/ P21DF / P21E0
/ P21E1 / P21E2
/ P21E3)
P21D2 (DTC
P0201 / P0202 /
P0203 / P0204 /
P0261 / P0262 /
P0264 / P0265 /
P0267 / P0268 /
P0270 / P0271 / Injector Circuit / Open – Cylinder 4 • ECM stops fuel injection of No.4 cylinder.
P21CF / P21D0 (Injector No.4-2) • ECM stops A/F feedback (closed loop) control.
/ P21D1 / P21D2
/ P21DB /
P21DC / P21DE
/ P21DF / P21E0
/ P21E1 / P21E2
/ P21E3)
P21DB (DTC
P0201 / P0202 /
P0203 / P0204 /
P0261 / P0262 /
P0264 / P0265 /
P0267 / P0268 /
P0270 / P0271 / Cylinder 1 Injector Circuit Low (Injector • ECM stops fuel injection of No.1 cylinder.
/ P21D1 / P21D2
/ P21DB /
P21DC / P21DE
/ P21DF / P21E0
/ P21E1 / P21E2
/ P21E3)
P21DC (DTC
P0201 / P0202 /
P0203 / P0204 /
P0261 / P0262 /
P0264 / P0265 /
P0267 / P0268 /
P0270 / P0271 / Cylinder 1-2 Injector Circuit High (Injector • ECM stops fuel injection of No.1 cylinder.
/ P21D1 / P21D2
/ P21DB /
P21DC / P21DE
/ P21DF / P21E0
/ P21E1 / P21E2
/ P21E3)

P21DE (DTC
P0201 / P0202 /
P0203 / P0204 /
P0261 / P0262 /
P0264 / P0265 /
P0267 / P0268 /
/ P21D1 / P21D2
/ P21DB /
P21DC / P21DE
/ P21DF / P21E0
/ P21E1 / P21E2
/ P21E3)
P21DF (DTC
P0201 / P0202 /
P0203 / P0204 /
P0261 / P0262 /
P0264 / P0265 /
P0267 / P0268 /
/ P21D1 / P21D2
/ P21DB /
P21DC / P21DE
/ P21DF / P21E0
/ P21E1 / P21E2
/ P21E3)
P21E0 (DTC
P0201 / P0202 /
P0203 / P0204 /
P0261 / P0262 /
P0264 / P0265 /
P0267 / P0268 /
/ P21D1 / P21D2
/ P21DB /
P21DC / P21DE
/ P21DF / P21E0
/ P21E1 / P21E2
/ P21E3)
P21E1 (DTC
P0201 / P0202 /
P0203 / P0204 /
P0261 / P0262 /
P0264 / P0265 /
P0267 / P0268 /
/ P21D1 / P21D2
/ P21DB /
P21DC / P21DE
/ P21DF / P21E0
/ P21E1 / P21E2
/ P21E3)

P21E2 (DTC
P0201 / P0202 /
P0203 / P0204 /
P0261 / P0262 /
P0264 / P0265 /
P0267 / P0268 /
/ P21D1 / P21D2
/ P21DB /
P21DC / P21DE
/ P21DF / P21E0
/ P21E1 / P21E2
/ P21E3)
P21E3(DTC
P0201 / P0202 /
P0203 / P0204 /
P0261 / P0262 /
P0264 / P0265 /
P0267 / P0268 /
P0270 / P0271 / Cylinder 4 Injector Circuit High (Injector • ECM stops fuel injection of No.4 cylinder.
/ P21D1 / P21D2
/ P21DB /
P21DC / P21DE
/ P21DF / P21E0
/ P21E1 / P21E2
/ P21E3)
*P2226 (DTC
Barometric Pressure Sensor “A” Circuit
P2226 / P2227) ECM controls actuators assuming that barometric
P2227 (DTC Barometric Pressure Sensor “A” Circuit pressure is specified value.
P2226 / P2227) Range/Performance
P2271 (DTC O2 Sensor Signal Biased/Stuck Rich
—
P0139 / P2271) Bank 1 Sensor 2
P2300 (DTC
P0351 / P0352 /
P0353 / P0354 /
Ignition Coil “A” Primary Control Circuit
P2300 / P2301 / —
Low
P2303 / P2304 /
P2306 / P2307 /
P2309 / P2310)
P2301 (DTC
P0351 / P0352 /
P0353 / P0354 /
Ignition Coil “A” Primary Control Circuit
P2300 / P2301 / —
High
P2303 / P2304 /
P2306 / P2307 /
P2309 / P2310)
P2303 (DTC
P0351 / P0352 /
P0353 / P0354 /
Ignition Coil “B” Primary Control Circuit
P2300 / P2301 / —
Low
P2303 / P2304 /
P2306 / P2307 /
P2309 / P2310)

P2304 (DTC
P0351 / P0352 /
P0353 / P0354 /
Ignition Coil “B” Primary Control Circuit
P2300 / P2301 / —
High
P2303 / P2304 /
P2306 / P2307 /
P2309 / P2310)
P2306 (DTC
P0351 / P0352 /
P0353 / P0354 /
Ignition Coil “C” Primary Control Circuit
P2300 / P2301 / —
Low
P2303 / P2304 /
P2306 / P2307 /
P2309 / P2310)
P2307 (DTC
P0351 / P0352 /
P0353 / P0354 /
Ignition Coil “C” Primary Control Circuit
P2300 / P2301 / —
High
P2303 / P2304 /
P2306 / P2307 /
P2309 / P2310)
P2309 (DTC
P0351 / P0352 /
P0353 / P0354 /
Ignition Coil “D” Primary Control Circuit
P2300 / P2301 / —
Low
P2303 / P2304 /
P2306 / P2307 /
P2309 / P2310)
P2310 (DTC
P0351 / P0352 /
P0353 / P0354 /
Ignition Coil “D” Primary Control Circuit
P2300 / P2301 / —
High
P2303 / P2304 /
P2306 / P2307 /
P2309 / P2310)
P254F (DTC
P254F) in Engine Hood Switch Circuit Refer to “Fail-Safe Table” in Section 10I.
Section 10I

U0073 (DTC
Control Module Communication Bus Off
U0073)
U0101 (DTC
U0101 / U0121 /
Lost Communication with TCM
U0131 / U0140 /
U0155)
U0121 (DTC
U0101 / U0121 / Lost Communication With ABS / ESP®
U0131 / U0140 / Control Module
U0155)
U0131 (DTC
—
U0101 / U0121 / Lost Communication With Power
U0131 / U0140 / Steering Control Module
U0155)
U0140 (DTC
U0101 / U0121 / Lost Communication With Body Control
U0131 / U0140 / Module
U0155)
U0155 (DTC
U0101 / U0121 / Lost Communication With Instrument
U0131 / U0140 / Panel Cluster (IPC) Control Module
U0155)
U2001 (DTC
LIN Lost Communication With Generator
U2001)
ECM stops generator control.
U2021 (DTC
LIN Invalid Data from ECM to Generator
U2021)
Scan Tool Data

AENNTA0E1104007 (06(01)
ECM
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. (Ignition Timing Inspection) in Section 1H
NOTE
• A communication error may occur due to temporary overlap of communication load. If
communication error occurs, wait about 10 seconds and try the operation again.
• 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 CAN communication circuit and connectors between DLC and central gateway control
module. (Refer to “Diagnosis flow: [a]” in “Troubleshooting” of “Troubleshooting for Lost
Communication”.) (Troubleshooting for Lost Communication): CAN in Section 10H
– 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.) (Troubleshooting for Communication Bus Off): CAN in Section 10H
– Check central gateway control module power supply circuit and ground circuit. (Inspection of
Central Gateway Control Module and Its Circuits): CAN (Central Gateway) in Section 10H
– Check ECM power circuit and ground circuit. (ECM Power Supply and Ground Circuit Check)
• 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, place gear shift lever in neutral position
(M/T model) or shift selector N range (AGS 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.
• Data with asterisk 1 (*1) in the table below are applicable to M/T model.
• Data with asterisk 2 (*2) in the table below are applicable to AGS model.
Normal condition /
Scan tool data Vehicle condition
Reference value
Engine Oil Temperature Engine: Idle speed after warming up Approx. 70 to 110 °C (158 to
* (Engine Oil Temperature 230 °F)
(°C, °F))
Open loop control before satisfaction of closed loop
control conditions (ECT >10 °C, IAT, TP, HO2S/system = OL (open loop)
OK)
Fuel System (Fuel Open loop control due to driving conditions (Power
OL-Drive (open loop)
System (OL/CL/OL- enrichment, etc.)
*
DRIVE/OL-FAULT/CL- Open loop control due to system fault detected OL-Fault (open loop)
FAULT)) Closed loop control using HO2S as feedback sensors for
CL (closed loop)
fuel control
Closed loop control due to system fault detected CL-Fault (closed loop)
When engine stops with ignition “ON” —
Short Term Fuel Trim
* (Short Term Fuel Trim Engine: Idle speed after warming up Approx. –20 to 20%
(%))
Long Term Fuel Trim
* (Long Term Fuel Trim Engine: Idle speed after warming up Approx. –20 to 20%
(%))
Total Fuel Trim (Total Fuel
Engine: Idle speed after warming up Approx. –30 to 30%
Trim (%))
Inj Pulse Width (Inj Pulse
Engine: Idle speed with no load after warming up Approx. 1.0 to 4.0 msec
Width (msec.))
Ignition Advance (Ignition
* Engine: Idle speed with no load after warming up –10 to 10° BTDC
Advance (° BTDC))
Calculated Load
* Engine: Idle speed with no load after warming up Approx. 10 to 40%
(Calculated Load (%))
All of the following conditions are met.
• Engine: Idle speed after warming up
Engine Speed (Engine
* • Radiator cooling fan: Stopped 590 to 690 rpm
Speed (rpm))
• All electrical equipment: OFF
• Gear shift lever: Neutral position
Desired Idle (Desired Idle
• Radiator cooling fan: Stopped 590 to 690 rpm
(rpm))
* MAF (MAF (g/sec.)) Engine: Idle speed with no load after warming up 1.0 to 4.0 g/sec
Vehicle Speed (Vehicle Almost the same as
* Vehicle running
Speed (km/h, mph)) speedometer reading
* MAP (MAP (kPa)) Engine: Idle speed after warming up Approx. 25 to 55 kPa
Approx. 80 to 105 °C (176
* ECT (ECT (°C, °F)) Engine: Idle speed after warming up
to 221 °F)
–5 °C (–9 °F) +
Intake Air Temperature
environmental temperature
* (Intake Air Temperature. Engine: Idle speed after warming up
to 40 °C (72 °F) +
(°C, °F))
environmental temperature
Barometric Pres Barometric pressure is
* —
(Barometric Pres (kPa)) displayed.
Normal condition /
Reference value
EVAP Canist Prg Duty
* (Evap Canist Prg Duty Engine: Idle speed after warming up 0%
(%))
EGR Valve Opening When vehicle is in fuel cut driving condition after warming 0 to 20%
*
(EGR Valve Opening (%)) up.
VVT Gap B1 IN (VVT
Engine: Idle speed with no load after warming up –2.0 to 2.0° CA
Gap B1 IN (°CA))
VVT Gap B1 EX (VVT
Engine: Idle speed with no load after warming up –2.0 to 2.0° CA
Gap B1 EX (°CA))
Engine: Idle speed with no load after warming up Approx. 10 to 50%
IAC Throttle Opening All of the following conditions are met.
(IAC Throttle Opening • Engine: Idle speed after warming up
Approx. 20 to 80%
(%)) • A/C switch: ON
• Blower speed selector: Max
• Ignition: “ON” 0.8 to 1.0 V
TP Sensor 1 Volt (TP • Accelerator pedal: Released
Sensor 1 Volt (V)) All of the following conditions are met.
• Accelerator pedal: Fully depressed
TP Sensor 2 Volt (TP • Accelerator pedal: Released
Sensor 2 Volt (V)) All of the following conditions are met.
APP Sensor 1 Voltage
• Accelerator pedal: Released
(APP Sensor 1 Voltage
(V))
• Ignition: “ON” 0.325 to 0.425 V
APP Sensor 2 Voltage
(APP Sensor 2 Voltage
(V))
• Ignition: “ON” 0 to 2%
Accelerator Position • Accelerator pedal: Released
*
(Accelerator Position (%)) All of the following conditions are met.
Throttle Position (Throttle • Accelerator pedal: Released
*
Position (%)) All of the following conditions are met.
Normal condition /
Reference value
Target Throttle Posi • Accelerator pedal: Released
*
(Target Throttle Posi (%)) All of the following conditions are met.
O2S B1 S1 (O2S B1 S1
* Engine: 2,000 rpm for 3 min. or more after warming up Approx. 0 to 1.0 V
(V))
O2S B1 S2 (O2S B1 S2
* Engine: Idle speed after warming up Approx. 0 to 1.0 V
(V))
Battery Voltage (Battery
* Engine: Idle speed 10.7 to 16.0 V
Voltage (V))
Fuel Tank Level (Fuel
Ignition: “ON” 0 to 100%
Tank Level (%))
Refer to “A/C System
A/C Pressure (A/C
— Performance Inspection” in
Pressure (kPa))
Section 7B.
Generator Field Duty
(Generator Field Duty Engine: Idle speed after warming up Approx. 20 to 100%
(%))
Ignition: “ON” 2 to 8 A
• Ignition: “ON” 14 to 22 A
Battery Current (Battery • Headlight: ON
Current (A)) All of the following conditions are met.
• Ignition: “ON”
22 to 33 A
• Headlight: ON
• Blower speed switch: MAX
Battery Temperature Value equivalent to ambient
(Battery Temperature (°C, Ignition: “ON” temperature around the
°F)) battery
2WD/4WD Variant
Information (2WD/4WD
Variant Information Ignition: “ON” 2WD
(Undetermined/2WD/
4WD))
ABS Variant Information
(ABS Variant Information
Ignition: “ON” with ABS
(Undetermined/w/o ABS/
with ABS))
A/C Variant Information
(A/C Variant Information Ignition: “ON” w/ A/C
(w/ A/C/w/o A/C))
• Ignition: “ON” 0 kPa
Brake Booster Pressure
• Brake pedal: Fully depressed 3 or more times
(Brake Booster Pressure
(kPa))
• Engine: Idle speed” 60 to 80 kPa
• Brake pedal: Released
Generator Reg Volt
(Com) (Generator Reg Engine: Idle speed 10.7 to 16.0 V
Volt (Com) (V))
Normal condition /
Reference value
ACC Variant Information
(ACC Variant Information Accessory connected is
Ignition: “ON”
(Undetermined/No ACC displayed.
detected/ACC detected))
ESP Variant Information
(ESP Variant Information Accessory connected is
Ignition: “ON”
(Undetermined/No ESP displayed.
detected/ESP detected))
Camera AEB Variant
Information (Camera AEB
Variant Information Accessory connected is
Ignition: “ON”
(Undetermined/w/o displayed.
Camera AEB/with
Camera AEB/Reserved))
Rear AEB Variant
Information (Rear AEB
Variant Information Ignition: “ON” Without Rear AEB
(Undetermined/No ACC
detected/ACC detected))
Radiator cooling fan: Off Off
Radiator Fan (Radiator
Radiator cooling fan: Low speed Low
Fan (Low/High/Off))
Radiator cooling fan: High speed High
A/C Comp Relay (A/C • A/C switch: ON ON
Comp Relay (ON/OFF)) • Blower speed selector: ON
Other than above condition OFF
Fuel Pump (Fuel Pump Engine running ON
(ON/OFF)) Other than above condition OFF
Starter Switch (Starter Ignition: “START” (engine cranking) ON
Switch (ON/OFF)) Other than above condition OFF
A/C Switch (A/C Switch A/C switch: ON ON
Blower Fan (Blower Fan 4th or higher speed position ON
Brake Booster Vacuum Brake booster switch: ON Value Lo (insufficient)
Condition (*1) (Brake
Booster Vacuum
Condition (Value Lo Brake booster switch: OFF Value Hi (sufficient)
(insufficient)/Value Hi
(sufficient)))
Brake Switch (Brake Brake pedal: Depressed ON
Switch (ON/OFF)) Brake pedal: Released OFF
Electric Load (Electric Headlight switch: ON ON
Load (ON/OFF)) Headlight switch: OFF OFF
PNP Signal (*2) (PNP Select lever: Other than P range D
Signal (D/P/N)) Select lever: P range P/N
Clutch Switch (*1) (Clutch Clutch pedal: Fully depressed Declutch
Switch (Declutch/
Clutch pedal: Released Clutched
Clutched))
Cruise RES/ACC Switch RES/ACC switch pressed ON
(Cruise RES/ACC Switch
RES/ACC switch released OFF
(ON/OFF))
Cruise SET/COAST SET/COAST switch pressed ON
Switch (Cruise SET/
COAST Switch (ON/ SET/COAST switch released OFF
OFF))
Normal condition /
Reference value
Cruise CANCEL Switch CANCEL switch pressed ON
(Cruise CANCEL Switch
CANCEL switch released OFF
(ON/OFF))
Cruise ON/OFF Switch ON/OFF switch pressed Pushed
(Cruise ON/OFF Switch
ON/OFF switch released Released
(Released/Pushed))
Engine: Idle speed after warming up OFF
Fuel Cut (Fuel Cut (ON/ All of the following conditions are met.
OFF)) • Accelerator pedal: Released ON
• Engine condition: 2,000 rpm or more after warming up
• Ignition: “ON” ON
Closed Throttle Pos
(Closed Throttle Pos (ON/
OFF))
• Ignition: “ON” OFF
O2S B1 S1 Act (O2S B1
Engine: Idle speed after warming up Active
S1 ACT (Active/Inactive))
O2S B1 S2 Act (O2S B1
Engine: Idle speed after warming up Active
S2 ACT (Active/Inactive))
ENG A-STOP (Mon) Engine is auto-stopped. Eng Stop
(ENG A-STOP (Mon)
Other than above condition Eng Run
(Eng Run/Eng Stop))
ENG A-STOP (Com) ENG A-STOP control module requests engine auto stop. Req
(ENG A-STOP (Com)
Other than above condition Not Req
(Not Req/Req))
Battery Ambient
Value equivalent to ambient
Temperature (Battery
Ignition: “ON” temperature around the
Ambient Temperature
battery
(°C, °F))
Battery Temperature
(Battery Temperature (°C, Engine auto stop control: Permitted 5 to 55 °C
°F))
Engine: Idle speed 10 to 14 V
Voltage (V))
Battery Current (Battery • Headlight: ON
Current (A)) All of the following conditions are met.
22 to 33 A
• Headlight: ON
• Blower speed switch: MAX
Battery Current Raw All of the following conditions are met.
Value (Battery Current
Raw Value (A))
• Headlight: ON
Battery DOD (Battery
Engine: Idle speed with no-load after warming up 0 to 10%
DOD (%))
Battery Current Sensor
Voltage (Battery Current Engine: Idle speed with no-load after warming up Approx. 3.0 to 4.0 V
Sensor Voltage (V))
Normal condition /
Reference value
Minimum Voltage at
Engine Start (Minimum
After engine starts 6 to 16 V
Voltage at Engine Start
(V))
Generator Adjusting
Command Voltage
Engine: Idle speed 10 to 14 V
(Generator Adjusting
Command Voltage (V))
Alternator Temperature Value equivalent to ambient
(Alternator Temperature Ignition: “ON” temperature around the
(°C)) generator
Generator Field Coil
Operation Rate
Engine: Idle speed with no-load after warming up 0 to 100%
(Generator Field Coil
Operation Rate (%))
• Radiator cooling fan: Stopped 590 to 690 rpm
Speed (rpm))
Engine Coolant
Temperature (Engine Approx. 80 to 105 °C (176 –
Engine: Idle speed after warming up
Coolant Temperature 221 °F)
(°C))
Vehicle Speed (Vehicle Almost the same as
Vehicle running
Speed (km/h, mph)) speedometer reading
Accelerator Position • Accelerator pedal: Released
(Accelerator Position (%)) All of the following conditions are met.
When brake pedal is depressed 3 or more times with
0 kPa
engine stopped.
Brake Booster (Brake • Engine: Idle speed 60 to 70 kPa
Booster (kPa)) • Brake pedal: Released
• Engine: Idle speed 50 to 60 kPa
• Brake pedal: Fully depressed
Slope Range (Slope
• Ignition: “ON” 0%
Range (%))
• Vehicle: Parked on level surface
Starter Drive Count
Number of starting motor
(Starter Drive Count Ignition: “ON”
drive
(Times))
Ignition Switch (Ignition Ignition: “ON” ON
Switch (ON/OFF)) Other than above condition OFF
Starting Switch (Starting • Ignition: “START” ON
Switch (ON/OFF)) • Clutch pedal: Fully depressed
Normal condition /
Reference value
Idle SW (Idle SW (ON/ • Accelerator pedal: Released
OFF)) All of the following conditions are met.
• Accelerator pedal: Depressed
Half Clutch Switch (*1)
• Clutch pedal: Depressed
(Half Clutch Switch (ON/
OFF))
• Clutch pedal: Released
Clutch Pressed Switch
• Clutch pedal: Fully depressed
(*1) (Clutch Pressed
Switch (ON/OFF))
Neutral SW (*1) (Neutral • Gear position: “Neutral”
SW (ON/OFF)) All of the following conditions are met.
• Gear position: Other than “Neutral”
Brake Switch (*2) (Brake Brake pedal: Depressed ON
Switch (ON/OFF)) Brake pedal: Released OFF
Charge Lamp Switch Engine stationary ON
(Charge Lamp Switch Engine: Running or at engine auto stop control (other
OFF
(ON/OFF)) than engine auto start inhibit control)
ENG A-STOP Indicator Engine auto stop control: Operating ON
Light (ENG A-STOP
Indicator Light (ON/OFF))
Stop Mode (Stop Mode Engine stationary (other than engine auto stop control) ON
Normal Mode (Normal Engine stationary OFF
Mode (ON/OFF)) Engine running ON
Auto Stop Mode (Auto During engine auto stop control ON
Stop Mode (ON/OFF)) Other than above condition OFF
Starting Mode (Starting During engine auto restart control ON
Mode (ON/OFF)) Other than above condition OFF
Engine Restart Request During engine auto restart request True
(Engine Restart Request
Other than above condition False
(True/False))
Driver Door Switch
• Driver door: Open
(Driver Door Switch (ON/
OFF))
• Driver door: Closed
Normal condition /
Reference value
• Ignition: “ON” Fasten
Driver Seatbelt Switch
• Driver seat belt: Fastened
(Driver Seatbelt Switch
(Fasten/Unfasten))
• Ignition: “ON” Unfasten
• Driver seat belt: Unfastened
Hood Switch1 (Hood • Hood: Open
Switch1 (ON/OFF)) All of the following conditions are met.
• Hood: Closed
Hood Switch2 (Hood • Hood: Open
Switch2 (ON/OFF)) All of the following conditions are met.
• Hood: Closed
Idling Stop Prohibit • Ignition: “ON” ON
Switch (Idling Stop • ENG A-STOP OFF switch: Pushed
Prohibit Switch (ON/ All of the following conditions are met.
OFF)) • Ignition: “ON” OFF
• ENG A-STOP OFF switch: Released
Air Conditioning Engine auto restart control: Requested ON
Compressor Engine Run
Request (Air Conditioning
Compressor Engine Run
request (ON/OFF))
A/C Compressor Engine Engine run ordered ON
Run Order (A/C
Compressor Engine Run No action OFF
Order (ON/OFF))
Normal condition /
Reference value
1st
• Select lever: D or M range
• Gear position: 1st
2nd
• Select lever: D or M range
• Gear position: 2nd
Shift Position (*2) (Shift
• Ignition: “ON” R
Position (1st/2nd/R/N/D/
M)) • Select lever: R range
• Ignition: “ON” N
• Select lever: N range
• Ignition: “ON” D
• Select lever: D range
• Ignition: “ON” M
• Select lever: M range
Engine Stop Request The state of engine stop request from TCM to ECM. True
from AMT (*2) (Engine
Stop Request from AMT Other than above condition False
(True/False))
Hill Hold Maintain When brake pedal is depressed during engine auto stop
Request from TCM control or when brake pedal is depressed immediately ON
During Idle Stop (*2) (Hill after engine restart control.
Hold Maintain Request
from TCM During Idle Brake pedal is released. OFF
Stop (True/False))
Charge Request 1 Discharged level of lead-acid battery: ECM requests level
ON
(Charge Request 1 (ON/ 1 charge
OFF)) Other than above condition OFF
ON
ON
ON
ON
ON
ON
ON
Normal condition /
Reference value
ABS/ESP® Status for A- ABS/ESP® system: Malfunctioning Failure
STOP (ABS/ESP® Status ENG A-STOP control inhibition requested Inhibit
for A-STOP (Failure/ CAN communication: Malfunctioning Backup Disconnect
Inhibit/Backup
ABS/ESP® system: Normal condition Normal
Disconnect/Normal))
Brake Pressure SW Brake booster pressure is higher than specified value True
(Brake Pressure SW
Brake booster pressure is lower than specified value False
(True/False))
Reverse SW (*1) Back up light switch: OFF True
(Reverse SW (True/
Back up light switch: ON False
False))
ECM Status for A-STOP ENG A-STOP control inhibition requested Auto Stop Inhibit Request
(ECM Status for A-STOP Engine auto start control requested Auto Start Request
(Auto Stop Inhibit
Request/Auto Start
Engine auto start control inhibition requested Auto Start Inhibit Request
Request/Auto Start Inhibit
Request))
Engine Stop Request During engine auto stop control True
from ICM (Engine Stop
Request from ICM (True/ Other than above condition False
False))
TCM check request (*2) Other than condition below False
(TCM Check Request Engine auto stop control: Ready (Waiting for TCM
True
(True/False)) permission)
ESP check request Other than condition below False
(*2)(ESP Check Request Engine auto stop control: Ready (Waiting for ESP®
True
(True/False)) control module permission)
Stop A-STOP Permission Engine auto stop control by TCM with vehicle stationary:
False
(TCM) (*2) (Stop A-STOP Inhibited
Permission (ABS/ESP®) Engine auto stop control by TCM with vehicle stationary:
True
(True/False)) Permitted
Idle Stop Maintain Other than condition below False
Request (*2) (Idle Stop
Maintain Request (True/ Engine auto restart control: Inhibited True
False))
Stop A-STOP Permission Other than condition below False
(ABS/ESP®) (*2) (Stop A-
STOP Permission (ABS/ Engine auto restart control: Permission True
ESP®) (ON/OFF))
Brake Pressure Hold Other than condition below False
Request (Brake Pressure
Hold Request (True/ Brake pressure hold request: Permission True
False))
Engine Stop Request Engine auto stop control: Inhibited False
(Engine Stop Request
Engine auto stop control: Permitted True
(True/False))
DTC Condition for A- The ENG A-STOP system is abnormal True
STOP Inhibition (ECM)
(DTC Condition for A-
Other than above conditions False
STOP Inhibition (ECM)
(True/False))
ENG A-STOP OFF ENG A-STOP OFF switch: OFF (permits engine auto
True
Switch Condition (ENG A- stop control)
STOP OFF Switch Other than above condition (inhibits engine auto stop
False
Condition (True/False)) control)
Hood Switch Condition Hood is open False
(Hood Switch Condition
Other than above condition True
(True/False))
Normal condition /
Reference value
Driver seat belt: Fastened
Seat Belt / Door Condition True
Driver door: Closed
(Seat Belt / Door
Other than above conditions (inhibits engine auto stop
Condition (True/False)) False
control)
HVAC Demand Condition Engine auto stop control: Permitted True
(HVAC Demand
Engine auto stop control: Inhibited by BCM False
Condition (True/False))
®
ABS/ESP Demand Engine auto stop control: Permitted True
Condition (ABS/ESP®
Engine auto stop control: Inhibited by ABS/ESP® control
Demand Condition (True/ False
module
False))
Brake booster pressure is higher than specified range to
Brake Booster Condition True
execute engine auto stop control.
(Brake Booster Condition
Other than above condition (inhibits engine auto stop
(True/False)) False
control)
Battery charged condition is within specified range to
True
Battery Condition (Battery execute engine auto stop control.
Condition (True/False)) Other than above condition (inhibits engine auto stop
False
control)
Battery Temperature Battery temperature is within specified range to execute
True
Condition (Battery engine auto stop control.
Temperature Condition Other than above condition (inhibits engine auto stop
False
(True/False)) control)
• Ignition: “ON” True
Accel Pedal Condition • Accelerator pedal: Released
(Accel Pedal Condition All of the following conditions are met.
(True/False)) • Ignition: “ON”
False
• Accelerator pedal: Depressed (inhibits engine auto
stop control)
Shift Position Condition Shift position: “N” or “D” True
(Shift Position Condition Other than above condition (Inhibits engine auto stop
False
Master Cylinder Pressure Other than above condition False
Condition (*2) (Master
Cylinder Pressure Brake pedal: Depressed True
Brake Switch Condition Brake pedal: Depressed True
(*2) (Brake Switch
Brake pedal: Released False
• Ignition: “ON” True
Clutch SW Condition (*1)
(Clutch SW Condition
(True/False))
• Ignition: “ON” False
Speed History Condition Speed history is within specified range to execute engine
True
(A-STOP) (Speed History auto stop control.
Condition (A-STOP) Other than above condition (inhibits engine auto stop
False
Tilt Angle Condition (A- Other than condition below (inhibits engine auto stop
False
STOP) (*2) (Tilt Angle control while vehicle is stationary)
Condition (A-STOP) Tilt angle is within specified range to execute engine auto
True
(True/False)) stop control while vehicle is stationary.
Normal condition /
Reference value
TCM Demand Condition Engine auto stop control while vehicle is stationary by
False
(A-STOP) (*2) (TCM TCM: Inhibited
Demand Condition (A- Engine auto stop control while decelerating by TCM:
True
STOP) (True/False)) Permitted
Engine: Idle speed after warming up True
Fuel Cut (Fuel Cut (ON/ All of the following conditions are met.
OFF)) • Accelerator pedal: Released False
• Engine condition: 2,000 rpm or more after warming up
DCDC1 Mode (DCDC1 DC/DC converter: Normal condition Normal
Mode (Stop, Normal, DC/DC converter: Malfunctioning Serious Failure
Serious Failure, Minor
DC/DC converter: Overheating Minor Failure
Failure))
While engine auto start control or starting motor is
Starter Drive Relay (+)
operating (using “Starting Motor” of “Active Test” mode on ON
(Starter Drive Relay (+)
SUZUKI scan tool
(ON/OFF))
Starter Drive Relay (-)
operating (using “Starting Motor” of “Active Test” mode on ON
(Starter Drive Relay (-)
SUZUKI scan tool (: ON)
(ON/OFF))
Other than above condition (: OFF) OFF
DCDC1 Drive (DCDC1 ON
operating
Drive (ON/OFF))
Charge Request9 Discharged level of lead-acid battery: ECM requests level
True
(Charge Request 9 (True/ 9 charge
False)) Other than above condition False
Charge Request11 Discharged level of lead-acid battery: ECM requests level
True
(Charge Request 11 11 charge
(True/False)) Other than above condition False
Scan Tool Data Definitions Long Term Fuel Trim (%)

Engine Oil Temperature (°C, °F) Long term fuel trim value represents long term
It is detected by oil temperature sensor. corrections to air/fuel mixture. 0 (zero) indicates no
correction, a value greater than 0 indicates enrichment
Fuel System (OL/CL/OL-DRIVE/OL-FAULT/CL- correction, and a value less than 0 indicates enleanment
FAULT) correction.
A/F ratio feedback loop status is displayed as follows.
OL: Open loop control before satisfaction of closed loop Total Fuel Trim (%)
control conditions (ECT > 10 °C, IAT, TP, HO2S/system Total fuel trim is calculated from short term fuel trim and
= OK). long term fuel trim. This value indicates how much
CL: Closed loop control using oxygen sensors. correction is necessary to keep the air/fuel mixture
OL-DRIVE: Open loop control due to driving requirement stoichiometrical.
(power-up enrichment etc.).
OL-FAULT: Open loop control due to system fault Inj Pulse Width (msec.)
detected. This parameter indicates the injector drive pulse width
CL-FAULT: Closed loop control due to system fault (time) during which the injector valve stays open as
detected. commanded by ECM. (For multipoint fuel injection, the
injector drive time means that of the No.1 cylinder.)
Short Term Fuel Trim (%)
Short term fuel trim value represents short term Ignition Advance (° BTDC)
corrections to air/fuel mixture. 0 (zero) indicates no This parameter indicates the ignition timing of No.1
correction, a value greater than 0 indicates enrichment cylinder commanded by ECM. The actual ignition timing
correction, and a value less than 0 indicates enleanment should be checked using a timing light.
correction.
Calculated Load (%) TP Sensor 1 Volt (V)

This parameter indicates calculated engine load in TP Sensor (Main) data provides throttle valve opening
percent. The load is calculated based on input signals to information in the form of voltage.
ECM from various engine sensors.
TP Sensor 2 Volt (V)
Engine Speed (rpm) TP Sensor (Sub) data provides throttle valve opening
The engine speed is calculated from reference pulses information in the form of voltage.
from the camshaft position sensor.
APP Sensor 1 Voltage (V)
Desired Idle (rpm) APP Sensor (Main) data provides accelerator pedal
The Desired Idle Speed is an ECM internal parameter position information in the form of voltage.
which indicates idle speed requested by ECM. If the
engine is not running, this number is not valid. APP Sensor 2 Voltage (V)
APP Sensor (Sub) data provides accelerator pedal
MAF (g/sec.) position information in the form of voltage.
It represents total mass of air entering intake manifold
which is measured by MAF sensor. Accelerator Position (%)
This parameter indicates calculated accelerator pedal
Vehicle Speed (km/h, mph) position in percent based on input from accelerator pedal
The vehicle speed is calculated based on pulse signals position sensor.
from wheel speed sensors.
Throttle Position (%)
MAP (kPa) This parameter indicates calculated throttle opening in
This parameter indicates the calculated manifold percent based on input from throttle position sensor.
pressure based on MAP sensor signal.
Target Throttle Posi (%)
ECT (°C, °F) Target Throttle Valve Position is an ECM internal
It is detected by engine coolant temperature sensor. parameter which indicates throttle valve position
requested by ECM.
Intake Air Temperature. (°C, °F)
It is detected by intake air temperature sensor. O2S B1 S1 (V)
This parameter indicates output voltage of HO2S-1
Barometric Pres (kPa) installed on exhaust manifold (pre-TWC).
This parameter represents barometric air pressure
measurement and is used for altitude correction of the O2S B1 S2 (V)
fuel injection rate. This parameter indicates output voltage of HO2S-2
installed on exhaust manifold (post-TWC). It is used to
Evap Canist Prg Duty (%) detect catalyst deterioration.
This parameter indicates valve ON (valve open) time
rate within a certain set cycle of EVAP canister purge Battery Voltage (V)
valve which controls the amount of EVAP purge. This parameter indicates battery voltage inputted from
main relay to ECM.
EGR Valve Opening (%)
This parameter indicates opening rate of EGR valve Fuel Tank Level (%)
which controls the amount of EGR flow. This parameter indicates approximate fuel level in the
fuel tank. The fuel level data is provided in percentage
VVT Gap B1 IN (°CA) from 0 to 100%.
This parameter indicates difference between target
camshaft position (intake side) and actual camshaft A/C Pressure (kPa)
position (intake side). This parameter indicates A/C refrigerant pressure
calculated by ECM based on A/C refrigerant pressure
VVT Gap B1 EX (°CA) sensor voltage.
This parameter indicates difference between target
camshaft position (exhaust side) and actual camshaft Generator Field Duty (%)
position (exhaust side). This parameter indicates operating rate (status of output)
of the generator by field coil duty ratio.
IAC Throttle Opening (%) 0%: Minimum operation
This parameter indicates throttle valve opening of idle air 100%: Maximum operation
control in % (100% indicates the maximum idle air flow).
Battery Current (A) A/C Comp Relay (ON/OFF)

This parameter indicates filtered electric load value This parameter indicates the state of the A/C
(current consumption) as detected by battery current compressor relay.
sensor.
Fuel Pump (ON/OFF)
Slope Range (%) ON is displayed when ECM activates the fuel pump via
This parameter indicates the slope rate of the road the fuel pump relay switch.
surface detected by the slope sensor in percentage.
Starter Switch (ON/OFF)
Battery Temperature (°C, °F) This parameter indicates state of starting motor relay
This parameter indicates battery temperature measured output.
by battery temperature sensor. ON: Starting motor control relay is ON.
OFF: Starting motor control relay is OFF.
2WD/4WD Variant Information (Undetermined/2WD/
4WD) A/C Switch (ON/OFF)
This parameter indicates the vehicle drive train type. This parameter indicates the state that ECM operates A/
C by request from BCM.
ABS Variant Information (Undetermined/w/o ABS/
with ABS) Blower Fan (ON/OFF)
This parameter indicates whether vehicle is equipped This parameter indicates the state of the blower speed
with ABS system. selector.
A/C Variant Information (w/ A/C/w/o A/C) Brake Booster Vacuum Condition (Value Lo
This parameter indicates whether vehicle is equipped (insufficient)/Value Hi (sufficient))
with A/C system. This parameter indicates the state of brake booster
switch.
Brake Booster Pressure (kPa)
This parameter indicates difference between Brake Switch (ON/OFF)
atmospheric pressure and brake booster pressure. This parameter indicates the state of the brake switch.
Generator Reg Volt (Com) (V) Electric Load (ON/OFF)

This parameter indicates commanded regulated-voltage ON: ON signal of headlight, clearance lights or rear end
to generator. door window defogger is input.
OFF: Above electric loads all turned off.
ACC Variant Information (Undetermined/No ACC
detected/ACC detected) PNP Signal (D/P/N)
This parameter indicates whether vehicle is equipped This parameter indicates shift position informed from
with adaptive cruise control system. TCM through CAN.
ESP Variant Information (Undetermined/No ESP Clutch Switch (Declutch/Clutched)

detected/ESP detected) Declutch: Clutch pedal is fully depressed.
This parameter indicates whether vehicle is equipped Clutched: Clutch pedal is released.
with ESP® system.
Cruise RES/ACC Switch (ON/OFF)
Camera AEB Variant Information (Undetermined/w/o OFF: “RES / +” switch is released.
Camera AEB/with Camera AEB/Reserved) ON: “RES / +” switch is pushed.
This parameter indicates whether vehicle is equipped
with brake support system. Cruise SET/COAST Switch (ON/OFF)
OFF: “SET / -” switch is released.
Rear AEB Variant Information (Undetermined/No ON: “SET / -” switch is pushed.
ACC detected/ACC detected)
This parameter indicates whether vehicle is equipped Cruise CANCEL Switch (ON/OFF)
with reversing brake support system. OFF: “CANCEL” switch is released.
ON: “CANCEL” switch is pushed.
Radiator Fan (Low/High/Off)
This parameter indicates the state that ECM operates Cruise ON/OFF Switch (Released/Pushed)
radiator cooling fan relay. Released: “CRUISE” switch is released.
Pushed: “CRUISE” switch is pushed.
Fuel Cut (ON/OFF) Minimum Voltage at Engine Start (V)

ON: Fuel injection is cut (output signal to injector is This parameter indicates minimum battery voltage at
stopped). engine starting.
OFF: Fuel injection is not cut.
Generator Adjusting Command Voltage (V)
Closed Throttle Pos (ON/OFF) This parameter indicates the generator voltage.
This parameter is ON when throttle valve is fully closed
and OFF when the valve is not fully closed. Alternator Temperature (°C)
This parameter indicates ambient temperature of
O2S B1 S1 ACT (Active/Inactive) generator as calculated by ECM.
This parameter indicates the activation condition of
HO2S-1. Generator Field Coil Operation Rate (%)
Active: The sensor is activated. This parameter indicates calculated operation rate of
Inactive: The sensor is being warmed up or not generator field coil based on CAN data from ECM.
activated.
Engine Speed (rpm)
O2S B1 S2 ACT (Active/Inactive) The engine speed is calculated from reference pulses
This parameter indicates the activation condition of from the camshaft position sensor.
HO2S-2.
Active: The sensor is activated. Engine Coolant Temperature (°C)
Inactive: The sensor is being warmed up or not This parameter indicates engine coolant temperature as
activated. detected by ECT sensor.
ENG A-STOP (Mon) (Eng Run/Eng Stop) Vehicle Speed (km/h, mph)
This parameter indicates the state of the engine auto The vehicle speed is calculated based on pulse signals
stop. from wheel speed sensors.
ENG A-STOP (Com) (Not Req/Req) Accelerator Position (%)

This parameter indicates the state of the engine auto This parameter indicates calculated accelerator pedal
stop request. position in percent based on input from accelerator pedal
position sensor.
Battery Ambient Temperature (°C, °F)
This parameter indicates battery side and ambient Brake Booster (kPa)
temperature based on battery temperature sensor. This parameter indicates brake booster negative
pressure.
Battery Temperature (°C, °F)
This parameter indicates the calculated battery Starter Drive Count (Times)
temperature. This parameter indicates the count of starting motor
drive.
Battery Voltage (V)
This parameter indicates battery voltage inputted from Ignition Switch (ON/OFF)
main relay to ECM. This parameter indicates the state of ignition “ON”.
Battery Current (A) Starting Switch (ON/OFF)

This parameter indicates filtered electric load value This parameter indicates the state of ignition “START”.
(current consumption) as detected by battery current
sensor. Idle SW (ON/OFF)
This parameter indicates the state of accelerator pedal
Battery Current Raw Value (A) position sensor.
This parameter indicates electric load value (current ON: Accelerator pedal position is in idle position.
consumption) detected by electric load current sensor. OFF: Accelerator pedal position is out of idle position.
Battery DOD (%) Half Clutch Switch (ON/OFF)

This parameter indicates the depth of discharge of This parameter indicates the state of CPP No.2 switch.
battery.
Clutch Pressed Switch (ON/OFF)
Battery Current Sensor Voltage (V) This parameter indicates the state of CPP No.1 switch.
This parameter indicates voltage value detected by
electric load current sensor.
Neutral SW (ON/OFF) A/C Compressor Engine Run Order (ON/OFF)

This parameter indicates the state of neutral position This parameter indicates the state of engine auto restart
switch. command by ECM during engine auto stop control.
Brake Switch (ON/OFF) Shift Position (1st/2nd/R/N/D/M)

This parameter indicates the state of the brake switch. This parameter indicates the state of shift position sent
from TCM through CAN.
Charge Lamp Switch (ON/OFF)
This parameter indicates the state of electricity Engine Stop Request from AMT (True/False)
generated by generator. This parameter indicates the state of engine stop
ON: Engine is stationary. request from TCM to ECM.
OFF: Engine is running or stationary by engine auto stop
control (other than engine auto start inhibit control). Hill Hold Maintain Request from TCM During Idle
Stop (True/False)
ENG A-STOP Indicator Light (ON/OFF) This parameter indicates that a hill hold operation is
This parameter indicates the state of ENG A-STOP being requested during engine auto stop control.
indicator light for ENG A-STOP system operation.
Charge Request 1 (ON/OFF)
Stop Mode (ON/OFF) OFF: “Charge Request 1” is not requested by ECM.
This parameter indicates the state of the engine stop. ON: “Charge Request 1” is requested by ECM.
Normal Mode (ON/OFF) Charge Request 2 (ON/OFF)

This parameter indicates the state of the engine running. OFF: “Charge Request 2” is not requested by ECM.
ON: “Charge Request 2” is requested by ECM.
Auto Stop Mode (ON/OFF)
This parameter indicates the state of the engine auto Charge Request 3 (ON/OFF)
stop. OFF: “Charge Request 3” is not requested by ECM.
Starting Mode (ON/OFF)
This parameter indicates the state of the engine Charge Request 4 (ON/OFF)
cranking. OFF: “Charge Request 4” is not requested by ECM.
Engine Restart Request (True/False)
This parameter indicates the state of the engine restart Charge Request 5 (ON/OFF)
request. OFF: “Charge Request 5” is not requested by ECM.
Driver Door Switch (ON/OFF)
This parameter indicates the state of driver door switch Charge Request 6 (ON/OFF)
sent from BCM through CAN. OFF: “Charge Request 6” is not requested by ECM.
Driver Seatbelt Switch (Fasten/Unfasten)
This parameter indicates the state of driver seat belt Charge Request 7 (ON/OFF)
switch sent from BCM through CAN. OFF: “Charge Request 7” is not requested by ECM.
Hood Switch1 (ON/OFF)
This parameter indicates the state of hood latch switch 1. Charge Request 8 (ON/OFF)
OFF: “Charge Request 8” is not requested by ECM.
Hood Switch2 (ON/OFF) ON: “Charge Request 8” is requested by ECM.
This parameter indicates the state of hood latch switch 2.
ABS/ESP® Status for A-STOP (Failure/Inhibit/
Idling Stop Prohibit Switch (ON/OFF) Backup Disconnect/Normal)
This parameter indicates pushed state of ENG A-STOP This parameter indicates the state of control by ABS/
OFF switch. ESP® control module.
Air Conditioning Compressor Engine Run request Brake Pressure SW (True/False)

(ON/OFF) This parameter indicates the state of brake booster
This parameter indicates the state of engine auto restart switch.
request from BCM during engine auto stop control.
Reverse SW (True/False) HVAC Demand Condition (True/False)

This parameter indicates the state of the back up light This parameter indicates the state of inhibition request
switch. by BCM for engine auto stop control.
ECM Status for A-STOP (Auto Stop Inhibit Request/ ABS/ESP® Demand Condition (True/False)
Auto Start Request/Auto Start Inhibit Request) This parameter indicates the state of inhibition request
This parameter indicates the state of ECM request for by ABS/ESP® control module for engine auto stop
ENG A-STOP system. control.
Engine Stop Request from ICM (True/False) Brake Booster Condition (True/False)
This parameter indicates the state of engine stop This parameter indicates the state of brake booster
request. negative pressure for execution of engine auto stop
control.
TCM Check Request (True/False)
This parameter indicates a permit request to TCM for Battery Condition (True/False)
engine auto stop control. This parameter indicates the state of battery charge for
execution of engine auto stop control.
ESP Check Request (True/False)
This parameter indicates a permit request to ESP® Battery Temperature Condition (True/False)
control module for engine auto stop control. This parameter indicates the state of estimated battery
temperature for execution of engine auto stop control.
Stop A-STOP Permission (ABS/ESP®) (True/False)
This parameter indicates the state of permission by ABS/ Accel Pedal Condition (True/False)
ESP® control module for execution of engine auto stop This parameter indicates the state of accelerator pedal
control. position for execution of engine auto stop control.
Idle Stop Maintain Request (True/False) Shift Position Condition (True/False)

This parameter indicates the state of inhibition request This parameter indicates the state of each shift position
for engine auto restart control from TCM to ECM. in transmission range sensor.
Stop A-STOP Permission (ABS/ESP®) (ON/OFF) Master Cylinder Pressure Condition (True/False)
This parameter indicates the state of permission by ABS/ This parameter indicates the state of master cylinder
ESP® control module for execution of engine auto stop pressure for execution of engine auto stop control.
control.
Brake Switch Condition (True/False)
Brake Pressure Hold Request (True/False) This parameter indicates the state of brake switch for
This parameter indicates the brake pressure hold execution of engine auto stop control.
request.
Clutch SW Condition (True/False)
Engine Stop Request (True/False) This parameter indicates operating state of CPP No.2
This parameter indicates the state of permission by ECM switch.
for execution of engine auto stop control.
Speed History Condition (A-STOP) (True/False)
DTC Condition for A-STOP Inhibition (ECM) (True/ This parameter indicates the state of engine auto stop
False) permission based on vehicle running speed after the
This parameter indicates the state of DTC in engine auto previous engine auto stop.
stop system detected by ECM.
Tilt Angle Condition (A-STOP) (True/False)
ENG A-STOP OFF Switch Condition (True/False) This parameter indicates the state of tilt angle for
This parameter indicates the state of ENG A-STOP OFF execution of engine auto stop control while vehicle is
switch for execution of engine auto stop control. stationary.
Hood Switch Condition (True/False) TCM Demand Condition (A-STOP) (True/False)

This parameter indicates the state of hood latch switch This parameter indicates the state of inhibition request
for execution of engine auto stop control. by TCM for engine auto stop control while vehicle is
stationary.
Seat Belt / Door Condition (True/False)
This parameter indicates the state of seat belt buckle Fuel Cut (ON/OFF)
switch and front door switch (driver side) for execution of ON: Fuel injection is cut (output signal to injector is
engine auto stop control. stopped).
OFF: Fuel injection is not cut. DCDC1 Drive (ON/OFF)

This parameter indicates the state of ECM output to
DCDC1 Mode (Stop, Normal, Serious Failure, Minor drive DC/DC converter at engine restart (cranking).
Failure)
This parameter indicates the state of DC/DC converter. Charge Request 9 (True/False)
False: “Charge Request 9” is not requested by ECM.
Starter Drive Relay (+) (ON/OFF) True: “Charge Request 9” is requested by ECM.
This parameter indicates the state of starter drive relay
(+) for starting motor operation. Charge Request 11 (True/False)
False: “Charge Request 11” is not requested by ECM.
Starter Drive Relay (-) (ON/OFF) True: “Charge Request 11” is requested by ECM.
This parameter indicates the state of starter drive relay
(–) for starting motor operation.
Visual Inspection
AENNTA0E1104008 (06(01)
Visually check the following parts and systems.
Inspection item Referring section
Level “Engine Oil and Filter Change” in Section 0B
Engine oil
Leakage —
Level “Coolant Level Check” in Section 1F
Engine coolant “Engine Cooling System Inspection” in
Leakage
Section 1F
Level —
Fuel “Fuel Leakage Check Procedure” in Section
Leakage
1G
Dirt “Air Cleaner Filter Inspection and Cleaning”
Air cleaner filter
Clogging in Section 1D
Fluid level
Battery “Battery Inspection” in Section 1J
Corrosion of terminal
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.

MIL Operation “MIL Check”
“Generator Symptom Diagnosis” in Section
Charge warning light Operation
1J
“Oil Pressure Switch On-Vehicle Inspection”
Engine oil pressure light Operation
in Section 1E
Fuel level sensor Operation “Fuel Level Sensor Inspection” in Section 1G
Tachometer Operation Section 9C.
Exhaust system Leakage of exhaust gas, noise “Exhaust System Check” in Section 1K
Abnormal air being inhaled at air intake system —
Other parts that can be checked visually —
Engine Basic Inspection

AENNTA0E1104009 (06(01)
This check is very important for troubleshooting when ECM has detected no DTC and no abnormality has been found
in “Visual Inspection”.
Follow the flow carefully.
Step 1 Was “Engine and Emission Control System Check” performed?
Yes Go to Step 2.
No Go to “Engine and Emission Control System Check”.
Step 2 Check battery voltage
Is it 12 V or more?
Yes Go to Step 3.
No Charge or replace battery.
Step 3 Is engine cranked?
Yes Go to Step 4.
No Go to “Cranking System Symptom Diagnosis” in Section 1I.
Step 4 Does engine start?
Yes Go to Step 5.
No Go to Step 7.
Step 5 Check idle speed

1) Check engine idle speed. (Idle Speed Inspection)
Is check result OK?
Yes Go to Step 6.
No Go to “Engine Symptom Diagnosis”.
Step 6 Check ignition system

1) Check ignition system. (Ignition System Check) in Section 1H
Is check result OK?
Yes Go to “Engine Symptom Diagnosis”.

No Repair or replace defective part.
Step 7 Check immobilizer system

1) Check immobilizer control system.
• Ignition switch model: (Immobilizer Control System Check): Ignition Switch Model in Section 10C
• Keyless push start model: (Immobilizer Control System Check): Keyless Push Start Model in Section
10C
Is check result OK?
Yes Go to Step 8.
No Immobilizer control system malfunction.
Step 8 Check fuel supply

1) Check fuel supply. (Fuel Pump On-Vehicle Inspection) in Section 1G
Is check result OK?
Yes Go to Step 9.
Step 9 Check fuel injector circuit

1) Check fuel injector circuit referring to “Fuel Injector Circuit Check” in Section 1G.
Is check result OK?
Yes Go to “Engine Symptom Diagnosis”.

Engine Symptom Diagnosis

AENNTA0E1104010 (06(04)
Perform troubleshooting referring to the following points when ECM has detected no DTC and no abnormality has
been found in “Visual Inspection” and “Engine Basic Inspection”.
Hard starting (Engine can be cranked)

• Faulty spark plug “Spark Plug Inspection” in Section 1H
• Faulty ignition coil “Ignition Coil Assembly Inspection” in Section 1H
• Dirty or clogged fuel hoses or pipes “Fuel Pressure Check” in Section 1G
• Malfunctioning fuel pump “Fuel Pressure Check” in Section 1G
• Air drawn in through intake manifold gasket or
throttle body gasket Check air intake system.
• Faulty electric throttle body assembly “Electric Throttle Body Assembly On-Vehicle Inspection” in
Section 1C
• Faulty APP sensor “APP Sensor Inspection” in Section 1C
• Faulty ECT sensor, MAF sensor or MAP sensor “ECT Sensor Inspection” in Section 1C, “MAF Sensor with
IAT Sensor Inspection” in Section 1C and “MAP Sensor
Inspection” in Section 1C
• Faulty ECM “Inspection of ECM and Its Circuits”
• Low compression “Compression Check” in Section 1D
• Poor spark plug tightening or faulty gasket “Spark Plug Inspection” in Section 1H
• Compression leakage from valve seat “Valve and Valve Guide Inspection” in Section 1D
• Sticky valve stem “Valve and Valve Guide Inspection” in Section 1D
• Weak or damaged valve springs “Valve Spring Inspection” in Section 1D
• Compression leakage at cylinder head gasket “Cylinder Head Inspection” in Section 1D
• Sticky or damaged piston ring “Cylinder, Piston and Piston Ring Inspection” in Section 1D
• Worn piston, piston ring or cylinder “Cylinder, Piston and Piston Ring Inspection” in Section 1D
• Malfunctioning PCV valve “PCV Valve Inspection” in Section 1B
• VVT system out of order • VVT actuator: “Camshaft Inspection” in Section 1D
• Valve timing: “Timing Chain and Chain Tensioner
Inspection” in Section 1D
• OCV oil circuit: “Timing Chain Cover Inspection” in
Section 1D
• Faulty EGR system “EGR Valve System Inspection” in Section 1B
• Faulty valve rocker arm “Valve Rocker Arm Inspection” in Section 1D
• Faulty valve lash adjuster “Valve and Cylinder Head Removal and Installation” in
Section 1D
Low oil pressure

• Improper oil viscosity “Engine Oil and Filter Change” in Section 0B
• Malfunctioning oil pressure switch “Oil Pressure Switch On-Vehicle Inspection” in Section 1E
• Clogged oil strainer Check oil strainer for clog.
• Functional deterioration of oil pump “Oil Pump Inspection” in Section 1E
• Worn oil pump relief valve “Oil Pump Inspection” in Section 1E

• Excessive clearance in various sliding parts —
Engine noise – Valve noise
NOTE
Before checking mechanical noise, check that:
• Specified spark plug is used.
• Specified fuel is used.
• Worn valve stem and guide “Valve and Valve Guide Inspection” in Section 1D
• Weak or broken valve spring “Valve Spring Inspection” in Section 1D
• Warped or bent valve “Valve and Valve Guide Inspection” in Section 1D
• Faulty valve rocker arm “Valve Rocker Arm Inspection” in Section 1D
• Faulty valve lash adjuster “Valve and Cylinder Head Removal and Installation” in
Section 1D
Engine noise – Piston, piston ring and cylinder noise
NOTE
• Worn piston, piston ring and cylinder bore “Cylinder, Piston and Piston Ring Inspection” in Section 1D
Engine noise – Connecting rod noise
NOTE
• Worn piston, piston ring and cylinder bore “Cylinder, Piston and Piston Ring Inspection” in Section 1D
• Worn connecting rod bearing “Crankshaft Pin and Connecting Rod Bearing Inspection” in
Section 1D
• Worn crankshaft pin “Crankshaft Pin and Connecting Rod Bearing Inspection” in
Section 1D
• Loose connecting rod bolts “Piston, Piston Ring and Connecting Rod Removal and
Installation” in Section 1D
• Low oil pressure Condition “Low oil pressure”
Engine noise – Crankshaft noise
NOTE
• Low oil pressure Condition “Low oil pressure”

• Worn main bearing “Main Bearing Inspection” in Section 1D
• Worn crankshaft journal “Crankshaft Inspection” in Section 1D
• Loose bearing cap bolts “Main Bearing Inspection” in Section 1D
• Excessive crankshaft thrust play “Crankshaft Inspection” in Section 1D
Engine overheating
• Inoperative thermostat “Thermostat Inspection” in Section 1F
• Poor water pump performance “Water Pump Inspection” in Section 1F
• Clogged or leaky radiator “Radiator On-Vehicle Inspection and Cleaning” in Section
1F
• Improper engine oil grade “Engine Oil and Filter Change” in Section 0B
• Clogged oil filter or oil strainer “Oil Pressure Check” in Section 1E
• Poor oil pump performance “Oil Pressure Check” in Section 1E
• Faulty radiator cooling fan control system “Radiator Cooling Fan System Check” in Section 1F
• Dragging brakes Condition “Dragging brakes” in “Brake Symptom Diagnosis”
in Section 4A
• Slipping clutch Condition “Slipping” in “Clutch System Symptom Diagnosis”
in Section 5C
• Blown cylinder head gasket “Cylinder Head Inspection” in Section 1D
• Air mixed in cooling system “Cooling System Refilling” in Section 1F
Poor fuel mileage

• Faulty spark plug (improper gap, heavy deposits
and burned electrodes, etc.) “Spark Plug Inspection” in Section 1H
• High idle speed Condition “Improper engine idling or engine fails to idle”
• Poor performance of ECT sensor, MAF sensor or
MAP sensor “ECT Sensor Inspection” in Section 1C, “MAF Sensor with
Section 1C
• Faulty fuel injector(s) “Fuel Injector Circuit Check” in Section 1G
• Poor valve seating “Valve and Valve Guide Inspection” in Section 1D
in Section 4A
in Section 5C
• Thermostat out of order “Thermostat Inspection” in Section 1F
• Improper tire pressure “Tire Description” in Section 2D
Section 1D
Excessive engine oil consumption – Oil leakage

• Broken cylinder head gasket “Cylinder Head Inspection” in Section 1D
• Leaky crankshaft pulley oil seal “Timing Chain Cover Removal and Installation” in Section
1D
• Leaky crankshaft rear oil seal “Main Bearing, Crankshaft and Cylinder Block Removal and
Installation” in Section 1D
• Leaky cylinder head cover gasket “Cylinder Head Cover Components” in Section 1D
Excessive engine oil consumption – Oil entering combustion chamber

• Sticky piston ring “Cylinder, Piston and Piston Ring Inspection” in Section 1D
• Worn piston and cylinder “Cylinder, Piston and Piston Ring Inspection” in Section 1D
• Worn piston ring groove and ring “Cylinder, Piston and Piston Ring Inspection” in Section 1D
• Improper location of piston ring gap “Piston, Piston Ring and Connecting Rod Disassembly and
Reassembly” in Section 1D
• Worn or damaged valve stem seal “Valve and Valve Guide Inspection” in Section 1D
• Worn valve stem “Valve and Valve Guide Inspection” in Section 1D
Engine hesitation– Momentary lack of response as accelerator is depressed. Can occur at all vehicle speeds.
Usually severest when moving out from a stop at stop signal etc.
• Faulty spark plug or plug gap out of adjustment “Spark Plug Inspection” in Section 1H
• Fuel pressure out of specification “Fuel Pressure Check” in Section 1G
Section 1C
• Faulty fuel injector “Fuel Injector Circuit Check” in Section 1G
• Engine overheating Condition “Engine overheating”
Surge – Engine power variation under steady throttle or cruise. Vehicle speed changes up and down with no
change in accelerator pedal position.
• Faulty spark plug (excessive carbon deposits,
improper gap, burned electrodes, etc.) “Spark Plug Inspection” in Section 1H
• Variable fuel pressure “Fuel Pressure Check” in Section 1G
• Kinky or damaged fuel lines “Fuel Pressure Check” in Section 1G
• Faulty fuel pump (clogged fuel filter) “Fuel Pump and Its Circuit Check” in Section 1G
• Poor performance of MAF sensor or MAP sensor “MAF Sensor with IAT Sensor Inspection” in Section 1C and
“MAP Sensor Inspection” in Section 1C
• Faulty fuel injector “Fuel Injector Circuit Check” in Section 1G
Section 1C
Section 1D
Excessive detonation – Engine continuously generates sharp, metallic knocking sound that changes with
throttle opening.
• Clogged fuel filter (faulty fuel pump) or fuel lines “Fuel Pressure Check” in Section 1G or “Fuel Pump and Its
Circuit Check” in Section 1G
• Air drawn in through intake manifold or throttle

body gasket Check air intake system.
• Poor performance of knock sensor, ECT sensor,
MAF sensor or MAP sensor “Knock Sensor On-Vehicle Inspection” in Section 1C, “ECT
Sensor Inspection” in Section 1C, “MAF Sensor with IAT
Sensor Inspection” in Section 1C and “MAP Sensor
• Faulty fuel injector(s) “Fuel Injector Circuit Check” in Section 1G or “Fuel Injector
Inspection” in Section 1G
• Excessive combustion chamber deposits “Cylinder, Piston and Piston Ring Inspection” in Section 1D
and/or “Piston Pin and Connecting Rod Inspection” in
Section 1D
Section 1D
Poor engine power

• Faulty ignition coil assembly “Ignition Coil Assembly Inspection” in Section 1H
• Faulty knock sensor “Knock Sensor On-Vehicle Inspection” in Section 1C
• Clogged fuel hoses or pipes “Fuel Pressure Check” in Section 1G
• Malfunctioning fuel pump “Fuel Injector Circuit Check” in Section 1G
• Air drawn in through intake manifold gasket or
throttle body gasket Check air intake system.
Section 1C
in Section 4A
in Section 5C
Section 1D
Improper engine idling or engine fails to idle

• Leaky manifold, throttle body, or cylinder head

gasket Check air intake system.
• Faulty evaporative emission control system “EVAP Canister Purge Valve Inspection” in Section 1B
• Poor performance of ECT sensor, MAF sensor and
Section 1C
• Loose connection or disconnection of vacuum
hoses Check connection of vacuum hoses.
• Malfunctioning PCV valve “PCV Valve Inspection” in Section 1B
• Camshaft position control (VVT) system out of
order “OCV Inspection” in Section 1C
• Faulty oil temperature sensor “Oil Temperature Sensor Inspection” in Section 1C
Excessive hydrocarbon (HC) emission or carbon monoxide (CO) emission

• Lead contamination of three-way catalytic
converter Check for absence of filler neck restrictor.
• Faulty evaporative emission control system “EVAP Canister Purge System Inspection” in Section 1B
• Faulty closed loop system (A/F feedback
compensation) (Poor performance of ECT sensor,
MAF sensor or MAP sensor) “ECT Sensor Inspection” in Section 1C, “MAF Sensor with
IAT Sensor Inspection” in Section 1C or “MAP Sensor
Section 1C
• Faulty injector(s) “Fuel Injector Circuit Check” in Section 1G
• Engine not at normal operating temperature —
• Clogged air cleaner “Air Cleaner Filter Inspection and Cleaning” in Section 1D
• Vacuum leaks “Engine Vacuum Check” in Section 1D
Section 1D
Excessive nitrogen oxides (NOx) emission

• Improper ignition timing “Ignition Timing Inspection” in Section 1H
• Lead contamination of three-way catalytic
converter Check for absence of filler neck restrictor.
• Faulty closed loop system (A/F feedback

compensation) (Poor performance of ECT sensor,
MAF sensor or MAP sensor) “ECT Sensor Inspection” in Section 1C, “MAF Sensor with
IAT Sensor Inspection” in Section 1C or “MAP Sensor
Section 1C
• Faulty injector(s) “Fuel Injector Circuit Check” in Section 1G or “Fuel Injector
Section 1D
MIL Does Not Come ON with Ignition “ON” and Engine Stopped (but Engine Can Be Started)
AENNTA0E1104011 (06(03)
Troubleshooting
Step 1 DTC check

1) Check DTC related to CAN communication. (DTC Check)
Is there any CAN-DTC(s) detected?
Yes Go to troubleshooting for applicable DTC.

No Go to Step 2.
Step 2 DTC check

1) Check combination meter for DTC. (Combination Meter Diagnosis Function Description) in Section 9C
Is there any DTC(s) detected?

No Replace ECM and recheck MIL operation. (ECM Removal and Installation) in Section 1C
MIL Remains ON after Engine Starts

AENNTA0E1104012 (06(03)
Troubleshooting
Step 1 DTC check

1) Start engine and check DTC while engine running. (DTC Check)

No Substitute a known-good combination meter and recheck MIL operation. (Combination Meter
Removal and Installation) in Section 9C
If MIL still remains ON, replace ECM and recheck MIL operation. (ECM Removal and Installation)
in Section 1C
DTC P0010 / P0013 / P2088 / P2089 / P2090 / P2091

AENNTA0E1104013 (06(02)
DTC Detecting Condition and Trouble Area

DTC detecting condition Trouble area
P0010: “A” Camshaft Position Actuator Circuit/Open Bank 1 • Intake OCV and/or its circuit
Intake OCV control circuit is open. • Exhaust OCV and/or its circuit
(3 D/C detection logic)
• ECM
P0013: “B” Camshaft Position Actuator Circuit / Open
Exhaust OCV control circuit is open.
P2088: “A” Camshaft Position Actuator Control Circuit Low
Bank 1
Intake OCV drive circuit is shorted to ground.
P2089: “A” Camshaft Position Actuator Control Circuit High
Bank 1
Intake OCV drive circuit is shorted to power supply.
P2090: “B” Camshaft Position Actuator Control Circuit Low
Exhaust OCV control circuit is shorted to ground.
P2091: “B” Camshaft Position Actuator Control Circuit High
Exhaust OCV control circuit is shorted to power supply.
Circuit Diagram
3
+B
12V A2 A1
1 BLU
C01-42 GRN
12V B2 B1
2
C01-43 WHT
[A] C01
[a]
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49
IMTA0A110010-01
[A]: ECM connector (View: [a]) B1: Exhaust OCV power supply circuit 2. Exhaust OCV
A1: Intake OCV power supply circuit B2: Exhaust OCV drive circuit 3. ECM
A2: Intake OCV drive circuit 1. Intake OCV
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.

DTC Troubleshooting
Reference: “Precautions for Electrical System Work”
Yes Go to Step 2.
Step 2 OCV power supply circuit check

1) When ignition is “OFF”, disconnect connector from OCV related to DTC.
2) Check for proper terminal connection to OCV connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between each of “A1” and “B1” and ground is battery voltage.
Is check result OK?
Yes Go to Step 3.
No Repair or replace defective wire harness.
Step 3 OCV drive circuit check

1) When ignition is “OFF”, disconnect ECM connectors.
2) Check for proper terminal connection to ECM connectors.
3) If connections are OK, check the following points.
• Resistance of “A2” or “B2” circuit: less than 1 Ω
• Resistance between “A2” or “B2” circuit and ground: infinity
• Resistance between “A2” or “B2” circuit terminal and other terminal at ECM connector: infinity
• Voltage of “A2” or “B2” circuit: approx. 0 V (When ignition is “ON”)
Is check result OK?
Yes Go to Step 4.
Step 4 OCV check

1) Check OCV related to DTC. (OCV Inspection) in Section 1C
Is check result OK?
Yes Go to Step 5.
No Replace OCV. (OCV Removal and Installation) in Section 1D
Step 5 Troubleshooting of other DTC(s) at the same time
Is other DTC(s) detected together?

No Replace ECM and recheck DTC. (ECM Removal and Installation) in Section 1C
DTC P0011 / P0014

AENNTA0E1104014 (06(02)

P0011: “A” Camshaft Position - Timing Over - Advanced or System • OCV and/or its circuit
Performance Bank 1 • CKP sensor and sensor plate
Measured intake CMP does not reach target intake CMP for specified time.
• CMP sensor and signal rotor
P0014: “B” Camshaft Position - Timing Over - Advanced or System • OCV oil passage
Performance • VVT actuator
Measured exhaust CMP does not reach target exhaust CMP for specified time. • Timing chain
• Timing chain tensioner
• Timing chain tensioner
adjuster
• Crankshaft timing sprocket
• ECM
Circuit Diagram
3
+B
12V A2 A1
1 BLU
C01-42 GRN
12V B2 B1
2
C01-43 WHT
[A] C01
[a]
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49
IMTA0A110010-01
! 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”.
– Intake OCV (P0010, P2088 and P2089)
– Exhaust OCV (P0013, P2090 and P2091)
1) Start engine and drive vehicle at 60 to 80 km/h (37 to 50 mile/h) for more than 10 min with engine speed 1,600 rpm
or more.
DTC Troubleshooting
Yes Go to Step 2.
Step 2 DTC check

1) Check DTC. (DTC Check)
Is there DTC(s) other than P0011 and P0014?
Yes Go to troubleshooting for applicable DTC(s).

No Go to Step 3.
Step 3 OCV power supply circuit and OCV drive circuit check
1) Check “A1” or “B1” and “A2” or “B2” circuits according to Step 2 – 3 under “DTC P0010 / P0013 / P2088
/ P2089 / P2090 / P2091”.
Is check result OK?
Yes Go to Step 4.
Step 4 Oil pressure check

1) Check oil pressure. (Oil Pressure Check) in Section 1E
Is check result OK?
Yes Go to Step 5.
Step 5 OCV oil circuit visual check

1) Remove cylinder head cover. (Cylinder Head Cover Removal and Installation) in Section 1D
2) Check oil pressure leakage from OCV oil circuit. (Timing Chain Cover Inspection) in Section 1D
Is check result OK?
Yes Go to Step 6.
No Repair or replace defective parts.
Step 6 CKP sensor and sensor plate check

1) Check CKP sensor and sensor plate.
• CKP sensor: (CKP Sensor Inspection) in Section 1C
• Sensor plate: (Sensor Plate Inspection) in Section 1D
Is check result OK?
Yes Go to Step 7.
Step 7 CMP sensor and signal rotor check

1) Check CMP sensor and signal rotor.
• CMP sensor: (CMP Sensor On- Vehicle Inspection) in Section 1C
• Signal rotor: (Camshaft Inspection) in Section 1D
Is check result OK?
Yes Go to Step 8.
Step 8 OCV check

1) Check OCV. (OCV Inspection) in Section 1C
Is check result OK?
Yes Go to Step 9.
Step 9 VVT actuator check

1) Check VVT actuator. (Camshaft Inspection) in Section 1D
Is check result OK?
Yes Go to Step 10.

No Replace VVT actuator. (Camshaft Removal and Installation) in Section 1D
Step 10 Timing mark on VVT actuator and crankshaft timing sprocket key position check
1) Check that timing marks on VVT actuators and crankshaft timing sprocket key position is in specified
position. (Timing Chain and Chain Tensioner Removal and Installation) in Section 1D
Is check result OK?
Yes Replace ECM and recheck DTC. (ECM Removal and Installation) in Section 1C
No Go to Step 11.
Step 11 Timing chain, timing chain tensioner, timing chain tensioner adjuster and crankshaft timing sprocket
check
1) Check timing chain, timing chain tensioner, timing chain tensioner adjuster and crankshaft timing
sprocket. (Timing Chain and Chain Tensioner Inspection) in Section 1D
Is check result OK?
Yes Reinstall parts related to timing chain correctly and recheck DTC. (Timing Chain and Chain
Tensioner Removal and Installation) in Section 1D
DTC P0016 / P0017

AENNTA0E1104015 (06(02)

P0016: Crankshaft Position - Camshaft Position • OCV and/or its circuit
Correlation Bank 1 Sensor A • CMP sensor and/or its circuit
Difference between intake camshaft position and
• CKP sensor and/or its circuit
crankshaft position is out of specified range.
(3 D/C detection logic) • Sensor plate
P0017: Crankshaft Position - Camshaft Position • Signal rotor
Correlation Bank 1 Sensor B • VVT actuator
Difference between exhaust camshaft position and
• Timing chain
crankshaft position is out of specified range.
(3 D/C detection logic) • Timing chain tensioner
• Timing chain tensioner adjuster
• Crankshaft timing sprocket
• ECM
Circuit Diagram
OCV Circuit
3
+B
12V A2 A1
1 BLU
C01-42 GRN
12V B2 B1
2
C01-43 WHT
[A] C01
[a]
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49
IMTA0A110010-01
CMP sensor and CKP sensor Circuit
+B
BLU
4
A1 5V
1 A2
PPL C01-30
A3
B1 5V
2 B2
YEL C01-40
B3
C1 5V
3 C2
PNK C01-39
C3
GRY
[A] C01
[a]
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49
IMTA0A110011-01
[A]: ECM connector (View: [a]) B2: Exhaust CMP sensor signal circuit 1. Intake CMP sensor
A1: Intake CMP sensor power supply circuit B3: Exhaust CMP sensor ground circuit 2. Exhaust CMP sensor
A2: Intake CMP sensor signal circuit C1: CKP sensor power supply circuit 3. CKP sensor
A3: Intake CMP sensor ground circuit C2: CKP sensor signal circuit 4. ECM
B1: Exhaust CMP sensor power supply circuit C3: CKP sensor ground circuit
! WARNING
accident can occur.
NOTE
– OCV (P0010, P0013, P2088, P2089, P2090 and P2091)
– CKP sensor (P0335 and P0336)
– CMP sensor (P0340 and P0365)
1) Warm up engine to normal operating temperature.

2) Run engine at idle speed for 3 min.
3) With engine speed at 1,000 to 1,200 rpm, drive vehicle at 40 to 60 km/h (25 to 37 mile/h) for 5 min.
DTC Troubleshooting
Yes Go to Step 2.
Step 2 DTC check

Is there DTC(s) other than P0016 and P0017?

No Go to Step 3.
Step 3 OCV power supply circuit and OCV drive circuit check
1) Check “A1” or “B1” and “A2” or “B2” circuits according to Step 2 – 3 under “DTC P0010 / P0013 / P2088
/ P2089 / P2090 / P2091”.
Is check result OK?
Yes Go to Step 4.
Step 4 CKP sensor power supply circuit, signal circuit and ground circuit check
1) Check “C1”, “C2” and “C3” circuits according to Step 2 – 4 under “DTC P0335 / P0336”.
Is check result OK?
Yes Go to Step 5.
Step 5 CMP sensor power supply circuit, signal circuit and ground circuit check
1) Check “A1” or “B1”, “A2” or “B2” and “A3” or “B3” circuits according to Step 2 – 4 under “DTC P0340 /
P0365”.
Is check result OK?
Yes Go to Step 6.
Step 6 Oil pressure check

1) Check oil pressure. (Oil Pressure Check) in Section 1E
Is check result OK?
Yes Go to Step 7.
Step 7 OCV oil circuit visual check

1) Check OCV oil circuit. (Timing Chain Cover Inspection) in Section 1D
Is check result OK?
Yes Go to Step 8.

• CKP sensor: (CKP Sensor Inspection) in Section 1C
• Sensor plate: (Sensor Plate Inspection) in Section 1D
Is check result OK?
Yes Go to Step 9.

1) Check CMP sensor and signal rotor.
Is check result OK?
Yes Go to Step 10.

Step 10 OCV check

1) Check OCV. (OCV Inspection) in Section 1C
Is check result OK?
Yes Go to Step 11.

Step 11 VVT actuator check

1) Check VVT actuator. (Camshaft Inspection) in Section 1D
Is check result OK?
Yes Go to Step 12.

No Replace VVT actuator. (Camshaft Removal and Installation) in Section 1D
Step 12 Timing mark on VVT actuator and crankshaft timing sprocket key position check
1) Check that timing marks on VVT actuators and crankshaft timing sprocket key position is in specified
position. (Timing Chain and Chain Tensioner Removal and Installation) in Section 1D
Is check result OK?
No Go to Step 13.
Step 13 Timing chain, timing chain tensioner, timing chain tensioner adjuster and crankshaft timing sprocket
check
1) Check timing chain, timing chain tensioner, timing chain tensioner adjuster and crankshaft timing
sprocket. (Timing Chain and Chain Tensioner Inspection) in Section 1D
Is check result OK?
Yes Reinstall parts related to timing chain correctly and recheck DTC. (Timing Chain and Chain
DTC P0030 / P0031 / P0032

AENNTA0E1104016 (06(02)
P0030: HO2S Heater Control Circuit Bank 1 Sensor 1 • HO2S-1 heater and/or its circuit
HO2S-1 heater drive circuit is open. • ECM
P0031: HO2S Heater Control Circuit Low Bank 1
Sensor 1
HO2S-1 heater drive circuit is shorted to ground.
P0032: HO2S Heater Control Circuit High Bank 1
Sensor 1
HO2S-1 heater drive circuit is shorted to power supply.
Circuit Diagram
3
5V
+B 1 4 A3
RED C01-6
A2
GRN C01-7
A4
BLU PPL C01-49
A1 LT GRN C01-55
5V
2 4 B3
YEL C01-8
B2
BRN C01-19
B4
BLU RED C01-52
B1 BEG C01-56
[A] C01
[a]
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49
IMTA0A110012-01
[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 Troubleshooting
Yes Go to Step 2.
Step 2 HO2S-1 heater power supply circuit check

1) When ignition is “OFF”, disconnect HO2S-1 connector.
2) Check for proper terminal connection to HO2S-1 connector.
4) Check that voltage between “A1” circuit and ground is battery voltage.
Is check result OK?
Yes Go to Step 3.
No Repair or replace defective wiring harness.
Step 3 HO2S-1 heater drive circuit check

• Resistance of “A4” circuit: less than 1 Ω
• Resistance between “A4” circuit and ground: infinity
• Resistance between “A4” circuit terminal and other terminal at ECM connector: infinity
• Voltage of “A4” circuit: approx. 0 V (When ignition is “ON”)
Is check result OK?
Yes Go to Step 4.
Step 4 HO2S-1 heater check

1) Check HO2S-1 heater. (HO2S On-Vehicle Inspection) in Section 1C
Is check result OK?
No Replace HO2S-1. (HO2S Removal and Installation) in Section 1C
DTC P0036 / P0037 / P0038

AENNTA0E1104017 (06(02)
P0036: HO2S Heater Control Circuit Bank 1 Sensor 2 • HO2S-2 heater and/or its circuit
HO2S-2 heater drive circuit is open. • ECM
P0037: HO2S Heater Control Circuit Low Bank 1
Sensor 2
HO2S-2 heater drive circuit is shorted to ground.
P0038: HO2S Heater Control Circuit High Bank 1
Sensor 2
HO2S-2 heater drive circuit is shorted to power supply.
Circuit Diagram
3
5V
+B 1 4 A3
RED C01-6
A2
GRN C01-7
A4
BLU PPL C01-49
A1 LT GRN C01-55
5V
2 4 B3
YEL C01-8
B2
BRN C01-19
B4
BLU RED C01-52
B1 BEG C01-56
[A] C01
[a]
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49
IMTA0A110012-01
NOTE
DTC Troubleshooting
Yes Go to Step 2.
Step 2 HO2S-2 heater power supply circuit check

1) When ignition is “OFF”, disconnect HO2S-2 connector.
2) Check for proper terminal connection to HO2S-2 connector.
4) Check that voltage between “B1” circuit and ground is battery voltage.
Is check result OK?
Yes Go to Step 3.
Step 3 HO2S-2 heater drive circuit check

• Resistance of “B4” circuit: less than 1 Ω
• Resistance between “B4” circuit and ground: infinity
• Resistance between “B4” circuit terminal and other terminal at ECM connector: infinity
• Voltage of “B4” circuit: approx. 0 V (When ignition is “ON”)
Is check result OK?
Yes Go to Step 4.
Step 4 HO2S-2 check

Is check result OK?
DTC P0102 / P0103

AENNTA0E1104018 (06(02)
P0102: Mass or Volume Air Flow “A” Circuit Low • MAF sensor and/or its circuit
Output voltage of MAF sensor signal circuit is lower than specified value. • ECM
P0103: Mass or Volume Air Flow “A” Circuit High
Output voltage of MAF sensor signal circuit is higher than specified value.
Circuit Diagram
4 3
A1
5V
LT BLU C01-14
A2 5V
1 LT GRN C01-9
2 B1 5V
YEL C01-22
BEG C01-29
C1
[A] C01
[a]
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49
IMTA0A110013-01
[A]: ECM connector (View: [a]) B1: IAT sensor signal circuit 2. IAT sensor
A1: MAP sensor and MAF sensor power supply C1: MAF sensor with IAT sensor ground circuit 3. ECM
circuit
A2: MAF sensor signal circuit 1. MAF sensor 4. To MAP sensor
NOTE
• Check that the following condition is met in this “DTC Confirmation Procedure”.
– Battery voltage > 10.5 V
• Check that the following DTCs are not detected in this “DTC Confirmation Procedure”
– System voltage (P0560, P0562 and P0563)
DTC Troubleshooting
Yes Go to Step 2.
Step 2 MAP sensor and MAF sensor power supply circuit check
1) When ignition is “OFF”, disconnect MAF sensor with IAT sensor connector and MAP sensor connector.
2) Check for proper terminal connection to MAF sensor with IAT sensor connector.
4) Check that voltage between “A1” and “C1” is approx. 5V.
Is check result OK?
Yes Go to Step 5.
No Go to Step 3.
Step 3 MAF sensor ground circuit check

1) Check that voltage between “A1” and ground is approx. 5V.
Is check result OK?
Yes Repair or replace “C1” circuit.

If this DTC is detected again, replace ECM and recheck DTC. (ECM Removal and Installation) in
Section 1C
No Go to Step 4.
Is check result OK?
Step 5 MAF sensor signal circuit check

Is check result OK?
Yes Go to Step 6.
Step 6 MAF sensor check

1) Check MAF sensor. (MAF Sensor with IAT Sensor Inspection) in Section 1C
Is check result OK?
No Replace MAF sensor with IAT sensor. (MAF Sensor with IAT Sensor Removal and Installation) in
Section 1C
DTC P0107 / P0108

AENNTA0E1104019 (06(02)

P0107: Manifold Absolute Pressure/Barometric Pressure Circuit Low • MAP sensor and/or its circuit
Output voltage of MAP sensor signal circuit is lower than 0.08 V for 5 sec. • ECM
P0108: Manifold Absolute Pressure/Barometric Pressure Circuit High
Output voltage of MAP sensor signal circuit is higher than 4.83 V for 5 sec.
Circuit Diagram
2
3 A1 5V
LT BLU C01-14
A2 12V
1
BRN C01-27
GRY C01-4
4 A3
[A] C01
[a]
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49
IMTA0A110014-01
[A]: ECM connector (View: [a]) A3: MAP sensor and ECT sensor ground circuit 3. To MAF sensor with IAT sensor
A1: MAP sensor and MAF sensor power supply 1. MAP sensor 4. To ECT sensor
circuit
A2: MAP sensor signal circuit 2. ECM

1) Set ignition “ON” for 10 sec.
DTC Troubleshooting
Yes Go to Step 2.
1) When ignition is “OFF”, disconnect MAP sensor connector, MAF sensor with IAT sensor connector and
ECT sensor connector.
2) Check for proper terminal connection to MAP sensor connector.
4) Check that voltage between “A1” and “A3” is approx. 5 V.
Is check result OK?
Yes Go to Step 5.
No Go to Step 3.
Step 3 MAP sensor and ECT sensor ground circuit check

1) Check that voltage between “A1” and ground is approx. 5 V.
Is check result OK?
Yes Repair or replace “A3” circuit.

Section 1C
No Go to Step 4.
Is check result OK?
Step 5 MAP sensor signal circuit check

Is check result OK?
Yes Go to Step 6.
Step 6 MAP sensor check

1) Check MAP sensor. (MAP Sensor Inspection) in Section 1C
Is check result OK?
No Replace MAP sensor. (MAP Sensor Removal and Installation) in Section 1C
DTC P0112 / P0113

AENNTA0E1104020 (06(02)

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 0.03 V for 5 sec. • ECM
P0113: Intake Air Temperature Sensor 1 Circuit High Bank 1
Output voltage of IAT sensor signal circuit is higher than 4.97 V for 5 sec.
Circuit Diagram
4 3
A1
5V
LT BLU C01-14
A2 5V
1 LT GRN C01-9
2 B1 5V
YEL C01-22
BEG C01-29
C1
[A] C01
[a]
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49
IMTA0A110013-01
[A]: ECM connector (View: [a]) B1: IAT sensor signal circuit 2. IAT sensor
A1: MAP sensor and MAF sensor power supply C1: MAF sensor with IAT sensor ground circuit 3. ECM
circuit
A2: MAF sensor signal circuit 1. MAF sensor 4. To MAP sensor

DTC Troubleshooting
Yes Go to Step 2.
Step 2 IAT sensor signal circuit and MAF sensor with IAT sensor ground circuit check
1) When ignition is “OFF”, disconnect ECM connectors, MAF sensor with IAT sensor connector and MAP
sensor connector.
2) Check for proper terminal connection to ECM connectors and MAF sensor with IAT sensor connector.
• Resistance of “B1” and “C1” circuits: less than 1 Ω
• Resistance between each of “B1” and “C1” circuits and ground: infinity
• Resistance between “C1” circuit terminal and other terminal at ECM connector: infinity
• Voltage of “B1” and “C1” circuits: approx. 0 V (When ignition is “ON”)
Is check result OK?
Yes Go to Step 3.
Step 3 IAT sensor check

1) Check IAT sensor. (MAF Sensor with IAT Sensor Inspection) in Section 1C
Is check result OK?
No Replace MAF sensor with IAT sensor. (MAF Sensor with IAT Sensor Removal and Installation) in
Section 1C
DTC P0116
AENNTA0E1104021 (06(02)
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 C01-20
GRY C01-4
2
A2
[A] C01
[a]
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49
IMTA0A110015-01
[A]: ECM connector (View: [a]) A2: MAP sensor and ECT sensor ground circuit 2. To MAP sensor
A1: ECT sensor signal circuit 1. ECT sensor 3. ECM

DTC Troubleshooting

Yes Go to Step 2.
Step 2 Coolant level check

1) Check coolant level. (Coolant Level Check) in Section 1F
Is check result OK?
Yes Go to Step 3.
No Add coolant and recheck DTC.
Step 3 ECT sensor circuit check

1) Check ECT sensor circuits according to Step 2 under “DTC P0117 / P0118”.
Is check result OK?
Yes Go to Step 4.
Step 4 ECT sensor check

1) Check ECT sensor. (ECT Sensor Inspection) in Section 1C
Is check result OK?
Yes Go to Step 5.
No Replace ECT sensor.
Step 5 Thermostat check

1) Check thermostat. (Thermostat Inspection) in Section 1F
Is check result OK?
Yes Replace ECM and recheck for DTC. (ECM Removal and Installation) in Section 1C
No Replace thermostat. (Thermostat Removal and Installation) in Section 1F
DTC P0117 / P0118

AENNTA0E1104022 (06(02)
P0117: Engine Coolant Temperature Sensor 1 Circuit Low • ECT sensor and/or its circuit
Output voltage of ECT sensor signal circuit is lower than 0.03 V for 5 sec. • ECM
P0118: Engine Coolant Temperature Sensor 1 Circuit High
Output voltage of ECT sensor signal circuit is higher than 4.97 V for 5 sec.
Circuit Diagram
3
A1 5V
1
BLU C01-20
GRY C01-4
2
A2
[A] C01
[a]
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49
IMTA0A110015-01
[A]: ECM connector (View: [a]) A2: MAP sensor and ECT sensor ground circuit 2. To MAP sensor
A1: ECT sensor signal circuit 1. ECT sensor 3. ECM

DTC Troubleshooting
Yes Go to Step 2.
Step 2 ECT sensor signal circuit and MAP sensor and ECT sensor ground circuit check
1) When ignition is “OFF”, disconnect ECM connectors, ECT sensor connector and MAP sensor connector.
2) Check for proper terminal connection to ECM connectors and ECT sensor connector.
• Resistance of “A1” and “A2” circuits: less than 1 Ω
• Resistance between each of “A1” and “A2” circuits and ground: infinity
• Voltage of “A1” and “A2” circuits: approx. 0 V (When ignition is “ON”)
Is check result OK?
Yes Go to Step 3.
Step 3 ECT sensor check

1) Check ECT sensor. (ECT Sensor Inspection) in Section 1C
Is check result OK?
No Replace ECT sensor. (ECT Sensor Removal and Installation) in Section 1C
DTC P0122 / P0123

AENNTA0E1104023 (06(02)
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. • Electric throttle body assembly
• ECM
P0123: Throttle/Pedal Position Sensor/Switch “A” Circuit High
Output voltage of TP sensor (main) signal circuit is higher than 4.8 V.
Circuit Diagram
12V
1
A1
C01-54 BRN
A2
C01-51 LT GRN 4
5V B1
C01-13 RED B2 2
C01-26 GRN
B3 3
C01-16 WHT
C01-15 BLK
B4
C01-17 BLK
[A] C01
[a]
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49
IMTA0A110016-01
[A]: ECM connector (View: [a]) B2: TP sensor (main) signal circuit 2. TP sensor (main)
A1: Throttle actuator drive circuit (open) B3: TP sensor (sub) signal circuit 3. TP sensor (sub)
A2: Throttle actuator drive circuit (close) B4: TP sensor ground circuit 4. Throttle actuator
B1: TP sensor power supply circuit 1. Electric throttle body assembly 5. ECM
NOTE
Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.
DTC Troubleshooting
Yes Go to Step 2.
Step 2 TP sensor power supply circuit check

1) When ignition is “OFF”, disconnect electric throttle body assembly connector.
2) Check for proper terminal connection to electric throttle body assembly connector.

4) Check that voltage between “B1” and “B4” is approx. 5 V.
Is check result OK?
Yes Go to Step 5.
No Go to Step 3.
Step 3 TP sensor ground circuit check

1) Check that voltage between “B1” and ground is approx. 5 V.
Is check result OK?
Yes Repair or replace “B4” circuit.

Section 1C
No Go to Step 4.

Is check result OK?
Step 5 TP sensor (main) signal circuit check

Is check result OK?
Yes Go to Step 6.
Step 6 TP sensor check

1) Check TP sensor referring to “Throttle Position Sensor Performance Check” under “Electric Throttle
Body Assembly On-Vehicle Inspection” in Section 1C.
Is check result OK?
No Replace electric throttle body assembly. (Electric Throttle Body Assembly Removal and
Installation) in Section 1D
DTC P0130
AENNTA0E1104024 (06(02)
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 0.05 V and 0.41 V for 25 sec. • HO2S-1 heater and/or its circuit
even if HO2S-2 signal voltage is higher than 0.6 V.
• HO2S-2 heater and/or its circuit
• HO2S-1 signal voltage is between 0.6 V and 1.26 V for 25 sec.
• ECM
even if HO2S-2 signal voltage is lower than 0.1 V.
Circuit Diagram
3
5V
+B 1 4 A3
RED C01-6
A2
GRN C01-7
A4
BLU PPL C01-49
A1 LT GRN C01-55
5V
2 4 B3
YEL C01-8
B2
BRN C01-19
B4
BLU RED C01-52
B1 BEG C01-56
[A] C01
[a]
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49
IMTA0A110012-01
! WARNING
accident can occur.
NOTE
• Check that the following conditions are met in this “DTC Confirmation Procedure”.
– A/F feedback (closed loop) control is activated.
– Battery voltage > 11 V
– HO2S-1 heater (P0030, P0031 and P0032)
– Fuel injector (P0201, P0202, P0203, P0204, P0261, P0262, P0264, P0265, P0267, P0268, P0270,
P0271, P21CF, P21D0, P21D1, P21D2, P21DB, P21DC, P21DE, P21DF, P21E0, P21E1, P21E2 and
P21E3)

2) Drive vehicle at 50 to 80 km/h (31 to 50 mile/h) constantly for 10 min. or more.
DTC Troubleshooting
Yes Go to Step 2.
Step 2 DTC check

1) Check DTC.
Is there DTC(s) detected other than P0130?

No Go to Step 3.
Step 3 HO2S-1 heater, HO2S-1 circuit and HO2S-1 heater circuit check
1) Check the following points.
• HO2S-1 heater: (HO2S On-Vehicle Inspection) in Section 1C
• “A2” and “A3” circuits: Step 3 under “DTC P0131 / P0132”
• “A1” and “A4” circuits: Step 2 – 3 under “DTC P0030 / P0031 / P0032”
Is check result OK?
Yes Go to Step 4.
Step 4 HO2S-2 heater, HO2S-2 circuit and HO2S-2 heater circuit check
• HO2S-2 heater: (HO2S On-Vehicle Inspection) in Section 1C
• “B2” and “B3” circuits: Step 3 under “DTC P0137 / P0138 / P0140”
• “B1” and “B4” circuits: Step 2 – 3 under “DTC P0036 / P0037 / P0038”
Is check result OK?
Yes Go to Step 5.
Step 5 DTC recheck

1) Replace HO2S-1. (HO2S Removal and Installation) in Section 1C
2) Perform “DTC Confirmation Procedure” and check DTC. (DTC Check)
Is DTC P0130 still detected?

Yes Go to Step 6.
No End.
Step 6 DTC recheck

No End.
DTC P0131 / P0132

AENNTA0E1104025 (06(02)
P0131: O2 Sensor Circuit Low Voltage Bank1 Sensor 1 • HO2S-1 and/or its circuit
Output voltage of HO2S-1 signal circuit is lower than 0.05 V for 25 sec. • ECM
P0132: O2 Sensor Circuit High Voltage Bank 1 Sensor 1
Output voltage of HO2S-1 signal circuit is higher than 1.25 V for 25 sec.
Circuit Diagram
3
5V
+B 1 4 A3
RED C01-6
A2
GRN C01-7
A4
BLU PPL C01-49
A1 LT GRN C01-55
5V
2 4 B3
YEL C01-8
B2
BRN C01-19
B4
BLU RED C01-52
B1 BEG C01-56
[A] C01
[a]
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49
IMTA0A110012-01
! WARNING
accident can occur.
NOTE
– ECT sensor (P0116, P0117 and P0118)
P21E3)

DTC Troubleshooting
Yes Go to Step 2.
Step 2 DTC check
Is there any DTC(s) other than P0131 and P0132?

No Go to Step 3.
Step 3 HO2S-1 signal circuit and ground circuit check

1) When ignition is “OFF”, disconnect ECM connectors and HO2S-1 connector.
2) Check for proper terminal connection to ECM connectors and HO2S-1 connector.
• Voltage of “A2” and “A3” circuits: approx. 0 V (when ignition is “ON”)
Is check result OK?
Yes Go to Step 4.
Step 4 DTC recheck

Is DTC P0131 and/or P0132 still detected?
No End.
DTC P0133
AENNTA0E1104026 (06(02)
P0133: O2 Sensor Circuit Slow Response Bank 1 • HO2S-1 and/or its circuit
Sensor 1 • Air intake system
Cycle duration from rich to lean and lean to rich of HO2S-
• Exhaust system
1 is longer than specified time.
(3 D/C detection logic) • Fuel system
• ECM
Circuit Diagram
3
5V
+B 1 4 A3
RED C01-6
A2
GRN C01-7
A4
BLU PPL C01-49
A1 LT GRN C01-55
5V
2 4 B3
YEL C01-8
B2
BRN C01-19
B4
BLU RED C01-52
B1 BEG C01-56
[A] C01
[a]
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49
IMTA0A110012-01
! WARNING
accident can occur.

NOTE
– HO2S-2 (P0137, P0138 and P0140)
– MAF sensor (P0102 and P0103)
– MAP sensor (P0107 and P0108)
– IAT sensor (P0112 and P0113)
– ECT sensor (P0117 and P0118)
– Cylinder misfire detected (P0300, P0301, P0302, P0303 and P0304)
– EGR valve (P0400 and P0403)
– EVAP canister purge valve (P0443, P0458 and P0459)
– System voltage (P0563)

2) With engine speed at 1,600 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
Yes Go to Step 2.
Step 2 DTC check
Is there any DTC(s) other than P0133?

No Go to Step 3.
Step 3 Exhaust system and air intake system check

1) Check the following parts for clogging, leakage, damage and mounting failure.
• PCV hose
• Breather hose
• Air cleaner suction pipe and hose
• Air cleaner outlet hose
• Intake manifold
• Exhaust manifold
• Exhaust pipe
• Muffler
Is check result OK?
Yes Go to Step 4.
Step 4 Fuel system inspection

1) Check fuel system according to “Fuel System Inspection” in Section 1G.
Is check result OK?
Yes Go to Step 5.
Step 5 HO2S-1 signal circuit check

1) Check “A2” and “A3” circuits according to Step 3 under “DTC P0131 / P0132”.
Is check result OK?
Yes Go to Step 6.

Is check result OK?
Yes Go to Step 7.
Step 7 DTC recheck

No End.
DTC P0134
AENNTA0E1104027 (06(02)
P0134: O2 Sensor Circuit No Activity Detected Bank 1 • HO2S-1 and/or its circuit
Sensor 1 • Air intake system
Output voltage of HO2S-1 circuit stays between 0.4 V and 0.6 V
• Exhaust system
for 25 sec.
Circuit Diagram
3
5V
+B 1 4 A3
RED C01-6
A2
GRN C01-7
A4
BLU PPL C01-49
A1 LT GRN C01-55
5V
2 4 B3
YEL C01-8
B2
BRN C01-19
B4
BLU RED C01-52
B1 BEG C01-56
[A] C01
[a]
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49
IMTA0A110012-01
! WARNING
accident can occur.
NOTE
P21E3)

DTC Troubleshooting
Yes Go to Step 2.
No Go to “Engine and Emission Control System Check”
Step 2 DTC check

No Go to Step 3.

• PCV hose
• Breather hose
• Intake manifold
• Exhaust pipe
• Muffler
Is check result OK?
Yes Go to Step 4.
Step 4 HO2S-1 signal circuit and HO2S-1 ground circuit check

Is check result OK?
Yes Go to Step 5.

Is check result OK?
Yes Go to Step 6.
Step 6 DTC recheck

No End.
DTC P0137 / P0138 / P0140

AENNTA0E1104028 (06(02)
P0137: O2 Sensor Circuit Low Voltage Bank 1 Sensor 2 • HO2S-2 and/or its circuit
Output voltage of HO2S-2 circuit is lower than 0.05 for 25 sec. after warning up. • Exhaust system
• Air intake system
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. • Fuel system
P0140: O2 Sensor Circuit No Activity Detected Bank 1 Sensor 2
Output voltage of HO2S-2 circuit stays between 0.4 V and 0.6 V for 25 sec.
Circuit Diagram
3
5V
+B 1 4 A3
RED C01-6
A2
GRN C01-7
A4
BLU PPL C01-49
A1 LT GRN C01-55
5V
2 4 B3
YEL C01-8
B2
BRN C01-19
B4
BLU RED C01-52
B1 BEG C01-56
[A] C01
[a]
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49
IMTA0A110012-01
! WARNING
accident can occur.
NOTE

P21E3)

DTC Troubleshooting
Yes Go to Step 2.
Step 2 DTC check
Is there any DTC(s) other than P0137, P0138 and P0140?

No Go to Step 3.

1) When ignition is “OFF”, disconnect ECM connectors and HO2S-2 connector.
2) Check for proper terminal connection to ECM connectors and HO2S-2 connector.
• Resistance of “B2” and “B3” circuits: less than 1 Ω
• Resistance between each of “B2” and “B3” circuits and ground: infinity
• Voltage of “B2” and “B3” circuits: approx. 0 V (When ignition is “ON”)
Is check result OK?
Yes Go to Step 4.

• PCV hose
• Breather hose
• Intake manifold
• Exhaust pipe
• Muffler
Is check result OK?

Yes Go to Step 5.
Step 5 HO2S-2 heater power supply circuit and HO2S-2 heater drive circuit check
1) Check HO2S-2 heater circuits according to Step 2 – 3 under “DTC P0036 / P0037 / P0038”.
Is check result OK?
Yes Go to Step 6.
Step 6 Fuel system check

1) Check fuel system. (Fuel System Inspection) in Section 1G
Is check result OK?
Yes Go to Step 7.
Step 7 DTC recheck

Is DTC P0137, P0138 or P0140 still detected?
No End.
DTC P0139 / P2271

AENNTA0E1104029 (06(02)
P0139: O2 Sensor Circuit Slow Response Bank1 Sensor 2 • HO2S-2 and/or its circuit
Signal response time from rich to lean is longer than specified time even • Exhaust system
during fuel cut-off.
• Air intake system
P2271: O2 Sensor Signal Biased/Stuck Rich Bank 1 Sensor 2 • Fuel system
HO2S signal stays in rich state for specified time during fuel cut-off. • Engine compression
(3 D/C detection logic) • Emission control system
• Ignition system
• ECM
Circuit Diagram
3
5V
+B 1 4 A3
RED C01-6
A2
GRN C01-7
A4
BLU PPL C01-49
A1 LT GRN C01-55
5V
2 4 B3
YEL C01-8
B2
BRN C01-19
B4
BLU RED C01-52
B1 BEG C01-56
[A] C01
[a]
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49
IMTA0A110012-01
! WARNING
accident can occur.
NOTE
– HO2S-2 (P0137, P0138 and P0140)

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
Yes Go to Step 2.
Step 2 DTC check
Is there any DTC(s) other than P0139 or P2271?

No Go to Step 3.

• PCV hose
• Breather hose
• Intake manifold
• Exhaust pipe
• Muffler
Is check result OK?
Yes Go to Step 4.
Step 4 HO2S-2 signal and HO2S-2 ground circuit check

1) Check the following point.
• “B2” and “B3” circuits: Refer to Step 3 under “DTC P0137 / P0138 / P0140”.
Is check result OK?
Yes Go to Step 5.
Step 5 Engine mechanical system check

1) Check the following points related to engine mechanical system.
• Engine compression: (Compression Check) in Section 1D
• Fuel pressure: (Fuel Pressure Check) in Section 1G
• Spark plug: (Ignition Spark Test) in Section 1H
Is check result OK?
Yes Go to Step 6.
Step 6 Fuel system and emission control system check

1) Check the following points related to fuel system and emission control system.
• EVAP canister purge valve: (EVAP Canister Purge Valve Inspection) in Section 1B
• MAF sensor: (MAF Sensor with IAT Sensor Inspection) in Section 1C
• PCV valve: (PCV Valve Inspection) in Section 1B
• Fuel injector: (Fuel Injector Inspection) in Section 1G
• Fuel injector circuit: (Fuel Injector Circuit Check) in Section 1G
Is check result OK?
Yes Go to Step 7.
Step 7 Recheck DTC

2) Clear DTC. (DTC Clearance)
Is DTC P0139 or P2271 still detected?
No End.
DTC P0171 / P0172

AENNTA0E1104030 (06(02)
P0171: System Too Lean Bank 1 • Exhaust system
Fuel trim correction is higher than specified value for • Air intake system
specified time under specified vehicle condition.
• Fuel system
P0172: System Too Rich Bank 1 • MAF sensor
Fuel trim correction is lower than specified value for • EVAP canister purge valve
specified time under specified vehicle condition. • PCV valve
• EGR system
• HO2S-1 and/or its circuit
• ECM
Circuit Diagram
3
5V
+B 1 4 A3
RED C01-6
A2
GRN C01-7
A4
BLU PPL C01-49
A1 LT GRN C01-55
5V
2 4 B3
YEL C01-8
B2
BRN C01-19
B4
BLU RED C01-52
B1 BEG C01-56
[A] C01
[a]
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49
IMTA0A110012-01
! WARNING
accident can occur.
NOTE
– OCV (P0010, P0011, P0013, P0014, P2088, P2089, P2090 and P2091)
– HO2S-1 (P0130, P0131, P0132 and P0134)
– Cylinder misfire detected (P0300, P0301, P0302, P0303, and P0304)
– CMP sensor (P0340 and P0365)

– Throttle actuator (P2176)

DTC Troubleshooting
Yes Go to Step 2.
Step 2 DTC check
Is there any DTC(s) other than P0171 and P0172?

No Go to Step 3.
Step 3 Fuel system and emission system check

1) Check the following points related to fuel and emission control systems.
• Fuel pressure: (Fuel Pressure Check) in Section 1G
• Fuel injector circuit: (Fuel Injector Circuit Check) in Section 1G
• Fuel injector: (Fuel Injector Inspection) in Section 1G
• EVAP canister purge valve: (EVAP Canister Purge System Inspection) in Section 1B
• PCV valve: (PCV Valve Inspection) in Section 1B
• EGR system: (EGR Valve System Inspection) in Section 1B
Is check result OK?
Yes Go to Step 4.

• PCV hose
• Breather hose
• Intake manifold
• Exhaust pipe
• Muffler
Is check result OK?
Yes Go to Step 5.
Step 5 HO2S-1 signal circuit check

1) Check “A2”and “A3” circuits according to Step 3 under “DTC P0131 / P0132”.
Is check result OK?
Yes Go to Step 6.
Step 6 DTC recheck

No End.
DTC P0197 / P0198

AENNTA0E1104031 (06(02)
P0197: Engine Oil Temperature Sensor Circuit Low • Oil temperature sensor and/or its circuit
Output voltage of oil temperature sensor signal circuit is • ECM
lower than 0.02 V for 5 sec.
(3 D/C detection logic but MIL does not light up)
P0198: Engine Oil Temperature Sensor Circuit High
Output voltage of oil temperature sensor signal circuit is
higher than 4.65 V for 5 sec.
Circuit Diagram
2
A1 5V
1
BLU C01-21
WHT C01-5
A2
[A] C01
[a]
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49
IMTA0A110017-01
[A]: ECM connector (View: [a]) A2: Oil temperature sensor ground circuit 2. ECM
A1: Oil temperature sensor signal circuit 1. Oil temperature sensor

DTC Troubleshooting
Yes Go to Step 2.
Step 2 Oil temperature sensor signal circuit and ground circuit check
1) When ignition is “OFF”, disconnect ECM connectors and oil temperature sensor connector.
2) Check for proper terminal connection to ECM connectors and oil temperature sensor connector.
Is check result OK?
Yes Go to Step 3.
Step 3 Oil temperature sensor check

1) Check oil temperature sensor. (Oil Temperature Sensor Inspection) in Section 1C
Is check result OK?
No Replace oil temperature sensor. (Oil Temperature Sensor Removal and Installation) in Section 1C
DTC P0201 / P0202 / P0203 / P0204 / P0261 / P0262 / P0264 / P0265 / P0267 / P0268 / P0270 / P0271 /
P21CF / P21D0 / P21D1 / P21D2 / P21DB / P21DC / P21DE / P21DF / P21E0 / P21E1 / P21E2 / P21E3
AENNTA0E1104032 (06(02)

P0201: Injector Circuit / Open - Cylinder 1 (Injector No.1-1) • Fuel injector and/or its circuit
Fuel injector No.1-1 and/or its circuit is open with engine running. • ECM
P0202: Injector Circuit / Open - Cylinder 2 (Injector No.2-1)
Fuel injector No.2-1 and/or its circuit is open with engine running.
P0261: Cylinder 1 Injector Circuit Low (Injector No.1-1)
Fuel injector No.1-1 drive circuit is shorted to ground with engine running.
P0262: Cylinder 1 Injector Circuit High (Injector No.1-1)
Fuel injector No.1-1 drive circuit is shorted to power supply with engine running.

P21CF: Cylinder 1-2 Injector Circuit Low (Injector No.1-2) • Fuel injector and/or its circuit
Fuel injector No.1-2 and/or its circuit is open with engine running. • ECM
P21D0: Cylinder 2-2 Injector Circuit Low (Injector No.2-2)
P21D1: Cylinder 3-2 Injector Circuit Low (Injector No.3-2)
P21D2: Injector Circuit / Open - Cylinder 4 (Injector No.4-2)
P21DB: Cylinder 1 Injector Circuit Low (Injector No.1-2)
P21DC: Cylinder 1-2 Injector Circuit High (Injector No.1-2)
P21DE: Cylinder 2 Injector Circuit Low (Injector No.2-2)
P21DF: Cylinder 2-2 Injector Circuit High (Injector No.2-2)
P21E0: Cylinder 3 Injector Circuit Low (Injector No.3-2)
P21E1: Cylinder 3-2 Injector Circuit High (Injector No.3-2)
P21E2: Cylinder 4 Injector Circuit Low (Injector No.4-2)
P21E3: Cylinder 4 Injector Circuit High (Injector No.4-2)
Circuit Diagram
9 +B
A2 A1 BLU
1
C01-31 PNK
B2 B1
2
C01-36 BRN
C2 C1
3
C01-11 WHT
D2 D1
4
C01-23 GRY
E2 E1
5
C01-10 RED
F2 F1
6
C01-32 BEG
G2 G1
7
C01-12 GRN
H2 H1
8
C01-24 LT GRN
[A] C01
[a]
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49
IMTA0A110018-01
[A]: ECM connector (View: [a]) E1: Fuel injector No.3-1 power supply circuit 2. Fuel injector No.1-2
A1: Fuel injector No.1-1 power supply circuit E2: Fuel injector No.3-1 drive circuit 3. Fuel injector No.2-1
A2: Fuel injector No.1-1 drive circuit F1: Fuel injector No.3-2 power supply circuit 4. Fuel injector No.2-2
B1: Fuel injector No.1-2 power supply circuit F2: Fuel injector No.3-2 drive circuit 5. Fuel injector No.3-1
B2: Fuel injector No.1-2 drive circuit G1: Fuel injector No.4-1 power supply circuit 6. Fuel injector No.3-2
C1: Fuel injector No.2-1 power supply circuit G2: Fuel injector No.4-1 drive circuit 7. Fuel injector No.4-1
C2: Fuel injector No.2-1 drive circuit H1: Fuel injector No.4-2 power supply circuit 8. Fuel injector No.4-2
D1: Fuel injector No.2-2 power supply circuit H2: Fuel injector No.4-2 drive circuit 9. ECM
D2: Fuel injector No.2-2 drive circuit 1. Fuel injector No.1-1
NOTE
DTC Troubleshooting
NOTE
Before troubleshooting, check that fuel injector connector(s) related to detected DTC(s) is connected
correctly as follows. If any abnormality is found, correct it and troubleshoot again.
• Black connector / black harness tube: Connect each one to crankshaft pulley side fuel injector
(No.1-1, No.2-1, No.3-1 or No.4-1).
• Gray connector / blue harness tube: Connect each one to transaxle side fuel injector (No.1-2, No.2-2,
No.3-2 or No.4-2).
Yes Go to Step 2.
Step 2 Fuel injector power supply circuit check

1) When ignition is “OFF”, disconnect connector(s) from fuel injector related to DTC(s).
2) Check for proper terminal connection to fuel injector connector(s).
3) If connection is OK, set ignition “ON”.
4) Check that voltage between each of “A1”, “B1”, “C1”, “D1”, “E1”, “F1”, “G1” and “H1” and ground is
battery voltage.
Is check result OK?
Yes Go to Step 3.
Step 3 Fuel injector drive circuit check

3) If connection is OK, check the following points.
• Resistance of “A2”, “B2”, “C2”, “D2”, “E2”, “F2”, “G2” or “H2” circuit: less than 1 Ω
• Resistance between each of “A2”, “B2”, “C2”, “D2”, “E2”, “F2”, “G2” and “H2” circuit and ground:
infinity
• Resistance between “D2” circuit terminal and other terminal at ECM connector: infinity
• Resistance between “E2” circuit terminal and other terminal at ECM connector: infinity
• Resistance between “F2” circuit terminal and other terminal at ECM connector: infinity
• Resistance between “G2” circuit terminal and other terminal at ECM connector: infinity
• Resistance between “H2” circuit terminal and other terminal at ECM connector: infinity
• Voltage of “A2”, “B2”, “C2”, “D2”, “E2”, “F2”, “G2” or “H2” circuit: approx. 0 V (When ignition is “ON”)
Is check result OK?
Yes Go to Step 4.
Step 4 Fuel injector check

1) Check fuel injector(s) related to DTC(s). (Fuel Injector Inspection) in Section 1G
Is check result OK?
No Replace fuel injector(s) related to DTC(s). (Fuel Injector Removal and Installation) in Section 1G
DTC P0222 / P0223

AENNTA0E1104033 (06(02)

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 0.20 V. • Electric throttle body assembly
• ECM
P0223: Throttle/Pedal Position Sensor/Switch “B” Circuit High
Output voltage of TP sensor (sub) signal circuit is higher than 4.81 V.
Circuit Diagram
12V
1
A1
C01-54 BRN
A2
C01-51 LT GRN 4
5V B1
C01-13 RED B2 2
C01-26 GRN
B3 3
C01-16 WHT
C01-15 BLK
B4
C01-17 BLK
[A] C01
[a]
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49
IMTA0A110016-01

1) Start engine.
2) Keep accelerator pedal in fully depressed position for a moment.
3) Keep accelerator pedal in released position for 2 sec.
DTC Troubleshooting
Yes Go to Step 2.

1) When ignition is “OFF”, disconnect electric throttle body assembly connector.
2) Check for proper terminal connection to electric throttle body assembly connector.
Is check result OK?
Yes Go to Step 5.
No Go to Step 3.
Step 3 TP sensor ground circuit check

Is check result OK?

Section 1C
No Go to Step 4.

Is check result OK?
Step 5 TP sensor (sub) signal circuit check

Is check result OK?
Yes Go to Step 6.
No Repair or replace TP sensor (sub) signal circuit.

1) Check TP sensor for performance. (Electric Throttle Body Assembly On-Vehicle Inspection) in Section
1C
Is check result OK?
DTC P0300 / P0301 / P0302 / P0303 / P0304

AENNTA0E1104034 (06(02)

P0300: Random/Multiple Cylinder Misfire Detected • Fuel
Any of the following conditions is met. • Exhaust system
• Misfire, which causes catalyst to overheat during 200 engine • Air intake system
revolutions, is detected at 2 or more cylinders.
• Ignition system
(MIL blinks as long as misfire lasts.)
• Fuel system
• Misfire, which affects exhaust emission adversely during
1,000 engine revolutions, is detected at 2 or more cylinders. • EVAP system
(3 D/C detection logic) • Engine mechanical system
P0301: Cylinder 1 Misfire Detected • ECM
P0302: Cylinder 2 Misfire Detected
Any of the following conditions is met.
• Misfire, which causes catalyst to overheat during 200 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.
! WARNING
accident can occur.
NOTE
– Fuel level ≥ 34.0%
• In case it is suspected that inferior quality fuel is mixed into the fuel tank, replace all the fuel in the
tank with high quality one.
• For ESP® model, engine torque control by ESP® control module is not activated.
– TP sensor (P0122, P0123, P0222, P0223 and P2135)

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.
DTC Troubleshooting
Yes Go to Step 2.
Step 2 DTC check
Is there any DTC(s) other than P0300, P0301, P0302, P0303 and P0304?

No Go to Step 3.

• PCV hose
• Breather hose
• Intake manifold
• Exhaust pipe
• Muffler
Is check result OK?
Yes Go to Step 4.
Step 4 Ignition system check

1) Check ignition system. (Ignition System Check) in Section 1H
Is check result OK?
Yes Go to Step 5.
Step 5 Fuel system inspection

1) Check fuel system. (Fuel System Inspection) in Section 1G
Is check result OK?
Yes Go to Step 6.
Step 6 EVAP system inspection

• EVAP system (EVAP Canister Purge System Inspection) in Section 1B
• EVAP canister (EVAP Canister Inspection) in Section 1B
• Fuel EVAP valve (Fuel EVAP Valve Inspection) in Section 1B
Is check result OK?
Yes Go to Step 6.
Step 7 Engine mechanical system check

• Engine compression: (Compression Check) in Section 1D
• Timing marks on VVT actuators and crankshaft timing sprocket key position: (Timing Chain and Chain
• VVT actuator: (Camshaft Inspection) in Section 1D
• Timing chain, timing chain tensioner, timing chain tensioner adjuster and crankshaft timing sprocket:
(Timing Chain and Chain Tensioner Inspection) in Section 1D
Is check result OK?
Yes Check ECM power supply and ground circuits. (ECM Power Supply and Ground Circuit Check)
If circuit is OK, replace ECM and recheck DTC. (ECM Removal and Installation) in Section 1C
DTC P0327 / P0328

AENNTA0E1104035 (06(02)
P0327: Knock Sensor 1 Circuit Low Bank 1 or Single • Knock sensor and/or its circuit
Sensor • ECM
Output voltage of knock sensor signal circuit is lower than
specified value for specified time with engine running.
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.
Circuit Diagram
2
1 A1
WHT C01-25
BLU C01-37
B1
[A] C01
[a]
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49
IMTA0A110019-01
[A]: ECM connector (View: [a]) B1: Knock sensor signal circuit 2 2. ECM
A1: Knock sensor signal circuit 1 1. Knock sensor
! WARNING
accident can occur.
NOTE

2) With engine speed at 2,400 rpm or more, drive vehicle at 80 to 100 km/h (50 to 60 mile/h) or more for 3 min.
3) Repeat Step 2) 5 times.
DTC Troubleshooting
Yes Go to Step 2.
Step 2 Knock sensor signal circuit check

1) When ignition is “OFF”, disconnect ECM connectors and knock sensor connector.
2) Check for proper terminal connection to ECM connectors and knock sensor connector.
• Resistance of “A1” and “B1” circuits: less than 1 Ω
• Resistance between each of “A1” and “B1” circuits and ground: infinity
• Voltage of “A1” and “B1” circuits: approx. 0 V (When ignition is “ON”)
Is check result OK?
Yes Go to Step 3.
Step 3 Knock sensor check

1) Check knock sensor. (Knock Sensor On-Vehicle Inspection) in Section 1C
Is check result OK?
No Replace knock sensor. (Knock Sensor Removal and Installation) in Section 1C
DTC P0335 / P0336

AENNTA0E1104036 (06(02)

P0335: Crankshaft Position Sensor “A” Circuit • CKP sensor and/or its circuit
CKP sensor signal is not inputted while CMP sensor signal is being inputted. • Sensor plate
• ECM
P0336: Crankshaft Position Sensor “A” Circuit Range/Performance
• 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.
Circuit Diagram
+B
BLU
4
A1 5V
1 A2
PPL C01-30
A3
B1 5V
2 B2
YEL C01-40
B3
C1 5V
3 C2
PNK C01-39
C3
GRY
[A] C01
[a]
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49
IMTA0A110011-01

DTC Troubleshooting
Yes Go to Step 2.
Step 2 CKP sensor power supply circuit check

1) When ignition is “OFF”, disconnect CKP sensor connector.
2) Check for proper terminal connection to CKP sensor connector.
4) Check that voltage between “C1” and “C3” is battery voltage.
Is check result OK?
Yes Go to Step 4.
No Go to Step 3.
Step 3 CKP sensor ground circuit check

1) Check that voltage between “C1” and ground is battery voltage.
Is check result OK?

No Repair or replace “C1” circuit.
Step 4 CKP sensor signal circuit check

• Resistance of “C2” circuit: less than 1 Ω
• Resistance between “C2” circuit and ground: infinity
• Voltage of “C2” circuit: approx. 0 V (When ignition is “ON”)
Is check result OK?
Yes Go to Step 5.

• CKP sensor (CKP Sensor Inspection) in Section 1C
• Sensor plate (Sensor Plate Inspection) in Section 1D
Is check result OK?
DTC P0340 / P0365

AENNTA0E1104037 (06(02)

P0340: Camshaft Position Sensor “A” Circuit Bank 1 • Intake CMP sensor and/or its circuit
or Single Sensor • Signal rotor
• ECM
• Intake CMP sensor signal is not inputted while CKP
sensor signal is being inputted.
• Intake CMP sensor signal pattern is not equal to the
expected pattern.
P0365: Camshaft Position Sensor “B” Circuit • Exhaust CMP sensor and/or its circuit
Any of the following error counters is more than specified • Signal rotor
value with engine running.
• ECM
• Exhaust CMP sensor signal is not inputted while CKP
sensor signal is being inputted.
• Exhaust CMP sensor signal is more than specified
counters when output signal of CKP sensor is normal.
Circuit Diagram
+B
BLU
4
A1 5V
1 A2
PPL C01-30
A3
B1 5V
2 B2
YEL C01-40
B3
C1 5V
3 C2
PNK C01-39
C3
GRY
[A] C01
[a]
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49
IMTA0A110011-01

DTC Troubleshooting
Yes Go to Step 2.
Step 2 CMP sensor power supply circuit check

1) When ignition is “OFF”, disconnect CMP sensor connector related to DTC.
2) Check for proper terminal connection to CMP sensor connector.
4) Check that voltage between “A1” and “A3” or “B1” and “B3” is battery voltage.
Is check result OK?
Yes Go to Step 4.
No Go to Step 3.
Step 3 CMP sensor ground circuit check

1) Check that voltage between each of “A1” and “B1” and ground is battery voltage.
Is check result OK?
Yes Repair or replace “A3” or “B3” circuit.

No Repair or replace “A1” or “B1” circuit.
Step 4 CMP sensor signal circuit check

• Resistance of “A2” or “B2” circuit: less than 1 Ω
• Resistance between “A2” or “B2” circuit and ground: infinity
• Voltage of “A2” or “B2” circuit: approx. 0 V (When ignition is “ON”)
Is check result OK?
Yes Go to Step 5.

1) Check the following items:
Is check result OK?
DTC P0351 / P0352 / P0353 / P0354 / P2300 / P2301 / P2303 / P2304 / P2306 / P2307 / P2309 / P2310
AENNTA0E1104038 (06(02)

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
P0352: Ignition Coil “B” Primary / Secondary Circuit
Ignition coil assembly No.2 and/or its circuit is open with engine running.
P0353: Ignition Coil “C” Primary / Secondary Circuit
P0354: Ignition Coil “D” Primary / Secondary Circuit
P2300: Ignition Coil “A” Primary Control Circuit Low
Ignition coil assembly No.1 drive circuit is shorted to ground with engine running.
P2301: Ignition Coil “A” Primary Control Circuit High
Ignition coil assembly No.1 drive circuit is shorted to power supply with engine running.
P2303: Ignition Coil “B” Primary Control Circuit Low
P2304: Ignition Coil “B” Primary Control Circuit High
P2306: Ignition Coil “C” Primary Control Circuit Low
P2307: Ignition Coil “C” Primary Control Circuit High
P2309: Ignition Coil “D” Primary Control Circuit Low
P2310: Ignition Coil “D” Primary Control Circuit High
Circuit Diagram
IG1
5 A1 WHT
1
5V A2
C01-44 YEL
A3 B1
BLK
2
5V B2
C01-33 GRN
B3 C1
BLK 3
5V C2
C01-34 PNK
C3 D1
BLK 4
5V D2
C01-35 BEG
D3
BLK
[A] C01
[a]
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49
IMTA0A110020-01
[A]: ECM connector (View: [a]) B3: Ignition coil assembly No.2 ground circuit D3: Ignition coil assembly No.4 ground circuit
A1: Ignition coil assembly No.1 power supply circuit C1: Ignition coil assembly No.3 power supply circuit 1. Ignition coil assembly No.1
A2: Ignition coil assembly No.1 drive circuit C2: Ignition coil assembly No.3 drive circuit 2. Ignition coil assembly No.2
A3: Ignition coil assembly No.1 ground circuit C3: Ignition coil assembly No.3 ground circuit 3. Ignition coil assembly No.3
B1: Ignition coil assembly No.2 power supply circuit D1: Ignition coil assembly No.4 power supply circuit 4. Ignition coil assembly No.4
B2: Ignition coil assembly No.2 drive circuit D2: Ignition coil assembly No.4 drive circuit 5. ECM
NOTE
DTC Troubleshooting
Yes Go to Step 2.
Step 2 Ignition coil assembly power supply circuit check

1) When ignition is “OFF”, disconnect connector from ignition coil assembly related to DTC.
2) Check for proper terminal connection to ignition coil assembly connector.

4) Check that voltage between “A1” and “A3”, “B1” and “B3”, “C1” and “C3” or “D1” and “D3” is battery
voltage.
Is check result OK?
Yes Go to Step 4.
No Go to Step 3.
Step 3 Ignition coil assembly ground circuit check

1) Check that voltage between each of “A1”, “B1”, “C1” and “D1” and ground is battery voltage.
Is check result OK?
Yes Repair or replace “A3”, “B3”, “C3” or “D3” circuit.

No Repair or replace “A1”, “B1”, “C1” or “D1” circuit.
Step 4 Ignition coil assembly drive circuit check

• Resistance of “A2”, “B2”, “C2” or “D2” circuit: less than 1 Ω
• Resistance between each of “A2”, “B2”, “C2” or “D2” circuit and ground: infinity
• Resistance between “D2” circuit terminal and other terminal at ECM connector: infinity
• Voltage of “A2”, “B2”, “C2” or “D2” circuit: approx. 0 V (When ignition is “ON”)
Is check result OK?
Yes Go to Step 5.
Step 5 Ignition coil assembly check

1) Check ignition coil assembly related to DTC. (Ignition Coil Assembly Inspection) in Section 1H
Is check result OK?
No Replace ignition coil. (Ignition Coil Assembly Removal and Installation) in Section 1H
DTC P0400
AENNTA0E1104039 (06(02)
P0400: Exhaust Gas Recirculation “A” Flow • Cylinder head
EGR is operated during fuel cut and the amount of EGR • Intake manifold
flow is less than specified volume for specified time.
• EGR pipe
• EGR cooler
• EGR valve
• MAP sensor
• MAF sensor
• ECM
! WARNING
accident can occur.
NOTE
– IAT > -10 °C (14 °F)
– ECT > 70 °C (158 °F)
– OCV (P0010, P0011, P0013, P0014, P2088, P2089, P2090 and P2091)
– TP sensor (P0122, P0123, P0222, P0223, P2101 and P2135)
– MAF sensor (DTC P0102 and P0103)
– EGR valve (P0403)
– System voltage (P0560, P0562 and P0563)
– Throttle actuator (P2119 and P2176)
1) Drive vehicle at 80 km/h (50 mile/h).

2) Release accelerator pedal, and keep vehicle coasting for 15 sec. with engine braking applied (fuel cut condition).
3) Check whether EGR readiness / monitoring test has completed or not using scan tool. If EGR readiness /
monitoring test has not completed, check vehicle conditions (environmental) and repeat Step 1) – 2).
DTC Troubleshooting
Yes Go to Step 2.
Step 2 DTC check

No Go to Step 3.
Step 3 EGR valve system check

1) Check EGR valve system. (EGR Valve System Inspection) in Section 1B
Is check result OK?
Yes Check the following points.

• MAP sensor: (MAP Sensor Inspection) in Section 1C
No Go to Step 4.
Step 4 EGR passage check

1) Remove the following parts, check EGR passage for clogging.
• EGR valve: (EGR Valve Removal and Installation) in Section 1B
• EGR cooler: (EGR Valve Removal and Installation) in Section 1B
• EGR pipe: (EGR Pipe Inspection) in Section 1B
• Cylinder head
• Intake manifold
Is check result OK?
DTC P0403
AENNTA0E1104040 (06(02)
P0403: Exhaust Gas Recirculation “A” Control Circuit • EGR valve and/or its circuit
EGR valve and/or its circuit malfunction (open, short to • ECM
power supply or short to ground) is detected.
Circuit Diagram
2 +B
BLU
B1 A1
1
C01-48 GRN
B2
C01-45 GRY
B3 A2
C01-46 YEL
B4
C01-47 WHT
[A] C01
[a]
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49
IMTA0A110021-01
[A]: ECM connector (View: [a]) B1: EGR valve drive circuit 1 B4: EGR valve drive circuit 4
A1: EGR valve power supply circuit 1 B2: EGR valve drive circuit 2 1. EGR valve
A2: EGR valve power supply circuit 2 B3: EGR valve drive circuit 3 2. ECM
! WARNING
accident can occur.
NOTE
– IAT > -10 °C (14 °F)
– ECT > 70 °C (158 °F)
1) Drive vehicle at 50 to 80 km/h (31 to 50 mile/h) constantly for 3 min.
DTC Troubleshooting
Yes Go to Step 2.
Step 2 EGR valve power supply circuit check

1) When ignition is “OFF”, disconnect EGR valve connector.
2) Check for proper terminal connection to EGR valve connector.
4) Check that voltage between “A1” or “A2” and ground is battery voltage.
Is check result OK?
Yes Go to Step 3.
Step 3 EGR valve drive circuit check

• Resistance of “B1”, “B2”, “B3” or “B4” circuit: less than 1 Ω
• Resistance between each of “B1”, “B2”, “B3” and “B4” circuit and ground: infinity
• Voltage of “B1”, “B2”, “B3” or “B4” circuit: approx. 0 V (When ignition is “ON”)
Is check result OK?
Yes Go to Step 4.
Step 4 EGR valve check

1) Check EGR valve. (EGR Valve Inspection) in Section 1B
Is check result OK?
No Replace EGR valve. (EGR Valve Removal and Installation) in Section 1B
DTC P0420
AENNTA0E1104041 (06(02)
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
• HO2S-2 and/or its circuit
specified value under specified vehicle condition.
(3 D/C detection logic) • TWC
• ECM
Circuit Diagram
4
5V
RED C01-6
GRN C01-7
1
5V
3
YEL C01-8
BRN C01-19
[A] C01
[a]
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49
IMTA0A110022-01
[A]: ECM connector (View: [a]) 2. TWC 4. ECM

1. HO2S-1 3. HO2S-2
! WARNING
accident can occur.
NOTE
– ECT at engine start > –9 °C (15.8 °F)
– OCV (P0010, P0011, P0013, P0014, P2088, P2089, P2090 and P2091)
– MAF sensor (P0102 and P0103)
– HO2S-1 (P0130, P0131, P0132, P0133 and P0134)
– HO2S-2 (P0137, P0138, P0139, P0140 and P2271)
– Fuel trim system (P0171 and P0172)

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 (AGS 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
Yes Go to Step 2.
Step 2 DTC check

1) Check DTC.

No Go to Step 3.
Step 3 Exhaust system inspection

1) Check exhaust system for leakage, damage and looseness.
Is check result OK?
Yes Go to Step 4.

1) Check “B2” and “B3” circuits according to Step 3 under “DTC P0137 / P0138 / P0140”.
Is check result OK?
Yes Go to Step 5.

Is check result OK?
Yes Go to Step 6.
No Repair or replace defective wire.
Step 6 DTC recheck

1) Replace exhaust manifold (built in TWC). (Exhaust Manifold Removal and Installation) in Section 1K
Yes Go to Step 7.
No End.
Step 7 DTC recheck

Yes Go to Step 8.
No End.
Step 8 DTC recheck

No End.
DTC P0443 / P0458 / P0459

AENNTA0E1104042 (06(02)
P0443: Evaporative Emission System Purge Control Valve Circuit • EVAP canister purge
EVAP canister purge valve control circuit is open with engine running. valve and/or its circuit
P0458: Evaporative Emission System Purge Control Valve Circuit Low
EVAP canister purge valve control circuit is shorted to ground with engine running.
P0459: Evaporative Emission System Purge Control Valve Circuit High
EVAP canister purge valve control circuit is shorted to power supply with engine running.
Circuit Diagram
2
B1 A1
12V +B
1
C01-41 GRY BLU
[A] C01
[a]
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49
IMTA0A110023-01
[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
! WARNING
accident can occur.
NOTE
1) Drive vehicle at 50 to 80 km/h (31 to 50 mile/h) constantly for 10 min.
DTC Troubleshooting
Yes Go to Step 2.
Step 2 EVAP canister purge valve power supply circuit check

1) When ignition is “OFF”, disconnect EVAP canister purge valve connector.
2) Check for proper terminal connection to EVAP canister purge valve connector.
4) Check that voltage between “A1” and ground is battery voltage.
Is check result OK?
Yes Go to Step 3.
Step 3 EVAP canister purge valve drive circuit check

Is check result OK?
Yes Go to Step 4.
Step 4 EVAP canister purge valve check

1) Check EVAP canister purge valve. (EVAP Canister Purge Valve Inspection) in Section 1B
Is check result OK?
No Replace EVAP canister purge valve. (EVAP Canister Purge Valve Removal and Installation) in
Section 1B
DTC P0480 / P0691 / P0692

AENNTA0E1104043 (06(02)
P0480: Fan 1 Control Circuit • Radiator cooling fan relay No.1 and/or
Radiator cooling fan relay No.1 drive circuit is open. its circuit
(3 D/C detection logic but MIL does not light up) • ECM
P0691: Fan 1 Control Circuit low
Radiator cooling fan relay No.1 drive circuit is shorted to ground.
P0692: Fan 1 Control Circuit High
Radiator cooling fan relay No.1 drive circuit is shorted to power supply.
Circuit Diagram
+B
+BB 6
BLU A1 1 B1
BLK LT GRN E01-2
GRY
5 BLU
C1 A3
A2
2 B2
BRN E01-27
GRY 3
L+
C2 PNK
H+ L-
4 BLK
H- C3
BLK
[A] E01
[a]
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49
IMTA0A110024-01
[A]: ECM connector (View: [a]) B2: Radiator cooling fan relay No.2 and No.3 drive circuit 2. Radiator cooling fan relay No.2
A1: Radiator cooling fan relay No.1 power C1: Radiator cooling fan relay No.1 power supply circuit 3. Radiator cooling fan relay No.3
supply circuit (coil side) (switch side)
A2: Radiator cooling fan relay No.2 power C2: Radiator cooling fan relay No.2 power supply circuit 4. Radiator cooling fan motor
A3: Radiator cooling fan relay No.3 power C3: Radiator cooling fan relay No.3 power supply circuit 5. “RDTR” fuse
B1: Radiator cooling fan relay No.1 drive circuit 1. Radiator cooling fan relay No.1 6. ECM
NOTE
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.
DTC Troubleshooting
Yes Go to Step 2.
Step 2 Radiator cooling fan relay No.1 power supply circuit (coil side) check
1) When ignition is “OFF”, remove radiator cooling fan relay No.1.
2) Check for proper terminal connection to radiator cooling fan relay No.1 connector.
Is check result OK?
Yes Go to Step 3.
Step 3 Radiator cooling fan relay No.1 check

1) Check radiator cooling fan relay No.1. (Radiator Cooling Fan Relay Inspection) in Section 1F
Is check result OK?
Yes Go to Step 4.
No Replace radiator cooling fan relay No.1.
Step 4 Radiator cooling fan relay drive circuit check

Is check result OK?
DTC P0481 / P0693 / P0694

AENNTA0E1104044 (06(02)
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
open. • Radiator cooling fan relay No.3 (coil side) and/or its
(3 D/C detection logic but MIL does not light up) circuit
P0693: Fan 2 Control Circuit Low
• ECM
Radiator cooling fan relay No.2 and/or No.3 drive circuit is
shorted to ground.
P0694: Fan 2 Control Circuit High
Radiator cooling fan relay No.2 and/or No.3 drive circuit is
shorted to power supply.
Circuit Diagram
+B
+BB 6
BLU A1 1 B1
BLK LT GRN E01-2
GRY
5 BLU
C1 A3
A2
2 B2
BRN E01-27
GRY 3
L+
C2 PNK
H+ L-
4 BLK
H- C3
BLK
[A] E01
[a]
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49
IMTA0A110024-01
[A]: ECM connector (View: [a]) B2: Radiator cooling fan relay No.2 and No.3 drive circuit 2. Radiator cooling fan relay No.2
A1: Radiator cooling fan relay No.1 power C1: Radiator cooling fan relay No.1 power supply circuit 3. Radiator cooling fan relay No.3
A2: Radiator cooling fan relay No.2 power C2: Radiator cooling fan relay No.2 power supply circuit 4. Radiator cooling fan motor
A3: Radiator cooling fan relay No.3 power C3: Radiator cooling fan relay No.3 power supply circuit 5. “RDTR” fuse
B1: Radiator cooling fan relay No.1 drive circuit 1. Radiator cooling fan relay No.1 6. ECM
NOTE
• Check that the following DTC is 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.
DTC Troubleshooting
Yes Go to Step 2.
Step 2 Radiator cooling fan relay No.2 and No.3 power supply circuit (coil side) check
1) When ignition is “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.
4) Check that voltage between each of “A2” and “A3” and ground is battery voltage.
Is check result OK?
Yes Go to Step 3.
Step 3 Radiator cooling fan relay No.2 and No.3 check

1) Check radiator cooling fan relays No.2 and No.3. (Radiator Cooling Fan Relay Inspection) in Section 1F
Is check result OK?
Yes Go to Step 4.
No Replace radiator cooling fan relays No.2 and/or No.3.
Step 4 Radiator cooling fan relay No.2 and No.3 drive circuit check
Is check result OK?
DTC P0500
AENNTA0E1104045 (06(02)
P0500: Vehicle Speed Sensor “A” • CAN communication line
Any of the following conditions is met. • Wheel speed sensor and/or its circuit
• Vehicle speed is slower than 4 km/h (2.5 mile/h) for 13 sec. at fuel cut. • ABS/ESP® control module
• Vehicle speed is not inputted by CAN communication. • ECM
! WARNING
accident can occur.
NOTE
– ECT sensor (P0117)

3) Release accelerator pedal, and keep vehicle coasting for 15 sec. with engine brakes applied (fuel cut condition).
DTC Troubleshooting
Yes Go to Step 2.
Step 2 DTC check
Is there any CAN-DTC detected?
Yes Go to troubleshooting for CAN-DTC. (CAN DTC (Lost Communication and Communication Bus
Off) Table): CAN in Section 10H
No Go to Step 3.
Step 3 DTC check

1) Check DTC for ABS/ESP® control module.
• ABS model: (DTC Check) in Section 4E
• ESP® model: (DTC Check) in Section 4F

DTC P0504
AENNTA0E1104046 (06(02)
P0504: Brake Switch “A/B” Correlation • Brake light switch with brake switch and/
There is no correlation between brake light switch signal and brake or its circuit
switch signal. • ECM
Circuit Diagram
4
IG1
1 A1
2 [B] A2
LT GRN
B1 BLU E01-44
PNK
BLK YEL LT BLU E01-18
C1
B2
YEL
3
[A] E01
[a]
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49
IMTA0A110034-04
[A]: ECM connector (View: [a]) B1: Brake light switch power supply circuit 2. Brake light switch with brake
switch
[B]: Cruise control model B2: Brake light switch signal circuit 3. Brake light
A1: Brake switch power supply circuit C1: Brake light switch with brake switch ground 4. ECM
circuit
A2: Brake switch signal circuit 1. To battery

2) Run engine at idle speed.
3) Depress and release brake pedal 30 times.
DTC Troubleshooting
Yes Go to Step 2.
Step 2 Brake switch power supply circuit and brake light switch power supply circuit check
1) When ignition is “OFF”, disconnect brake light switch with brake switch connector.
2) Check for proper terminal connection to brake light switch with brake switch connector.
4) Check that voltage between each of “A1” and “B1” circuits and ground is battery voltage.
Is check result OK?
Yes Go to Step 3.
No Check “STOP” fuse or “IG1 SIG” fuse has not blown. If check result is OK, repair or replace
defective wire harness.
Step 3 Brake switch signal circuit and brake light switch signal circuit check
• Resistance of “A2” and “B2” circuits: less than 1 Ω
• Resistance between each of “A2” and “B2” circuits and ground: infinity
• Voltage of “A2” and “B2” circuits: approx. 0 V (when ignition is “ON”)
Is check result OK?
Yes Go to Step 4.
Step 4 Brake light switch with brake switch check

1) Check brake light switch with brake switch. (Brake Light Switch Inspection) in Section 4A
Is check result OK?
No Replace brake light switch with brake switch. (Brake Light Switch Removal and Installation) in
Section 4A
DTC P0515
AENNTA0E1104047 (06(02)
P0515: Battery Temperature Sensor Circuit • Electric load current sensor with battery
Any of the following conditions is met. temperature sensor and/or its circuit
• Output voltage of battery temperature signal circuit is lower than 0.1 • ECM
V for 5 sec.
• Output voltage of battery temperature signal circuit is higher than 4.8
V for 5 sec.
Circuit Diagram
4
A1
1
5V
2 LT BLU E01-4
A2
5V
BLU E01-48
A3
3 5V
PNK E01-47
A4
BEG E01-22
[A] E01
[a]
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49
IMTA0A110035-02
[A]: ECM connector (View: [a]) A3: Battery temperature sensor signal circuit 2. Electric load current sensor
A1: Electric load current sensor power supply circuit A4: Electric load current sensor with battery 3. Battery temperature sensor
temperature sensor ground circuit
A2: Electric load current sensor signal circuit 1. Electric load current sensor with battery 4. ECM
temperature sensor

DTC Troubleshooting
Yes Go to Step 2.
Step 2 Battery temperature sensor signal circuit and ground circuit check
1) When ignition is “OFF”, disconnect ECM connectors and electric load current sensor with battery
temperature sensor connector.
2) Check for proper terminal connection to ECM connectors and electric load current sensor with battery
temperature sensor connector.
• Voltage of “A3” and “A4” circuits: approx. 0 V (when ignition is “ON”)
Is check result OK?
Yes Go to Step 4.
Step 3 Battery temperature sensor check

1) Check battery temperature sensor. (Electric Load Current Sensor with Battery Temperature Sensor On-
Vehicle Inspection) in Section 1C
Is check result OK?
No Replace electric load current sensor with battery temperature sensor. (Electric Load Current
Sensor with Battery Temperature Sensor Removal and Installation) in Section 1C
DTC P0530
AENNTA0E1104048 (06(02)
P0530: A/C Refrigerant Pressure Sensor “A” Circuit • A/C refrigerant pressure
Any of the following conditions is met. sensor and/or its circuit
• Output voltage of A/C refrigerant pressure sensor signal circuit is lower than 0.15 V. • ECM
• Output voltage of A/C refrigerant pressure sensor signal circuit is higher than 4.93 V.
Circuit Diagram
5V A1
E01-14 GRY 1
5V A2
E01-33 RED
A3
E01-9 BLU
[A] E01
[a]
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49
IMTA0A110026-01
[A]: ECM connector (View: [a]) A2: A/C refrigerant pressure sensor signal circuit 1. A/C refrigerant pressure sensor
A1: A/C refrigerant pressure sensor power supply circuit A3: A/C refrigerant pressure sensor ground circuit 2. ECM

2) Set A/C ON for 10 sec.
3) Set A/C switch to OFF.
DTC Troubleshooting
Yes Go to Step 2.
Step 2 A/C refrigerant pressure sensor power supply circuit check

1) When ignition is “OFF”, disconnect A/C refrigerant pressure sensor connector.
2) Check for proper terminal connection to A/C refrigerant pressure sensor connector.
Is check result OK?
Yes Go to Step 5.
No Go to Step 3.
Step 3 A/C refrigerant pressure sensor ground circuit check

Is check result OK?

Section 1C
No Go to step 4.
Step 4 A/C refrigerant pressure sensor power supply circuit check

Is check result OK?
Step 5 A/C refrigerant pressure sensor signal circuit check

Is check result OK?
Yes Go to Step 6.
Step 6 A/C refrigerant pressure sensor check

1) Check A/C refrigerant pressure sensor. (A/C Refrigerant Pressure Sensor and Its Circuit Inspection) in
Section 7B
Is check result OK?
No Replace A/C refrigerant pressure sensor. (A/C Refrigerant Pressure Sensor Removal and
DTC P0560 / P0562 / P0563

AENNTA0E1104049 (06(02)
P0560: System Voltage • ECM power supply circuit and/or ground circuit
Main power supply voltage is lower than 2.55 V for 10 sec. • Charging system
• ECM
P0562: System Voltage Low
Main power supply circuit voltage is between 2.54 V and
9.7 V for 10 sec. with engine running.
P0563: System Voltage High
Main power supply circuit voltage is higher than 16.4 V for
10 sec. with engine running.

P0560
1) Set ignition “ON” for 1 min.
P0562 / P0563
! WARNING
accident can occur.
NOTE
• Check that the following DTC is not detected in this “DTC Confirmation Procedure”.
– Wheel speed sensor (P0500)

DTC Troubleshooting
Yes Go to Step 2.
Step 2 ECM power supply and ground circuit check

1) Check ECM power supply and ground circuits. (ECM Power Supply and Ground Circuit Check)
Is check result OK?

Yes Go to Step 3.
Step 3 Charging system check

1) Check that charging system is working properly. (Generator Test) in Section 1J
Is check result OK?
DTC P0571
AENNTA0E1104050 (06(02)
P0571: Brake Switch “A” Circuit • Brake light switch with brake switch and/or its
Brake light switch signal does not change for specified time. circuit
Circuit Diagram
4
IG1
1 A1
2 [B] A2
LT GRN
B1 BLU E01-44
PNK
C1
B2
YEL
3
[A] E01
[a]
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49
IMTA0A110034-04
switch
circuit

2) Depress brake pedal to hard.
3) Release brake pedal.
4) Repeat Steps 2) to 3) for 20 times.
5) When depressing or releasing brake pedal, check indication on “Brake Switch” in “Data List” mode on SUZUKI
scan tool.
DTC Troubleshooting
Yes Go to Step 2.
Step 2 Brake light switch power supply voltage check

4) Check that voltage between “B1” and “C1” is battery voltage.
Is check result OK?
Yes Go to Step 4.
No Go to Step 3.
Step 3 Brake light switch with brake switch ground circuit check
1) Check that voltage between “B1” and ground is battery voltage.
Is check result OK?

No Repair or replace “B1” circuit.
Step 4 Brake light switch signal circuit check

Is check result OK?
Yes Go to Step 5.

Is check result OK?
Section 4A
DTC P0602
AENNTA0E1104051 (06(02)
NOTE
After reprogramming of ECM is executed, if DTC P0602 is indicated, it is possible that the
reprogramming of ECM is not completed correctly.

P0602: Control Module Programming Error • Reprogramming failure of ECM
ECM internal failure or ECM programming error. • “ECM Data Writing” not performed
• ECM power supply circuit and/or ground circuit
• ECM

DTC Troubleshooting
Step 1 DTC recheck

Yes Go to Step 2.
No Check for intermittent trouble. (Intermittent Connection and Poor Contact Inspection) in Section 00
Step 2 ECM reprogramming check
Was reprogramming of ECM executed?
Yes Execute reprogramming of ECM correctly once again.

No Go to Step 3.
Step 3 ECM check
Is new ECM installed?
Yes Perform “Procedure after ECM Replacement” in Section 1C.

No Go to Step 3.
Step 4 ECM power and ground circuit check

1) Check ECM power and ground circuits. (ECM Power Supply and Ground Circuit Check)
Is check result OK?
DTC P0606
AENNTA0E1104052 (06(02)
P0606: Control Module Processor • ECM power supply circuit and/or ground circuit
ECM internal processor failure • HO2S-1
• ECM
! WARNING
accident can occur.
NOTE
1) With engine speed at 1,000 rpm, drive vehicle for 1 min.
DTC Troubleshooting
Step 1 DTC recheck

Yes Go to Step 2.

Is check result OK?
Yes Go to Step 3.
Step 3 DTC recheck

No End.
DTC P060A / P060B / P060D / P0611 / P061A / P061B / P061C / P061D / P061F / P062B / P062D /
P06D1 / P160B / P161A / P161B / P161C
AENNTA0E1104053 (06(02)

P060A: Internal Control Module Monitoring • ECM power supply circuit and/or ground circuit
Processor Performance • ECM
Internal failure in ECM is detected.
P060B: Internal Control Module A/D Processing
Performance
P060D: Internal Control Module Accelerator
Pedal Position Performance
P0611: Fuel Injector Control Module
Performance
P061A: Internal Control Module Torque
Performance
P061B: Internal Control Module Torque
Calculation Performance
P061C: Internal Control Module Engine RPM
Performance
P061D: Internal Control Module Engine Air Mass
Performance

P061F: Internal Control Module Throttle Actuator • ECM power supply circuit and/or ground circuit
Controller Performance • ECM
P062B: Internal Control Module Fuel Injector
Control Performance
P062D: Fuel Injector Driver Circuit Performance
Bank1
P06D1: Internal Control Module Ignition Coil
Control Performance
P160B: Internal Control Module A/D Converter
Performance
P161A: Internal Control Module Ignition Timing
P161B: Internal Control Module Comparison of
Lambda and Operation Mode
P161C: Internal Control Module Engine Mixture
Check

1) Set ignition “ON” for 1 min. or more.
2) Start engine, if possible.
DTC Troubleshooting
Step 1 DTC recheck

Is DTC P060A, P060B, P060D, P0611, P061A, P061B, P061C, P061D, P061F, P062B, P062D, P06D1,
P160B, P161A, P161B or P161C still detected?
Yes Go to Step 2.

1) Check ECM power supply circuit and ECM ground circuit. (ECM Power Supply and Ground Circuit
Check)
Is check result OK?
Yes Go to Step 3.
Step 3 Sensor power supply circuit check

1) Check sensor power supply circuits according to Step 8 under “ECM Power Supply and Ground Circuit
Check”.
Is check result OK?
DTC P0645 / P0646 / P0647

AENNTA0E1104054 (06(02)
P0645: A/C Clutch Relay Control Circuit • A/C compressor relay and/or its circuit
A/C compressor relay drive circuit is open. • ECM
P0646: A/C Clutch Relay Control Circuit Low
A/C compressor relay drive circuit is shorted to ground.
(3 D/C detection 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.
Circuit Diagram
4
B1 A1
+B
1
+BB
E01-41 GRY BLU
GRY GRN
2 3
[A] E01
[a]
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49
IMTA0A110028-01
[A]: ECM connector (View: [a]) 1. A/C compressor relay 4. ECM

A1: A/C compressor relay power supply circuit (coil side) 2. A/C compressor magnet clutch
B1: A/C compressor relay drive circuit 3. “CPRSR” fuse
NOTE
– Evaporator temperature > 3 °C
– ECT sensor (P0116, P0117 and P0118)
– A/C refrigerant pressure sensor (P0530)

2) Set A/C switch to ON for 10 sec.
3) Set A/C switch to OFF.
DTC Troubleshooting
Yes Go to Step 2.
Step 2 A/C compressor relay power supply circuit (coil side) check
1) When ignition is “OFF”, remove A/C compressor relay.
2) Check for proper terminal connection to A/C compressor relay connector.
Is check result OK?
Yes Go to Step 3.
Step 3 A/C compressor relay check

1) Check A/C compressor relay. (HVAC System Relay Inspection) in Section 7B
Is check result OK?
Yes Go to Step 4.
No Replace A/C compressor relay.
Step 4 A/C compressor relay drive circuit check

Is check result OK?
DTC P0703
AENNTA0E1104055 (06(02)
P0703: Brake Switch “B” Circuit • Brake light switch with brake switch and/or its
Brake switch signal does not change for specified time. circuit
Circuit Diagram
4
IG1
1 A1
2 [B] A2
LT GRN
B1 BLU E01-44
PNK
C1
B2
YEL
3
[A] E01
[a]
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49
IMTA0A110034-04
switch
circuit

2) Depress brake pedal to hard.
3) Release brake pedal.
4) Repeat Steps 2) to 3) for 20 times.
5) When depressing or releasing brake pedal, check indication on “Brake Switch” in “Data List” mode on SUZUKI
scan tool.
DTC Troubleshooting
Yes Go to Step 2.
Step 2 Brake light switch power supply voltage check

4) Check that voltage between “A1” and “C1” is battery voltage.
Is check result OK?
Yes Go to Step 4.
No Go to Step 3.
Step 3 Brake light switch with brake switch ground circuit check
Is check result OK?

No Repair or replace “A1” circuit.

Is check result OK?
Yes Go to Step 5.

Is check result OK?
Section 4A
DTC P0A5A
AENNTA0E1104056 (06(02)
P0A5A: Generator Current Sensor Circuit Range / Performance • Electric load current sensor with battery
Any of the following conditions is met. temperature sensor and/or its circuit
• Output voltage of electric load current sensor signal circuit is more • ECM
than 4.8 V for 5 sec.
• Output voltage of electric load current sensor signal circuit is lower
than 0.2 V for 5 sec.
• Output voltage of electric load current sensor signal circuit fluctuates
less than specified value for 5 sec.
Circuit Diagram
4
A1
1
5V
2 LT BLU E01-4
A2
5V
BLU E01-48
A3
3 5V
PNK E01-47
A4
BEG E01-22
[A] E01
[a]
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49
IMTA0A110035-02
[A]: ECM connector (View: [a]) A3: Battery temperature sensor signal circuit 2. Electric load current sensor
A1: Electric load current sensor power supply circuit A4: Electric load current sensor with battery 3. Battery temperature sensor
temperature sensor ground circuit
A2: Electric load current sensor signal circuit 1. Electric load current sensor with battery 4. ECM
temperature sensor

DTC Troubleshooting
Yes Go to Step 2.
Step 2 Electric load current sensor power supply circuit check

1) When ignition is “OFF”, disconnect electric load current sensor with battery temperature sensor
connector.
2) Check for proper terminal connection to electric load current sensor with battery temperature sensor
connector.
Is check result OK?
Yes Go to Step 5.
No Go to Step 3.
Step 3 Electric load current sensor and battery temperature sensor ground circuit check
Is check result OK?

Section 1C
No Go to Step 4.
Step 4 Electric load current sensor power supply circuit check

• Voltage of “A1” circuit: approx. 0 V (when ignition is “ON”)
Is check result OK?
Step 5 Battery temperature sensor signal circuit and ground circuit check
• Voltage of “A2” circuit: approx. 0 V (when ignition is “ON”)
Is check result OK?
Yes Go to Step 6.
Step 6 Electric load current sensor check

1) Check electric load current sensor. (Electric Load Current Sensor with Battery Temperature Sensor On-
Vehicle Inspection) in Section 1C
Is check result OK?
No Replace electric load current sensor with battery temperature sensor. (Electric Load Current
Sensor with Battery Temperature Sensor Removal and Installation) in Section 1C
DTC P1660
AENNTA0E1104057 (06(02)

P1660: Abnormal Refrigerant Pressure (High Pressure) • A/C refrigerant pressure sensor
Operated number of times of A/C compressor relay by • A/C refrigerant overcharged
abnormal A/C refrigerant pressure control (high pressure) is
• Expansion valve
more than specified number of times.
(1 D/C detection logic but MIL does not light up) • A/C compressor
• Condenser
• Radiator cooling fan motor and/or its circuit
• ECM
System Description
ECM stops A/C compressor for A/C system protection when A/C refrigerant pressure is abnormally high by
malfunction of A/C system.
NOTE
Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

2) Operate A/C system and run engine at idle speed for 10 min. or more.
DTC Troubleshooting
Yes Go to Step 2.

1) Check A/C refrigerant pressure sensor. (A/C Refrigerant Pressure Sensor and Its Circuit Inspection) in
Section 7B
Is check result OK?
Yes Go to Step 3.
Step 3 A/C system performance check

1) Check A/C system performance. (A/C System Performance Inspection) in Section 7B
Is check result OK?
Yes Go to Step 4.
No Perform “Trouble Diagnosis for Abnormal Pressure” in Section 7B.
Repair or replace defective part and recheck DTC.
Step 4 Radiator cooling fan system check

1) Check radiator cooling fan system. (Radiator Cooling Fan System Check) in Section 1F
Is check result OK?
No Repair or replace defective part and recheck DTC.
DTC P1693
AENNTA0E1104058 (06(02)
P1693: Equipment Information Mismatched • Combination meter
ECM detects incorrect vehicle variant data from ABS/ESP® • ABS/ESP® control module
control module and combination meter.
• ECM

DTC Troubleshooting
Yes Go to Step 2.
Step 2 DTC check for combination meter

1) Check DTC for combination meter. (Combination Meter Diagnosis Function Description) in Section 9C
Is check result OK?
Yes Go to Step 3.
No Go to troubleshooting for applicable DTC.
Step 3 Combination meter specification check

1) Check that combination meter with the correct part number is installed using its label.
Is check result OK?
Yes Go to Step 4.
No Replace combination meter and recheck DTC. (Combination Meter Removal and Installation) in
Section 9C
Step 4 DTC check for ABS/ESP® control module

1) Check DTC for ABS/ESP® control module.
• ABS model: (DTC Check) in Section 4E
• ESP® model: (DTC Check) in Section 4F
Is check result OK?
Yes Go to Step 5.
No Go to troubleshooting for applicable DTC.
Step 5 ABS/ESP® control module specification check

1) Check that ABS/ESP® control module with the correct part number is installed using its label.
Is check result OK?
No • ABS model:
Replace ABS control module and recheck DTC. (ABS Hydraulic Unit / Control Module Assembly
Removal and Installation) in Section 4E
• ESP® model:
Replace ESP® control module and recheck DTC. (ESP® Hydraulic Unit / Control Module
Assembly Removal and Installation) in Section 4F
DTC P2100
AENNTA0E1104059 (06(02)
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.
Circuit Diagram
12V
1
A1
C01-54 BRN
A2
C01-51 LT GRN 4
5V B1
C01-13 RED B2 2
C01-26 GRN
B3 3
C01-16 WHT
C01-15 BLK
B4
C01-17 BLK
[A] C01
[a]
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49
IMTA0A110016-01

2) Keep the accelerator pedal at fully depressed position for 2 sec.
3) Keep the accelerator pedal at idle position for 2 sec.
DTC Troubleshooting
Yes Go to Step 2.
Step 2 Throttle actuator drive circuit check

1) When ignition is “OFF”, disconnect ECM connectors and electric throttle body assembly connector.
2) Check for proper terminal connection to ECM connectors and electric throttle body assembly connector.

Is check result OK?
Yes Go to Step 3.
Step 3 Electric throttle body assembly check

1) Check electric throttle body assembly for performance. (Electric Throttle Body Assembly On-Vehicle
Inspection) in Section 1C
Is check result OK?
DTC P2101 / P2119

AENNTA0E1104060 (06(02)
P2101: Throttle Actuator “A” Control Motor Circuit Range/Performance • Throttle actuator and/or its circuit
Any of the following conditions is met. • TP sensor and/or its circuit
• Difference between measured throttle valve position and targeted throttle • Electric throttle body assembly
valve position is more than specified value.
• ECM
• Duty ratio of throttle actuator signal is out of specified range for specified time.
P2119: Throttle Actuator Control Throttle Body Range/Performance
• Time taken by throttle valve to return from partially open position to
mechanical default position is more than specified time during return spring
check process after setting ignition “OFF”.
• Measured default throttle position is out of specified range.
Circuit Diagram
12V
1
A1
C01-54 BRN
A2
C01-51 LT GRN 4
5V B1
C01-13 RED B2 2
C01-26 GRN
B3 3
C01-16 WHT
C01-15 BLK
B4
C01-17 BLK
[A] C01
[a]
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49
IMTA0A110016-01
NOTE
– ECT > 5 °C
– IAT > 5 °C
– TP sensor (P0122, P0123, P0222, P0223 and P2135)

3) Keep the accelerator pedal at idle position for 2 sec.
4) Set ignition “OFF” for 1 min. and then set ignition “ON”.
DTC Troubleshooting
Yes Go to Step 2.
Step 2 DTC recheck

1) Perform electric throttle control system calibration. (Electric Throttle Control System Calibration) in
Section 1C
Yes Go to Step 3.
No End.
Step 3 Throttle actuator drive circuit check

1) Check throttle actuator drive circuits according to Step 2 under “DTC P2100”.
Is check result OK?
Yes Go to Step 4.
Step 4 TP sensor (main) circuit and TP sensor (sub) circuit check

• “B1”, “B2” and “B4” circuits: Step 2 to 5 under “DTC P0122 / P0123”
• “B1”, “B3” and “B4” circuits: Step 2 to 5 under “DTC P0222 / P0223”
Is check result OK?
Yes Go to Step 5.
Step 5 Electric throttle body assembly check

1) Check electric throttle body assembly. (Electric Throttle Body Assembly On-Vehicle Inspection) in
Section 1C
Is check result OK?
DTC P2122 / P2123

AENNTA0E1104061 (06(02)
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
P2123: Throttle / Pedal Position Sensor/Switch “D” Circuit High
Output voltage of APP sensor (main) signal circuit is higher than 4.8 V.
Circuit Diagram
4 3
A1 5V
BRN E01-20
A2
1 PNK E01-16
A3
BLU E01-19
B1 5V
BLK E01-6
B2
2 YEL E01-3
B3
WHT E01-5
[A] E01
[a]
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49
IMTA0A110029-01
[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 4. Accelerator pedal assembly (incorporating
APP sensor)
A3: APP sensor (main) ground circuit 1. APP sensor (main)
NOTE
• Battery voltage > 8 V
DTC Troubleshooting
Yes Go to Step 2.
Step 2 APP sensor (main) power supply voltage check

1) When ignition is “OFF”, disconnect accelerator pedal assembly connector.
2) Check for proper terminal connection to accelerator pedal assembly connector.
Is check result OK?
Yes Go to Step 5.
No Go to Step 3.
Step 3 APP sensor (main) ground circuit check

Is check result OK?

Section 1C
No Go to Step 4.
Step 4 APP sensor (main) power supply circuit check

Is check result OK?
Step 5 APP sensor (main) signal circuit check

Is check result OK?
Yes Go to Step 6.
Step 6 APP sensor check

1) Check APP sensor. (APP Sensor Inspection) in Section 1C
Is check result OK?
No Replace accelerator pedal assembly (incorporating APP sensor). (Accelerator Pedal Assembly
(Incorporating APP Sensor) Removal and Installation) in Section 1C
DTC P2127 / P2128

AENNTA0E1104062 (06(02)
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
P2128: Throttle / Pedal Position Sensor/Switch “E” Circuit High
Output voltage of APP sensor (sub) signal circuit is higher than 2.4 V.
Circuit Diagram
4 3
A1 5V
BRN E01-20
A2
1 PNK E01-16
A3
BLU E01-19
B1 5V
BLK E01-6
B2
2 YEL E01-3
B3
WHT E01-5
[A] E01
[a]
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49
IMTA0A110029-01
APP sensor)
NOTE
DTC Troubleshooting
Yes Go to Step 2.
Step 2 APP sensor (sub) power supply voltage check

1) When ignition is “OFF”, disconnect accelerator pedal assembly connector.
2) Check for proper terminal connection to accelerator pedal assembly connector.
Is check result OK?
Yes Go to Step 5.
No Go to Step 3.
Step 3 APP sensor (sub) ground circuit check

Is check result OK?

Section 1C
No Go to Step 4.
Step 4 APP sensor (sub) power supply circuit check

Is check result OK?
Step 5 APP sensor (sub) signal circuit check

Is check result OK?
Yes Go to Step 6.

1) Check APP sensor. (APP Sensor Inspection) in Section 1C
Is check result OK?
No Replace accelerator pedal assembly (incorporating APP sensor). (Accelerator Pedal Assembly
(Incorporating APP Sensor) Removal and Installation) in Section 1C
DTC P2135
AENNTA0E1104063 (06(02)
P2135: Throttle / Pedal Position Sensor/Switch “A”/“B” Voltage Correlation • TP sensor and/or its circuit
Difference between TP sensor (main) signal voltage and TP sensor (sub) signal • Electric throttle body assembly
voltage is higher than specified value.
• ECM
Circuit Diagram
12V
1
A1
C01-54 BRN
A2
C01-51 LT GRN 4
5V B1
C01-13 RED B2 2
C01-26 GRN
B3 3
C01-16 WHT
C01-15 BLK
B4
C01-17 BLK
[A] C01
[a]
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49
IMTA0A110016-01
NOTE
– TP sensor (P0122, P0123, P0222 and P0223)
1) Start engine.
2) Keep accelerator pedal in fully depressed position for a moment.
3) Keep accelerator pedal in released position for 2 sec.
DTC Troubleshooting
Yes Go to Step 2.
Step 2 Wire harness check

• “B1”, “B2” and “B4” circuits: Refer to Step 2 to 5 under “DTC P0122 / P0123”.
Is check result OK?
Yes Go to Step 3.

1) Check TP sensor for performance referring to “Throttle Position (TP) Sensor Performance Check” under
“Electric Throttle Body Assembly On-Vehicle Inspection” in Section 1C.
Is check result OK?
DTC P2138
AENNTA0E1104064 (06(02)
P2138: Throttle/Pedal Position Sensor/Switch “D”/“E” • APP sensor and/or its circuit
Voltage Correlation • ECM
Difference between half of APP (main) sensor signal and
APP (sub) sensor signal is more than specified value.
Circuit Diagram
4 3
A1 5V
BRN E01-20
A2
1 PNK E01-16
A3
BLU E01-19
B1 5V
BLK E01-6
B2
2 YEL E01-3
B3
WHT E01-5
[A] E01
[a]
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49
IMTA0A110029-01
APP sensor)
NOTE
– System voltage > 8 V
– APP sensor (P2122, P2123, P2127 and P2128)

3) Release accelerator pedal for 2 sec.
DTC Troubleshooting
Yes Go to Step 2.
Step 2 Wire harness check

• “A1”, “A2” and “A3” circuits: Refer to Step 2 to 5 under “DTC P2122 / P2123”.
Is check result OK?
Yes Go to Step 3.

1) Check APP sensor. (APP Sensor On-Vehicle Inspection) in Section 1C
Is check result OK?
No Replace accelerator pedal assembly. (Accelerator Pedal Assembly (Incorporating APP Sensor)
DTC P2176
AENNTA0E1104065 (06(02)
P2176: Throttle Actuator Control System – Idle Position Not Learned • TP sensor and/or its circuit
Any of the following conditions is met. • Electric throttle body assembly
• TP sensor (main) or TP sensor (sub) signal voltage at default position is out • ECM
of specified range for specified time.
• Electric throttle control system calibration is not completed.
Circuit Diagram
12V
1
A1
C01-54 BRN
A2
C01-51 LT GRN 4
5V B1
C01-13 RED B2 2
C01-26 GRN
B3 3
C01-16 WHT
C01-15 BLK
B4
C01-17 BLK
[A] C01
[a]
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49
IMTA0A110016-01
NOTE
Check that the following conditions are met in this “DTC Confirmation Procedure”.
• ECT > 5 °C
• IAT > 5 °C
1) Set ignition “ON” with accelerator pedal released for 1 min.

DTC Troubleshooting
Yes Go to Step 2.
Step 2 DTC check

1) Perform electric throttle control system calibration. (Electric Throttle Control System Calibration) in
Section 1C
Yes Go to Step 3.
No End.
Step 3 TP sensor circuit check

• “B1”, “B2” and “B4” circuit: Refer to Step 2 to 5 under “DTC P0122 / P0123”.
• “B1”, “B3” and “B4” circuit: Refer to Step 2 to 5 under “DTC P0222 / P0223”.
Is check result OK?
Yes Go to Step 4.

1) Check TP sensor referring to “Throttle Position (TP) Sensor Performance Check” under “Electric Throttle
Is check result OK?
DTC P2226 / P2227

AENNTA0E1104066 (06(02)
P2226: Barometric Pressure Sensor “A” Circuit • Barometric pressure sensor in ECM
Barometric pressure sensor and/or its circuit malfunction (open, • ECM power supply circuit and/or ground circuit
short to power supply or short to ground) is detected.
P2227: Barometric Pressure Sensor “A” Circuit Range/
Performance
This DTC is detected if any one of the following conditions is met.
• 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.

P2226
P2227
DTC Troubleshooting
Yes Go to Step 2.

Is check result OK?

DTC U0073
AENNTA0E1104067 (06(02)
Refer to “Troubleshooting for Communication Bus Off”: CAN in Section 10H.
DTC U0101 / U0121 / U0131 / U0140 / U0155

AENNTA0E1104068 (06(02)
Refer to “Troubleshooting for Lost Communication”: CAN in Section 10H.
DTC U2001
AENNTA0E1104069 (06(02)
U2001: LIN Lost Communication With Generator • Generator LIN communication circuit
Received data from generator via LIN is faulty. • Regulator (stator assembly)
• ECM
Circuit Diagram
3
1
12V
A1
2 BLU C01-1 4
[A] C01
[a]
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49
IMTA0A110030-01
[A]: ECM connector (View: [a]) 1. Generator 3. ECM

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

DTC Troubleshooting
Yes Go to Step 2.
Step 2 Generator LIN communication circuit check

1) When ignition is “OFF”, disconnect ECM connectors and generator connector.
2) Check for proper terminal connection to ECM connectors and generator connector.
Is check result OK?
Yes Go to Step 3.
Step 3 DTC recheck

1) Replace stator assembly. (Generator Disassembly and Reassembly) in Section 1J
Is DTC U2001 still detected?
No End.
DTC U2021
AENNTA0E1104070 (06(02)
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

DTC Troubleshooting
Step 1 DTC recheck

Is DTC U2021 still detected?
Yes Go to Step 2.

1) Check ECM power supply and ground circuits. (Inspection of ECM and Its Circuits)
Is check result OK?
Inspection of ECM and Its Circuits

AENNTA0E1104071 (06(01)
Terminal Arrangement of ECM Connector
[A] C01 E01
[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49
IMTA0A110007-01
[A]: ECM connector (View: [a])
Voltage Check
NOTICE
Improper measurement of voltage can damage the vehicle or each component.
Be sure to read and observe “Precautions for Electrical Circuit Service” in Section 00.
NOTE
• Before performing this inspection, read “Precautions for ECM Circuit Inspection” under
“Precautions for Engine” in Section 1.
• 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.
“C01” connector
Terminal Wire Normal
Circuit Condition
No. color voltage
Refer to reference waveform.
C01-1* BLU Generator LIN communication circuit
“Generator LIN communication signal”
C01-2* WHT CAN (low) communication circuit
“CAN communication signal”
C01-3* RED CAN (high) communication circuit
MAP sensor and ECT sensor ground
C01-4 GRY Below 0.3 V Ignition: “ON”
circuit
C01-5 WHT Oil temperature sensor ground circuit Below 0.3 V Ignition: “ON”
C01-6 RED HO2S-1 ground circuit Below 0.3 V Ignition: “ON”
C01-7* GRN HO2S-1 signal circuit
“HO2S-1 signal”
C01-8 YEL HO2S-2 ground circuit Below 0.3 V Ignition: “ON”
C01-9* LT GRN MAF sensor signal circuit
“MAF sensor signal”
10 to 14 V Ignition: “ON”
C01-10* RED Fuel injector No.3-1 drive circuit • “Fuel injector signal”
• “Fuel injector No.3 signal and ignition coil No.3
signal”

Circuit Condition
No. color voltage
C01-11* WHT Fuel injector No.2-1 drive circuit • “Fuel injector signal”
signal”
C01-12* GRN Fuel injector No.4-1 drive circuit • “Fuel injector signal”
signal”
C01-13 RED TP sensor power supply circuit 4.5 to 5.5 V Ignition: “ON”
MAP sensor and MAF sensor power
C01-14 LT BLU 4.5 to 5.5 V Ignition: “ON”
supply circuit
C01-15 BLK TP sensor ground circuit Below 0.3 V Ignition: “ON”
4.0 to 4.2 V • Ignition: “ON”
C01-16 WHT TP sensor (sub) signal circuit
C01-17 BLK TP sensor shield ground circuit Below 0.3 V Ignition: “ON”
C01-18 — — — —
C01-19* BRN HO2S-2 signal circuit
“HO2S-2 signal”
• ECT: 0 °C (32 °F)
C01-20 BLU ECT sensor signal circuit 1.0 to 1.4 V • Ignition: “ON”
• ECT: 50 °C (122 °F)
• ECT: 100 °C (212 °F)
2.35 to 2.73 V
• Engine oil temperature: 20 °C (68
°F)
C01-21 BLU Oil temperature sensor signal circuit 0.68 to 1.00 V
°F)
0.24 to 0.27 V
°F)

Circuit Condition
No. color voltage
• IAT: 20 °C (68 °F)
C01-22 YEL IAT sensor signal circuit 1.3 to 1.7 V • Ignition: “ON”
• IAT: 40 °C (104 °F)
• IAT: 60 °C (140 °F)
C01-23* GRY Fuel injector No.2-2 drive circuit • “Fuel injector signal”
signal”
C01-24* LT GRN Fuel injector No.4-2 drive circuit • “Fuel injector signal”
signal”
1 to 2 V Engine: Idle speed
C01-25* WHT Knock sensor signal circuit 1 Refer to reference waveform.
“Knock sensor signal”
C01-26 GRN TP sensor (main) signal circuit
4.0 to 4.2 V Ignition: “ON”
1.5 to 1.8 V
C01-27* BRN MAP sensor signal circuit • Barometric pressure: 100 kPa, 760
mmHg
“MAP sensor signal”
C01-28 — — — —
MAF sensor with IAT sensor ground
C01-29 BEG Below 0.3 V Ignition: “ON”
circuit
Approx. 0 V or
Ignition: “ON”
4 to 5 V
C01-30* PPL Intake CMP sensor signal circuit
“CMP sensor signal and CKP sensor signal”
C01-31* PNK Fuel injector No.1-1 drive circuit • “Fuel injector signal”
signal”
C01-32* BEG Fuel injector No.3-2 drive circuit • “Fuel injector signal”
signal”

Circuit Condition
No. color voltage
Approx. 0 V Ignition: “ON”
Ignition coil assembly No.2 drive
C01-33* GRN • “Ignition coil signal”
circuit
signal”
C01-34* PNK • “Ignition coil signal”
circuit
signal”
C01-35* BEG • “Ignition coil signal”
circuit
signal”
C01-36* BRN Fuel injector No.1-2 drive circuit • “Fuel injector signal”
signal”
1 to 2 V Engine: Idle speed
C01-37* BLU Knock sensor signal circuit 2 Refer to reference waveform.
“Knock sensor signal”
C01-38 — — — —
Approx. 0 V or
Ignition: “ON”
4 to 5 V
C01-39* PNK CKP sensor signal circuit
Approx. 0 V or
Ignition: “ON”
4 to 5 V
C01-40* YEL Exhaust CMP sensor signal circuit
EVAP canister purge valve drive
C01-41* GRY Refer to reference waveform.
circuit
“EVAP canister purge valve signal”
C01-42* GRN Intake OCV drive circuit Refer to reference waveform.
“OCV signal and TP (main) sensor signal”
C01-43* WHT Exhaust OCV drive circuit Refer to reference waveform.
“OCV signal and TP (main) sensor signal”
C01-44* YEL • “Ignition coil signal”
circuit
signal”
C01-45* GRY EGR valve drive circuit 2
“EGR valve signal”
C01-46* YEL EGR valve drive circuit 3
C01-47* WHT EGR valve drive circuit 4
C01-48* GRN EGR valve drive circuit 1

Circuit Condition
No. color voltage
C01-49* PPL HO2S-1 heater drive circuit
“HO2S heater signal”
C01-50 BLK ECM ground circuit 1 Below 0.3 V Ignition: “ON”
C01-51* LT GRN Throttle actuator drive circuit (close)
“Throttle actuator signal”
C01-52* RED HO2S-2 heater drive circuit
“HO2S heater signal”
C01-53 BLK ECM ground circuit 2 Below 0.3 V Ignition: “ON”
C01-54* BRN Throttle actuator drive circuit (open)
“Throttle actuator signal”
C01-55 LT GRN HO2S-1 shield ground circuit Below 0.3 V Ignition: “ON”
C01-56 BEG HO2S-2 shield ground circuit Below 0.3 V Ignition: “ON”
“E01” connector
Terminal Wire
Circuit Normal voltage Condition
No. color
Approx. 0 V Ignition: “OFF” or “ACC”
E01-1 WHT Ignition “ON” signal circuit
10 to 14 V
• ECT < 95 °C (203 °F)
Radiator cooling fan relay No.1 drive • A/C switch: OFF
E01-2 LT GRN
circuit All of the following conditions are met.
Approx. 0 V
• ECT ≥ 97 °C (207 °F)
• A/C switch: OFF
0.325 to 0.425 V • Ignition: “ON”
E01-3 YEL APP sensor (sub) signal circuit
Electric load current sensor power
E01-4 LT BLU 4.5 to 5.5 V Ignition: “ON”
supply circuit
E01-5 WHT APP sensor (sub) ground circuit Below 0.3 V Ignition: “ON”
E01-6 BLK APP sensor (sub) power supply circuit 4.5 to 5.5 V Ignition: “ON”
3 to 5 V • Ignition: “ON”
Neutral position switch signal circuit (– • Gear position: “Neutral”
E01-7 YEL
) All of the following conditions are met.
Approx. 0 V • Ignition: “ON”
Terminal Wire
No. color
3.5 to 4.3 V Ignition: “ON”
2.0 to 2.4 V
• “RES / +” switch: ON (RES / +
switch kept depressed)
1.2 to 1.6 V
• “SET / –” switch: ON (SET / –
Cruise control command switch signal
E01-8 LT GRN switch kept depressed)
circuit (cruise control model)
0.3 to 0.6 V
• “CANCEL” switch: ON (CANCEL
0 to 0.2 V
• “CRUISE” switch: ON (CRUISE
A/C refrigerant pressure sensor
E01-9 BLU Below 0.3 V Ignition: “ON”
ground circuit
E01-10 — — — —
• ST2 relay: Operating
E01-11 GRY ST2 relay drive circuit (-)
Approx. 2.5 to
4.5 V
• ST2 relay: Not operating
Approx. 0 V
• Brake pedal: Fully depressed after
E01-12 PNK Brake booster switch signal circuit depressing several times
10 to 14 V • Engine: Running
E01-13 — — — —
A/C refrigerant pressure sensor power
E01-14 GRY 4.5 to 5.5 V Ignition: “ON”
supply circuit
E01-15 — — — —
E01-16 PNK APP sensor (main) signal circuit
approx. 0 V • Ignition: “ON”
E01-17 GRN CPP No.1 switch signal circuit
Terminal Wire
No. color
E01-18 LT BLU Brake light switch signal circuit
E01-19 BLU APP sensor (main) ground circuit Below 0.3 V Ignition: “ON”
APP sensor (main) power supply
E01-20 BRN 4.5 to 5.5 V Ignition: “ON”
circuit
E01-21 — — — —
Electric load current sensor with
E01-22 YEL battery temperature sensor ground Below 0.3 V Ignition: “ON”
circuit
E01-23 — — — —
E01-24* RED Fuel pump relay drive circuit
“Fuel pump relay signal”
E01-25 — — — —
E01-26 — — — —
10 to 14 V
• ECT < 100 °C (212 °F)
Radiator cooling fan relay No.2 and • A/C switch: OFF
E01-27 GRN
No.3 drive circuit All of the following conditions are met.
Approx. 0 V
• ECT ≥ 102 °C (216 °F)
• A/C switch: OFF
E01-28* RED CAN (high) communication circuit
E01-29* WHT CAN (low) communication circuit
E01-30 — — — —
10 to 14 V
• Starting motor control relay:
Starting motor control relay drive Operating
E01-31 PNK
Approx. 0 V
• Starting motor control relay: Not
operating
E01-32 — — — —
0.9 to 1.3 V • Engine: Running
A/C refrigerant pressure sensor signal • A/C compressor: Not operating
E01-33 RED
1.3 to 2.2 V • Engine: Running
• A/C compressor: Operating
Ignition: At the moment of “ON” or 10
10 to 14 V
E01-34 GRN DC/DC converter input signal circuit sec. after “OFF”
Approx. 0 V Other than above condition
E01-35 — — — —
Terminal Wire
No. color
• ST2 relay: Operating
E01-36 BRN ST2 relay drive circuit (+)
• ST2 relay: Not operating
At engine auto restart after engine
E01-37 PPL DC/DC converter output signal circuit 10 to 14 V
auto stop
Approx. 0 V Ignition: 10 sec. after “OFF”
E01-38 — — — —
E01-39 — — — —
• Gear position: “Neutral”
E01-40 PNK Neutral position switch signal circuit
10 to 14 V A/C compressor: Not operating
E01-41 GRY A/C compressor relay drive circuit
Approx. 0 V A/C compressor: Operating
E01-42 PPL CPP No.2 switch signal circuit
Starting motor control relay signal Approx. 0 V Ignition: “ON”
E01-43 LT GRN
circuit 6 to 12 V Ignition: “START”
Brake switch signal circuit (cruise • Brake pedal: Released
E01-44 BLU
control model) All of the following conditions are met.
E01-45 — — — —
E01-46 — — — —
2.0 to 2.3 V
• Temperature in the vicinity of
Battery temperature sensor signal battery: 25 °C (77 °F)
E01-47 PNK
0.3 to 0.5 V
• Temperature in the vicinity of
battery: 90 °C (194 °F)
Approx. 2.4 V Ignition: “ON”
Electric load current sensor signal • Ignition: “ON”
E01-48 BLU
circuit Approx. 1.9 V • Headlight: ON
• Blower speed selector / switch:
Max position
E01-49 PNK Main relay drive circuit
10 to 14 V Ignition: 10 sec. after “OFF”
Terminal Wire
No. color
E01-50 — — — —
E01-51 — — — —
E01-52 — — — —
E01-53 — — — —
E01-54 — — — —
E01-55 BLU Main power supply circuit 2 10 to 14 V Ignition: “ON”
E01-56 BLU Main power supply circuit 1 10 to 14 V Ignition: “ON”
Reference Waveform CAN communication signal
NOTE CAN (high) communication signal (1):

• Display includes the following types of Channel Probe Terminal No.
data: C01-3
+
1 E01-28
– C01-50
CAN (low) communication signal (2):

Channel Probe Terminal No.
C01-2
+
2 E01-29
– C01-50
Measurement condition
• Engine: Stop
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.
Generator LIN communication signal

+ C01-1
1
– C01-50
I7RW01110028-01
Measurement condition .
• Engine: Idle speed after warming up.

HO2S-1 signal
+ C01-7
1
– C01-50
Engine: Warm up engine → Keep engine speed at 2,000
rpm for approx. 60 sec. → Release accelerator pedal
fully → Keep engine speed at 2,000 rpm
ICV00P111021-02
1. Generator LIN communication signal
.
Fuel injector No.3 signal and ignition coil No.3 signal
Fuel injector No.3-1 / No.3-2 signal (1):

C01-10 (No.3-1)
+
1 C01-32 (No.3-2)
– C01-50
Ignition coil No.3 signal (2):

+ C01-34
2
– C01-50
IFKA0P110004-01
1. HO2S-1 signal
Intake CMP sensor signal (3):
.
+ C01-30
3
– C01-50
MAF sensor signal
Channel Probe Terminal No. CKP sensor signal (4):
+ C01-9 Channel Probe Terminal No.
1
– C01-50 + C01-39
4
– C01-50
• Engine: Idle speed after warming up. Measurement condition
IFKA0P110005-01
1. MAF sensor signal IFKA0P110009-01
5. Camshaft 360° angle 6. Crankshaft 720° angle

• Engine: Running at 2,000 rpm after warming up.
.
Fuel injector No.2 signal and ignition coil No.2 signal

C01-11 (No.2-1)
+
1 C01-23 (No.2-2)
– C01-50

IFKA0P110006-01 Channel Probe Terminal No.
1. MAF sensor signal + C01-33
2
– C01-50
.

+ C01-30
3
– C01-50
CKP sensor signal (4):

+ C01-39
4
– C01-50
IFKA0P110010-01
HO2S-2 signal
IFKA0P110008-01
+ C01-19
1
5. Camshaft 360° angle 6. Crankshaft 720° angle – C01-50
.
Engine: Warm up engine → Keep engine speed at 3,000
Fuel injector No.4 signal and ignition coil No.4 signal rpm for a specified period of time → Release accelerator
pedal fully
C01-12 (No.4-1)
+
1 C01-24 (No.4-2)
– C01-50

+ C01-35
2
– C01-50

IFRA0B112028-01
+ C01-30 1. HO2S-2 signal 3. Accelerator pedal: Released
3 2. Accelerator pedal: Depressed
– C01-50
CKP sensor signal (4): .

+ C01-39 Knock sensor signal
4
– C01-50
Knock sensor signal 1 (1):
Measurement condition Channel Probe Terminal No.
Engine: Idle speed after warming up + C01-25
1
– C01-50
Knock sensor signal 2 (2):

+ C01-37
2
– C01-50
IFKA0P110011-01
IFKA0P110013-01
.
MAP sensor signal

Fuel injector signal
+ C01-27 Fuel injector signal (No.1-1 / No.2-1 / No.3-1 / No.4-1)
1
– C01-50 (1):
Measurement condition C01-31 (No.1-1)
Engine: Racing after warming up C01-11 (No.2-1)
+
1 C01-10 (No.3-1)
C01-12 (No.4-1)
– C01-50
Fuel injector signal (No.1-2 / No.2-2 / No.3-2 / No.4-2)

(2):
C01-36 (No.1-2)
C01-23 (No.2-2)
+
2 C01-32 (No.3-2)
C01-24 (No.4-2)
IFKA0P110012-01 – C01-50
1. MAP sensor signal 3. Accelerator pedal: Fully
depressed Measurement condition
2. Accelerator pedal: Released Engine: Idle speed after warming up
CMP sensor signal and CKP sensor signal
Intake CMP signal (1):

+ C01-30
1
– C01-50
Exhaust CMP signal (2):

IDP70P112032-01
+ C01-40
2
– C01-50 .
CKP signal (3): Fuel injector No.1 signal and ignition coil No.1 signal
+ C01-39 Fuel injector No.1-1 / No.1-2 signal (1):
3 Channel Probe Terminal No.
– C01-50
C01-31 (No.1-1)
+
1 C01-36 (No.1-2)
Measurement condition – C01-50
Ignition coil No.1 signal (2): OCV signal and TP (main) sensor signal
+ C01-44 Intake OCV signal (1):
2
– C01-50 Channel Probe Terminal No.
+ C01-42
1
Intake CMP sensor signal (3): – C01-50
+ C01-30 Exhaust OCV signal (2):
3
+ C01-43
2
CKP sensor signal (4): – C01-50
+ C01-39 TP (main) signal (3):
4
+ C01-26
3
– C01-50
Engine: Idle speed after warming up Measurement condition
• Accelerator pedal: Released → Fully depressed →
Released
IFKA0P110007-01
.
IFKA0P110015-01
4. Accelerator pedal: Released 5. Accelerator pedal: Fully

EVAP canister purge valve signal depressed
+ C01-41 .
1
– C01-50
• Accelerator pedal: Fully depressed → Released
EVAP canister purge valve: 10% open
(using active test of SUZUKI scan tool)
IFKA0P110016-01
IA1J0P111033-01
1. EVAP canister purge valve signal
.
Ignition coil signal

C01-44 (No.1)
C01-33 (No.2)
+
1 C01-34 (No.3)
C01-35 (No.4)
– C01-50
IFKA0P110017-01
HO2S heater signal
HO2S-1 heater signal (1):

+ C01-49
1
– C01-50
IFKA0P110014-01
HO2S-2 heater signal (2):
1. Ignition coil signal Channel Probe Terminal No.
+ C01-52
2
.
– C01-50
EGR valve signal Measurement condition

EGR valve signal 1 (1):
+ C01-48
1
– C01-50

+ C01-45
2
– C01-50

IFKA0P110018-01
+ C01-46
3
– C01-50 .
EGR valve signal 4 (4): Throttle actuator signal

+ C01-47 Throttle actuator signal (open) (1):
4 Channel Probe Terminal No.
– C01-50
+ C01-54
1
Measurement condition – C01-50
Engine: Right after engine start
Throttle actuator signal (close) (2):
+ C01-51
2
– C01-50
• Ignition: For 10 sec. after ignition “ON”
IFKA0P110019-01 IFKA0P110021-01
. .
Measurement condition Fuel pump relay signal

• Ignition: More than 10 sec. after ignition “ON” Channel Probe Terminal No.
• Accelerator pedal: Released + E01-24
1
– C01-50
Ignition: “OFF” → “ON” → “START”
IFKA0P110020-01
Measurement condition I7K101113037-01

• Ignition: “ON” 1. Fuel pump relay signal 4. Ignition: “START”
• Accelerator pedal: Fully depressed 2. Ignition: “OFF” 5. Fuel pump relay signal: ON
3. Ignition: “ON” 6. Fuel pump relay signal: OFF
ECM Power Supply and Ground Circuit Check

AENNTA0E1104072 (06(01)
Circuit Diagram
2 A1 5V 12V 13
BRN E01-20 C01-54 BRN
3 BEG E01-16 C01-51 LT GRN 14
BLU E01-19 5V E1
A2 5V C01-13 RED
5V 15
BLK E01-6 C01-26 GRN
5V 16
4 YEL E01-3 C01-16 WHT
WHT E01-5 C01-15 BLK
5 5V
C01-17 BLK
6 LT GRN C01-9 F1 17 H1
5V
7 E01-49 PNK
G1
YEL C01-22 18
E01-56 BLU
BEG C01-29 12V
5V E01-55 BLU H2
B1 5V 3.3V
G2
LT BLU C01-14
12V IG2 [B]
8
20 I1 19
BRN C01-27 IG1
E01-1 WHT
GRY C01-4
9 21 [C]
C1 5V
10 LT BLU E01-4 5V IG2
BLU E01-48 22 23
11 5V
PNK E01-47
BEG E01-22 24
J1
C01-50 BLK
J2
12 D1 5V 5V C01-53 BLK
GRY E01-14 25
RED E01-33
BLU E01-9
[A] C01 E01
[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49
IMTA0A110031-02
[A]: ECM connector (View: [a]) I1: Ignition “ON” signal circuit 12. A/C refrigerant pressure sensor
[B]: Ignition switch model J1: ECM ground circuit 1 13. Electric throttle body assembly
[C]: Keyless push start model J2: ECM ground circuit 2 14. Throttle actuator
A1: APP sensor (main) power supply circuit 1. ECM 15. TP sensor (main)
A2: APP sensor (sub) power supply circuit 2. Accelerator pedal assembly (incorporating APP 16. TP sensor (sub)
sensor)
B1: MAP sensor and MAF sensor power supply circuit 3. APP sensor (main) 17. Main relay
C1. Electric load current sensor power supply circuit 4. APP sensor (sub) 18. “FI” fuse
D1: A/C refrigerant pressure sensor power supply circuit 5. MAF sensor with IAT sensor 19. Ignition switch
E1: TP sensor power supply circuit 6. MAF sensor 20. “IGN” fuse
F1: Main relay drive circuit 7. IAT sensor 21. IG11 relay
G1: Main power supply circuit 1 8. MAP sensor 22. BCM
G2: Main power supply circuit 2 9. Electric load current sensor with battery temperature 23. IG12 relay
sensor
H1: Main relay power supply circuit (coil side) 10. Electric load current sensor 24. Main fuse box
H2: Main relay power supply circuit (switch side) 11. Battery temperature sensor 25. Battery
Troubleshooting
NOTICE
Improper measurement of voltage can damage the vehicle or each component.
Be sure to read and observe “Precautions for Electrical Circuit Service” in Section 00.
NOTE
Before troubleshooting, perform the following checks.
• Before troubleshooting, read “Precautions for ECM Circuit Inspection” under “Precautions for
Engine” in Section 1.
• Check that battery voltage is 12 V or more.
• 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 1 Battery check

1) Check that battery and charging system.
• Battery: (Battery Inspection) in Section 1J
• Charging system: (Generator Test) in Section 1J
Is check result OK?
Yes Go to Step 2.
Step 2 Main relay power supply check

1) With ignition “OFF”, remove main relay (1) from individual circuit fuse box No.1 (2).
IMTA0A110032-01
2) Check for proper terminal connection to main relay connector.

4) Check that voltage between each of “H1” and “H2” circuit and ground is battery voltage.
Is check result OK?
Yes Go to Step 3.
No Check the “FI” fuse has not blown.
If check result OK, repair or replace defective wire harness.
Step 3 Main relay check

1) Check main relay. (Engine and Emission Control System Relay Inspection) in Section 1C
Is check result OK?
Yes Go to Step 4.
No Replace main relay.
Step 4 Ignition signal circuit check

1) When ignition is “OFF”, install main relay to individual circuit fuse box No.1.
2) Disconnect ECM connectors.
5) Check that voltage between “I1” and ground is battery voltage.
Is check result OK?
Yes Go to Step 5.
No Check that “IGN” fuse has not blown.
If check result OK, repair or replace defective wire harness.
Step 5 Main relay drive circuit check

2) Check that voltage between “F1” and ground is battery voltage.
Is check result OK?
Yes Go to Step 6.
Step 6 Main power supply circuit check

1) Using service wire, ground “F1” circuit.
3) Check that voltage between each of “G1” and “G2” circuit and ground is battery voltage.
Is check result OK?
Yes Go to Step 7.
Step 7 ECM ground circuit check

2) Check that resistance between each of “J1” and “J2” circuit and ground is less than 1 Ω.
Is check result OK?
Yes Go to Step 8.
Step 8 Sensor power supply circuit check

1) When ignition is “OFF”, connect ECM connectors.
2) Disconnect connectors from accelerator pedal assembly (incorporating APP sensor), MAF sensor with
IAT sensor, MAP sensor, electric load current sensor with battery temperature sensor, A/C refrigerant
pressure sensor and electric throttle body assembly.
3) Check for proper terminal connection to each sensor connector.
5) Check that voltage between each of the following circuits and ground is approx. 5 V.
• A1
• A2
• B1
• C1
• D1
• E1
Is check result OK?
Yes ECM power supply and ground circuit is in good condition.

No Check wiring harness for open, short circuit to battery and short circuit to ground. If wiring harness
is in good condition, replace ECM and recheck ECM power supply and ground circuits. (ECM
Repair Instructions
Idle Speed Inspection – Blower Fan
AENNTA0E1106001 (08(03)
Before idle speed check, check the following. – Brake Switch
• Lead wires and hoses of electronic fuel injection and – Electric Load
engine and emission control systems are connected • A/C ON
securely. – Brake Switch
• Battery voltage is 12 V or more. – Electric Load
• Ignition timing is within specification. 4) Check engine idle speed using “Data List” mode on
• All electrical systems (wipers, heater, lights, A/C, etc.) scan tool.
are off. Engine idle speed
• Air cleaner is properly installed and is in good A/C OFF: 590 to 690 rpm
condition. A/C ON: 700 to 900 rpm
• There are no air abnormally drawn in from air intake 5) If check result is not as specified, check engine idle
system. speed referring to “Improper engine idling or engine
• There is no obstruction in PCV valve or its hoses. fails to idle” under “Engine Symptom Diagnosis”.
• There is no DTCs in ECM. 6) Disconnect SUZUKI scan tool from DLC. (Suzuki
• The following items are turned OFF as checked using SDT-II Connection and Disconnection) in Section 0A
“Data List” mode of scan tool.
– A/C Comp Relay
– A/C Switch
– Brake Switch
– Electric Load
– Blower Fan
After checking all items, check idle speed as follows.
NOTE
Before starting engine, place gear shift lever
in neutral position (M/T model), or shift
selector in N range (AGS model), apply
parking brake and block drive wheels.
1) Connect SUZUKI scan tool to DLC. (Suzuki SDT-II

Connection and Disconnection) in Section 0A
3) Confirm that the following items are turned off using
“Data List” mode on scan tool.
• A/C OFF
– Radiator Fan
– A/C Comp Relay
– A/C Switch
1B-1 Aux. Emission Control Devices:
Aux. Emission Control Devices

Engine
Precautions
Precautions for EVAP system inspection
AENNTA0E1200001 (01(01)
! WARNING
Inhale harmful fuel vapor may be affect health.
Use vacuum pump when vacuum is applied to EVAP hose, pipe and nozzle.
General Description
EGR (Exhaust Gas Recirculation) System Description
AENNTA0E1201001 (03(01)
In this system, purified exhaust gas (1) passed through three-Way catalytic converter flows into EGR cooler for cooling
and recirculated into combustion chamber (2) through the intake manifold (3). This cooled exhaust gas in the
combustion chamber improves the engine performance reducing abnormal combustion (knocking), pumping loss and
fuel consumption.
2 3
:1
:4
IMTA0A120035-01
4. Fresh air
The system mainly consists of EGR pipe (1), EGR cooler (2) and EGR valve (3).
EGR valve is controlled by ECM corresponding to signals from ECT sensor, IAT sensor, barometric pressure sensor,
etc., and the driving conditions.
EGR valve is composed of a motor (4), valve (5), spring (6), bushing (7), etc.
Purified exhaust gas downstream of three-Way catalytic converter flows into EGR cooler and, the cooled exhaust gas
recirculates in the combustion chamber. Through this recirculation, engine performance is substantially improved
reducing piston knocking, pumping loss and fuel consumption, not to mention reduction of NOx.
Aux. Emission Control Devices: 1B-2
4
3
2
5
:8
:9
1
IMTA0A120036-01
8. Exhaust gas 9. Engine coolant
EGR flow rate is electrically regulated by ECM.

When ECM stops the power supply to EGR valve, the internal valve is stopped.
Under any one of the following conditions, ECM closes EGR valve.
• When engine coolant temperature is lower or higher than specified value.
• When intake air temperature is lower or higher than specified value.
• When engine is running under supercharged condition.
• When vehicle is stopped (at idling).

EVAP Canister Purge System Inspection c. Select “EVAP Purge Duty” under “Active Test”
AENNTA0E1204001 (06(01) mode on SUZUKI scan tool.
• Without using SUZUKI scan tool:
NOTICE a. Connect service wire (1) between EVAP
If excessive vacuum is applied, the EVAP canister purge valve (2) and EVAP canister
canister purge valve may be damaged. purge valve connector.
Do not exceed a vacuum of –66 kPa (–0.67 b. Connect service wire (3) to EVAP canister
kgf/cm2, –9.57 psi, –0.66 bar). purge valve.
1) Prepare to operate EVAP canister purge valve as

follows.
• Using SUZUKI scan tool:
a. Connect SUZUKI scan tool to DLC. (Suzuki
SDT-II Connection and Disconnection) in
Section 0A
b. Check DTC. (DTC Check) in Section 1A
If DTC is detected, go to troubleshooting for
applicable DTC. (DTC Table) in Section 1A
– EVAP canister purge valve is ON:

[b]: Ground “GRY” harness side
3 terminal of EVAP canister purge valve.
[a]
[b]
1
2
IMTA0A120001-01
c. Set ignition “ON”.

2) Disconnect vacuum hose (1) from intake manifold IMTA0A120002-01
and disconnect purge hose (2) from EVAP canister
purge valve (3). a) Check that negative pressure of –60 kPa (–0.6
3) Connect special tool to vacuum hose and set the tool kgf/cm2, –8.7 psi, –0.6 bar) can be applied when
in “VACUUM” mode. EVAP canister purge valve is turned off.
b) Check that negative pressure cannot be applied
NOTE
when EVAP canister purge valve is turned on.
Before using special tool (vacuum pump If faulty condition is found, check the following items.
gauge), read its Operator’s Manual to know
• Wire harness and connections
how to use it.
• EVAP canister purge valve: (EVAP Canister Purge
Special tool Valve Inspection)
(A): 09917M47020 • Vacuum hose: (EVAP Connection Hose
Inspection)
(A)
1 EGR Valve System Inspection

AENNTA0E1204002 (06(01)
2) Check DTC. (DTC Check) in Section 1A
3
2 If DTC is detected, go to troubleshooting for
applicable DTC. (DTC Table) in Section 1A
IMKC0A120003-01
4) Select “Stepping EGR” under “Active Test” mode on
4) Check EVAP canister purge valve operation as SUZUKI scan tool.
follows.
5) Check that engine idling becomes unsteady with
NOTE increasing of EGR valve open command.
If faulty condition is found, check the following items.
• EVAP canister purge valve is operated
using scan tool as follows.
• EGR valve (EGR Valve Inspection)
– EVAP canister purge valve is OFF: 0%
• EGR passage (Cylinder head and intake manifold)
– EVAP canister purge valve is ON: 100%
(EGR System Components)
• EVAP canister purge valve is operated
• EGR pipe (EGR Pipe Inspection)
using service wire as follows.
• EGR cooler (EGR Cooler Inspection)
– EVAP canister purge valve is OFF:
[a]: Unground “GRY” harness side
terminal of EVAP canister purge valve.
Repair Instructions
EVAP System Components
AENNTA0E1206001 (12(01)
(a)
1
4
IMTA0A120003-01
1. EVAP canister purge valve 4. To intake manifold : 7.0 Nm (0.71 kgf-m, 5.5 lbf-ft)
2. Engine harness bracket 5. To fuel tank
3. EVAP canister 6. To fuel filler neck
EVAP Canister Purge Valve Removal and 3) Disconnect the following connectors and clamp (1).
Installation • EVAP canister purge valve (2)
AENNTA0E1206002 (08(01)
Reference: “Precautions for Electrical System Work” • ECT sensor (3)
Reference: “EVAP System Components” • A/F sensor (4)
• Exhaust CMP sensor (5)
Removal
• EGR valve (6)
1) Remove air cleaner outlet hose and breather hose.
(Electric Throttle Body Assembly Removal and
2) Remove engine harness protector bolt (1) and 4
disconnect clamp (2) from engine harness bracket.
1 1
2
2
6
5 3
IMTA0A120009-01
4) Remove engine harness protector bracket bolt (1)

and thermostat case nut (2).
5) Remove engine harness protector bracket (3) and
EVAP canister purge valve (4).
IMTA0A120008-01
1, (a)
1
3
2 4
IMTA0A120011-02 IMTA0A120013-01
6) Disconnect purge hoses (1) from EVAP canister • Tighten engine harness protector bracket bolt (1) to
purge valve (2). specified torque.
Tightening torque
Engine harness protector bracket bolt (a): 11 N·m
(1.1 kgf-m, 8.5 lbf-ft)
1, (a)
2 1
IMTA0A120010-02
7) Remove EVAP canister purge valve nut (1).

8) Remove EVAP canister purge valve (3) from engine
harness protector bracket (2). IMTA0A120014-02
• Tighten thermostat case nut to specified torque.

1 (Cooling System Components) in Section 1F
• Tighten engine harness protector bolt (1) to specified
torque.
3 Tightening torque
Engine harness protector bolt (a): 10 N·m (1.0
kgf-m, 7.5 lbf-ft)
1, (a)
2
IMTA0A120012-01
Installation
Reference: “EVAP Canister Purge Valve Inspection”
Reverse removal procedure noting the following points.
• Tighten EVAP canister purge valve nut (1) to specified
torque.
Tightening torque IMTA0A120015-01
EVAP canister purge valve nut (a): 7.0 N·m (0.71
kgf-m, 5.5 lbf-ft)
EVAP Canister Purge Valve Inspection
AENNTA0E1206003 (08(03)
Reference: “EVAP Canister Purge Valve Removal and

Installation” [A]
NOTICE
If excessive vacuum is applied, the EVAP
canister purge valve may be damaged. 1
Do not exceed a vacuum of –66 kPa (–0.67
kgf/cm2, –9.57 psi, –0.66 bar). (A)
1) Remove EVAP canister purge valve. (EVAP Canister 2

Purge Valve Removal and Installation)
2) Check resistance between terminals of EVAP
canister purge valve (1). [B]
If faulty condition is found, replace EVAP canister
purge valve. (EVAP Canister Purge Valve Removal
and Installation)
1
EVAP canister purge valve resistance
22 to 26 Ω at 20 °C (68 °F)
(A)
IMKC0A120004-01
[A]: EVAP canister purge valve OFF

[B]: EVAP canister purge valve ON
1
I8T401122005-01
3) Check purge valve operation as follows. EVAP Canister Removal and Installation
If faulty condition is found, replace EVAP canister AENNTA0E1206004 (08(01)
purge valve. (EVAP Canister Purge Valve Removal Reference: “EVAP System Components”
and Installation)
a) Connect special tool and vacuum hose (1) to Removal
EVAP canister purge valve (2) and set the tool in 1) Remove EVAP canister (1) from fuel tank (2) by
“VACUUM” mode. sliding EVAP canister in arrow direction as shown in
figure.
NOTE
Before using special tool (vacuum pump
gauge), read its Operator’s Manual to know
how to use it.
Special tool
(A): 09917M47020
b) When not connecting 12 V battery to EVAP 1
canister purge valve terminals, check that

negative pressure (–67 kPa, –0.6 kgf/cm2, –9.7
psi, –0.6 bar) can be applied to EVAP canister
purge valve.
2
c) When connecting 12 V battery to EVAP canister IMTA0A120037-01
purge valve terminals, check that negative
2) Disconnect air suction pipe (1) and purge pipe (2)
pressure (–67 kPa, –0.6 kgf/cm2, –9.7 psi, –0.6
from EVAP canister (3). (Fuel Hose Disconnection
bar) cannot be applied to EVAP canister purge
and Reconnection) in Section 1G
valve.
3) Disconnect fuel EVAP hose (4) from EVAP canister.
c) Using special tool, apply specified negative

2 4 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)
1 4 5 3
3
2
IMTA0A120038-01
Installation
Reference: “EVAP Canister Inspection”
Reverse removal procedure.
EVAP Canister Inspection

AENNTA0E1206005 (08(03)
IMTA0A120004-01
Reference: “EVAP Canister Removal and Installation”
1) Check outside of EVAP canister visually.
EVAP Connection Hose Inspection
2) Disconnect hoses from EVAP canister. AENNTA0E1206006 (08(03)
Check hoses related to EVAP system for connection,
3) Check that there is no restriction of flow through
leakage, clogging and deterioration.
purge port (1) and air port (2) when air is blown (4)
Replace hose if defective.
into tank port (3).
PCV Hose Inspection

AENNTA0E1206007 (08(03)
3 Check PCV hoses for connection, leakage, clogging and
deterioration.
4
2 Replace hose if defective.
1
PCV Valve Removal and Installation
AENNTA0E1206008 (08(01)
Removal
1) Remove intake manifold. (Intake Manifold Removal
2) Remove PCV valve (1) with PCV hose (2) from
breather plate (3).
2
IFRA0A121005-01 1
4) Check EVAP canister for air leakage according to

the following procedure.
If faulty condition is found, replace EVAP canister.
(EVAP Canister Removal and Installation)
a) Plug purge port (1) and air port (2) using rubber
plug (3).
b) Install hose (4) and special tool to tank port (5).
NOTE 3
Before using special tool (vacuum pump ILKC0P120018-01
gauge), read its Operator’s Manual to know 3) Remove PCV valve (1) from PCV hose (2).
how to use it.
Special tool
: 09917M47020
3
2
1
[b]
[a]
2
3 1
ILKC0P120019-01
3. Clamp IBD30P120004-02
Installation Fuel EVAP Valve Inspection

Reference: “PCV Valve Inspection” AENNTA0E1206010 (08(03)
Reverse removal procedure noting the following points. 1) Remove EVAP canister. (EVAP Canister Removal
• Install PCV valve (1) to breather plate (3) as shown in and Installation)
figure. 2) Connect special tool to fuel EVAP hose (1).
PCV valve installation angle NOTE
1 to 21° to cylinder block top surface
Before using vacuum pump gauge, read its
Operator’s Manual to know how to use it.
2 Special tool
(A): 09917M47020
3) Using “VACUUM” mode of the special tool, check
that air can be sucked when negative pressure is
applied to fuel EVAP valve.
4) Using “PRESSURE” mode of the special tool, check
that air flows into tank when pressure is applied to
1
fuel EVAP valve.
3
IMTA0A120005-01
2
2. Cylinder block top surface
PCV Valve Inspection

AENNTA0E1206009 (08(03) 1
Reference: “PCV Valve Removal and Installation”
1) Remove PCV valve. (PCV Valve Removal and
Installation)
2) Check the following items.
If faulty condition is found, replace PCV valve (1).
(PCV Valve Removal and Installation)
• Check rattle sound by shaking PCV valve lightly. (A)
• Install clean hose to PCV valve and check that
there is air flow when blowing air into hose from
[a] to [b] (2) and that there is no air flow when
blowing air into hose from [b] to [a] (3) as shown in
figure.
IMTA0A120039-01
2. Adapter included in special tool.
5) If faulty condition is found, replace fuel tank. (Fuel

Tank Removal and Installation) in Section 1G
EGR System Components

AENNTA0E1206011 (12(01)
1 (a) 2 3
16
4 (a)
15
6 (a)
7 8
9
10 (a) 17
11
12
13 (b)
14
13 (b)
IMTA0A120006-01
1. EGR valve bolt No.1 8. To EGR cooler outlet hose 15. Cylinder head
: For tightening order, refer to the following
installation.
• EGR valve: (EGR Valve Removal and
Installation)
• EGR cooler: (EGR Cooler Removal and
Installation)
2. EGR valve 9. To EGR cooler inlet hose No.2 16. Intake manifold
3. EGR valve gasket 10. EGR cooler bolt 17. EGR passage
: EGR valve gasket has no specified : For tightening order, refer to the following
direction. installation.
Installation)
Installation)
4. EGR valve nut No.2 11. To cylinder block : 25 Nm (2.5 kgf-m, 18.5 lbf-ft)
: For tightening order, refer to the following
installation.
Installation)
Installation)
5. EGR cooler gasket 12. EGR pipe gasket : 11 Nm (1.1 kgf-m, 8.5 lbf-ft)
: Install EGR cooler gasket to EGR cooler. : Install gasket to EGR cooler and exhaust
manifold.
6. EGR valve nut 13. EGR pipe bolt : Do not reuse.
: For tightening order, refer to the following : For tightening order, refer to the following
installation. installation.
• EGR valve: (EGR Valve Removal and • EGR valve: (EGR Valve Removal and
Installation) Installation)
• EGR cooler: (EGR Cooler Removal and • EGR cooler: (EGR Cooler Removal and
Installation) Installation)
• EGR pipe: (EGR Pipe Removal and
Installation)
7. EGR cooler 14. EGR pipe
EGR Valve Removal and Installation 2) Install EGR valve (1), and then tighten EGR valve
AENNTA0E1206012 (08(01) nuts No.2 (2) temporarily.
Reference: “EGR System Components” NOTE
EGR valve nuts No.2 are temporarily
Removal
tightened by hand until seat surface of bolt
1) Remove EGR cooler. (EGR Cooler Removal and comes into contact with EGR valve.
Installation)
2) Disconnect EGR valve connector (1).
3) Remove EGR valve nuts No.2 (2), and then remove
1
EGR valve (3).
IMTA0A120029-02
1
2 3) Install new EGR cooler gasket (1) to EGR cooler (2).
IMTA0A120040-02
1
4) Remove EGR valve gasket (1).
IMTA0A120031-01
4) Install EGR cooler (1) to EGR valve (2).

5) Tighten EGR valve bolt No.1 (3) and EGR valve nut
IMTA0A120030-01 (4) to specified torque.
Tightening torque
Installation
EGR valve bolt No.1 (a): 25 N·m (2.5 kgf-m, 18.5
Reference: “EGR Valve Inspection”
lbf-ft)
1) Install new EGR valve gasket (1) to cylinder head. EGR valve nut (b): 25 N·m (2.5 kgf-m, 18.5 lbf-ft)
2
4, (b)
1
3, (a)
IMTA0A120030-01 IMTA0A120032-01
6) Tighten EGR cooler bolt (1) temporarily.

1, (a)
NOTE
EGR cooler bolt is temporarily tightened by
hand until seat surface of bolt comes into
contact with EGR cooler.
7) Install new EGR pipe gaskets (2) to EGR cooler and

exhaust manifold.
2, (b)
2
IMTA0A120024-01
12) Tighten EGR valve nuts No.2 (1) to specified torque.

Tightening torque
1
EGR valve nut No.2 (a): 25 N·m (2.5 kgf-m, 18.5
lbf-ft)
IMTA0A120023-01
8) Install EGR pipe (3) and Tighten EGR pipe bolt

(upper side) (1) temporarily.
9) Tighten EGR pipe bolts (lower side) (2) temporarily.
1, (a)
IMTA0A120025-01
13) Tighten EGR cooler bolt (1) to specified torque.

Tightening torque
2 3 EGR cooler bolt (a): 25 N·m (2.5 kgf-m, 18.5 lbf-
ft)
IMTA0A120019-01
10) Tighten EGR pipe bolts (upper side) (1) to specified

torque. 1, (a)
Tightening torque
EGR pipe bolt (a): 11 N·m (1.1 kgf-m, 8.5 lbf-ft)
11) Tighten EGR pipe bolts (lower side) (2) to specified
torque.
Tightening torque
EGR pipe bolt (b): 11 N·m (1.1 kgf-m, 8.5 lbf-ft)
IMTA0A120026-01
14) Connect EGR cooler outlet hose (2) and EGR cooler
inlet hose No.2 (1) to EGR cooler (3).
EGR Cooler Removal and Installation

AENNTA0E1206014 (08(01)
2
Reference: “EGR System Components”
Removal
1) Drain coolant. (Cooling System Draining) in Section
1F
3
2) Remove EGR pipe bolts (upper side) (1) and EGR
pipe bolts (lower side) (2), and then remove EGR
pipe (3).
1
1
IMTA0A120027-01
15) Connect EGR valve connector.

16) Refill cooling system with coolant. (Cooling System
Refilling) in Section 1F
17) Check cooling system for leakage. (Engine Cooling
System Inspection) in Section 1F
18) Run engine and check for exhaust gas leakage. 2 3
EGR Valve Inspection

AENNTA0E1206013 (08(03)
Reference: “EGR Valve Removal and Installation”
IMTA0A120019-01
1) Remove EGR valve. (EGR Valve Removal and 3) Remove EGR pipe gaskets (2).
Installation)
4) Remove EGR cooler bolt (1).
If faulty condition is found, replace EGR valve (1).
• Check EGR passage (2) for clogging.
• Measure resistance between terminals of EGR
2
valve connector (3) shown in the following table.
EGR valve resistance
Terminal Resistance at 20 °C (68 °F)
1
2–1
2–3
20 – 24 Ω
5–4
5–6
2–5
2 – EGR valve body Infinity IMTA0A120023-01
5 – EGR valve body
5) Disconnect EGR cooler inlet hose No.2 (1) and EGR
cooler outlet hose (2) from EGR cooler (3).
3
3 2 1
2
6 5 4
1
2
IMTA0A120027-01
6) Remove EGR valve bolt No.1 (1) and EGR valve nut
IFRA0B122017-01 (2), and then remove EGR cooler (3).
2 1
3
2
IMTA0A120028-01 IMTA0A120029-02
5) Install new EGR cooler gasket (1) to EGR cooler (2).

Installation
Reference: “EGR Cooler Inspection”
1) Remove EGR valve connector. 1
2) Remove EGR valve nuts No.2 (2), and then remove

EGR valve (1).
1
2
IMTA0A120031-01
6) Install EGR cooler (1) to EGR valve (2).

7) Tighten EGR valve bolt No.1 (3) and EGR valve nut
2
(4) to specified torque.
IMTA0A120029-02
Tightening torque
EGR valve bolt No.1 (a): 25 N·m (2.5 kgf-m, 18.5
3) Install new EGR valve gasket (1) to cylinder head.
lbf-ft)
EGR valve nut (b): 25 N·m (2.5 kgf-m, 18.5 lbf-ft)
1 2
4, (b)
3, (a)
IMTA0A120030-01
4) Install EGR valve (1), and then tighten EGR valve IMTA0A120032-01
nuts No.2 (2) temporarily.
8) Tighten EGR cooler bolt (1) temporarily.
NOTE
NOTE
EGR valve bolts No.2 are temporarily
EGR cooler bolt is temporarily tightened by
tightened by hand until seat surface of bolt
hand until seat surface of bolt comes into
comes into contact with EGR valve.
contact with EGR cooler.
9) Install new EGR pipe gaskets (2) to EGR cooler and Tightening torque
exhaust manifold. EGR valve nut No.2 (a): 25 N·m (2.5 kgf-m, 18.5
lbf-ft)
1, (a)
IMTA0A120023-01
10) Install EGR pipe (3) and Tighten EGR pipe bolt IMTA0A120025-01
(upper side) (1) temporarily. 15) Tighten EGR cooler bolt (1) to specified torque.
11) Tighten EGR pipe bolts (lower side) (2) temporarily. Tightening torque
EGR cooler bolt (a): 25 N·m (2.5 kgf-m, 18.5 lbf-
1 ft)
1, (a)
2 3
IMTA0A120019-01
12) Tighten EGR pipe bolts (upper side) (1) to specified

torque. IMTA0A120026-01
Tightening torque 16) Connect EGR cooler outlet hose (2) and EGR cooler
EGR pipe bolt (a): 11 N·m (1.1 kgf-m, 8.5 lbf-ft) inlet hose No.2 (1) to EGR cooler (3).
13) Tighten EGR pipe bolts (lower side) (2) to specified

torque.
Tightening torque 2
EGR pipe bolt (b): 11 N·m (1.1 kgf-m, 8.5 lbf-ft)
1, (a)
IMTA0A120027-01
2, (b) 17) Connect EGR valve connector.

18) Refill cooling system with coolant. (Cooling System
IMTA0A120024-01
System Inspection) in Section 1F
14) Tighten EGR valve nuts No.2 (1) to specified torque.
20) Run engine and check for exhaust gas leakage.
EGR Cooler Inspection Installation

AENNTA0E1206015 (08(03) Reference: “EGR Pipe Inspection”
Reference: “EGR Cooler Removal and Installation”
Check the following items.
If faulty condition is found, replace EGR cooler. (EGR • Install new EGR pipe gasket to EGR cooler and
Cooler Removal and Installation) exhaust manifold.
• Check EGR cooler for crack and damage. • Tighten EGR pipe bolts (1) in numerical order (“1” –
“2”) to specified torque.
• Check for coolant leakage from EGR cooler.
• Check for exhaust leakage from EGR cooler. Tightening torque
EGR pipe bolt (a): 11 N·m (1.1 kgf-m, 8.5 lbf-ft)
• Check EGR cooler for clogged.
1, “1”, (a)
EGR Pipe Removal and Installation
AENNTA0E1206016 (08(01)
Reference: “EGR System Components”
Removal
1) Remove engine under cover. (Engine Under Cover
and Engine Under Side Cover Removal and
Installation) in Section 9H
2) Remove EGR pipe bolts (1), and then remove EGR 2
pipe (2).
1, “2”, (a)
1 IMTA0A120034-01
2. EGR pipe
EGR Pipe Inspection

AENNTA0E1206017 (08(03)
Reference: “EGR Pipe Removal and Installation”
If faulty condition is found, replace EGR pipe. (EGR Pipe
1
Removal and Installation)
2
• Check EGR pipe for crack and damage.
• Check EGR pipe for clogged.
IMTA0A120033-01
Specifications
Tightening Torque Specifications
AENNTA0E1207001 (09(t)
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
EVAP canister purge valve nut 7.0 0.71 5.5 (T1B001)
Engine harness protector bracket bolt 11 1.1 8.5 (T1B002)
Engine harness protector bolt 10 1.0 7.5 (T1B003)
EGR valve bolt No.1 25 2.5 18.5 (T1B004) / (T1B010)
EGR valve nut 25 2.5 18.5 (T1B005) / (T1B011)
EGR pipe bolt (T1B006) / (T1B007) /
11 1.1 8.5 (T1B012) / (T1B013) /
(T1B016)
EGR valve nut No.2 25 2.5 18.5 (T1B008) / (T1B014)
EGR cooler bolt 25 2.5 18.5 (T1B009) / (T1B015)
Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“EVAP System Components”
“EGR System Components”
“Caution for Fastener” in Section 00

Special Tool
AENNTA0E1208001 (11(s)
09917M47020
Vacuum pump gauge set
(L1B001) / (L1B002) /
(L1B003) / (L1B004)
1C-1 Engine Electrical Devices:
Engine Electrical Devices

Engine
Precautions
Precaution for Engine Electrical devices
AENNTA0E1300001 (01(01)
NOTICE
Do not short circuit between terminals when check
part(s) using battery. Failure to take proper precautions when
handling the electric throttle body assembly
Precautions for Replacing ECM may lead to malfunction of the electric
AENNTA0E1300002 (01(01) throttle body assembly or damage to its
Refer to “Precautions for Replacing ECM” under components.
“Precautions for Engine” in Section 1.
• Do not disassemble the electric throttle
body assembly.
Precaution for MAF Sensor with IAT Sensor • Do not drop or expose the electric throttle
AENNTA0E1300003 (01(01)
NOTICE body assembly to large shock. Any electric
throttle body assembly that has received
large shock should be replaced.
handling the MAF sensor with IAT sensor
may lead to malfunction of the MAF sensor • Keep the throttle body housing and/or
with IAT sensor or damage to its throttle valve free of dust, metallic particles
components. or other foreign materials.
• Do not disassemble the MAF sensor with • Do not apply undue forces to the throttle
IAT sensor. valve when checking operation of the
throttle valve or performance of the TP
• Do not drop or expose the MAF sensor
sensor; otherwise the plastic gears in the
with IAT sensor to large shock. Any MAF
throttle valve actuator will be damaged.
sensor with IAT sensor that has received
large shock should be replaced.
• Do not clean the sensor part. Precaution for Accelerator Pedal Assembly
• Do not blow compressed air to the (Incorporating APP Sensor)
AENNTA0E1300005 (01(01)
passage of MAF sensor with IAT sensor. NOTICE
• Do not touch the sensor part with fingers. Failure to take proper precautions when
• Do not heat the MAF sensor with IAT handling the accelerator pedal assembly
sensor to a temperature higher than 100 °C (incorporating APP sensor) may lead to
(212 °F). malfunction of the accelerator pedal
assembly (incorporating APP sensor).
Precaution for Electric Throttle Body Assembly • Do not disassemble the accelerator pedal
AENNTA0E1300004 (01(01) assembly (incorporating APP sensor).
! CAUTION • Do not drop or expose the accelerator
If you touch the throttle valve with your finger pedal assembly to large shock. Any
when the ignition is “ON” and the accelerator accelerator pedal assembly (incorporating
pedal is depressed, finger may be pinched in APP sensor) that has received large shock
the gap between the throttle valve and must be replaced.
throttle body housing if the accelerator pedal • Keep the sensor section of the accelerator
is released. pedal assembly (incorporating APP
Never touch the throttle valve with your sensor) away from water and/or oil.
finger when the ignition is “ON” and the
accelerator pedal is depressed.
General Description
Engine Electrical Devices Description Barometric Pressure Sensor
AENNTA0E1301001 (03(01)
Various sensors for the engine control in this model are • Barometric pressure sensor is incorporated in the
outlined as follows. ECM.
• This sensor detects barometric pressure.
Engine Electrical Devices: 1C-2
Intake and Exhaust CMP Sensor

• CMP sensors are mounted on the cylinder head.
• Magnetic variation induced by a signal rotor 2
pressfitted on intake and exhaust camshaft end is
converted to voltage signal in the sensor and the
[b]
signal is inputted to ECM.
• Based on CMP signal and CKP signal, ECM reads 1
each piston position in cylinder and controls fuel
injection and ignition timing. Further, detecting open/
close timing of intake valves, ECM controls VVT
operation.
CKP Sensor
• CKP sensor is mounted on intake side of cylinder
block near the crankshaft pulley.
• Magnetic variation induced by a sensor plate installed
[a]
on crankshaft is converted to voltage signal in the
IMKC0A130001-01
sensor and the signal is inputted to ECM. Using the
[b]: A part of intake air
signal, ECM calculates engine speed.
• Based on intake and exhaust CMP signal and CKP IAT Sensor
signal, ECM reads each piston position in cylinder and
controls fuel injection and ignition timing. • IAT sensor is incorporated in MAF sensor.
• A thermistor in changes resistance corresponding to
MAP Sensor intake air temperature and the resistance converted to
• MAP sensor mounted on intake manifold. signal is outputted to ECM. Receiving the signal, ECM
calculates intake air temperature.
• A pressure responsive silicon membrane incorporated
in diaphragm generates voltage signal corresponding Knock Sensor
to intake pressure (absolute pressure) and the signal
is inputted to ECM. Based on the signal, ECM • Knock sensor is mounted on the upper part of the
calculates manifold absolute pressure. cylinder block at intake side.
• A piezoelectric ceramic element incorporated in the
MAF Sensor sensor generates electromotive force in proportion to
• MAF sensor mounted on air cleaner outlet. degree of shock and the generated voltage signal is
inputted to ECM. Using the signal, ECM detects
• MAF sensor is consists of a heater (1) on a hot film piston knocking.
and 2 temperature sensors (2) arranged in upstream
side and downstream side of the intake air [a]. HO2S-1/2
• When air flows across the hot film, the upstream side • HO2S-1 is mounted on the upper part of the three-
sensor cools differently from the downstream side. way catalytic converter.
The temperature difference between the 2
proportionally increases with increase of the mass • HO2S-2 is mounted on the lower part of the three-way
airflow and the value is converted to digital signal and catalytic converter.
outputted to ECM. Receiving the signal, ECM • The sensor is composed of a platinum coated zirconia
calculates mass airflow. element which generates electromotive force sensing
difference of oxygen concentration. Voltage signal
corresponding to variation of oxygen concentration in
exhaust gas after flowing out of catalyst is inputted to
ECM.
• Judging from signals of HOS2-1 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.
TP Sensor (Main and Sub)

• TP sensor is incorporated in electric throttle body
assembly.
• A noncontact type sensor with hall IC generates dual • This sensor detects variation of A/C refrigerant
voltage signals in response to throttle valve opening pressure and sends it to ECM. ECM uses this signal
and these signals, main and sub, are inputted to ECM. to A/C compressor relay control.
Based on the signals, ECM calculates opening degree
of the throttle valve. Electric Load Current Sensor with Battery
Temperature Sensor
APP Sensor (Main and Sub) • Electric load current sensor with battery temperature
• APP sensor is incorporated in accelerator pedal sensor is mounted on battery negative (-) cable.
assembly. • This sensor detects electric current responding to the
• A noncontact type sensor applying electromagnetic load and ambient temperature of lead-acid battery,
induction detects depressing degree of accelerator and sends these signals to ECM.
pedal.
• Dual voltage signals, main and sub, are inputted to Brake Booster Pressure Sensor (ESP® model)
ECM. Based on the signals, ECM controls throttle • Brake booster sensor is mounted on brake booster.
valve opening activating throttle actuator. • This sensor detects variation of brake booster
negative pressure and sends it to ESP® control
ECT Sensor module. ECM receives this signal via CAN
• ECT sensor is mounted on thermostat case. communication system and uses this signal to A/C
• A thermistor incorporated in the sensor changes compressor relay control.
electrical resistance corresponding to temperature
and the resistance converted to voltage is inputted to Brake Booster Switch (ABS model)
ECM. Based on the voltage signal, ECM calculates • Brake booster sensor is mounted on brake booster.
coolant temperature. • Depending on state of brake booster negative
pressure, voltage signal of 0 V (brake booster
Brake Light Switch with Brake Switch negative pressure is higher than specified value) or 12
• Brake light switch with brake switch is mounted on V (brake booster negative pressure is lower than
brake pedal assembly. specified value) is output to ECM. ECM uses this
• Depending on state of brake pedal, voltage signal of 0 signal to A/C compressor relay control.
V (When brake pedal is released) or 12 V (When
brake pedal is depressed) is output to ECM. ECM Oil temperature sensor
detects state of brake pedal based on the signal. • Oil temperature sensor is mounted on cylinder block
• A voltage signal opposite to brake light switch signal is at exhaust side.
output to the ECM as a brake switch signal. ECM • A thermistor in changes resistance corresponding to
uses the brake switch signal for cruise control. engine oil temperature and the resistance converted
to signal is outputted to ECM. Receiving the signal,
A/C Refrigerant Pressure Sensor ECM calculates engine oil temperature.
• A/C refrigerant pressure sensor is mounted on liquid
pipe.
Component Location
Electric Control System Component Location
AENNTA0E1303001 (04(01)
Refer to “Electronic Control System Component Location” in Section 1A.
Repair Instructions
ECM Removal and Installation Handle the ECM carefully and do not expose
AENNTA0E1306001 (08(01) it to large shock.
Reference: “Electric Control System Component
NOTE
Location”
• When replacing ECM, replace it with a new
NOTICE one.
The ECM is a precision unit and can be easily
damaged.
• Before ECM replacement, perform

“Procedure for saving data before ECM
replacement” under “Saving / Writing of
Starter Drive Count” in Section 10I.
• Before replacing ECM, if the “Starter Drive
Count” cannot be counted due to
malfunction, check the normality of
communication between SUZUKI scan tool
and ECM communication line and other
control module.
If it is normally operated, replace ECM and
1 2
Starting Motor, then perform “Procedure
after Starting Motor Replacement” in
Section 10I. IMTA0A130002-01
• After ECM replacement, perform following

Installation
procedure.
– “Procedure after ECM Replacement”
• Tighten ECM bracket nuts(1) to specified torque, if
– “Procedure for writing data after ECM removed.
replacement” under “Saving / Writing of
Starter Drive Count” in Section 10I Tightening torque
ECM bracket nut (a): 8.8 N·m (0.90 kgf-m, 6.5 lbf-
Removal ft)
1) Turn lock lever (1) in arrow direction until it stops.
Then, disconnect connector from ECM.
1
1
IFRA0A131001-01
1, (a)
2) Remove ECM bolts (1) from ECM (2), and then
remove ECM.
IMTA0A130003-01
• Connect connectors to ECM as follows:

2
a. Check that lock lever of ECM connectors is in
unlocked position.
1
IFRA0A131003-01
b. Insert ECM connectors to ECM until they stop with

lock lever in unlocked position.
IMTA0A130001-01
3) Remove ECM bracket nuts (1), and then remove

ECM bracket (2), if necessary.
IFRA0A131004-01
c. Pull lock lever down to lock ECM connectors

securely.
Throttle Valve Operation Check

1) Remove air cleaner outlet hose. (Electric Throttle
Body Assembly Removal and Installation) in Section
1D
2) Check throttle valve operation as follows.
If faulty condition is found, replace electric throttle
IFRA0A131005-01 body assembly. (Electric Throttle Body Assembly
Removal and Installation) in Section 1D
Procedure after ECM Replacement a) Check that throttle valve (1) moves smoothly to
AENNTA0E1306002 (08(03) both fully closed position and fully open position
NOTE when pressed manually.
When ECM and BCM are replaced with new
ones at the same time, perform “ECU
Programing for ECM”, and then perform
1
“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:
IMTA0A130005-01
1) Perform “ECM Registration” in “Immobilizer” menu
on SUZUKI scan tool. b) Check throttle valve returns to default position
Refer to “SUZUKI Immobilizer Control System when finger pressure on throttle valve is
Operator’s Manual”. released at both fully closed position and fully
open position.
2) Perform electric throttle control system calibration.
(Electric Throttle Control System Calibration) Throttle valve default position
3) Perform ECM learning procedure of engine torque. “a”: A slight opening from fully closed
(ECM Learning Procedure of Engine Torque) position (1)
4) Perform “Procedure for writing data after ECM
replacement” under “Saving / Writing of Starter Drive
Count” in Section 10I. 1
Electric Throttle Body Assembly On-Vehicle

Inspection
AENNTA0E1306003 (08(03)
“a”
Location” I7V20A131002-04
NOTE
Electric Throttle Body System Operation Check
After replacing electric throttle body
1) Check that engine idle speed is specified value. (Idle
assembly, calibration of throttle valve
Speed Inspection) in Section 1A
position is required. “Electric Throttle
Control System Calibration” 2) Check that engine speed increases smoothly in
response to depressing of accelerator pedal, and
Throttle Valve Visual Check engine speed decreases to specified idle speed
when accelerator pedal is released.
1) Remove air cleaner outlet hose. (Air Cleaner
Assembly Removal and Installation) in Section 1D 3) Stop engine and with ignition is “ON”.
2) Check that there is no foreign material caught 4) Select “Target Throttle Posi” and “Throttle Position”
between throttle valve and throttle body housing. If in “Data List” mode on SUZUKI scan tool. And check
foreign materials are present, remove electric throttle the following points. Refer to “Scan Tool Data” in
body assembly and clean its inside thoroughly. Section 1A.
(Electric Throttle Body Assembly Removal and • “Throttle Position” value when accelerator pedal is
Installation) in Section 1D released.
• “Throttle Position” value when accelerator pedal is
fully depressed.
• “Throttle Position” follows “Target Throttle Posi”

when accelerator pedal is opened fully from fully [A]
closed position. 6 5 4 32 1
5) If faulty condition is found in Step 1) – 4), check the
following points.
• Wire harness and connections 2
• APP sensor: (APP Sensor On-Vehicle Inspection)

• TP sensor: (TP Sensor Performance Check)
• Throttle actuator: (Throttle Actuator Check) 1
• ECM: (Inspection of ECM and Its Circuits) in

Section 1A [B]
6) If check result is OK in Step 5), replace ECM. (ECM 6 5 4 32 1
Throttle Actuator Check

2
1) Disconnect connector from electric throttle body
assembly.
2) Measure resistance between terminal “5” and
terminal “6” of electric throttle body assembly. 1
If faulty condition is found, replace electric throttle IBV10A131001-01
body assembly. (Electric Throttle Body Assembly [A]: TP sensor (main) [B]: TP sensor (sub)
Throttle actuator resistance c) Check that voltage varies depending on throttle
0.3 to 100 Ω at 20 °C (68 °F) opening angle as shown in the following graph
while throttle valve is opened and closed
manually.
6 5 4 32 1
[c]
4.4 - 4.6 4.4 - 4.7
4.3 - 4.5
4.0 - 4.2 [a]
IA1J0P130058-01
[b]
TP Sensor Performance Check 0.8 - 1.0 0.5 - 0.7
1) Remove air cleaner outlet hose. (Air Cleaner 0.4 - 0.6 0.3 - 0.6
[e] [d]
Assembly Removal and Installation) in Section 1D
[f]
2) Disconnect connector from electric throttle body
[g]
assembly.
IDLA0A130003-02
3) Check output voltage of TP sensor main and sub
[a]: TP sensor (main) voltage
signals as follows. [b]: TP sensor (sub) voltage
If faulty condition is found, replace electric throttle [c]: TP sensor output voltage (V)
body assembly. (Electric Throttle Body Assembly [d]: Throttle valve opening
Removal and Installation) in Section 1D [e]: Position where throttle valve is open by a slight opening from fully
closed position (default position)
a) Arrange 3 new 1.5 V batteries (1) in series, and
[f]: Angle obtained when accelerator pedal is depressed fully
check that total voltage is 4.5 to 5.0 V. [g]: Angle obtained when throttle valve is fully opened manually
b) Connect voltmeter (2) and batteries to TP sensor
as shown in figure. Electric Throttle Control System Calibration
AENNTA0E1306004 (08(03)
1) After performing any one of the following services, it
is necessary to calibrate electric throttle control
system.
• Replacement of ECM
• Clearance of DTC related to ECM
• Removal and installation of electric throttle body
assembly (cleaning or replacement)
• Replacement of accelerator pedal assembly If faulty condition is found, check the following items.
(incorporating APP sensor) • Wire harness and connections
2) Check that the following conditions are satisfied • APP sensor (APP Sensor Inspection)
when performing this calibration procedure.
• DTC: Not detected [c]
4.350 - 4.450
• Vehicle: Stop
• Engine: Stationary
[a]
• 6 °C (43 °F) < ECT < 100 °C (212 °F)
• IAT > 6 °C (43 °F). 2.150 - 2.250
• Accelerator pedal position: Idle position

• Battery voltage > 10 V. 0.700 - 0.800
[b]
3) Clear DTC. (DTC Clearance) in Section 1A 0.325 - 0.425
[d] [e]
NOTE IA1J0P130056-01
Perform “DTC clear” although DTC is not [a]: APP sensor (main) voltage
detected. [b]: APP sensor (sub) voltage
[c]: Voltage (V)
4) Set ignition “ON” and leave it for 40 sec. or more. [d]: Idle position of accelerator pedal
5) Set ignition “OFF” and leave it for 10 sec. or more. [e]: Fully depressed position of accelerator pedal
6) Perform ECM learning procedure of engine torque.

(ECM Learning Procedure of Engine Torque)
Accelerator Pedal Assembly (Incorporating
ECM Learning Procedure of Engine Torque APP Sensor) Removal and Installation
AENNTA0E1306007 (08(01)
AENNTA0E1306005 (08(03)
Perform the “Electric Throttle Control System Reference: “Precautions for Electrical System Work”
Calibration” first, then perform the following procedure. Reference: “Electric Control System Component
Location”
1) Check that the following conditions are satisfied Reference: “APP Sensor On-Vehicle Inspection”
when performing this procedure.
• DTC: Not detected NOTE
• Vehicle: Stop After replacing accelerator pedal assembly
• Engine: Stationary (incorporating APP sensor), calibrate throttle
valve position. “Electric Throttle Control
• 6 °C (43 °F) < ECT < 100 °C (212 °F)
System Calibration”
• IAT > 6 °C (43 °F).
• Accelerator pedal position: Idle position Removal
• Battery voltage > 10 V. 1) Disconnect accelerator pedal assembly connector
2) Start engine. (1).
3) Warm up engine at idle speed until radiator fan is 2) Remove accelerator pedal assembly nuts (3) and
operated. then remove accelerator pedal assembly
(incorporating APP sensor) (2).
APP Sensor On-Vehicle Inspection
AENNTA0E1306006 (08(03) 1
Location”
1) Check that accelerator pedal assembly 3
(incorporating APP sensor) has been mounted to
vehicle body properly (no pinched floor carpet, etc.).
If mounting is improper, reinstall accelerator pedal
assembly (incorporating APP sensor). (Accelerator
Pedal Assembly (Incorporating APP Sensor)
2
IMTA0A130006-01
3) Display “Data List” mode.
4) Check that voltage varies depending on accelerator Installation
position as shown in the following graph. Reference: “APP Sensor Inspection”
Reverse removal procedure noting the following point.

[A]
• Tighten accelerator pedal assembly nuts (1) to
specified torque.
6 5 4 3 21
Tightening torque
Accelerator pedal assembly nut (a): 13 N·m (1.3 2
kgf-m, 9.5 lbf-ft)
1, (a) [B]
6 5 4 3 21
1
IMTA0A130007-02 I8G001130011-01
[A]: APP sensor (main) [B]: APP sensor (sub)
APP Sensor Inspection

AENNTA0E1306008 (08(03) c) Check that voltage varies depending on
Reference: “Electric Control System Component accelerator pedal stroke as shown in the
Location” following graph.
Reference: “Accelerator Pedal Assembly (Incorporating
APP Sensor) Removal and Installation” [c]
3.915 - 4.450
1) Remove accelerator pedal assembly (incorporating
APP sensor). (Accelerator Pedal Assembly
(Incorporating APP Sensor) Removal and [a]
Installation)
1.935 - 2.250
2) Check APP sensor output voltage as follows.
If faulty condition is found, replace accelerator pedal
assembly (incorporating APP sensor). (Accelerator [b]
0.630 - 0.800
Pedal Assembly (Incorporating APP Sensor) 0.293 - 0.425
[d] [e]
a) Arrange 3 new 1.5 V batteries (1) in series, and IE3J0P130040-01
check that total voltage is 4.5 – 5.0 V. [a]: APP sensor (main) voltage
b) Connect voltmeter (2) and batteries to APP [b]: APP sensor (sub) voltage
sensor as shown in figure. [c]: Voltage (V)
[d]: Idle position of accelerator pedal
[e]: Fully depressed position of accelerator pedal
MAP Sensor Removal and Installation

AENNTA0E1306009 (08(01)
Location”
Removal
1) Remove electric throttle body assembly. (Electric
Throttle Body Assembly Removal and Installation) in
Section 1D
2) Disconnect MAP sensor connector (1).
3) Remove MAP sensor bolt (2), and then remove MAP
sensor (3) from intake manifold.
2
3 2 1
1
IFRA0Q131007-01
3
3) Check MAP sensor output voltage as follows. If
1 faulty condition is found, replace MAP sensor (3).
(MAP Sensor Removal and Installation)
a) Arrange 3 new 1.5 V batteries (1) in series, and
check that total voltage is 4.5 to 5.0 V.
IMTA0A130008-01
b) Connect voltmeter (2), special tool and batteries
Installation to MAP sensor as shown in figure and set the
Reference: “MAP Sensor Inspection” tool in “VACUUM” mode.
Reverse removal procedure noting the following points. NOTE
• Check that O-ring is free from damage.
Before using special tool (vacuum pump
• Tighten MAP sensor bolt (1) to specified torque. gauge), read its Operator’s Manual to know
Tightening torque how to use it.
MAP sensor bolt (a): 4 N·m (0.41 kgf-m, 3.0 lbf-ft)
Special tool
(A): 09917M47020
1, (a)
3 (A)
3 2 1
IMTA0A130009-01
MAP Sensor Inspection 1

AENNTA0E1306010 (08(03)
Reference: “Electric Control System Component IMTA0A130010-01
Location” 4. Adapter included in special tool.

Reference: “MAP Sensor Removal and Installation”
c) Check that voltage drops gradually when
NOTICE negative pressure is gradually applied with
If excessive vacuum is applied, the MAP special tool.
sensor may be damaged.
Do not exceed a vacuum of –70 kPa (–0.7 kgf/ NOTICE
cm2, –10.2 psi, –0.7 bar). Environmental condition affects output
voltage largely.
1) Remove MAP sensor. (MAP Sensor Removal and The sensor voltage below is reference value
Installation) when measuring under the following
2) Check O-ring (1) for damage and deterioration. conditions.
If faulty condition is found, replace MAP sensor. • Power supply voltage: 5 V
(MAP Sensor Removal and Installation) • 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
Vacuum of –30 kPa (–0.3 kgf/cm2, –4.35 psi, –0.3 • Use new gasket.
bar): Approx. 2.9 V • Tighten oil temperature sensor (1) to specified torque.
Vacuum of –60 kPa (–0.6 kgf/cm2, –8.70 psi, –0.6
bar): Approx. 1.7 V Tightening torque
Oil temperature sensor (a): 25 N·m (2.5 kgf-m,
18.5 lbf-ft)
Oil Temperature Sensor On-Vehicle Inspection
AENNTA0E1306011 (08(03)
Location” 1, (a)

2) With ignition “ON”, select “Scan Tool Data” mode on
SUZUKI scan tool.
3) Check that “Engine Oil Temperature” value displayed
on SUZUKI scan tool varies depending on engine oil
temperature. (Scan Tool Data) in Section 1A
If check result is not as specified, check the following
points.
• Wire harness and connections IMTA0A130014-01
• Oil temperature sensor: (Oil Temperature Sensor

Inspection) Oil Temperature Sensor Inspection
AENNTA0E1306013 (08(03)
Oil Temperature Sensor Removal and Location”
Installation Reference: “Oil Temperature Sensor Removal and
AENNTA0E1306012 (08(01)
Reference: “Precautions for Electrical System Work” Installation”
Reference: “Electric Control System Component NOTE
Location”
Reference: “Oil Temperature Sensor On-Vehicle If sensor connector is connected while its
Inspection” terminals are wet, contact failure or short
circuit may occur.
NOTICE Check that the terminals are dry when
Gasket of oil temperature sensor is reused, connecting the sensor connector.
may cause oil leakage.
Once oil temperature sensor is removed, 1) Remove oil temperature sensor. (Oil Temperature
replace gasket with new one. Sensor Removal and Installation)
2) Check resistance between terminal “1” and terminal
Removal “2” varies depending on water temperature as shown
1) Disconnect oil temperature sensor connector (2). in the following graph.
If faulty condition is found, replace oil temperature
2) Remove oil temperature sensor (1) from cylinder
sensor (1). (Oil Temperature Sensor Removal and
block.
Installation)
2
1
1
2 1
4
IMTA0A130013-01
Installation IFRA0B132008-01
Reference: “Oil Temperature Sensor Inspection” 2. Ohmmeter 4. Heater

Reverse removal procedure noting the following points. 3. Temperature gauge
[a]
1, (a)
2.35 - 2.73
0.68 - 1.00
0.24 - 0.26
20 50 90 [b]
IFRA0B132009-01
IMTA0A130012-01
[a]: Resistance [b]: Temperature
• Refill cooling system. (Cooling System Refilling) in
Section 1F
ECT Sensor Removal and Installation • Check cooling system for leakage. (Engine Cooling
AENNTA0E1306014 (08(01)
Reference: “Precautions for Electrical System Work” System Inspection) in Section 1F
Location” ECT Sensor Inspection
AENNTA0E1306015 (08(03)
Removal
Location”
1) Drain coolant. (Cooling System Draining) in Section Reference: “ECT Sensor Removal and Installation”
1F
2) Disconnect ECT sensor connector (1). NOTE
3) Remove ECT sensor (2) from thermostat case. If sensor connector is connected while its
terminals are wet, contact failure or short
circuit may occur.
Check that the terminals are dry when
connecting the sensor connector.
1
1) Remove ECT sensor. (ECT Sensor Removal and
Installation)
2) Check O-ring for damage. If faulty condition is found,
replace ECT sensor (1). (ECT Sensor Removal and
Installation)
2
IMTA0A130034-01
Installation
Reference: “ECT Sensor Inspection”
• Clean thread part of ECT sensor and thermostat case.
• Check O-ring for damage.
• Tighten ECT sensor (1) to specified torque. 1
IDX00P130013-01
Tightening torque 3) Check resistance between terminal “1” and terminal

ECT sensor (a): 12 N·m (1.2 kgf-m, 9.0 lbf-ft) “2” varies depending on water temperature as shown
in the following graph.
If faulty condition is found, replace ECT sensor (1).
(ECT Sensor Removal and Installation)
2 1
IBV10A131003-01
1. HO2S-1 connector (viewed from terminal side)
1 HO2S-2 heater resistance

2 1
Between terminals “1” and “2”: 5.0 to 6.4 Ω at 20 °C
(68 °F)
4
1
IAW101130017-01
2. Ohmmeter 4. Heater
3. Temperature gauge
I7V20A131012-01
1. HO2S-2 connector (viewed from terminal side)

[a]
HO2S Removal and Installation

(5.74) AENNTA0E1306017 (08(01)
Location”
Reference: “HO2S On-Vehicle Inspection”
2.29 - 2.62
(1.16)
! CAUTION
(0.59)
0.31 - 0.33
Touching exhaust system components when
they are still hot may cause burns.
20 40 60 80 [b]
Check that the exhaust system has cooled
I9P60A131005-04 down before removing the HO2S.
Removal
HO2S On-Vehicle Inspection HOS2-1
AENNTA0E1306016 (08(03)
1) Disconnect HO2S-1 connector (1).
Reference: “Electric Control System Component 2) Disconnect HO2S-1 harness from clamps (2).
Location” 3) Remove HO2S-1 (3) from exhaust manifold.
1) Disconnect HO2S-1 or HO2S-2 connector.
2) Using ohmmeter, measure heater resistance of
HO2S-1 or HO2S-2 connector (sensor side). 1
If faulty condition is found, replace HO2S-1 or
HO2S-2. (HO2S Removal and Installation)
NOTE
Temperature of sensor affects resistance
largely. Check that sensor heater is at 2
specified temperature.
3
HO2S-1 heater resistance
Between terminal “3” and “4”: 5.0 to 6.4 Ω at 20 °C
(68 °F) IMTA0A130015-01
HO2S-2
1) Hoist vehicle and remove engine under cover, if
necessary. (Engine Under Cover and Engine Under
Side Cover Removal and Installation) in Section 9H
2) Disconnect HO2S-2 connector (1).
3) Detach HO2S-2 harness clamp (2) from exhaust • Tighten HO2S-2 (1) to specified torque.
manifold cover.
Tightening torque
HO2S-2 (a): 45 N·m (4.6 kgf-m, 33.5 lbf-ft)
1 • Fix HO2S-2 harness with clamp (2) as shown in
figure.
2 3
IMTA0A130016-01
4) Disconnect HO2S-2 harness from clamp (1).

5) Remove HO2S-2 (2) from exhaust manifold. 1, (a)
IMTA0A130019-01
1 3. Tape
• After installation, check that exhaust gas no leakage

from HO2S-2 with engine running.
• Install engine under cover, if removed. (Engine Under
Cover and Engine Under Side Cover Removal and
CMP Sensor On- Vehicle Inspection

AENNTA0E1306018 (08(03)
2 Reference: “Precautions for Electrical System Work”
IMTA0A130017-01
Location”
Installation 1) Disconnect intake CMP sensor or exhaust CMP
HO2S-1 sensor connector. “CMP Sensor Removal and
Reverse removal procedure noting the following points. Installation”
• Tighten HO2S-1 (1) to specified torque. 2) Using service wires, connect CMP sensor (1), CMP
sensor connector (2) and voltmeter (3).
Tightening torque
HO2S-1 (a): 45 N·m (4.6 kgf-m, 33.5 lbf-ft)
1
1 2 3
1, (a)
3 2 1 1 2 3
IMTA0A130018-01
• After installation, check that exhaust gas no leakage

from HO2S-1 with engine running.
IMTA0A130020-01
HO2S-2
3) Set ignition “ON” and check that output voltage

alternates between approx. 0 V and 5 V while turning
crankshaft. If faulty condition is found, go to Step 4).
4) Check signal rotor. (Camshaft Inspection) in Section
1D
If check result is not OK, replace CMP sensor. (CMP
Sensor Removal and Installation)
CMP Sensor Removal and Installation

AENNTA0E1306019 (08(01) 1, (a)
Reference: “Precautions for Electrical System Work” 2, (b)
Location”
Reference: “CMP Sensor On- Vehicle Inspection” IMTA0A130022-01
NOTICE
CKP Sensor Removal and Installation
Reinstallation of intake CMP sensor or AENNTA0E1306020 (08(01)
exhaust CMP sensor may cause oil leakage. Reference: “Precautions for Electrical System Work”
Once intake CMP sensor or exhaust CMP Reference: “Electric Control System Component
sensor is removed, replace it with new one. Location”
Removal NOTICE
1) For intake CMP sensor removed, remove engine • The CKP sensor bolt is pre-coated with
harness protector and EVAP canister purge valve. adhesive. If the bolt is reused, it may work
(EVAP Canister Purge Valve Removal and loose.
Installation) in Section 1B Once intake CKP sensor bolt is removed,
2) Disconnect connector from intake CMP sensor or Replace it with new one.
exhaust CMP sensor. • Reinstallation of CKP sensor may cause oil
3) Remove intake CMP sensor bolt (1) or exhaust CMP leakage.
sensor bolt (2), and then remove intake CMP sensor Once intake CKP sensor is removed,
(3) or exhaust CMP sensor (4) from cylinder head. replace it with new one.
Removal
3 1) Remove engine under cover. (Engine Under Cover
4 and Engine Under Side Cover Removal and
2) Remove generator. (Generator Removal and
Installation) in Section 1J
3) Disconnect connector (1) from CKP sensor (2).
1
4) Remove CKP sensor bolt (3), and then remove CKP
2 sensor from cylinder block.
IMTA0A130021-01
1
2
Installation
• Check that O-ring is free from damage.
• Apply engine oil to O-ring.
• Tighten intake CMP sensor bolt (1) and exhaust CMP
senor bolt (2) to specified torque.
Tightening torque 3
Intake CMP sensor bolt (a): 11 N·m (1.1 kgf-m, 8.5

IMTA0A130023-02
lbf-ft)
Exhaust CMP sensor bolt (b): 11 N·m (1.1 kgf-m,
Installation
8.5 lbf-ft)
Reference: “CKP Sensor Inspection”
• Apply engine oil to O-ring. CKP sensor resistance

• Tighten new CKP sensor bolt (1) to specified torque. Resistance alternates between 220 Ω or smaller and
infinity
Tightening torque
CKP sensor bolt (a): 11 N·m (1.1 kgf-m, 8.5 lbf-ft)
“a”
3 2 1
2
1
IBP60B130014-02
Knock Sensor On-Vehicle Inspection

1, (a) AENNTA0E1306022 (08(03)
IMTA0A130042-01 Reference: “Electric Control System Component
Location”
CKP Sensor Inspection 1) Remove intake manifold. (Intake Manifold Removal
AENNTA0E1306021 (08(03)
Reference: “Electric Control System Component and Installation) in Section 1D
Location” 2) Disconnect knock sensor connector.
Reference: “CKP Sensor Removal and Installation” 3) Connect oscilloscope (2) to knock sensor connector
1) Remove CKP sensor. (CKP Sensor Removal and (1) as shown in figure.
Installation) 4) Check that oscilloscope displays waveform (4) like a
2) Check the following points. one shown below when knock sensor bolt (3) is
If faulty condition is found, replace CKP sensor. given a shock by flat-bladed screwdriver or the like.
(CKP Sensor Removal and Installation) If faulty condition is found, replace knock sensor.
• O-ring (1) is free from damage. (Knock Sensor Removal and Installation)
• End face of sensor and sensor plate teeth are free NOTICE
from any metal particles and damage.
If excessive shock is applied to knock
sensor, the knock sensor may be damaged.
When performing on-vehicle inspection,
lightly tap the knock sensor bolt using a flat-
bladed screwdriver.
1 3
IBP60B130013-01
3) Check CKP sensor as follows.

If faulty condition is found, replace CKP sensor.
(CKP Sensor Removal and Installation)
a) Connect battery (1) and ohmmeter (3) to CKP
sensor as shown in figure. 2 1
1
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” 2
between ferromagnetic material (iron) and IMTA0A130024-02
end face of CKP sensor.
3
“a”
1, “a” 2
IFKA0P130031-01
IMTA0A130026-01
Knock Sensor Removal and Installation
AENNTA0E1306023 (08(01)
Reference: “Precautions for Electrical System Work” Engine and Emission Control System Relay
Reference: “Electric Control System Component Inspection
AENNTA0E1306024 (08(03)
Location”
Refer to “Control Relay Inspection” in Section 10B.
Reference: “Knock Sensor On-Vehicle Inspection”
Removal MAF Sensor with IAT Sensor On-Vehicle

1) Remove intake manifold. (Intake Manifold Removal Inspection
AENNTA0E1306025 (08(03)
and Installation) in Section 1D Reference: “Electric Control System Component
2) Disconnect knock sensor connector (1). Location”
3) Remove knock sensor bolt (2) and then remove 1) Connect SUZUKI scan tool to DLC. (Suzuki SDT-II
knock sensor (3) from cylinder block. Connection and Disconnection) in Section 0A
2) Check that parameters “MAF” and “Intake Air
Temperature” displayed on SUZUKI scan tool varies
1 2 depending on vehicle condition. (Scan Tool Data) in
Section 1A
If faulty condition is found, check the following
points.
• MAF sensor: (MAF Sensor with IAT Sensor
3
Inspection)
MAF Sensor with IAT Sensor Removal and

Installation
AENNTA0E1306026 (08(01)
IMTA0A130025-01
Installation Location”
Reverse removal procedure noting the following points. Reference: “MAF Sensor with IAT Sensor On-Vehicle
• Install knock sensor (2) to cylinder block at an angle to Inspection”
top surface (3) of cylinder block as shown in figure.
Knock sensor installation angle Removal
“a”: 0° - 20° to top surface of cylinder block 1) Slide lock lever (1) in arrow direction “1” as shown in
figure.
• Tighten knock sensor bolt (1) to specified torque.
2) Release lock by pushing lock lever in arrow direction
Tightening torque “2”, and then disconnect MAF sensor with IAT
Knock sensor bolt (a): 23 N·m (2.3 kgf-m, 17.0 lbf-ft) sensor connector (2).

Location”
MAF Sensor
1) Remove MAF sensor with IAT sensor (1). (MAF
Sensor with IAT Sensor Removal and Installation)
“2” 2) Check sensor O-ring (2) for damage and
2 deterioration. If faulty condition is found, replace
MAF sensor with IAT sensor. (MAF Sensor with IAT
“1”
3) Arrange 3 new 1.5 V batteries (3) in series, and
check that total voltage is 4.5 to 5.0 V.
4) Connect MAF sensor with IAT sensor to batteries
1 and oscilloscope (4) as shown in figure.
IMTA0A130027-01
3) Remove MAF sensor with IAT sensor screws (1),

and then remove MAF sensor with IAT sensor (2) 1
4 3 2 1
from air cleaner assembly.
2
[a]
4
3
IFRA0B132022-01
5) Check signal waveform changes depending on

amount of blowing air as shown in figures.
IMTA0A130028-01 If faulty condition is found, replace MAF sensor with
IAT sensor. (MAF Sensor with IAT Sensor Removal
Installation and Installation)
Reference: “MAF Sensor with IAT Sensor Inspection” Blowing air [a]: Small
• Tighten MAF sensor with IAT sensor screws (1) to
specified torque.
Tightening torque
MAF sensor with IAT sensor screw (a): 0.7 N·m (
0.07 kgf-m, 0.5 lbf-ft)
IFRA0B132023-01
1, (a)
IMTA0A130030-01
MAF Sensor with IAT Sensor Inspection

AENNTA0E1306027 (08(03)
Blowing air [a]: Large OCV Inspection

AENNTA0E1306028 (08(03)
Location”
Reference: “OCV Removal and Installation”
1) Remove intake OCV or exhaust OCV. (OCV
2) Check OCV as follows.
• Check resistance between terminals of OCV
connector (1).
If check result is not as specified, replace OCV.
(OCV Removal and Installation) in Section 1D
IFRA0B132024-01
OCV resistance
IAT Sensor 6.7 to 7.7 Ω at 20 ° C (68 °F)
1) Remove MAF sensor with IAT sensor (1). (MAF
Sensor with IAT Sensor Removal and Installation)
2) Check sensor O-ring (2) for damage and
deterioration. If faulty condition is found, replace
MAF sensor with IAT sensor. (MAF Sensor with IAT
3) Check that resistance between sensor terminals
varies depending on temperature while blowing hot
air to temperature sensing part (4) of MAF sensor
with IAT sensor using hot air drier (3).
If faulty condition is found, replace MAF sensor with 1
IAT sensor. (MAF Sensor with IAT Sensor Removal
and Installation)
I9T401132006-02
1
• Connect battery to OCV connector (1) as shown in
figure, and check operating sound caused by
5 4 3 2 1 movement of spool valve (2).
2
IFKA0P130034-01
[a] 1
I9T401132007-02
• Check OCV O-ring (1) for damage and

deterioration.
If check result is not as specified, replace O-ring.
2.3 - 2.5
1.1 - 1.2
0.5 - 0.6
0 20 40 60 [b] 1
IBK80P130011-01
IBK80P130014-01
[a]: Resistance 5. Temperature gauge
[b]: Temperature
Electric Load Current Sensor with Battery

3
Temperature Sensor On-Vehicle Inspection
AENNTA0E1306029 (08(03) 1
2
Location”
Electric Load Current Sensor

Using SUZUKI scan tool
2 1
Connection and Disconnection) in Section 0A 4 3
2) Select “Scan Tool Data” mode on SUZUKI scan tool.

3) Check that “Battery Current” value displayed on
SUZUKI scan tool varies depending on electric load
increases. (Scan Tool Data) in Section 1A
IA1J0P130053-02
points.
• Electric load current sensor circuits (power, signal points.
and ground)
• Electric load current sensor circuits (power,
• Battery negative (–) cable ground and signal)
• The following charging system components • Battery negative (–) cable
– Battery (Battery Inspection) in Section 1J • The following charging system components
– Generator (Generator Symptom Diagnosis) in – Battery (Battery Inspection) in Section 1J
Section 1J
– Generator (Generator Symptom Diagnosis) in
– Generator output circuit (Generator Removal Section 1J
and Installation) in Section 1J
– Generator output circuit (Generator Removal
– Generator LIN communication circuit and Installation) in Section 1J
(Generator Removal and Installation) in Section
1J – Generator LIN communication circuit
If electric load current sensor circuit and charging (Generator Removal and Installation) in Section
system are in good condition, replace electric load 1J
current sensor with battery temperature sensor (1). If electric load current sensor circuit and charging
(Electric Load Current Sensor with Battery system are in good condition, replace electric load
Temperature Sensor Removal and Installation) current sensor with battery temperature sensor.
(Electric Load Current Sensor with Battery
Temperature Sensor Removal and Installation)
1
Battery Temperature Sensor
1) Disconnect connector from electric load current
sensor with battery temperature sensor.
2) Connect ohmmeter to electric load current sensor
with battery temperature sensor as shown in figure.
3) Check that resistance between sensor terminals
varies depending on temperature while blowing hot
air to electric load current sensor with battery
temperature sensor using hot air drier (1).
If check result is not as specified, replace electric
IMTA0A130031-01 load current sensor with battery temperature sensor.
(Electric Load Current Sensor with Battery
Without using SUZUKI scan tool Temperature Sensor Removal and Installation)
1) Disconnect connector (1) from electric load current
sensor with battery temperature sensor (3).
2) Using service wire (2), connect electric load current
sensor with battery temperature sensor and
connector.
3) With ignition “ON”, check that voltage varies
depending on electric load.
Removal
1
1) Disconnect electric load current sensor with battery
temperature sensor connector (1).
2) Remove electric load current sensor with battery
temperature sensor nut (2).
3) Remove electric load current sensor with battery
temperature sensor (3) from negative (–) cable.
2 2 1
4 3
3
IGSA0P132012-01
2. Temperature gauge
1
[a] IMTA0A130032-01
Installation
• Tighten electric load current sensor nut (1) to
specified torque.
Tightening torque
Electric load current sensor with battery
temperature sensor nut (a): 14 N·m (1.4 kgf-m,
10.5 lbf-ft)
0 20 40 60 80 90 [b]
68 104 140 176 194
I8C50B130012-03
Electric Load Current Sensor with Battery 1, (a)

Temperature Sensor Removal and Installation
AENNTA0E1306030 (08(01)
Location” IMTA0A130033-01
Specifications
AENNTA0E1307001 (09(t)
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
ECM bracket nut 8.8 0.90 6.5 (T1C001)
Accelerator pedal assembly nut 13 1.3 9.5 (T1C002)
MAP sensor bolt 4 0.41 3.0 (T1C003)
Oil temperature sensor 25 2.5 18.5 (T1C004)
ECT sensor 12 1.2 9.0 (T1C005)
HO2S-1 45 4.6 33.5 (T1C006)
HO2S-2 45 4.6 33.5 (T1C007)
Intake CMP sensor bolt 11 1.1 8.5 (T1C008)
Exhaust CMP sensor bolt 11 1.1 8.5 (T1C009)
CKP sensor bolt 11 1.1 8.5 (T1C010)
Knock sensor bolt 23 2.3 17.0 (T1C011)
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
MAF sensor with IAT sensor screw 0.7 0.07 0.5 (T1C012)
Electric load current sensor with battery (T1C013)
14 1.4 10.5
temperature sensor nut
Reference:
“Caution for Fastener” in Section 00

Special Tool
AENNTA0E1308001 (11(s)
09917M47020
Vacuum pump gauge set
(L1C001)
Engine Mechanical: 1D-1
Engine Mechanical
Engine
General Description
Engine Construction Description
AENNTA0E1401001 (03(01)
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.
Each of the intake camshaft (1) and exhaust camshaft (2) is equipped with a VVT actuator (3) and mounted over the
cylinder head. The camshafts are driven by the crankshaft (4) with a silent type timing chain (5).
The valves are operated by roller type rocker arms (6) driven by intake and exhaust camshafts. And, end of the valve
rocker arms are supported by hydraulic valve lash adjusters (7) which require no valve clearance adjustment.
The engine has realized high combustion efficiency increasing compression ratio.
To establish the high combustion efficiency restricting engine knocking, the cylinder head is improved in the water
cooling efficiency increasing water jacket capacity by an effect of long reach spark plugs and, the cylinder block is
equipped with piston cooling jets (8) for additional piston cooling corresponding to high load running.
Further, combined with DUALJET injector system (9) which allows fuel to be injected in extremely fine mist effective for
stable combustion and cooled EGR system, engine output is improved reducing knocking.
Crankcase ventilation device (10) is located at cylinder block intake side and labyrinth of breather plate in the device
separates oil and blow-by gas. The blow-by gas is sucked in intake manifold through PCV valve (11) and the
separated oil returns in oil pan.
As another ventilation route, a breather hose is provided between the upper part of the cylinder head cover and air
cleaner outlet hose.
Oil temperature sensor (12) transmits the oil temperature for engine idle speed control.
1D-2 Engine Mechanical:
6
3
7
11
12
10
IMTA0A140001-01
VVT System Description

AENNTA0E1401002 (03(01)
The VVT system for this engine controls both the intake and exhaust sides.
This system consists of the following components:
• ECM
• OCVs
• VVT actuators
• Camshafts
The VVT system improves the characteristics of the following factors by continuously varying both intake valve timing
and exhaust valve timing most suitably according to the engine operating condition.
• Engine power
• Fuel efficiency
• Exhaust emission control
System Description
The valve timing is varied when ECM controls each OCV to switch the hydraulic oil path between two circuits, one
leading to the chamber for retarding the timing and the other to the chamber for advancing the timing. Because these
chambers are formed inside the housing of each VVT actuator and separated by a rotor that is directly fixed to the
camshaft, the phase between the housing of VVT actuator and the rotor-camshaft unit can be changed by switching
the hydraulic circuit as described above and thus the valve timing can be accordingly varied.
The VVT system can vary the valve timing within a range of 50° in crankshaft rotational angle for intake camshaft and
40° for exhaust camshaft.
[A] 1 [B] 1
7 2 2 6
7
6 3
3
5 4
4 5
8
12 12
9
11 11
10
40° (variable angle) 50° (variable angle)

Valve lift
Exhaust valve
Intake valve
Crank angle
: Most advanced timing

: Most retarded timing Overlap of valves
IELA0A142003-02
[A]: Intake 4. Oil passage to chamber for timing advancing 9. Oil pump
[B]: Exhaust 5. Oil passage to chamber for timing retarding 10. Oil pan
1. Housing 6. Chamber for timing retarding 11. Control signal from ECM
2. Rotor 7. Chamber for timing advancing 12. OCV
3. Camshaft 8. Oil filter
OCV [A] [B]
The OCV switches and adjusts the hydraulic pressure 3 3
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 250 Hz
to the OCV.
1 2 1 2
4 4
I9P60A141074-01
[A]: Intake 2. Drain

[B]: Exhaust
I5RW0C140034-01
Timing holding
VVT actuator When ECM keeps the duty ratio of the signal sent to the
The VVT actuator has chambers for timing advancing (2) OCV constant, the valve spool of the OCV is held in the
and retarding (3) which are separated by the rotor (5). same position. Because this condition creates no oil
The rotor turns according to change in balance between pressure change in both chambers, the rotor is fixed at a
the hydraulic pressures applied to both chambers. The target position.
sprocket (1) is installed on the housing (4) and the rotor
is secured on the camshaft by bolt. Therefore, the
rotation of the rotor changes the phase between the
sprocket and camshaft.
[A] [B]
5 5
1
1 2
3
I5RW0C140036-01
Timing retarding
When the duty ratio of the signal from the ECM to the
intake OCV is low (or to the exhaust OCV is high), the
2 valve spool of the OCV moves to the right. By this valve
6
3 spool movement, the pressurized oil is led into the timing
6 4 4 retarding chamber and the oil in the timing advancing
I9P60A141069-01
chamber is drained. As a result, the rotor turns in the
[A]: Intake 6. Seal timing retarding direction.
[B]: Exhaust
[A] [B]
Timing advancing
When the duty ratio of the signal from the ECM to the
intake OCV is high (or to the exhaust OCV is low), 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.
I9P60A141075-01
[A]: Intake [B]: Exhaust

Compression Check Reference: “Precautions for Electrical System Work”
AENNTA0E1404001 (06(01)
1) Warm up engine to normal operating temperature. – If the compression pressure does not
2) Stop engine after warming up. increase, one of the following may be
the cause:
3) Set the vehicle in the following conditions.
– Incorrect valve clearance (defective
• For 5M/T model, place gear shift lever in “Neutral”.
valve lash adjuster)
• For AGS model, place select lever in N range.
– Incorrect valve timing
• Apply parking brake.
– Pressure leakage from the valve or
• Block drive wheels. valve seats
4) Remove air cleaner assembly. (Air Cleaner – Pressure leakage from the cylinder
Assembly Removal and Installation) head gasket
5) Remove all ignition coil assemblies and all spark
plugs. (Spark Plug Removal and Installation) in Compression pressure
Section 1H • Standard: 1,300 kPa (13.3 kgf/cm2, 188 psi)
6) Disconnect all fuel injector connectors. • Limit: 1,050 kPa (10.7 kgf/cm2, 152 psi)
7) Install special tools into spark plug hole. • Max difference between any two cylinders: 100
Special tool kPa (1.02 kgf/cm2, 14.5 psi)
(A): 09915M64512 10) Carry out Step 7) – 9) on each cylinder to obtain 4
(B): 09915M64530 readings.
(C): 09915M64550 11) Install spark plugs and ignition coil assemblies.
(Spark Plug Removal and Installation) in Section 1H
(A)
12) Connect fuel injector connectors.
NOTE
(B)
Connect fuel injector connectors to correct
location, referring to “Fuel Injector Removal
(C) and Installation” in Section 1G.
13) Install air cleaner assembly. (Air Cleaner Assembly

Engine Vacuum Check

AENNTA0E1404002 (06(01)
Using SUZUKI Scan Tool
IMTA0A140002-01 1) Warm up engine to normal operating temperature.
8) Depress accelerator pedal all the way to make 2) Set the vehicle in the following conditions.
throttle fully open. • For 5M/T model, place gear shift lever in “Neutral”.
9) Crank engine with fully charged battery, and read the • For AGS model, place select lever in N range.
highest pressure on special tool. • Apply parking brake.
NOTE • Block drive wheels.
• For measuring compression pressure, 3) Turn off all electrical systems and stop engine.
crank engine at least 200 rpm with fully 4) Connect SUZUKI scan tool to DLC. (Suzuki SDT-II
charged battery. Connection and Disconnection) in Section 0A
• Check installation condition of special tool 5) Run engine at specified idle speed. (Idle Speed
if measured compression pressure is Inspection) in Section 1A
lower than the limit. 6) Select “MAP” under “Data List” mode on scan tool.
• If the measured compression pressure of Check manifold absolute pressure displayed on scan
particular cylinder is lower than the limit, tool.
add a bit of engine oil into the cylinder Manifold absolute pressure should be within
through the spark plug hole, and then specification.
repeat the compression check. Manifold absolute pressure specification (at sea
– If the compression pressure increases level)
after adding engine oil, the following 25 – 55 kPa (0.25 – 0.56 kgf-cm2, 3.63 – 7.98 psi,
may be the cause: 0.25 – 0.55 bar) at specified idle speed
– Pressure leakage due to worn piston
rings or worn cylinder
Not Using SUZUKI Scan Tool

• For 5M/T model, place gear shift lever in “Neutral”. (A)
1
• Block drive wheels.
3) Turn off all electrical systems and stop engine.
4) Remove vacuum hose (1) from EVAP canister purge
valve (2).
5) Connect special tool to vacuum hose.
Special tool
(A): 09915M67311 2 1
IMTA0A140004-01
6) Run engine at specified idle speed. (Idle Speed

Inspection) in Section 1A
7) Read vacuum gauge. Vacuum should be within
specification.
Vacuum specification (at sea level)
–76 to –46 kPa (–0.77 to –0.47 kgf/cm2, –11.0 to –
6.67 psi, –0.76 to –0.46 bar)
8) Disconnect special tool from vacuum hose.
9) Connect vacuum hose to EVAP canister purge valve.
Repair Instructions
Air Cleaner Components
AENNTA0E1406001 (12(01)
7
(a)
4 (c)
11
(a)
10
8 9
2 (c)
3
2
1
12
2
6
2
5
(b)
IMTA0A140003-01
1. Air cleaner suction pipe 6. To cylinder head 11. Air cleaner outlet hose
2. To cylinder head cover 7. MAF sensor with IAT sensor 12. To electric throttle body assembly
: For installation, refer to “MAF Sensor with IAT
Sensor Removal and Installation” in Section 1C.
3. Air cleaner suction hose 8. Breather hose : 11 Nm (1.1 kgf-m, 8.5 lbf-ft)
4. Air cleaner assembly 9. To intake manifold : 25 Nm (2.5 kgf-m, 18.5 lbf-ft)
5. Air cleaner suction bracket 10. Breather hose pipe : 1.3 Nm (0.13 kgf-m, 1.0 lbf-ft)
: For installation, refer to “Air Cleaner Assembly
Removal and Installation”.
Air Cleaner Filter Removal and Installation Air Cleaner Assembly Removal and Installation
AENNTA0E1406002 (08(01) AENNTA0E1406004 (08(01)
Reference: “Air Cleaner Components” Reference: “Air Cleaner Components”
Removal
1) Unhook air cleaner case clamps (1). Removal
2) Move air cleaner cap (2) in arrow direction to release 1) Disconnect MAF sensor with IAT sensor connector
hook (3), and then open air cleaner cap. (1). (MAF Sensor with IAT Sensor Removal and
Installation) in Section 1C
3) Remove air cleaner filter from air cleaner case.
2) Loosen air cleaner outlet hose clamp (2).
3) Disconnect air cleaner outlet hose (3) from air
cleaner cap (4).
2 4 1 2 3
3
IMTA0A140007-02 IMTA0A140006-02
4) Remove air cleaner suction pipe bolts (1).

Installation
5) Remove air cleaner suction pipe (2).
Reference: “Air Cleaner Filter Inspection and Cleaning”
Reverse removal procedure. 6) Remove air cleaner bolts (3).
7) Remove air cleaner suction bracket bolt (4), and
Air Cleaner Filter Inspection and Cleaning then remove air cleaner suction bracket (5).
AENNTA0E1406003 (08(03)
Reference: “Air Cleaner Filter Removal and Installation” 3
Inspection
Check air cleaner filter for dirt.
Replace excessively dirty filter. 5
Cleaning
Blow off dust by compressed air from air outlet side of
filter.
2 1
4 5
IMTA0A140009-01
8) Disconnect protrusions (1) of air cleaner assembly

(2) from grommets (3) of intake manifold and remove
air cleaner assembly.
IMTA0A140071-01
1 3
2
3 1
IMTA0A140010-01
9) Remove MAF sensor with IAT sensor from air

cleaner assembly, if necessary. (MAF Sensor with 2 1
IMTA0A140011-01
IAT Sensor Removal and Installation) in Section 1C
• Tighten air cleaner suction pipe bolts (1) and air
Installation cleaner outlet hose clamp (2) to specified torque. (Air
Reverse removal procedure noting the following points. Cleaner Components)
• Install air cleaner suction bracket (1) as follows. 2
a. Install air cleaner suction bracket to cylinder head
and temporarily tighten air cleaner suction bracket
bolt (2).
b. Temporarily tighten air cleaner bolts (3) until
seated.
c. Tighten air cleaner suction bracket bolt to
specified torque. (Air Cleaner Components)
d. Tighten air cleaner bolt to specified torque. (Air
Cleaner Components)
1
IMTA0A140012-01
• Install MAF sensor with IAT sensor to air cleaner

assembly, if removed. (MAF Sensor with IAT Sensor
Electric Throttle Body and Intake Manifold Components

AENNTA0E1406005 (12(01)
4 (a)
(b)
4 6
7
2
1 1
1 1
8
3
1
IMTA0A140013-01
1. To cylinder head. 5. EGR gasket : 25 Nm (2.5 kgf-m, 18.5 lbf-ft)

2. Intake manifold 6. MAP sensor : 11 Nm (1.1 kgf-m, 8.5 lbf-ft)
: For installation, refer to “MAP Sensor Removal and Installation” in Section 1C.
3. Intake manifold gasket 7. Electric throttle body assembly : Do not reuse.
: Do not disassemble.
4. Grommet 8. Electric throttle body gasket
Electric Throttle Body On-Vehicle Inspection Removal

AENNTA0E1406006 (08(03)
Check electric throttle body assembly. (Electric Throttle 1) Disconnect breather hose (1) and engine harness
Body Assembly On-Vehicle Inspection) in Section 1C clamps (2) from air cleaner outlet hose (3).
2) Loosen air cleaner outlet hose clamps (4) and
Electric Throttle Body Assembly Removal and remove air cleaner outlet hose.
Installation 4
AENNTA0E1406007 (08(01)
Reference: “Electric Throttle Body and Intake Manifold 3 2
Components”
Reference: “Electric Throttle Body On-Vehicle
Inspection”
NOTICE
The electric throttle body assembly will lose
its original performance if it is disassembled.
Do not disassemble the electric throttle body 1 4
assembly. If any faulty condition is found, IMTA0A140014-01
replace the electric throttle body assembly 3) Disconnect electric throttle body connector (1) from
with a new one. electric throttle body assembly (2).
4) Remove electric throttle body bolt (3) and nuts (4).
NOTE
5) Remove electric throttle body assembly from intake
After replacing electric throttle body manifold.
assembly, perform “Electric Throttle Control
System Calibration” in Section 1C.
4 3 3, (b) 2, (a)
2 1 1 4
IMTA0A140015-01 IMTA0A140017-01
6) Remove electric throttle body gasket (1) from intake 6) Install air cleaner outlet hose (1) and tighten air
manifold. cleaner outlet hose clamps (2) to specified torque.
(Air Cleaner Components)
7) Connect breather hose (3) and engine harness
clamps (4) to air cleaner outlet hose.
1 4
1
IMTA0A140016-02
Installation
Reference: “Electric Throttle Body Cleaning”
3 2
1) Clean mating surfaces of electric throttle body IMTA0A140018-01
assembly and intake manifold.

2) Install new electric throttle body gasket (1) to intake Electric Throttle Body Cleaning
AENNTA0E1406008 (08(03)
manifold. Reference: “Electric Throttle Body Assembly Removal
and Installation”
Clean electric throttle body assembly referring to
“Throttle Valve Visual Check” under “Electric Throttle
Intake Manifold Removal and Installation

AENNTA0E1406009 (08(01)
Reference: “Electric Throttle Body and Intake Manifold
Components”
1
IMTA0A140016-02 Removal
3) Install electric throttle body assembly (1) to intake 1) Remove air cleaner assembly and air cleaner outlet
manifold. hose. (Air Cleaner Assembly Removal and
4) Tighten electric throttle body bolt (2) and nuts (3) to Installation)
specified torque. 2) Remove electric throttle body assembly. (Electric
Throttle Body Assembly Removal and Installation)
Tightening torque
Electric throttle body bolt (a): 11 N·m (1.1 kgf- 3) Remove ECM from ECM bracket. (ECM Removal
m, 8.5 lbf-ft) and Installation) in Section 1C
Electric throttle body nut (b): 11 N·m (1.1 kgf-m, 4) Disconnect MAP sensor connector (1).
8.5 lbf-ft) 5) Remove fuel feed hose clamp (2).
5) Connect electric throttle body connector (4) to 6) Disconnect the following hoses from intake manifold.
electric throttle body assembly. • Brake booster hose (3)
• EVAP canister purge valve hose (4) 12) Disconnect PCV hose (1) from intake manifold (2),
and then take intake manifold out of engine
2 3 1 compartment.
1
4
IMTA0A140019-01 IMTA0A140022-01
7) With fuel feed hose connected to fuel delivery pipe, 13) Remove intake manifold gasket and EGR gasket
remove fuel delivery pipe together with fuel injectors. from intake manifold. (Electric Throttle Body and
(Fuel Injector Removal and Installation) in Section Intake Manifold Components)
1G
14) Remove MAP sensor from intake manifold, if
8) Remove heater inlet hose (1) and heater outlet hose necessary. (MAP Sensor Removal and Installation)
(2) from heater hose clamp (3). in Section 1C
Installation
• Use new gaskets.
• Tighten each bolt and nut to specified torque.
– Intake manifold bolts (1) and nuts (2)
Tightening torque
Intake manifold bolt (a): 25 N·m (2.5 kgf-m, 18.5
lbf-ft)
3 2 1 Intake manifold nut (b): 25 N·m (2.5 kgf-m, 18.5
IMTA0A140020-01 lbf-ft)
9) Disconnect engine harness clamps (1) from intake
manifold (2). 2, (b)
10) Remove engine harness intake protector bolt (3)

from intake manifold.
11) Remove intake manifold bolts (4) and nuts (5), and
then remove intake manifold from cylinder head.
NOTE
After removal of intake manifold, cover intake
ports using a cloth to prevent foreign
material from entering.
1, (a)
IMTA0A140023-01
5 – MAP sensor screw (MAP Sensor Removal and
2 Installation) in Section 1C
1
– Electric throttle body bolt and nuts (Electric Throttle
Body Assembly Removal and Installation)
– Air cleaner outlet hose clamps (Air Cleaner
Components)
– Air cleaner bolts (Air Cleaner Assembly Removal
3
and Installation)
• Refer to “Fuel Injector Removal and Installation” in
2
Section 1G, and then Install fuel delivery pipe and fuel
4 1
IMTA0A140021-02 injectors.
• Check that all removed parts are back in place.
Cylinder Head Cover Components

AENNTA0E1406010 (12(01)
8
7
(c)
1 (a) 5 (b)
9
IMTA0A140024-01
1. Cylinder head cover bolt No.1 6. Breather hose : 5.0 Nm →10 Nm (0.51 kgf-m
: For tightening order, refer to “Cylinder Head Cover →1.0 kgf-m, 4.0 lbf-ft →7.5 lbf-ft)
2. Cylinder head cover 7. Breather hose pipe : 11 Nm (1.1 kgf-m, 1.0 lbf-ft)
3. Cylinder head cover gasket 8. To air cleaner outlet hose. : Do not reuse.
4. Oil filler cap 9. HO2S-1 bracket
5. Cylinder head cover bolt No.2 : 5.0 Nm →7.5 Nm (0.51 kgf-m →0.76
: For tightening order, refer to “Cylinder Head Cover kgf-m, 4.0 lbf-ft →5.5 lbf-ft)
Cylinder Head Cover Removal and Installation

AENNTA0E1406011 (08(01) 2
Reference: “Cylinder Head Cover Components”
1
Removal
1
1) Remove air cleaner assembly. (Air Cleaner
Assembly Removal and Installation)
2) Remove oil level gauge.
3) Remove the following components from cylinder
5
head cover.
3 4
• Clamps (1) of engine harness IMTA0A140025-03
• Bolts (2) of engine harness protector 4) Remove ignition coil assemblies. (Ignition Coil
• Clamp (3) of HO2S-2 Assembly Removal and Installation) in Section 1H
• HO2S-1 bracket (4) 5) Loosen cylinder head cover bolts No.1 (1) and
• Breather hose (5) cylinder head cover bolts No.2 (2) in numerical order
(“1” – “14”) evenly and gradually.
a) Tighten cylinder head cover bolts No.1 and

2, “13” 2, “14” cylinder head cover bolts No.2 to 5.0 Nm (0.51
1, “2” 1, “8” 1, “12” 1, “10”
kgf-m, 4.0 lbf-ft) in numerical order (“1” – “14”)
evenly and gradually.
b) Retighten cylinder head cover bolts No.2 to 10
1, “6” Nm (1.0 kgf-m, 7.5 lbf-ft) in numerical order (“1”
1, “3” – “2”).
c) Retighten cylinder head cover bolts No.1 to 7.5
Nm (0.76 kgf-m, 5.5 lbf-ft) in numerical order (“3”
– “14”).
1, “5”
Tightening torque
Cylinder head cover bolt No.1* (a): 5.0 Nm →
1, “4” 1, “9” 1, “11” 1, “7” 1, “1” 7.5 Nm (0.51 kgf-m → 0.76 kgf-m, 4.0 lbf-ft → 5.5
IMTA0A140026-01
lbf-ft)
6) Remove cylinder head cover with cylinder head Cylinder head cover bolt No.2* (b): 5.0 Nm → 10
cover gasket. Nm (0.51 kgf-m → 1.0 kgf-m, 4.0 lbf-ft → 7.5 lbf-ft)
7) Remove oil filler cap, if necessary.
1, “7” , (a) 2, “2” , (b) 2, “1” , (b)
Installation 1, “13” , (a) 1, “3” , (a) 1, “5” , (a)
1) Remove oil, old sealant and dust from sealing

surfaces on cylinder head (1) and timing chain cover 1, “9”
(2). , (a)
2) Apply sealant to the mating surface as shown. 1, “12”

, (a)
NOTICE
After having applied sealant, oil leak is
1, “10”
caused when it is not installed immediately. , (a)
Install within 2 minutes after applying
sealant.
1, “11” , (a) 1, “4” , (a) 1, “14” , (a)
“A”: Sealant 99000–31260 (SUZUKI Bond 1, “6” , (a) 1, “8” , (a)

IMTA0A140028-01
No.1217G)
7) Install ignition coil assemblies to cylinder head cover.
2 1 (Ignition Coil Assembly Removal and Installation) in
Section 1H
8) Install the following components to cylinder head
cover.
• Clamps (1) of engine harness
“A” • Bolts (2) of engine harness protector
• Clamp (3) of HO2S-2
• HO2S-1 bracket (4)
• Breather hose (5)
IMTA0A140027-01
2
3) Install new cylinder head cover gasket to cylinder
head cover.
1
4) Install oil filler cap, if removed.
5) Install cylinder head cover to cylinder head. 1
NOTE
When installing cylinder head cover, use care
so that cylinder head cover gasket will not
get out of place or fall off. 5
3 4
6) Tighten cylinder head cover bolts No.1 (1) and IMTA0A140025-03
cylinder head cover bolts No.2 (2) according to the 9) Install oil level gauge.
following procedure. 10) Install air cleaner assembly. (Air Cleaner Assembly
Engine Mounting Components

AENNTA0E1406012 (12(01)
(a)
(b)
(a)
(a)
1 2
1
1
1 1
(c)
(d)
(e)
5
IMTA0A140029-02
1. To vehicle body 4. Front suspension frame : 55 Nm (5.6 kgf-m, 40.5 lbf-ft) : 85 Nm (8.7 kgf-m, 63.0 lbf-ft)
2. Engine left mounting 5. Engine rear torque rod : 65 Nm (6.6 kgf-m, 48.0 lbf-ft) : 93 Nm (9.5 kgf-m, 68.5 lbf-ft)
3. Engine right mounting 6. Engine rear torque rod bracket : 60 Nm (6.1 kgf-m, 44.5 lbf-ft) : Do not reuse.
Engine Left Mounting Removal and Installation 6) Support the area (1) shown in the figure of transaxle
AENNTA0E1406013 (08(01) using jack, etc.
Reference: “Engine Mounting Components”
Removal 1
1) Hoist vehicle. (Vehicle Lifting Points) in Section 0A

3) Remove engine under side cover of left side.
(Engine Under Cover and Engine Under Side Cover
Removal and Installation) in Section 9H IMTA0A140041-01
4) Lower hoist. 7) For 5M/T model, release clutch pipe clamp (1).
5) Remove battery and battery tray. (Battery Removal 8) Remove mounting to transaxle bolt (2).
and Installation) in Section 1J 9) Remove mounting to transaxle nuts (3).
Engine Right Mounting Removal and

3 Installation
AENNTA0E1406014 (08(01)
Reference: “Engine Left Mounting Removal and
Installation”
Removal
2 1 Installation) in Section 9H
IMTA0A140042-01
3) Remove engine under side cover of right side.
10) Remove mounting to body nut (1). (Engine Under Cover and Engine Under Side Cover
11) Remove mounting to body bolts (2). Removal and Installation) in Section 9H
12) Remove engine left mounting (3) from vehicle body. 4) Lower hoist.
5) Support the area (1) shown in the figure of oil pan
2 1 3
using jack, etc.
2
IMTA0A140043-01
IMTA0A140046-01
Installation 6) Remove ground cable bolt (1).

Reverse removal procedure noting the following points. 7) Remove mounting to engine bolt (2).
• Tighten mounting to transaxle bolt (1), mounting to 8) Remove mounting to engine nuts (3).
transaxle nuts (2), mounting to body bolts (3), and
mounting to body nut (4) to specified torque. 2 3
Tightening torque
Mounting to transaxle bolt (a): 55 N·m (5.6 kgf-m,
40.5 lbf-ft)
Mounting to transaxle nut (b): 55 N·m (5.6 kgf-m,
40.5 lbf-ft)
Mounting to body bolt (c): 55 N·m (5.6 kgf-m, 40.5
lbf-ft)
Mounting to body nut (d): 55 N·m (5.6 kgf-m, 40.5
lbf-ft)
1
IMTA0A140045-01
3, (c) 4, (d)
9) Remove mounting to body nut (1).
2, (b)
10) Remove mounting to body bolts (2).
11) Remove engine right mounting (3) from vehicle body.
1, (a) 3, (c)
IMTA0A140044-01
• Refer to “Battery Removal and Installation” in Section

1J, and then install battery tray.
b) Release lock (4) and open hinge cover (5) in

1 2 arrow direction.
5 3
3
IMTA0A140047-01
1 4 2
Installation IMTA0A140030-01
Reverse removal procedure noting the following points. 5) Remove battery and battery tray. (Battery Removal
• Tighten mounting to engine bolt (1), mounting to and Installation) in Section 1J
engine nuts (2), mounting to body bolts (3) and 6) Remove the following bolt, connectors and clumps.
mounting to body nut (4) to specified torque. 5M/T model
Tightening torque • Main fuse box connectors (1)
Mounting to engine bolt (a): 65 N·m (6.6 kgf-m, • Clamp (2)
48.0 lbf-ft)
Mounting to engine nut (b): 65 N·m (6.6 kgf-m, 2
48.0 lbf-ft)
Mounting to body bolt (c): 55 N·m (5.6 kgf-m, 40.5
lbf-ft)
Mounting to body nut (d): 55 N·m (5.6 kgf-m, 40.5
lbf-ft)
4, (d) 3, (c)
1
IMTA0A140031-01
AGS model
• Ground cable bolt (1)
• Electric load current sensor connector (2)
• Main fuse box connectors (3)
2, (b) 1, (a) • Clamps (4)
IMTA0A140048-01
• To main harness connector (5)
• Tighten ground cable bolt to specified torque. (Around
Engine) in Section 9A 4
5
Engine Assembly Removal and Installation
AENNTA0E1406015 (08(01)
Removal
1) Relieve fuel pressure. (Fuel Pressure Relief
Procedure) in Section 1G
2) Disconnect steering lower shaft from pinion shaft.
(Steering Lower Shaft Removal and Installation) in
2 3 1
Section 6B IMTA0A140032-02
3) Disconnect ECM connectors.(ECM Removal and 7) Disconnect the following hoses from vehicle side
Installation) in Section 1C components.
4) Remove engine harness (1) from individual circuit • Brake booster hose (1)
fuse box No.1 (2) as follows. • Fuel feed hose (2)
a) Disconnect connector (3).
• Canister purge hose (3) 19) Remove stabilizer bar joints from stabilizer bar at
each of right and left sides. (Front Suspension
1 2 Frame, Stabilizer Bar and Bushing Removal and
20) Remove exhaust pipe and muffler. (Exhaust Pipe
and Muffler Removal and Installation) in Section 1K
21) Remove compressor drive belt. (Compressor Drive
Belt Removal and Installation) in Section 7B
22) Detach compressor as follows. (Compressor
Assembly Removal and Installation) in Section 7B
a) With discharge hose and suction hose
connected to compressor, detach compressor
3
IMTA0A140033-01 from engine.
8) For 5M/T model, disconnect gear shift control cable b) Suspend detached compressor to vehicle body
and gear select control cable from transaxle. (Gear using string etc.
Shift Control Lever and Cable Removal and
Installation) in Section 5B NOTICE
9) Remove air cleaner suction pipe. (Air Cleaner Filter When compressor is detached, discharge
Removal and Installation) hose and suction hose receiving weight of
compressor and could be damaged.
10) Disconnect magnet clutch lead wire connector.
Suspend detached compressor to vehicle
(Compressor Assembly Removal and Installation) in
body while the compressor is detached.
Section 7B
11) Remove radiator cap. (Cooling System 23) Lower hoist.
Components) in Section 1F
24) Disconnect heater inlet hose (1) and heater outlet
12) Hoist vehicle. (Vehicle Lifting Points) in Section 0A hose (2) from HVAC unit.
13) Remove engine under cover. (Engine Under Cover 25) Disconnect radiator side of radiator inlet hose (3).
26) Disconnect engine side of radiator outlet hose (4).
14) Drain coolant. (Cooling System Draining) in Section
1F 2
15) Drain the following oils, if necessary.

• Engine oil: (Engine Oil and Filter Change) in
Section 1E 1
• Transaxle oil
– 5M/T model: (Manual Transaxle Oil Change) in
Section 5B
– AGS model: (Auto Gear Shift Transaxle Oil
4 3
Change) in Section 5D IMTA0A140035-01
16) Remove front wheels (with tire) at each of right and 27) Hoist vehicle. (Vehicle Lifting Points) in Section 0A
left sides. (Wheel (with Tire) Removal and 28) Support front suspension frame (1), engine (2) and
Installation) in Section 2D transaxle (3) using jack etc.
17) Remove engine under side cover at each of right
and left sides. (Engine Under Cover and Engine 2 3
Under Side Cover Removal and Installation) in
Section 9H
18) Disconnect the following components from steering
knuckle at each of right and left sides.
• Tie-rod end: (Tie-Rod End Removal and
• Suspension arm joint: (Suspension Arm Removal
and Installation) in Section 2B
• Drive shaft: (Front Drive Shaft Assembly Removal 1
and Installation): Front in Section 3A IMTA0A140036-01
29) Remove mounting to engine nuts (1) and bolt (2).

30) Remove mounting to transaxle nuts (3) and bolt (4). 1. Remove air cleaner assembly. (Air
Cleaner Assembly Removal and
3 Installation)
2. Install engine hook (1) (Suzuki genuine
part number: 11851M60B01) to timing
chain cover using bolt (2) and nut (3).
3. Hoist the engine hook installed in step 2.
and one of the following item.
– When not removing transaxle:
Use existing hook (4) of transaxle.
– When removing transaxle:
2 1 4 Attach special tool to cylinder block.
IMTA0A140037-01
Special tool
31) Remove front suspension frame bolts (1) and front
(A): 09910M66810
suspension frame rear bolts (2).
1 1 1 (A)
3 2
4
2 2
IMTA0A140039-01
IMTA0A140038-01
32) Before removing engine, check that all hoses, • Engine harness
electric wires and cables are disconnected from
• Front drive shaft: (Front Drive Shaft Assembly
engine or vehicle.
Removal and Installation): Front in Section 3A
33) Remove engine assembly with transaxle, front
• Engine rear torque rod and engine rear torque rod
suspension frame, drive shafts, steering gear case
bracket: (Engine Mounting Components)
all together from vehicle using the following methods
depending on the situation. • Transaxle:
– 5M/T model: (Manual Transaxle Unit
! WARNING Dismounting and Remounting) in Section 5B
A vehicle or engine assembly may fall and – AGS model: (Auto Gear Shift Unit Dismounting
can cause severe personal injury or death. and Remounting) in Section 5D
Do not get under a vehicle or engine • Clutch cover and disc:
assembly when removing the engine – 5M/T model: (Clutch Cover and Clutch Disc
assembly from the vehicle. Removal and Installation) in Section 5C
– AGS model: (Clutch Cover and Clutch Disc
NOTICE Removal and Installation) in Section 5D
The compressor may be damaged if it hits • Flywheel: (Flywheel Removal and Installation)
against or interferes with other parts.
Suspend the removed compressor in a place Installation
where no damage will be caused during Reverse removal procedure noting the following points.
removal of the engine assembly.
• Refer to the following and install each component, if
removed.
• Hoist vehicle.
– Flywheel: (Flywheel Removal and Installation)
• Lower jack etc.
– Clutch cover and disc:
34) Remove the following components, if necessary.
– 5M/T model: (Clutch Cover and Clutch Disc
NOTE Removal and Installation) in Section 5C
If hoisting engine, according to the following – AGS model: (Clutch Cover and Clutch Disc
procedures. Removal and Installation) in Section 5D
– Transaxle:
– 5M/T model: (Manual Transaxle Unit – Stabilizer bar joint nut: (Front Suspension Frame,
Dismounting and Remounting) in Section 5B Stabilizer Bar and Bushing Removal and
– AGS model: (Auto Gear Shift Unit Dismounting Installation) in Section 2B
and Remounting) in Section 5D – Drive shaft nut: (Front Drive Shaft Assembly
– Engine rear torque rod and engine rear torque rod Removal and Installation): Front in Section 3A
bracket: (Engine Mounting Components) – Suspension arm joint nut: (Suspension Arm
– Front drive shaft: (Front Drive Shaft Assembly Removal and Installation) in Section 2B
Removal and Installation): Front in Section 3A – Tie-rod end nut: (Tie-Rod End Removal and
– Engine harness: (Around Engine) in Section 9A Installation) in Section 6B
• Replace the following bolts, nuts, and clamps, if – Wheel nut: (Wheel (with Tire) Removal and
necessary. And then tighten them to specified torque. Installation) in Section 2D
– Suspension frame – torque rod bolt: (Engine – Ground cable bolt: (Around Engine) in Section 9A
Mounting Components) – Air cleaner suction pipe bolt: (Air Cleaner Filter
– Air cleaner outlet hose clamp: (Air Cleaner Removal and Installation)
Components) – Steering lower shaft bolt: (Steering Lower Shaft
– Air cleaner bolts: (Air Cleaner Assembly Removal Removal and Installation) in Section 6B
and Installation) – Battery tray bolt, battery tray nut and battery band
– Front suspension frame bolts and front suspension nut: (Battery Removal and Installation) in Section
frame rear bolts: (Front Suspension Frame, 1J
Stabilizer Bar and Bushing Removal and • Install all other removed electric wires, connectors
Installation) in Section 2B and hoses to original positions.
– Mounting to engine nuts (1), mounting to engine • Check that all removed parts are back in their places.
bolt (2), mounting to transaxle nuts (3) and Reinstall any necessary parts which have not been
mounting to transaxle bolt (4): reinstalled.
– Right side [A]: (Engine Right Mounting Removal • Refill the following coolant and oils, if drained.
and Installation) – Coolant: (Cooling System Refilling) in Section 1F
– Left side [B]: (Engine Left Mounting Removal – Engine oil: (Engine Oil and Filter Change) in
and Installation) Section 1E
[A] [B] 3
– Transaxle oil
– 5M/T model: (Manual Transaxle Oil Change) in
Section 5B
Change) in Section 5D
• Check for leakage of fuel, coolant, oil and exhaust
gas.
– Fuel leakage: (Fuel Leakage Check Procedure) in
Section 1G
– Coolant leakage: (Engine Cooling System
2 1 4
IMTA0A140040-01 Inspection) in Section 1F
– Compressor mounting bolt: (Compressor Assembly • After installing engine assembly, check front wheel
Removal and Installation) in Section 7B alignment. (Front Wheel Alignment Inspection and
– Exhaust pipe bolt: (Exhaust System Components) Adjustment) in Section 2B
in Section 1K
Timing Chain Cover Components

AENNTA0E1406016 (12(01)
[A] [B]
OIL
1217G
1 (d) 5 1217G
5
1322 (a)
2
(d)
11
OIL
6 (b)
10
12
3 (b)
4
13
3 (b)
14
OIL
9 (c)
7 13
14
8
IMTA0A140055-02
[A]: Crankshaft pulley side 10. Exhaust OCV

: Apply engine oil to O-ring.
[B]: Cylinder block side 11. Gasket
1. Intake OCV 12. Filter
: Apply engine oil to O-ring.
2. Oil pressure switch 13. O-ring
: Apply sealant 99000-32150 to thread.
3. Timing chain cover bolt No.1 14. Dowel Pin
: For tightening order, refer to “Timing Chain Cover Removal and Installation”.
4. Accessory drive belt auto tensioner : 13 Nm (1.3 kgf-m, 9.5 lbf-ft)
5. Timing chain cover : 25 Nm (2.5 kgf-m, 18.5 lbf-ft)
: Apply 99000-31260.
: For details, refer to “Timing Chain Cover Removal and Installation”.
6. Timing chain cover bolt No.2 : 19 Nm →+75° (1.9 kgf-m →+75°, 14.0 lbf-ft →+75°)
: For tightening order, refer to “Timing Chain Cover Removal and Installation”.
7. Oil seal : 11 Nm (1.1 kgf-m, 8.5 lbf-ft)
: Apply engine oil to oil seal lip.
8. Crankshaft pulley : Do not reuse.
9. Crankshaft pulley bolt
: For tightening order, refer to “Crankshaft Front Oil Seal Removal and Installation”.
Crankshaft Pulley Removal and Installation

AENNTA0E1406017 (08(01) 2
Removal
2) Remove front wheel (with tire) of right side. (Wheel
(with Tire) Removal and Installation) in Section 2D
(A) 1
5) Remove accessory drive belt. (Accessory Drive Belt IMTA0A140049-01
Removal and Installation) in Section 1J 7) Remove crankshaft pulley (1).
6) Hold crankshaft pulley (1) using special tool, and If it is hard to remove, use special tool and puller (2).
then loosen crankshaft pulley bolt (2).
Special tool
Special tool (A): 09926M58010
(A): 09917M68222
a. Put matchmark C (5) on crankshaft

1 pulley (4), aligning to matchmark B.
b. Retighten crankshaft pulley bolt, until
matchmark A is aligning to matchmark
2 C.
“a”
(A)
2
IFKA0P140048-01
3
Installation
1) Clean crankshaft pulley (1) and apply engine oil to
1 4
sealing surface (2). IJW60A140097-01
“a”: 75°
• Even if 12 angles of socket (1) is used in

substitution for protractor, matchmarks
can be put on crankshaft pulley bolt.
“a” 2
“b”
1 2
IMTA0A140050-01 “a”
2) Insert crankshaft pulley aligning key groove (1) with

3 3
key (2) on crankshaft.
1 2 1
IJW60A140098-01
“a”: 75° 2. Wind up masking tape.

“b”: 15° 3. Fill in a line for the confirmation of 75°.
a) Hold crankshaft pulley (1), using special tool.

Special tool
(A): 09917M68222
3 b) Tighten crankshaft pulley bolt (2) to 19 Nm (1.9

IMTA0A140051-01 kgf-m, 14.0 lbf-ft).
3. Oil seal c) Retighten crankshaft pulley bolt to 75°.
3) Tighten crankshaft pulley bolt according to the Tightening torque

following procedure. Crankshaft pulley bolt* (a): 19 Nm → +75°
(1.9 kgf-m → +75°, 14.0 lbf-ft → +75°)
NOTE
2, (a)
When specialized tool of angle tightening
(angular torque wrench etc.) cannot be used,
refer to following items.
• Put matchmark A (2) and matchmark B (3)
on crankshaft pulley bolt (1), using
protractor etc. before installing crankshaft
pulley bolt.
• Perform step c) by the following
procedure, and then check position of
matchmarks using mirror etc. (A) 1
IMTA0A140052-01
4) Install accessory drive belt. (Accessory Drive Belt

Removal and Installation) in Section 1J
(A)
5) Install compressor drive belt. (Compressor Drive Belt
Removal and Installation) in Section 7B “a”
6) Start engine and check for oil leakage.

7) Install engine under side cover of right side. (Engine 1
Under Cover and Engine Under Side Cover
8) Install front wheel (with tire) of right side. (Wheel
Crankshaft Front Oil Seal Removal and 2 3

IMTA0A140054-01
Installation
AENNTA0E1406018 (08(01) 3) Install crankshaft pulley. (Crankshaft Pulley Removal
1) Remove crankshaft pulley. (Crankshaft Pulley 4) Tighten mounting to engine bolt and nuts to specified
Removal and Installation) torque, if loosened. (Engine Right Mounting
2) Remove oil seal (1) from timing chain cover (2). Removal and Installation)
Timing Chain Cover Removal and Installation

AENNTA0E1406019 (08(01)
Reference: “Timing Chain Cover Components”
Removal
1) Remove engine assembly from vehicle. (Engine
2) Remove accessory drive belt. (Accessory Drive Belt
2 1
IMTA0A140053-01 3) Remove accessory drive belt auto tensioner.
(Accessory Drive Belt Auto Tensioner Removal and
Installation Installation) in Section 1J
1) Apply engine oil to lip (1) of new oil seal (2). 4) Remove water pump pulley. (Water Pump Removal
2) Install new oil seal to timing chain cover (3) using and Installation) in Section 1F
special tool. 5) Remove crankshaft pulley. (Crankshaft Front Oil
NOTICE Seal Removal and Installation)
6) Remove cylinder head cover. (Cylinder Head Cover
Damage to lip of oil seal may cause oil
leakage.
When performing this step and subsequent 7) Remove oil pan and oil pump strainer. (Oil Pan and
step, do not damage lip of oil seal. Oil Pump Strainer Removal and Installation) in
Section 1E
NOTE 8) Disconnect OCV connectors. (OCV Removal and
If special tool interferes with vehicle body, Installation)
loosen mounting to engine bolt and nuts and 9) Remove timing chain cover No.1 bolts (1) and No.2
then lower the engine slightly. (Engine Right bolt (2), and then remove timing chain cover (3).
Mounting Removal and Installation)
3 2
Special tool 1 1
(A): 09913M70123
Depth
“a”: 2.15 – 2.35 mm (0.0847 – 0.0925 in.)
IMTA0A140056-01
10) Remove the following components from timing chain

cover, if necessary. (A)
• Intake OCV and/or exhaust OCV: (OCV Removal

and Installation)
• Oil seal: (Crankshaft Front Oil Seal Removal and “a”
Installation)
• Filters: (Timing Chain Cover Components) 3 1
• Oil pressure switch: (Oil Pressure Switch Removal 2
and Installation) in Section 1E

11) Disassemble timing chain cover and oil pump, if
necessary. (Oil Pump Assembly Disassembly and ILKC0P140071-01
Reassembly) in Section 1E 5) Install new gasket (1) and new O-ring (2) to timing
chain cover (3).
Installation
Reference: “Timing Chain Cover Inspection” 3
1) Clean mating surfaces of timing chain cover, cylinder

block and cylinder head removing oil, old sealant
and dust.
2) Reassemble timing chain cover and oil pump, if
2
disassembled. (Oil Pump Assembly Disassembly
and Reassembly) in Section 1E
3) Install the following components to timing chain
1
cover, if removed.
ILKC0P140033-01
• Intake OCV and/or exhaust OCV: (OCV Removal
6) Install new O-ring (1) to oil pump (2).
and Installation)
• Filters: (Timing Chain Cover Components)
• Oil pressure switch: (Oil Pressure Switch Removal
and Installation) in Section 1E
4) Replace oil seal (1) with new one in the following 2
cases, and install it using special tool.
• If lip (2) of oil seal has defects and damage.
• When oil seal is removed from timing chain cover
(3).
1
NOTICE IMTA0A140072-01
Damage to lip of oil seal may cause oil 7) Install dowel pins (1) to cylinder block, if removed.
leakage.
When performing this step and subsequent
steps, do not damage lip of oil seal.
NOTE
Refer to “Crankshaft Front Oil Seal Removal
and Installation” for special tool (A) and
mounting depth “a”.
1
IFKA0P140051-01
8) Clean mating surfaces of timing chain cover (1),

cylinder block (3) and cylinder head (2) with cleaning
solvent.
9) Clean gaps (4) of cylinder block and cylinder head
with cleaning solvent particularly.
10) Fill cylinder head and cylinder block gaps with
sealant “A”.
11) Apply sealant “A” to mating surface of timing chain

cover as shown in figure.
2
NOTICE
caused when it is not installed immediately.
sealant. 3
3
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
4
Sealant bead size for timing chain cover
1
Width “a”: 3 mm (0.12 in.)
Height “b”: 2 mm (0.08 in.)
ILKC0P140037-01
2 “A” 1 “A”
15) Tighten timing chain cover bolts No.1 (1) and No.2
(2) in numerical order (“1” – “15”) evenly and
“A” gradually to specified torque.
4
“a” Tightening torque
“b” Timing chain cover bolt No.1* (a): 25 N·m (2.5
4
“A” kgf-m, 18.5 lbf-ft)
“A” 3
Timing chain cover bolt No.2* (b): 25 N·m (2.5
kgf-m, 18.5 lbf-ft)
16) For installation of accessory drive belt auto
ILKC0P140035-02
tensioner, remove “13” bolt and eliminate sealant.
12) Apply engine oil to lip (2) of oil seal (1).
13) Check that dowel pins (3) is not dropped from the 2, (b)
“5”
cylinder block (4). 1, (a) “7” “9” 1, (a)
“6”
4
“3” “2”
“1” “4”
3
“10” “8”
“11”
“12”
“13”
“15” “14”
IMTA0A140057-01
17) Install cylinder head cover. (Cylinder Head Cover

18) Connect OCV connectors. (OCV Removal and
2 1 Installation)
ILKC0P140036-01 19) Install oil pan and oil pump strainer. (Oil Pan and Oil
14) Align straight lines (3) of oil pump inner rotor (1) and Pump Strainer Removal and Installation) in Section
crankshaft sprocket (2), and then install timing chain 1E
cover (4). 20) Install crankshaft pulley. (Crankshaft Front Oil Seal
21) Install water pump pulley. (Water Pump Removal
and Installation) in Section 1F
22) Install accessory drive belt auto tensioner.
24) Install engine assembly to vehicle. (Engine
25) Check front wheel alignment. (Front Wheel If any defect is found, clean them.
Alignment Inspection and Adjustment) in Section 2B • Check O-ring for damage.
If any defect is found, replace OCV with new one.
Timing Chain Cover Inspection • Apply engine oil to O-ring.
AENNTA0E1406020 (08(03)
Reference: “Timing Chain Cover Removal and • Install carefully not to damage O-ring.
Installation” • Tighten OCV bolt to specified torque.
Oil Seal Tightening torque

Check lip (1) of oil seal (2) for crack, deformation, wear, OCV bolt (a): 11 N·m (1.1 kgf-m, 8.5 lbf-ft)
or other damage.
Replace oil seal if any abnormalities are found. 3
2, (a)
(Crankshaft Front Oil Seal Removal and Installation)
1
1 2 4
IMTA0A140060-03
IMTA0A140058-01
Flywheel Removal and Installation
AENNTA0E1406022 (08(01)
Oil Passage of Timing Chain Cover
Removal
Check oil passages (1) and filter (2) for VVT actuator
and oil pressure switch (3). 1) Remove transaxle from engine assembly.
Clean oil passages and filters if clogging or foreign • 5M/T model: (Manual Transaxle Unit Dismounting
material exists. and Remounting) in Section 5B
• AGS model: (Auto Gear Shift Unit Dismounting
1 1
and Remounting) in Section 5D
2) Remove clutch cover and clutch disc.
• 5M/T model: (Clutch Cover and Clutch Disc
• AGS model: (Clutch Cover and Clutch Disc
3) Lock flywheel using special tool as shown in figure.
Special tool
(A): 09924M17811
2 1 2 3
IMTA0A140059-01
OCV Removal and Installation

AENNTA0E1406021 (08(01)
Reference: “Timing Chain Cover Components”
(A)
Removal
1) Disconnect connectors (1).
2) Remove OCV bolts (2).
IMTA0A140067-01
3) Remove intake OCV (3) and/or exhaust OCV (4)
4) Remove flywheel from crankshaft.
from timing chain cover.
5) Using special tool and hydraulic press (1), remove
Installation input shaft bearing (2) from flywheel (3), if necessary.
Reverse removal procedure noting the following points. Special tool
• Check oil passages of OCV and oil passages of timing (A): 09925M96710
chain cover for clogged.
1, (a)
1
(A)
3 2 (A)
IMTA0A140068-01
3) Install clutch cover and clutch disc.

IMTA0A140061-01
Installation • AGS model: (Clutch Cover and Clutch Disc
Reference: “Flywheel Inspection” Removal and Installation) in Section 5D
1) Using special tool and hydraulic press (1), install 4) Install transaxle to engine assembly.
input shaft bearing (2) to flywheel (3), if removed. • 5M/T model: (Manual Transaxle Unit Dismounting
Depth and Remounting) in Section 5B
“a”: 0 – 0.5 mm (0 – 0.01 in.) • AGS model: (Auto Gear Shift Unit Dismounting
Special tool
(A): 09925M96710
Flywheel Inspection
AENNTA0E1406023 (08(03)
1 Reference: “Flywheel Removal and Installation”
2 (A) Visual Inspection

“a”
Check flywheel for damaged, cracked and excessively
2 worn.
3 • If ring gear is damaged, cracked or worn, replace
flywheel.
• If the surface contacting clutch disc is damaged or
excessively worn, replace flywheel.
• If input shaft bearing is damaged or does not rotate
smoothly, replace input shaft bearing.
IMTA0A140062-01
2) Install flywheel according to the following procedure. Flywheel Runout

Check runout of clutch disc contact surface (1).
NOTICE If runout exceeds its limit, replace flywheel.
The flywheel bolts are pre-coated with Flywheel runout
adhesive. If these bolts are reused, they may Limit: 0.2 mm (0.0079 in.)
work loose.
Replace the flywheel bolts with new ones
whenever they are removed.
a) Install new flywheel bolts.

b) Lock flywheel using special tool as shown in
figure.
Special tool
(A): 09924M17811
c) Tighten new flywheel bolts (1) to specified 1
torque.
IMTA0A140063-01
Tightening torque
Flywheel bolt (a): 83 Nm (8.5 kgf-m, 61.5 lbf-
ft)
Timing Chain and Chain Tensioner Components

AENNTA0E1406024 (12(01)
OIL
2
OIL
4
OIL
3
(a)
1
IELA0A142141-02
1. Crankshaft timing sprocket 5. Timing chain tensioner adjuster

: For installation, refer to “Timing Chain and Chain Tensioner Removal and Installation”.
2. Timing chain : 11 Nm (1.1 kgf-m, 8.5 lbf-ft)
3. Timing chain guide : Apply engine oil to sliding surface.
4. Timing chain tensioner
Timing Chain and Chain Tensioner Removal

and Installation 1
AENNTA0E1406025 (08(01) 2
Reference: “Timing Chain and Chain Tensioner
Components” “b” “b” 2
“b” “b”
Removal
NOTICE 4
After the timing chain has been removed, “a” “a”

independently turning the camshaft or
crankshaft beyond the range of “a” and “b”
shown in figure will cause interference
between piston and valve or between the 3
valves themselves, which will cause damage ILKC0P140064-02
to these parts. “a”: 90° 2. Top surface of cylinder head
Avoid turning the camshafts or crankshaft “b”: 15° 3. Key groove
beyond the range of “a” and “b” shown in 1. Matchmark on VVT actuator 4. Matchmark on cylinder block
figure.
NOTE
If it is necessary to rotate the camshaft after
removing timing chain, turn crankshaft
counterclockwise and position the key
groove (1) within an angle of “a” before
rotating the camshaft as shown in figure and Installation

keep the valves from coming in contact with Reference: “Timing Chain and Chain Tensioner
the piston. Inspection”
1) Turn crankshaft counterclockwise and position the
key groove (1) within an angle of “a” shown in figure.
2
“b”
“c”
“a” 2
“b”
“c”
“a”
1
ILKC0P140041-02
“b”: 30° “c”: 90° 2. Matchmark on cylinder block

1
ILKC0P140041-02
“b”: 30° “c”: 90° 2. Matchmark on cylinder block

1) Remove timing chain cover. (Timing Chain Cover
Removal and Installation) 2) Align camshafts and crankshaft at specific position
2) Align camshafts and crankshaft at specific position (cylinder No. 1 with exhaust TDC) as follows.
(cylinder No. 1 with exhaust TDC) as follows. a) Align matchmarks (1) on intake and exhaust VVT
a) Turn crankshaft, and then align matchmarks (1) actuators with top surface (2) of cylinder head.
on intake and exhaust VVT actuators with top b) Align key groove (3) with matchmark (4) on
surface (2) of cylinder head. cylinder block.
b) Align crankshaft timing sprocket key (3) with
matchmark (4) on cylinder block. 1
2
1 2
2
2
4 3
4 3
ILKC0P140042-01
3) Install timing chain while aligning two colored marks

ILKC0P140039-01
(2) of timing chain with timing marks (1) on intake
3) Remove timing chain tensioner adjuster (1). and exhaust VVT actuators.
4) Remove timing chain tensioner (2).
2 2
5) Remove timing chain guide (3).
6) Remove timing chain (4) and crankshaft timing
1
sprocket (5).
ILKC0P140043-01
4) Install crankshaft timing sprocket key (2) to

crankshaft (1).
2 3
5) Align colored mark (4) of timing chain with groove (3)
of crankshaft timing sprocket.
1 5
ILKC0P140040-01
1
3
2 3
2
1 4 4
ILKC0P140044-01 IJKA0P140005-01
6) Install crankshaft timing sprocket (1) together with c) Install timing chain tensioner adjuster (1) with the
timing chain (2) to crankshaft (3). retainer (2) inserted, and then tighten timing
7) Apply engine oil to sliding surface of timing chain chain tensioner adjuster bolts (3) to specified
guide (4) and timing chain tensioner (5). torque and remove the retainer.
8) Install timing chain guide and timing chain tensioner. Tightening torque
Timing chain tensioner adjuster bolt (a): 11
N·m (1.1 kgf-m, 8.5 lbf-ft)
1
1
4
3,(a)
5
3 2
ILKC0P140045-01
9) Check that all colored marks (1) of timing chain are

aligned with timing marks (2) on intake and exhaust
2
VVT actuators and groove (3) of timing sprocket.
IELA0A142071-02
1 1
11) Apply engine oil to timing chain, and turn crankshaft
clockwise 720°, and then check that the following
conditions are satisfied:
2
• Matchmarks (1) on intake and exhaust VVT
actuators are aligned with top surface (2) of
cylinder head.
3
• Crankshaft timing sprocket key (3) is aligned with
matchmark (4) of cylinder block.
NOTE
• Turn crankshaft just 720°. If it is turned
1 only 360°, the matchmarks on VVT
ILKC0P140046-01 actuators will not be aligned with top face
10) Install timing chain tensioner adjuster (1) as follows. of the cylinder head as shown in figure.
a) Release lock cam moving link plate (2) in arrow • After turning crankshaft 720°, colored
direction and push in plunger (3) fully. marks of the timing chain will not be
b) Install a retainer (1.0 – 1.2 mm (0.040 – 0.047 aligned with the timing marks on the VVT
in.) diameter wire or the like) to hole (4) and hold actuators, but this is normal.
plunger in place.
Crankshaft Timing Sprocket

1 Check crankshaft timing sprocket teeth for wear or
2
damage.
2
If abnormality is found, replace crankshaft timing
sprocket.
4 3
ILKC0P140039-01
12) Install timing chain cover and crankshaft pulley.

(Timing Chain Cover Removal and Installation)
I2RH0B140070-01
Timing Chain and Chain Tensioner Inspection Timing Chain

AENNTA0E1406026 (08(03)
Reference: “Timing Chain and Chain Tensioner Removal Check timing chain for wear or damage.
and Installation” If abnormality is found, replace timing chain.
Timing Chain Guide

Check sliding surface of timing chain guide (1) for wear
or damage.
If abnormality is found, replace timing chain guide.
I2RH01140077-01
Timing Chain Tensioner Adjuster

Check that teeth surface (1) is free from damage.
If abnormality is found, replace timing chain tensioner
adjuster.
1
IELA0A142147-02
Timing Chain Tensioner 1

Check sliding surface of timing chain tensioner (1) for
wear or damage.
If abnormality is found, replace timing chain tensioner. IELA0A142075-02
IELA0A142148-02
Camshaft Components
AENNTA0E1406027 (12(01)
9 (a) 10 (a)
8
5 7
6
13
13
OIL
1
11
13
OIL
2
13
(b)
(b) 12
IFKA0P140022-01
1. Intake camshaft 6. Camshaft No.3 housing 11. Intake VVT actuator

: Apply engine oil to sliding surface. : Do not disassemble.
2. Exhaust camshaft 7. Camshaft No.4 housing 12. Exhaust VVT actuator
: Apply engine oil to sliding surface. : Do not disassemble.
3. Camshaft No.1 upper housing 8. Camshaft No.5 housing 13. Dowel pin
4. Camshaft No.1 lower housing 9. Camshaft housing bolt No.1 : 11 Nm (1.1 kgf-m, 8.5 lbf-ft)
: For tightening order, refer to “Camshaft Removal and
Installation”.
5. Camshaft No.2 housing 10. Camshaft housing bolt No.2 : 60 Nm (6.1 kgf-m, 44.5 lbf-ft)
: For tightening order, refer to “Camshaft Removal and
Installation”.
Camshaft Removal and Installation

AENNTA0E1406028 (08(01) 2, “11” 2, “19” 2, “15”
Reference: “Camshaft Components” 2, “7”
1, “2” 2, “12” 2, “20” 2, “16”
2, “8”
Removal
1, “4”
1) Remove timing chain. (Timing Chain and Chain
Tensioner Removal and Installation)
2) Loosen camshaft housing bolts No.1 and No.2 in
numerical order (“1” – “20”) evenly and gradually.
1, “3”
2, “10” 2, “18” 2, “14” 2, “6”

1, “1”
2, “9” 2, “17” 2, “13” 2, “5”
ILKC0P140047-01
3) Remove camshaft No.1 upper housing (1) and

camshaft No.2 – No.5 housings (2). 1
4) Remove intake camshaft (3) and exhaust camshaft

(4).
1 2 3
2
ILKC0P140048-01
5) Remove camshaft No.1 lower housing (1) and dowel IJW60P140050-02
pins (2), if necessary.

Installation
1 1) Install intake and/or exhaust VVT actuator to
2
camshaft as follows, if removed.
a) Hold hexagonal section of camshaft using vice.
b) Install VVT actuator (1) and tighten VVT actuator
2 bolt (2) to specified torque.
Tightening torque
VVT actuator bolt (a): 60 N·m (6.1 kgf-m, 44.5
lbf-ft)
IFKA0P140024-01 2, (a)
6) Remove intake and/or exhaust VVT actuator from
camshaft as follows, if necessary.
a) Hold hexagonal section of camshaft using vice.
b) Remove VVT actuator bolt (1) and remove VVT
actuator (2).
1
NOTICE
The VVT actuator will lose its original
performance if it has been disassembled and
reassembled.
Do not disassemble and repair the VVT
actuator. If any faulty condition is found,
replace the VVT actuator with a new one.
IJW60P140051-02
2) Install camshaft No.1 lower housing (1) and dowel

pins (2), if removed.
1 2, “10” , (b) 2, “2” , (b) 2, “6” , (b)

2 2, “14” , (b)
1, “19” , (a) 2, “9” , (b) 2, “1” , (b) 2, “5” , (b) 2, “13” , (b)
1, “17” , (a)
2
IFKA0P140024-01 1, “18” , (a)

3) Apply engine oil to sliding surfaces of camshafts,
2, “11” , (b) 2, “3” , (b) 2, “7” , (b) 2, “15” , (b)
and then set intake and exhaust camshafts to 1, “20” , (a)
cylinder head. 2, “12” , (b) 2, “4” , (b) 2, “8” , (b) 2, “16” , (b)
ILKC0P140049-01
4) Check character (1), number (2) and arrow mark (3)
6) Install timing chain. (Timing Chain and Chain
on each camshaft housing (4), and then set
camshaft No.2 – No.5 housings to specified places
cylinder head.
Camshaft Inspection
AENNTA0E1406029 (08(03)
Reference: “Camshaft Removal and Installation”
1 2
Cam Wear
Using a micrometer, measure cam height “a”.
If measured height is below its limit, replace camshaft.
Cam height “a” of camshaft
3 4
Cam height Standard Limit
37.790 – 37.950 mm 37.690 mm
Intake cam
IMTA0A140070-01
(1.4878 – 1.4940 in.) (1.4839 in.)
37.376 – 37.536 mm 37.276 mm
1. I: Intake camshaft housing Exhaust cam
E: Exhaust camshaft housing (1.4715 – 1.4777 in.) (1.4676 in.)
2. Position from timing chain side
3. Point arrow to timing chain side
5) Tighten camshaft housing bolts No.1 and No.2 “a”

according to the following procedure.
a) Tighten camshaft housing bolts No.1 (1)
temporarily.
b) Tighten camshaft housing bolts No.1 and No.2
(2) to specified torque in numerical order (“1” –
“20”) evenly and gradually.
Tightening torque
IFKA0P140026-01
Camshaft housing bolt No.1* (a): 11 Nm (1.1
kgf-m, 8.5 lbf-ft)
Camshaft Runout
Camshaft housing bolt No.2* (b): 11 Nm (1.1
Set camshaft between two “V” blocks and measure its
kgf-m, 8.5 lbf-ft)
runout using a dial gauge.
If measured runout exceeds limit, replace camshaft.
Camshaft runout
Limit: 0.015 mm (0.00059 in.)
IFKA0P140028-01
IFKA0P140027-01
4) Install camshaft housings referring to Step 4) – 5) in
“Installation” under “Camshaft Removal and
Camshaft Journal Wear Installation”.
Check camshaft journals and camshaft housings for 5) Leave camshaft housing installed for at least 3
pitting, scratches, wear or damage. minutes.
If any defect is found, replace camshaft and/or cylinder 6) Remove camshaft housing.
head with camshaft housings as assembly.
7) Using scale (2) on gauging plastic envelope,
NOTICE measure gauging plastic (1) width at the widest
point.
Attempting to repair sliding surface of
camshaft housing by scraping etc. will Camshaft journal clearance
adversely affect lubrication. Item Standard Limit
Do not repair sliding surface of camshaft Camshaft 0.030 – 0.060 mm 0.08 mm
housing. housing No.1 (0.0012 – 0.0023 in.) (0.0031 in.)
0.051 – 0.087 mm 0.10 mm
Others
(0.0020 – 0.0034 in.) (0.0039 in.)
I9T401142013-01
Camshaft Journal Clearance
NOTE
• Do not apply engine oil to camshaft IFKA0P140029-01
housing and camshaft journal when oil If measured camshaft journal clearance exceeds
clearance checks. limit, measure camshaft journal diameter and
• Do not turn camshaft with piece of gauging camshaft journal housing bore diameter as follows.
plastic placed. a) Remove camshafts and install camshaft
housings to cylinder head. (Camshaft Removal
1) Clean camshaft housings and camshaft journals.
and Installation)
2) Install camshafts to cylinder head.
b) Measure camshaft journal diameter and
3) Place a piece of gauging plastic (1) to full width of camshaft journal housing bore diameter.
camshaft journal parallel to camshaft, avoiding oil If measured diameters are not as specified, replace
hole. corresponding camshaft or cylinder head and
camshaft housings.
Camshaft journal diameter
Item Standard
Intake and Exhaust side 29.006 – 29.021 mm
No.1 housing [A] (1.1420 – 1.1425 in.)
22.934 – 22.955 mm
Others
(0.9030 – 0.9037 in.)
2) Measure clearance between signal rotor (1) and

[A] intake CMP sensor (2) and between signal rotor and
exhaust CMP sensor (3).
If measured clearance are not as specified, replace
camshaft and/or cylinder head.
Clearance “a” between signal rotor and CMP
sensor
Standard: 0.2 – 1.5 mm (0.008 – 0.059 in.)
IFJA0P140016-01 2
Camshaft journal housing bore diameter

1
Item Standard
Intake and Exhaust side 29.051 – 29.066 mm “a”
No.1 housing (1.1438 – 1.1443 in.)

23.006 – 23.021 mm
Others 3
(0.9058 – 0.9063 in.)
“a”
IFKA0P140095-01
VVT Actuator
• Check VVT actuator (1) for wear or damage.
Replace VVT actuator if any defect is found.
• Install VVT actuator to camshaft. Hold hexagonal
section of camshaft stationary using spanner or
adjustable wrench.
Check that VVT actuator cannot be turned by hand.
Replace VVT actuator if it can be turned by hand.
IFKA0P140030-01
Camshaft Thrust Clearance

1) Install intake and exhaust camshafts, and then
measure intake and exhaust camshaft housing
thrust clearance using a dial gauge.
1 1
If measured clearance exceeds limit, replace
camshaft and/or cylinder head with camshaft
housings as assembly.
IFKA0P140033-01
Camshaft thrust play
Standard: 0.10 – 0.30 mm (0.0039 – 0.0118 in.) Signal Rotor
Limit: 0.40 mm (0.0157 in.) Check signal rotor (1) for crack and damage.
If any defect is found, replace camshaft.
IFKA0P140035-01
IFKA0P140032-01
Valve and Cylinder Head Components

AENNTA0E1406030 (12(01)
OIL
17 (c) 19
OIL
14 (a)
18
11 (b)
13
OIL
11 (b)
3
OIL
2
4
5
6
OIL
7
8 15
12 (c)
OIL
9
15 16
OIL
10
ILKC0P140074-01
1. Valve rocker arm 13. Cylinder head

: For applying engine oil, refer to “Valve and
Cylinder Head Removal and Installation”.
2. Valve lash adjuster 14. Cylinder head bolt
: Apply engine oil. : Check cylinder head bolt for deformation to reusing. (Cylinder Head Bolt Inspection)
: Apply engine oil to bolt thread.
: For tightening order, refer to “Valve and Cylinder Head Removal and Installation”.
3. Valve cotter 15. Dowel pin
4. Valve spring retainer 16. Cylinder head gasket
5. Intake valve spring 17. Water jacket plug (M12)
6. Exhaust valve spring 18. Water jacket plug gasket
7. Valve stem seal 19. Valve guide
: Apply engine oil to valve stem seal lip. : Apply engine oil to sliding surface.
8. Valve spring seat : 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°)
9. Intake valve : 13 Nm (1.3 kgf-m, 9.5 lbf-ft)
: Apply engine oil to sliding surface.
10. Exhaust valve : 25 Nm (2.5 kgf-m, 18.0 lbf-ft)
11. Oil gallery plug : Do not reuse.
: Check mounting surface for foreign objects.
12. Water jacket plug
Valve and Cylinder Head Removal and 2) Remove spark plugs. (Spark Plug Removal and
Installation Installation) in Section 1H
AENNTA0E1406031 (08(01)
Reference: “Valve and Cylinder Head Components”
and Installation)
Removal 4) Remove water inlet pipe. (Cooling System
1) Remove engine assembly from vehicle. (Engine
Assembly Removal and Installation) 5) Remove exhaust manifold. (Exhaust Manifold
Removal and Installation) in Section 1K
6) Remove EGR valve. (EGR Valve Removal and

Installation) in Section 1B 1
7) Remove accessory drive belt auto tensioner.

8) Remove oil pan and oil pump strainer. (Oil Pan and
Oil Pump Strainer Removal and Installation) in
Section 1E
9) Remove cylinder head cover. (Cylinder Head Cover
Tensioner Removal and Installation) 1
IFKA0P140059-01
12) Remove intake and exhaust camshafts. (Camshaft
Removal and Installation) 16) Remove cylinder head bolts in numerical order (“1” –
“10”) evenly and gradually.
13) Remove camshaft No.1 lower housing. (Camshaft
Removal and Installation) NOTE
14) Remove valve rocker arms (1). Use a 12-point and 10 mm socket wrench.
1
“3” “5” “10” “8” “2”
1
“1” “7” “9” “6” “4”
IFKA0P140058-01
IFKA0P140060-01
15) Remove valve lash adjusters (1). 17) Remove cylinder head (1), cylinder head gasket (2)
NOTE and dowel pins (3) from cylinder block.
Immerse removed valve lash adjusters in

clean engine oil and keep them as they are
until their reinstallation to prevent entering of 1
air in the adjusters.

2
3
IMTA0A140064-01
18) Remove the following components from cylinder

head, if necessary.
• Fuel injectors: (Fuel Injector Removal and
Installation) in Section 1G
• Thermostat assembly
– Thermostat: (Thermostat Removal and
Installation) in Section 1F
– Thermostat case: (Cooling System f) Repeat Step e).

Tightening torque
• Intake and exhaust CMP sensor: (CMP Sensor Cylinder head bolt* (a): 20 Nm → 40 Nm →
Removal and Installation) in Section 1C +60° → +60° (2.0 kgf-m → 4.1 kgf-m → +60° →
+60°, 15.0 lbf-ft → 29.5 lbf-ft → +60° → +60°)
Installation
NOTE “8”,(a) “6”,(a) “1”,(a) “3”,(a) “9”,(a)
If cylinder head bolt is reused, refer to

“Cylinder Head Bolt Inspection”, and then
check the bolt for deformation.
1) Clean mating surfaces of cylinder head and cylinder

block. Remove oil, old gasket and dust from mating
surfaces.
2) Install dowel pins (2) to cylinder block.
3) Install new cylinder head gasket (1) to cylinder block.
“10”,(a) “4”,(a) “2”,(a) “5”,(a) “7”,(a)

IFKA0P140062-01
5) Apply engine oil to valve lash adjusters (1), and then

1
install them to cylinder head.
IFKA0P140061-02
4) Install cylinder head to cylinder block according to

the following procedure.
a) Turn crankshaft counterclockwise and position
the key groove (1) within an angle of “a”.
2
“b”
“c”
1
“a” IFKA0P140059-01
6) Apply engine oil to following points of valve rocker

arms.
1
ILKC0P140050-01 • Roller (1).
“b”: 30° “c”: 90° 2. Matchmark on cylinder block • Between roller and body (2).
• Contact surface (3) of intake and exhaust valve.
b) Apply engine oil to thread portion of cylinder
• Contact surface (4) of valve lash adjuster.
head bolts.
c) Tighten cylinder head bolts to 20 Nm (2.0 kgf-m, 4 1
15.0 lbf-ft) in numerical order (“1” – “10”) as 2
shown.
NOTE
Use a 12-point and 10 mm socket wrench.
3
d) In the same numerical order as in Step c),
retighten cylinder head bolts to 40 Nm (4.1 kgf-
m, 29.5 lbf-ft).
e) In the same numerical order as in Step c),
IFKA0P140063-01
retighten cylinder head bolts to 60°.
7) Install valve rocker arms (1) to cylinder head.
22) Check front wheel alignment. (Front Wheel

1 Alignment Inspection and Adjustment) in Section 2B
Valve Rocker Arm Inspection

AENNTA0E1406032 (08(03)
Check valve rocker arm roller (1) for smooth rotation and
arm body for wear, rust, distortion or other damage.
If any abnormality is found, replace the valve rocker
arm(s).
1
IFKA0P140058-01
8) Install camshaft No.1 lower housing. (Camshaft

IELA0A142087-02
9) Install intake and exhaust camshafts. (Camshaft
Cylinder Head Disassembly and Reassembly
10) Install timing chain. (Timing Chain and Chain AENNTA0E1406033 (08(02)
Tensioner Removal and Installation) Disassembly
11) Install timing chain cover. (Timing Chain Cover Reference: “Valve and Cylinder Head Removal and
Removal and Installation) Installation”
12) Install cylinder head cover. (Cylinder Head Cover NOTICE
If any of the parts listed below is reinstalled
13) Install oil pan and oil pump strainer. (Oil Pan and Oil into a position different from the original
Pump Strainer Removal and Installation) in Section position, engine problems could occur.
1E If these parts are to be reused, keep them in
14) Install the following components to cylinder head, if numerical order so that they can be
removed. reinstalled in their original positions.
• Fuel injectors: (Fuel Injector Removal and • Valve cotters
Installation) in Section 1G • Valve spring retainers
• Thermostat assembly • Intake valve springs
– Thermostat: (Thermostat Removal and • Exhaust valve springs
Installation) in Section 1F
• Valve spring seats
– Thermostat case: (Cooling System
• Intake valves
• Exhaust valves
• Intake and exhaust CMP sensor: (CMP Sensor
NOTE
15) Install water inlet pipe. (Cooling System
Components) in Section 1F Intake valve (1) and exhaust valve (3), intake
valve spring (2) and exhaust valve spring (4)
16) Install intake manifold. (Intake Manifold Removal and
are not identical. Distinguish them before
Installation)
installing.
17) Install exhaust manifold. (Exhaust Manifold Removal
and Installation) in Section 1K 1
18) Install EGR valve. (EGR Valve Removal and 3

19) Install spark plugs. (Spark Plug Removal and 2
Installation) in Section 1H 4
20) Install accessory drive belt auto tensioner.

21) Install engine assembly. (Engine Assembly Removal
IFKA0P140064-01
and Installation)
1) Using special tools (A) and (B), compress valve

spring and then remove valve cotters (1) also using
special tool (C).
1
Special tool
(A): 09916M14510
(B): 09916M14530
2
(C): 09916M84511
(B)
(A) IFKA0P140066-01
5) Using special tool, remove valve guide from

combustion chamber side to valve spring side.
! CAUTION
If cylinder head is heated, may be hot enough
to cause burns.
Wear safety gloves.
NOTE
IFKA0P140065-01 Heating cylinder head to 80 to 100 °C (176 to
212 °F) may facilitate valve guide removal.
Special tool
(A): 09916M44310
(A)
I9T401142010-01
2) Release special tools, and remove spring retainer

and valve spring.
3) Remove valve from combustion chamber side.
4) Remove valve stem seal (1) and valve spring seat IFKA0P140067-01
(2).
Reassembly
Reference: “Valve and Valve Guide Inspection”
Reference: “Cylinder Head Inspection”
Reference: “Valve Spring Inspection”
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 tools to remove burrs and [A]
make the hole truly round.

Special tool (A)
(A): 09916M34542
(B): 09916M37320 (B)
“a”
IFKA0P140068-01
[B]
I2RH0B140096-01
2) Using special tools, install new valve guide to

cylinder head as follows. (C)
NOTE (D)
Intake and exhaust valve guides are identical.
Special tool “a”
(A): 09916M57330
(B): 09916M56011 IFKA0P140069-01
(C): 09916M43211 3) Ream valve guide bore with special tools.

(D): 09916M43220
NOTICE
a) Uniformly heat cylinder head to a temperature of
80 to 100 °C (176 to 212 °F) so that it will not be The engine could be damaged if shavings
distorted, and drive new valve guide into its hole remain inside the valve guide hole after
with special tools. reaming it.
Thoroughly remove shavings from the
! CAUTION reamed hole.
If cylinder head is heated, may be hot enough Special tool
to cause burns. (A): 09916M34542
Wear safety gloves. (B): 09916M34570
b) Install new valve guide until special tool contacts

cylinder head.
After installation, check that valve guide
protrudes from cylinder head by specified
dimension “a”.
Valve guide protrusion “a”
Intake [A]: 11.0 – 11.5 mm (0.4331 – 0.4527 in.)
Exhaust [B]: 14.7 – 15.2 mm (0.5788 – 0.5984
in.)
I2RH0B140096-01
4) Install valve spring seat to cylinder head.

5) Apply engine oil to new valve stem seal (1).
6) Set valve stem seal to special tools.
7) Install valve stem seal to valve guide by pushing
special tools by hand.
NOTICE Check seating position of the cotters

If the valve stem seal is installed by striking carefully when fitting them. Tapping of stem
the special tool with a hammer or other end with plastic hammer after fitting cotters
similar tool, the valve stem seal may be will help confirmation of their seating.
damaged, causing oil to get down past the
seal. NOTE
Be sure to push the special tools only by Applying of small amount of grease to valve
hand to force the valve stem seal into cotters may facilitate the fitting.
position.
Special tool
Special tool (A): 09916M14510
(A): 09917M98221 (B): 09916M14530
(B): 09916M57330 (C): 09916M84511
(B)
(A)
I2RH0B140101-01
IFKA0P140070-01
Valve and Valve Guide Inspection
AENNTA0E1406034 (08(03)
8) Check that valve stem seal is properly fixed to valve Reference: “Cylinder Head Disassembly and
guide. Reassembly”
9) Apply engine oil to valve stem seal, valve guide bore
and valve stem. Valve Guide
10) Install valve to valve guide. Valve stem-to-guide clearance
Using a micrometer and bore gauge, take diameter
11) Install valve springs and valve spring retainers.
readings on valve stems and guides to check stem-to-
Position each valve spring (1) with its large diameter
guide clearance.
end (3) to the bottom (valve spring seat side) and the
Take reading at more than one place along the length of
small diameter end (2) facing the top, and then put
each stem and guide.
valve spring retainer.
If clearance exceeds limit, replace valve and valve
[a]
guide.
2
Valve stem outside diameter
1 Intake: 4.965 – 4.980 mm (0.1955 – 0.1960 in.)
Exhaust: 4.940 – 4.955 mm (0.1945 – 0.1950 in.)
3
[b]
IA1J0P140113-02
[a]: Valve spring retainer side [b]: Valve spring seat side
12) Using special tools, compress valve spring and fit

two valve cotters (1) into groove in valve stem.
IMKC0A140002-01
NOTICE
Valve guide inside diameter
Insufficient seating of valve cotters between
Intake & Exhaust: 5.000 – 5.012 mm (0.1969 – 0.1973
retainer and valve stem neck may cause
in.)
coming off of the cotters after engine start.
Valve protrusion “a”

Standard
Intake: 49.62 – 50.42 mm (1.9536 – 1.9850 in.)
Exhaust: 40.32 – 41.12 mm (1.5875 – 1.6188 in.)
1
“a”
IMKC0A140003-01
Valve stem-to-valve guide clearance

3
Standard Limit
Intake 0.020 – 0.047 mm 0.070 mm
(0.0008 – 0.0018 in.) (0.0028 in.)
Exhaust 0.045 – 0.072 mm 0.090 mm
(0.0018 – 0.0028 in.) (0.0035 in.)
Valve stem end deflection

If bore gauge is not available, check end deflection of
valve stem with a dial gauge instead.
Move valve stem end in directions (1) and (2) to 2
measure end deflection.

IA1J0P140160-01
If deflection exceeds its limit, replace valve and valve
guide. 3. Valve guide
Valve stem end deflection limit Valve head radial runout

Intake: 0.14 mm (0.0055 in.) Check each valve for radial runout with a dial gauge and
Exhaust: 0.18 mm (0.0071 in.) “V” block. To check runout, rotate valve slowly.
If runout exceeds its limit, replace valve.
Valve head radial runout
Standard Limit
Intake 0 – 0.05 mm (0 – 0.0019 in.) 0.08 mm
Exhaust 0 – 0.03 mm (0 – 0.0011 in.) (0.0031 in.)
I8V101140017-01
Valve
Visual inspection
1) Remove all carbon deposits from valve (1) and valve
seat (2).
I2RH01140136-01
NOTICE
Seating contact width
Metal surfaces can be scuffed or nicked Create contact pattern on each valve in the usual
when removing carbon deposits with sharp- manner, i.e., by giving uniform coat of marking
edged tool. compound to valve seat and by rotating and tapping seat
Do not use any sharp-edged tool to scrape with valve head. Valve lapper (tool used in valve lapping)
off carbon deposits from engine parts. must be used.
Pattern produced on seating surface of valve must be a
continuous ring without any break, and the width of
• Check each valve for wear, burn or distortion at its pattern must be within specified range.
face and valve stem and, if necessary, replace it.
Standard seating width revealed by contact pattern
• Measure valve protrusion “a”.
on valve face
If measured length is out of standard value,
Intake & Exhaust: 1.0 –1.4 mm (0.040 – 0.055)
replace valve.
Valve seat repair NOTICE

If a valve seat does not contact its valve uniformly or Metal surfaces can be scuffed or nicked
shows width of seating contact out of specified range, when removing carbon deposits with sharp-
repair it by cutting, if necessary, and regrinding and then edged tool.
finish it by lapping. Do not use any sharp-edged tool to scrape
1) Intake valve seat: off carbon deposits from engine parts.
Use valve seat cutters (1) to make three cuts as
shown in figure. Three cutters must be used: the 1st
for making 15° angle, the 2nd for making 70° angle,
and 3rd for making 45° angle. The 3rd cut (45°) must
be made to produce desired seat width.
Seat width for intake valve seat
“a”: 1.0 – 1.4 mm (0.040 – 0.055 in.)
2) Exhaust valve seat:
Use valve seat cutters to make two cuts as shown 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 (0.040 – 0.055 in.)
ILJA0A143125-01
• Check cylinder head for crack on intake and exhaust

ports, combustion chambers and head surface.
Cylinder Head Flatness

1
Using straightedge (1) and feeler gauge (2) to 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
IDLA0A140048-01 abrasive paper on surface plate and rubbing gasket
surface against paper to grind high spots.
[A] [B] If it is impossible to correct cylinder head distortion,
replace cylinder head.
“a” “b” NOTE

“e”
Distorted mating surface of cylinder head
“d” “d” and cylinder head gasket causes combustion
“c” “c”
gas and/or coolant leakage, overheating and
ILKC0P140072-01
reduced power output.
[A]: Intake “c”: 15° “e”: 70°
Distortion of mating surface of cylinder head and
[B]: Exhaust “d”: 45°
cylinder head gasket
Limit: 0.03 mm (0.0012 in.)
3) Valve lapping:
Lap valve on seat in two steps, first with coarse size
lapping compound applied to face and the second
with fine-size compound, each time using valve
lapper according to usual lapping method.
Cylinder Head Inspection

AENNTA0E1406035 (08(03)
Reference: “Cylinder Head Disassembly and
Reassembly”
Combustion Chamber
• Remove all carbon deposits from all combustion
chambers.
[A]
[B]
IFKA0P140074-01
IFKA0P140071-01
[A]: Intake side [B]: Exhaust side
Cylinder Head Bolt Inspection

AENNTA0E1406036 (08(03)
NOTE
If cylinder head bolt is reused, check thread
diameter of cylinder head bolt (1) for
deformation as follows and replace it with
new one if thread diameter difference
exceeds limit.
Measure each thread diameter of cylinder head bolt “c”

IFKA0P140072-01 at “a” and “d” at “b” using micrometer (3).
Then calculate difference in diameters (“c” – “d”).
Manifold Seating Surface Flatness If it exceeds limit, replace cylinder head bolt with new
Using straightedge (1) and feeler gauge (2) to check one.
flatness of manifold seating surface.
Cylinder head bolt diameter difference (deformation)
If measured value exceeds its limit, correct seating
Limit (“c” – “d”): 0.2 mm (0.008 in.)
surface or replace cylinder head.
Distortion of seating face of intake manifold and 1
“c” “d”
exhaust manifold on cylinder head
Limit: 0.05 mm (0.0020 in.)
1
“a”
“b”
I9P60A141079-01
2 2
IFKA0P140073-01
I9T401142032-01
“a”: 70 mm (2.76 in.) “b”: 105 mm (4.13 in.) 2. Thread
Valve Spring Inspection

AENNTA0E1406037 (08(03)
Reference: “Cylinder Head Disassembly and
Reassembly”
Valve Spring Visual Inspection Limit: 113 N (11.5 kgf, 25.4 lbf)
Check each valve spring for cracks or other damage.
If any abnormality is found, replace valve spring.
Valve Spring Free Length and Preload

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
I9T401142035-01
decreased seating pressure.
Spring Squareness
Valve spring free length “a”
Use a square and surface plate to check each spring for
Standard
squareness in terms of clearance between the third turn
Intake: 55.15 mm (2.171 in.)
from top of valve spring and the square as shown. If
Exhaust: 44.83 mm (1.765 in.)
clearance exceeds limit, replace valve springs.
Intake valve spring squareness “a”
Limit: 2.41 mm (0.0948 in.)
Exhaust valve spring squareness “a”
Limit: 1.96 mm (0.0771 in.)
“a”
“a”
I9T401142034-01
Intake valve spring preload when compressed to

43.2 mm (1.701 in.)
Standard: 120 – 140 N (12.2 – 14.2 kgf, 27.0 – 31.5 lbf)
Limit: 108 N (11.0 kgf, 24.3 lbf)
Exhaust valve spring preload when compressed to
33.9 mm (1.335 in.) I9P60A141009-01
Standard: 126 – 146 N (12.8 – 14.9 kgf, 28.3 – 32.8 lbf)
Piston, Piston Ring and Connecting Rod Components

AENNTA0E1406038 (12(01)
OIL
1
OIL
2
OIL
3
OIL
5
OIL
11 9
OIL
11 4
OIL
8
9
OIL 6
10 (a)
IFKA0P140075-01
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”.
2. 2nd ring 9. Piston pin circlip
: For assembly, refer to “Piston, Piston Ring and Connecting Rod : For assembly, refer to “Piston, Piston Ring and Connecting Rod
Disassembly and Reassembly”. Disassembly and Reassembly”.
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. (Piston Pin
Disassembly and Reassembly”. and Connecting Rod Inspection)
: 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”.
4. Piston 11. Dowel pin
: For assembly, refer to “Piston, Piston Ring and Connecting Rod
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.
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”.
Piston, Piston Ring and Connecting Rod • Pistons

Removal and Installation • Connecting rods
AENNTA0E1406039 (08(01)
NOTICE • Connecting rod bearing caps
If any of the parts listed below is reinstalled • Connecting rod bearings
into a position different from the original
Removal
position, engine problems could occur.
Reference: “Piston, Piston Ring and Connecting Rod
If these parts are to be reused, keep them in
Components”
numerical order so that they can be
reinstalled in their original positions.
1) Remove engine assembly from vehicle. (Engine NOTICE

Assembly Removal and Installation) If oil is present between the bearing backside
2) Remove cylinder head. (Valve and Cylinder Head and connecting rod bearing cap and
Removal and Installation) connecting rod surface, the bearing could
3) Mark cylinder numbers on all pistons, connecting heat up to very high temperature, resulting in
rods and connecting rod bearing caps using silver seizure.
pencil or quick drying paint. Thoroughly wipe off any trace of oil that is
4) Remove connecting rod bearing caps. present between the bearing backside and
connecting rod bearing cap and connecting
NOTE rod surface.
Use a 12-point and 8 mm socket wrench.
b) Fit tab (1) of connecting rod bearing to groove (2)
5) Remove carbon deposits from top of cylinder bore of connecting rod or connecting rod bearing cap.
before removing piston from cylinder. c) Press connecting rod bearing end (3) until it
becomes flush with connecting rod or connecting
NOTICE rod bearing cap mating surface.
Metal surfaces can be scuffed or nicked
when removing carbon deposits with sharp-
edged tool.
Do not use any sharp-edged tool to scrape 1 3
off carbon deposits from engine parts.
6) Push piston and connecting rod assembly out from 2

the top of cylinder bore.
7) Remove connecting rod bearings from connecting I7V20A141088-01
rod and connecting rod bearing cap, if necessary. 3) Align front mark (1) of the piston head with
crankshaft pulley side (2), and then insert piston and
Installation connecting rod assembly to cylinder bore.
Disassembly and Reassembly” 1
Reference: “Crankshaft Pin and Connecting Rod

Bearing Inspection”
NOTICE
2
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 IFKA0P140076-01
• Connecting rod bearings 4) Use special tool to compress rings, and then tap
• Pistons piston head to insert piston into cylinder bore.
• Piston rings Special tool
• Cylinder walls (A): 09916M77310
1) Apply engine oil to pistons, piston rings, cylinder

walls, connecting rod bearings and crankshaft pins.
2) Install connecting rod bearing to connecting rod
bearing cap and connecting rod as follows.
a) Wipe off any trace of oil that is present between
the connecting rod bearing backside and
connecting rod bearing cap and connecting rod
surface.
7) Install cylinder head. (Valve and Cylinder Head

8) Install engine assembly. (Engine Assembly Removal
and Installation)
(A) Alignment Inspection and Adjustment) in Section 2B
Piston, Piston Ring and Connecting Rod

Disassembly and Reassembly
AENNTA0E1406040 (08(02)
Removal and Installation”
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
IFKA0P140077-01
5) Check that dowel pins (1) are installed to connecting reinstalled in their original positions.
rod bearing cap.
• Pistons
• Piston pins
• Piston rings
• Connecting rods
Disassembly
1
IELA0A142163-02
1) Using piston ring expander, remove 1st and 2nd
rings from piston.
6) Install connecting rod bearing cap as follows.
2) Remove oil ring from piston.
NOTE 3) Remove piston pin circlips (1), and then remove
• If connecting rod bolt is reused, refer to piston pin from connecting rod.
“Connecting Rod Bolt Inspection”, and
then check the bolt for deformation.
• Use a 12-point and 8 mm socket wrench.
a) Point front mark (2) on connecting rod bearing

cap (1) to crankshaft pulley side.
b) Apply engine oil to bolt thread and seat of
connecting rod bolt.
c) Tighten a pair of connecting rod bolts (3) evenly
and gradually to 15 Nm (1.5 kgf-m, 11.0 lbf-ft).
d) Retighten connecting rod bolts by 65°.
I2RH0B140113-01
Tightening torque
Connecting rod bolt* (a): 15 Nm → +65° (1.5 Reassembly
kgf-m → +65°, 11.0 lbf-ft → +65°) Reference: “Cylinder, Piston and Piston Ring Inspection”
Reference: “Piston Pin and Connecting Rod Inspection”
3, (a) Reference: “Crankshaft Pin and Connecting Rod
2
1 Bearing Inspection”
1) Remove carbon deposits from piston head and ring
grooves using a suitable tool, if piston is reused.
NOTICE
3, (a) edged tool.
IAP70P140031-01
Do not use any sharp-edged tool to scrape

2) Install piston pin, piston and connecting rod as

follows. 1
a) Apply engine oil to piston pin and piston pin
holes in piston and connecting rod.
b) Align front mark (2) on piston (1) with front mark
(protrusion) (4) on connecting rod (3), and then 1
install connecting rod to piston. 2
2
3
1
3
I8T401142098-02
4
4) After installing three rings (1st, 2nd and oil rings),
distribute their end gaps as shown in figure.
ILKC0P140053-01
c) Insert piston pin (1) into piston (2) and

connecting rod (3).
d) Install new piston pin circlips (4).
e) Set opening of piston pin circlip within range of
“a”. I9P60A141080-02
“a”: 45° 3. 1st ring end gap

2 1. Front mark 4. 2nd ring end gap and oil ring
spacer gap
“a” “a” 2. Oil ring upper rail gap 5. Oil ring lower rail gap
Cylinder, Piston and Piston Ring Inspection

AENNTA0E1406041 (08(03)
1
4 4 Reference: “Piston, Piston Ring and Connecting Rod
3
Disassembly and Reassembly”
Cylinder
Visual inspection
ILKC0P140052-01 Check cylinder walls for scratches, roughness or ridges
3) Install piston rings to piston noting the following which indicate excessive wear.
points. If cylinder bore is very rough, deeply scratched or ridged,
• As shown in figure, 1st and 2nd rings have top replace cylinder block, piston rings and/or pistons.
mark (1) respectively. When installing them, face
each top mark upward. Cylinder bore diameter, taper and out-of-round
Using a cylinder gauge, measure cylinder bore in thrust
• 1st ring (2) differs from 2nd ring (3) in shape [a] and axial [b] directions at two positions as shown in
contacting cylinder wall, distinguish them by the figure.
figure. If any of the following conditions is found, replace
• When installing oil ring (4), install spacer first and cylinder block.
then two rails.
Piston diameter specification

Standard size (used piston): 72.971 – 72.983 mm
(2.8729 – 2.8733 in.)
Standard size (new piston with coating): 72.977 –
73.009 mm (2.8732 – 2.8743 in.)
[b]
[a]
“a”
IJW60P140086-01 IDLA0A140057-01
• Cylinder bore diameter exceeds limit. “a”: 9.00 mm (0.354 in.)
Cylinder bore diameter

Standard: 73.000 – 73.014 mm (2.8740 – 2.8745 in.) Piston clearance
Limit: 73.056 mm (2.8762 in.) Measure cylinder bore diameter and piston diameter to
find their difference which is piston clearance.
• Difference between thrust [a] and axial [b] directions
• Measure cylinder bore diameter: (Cylinder)
measurements exceeds out-of-round limit.
• Measure piston diameter: (Piston)
Cylinder out-of-round (“a”–“b”) Check piston clearance should be within specification.
Limit: 0.010 mm (0.00040 in.) If it is not as specified, replace cylinder block, piston
rings and/or pistons.
[a]
NOTE
“a”
[b] “b” • Calculate piston clearance using cylinder
bore diameter values in thrust direction
measured at two points in cylinder bore.
IJW60P140087-01
• If cylinder bore diameters exceeds limit,
• Difference of measurements at top and bottom
replace cylinder block and recheck piston
measurements in the thrust [a] direction exceeds
clearance.
taper limit.
Cylinder taper (“c”–“d”) Piston clearance
Limit: 0.010 mm (0.00040 in.) Standard (used piston): 0.017 to 0.043 mm (0.0007 to
0.0016 in.)
[a] Standard (new piston with coating): – 0.009 to 0.037
mm (– 0.0003 to 0.0014 in.)
Limit: 0.086 mm (0.0033 in.)
“e” “f”
“c” Ring groove clearance

1) Remove carbon deposits from ring grooves and dry.
“d” NOTICE
IHD10P140031-02 when removing carbon deposits with sharp-
Measurement position at top “e”: 50 mm (1.97 in.) edged tool.
Measurement position at bottom “f”: 100 mm (3.94 in.) Do not use any sharp-edged tool to scrape
Piston
Visual inspection 2) Fit new piston ring (1) into ring groove.
Check piston for faults, crack or other damages. 3) Measure clearance between ring and ring groove
Damaged or faulty piston should be replaced. using feeler gauge (2).
If clearance is out of limit, replace piston.
Piston diameter
Ring groove clearance
As shown in figure, piston diameter should be measured
at specified position “a” from piston skirt end in the Item Standard Limit
direction perpendicular to piston pin. 0.03 – 0.07 mm
1st ring 0.12 mm (0.0047 in.)
If measured diameter is out of specification, replace (0.0012 – 0.0027 in.)
piston.
Item Standard Limit

0.03 – 0.07 mm 2
2nd ring 0.10 mm (0.0040 in.)
(0.0012 – 0.0027 in.)
0.04 – 0.12 mm
Oil ring —
(0.0016 – 0.0047 in.)
1 "a"
1
I8T401142101-01
2
“a”: 50 mm (2.0 in.)
Piston Pin and Connecting Rod Inspection

AENNTA0E1406042 (08(03)
IDLA0A140058-01
Piston Ring
Piston ring end gap Piston Pin
Visual inspection
1) Remove carbon deposit from top of cylinder.
Check piston pin, connecting rod small-end bore and
NOTICE 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
edged tool.
hole in piston is badly worn or damaged, replace piston
Do not use any sharp-edged tool to scrape
pin, connecting rod and/or piston.
Piston pin clearance
2) Using a piston, insert piston ring (1) to specified
Check piston pin clearance in connecting rod small-end
position “a”.
and piston. Replace connecting rod, piston pin and/or
3) Measure end gap using feeler gauge (2) with piston piston, if small-end is badly worn or damaged or if
ring perpendicular to cylinder. measured clearance exceeds limit.
If measured end gap exceeds limit, replace piston
ring. Piston pin outside diameter
16.996 – 17.000 mm (0.66914 – 0.66929 in.)
Piston ring end gap
Item Standard Limit Small-end bore
0.15 – 0.28 mm 17.003 – 17.010 mm (0.66945 – 0.66968 in.)
1st ring 0.7 mm (0.0275 in.)
(0.0060 – 0.0110 in.) Diameter of piston pin hole in piston
0.28 – 0.41 mm 17.004 – 17.010 mm (0.66941 – 0.66968 in.)
2nd ring 1.0 mm (0.0393 in.)
(0.0111 – 0.0161 in.)
0.2 – 0.5 mm (0.0079 Piston pin clearance in connecting rod small-end
Oil ring 1.2 mm (0.0472 in.) Standard: 0.003 – 0.014 mm (0.00012 – 0.00055 in.)
– 0.0196 in.)
Limit: 0.014 mm (0.00055 in.)
Piston pin clearance in piston
Standard: 0.004 – 0.014 mm (0.00016 – 0.00055 in.)
Limit: 0.014 mm (0.00055 in.)
I4RH01140053-01
Connecting Rod Bolt Inspection

AENNTA0E1406043 (08(03)
Measure each thread diameters (“c” and “d”) of
connecting rod bolt (1) at “a” position and “b” position
using a micrometer (3), and then calculate difference in
diameter (“c” – “d”).
If it exceeds limit, replace connecting rod bolt with new
one.
Connecting rod bolt diameter difference
Limit (“c” – “d”): 0.05 mm (0.002 in.)
I4RS0A140023-01
1 “c” “d”
Connecting Rod
Big-end side clearance
Check big-end of connecting rod for side clearance with
rod fitted and connected to its crankshaft pin in a normal
manner. “a”
If measured clearance exceeds its limit, replace
“b”
connecting rod.
Big-end side clearance
Standard: 0.10 – 0.30 mm (0.0040 – 0.0118 in.) 3
Limit: 0.55 mm (0.0217 in.)

2
I9P60A141082-01
“a”: 12 mm (0.47 in.) 2. Thread

“b”: 32 mm (1.26 in.)
Crankshaft Pin and Connecting Rod Bearing

Inspection
I8T401142102-01
AENNTA0E1406044 (08(03)
Connecting rod alignment Disassembly and Reassembly”
Mount connecting rod on aligner to check it for bow and
twist. Crankshaft Pin Diameter
If measured value exceeds the limit, replace connecting Check crankshaft pin for uneven wear or damage.
rod. Measure crankshaft pin for out-of-round or its taper with
a micrometer.
Connecting rod alignment If crankshaft pin is damaged or out-of round or taper is
Limit on bow: 0.05 mm (0.0020 in.) out of limit, replace crankshaft or regrind crankshaft pin
Limit on twist: 0.10 mm (0.0040 in.) to undersize and use undersize bearing.
NOTE
When regrinding crank pin to undersize, use
undersize connecting rod bearing.
Crankshaft pin diameter

Standard: 37.982 – 38.000 mm (1.49536 – 1.49606 in)
Crankshaft pin out-of-round ([a] –[b])
Limit: 0.01 mm (0.0004 in.)
Crankshaft pin taper ([c] –[d])
Limit: 0.01 mm (0.0004 in.)
1
IMTA0A140069-01
Visual inspection
Check bearing shells for signs of fusion, pitting, burn or
flaking and observe contact pattern.
Defective bearing shells must be replaced.
Bearing clearance inspection

[a] [c] [d]
NOTE
• Do not apply engine oil to connecting rod
[b] bearing and crankshaft pin in bearing
clearance inspection.
• Do not turn crankshaft with piece of
I8V101140019-02
gauging plastic placed.
• After checking the bearing clearance, refer
Connecting Rod Bearing to “Connecting Rod Bolt Inspection”, and
General information then check the bolt for deformation.
• Connecting rod bearing has 5 kinds of standard
bearing thickness and 1 kind of undersize bearing 1) Clean connecting rod bearings and crankshaft pin.
thickness and they are painted (1) in the following 2) Place a piece of gauging plastic (1) to full width of
colors. crankshaft pin as contacted by bearing (parallel to
• For identification of undersize bearing, it is painted red crankshaft), avoiding oil hole.
at the position as shown in figure. Undersize bearing
thickness is 1.6050 – 1.6150 mm (0.06319 – 0.06358 1
in.) at its center.
Identification of connecting rod bearing
Color Bearing thickness at
Size
painted its center
1.4860 – 1.4890 mm
Green
(0.05851 – 0.05862 in.)
1.4891 – 1.4920 mm
Black
(0.05863 – 0.05874 in.) I7V20A141100-01
1.4921 – 1.4950 mm 3) Install connecting rod bearings and its cap. (Piston,
Standard size Nothing
(0.05875 – 0.05885 in.) Piston Ring and Connecting Rod Removal and
1.4951 – 1.4980 mm Installation)
Yellow
(0.05887 – 0.05897 in.)
1.4981 – 1.5010 mm 4) Leave connecting rod bearing cap installed for at
Blue least 3 minutes.
(0.05899 – 0.05909 in.)
Undersize (0.25 mm 1.6050 – 1.6150 mm 5) Remove connecting rod bearing cap.
Red
(0.0098 in.)) (0.06319 – 0.06358 in.) 6) Measure gauging plastic (1) width (clearance) at the
widest point using a scale (2) on gauging plastic
envelope.
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
7) If clearance below its standard or exceeds its limit,

IFKA0P140078-01
refer to “Selection of Connecting Rod Bearing”and
replace connecting rod bearing with standard size of 1. Connecting rod big-end inside diameter number
new one, and then recheck clearance.
If recheck exceeds standard value as follows. 2) Check crankshaft pin diameter as follows.
• Standard or more: • The crank web of crankshaft is stamped with 3
Replace with new next thick size connecting rod kinds of alphabets (“A”, “B” or “C”) for each
bearing, or regrind crankshaft pin to undersize cylinder as shown in figure.
and use 0.25 mm (0.0098 in.) undersize bearing. • The alphabets indicate crankshaft pin diameter as
• Standard or less: shown in the following table.
Replace with new next thinner size connecting rod
Crankshaft pin outer diameter
bearing, or regrind crankshaft pin to undersize
Stamped
and use 0.25 mm (0.0098 in.) undersize bearing. Crankshaft pin diameter
alphabet
37.9940 – 38.0000 mm
Selection of Connecting Rod Bearing A
(1.49583 – 1.49606 in.)
Standard size
37.9880 – 37.9939 mm
If engine is under the following conditions, select a new B
(1.49560 – 1.49582 in.)
standard bearing as follows, and install it.
37.9820 – 37.9879 mm
• Bearing is defective. C
(1.49536 – 1.49558 in.)
• Bearing clearance is out of specification.
• Crankshaft or connecting rod is replaced.
1) Check connecting rod big-end inside diameter as 3
follows.
• The connecting rod and its cap stamped with 3
kinds of numbers (“1”, “2” or “3”) as shown in
figure.
• The numbers indicate connecting rod big-end
inside diameter as shown in the following table.
Connecting rod big-end inside diameter
Stamped
Connecting rod big-end inside diameter
number
41.0000 – 41.0060 mm 1 2 4
1
(1.61418 – 1.61440 in.) IFKA0P140079-01
41.0061 – 41.0120 mm 1. Crankshaft pin No.1 3. Crankshaft pin No.3

2
(1.61442 – 1.61464 in.) 2. Crankshaft pin No.2 4. Crankshaft pin No.4
41.0121 – 41.0180 mm
3
(1.61465 – 1.61488 in.) 3) From number stamped on connecting rod and its cap
and alphabets stamped on crank web, determine
new standard bearing to be installed to connecting
rod big-end inside, referring to the following table.
NOTE
• For example, if number stamped on
connecting rod and its cap is “1” and
alphabet stamped on crank web is “B”,
install a new standard bearing painted in b) Using bore gauge, measure connecting rod
“Black” to its connecting rod big-end bearing inside diameter “a”.
inside.
• Refer to “General information” for details
on connecting rod bearing thickness and “a”
painted.
Connecting rod bearing cross-reference

selection table (standard size)
Stamped number for
connecting rod big-end inside
diameter
1 2 3 IAP70P140036-01
Stamped A Green Black Colorless c) Calculate target diameter using the following
alphabet for B Black Colorless Yellow formula.
crankshaft pin
C Colorless Yellow Blue Formula for target diameter of crankshaft pin
diameter
A = B – 0.040 mm (0.0016 in.)
Undersize bearing (0.25 mm (0.0098 in.)) A: Target diameter of crankshaft pin
B: Measured connecting rod bearing inside
1) Determine target diameter of crankshaft pin for
diameter “a”
regrinding according to the following procedure.
a) Assemble connecting rod, connecting rod cap 2) Grind crankshaft pin to target diameter.
and undersize bearings (0.25 mm (0.0098 in.)), 3) Check connecting rod bearing oil clearance referring
referring to Step 2), 5) and 6) “Installation” under to “Bearing clearance inspection”.
“Piston, Piston Ring and Connecting Rod
Main Bearing, Crankshaft and Cylinder Block Components

AENNTA0E1406045 (12(01)
11
7
12 (c)
9 (b)
10
5
1
8 13
2 (a)
6 (b)
OIL
21
27 1217G
(b)
26
OIL
2 (a)
1
OIL
18
OIL
15
22
19
14 16
22
22
25
23
24
OIL
17 (b)
(a)
OIL
20 (d)
28 28 28 28
IMTA0A140065-01
1. Oil gallery gasket 18. Thrust bearing

: Install thrust bearing with oil grooves facing out.
2. Oil gallery plug 19. Timing chain oil jet
3. Knock sensor 20. Main bearing cap bolt

: For removal and installation, refer to “Knock Sensor Removal : Check main bearing cap bolt for deformation to reuse. (Main
and Installation” in Section 1C. Bearing Inspection)
: Apply engine oil to bolt thread and seat.
: For tightening order, refer to “Main Bearing, Crankshaft and
Cylinder Block Removal and Installation”.
4. CKP sensor 21. Cylinder block
: For installation, refer to “CKP Sensor Removal and Installation” : Do not apply engine oil to main bearing seating face.
in Section 1C. : Apply engine oil to sliding surface
5. Breather plate gasket 22. Dowel pin
6. Breather plate No.2 bolt 23. Main bearing cap
: For tightening order, refer to “Main Bearing, Crankshaft and : Do not apply engine oil to main bearing seating face.
7. Breather plate 24. Oil temperature sensor
: For installation, refer to “Oil Temperature Sensor Removal and
Installation” in Section 1C.
8. PCV valve grommet 25. Gasket
9. Breather plate No.1 bolt 26. Engine rear oil seal
: For tightening order, refer to “Main Bearing, Crankshaft and : Apply engine oil to oil seal lip.
10. PCV valve 27. Engine rear crankshaft oil seal housing
: For installation, refer to “PCV Valve Removal and Installation” in : Apply sealant 99000-31260 referring to “Main Bearing,
Section 1B Crankshaft and Cylinder Block Removal and Installation”.
11. Flywheel 28. Piston cooling jet
12. Flywheel bolt : 27 Nm (2.8 kgf-m, 20.0 lbf-ft)
13. Input shaft bearing : 11 Nm (1.1 kgf-m, 8.5 lbf-ft)
14. Sensor plate : 83 Nm (8.5 kgf-m, 61.5 lbf-ft)
15. Main bearing : 20 Nm →40 Nm →+60° (2.0 kgf-m →4.1 kgf-m →+60°, 15.0 lbf-
: For applying engine oil, refer to “Main Bearing, Crankshaft and ft →29.5 lbf-ft →+60°)
16. Crankshaft timing sprocket key : Do not reuse.
17. Crankshaft
Main Bearing, Crankshaft and Cylinder Block 5) Remove cylinder head cover. (Cylinder Head Cover
Removal and Installation Removal and Installation)
AENNTA0E1406046 (08(01)
Reference: “Main Bearing, Crankshaft and Cylinder
Block Components”
NOTICE Tensioner Removal and Installation)
If any of the parts listed below is reinstalled 8) Remove intake and exhaust camshafts. (Camshaft
into a position different from the original Removal and Installation)
position, engine problems could occur. 9) Remove cylinder head. (Valve and Cylinder Head
If these parts are to be reused, keep them in Removal and Installation)
10) Remove pistons and connecting rods. (Piston,
reinstalled in their original positions.
Piston Ring and Connecting Rod Removal and
• Main bearing caps Installation)
• Main bearings 11) Remove engine rear crankshaft oil seal housing (1).
• Thrust bearings
Removal
1) Remove engine assembly. (Engine Assembly
2) Remove transaxle from engine assembly.
• 5M/T model: (Manual Transaxle Unit Dismounting
and Remounting) in Section 5B
3) Remove flywheel. (Flywheel Removal and
Installation) 1
IFKA0P140081-01
4) Remove oil pan and oil pump strainer. (Oil Pan and
Oil Pump Strainer Removal and Installation) in 12) Remove main bearing cap bolts in numerical order
Section 1E (“1” – “10”) evenly and gradually, and then remove
main bearing caps.
NOTE 18) Remove CKP sensor, if necessary. (CKP Sensor

Use a 12-point and 10 mm socket wrench. Removal and Installation) in Section 1C
19) Remove knock sensor, if necessary. (Knock Sensor
“3” “7” “9” “5” “1”
20) Remove oil temperature sensor, if necessary. (Oil
Temperature Sensor Removal and Installation) in
Section 1C
21) Remove PCV valve, if necessary. (PCV Valve
22) Remove breather plate as follows, if necessary.
a) Remove breather plate No.2 bolt (1).
b) Remove breather plate No.1 bolts in numerical
order (“1” – “6”).
c) Remove breather plate (2) and its gasket.
“1” “6”
“4” “8” “10” “6” “2”

IFKA0P140082-01 “3” “4”
13) Remove crankshaft from cylinder block.
14) Remove sensor plate (1) from crankshaft (2), if
necessary.
NOTE
1
Use T-30 security TORX® to loosen sensor 2
plate screws (3).
2
1
“5” “2”
IFKA0P140084-01
3
Installation
Reference: “Crankshaft Inspection”
Reference: “Main Bearing Inspection”
Reference: “Sensor Plate Inspection”
ILKC0P140059-01
Reference: “Flywheel Inspection”
Reference: “Cylinder Block Inspection”
15) Remove piston cooling jets (1), if necessary.
NOTICE
reinstalling the main bearings, crankshaft
and cylinder block can cause damage to the
engine.
Take the following precautions when
reinstalling main bearings, crankshaft and
cylinder block.
• Apply engine oil to sliding surface of the
following parts.
– Crankshaft journals
1 – Main bearings
IFKA0P140083-01
– Thrust bearings
16) Remove generator, if necessary. (Generator
– Crankshaft pins
– Main bearing cap bolts (bolt thread and
17) Remove water pump, if necessary. (Water Pump
seat)
Removal and Installation) in Section 1F
• Do not apply engine oil to the following 3) Install oil temperature sensor, if removed. (Oil
portions. Temperature Sensor Removal and Installation) in
– Contact face of cylinder block and main Section 1C
bearings 4) Install knock sensor, if removed. (Knock Sensor
– Contact face of main bearing caps and Removal and Installation) in Section 1C
main bearings 5) Install CKP sensor, if removed. (CKP Sensor
• Reinstall the following parts in original Removal and Installation) in Section 1C
positions. 6) Install water pump, if removed. (Water Pump
– Main bearing caps Removal and Installation) in Section 1F
– Main bearings 7) Install generator, if removed. (Generator Removal
– Thrust bearings
8) Install piston cooling jets (1), if removed, and then
1) Install breather plate as follows, if removed. tighten piston cooling jet bolts (2) to specified torque.
a) Check PCV valve grommet (1). Tightening torque
Replace with new one in the following cases. Piston cooling jet bolt (a): 11 N·m (1.1 kgf-m, 8.5
• If there is damage. lbf-ft)
• If removed from breather plate.
2,(a)
b) Fit new gasket to breather plate.
c) Install breather plate (2) to cylinder block, and
then tighten breather plate No.1 bolts (3) in
numerical order (“1” – “6”) to specified torque.
NOTE
Do not insert breather plate No. 2 bolt (4) until
all breather plate No. 1 bolts are tightened to
specified torque.
Tightening torque
Breather plate No.1 bolt (a): 11 N·m (1.1 kgf- 1
IFKA0P140086-01
m, 8.5 lbf-ft)
9) Install sensor plate as follows, if removed.
d) Install new breather plate No.2 bolt and tighten it a) Flat surface of flange part (2) of sensor plate (1)
to specified torque. is directed to crankshaft side (3).
Tightening torque
Breather plate No.2 bolt (b): 11 N·m (1.1 kgf- 3
m, 8.5 lbf-ft)
1 3,“6”,(a) 3,“1”,(a) 2 1
3,“4”,(a)
3,“3”,(a)
1
ILKC0P140058-01
4,(b)
b) Align hole (2) of sensor plate (1) with hole (4) of
2
crankshaft (3), and install sensor plate to
crankshaft.
c) Tighten sensor plate screws to specified torque.
NOTE
3,“2”,(a) 3,“5”,(a) Use T-30 security TORX® to tighten sensor
IFKA0P140085-01
plate screws.
2) Install PCV valve, if removed. (PCV Valve Removal
and Installation) in Section 1B Tightening torque
Sensor plate screw (a): 11 N·m (1.1 kgf-m,
8.5 lbf-ft)
NOTICE
3 If oil is present between the bearing backside
1
and cylinder block or main bearing cap
surface, the bearing could heat up to very
(a)
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.
4
d) Apply engine oil to sliding surface (5) of main
2 bearing halves at cylinder block side.
ILKC0P140057-01
10) Install main bearings to cylinder block and main

bearing caps as follows.
NOTE 2 4
5
• Install main bearing halves with oil groove
(1) to cylinder block. 3
• Install main bearing halves with out oil

1
groove to main bearing caps. IJW60P140052-04
• Install wide main bearing to the No.1 11) Install thrust bearings (1) to cylinder block between
journal (crank pulley side) and narrow No.2 and No.3 cylinders with oil grooves (2) facing
main bearing to No.2 – No.5 journals. outward.
12) Apply engine oil to thrust bearings.
[A] [B]
“a” “b”
1
1 1
“a” “b”
IFKA0Q140014-01
13) Apply engine oil to sliding surface of crankshaft and

install crankshaft to cylinder block.
14) Install dowel pins (1) to main bearing cap (2).
ILKC0P140061-02
[A]: No.1 journal

1
[B]: No.2 – No.5 journals
“a”: Bearing width wide (18 mm (0.71 in.))
“b”: Bearing width narrow (16 mm (0.63 in.))
a) Check mating surfaces (1) of bearing and

corresponding cylinder block and main bearing
2
cap are clean and dry.
b) Fit the tab (2) on each bearing into groove (3) in
cylinder block and main bearing cap.
c) Press bearing end (4) until it fully seats in IFKA0Q140015-01
cylinder block and main bearing cap. 15) Place main bearing caps (1) in place.
NOTE
“8”,(a) “4”,(a) “2”,(a) “6”,(a) “10”,(a)
• Determine each predetermined position by
marking (2) of the bearing number.
• Align arrow mark (3) with crankshaft pulley
side (4).
2
4
“7”,(a) “3”,(a) “1”,(a) “5”,(a) “9”,(a)

IFKA0P140088-01
17) Check that crankshaft rotates smoothly when turning

it by hand.
1 18) Install new engine rear oil seal (1) to engine rear
ILKC0P140060-01
crankshaft oil seal housing (2) as follows.
16) Tighten main bearing cap bolts according to the
following procedure. a) Put special tool (A) on workbench with smaller
diameter side facing up.
NOTE
Special tool
• If main bearing cap bolt is reused, refer to (A): 09911M97710
“Main Bearing Cap Bolt Inspection”, and b) Put rear crankshaft oil seal housing on special
then check the bolt for deformation. tool (A).
• Use a 12-point and 10 mm socket wrench. c) Install engine rear oil seal to engine rear
crankshaft oil seal housing using special tool (B)
a) Apply engine oil to bolt thread and seat of main
until engine rear oil seal contacts special tool (A).
bearing cap bolt.
b) Tighten main bearing cap bolts to 20 Nm (2.0 Special tool
kgf-m, 15.0 lbf-ft) in numerical order (“1” – “10”) (B): 09914M88410
as shown. d) Check that installing position (depth) is the
c) In the same numerical order as in Step b), specified value.
tighten main bearing cap bolts to 40 Nm (4.1
Engine rear crankshaft oil seal installing
kgf-m, 29.5 lbf-ft).
position (depth)
d) In the same numerical order as in Step b), “a”: 0.5 – 1.5 mm (0.020 – 0.059 in.)
tighten all main bearing cap bolts 60°.
(B)
Tightening torque
Main bearing cap bolt* : 20 Nm → 40 Nm → (B)
1
+60° (2.0 kgf-m → 4.1 kgf-m → +60°, 15.0 lbf-ft
→ 29.5 lbf-ft → +60°)
“a”
2
2
1
(A) (A)
IMTA0A140066-01
19) Clean sealing surface between engine rear

crankshaft oil seal housing (1) and cylinder block.
20) Install dowel pins (2) to engine rear crankshaft oil
seal housing.
21) Apply sealant to mating surface of engine rear

crankshaft oil seal housing. (A)
NOTICE 3

1
sealant.
(A)
No.1217G) 2,(a)
Sealant amount for engine rear crankshaft oil I7V20A141112-01
seal housing 3. Crankshaft side

Width: “a”: 3.0 mm (0.12 in.)
Height “b”: 2.0 mm (0.079 in.) 25) Install pistons and connecting rods. (Piston, Piston
Ring and Connecting Rod Removal and Installation)
“a” 26) Install cylinder head. (Valve and Cylinder Head
“A” “b” Removal and Installation)
27) Install intake and exhaust camshafts. (Camshaft
“A” 1 28) Install timing chain. (Timing Chain and Chain
2
29) Install timing chain cover. (Timing Chain Cover
2
30) Install cylinder head cover. (Cylinder Head Cover
IELA0A142169-02
31) Install CKP sensor, if removed. (CKP Sensor
22) Apply engine oil to oil seal lip. Removal and Installation) in Section 1C
23) Install engine rear crankshaft oil seal housing (1) 32) Install oil pump strainer and oil pan. (Oil Pan and Oil
using special tool to cylinder block. Pump Strainer Removal and Installation) in Section
NOTICE 1E
33) Install flywheel. (Flywheel Removal and Installation)
Turning over of oil seal lip or coming off of
the inside spring will cause oil leakage. 34) Install transaxle from engine assembly.
While installing oil seal housing, pay • 5M/T model: (Manual Transaxle Unit Dismounting
attention not to turn over oil seal lip nor and Remounting) in Section 5B
disengage the inside spring. • AGS model: (Auto Gear Shift Unit Dismounting
Special tool
(A): 09911M98410 35) Install engine assembly. (Engine Assembly Removal
and Installation)
24) Tighten new oil seal housing bolts (2) to specified 36) Check front wheel alignment. (Front Wheel
torque. Alignment Inspection and Adjustment) in Section 2B
Tightening torque
Engine rear crankshaft oil seal housing bolt: 11 Engine Rear Oil Seal Removal and Installation
N·m (1.1 kgf-m, 8.5 lbf-ft) AENNTA0E1406047 (08(01)
Removal
1) Remove transaxle from engine assembly.
and Remounting) in Section 5B
2) Remove clutch cover and clutch disc.
• AGS model: (Clutch Cover and Clutch Disc
3) Remove engine rear crankshaft oil seal housing and 2) Using dial gauge, measure crankshaft thrust play as
engine rear oil seal from cylinder block. (Main shown in figure.
Bearing, Crankshaft and Cylinder Block Removal If measured thrust play exceeds limit, replace thrust
and Installation) bearing with new one (standard size or oversize) to
4) Remove engine rear oil seal from engine rear obtain standard thrust play.
crankshaft oil seal housing. (Main Bearing, Recheck crankshaft thrust play.
Crankshaft and Cylinder Block Removal and Crankshaft thrust play
Installation) Standard: 0.11 – 0.31 mm (0.0044 – 0.0122 in.)
Limit: 0.35 mm (0.0138 in.)
Installation
1) Install new engine rear oil seal to engine rear
crankshaft oil seal housing. (Main Bearing,
Crankshaft and Cylinder Block Removal and
Installation)
2) Install engine rear crankshaft oil seal housing and
engine rear oil seal to cylinder block. (Main Bearing,
Installation)
3) Install clutch cover and clutch disc.
I7V20A141115-01
Removal and Installation) in Section 5C Thrust bearing thickness
• AGS model: (Clutch Cover and Clutch Disc Standard size: 2.470 – 2.520 mm (0.9724 – 0.9921
Removal and Installation) in Section 5D in.)
Oversize (0.125 mm (0.00492 in.)): 2.533 – 2.583
4) Mount transaxle assembly.
mm (0.0997 – 0.1016 in.)
and Remounting) in Section 5B Out-of-Roundness and Taper (Uneven Wear) of
• AGS model: (Auto Gear Shift Unit Dismounting Journal
and Remounting) in Section 5D An unevenly worn crankshaft journal shows up as a
difference in diameter at a cross section or along its
Crankshaft Inspection length (or both). This difference, if any, is determined by
AENNTA0E1406048 (08(03) taking micrometer readings. If any one of journals is
Reference: “Main Bearing, Crankshaft and Cylinder badly damaged or uneven wear exceeds its limit, regrind
Block Removal and Installation” or replace crankshaft.
Crankshaft Runout Crankshaft journal outside diameter
Using dial gauge, measure runout at center journal. Standard: 45.000 – 45.018 mm (1.7717 – 1.7723 in.)
Rotate crankshaft slowly. Limit: 44.99 mm (1.771 in.)
If runout exceeds its limit, replace crankshaft. Crankshaft out-of-roundness ([a] – [b])
Crankshaft runout Limit: 0.01 mm (0.0004 in.)
Limit: 0.02 mm (0.0008 in.) Crankshaft taper ([c] – [d])
Limit: 0.01 mm (0.0004 in.)
[c] [d]
[a]
I7V20A141113-01
[b]
Crankshaft Thrust Play
1) Assemble crankshaft, main bearings, thrust bearings
and main bearing caps. (Main Bearing, Crankshaft IMKC0A140004-01
and Cylinder Block Removal and Installation)
Main Bearing Inspection

AENNTA0E1406049 (08(03)
Reference: “Main Bearing, Crankshaft and Cylinder 1
Block Removal and Installation”
NOTE
The width of main bearing differs between
No. 1 journal and No. 2 – No. 5 journals.
[A] [B]
“a” “b”
I7V20A141118-01
1 1 4) Install main bearing and its cap. (Main Bearing,

Installation)
5) Leave main bearing cap installed for at least 3
minutes.
6) Remove main bearing cap.
“a” “b” 7) Measure gauging plastic (1) width (clearance) at the
widest point using a scale (2) on gauging plastic
envelope.
Main bearing clearance
Journal Standard Limit
0.014 – 0.032 mm
0.055 mm
No.1 (0.00056 – 0.00125
(0.00216 in.)
in.)
ILKC0P140061-02
No.2 – 0.016 – 0.034 mm 0.055 mm
[A]: No.1 journal [B]: No.2 – No.5 journals No.5 (0.00063 – 0.00133 in.) (0.00216 in.)
Bearing width wide (18 mm Bearing width narrow (16 mm
“a”: “b”:
(0.71 in.)) (0.63 in.))
1. Oil groove
1
2
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.
Main Bearing Clearance

I7V20A141119-01
NOTE
If measured clearance is less than standard or more
• Do not apply engine oil to main bearings than service limit, replace main bearings with new ones
and crankshaft journals when bearing referring to “Selection of Main Bearing” and recheck
clearance checks. main bearing clearance.
• Do not turn crankshaft with piece of If result of recheck is more than limit or less than
gauging plastic placed. standard value as follows.
• After checking the bearing clearance, refer • More than limit:
to “Main Bearing Cap Bolt Inspection”, and Replace bearing with one size thicker or regrind
then check the bolt for deformation. crankshaft journal to undersize and use 0.25 mm
(0.0098 in.) undersize bearing.
1) Remove main bearing caps. • Less than standard:
2) Clean main bearings and crankshaft journals. Replace bearing with one size thinner or regrind
3) Place a piece of gauging plastic (1) to full width of crankshaft journal to undersize and use 0.25 mm
bearing (parallel to crankshaft) on journal, avoiding (0.0098 in.) undersize bearing.
oil hole.
Selection of Main Bearing

Standard size bearing 1 2 3 4 5
If engine is under one of the following conditions, select

new standard bearing as follows, and install it.
• Bearing is defective.
• Measured bearing clearance is less than standard or
more than service limit.
• Crankshaft or cylinder block is replaced. 6
1) Check journal diameter as follows.

• The crank web No.4 has stamped with 6 kinds of
numbers (“1” – “6”) in 5 places as shown in figure.
• The positions of 5 stamp numbers represent No. 1
– No. 5 journals as shown in figure.
IFKA0P140090-01
3 4 5
1. Cylinder block journal No.1 4. Cylinder block journal No.4
2. Cylinder block journal No.2 5. Cylinder block journal No.5
3. Cylinder block journal No.3 6. Crankshaft pulley side
• The 6 kinds of alphabets or numbers represent

the bearing cap bore diameter, as shown in the
following table.
6
Crankshaft bearing cap bore diameter
Stamped alphabet Bearing cap bore diameter
(number) (without bearing)
49.0000 – 49.0030 mm
A or 1
(1.92914 – 1.92925 in.)
49.0031 – 49.0060 mm
1 2
B or 2
(1.92926 – 1.92937 in.)
IFKA0P140089-01
49.0061 – 49.0090 mm
1. Crankshaft journal No.1 4. Crankshaft journal No.4 C or 3
(1.92938 – 1.92948 in.)
2. Crankshaft journal No.2 5. Crankshaft journal No.5
49.0091 – 49.0120 mm
3. Crankshaft journal No.3 6. Crankshaft pulley side D or 4
(1.92950 – 1.92960 in.)
49.0121 – 49.0150 mm
• The 6 kinds of numbers represent the journal E or 5
(1.92962 – 1.92972 in.)
diameter, as shown in the following table.
49.0151 – 49.0180 mm
F or 6
Crankshaft journal diameter (1.92973 – 1.92984 in.)
Stamped number Journal diameter
45.0150 – 45.0180 mm 3) There are 5 kinds of standard bearing thickness and
1 they are painted in the following colors.
(1.77225 – 1.77236 in.)
45.0120 – 45.0149 mm Each color indicates the following thickness at the
2 center of bearing.
(1.77213 – 1.77224 in.)
45.0090 – 45.0119 mm Standard size crankshaft main bearing thickness
3
(1.77201 – 1.77212 in.) for No.1
45.0060 – 45.0089 mm Color
4 Bearing thickness
(1.77189 – 1.77200 in.) painted
45.0030 – 45.0059 mm Pink 1.991 – 1.994 mm (0.07839 – 0.07850 in.)
5
(1.77178 – 1.77188 in.) Purple 1.994 – 1.997 mm (0.07850 – 0.07862 in.)
45.0000 – 45.0029 mm Brown 1.997 – 2.000 mm (0.07862 – 0.07874 in.)
6
(1.77166 – 1.77176 in.) Green 2.000 – 2.003 mm (0.07874 – 0.07885 in.)
Black 2.003 – 2.006 mm (0.07885 – 0.07897 in.)
2) Check main bearing cap bore diameter as follows.
• The mating surface of cylinder block has stamped Standard size crankshaft main bearing thickness
with 6 kinds of alphabets (“A” – “F”) or 6 kinds of for No.2 – No.5
numbers (“1” – “6”) in 5 places as shown in figure. Color
Bearing thickness
• The positions of 5 stamp alphabets or numbers painted
represent No. 1 – No. 5 journals as shown in Pink 1.990 – 1.993 mm (0.07835 – 0.07846 in.)
figure. Purple 1.993 – 1.996 mm (0.07846 – 0.07858 in.)
Color
Bearing thickness [A] [B]
painted
Brown 1.996 – 1.999 mm (0.07858 – 0.07870 in.)
Green 1.999 – 2.002 mm (0.07870 – 0.07881 in.)
Black 2.002 – 2.005 mm (0.07881 – 0.07893 in.)
1 1
1 1
ILKC0P140062-01
[A]: No.1 journal 1. Paint

[B]: No.2 – No.5 journals
4) From number stamped on crank web No.4 and alphabet or number stamped on cylinder block, determine new
standard bearing to be installed to journal, referring to the following table.
Main bearing cross – reference selection table (standard size)
Stamped number 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
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
Undersize bearing (0.25 mm (0.0098 in.))

• There are 5 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 for No.1
Painted color Bearing thickness
Red & Pink 2.116 – 2.119 mm (0.08331 – 0.08343 in.)
Red & Purple 2.119 – 2.122 mm (0.08343 – 0.08354 in.)
Red & Brown 2.122 – 2.125 mm (0.08354 – 0.08366 in.)
Red & Green 2.125 – 2.128 mm (0.08366 – 0.08378 in.)
Red & Black 2.128 – 2.131 mm (0.08378 – 0.08390 in.)
Undersize crankshaft main bearing thickness for No.2 – No.5

Painted color Bearing thickness
Red & Pink 2.115 – 2.118 mm (0.08327 – 0.08339 in.)
Red & Purple 2.118 – 2.121 mm (0.08339 – 0.08350 in.)
Red & Brown 2.121 – 2.124 mm (0.08350 – 0.08362 in.)
Red & Green 2.124 – 2.127 mm (0.08362 – 0.08374 in.)
Red & Black 2.127 – 2.130 mm (0.08374 – 0.08385 in.)
[A] [B]
1 1
1 1
ILKC0P140063-01
[A]: No.1 journal [B]: No.2 – No.5 journals 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
44.7500 – 44.7680 mm (1.76182 – 1.76251 in.)
b. Using micrometer, measure reground journal diameter. (Camshaft Inspection)
Measurement should be taken in two directions perpendicular to each other to check for out-of-roundness.
I2RH0B140144-01
c. Using journal diameter measured above and alphabets or numbers stamped on cylinder block, select an
undersize bearing referring to the following table.
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
d. Check bearing clearance with newly selected undersize bearing.

If value is not standard value as follows.
– More than standard:
Replace bearing with one size thicker and recheck bearing clearance.
– Less than standard:
Replace bearing with one size thinner and recheck bearing clearance.
Main Bearing Cap Bolt Inspection

AENNTA0E1406050 (08(03)
Measure each thread diameters (“c” and “d”) of main
bearing cap bolt (1) at “a” position and “b” position using
a micrometer (3), and then calculate difference in
diameter (“c” – “d”).
If it exceeds limit, replace main bearing cap bolt with new
one.
Main bearing cap bolt diameter difference
Limit (“c” – “d”): 0.20 mm (0.008 in.)
1
“c” “d” I7V20A141125-01
“a”
“b”
I9P60A141079-01
2
I7V20A141126-01
Sensor Plate Inspection

AENNTA0E1406052 (08(03)
I9T401142032-01 Block Removal and Installation”
“a”: 40 mm (1.57 in.) 2. Thread Check sensor plate for crack or damage.
“b”: 64 mm (2.52 in.) If any defect is found, replace sensor plate.
Cylinder Block Inspection

AENNTA0E1406051 (08(03)
Block Removal and Installation”
Distortion of Gasket Surface

Using straightedge and feeler gauge, check gasket
surface for distortion.
If distortion exceeds its limit, repair it. I7V20A141122-01
If repair is not possible, replace cylinder block.
Cylinder block distortion Piston Cooling Jet Inspection
AENNTA0E1406053 (08(03)
Limit: 0.03 mm (0.0012 in.)
Check piston cooling jet for clogging or deformation.
If clogged or deformed, clean or replace piston cooling
jet.
IELA0A142172-02
Specifications

AENNTA0E1407001 (09(t)
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
Electric throttle body bolt 11 1.1 8.5 (T1D001)
Electric throttle body nut 11 1.1 8.5 (T1D002)
Intake manifold bolt 25 2.5 18.5 (T1D003)
Intake manifold nut 25 2.5 18.5 (T1D004)
Cylinder head cover bolt No.1* 5.0 Nm → 7.5 Nm (0.51 kgf-m → 0.76 kgf- (T1D005)
m, 4.0 lbf-ft → 5.5 lbf-ft)
Cylinder head cover bolt No.2* 5.0 Nm → 10 Nm (0.51 kgf-m → 1.0 kgf- (T1D006)
m, 4.0 lbf-ft → 7.5 lbf-ft)
Mounting to transaxle bolt 55 5.6 40.5 (T1D007)
Mounting to transaxle nut 55 5.6 40.5 (T1D008)
Mounting to body bolt 55 5.6 40.5 (T1D009) / (T1D013)
Mounting to body nut 55 5.6 40.5 (T1D010) / (T1D014)
Mounting to engine bolt 65 6.6 48.0 (T1D011)
Mounting to engine nut 65 6.6 48.0 (T1D012)
Crankshaft pulley bolt* 19 Nm → +75° (1.9 kgf-m → +75°, 14.0 lbf- (T1D015)
ft → +75°)
Timing chain cover bolt No.1* 25 2.5 18.5 (T1D016)
Timing chain cover bolt No.2* 25 2.5 18.5 (T1D017)
OCV bolt (a) 11 1.1 8.5 (T1D018)
Flywheel bolt 83 Nm (8.5 kgf-m, 61.5 lbf-ft) (T1D019)
Timing chain tensioner adjuster bolt 11 1.1 8.5 (T1D020)
VVT actuator bolt 60 6.1 44.5 (T1D021)
Camshaft housing bolt No.1* 11 Nm (1.1 kgf-m, 8.5 lbf-ft) (T1D022)
Camshaft housing bolt No.2* 11 Nm (1.1 kgf-m, 8.5 lbf-ft) (T1D023)
Cylinder head bolt* 20 Nm → 40 Nm → +60° → +60° (2.0 kgf- (T1D024)
m → 4.1 kgf-m → +60° → +60°, 15.0 lbf-ft
→ 29.5 lbf-ft → +60° → +60°)
Connecting rod bolt* 15 Nm → +65° (1.5 kgf-m → +65°, 11.0 lbf- (T1D025)
ft → +65°)
Breather plate No.1 bolt 11 1.1 8.5 (T1D026)
Breather plate No.2 bolt 11 1.1 8.5 (T1D027)
Piston cooling jet bolt 11 1.1 8.5 (T1D028)
Sensor plate screw 11 1.1 8.5 (T1D029)
Main bearing cap bolt* 20 Nm → 40 Nm → +60° (2.0 kgf-m → 4.1 (T1D030)
kgf-m → +60°, 15.0 lbf-ft → 29.5 lbf-ft →
+60°)
Engine rear crankshaft oil seal housing bolt 11 1.1 8.5 (T1D031)
Reference:
“Air Cleaner Components”
“Electric Throttle Body and Intake Manifold Components”
“Cylinder Head Cover Components”
“Engine Mounting Components”
“Timing Chain Cover Components”
“Timing Chain and Chain Tensioner Components”
“Camshaft Components”
“Valve and Cylinder Head Components”
“Piston, Piston Ring and Connecting Rod Components”
“Main Bearing, Crankshaft and Cylinder Block Components”
“Fasteners Information” in Section 0A

Recommended Service Material
AENNTA0E1408001 (11(m)
Material SUZUKI recommended product or Specification Note
Sealant SUZUKI Bond No.1217G P/No.: 99000–31260 (M1D001) / (M1D002) /
(M1D003)
NOTE
Required service material(s) is also described in:
“Timing Chain Cover Components”
“Timing Chain and Chain Tensioner Components”
“Camshaft Components”
“Valve and Cylinder Head Components”
“Piston, Piston Ring and Connecting Rod Components”
“Main Bearing, Crankshaft and Cylinder Block Components”
Special Tool
AENNTA0E1408002 (11(s)
09910M66810 09911M97710
Engine hook Oil seal guide
(L1D005) (L1D032)
09911M98410 09913M70123
Oil seal installer Bearing installer
(L1D034) (L1D009)
09914M88410 09915M64512
Oil seal installer Compression gauge
(L1D033) (L1D001)
09915M64530 09915M64550
Compression gauge hose Compression gauge
attachment (B)
(L1D002) (L1D003)
09915M67311 09916M14510
Vacuum gauge Valve lifter
(L1D004) (L1D014) / (L1D028)
09916M14530 09916M34542
Valve spring compressor Reamer handle
attachment
(L1D015) / (L1D029) (L1D018) / (L1D024)
09916M34570 09916M37320
Valve guide reamer (5 mm) Valve guide outer reamer
(10.5 mm)
(L1D025) (L1D019)
09916M43211 09916M43220
Valve guide remover (4.4 Valve guide installer
mm) attachment
(L1D022) (L1D023)
09916M44310 09916M56011
Valve guide remover (5 mm) Valve guide installer
attachment (protrusion: 11.5
mm)
(L1D017) (L1D021)
09916M57330 09916M77310
Valve guide installer handle Piston ring compressor (50 -
125 mm)
(L1D020) / (L1D027) (L1D031)
09916M84511 09917M68222
Forceps Crankshaft pulley holder
(L1D016) / (L1D030) (L1D006) / (L1D008)
09917M98221 09924M17811
Valve guide stem Flywheel holder
attachment
(L1D026) (L1D010) / (L1D013)
09925M96710 09926M58010
Bearing installer Bearing remover attachment
(L1D011) / (L1D012) (L1D007)
Engine Lubrication System: 1E-1
Engine Lubrication System

Engine
General Description
Engine Lubrication Description
AENNTA0E1501001 (03(01)
The oil pump is of 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. An oil passage is connected to the sub gallery via backside of a crankshaft 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 between the main gallery and main bearing is supplied to the jet and injected for lubrication
of the timing chain, timing sprockets, timing chain tensioner and timing chain guide.
• Piston cooling jet
Oil from the sub gallery is injected through the jet to each piston for additional piston cooling.
• Tensioner adjuster
Oil from an oil passage connected to the main bearing provides pressure to the tensioner adjuster for adjustment of
the chain tension.
• Cylinder head
Oil from the main gallery is supplied to OCVs through the timing chain cover and the rest of oil goes up to camshaft
front lower housing and then divided into passages drilled in the cylinder head at intake side and exhaust side
independently.
– Intake and exhaust VVT actuators
Oil is supplied through the timing chain cover, each OCV, cylinder head, camshaft front lower housing, camshaft
front upper housing and each camshaft for the camshaft timing control.
– Camshaft journal
Oil is supplied through the passages in the cylinder head at intake side and exhaust side except No.1. No.1
journals are lubricated by oil from each OCV through passages in camshaft front lower housing and camshaft
front upper housing.
– Hydraulic lash adjuster
Through the same passages for the camshaft journals, oil is supplied. From top of each hydraulic lash adjuster,
oil is injected to the valve rocker arm according to the stroke.
– Valve rocker arm and cam surface
Splashed oil from top of the hydraulic lash adjuster through the valve rocker arm lubricates the valve rocker arm
including its roller bearing and corresponding cam surface.
The oil pump is equipped with an oil relief valve. This valve relieves oil pressure when the pressure exceeds
specified value.
The oil filter provides a relief valve to bypass oil when oil pressure exceeds the filter’s specification 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.
Cylinder block is provided with an oil temperature sensor. For the oil temperature sensor inspection, refer to “Oil
Temperature Sensor On-Vehicle Inspection” in Section 1C or “Oil Temperature Sensor Inspection” in Section 1C.
1E-2 Engine Lubrication System:
Cam surface Pressurized oil

Splashed oil
Return oil
Valve rocker arm Bypass line
Valve lash adjuster
Piston ring Piston pin

VVT actuator VVT actuator
Intake camshaft Exhaust camshaft Cylinder wall Piston
OCV Crankshaft pin - Connecting rod Piston cooling jet

OCV
Chain cover Chain cover
Crankshaft journal Cylinder block (sub gallery)

Cylinder head
(Camshaft front lower and upper housings)
Tensioner adjuster
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
IFRA0B152001-04

Oil Pressure Check • For AGS model, place select lever in N range.
AENNTA0E1504001 (06(01)
1) Before checking oil pressure, check the following
points. • Block drive wheels.
• Oil level in oil pan 3) Remove oil pressure switch. (Oil Pressure Switch
If oil level is low, add oil up to FULL level mark Removal and Installation)
(hole) on oil level gauge. (Engine Oil and Filter 4) Install special tools to threaded hole where oil
Change) pressure switch was removed.
• Oil quality Special tool
If oil is discolored or deteriorated, change it. (A): 09915M77311
(Engine Oil and Filter Change) (B): 09915M78211
• Oil leakage
If leakage is found, repair leaky point.
Oil pressure specification

(A) (B) More than 180 kPa (1.8 kgf/cm2, 26.1 psi) at 4,000
rpm
7) Stop engine.
8) Remove special tools.
9) Install oil pressure switch. (Oil Pressure Switch
IMTA0A150001-01
5) Start engine and warm it up to normal operating

temperature.
6) Measure oil pressure at 4,000 rpm.
Repair Instructions
Engine Oil and Filter Change
AENNTA0E1506001 (08(01) 2
! CAUTION
There is an increased risk of severe personal
injury or health problems if the procedure
described below is performed without taking
proper precautions.
• Engine oil has an adverse health effect.
Read and understand the instructions in
“General Precautions” in Section 00 and
follow all the instructions.
1 3
• Check that the engine is not running when IMTA0A150002-01
performing Step 1) – 13) of the procedure. 4) Drain engine oil by removing drain plug (1).
• Adequately ventilate the working area 5) Wipe engine oil from thread portion of drain plug.
when starting the engine in Step 16). 6) Replace drain plug gasket (2) with new one.
7) Reinstall drain plug and tighten it to specified torque.
Before draining engine oil, check engine for oil leakage.
If any evidence of leakage is found, correct defective Tightening torque
part before proceeding to the following procedure. Engine oil drain plug (a): 35 N·m (3.6 kgf-m, 26.0
1) Remove oil filler cap and oil level gauge from engine. lbf-ft)
3) Remove engine under cover lid screws (1), and then
turn engine under cover lid (2) in arrow direction (3).
NOTE
Do not turn engine under cover lid until it
touches front bumper.
2 1, (a)
IMTA0A150003-01
8) Loosen oil filter (1) using special tool and remove oil
filter.
Special tool Not using a torque wrench

(A): 09915M47341 a) Tighten the oil filter (1) by hand until its gasket
touches the oil pan.
1
b) Using the special tool, rotate the oil filter three-
quarter turn “a” to tighten it.
Special tool
(A): 09915M47341
1 (A)
(A)
IMTA0A150004-01 “a”
9) Wipe oil filter mounting surface of oil pan clean.
NOTICE
If gasket of oil filter is remaining to oil filter
mounting surface of oil pan, engine oil may IMTA0A150006-01
leak. 12) Add oil up to FULL level mark (hole) on oil level
If gasket is remaining, remove gasket. gauge (oil pan and oil filter capacity).
Use engine oil of the following quality classification.
10) Apply engine oil to gasket (1) of new oil filter. For market of P74
• API: SN
For market of except P74
• API: SN or SP
Select an appropriate SAE oil viscosity according to
the chart [A].
0W-16 oil is the best choice for good fuel economy
and good starting in cold weather.
NOTE
• Engine oil capacity is as specified below.
However, note that actual amount of oil
I8V101150003-02 required during oil change may somewhat
11) Install the oil filter according to the following differ from that indicated below depending
procedure. on such factors as temperature, viscosity,
Using a torque wrench etc.
a) Fit the oil filter (1) to the oil pan, and then tighten • Engine oil specification and viscosity chart
it to the specified torque using the special tool. [A] indicated in this manual are typical
ones.
Special tool For the specific information on the engine
(A): 09915M47341 oil and proper engine oil viscosity, refer to
Tightening torque “Engine Oil and Filter” section of the
Oil filter (a): 14 N·m (1.4 kgf-m, 10.5 lbf-ft) Owner's Manual.
1, (a)
Engine oil specifications
Oil pan capacity: About 3.3 liters (6.97 US pt. /
5.81 Imp pt.)
Oil filter capacity: About 0.2 liters (0.42 US pt. /
0.35 Imp pt.)
Others: About 0.5 liters (1.06 US pt. / 0.88 Imp pt.)
Total: About 4.0 liters (8.45 US pt. / 7.04 Imp pt.)
Proper engine oil viscosity chart
(A)
IMTA0A150005-01
For market of P74 Reference: “Oil Pressure Switch On-Vehicle Inspection”

[A]
Removal
0W-16
1) Remove air cleaner suction pipe and air cleaner
assembly. (Air Cleaner Assembly Removal and
o
C -30 -20 -10 0 10 20 30 40 Installation) in Section 1D
F -22
o
-4 14 32 50 68 86 104
IMTA0A150022-01 2) Disconnect oil pressure switch connector (1).
3) Remove oil pressure switch (2) from timing chain
For market of except P74 cover.
[A]
1
5W-30
0W-20
0W-16
o
C -30 -20 -10 0 10 20 30 40
o -22
F -4 14 32 50 68 86 104
IMKC0A150002-01
13) Install oil filler cap and oil level gauge to engine.
14) Check oil filter and drain plug for oil leakage.
15) Return engine under cover lid (1) to its original
position, and then tighten engine under cover lid 2
IMTA0A150008-01
screws (2) to specified torque.
Tightening torque Installation
Engine under cover lid screw (a): 3.0 N·m (0.31 1) Apply sealant to thread portion of oil pressure switch
kgf-m, 2.5 lbf-ft) (1).
1
2) 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

2, (a)
IMTA0A150007-01
Lock Cement Super 1322)
16) Start engine and run it for 3 minutes. Stop it and wait Tightening torque
for 5 minutes before checking oil level. Add oil, if Oil pressure switch (a): 13 N·m (1.3 kgf-m, 9.5
necessary, to bring oil level to FULL level mark (hole) lbf-ft)
(1) on oil level gauge.
3) Connect oil pressure switch connector (2).
1
1
2
“A”
IMTA0A150028-01
2 1, (a)
2. LOW level mark (hole) IMTA0A150009-01
4) Install air cleaner assembly and air cleaner suction

Oil Pressure Switch Removal and Installation pipe. (Air Cleaner Assembly Removal and
AENNTA0E1506002 (08(01) Installation) in Section 1D
5) Start engine and check oil pressure switch for oil At engine stop: Continuity exists
leakage.
2
Oil Pressure Switch On-Vehicle Inspection
AENNTA0E1506003 (08(03)
2
1) Disconnect oil pressure switch connector (1). 4 3
2) Check for continuity between oil pressure switch

terminal (2) and timing chain cover (3) as shown.
If check result is not as specified, replace oil
pressure switch (4).
1 4
Oil pressure switch specification IMTA0A150010-01
During engine running: No continuity
Oil Pan and Oil Pump Strainer Components

AENNTA0E1506004 (12(01)
(a)
OIL
1 3
2
(a)
4 (a)
OIL
1
6 (a)
7 1217G
5 5
8 (a)
14
9
12 (c)
11 (a)
10 (b)
OIL
13 (d)
IMTA0A150011-02
1. O-ring 11. Oil pan No.2 bolt

: Apply engine oil. : For tightening order, refer to “Oil Pan and Oil Pump Strainer
2. Strainer 12. Oil filter stand
3. Oil pan baffle plate 13. Oil filter
: For tightening order, refer to “Engine Oil and Filter Change”.
: Apply engine oil to oil filter gasket.
4. Oil pump strainer bolt 14. Transaxle to engine bolt
: For tightening order, refer to “Oil Pan and Oil Pump Strainer : For tightening torque, refer to the following items.
Removal and Installation”. • 5M/T model: “Manual Transaxle Unit Components” in Section
5B
• AGS model: “Auto Gear Shift Unit Components” in Section 5D
5. Dowel pin : 11 Nm (1.1 kgf-m, 8.5 lbf-ft)
6. Oil pump strainer nut : 35 Nm (3.6 kgf-m, 26.0 lbf-ft)
: For tightening order, refer to “Oil Pan and Oil Pump Strainer
7. Oil pan : 18 Nm (1.8 kgf-m, 13.5 lbf-ft)
: Apply sealant 99000–31260 to mating surface.
8. Oil pan No.1 bolt : 14 Nm (1.4 kgf-m, 10.5 lbf-ft)
: For tightening order, refer to “Oil Pan and Oil Pump Strainer
9. Gasket : Do not reuse.
10. Drain plug
Oil Pan and Oil Pump Strainer Removal and 10) Remove auto tensioner lower bolt (1).
Installation 11) Remove exhaust manifold stiffener bolts (2).
AENNTA0E1506005 (08(01)
Reference: “Oil Pan and Oil Pump Strainer Components” 12) Remove transaxle to engine bolts (3).
Reference: “Precautions for Electrical System Work” 13) Remove oil filter. (Engine Oil and Filter Change)
Removal 2
1) Remove oil level gauge.

4) Remove engine under side cover of right side. 1
5) Drain engine oil. (Engine Oil and Filter Change) 3
IMTA0A150012-01
6) Remove exhaust pipe No.1. (Exhaust Pipe and
14) Remove oil pan No.1 bolts (1) and oil pan No.2 bolt
Muffler Removal and Installation) in Section 1K
(2).
Belt Removal and Installation) in Section 7B 2 1
1
8) Detach compressor as follows. (Compressor
a) Disconnect magnet clutch lead wire connector.
b) With discharge hose and suction hose
connected to compressor, detach compressor
from engine.
c) Suspend the detached compressor to the vehicle
body using string etc.
NOTICE
When compressor is detached, discharge
hose and suction hose could be damaged IMTA0A150013-01
receiving weight of compressor. 15) Using a large flat-bladed screwdriver (heavy duty
Suspend detached compressor to vehicle type) or the like, open oil pan gradually and carefully
body while the compressor is detached. from the lug portions and remove it from cylinder
block.
Removal and Installation) in Section 1J 16) Remove oil pump strainer (1) with O-ring (2).
17) Remove oil pan baffle plate (3). 3) Install oil pan baffle plate (2), and then tighten oil pan
18) Remove oil pan baffle plate stud bolt (4) from baffle plate bolts (3) to specified torque.
cylinder block, if necessary. Tightening torque
Oil pan baffle plate bolt (b): 11 N·m (1.1 kgf-m,
8.5 lbf-ft)
3
4
2
1 2
1, (a)
3, (b)
IMTA0A150014-01
19) Remove oil filter stand (1) from oil pan using special IMTA0A150015-01
tool and wrenches, if necessary. 4) Apply engine oil to new O-ring (1), and install it to oil
pump strainer (2).
Special tool
(A): 09915M47350 5) Install oil pump strainer with O-ring to oil pump (3),
and then tighten oil pump strainer bolt (4) to
specified torque.
Tightening torque
Oil pump strainer bolt (a): 11 N·m (1.1 kgf-m, 8.5
(A) lbf-ft)
6) Tighten oil pump strainer nut (5) to specified torque.
1
Tightening torque
Oil pump strainer nut (b): 11 N·m (1.1 kgf-m, 8.5
lbf-ft)
3
IFKA0Q150001-01
Installation
1
1) Install oil filter stand (1) to oil pan, if removed, and
tighten it with special tool to specified torque.
2
Special tool
(A): 09915M47350 5, (b)
4, (a)
Tightening torque IMTA0A150016-02
Oil filter stand (a): 18 N·m (1.8 kgf-m, 13.5 lbf-ft) 7) Check that dowel pin (1) is installed in cylinder block
(2).
If not installed, install it to cylinder block.
(A)
1, (a)
IFRA0A151016-01
1
2) Install oil pan baffle plate stud bolt (1) if removed, IMTA0A150017-01
and tighten it to specified torque. 8) Check that dowel pin (1) is installed in oil pan (2).
Tightening torque If not installed, install it to oil pan.
Oil pan baffle plate stud bolt (a): 11 N·m (1.1 kgf- 9) Apply engine oil to new O-ring (3), and then install it
m, 8.5 lbf-ft) to the position as shown in figure.
1 2, “5” , (b) 1
2
“3” , (a) “11” , (a)
“9” , (a) “1” , (a) “7” , (a)
“17”
, (a)
“15”
“13” , (a)
, (a)
“12”
, (a)
3 1 “14”
IMTA0A150019-01 , (a)
“16”
10) Clean mating surfaces of oil pan and cylinder block. , (a)
11) Apply sealant to oil pan mating surface as shown in “8” , (a) “2” , (a) “10” , (a)
figure. “4” , (a) “6” , (a)
IMTA0A150020-01
NOTICE
13) Tighten auto tensioner lower bolt (1) to specified
After having applied sealant, oil leak is torque, referring to “Accessory Drive Belt Auto
caused when it is not installed immediately. Tensioner Removal and Installation” in Section 1J.
Install within 2 minutes after applying 14) Loosen exhaust manifold stiffener nuts (2).
sealant.
15) Tighten exhaust manifold stiffener bolts (3) and nuts
“A”: Sealant 99000–31260 (SUZUKI Bond to specified torque, referring to “Exhaust Manifold
No.1217G) Removal and Installation” in Section 1K.
16) Tighten transaxle to engine bolts (4) to specified
Sealant amount for oil pan
torque.
Width: “a”: 3 mm (0.12 in.)
Height “b”: 2 mm (0.08 in.) • For 5M/T model, referring to “Manual Transaxle
Unit Components” in Section 5B.
• For AGS model, referring to “Auto Gear Shift Unit
Components” in Section 5D.
3
“A”
1
“a”
“A”
“b”
2 4
IMTA0A150021-02
IFKA0P150018-01
17) Install oil filter. (Engine Oil and Filter Change)
12) Install oil pan 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. 19) Install compressor to cylinder block and oil pan.
(Compressor Assembly Removal and Installation) in
Tightening torque Section 7B
Oil pan No.1 bolt* (a): 11 N·m (1.1 kgf-m, 8.5 lbf-
20) Install compressor drive belt. (Compressor Drive Belt
ft)
Oil pan No.2 bolt* (b): 11 N·m (1.1 kgf-m, 8.5 lbf-
ft) 21) Install exhaust pipe No.1. (Exhaust Pipe and Muffler
22) Install drain plug and oil filter, and then refill engine
with engine oil. (Engine Oil and Filter Change)
23) Install oil level gauge.
24) Check that there is no engine oil leakage and
exhaust gas leakage.
25) Install engine under side cover of right side. (Engine 26) Install engine under cover. (Engine Under Cover and
Under Cover and Engine Under Side Cover Engine Under Side Cover Removal and Installation)
Removal and Installation) in Section 9H in Section 9H
Oil Pump Assembly Components

AENNTA0E1506006 (12(01)
OIL
2
OIL
3 4
(a)
OIL
5
OIL
6
7
8
IMTA0A150027-01
1. Timing chain cover 6. Relief valve spring

2. Inner rotor 7. Retainer
: For installation, refer to “Oil Pump Assembly Disassembly and Reassembly”.
3. Outer rotor 8. Circlip
: For installation, refer to “Oil Pump Assembly Disassembly and Reassembly”.
4. Rotor plate : 11 Nm (1.1 kgf-m 8.5 lbf-ft)
5. Relief valve : Do not reuse.
Oil Pump Assembly Removal and Installation

AENNTA0E1506007 (08(01) 1 2
Reference: “Oil Pump Assembly Components”
Oil pump is incorporated in timing chain cover.
For removal and installation, refer to “Timing Chain
Cover Removal and Installation” in Section 1D.
Oil Pump Assembly Disassembly and

Reassembly
AENNTA0E1506008 (08(02)
Reference: “Oil Pump Assembly Components”
Reference: “Oil Pump Assembly Removal and
IMTA0A150024-01
Installation”
2) Remove outer rotor (1) and inner rotor (2).
Disassembly
1) Remove rotor plate (1) by removing its mounting
bolts (2).
1
5 1
2
2
3
IFKA0P150023-01 4
3) Remove relief valve (1), relief valve spring (2) and
retainer (3) from rotor plate (5) by removing circlip IMTA0A150026-02
(4). 5) Install rotor plate (1) to timing chain cover, and

tighten all bolts (2) to specified torque.
5 1 Tightening torque
Oil pump rotor plate bolt (a): 11 N·m (1.1 kgf-m,
8.5 lbf-ft)
2 6) Check that inner rotor (3) turn smoothly by hand.
3 1 2, (a)
4
IMTA0A150026-02
Reassembly
Reference: “Oil Pump Inspection”
1) Clean and then dry all disassembled parts.
2) Apply thin coat of engine oil to inner rotor (2) and
outer rotor (1).
3
3) Facing each front mark (3) toward cylinder block, IMTA0A150023-01
install outer rotor and inner rotor to timing chain
cover. Oil Pump Inspection
AENNTA0E1506009 (08(03)
3 Reference: “Oil Pump Assembly Disassembly and
Reassembly”
1
Oil Seal
For inspection of oil seal, refer to “Timing Chain Cover
Inspection” in Section 1D.
2
Oil Pump
• Check outer rotor (1), inner rotor (2), rotor plate (3)
IFKA0P150025-01 and oil pump case portion (5) of timing chain cover (4)
4) Apply engine oil to relief valve (1) and relief valve for excessive wear or damage.
spring (2), and install them with retainer (3) and new
circlip (4) to rotor plate (5). 5 4
1 2
IMTA0A150025-01
• Check that relief valve (1) is not excessively worn or Side clearance for oil pump outer rotor
damaged and operates smoothly. Standard: 0.03 – 0.08 mm (0.0012 – 0.0031 in.)
Limit: 0.10 mm (0.0039 in.)
1
1 2
IFKA0P150027-01
Radial clearance
Check radial clearance between outer rotor (2) and
timing chain cover (3) using feeler gauge (1).
If radial clearance is out of specification, replace timing
chain cover or inner rotor (4) and outer rotor as set.
3 5 4
Radial clearance between outer rotor and case of oil ILKC0P150022-01
pump
Standard: 0.265 – 0.335 mm (0.0105 – 0.0131 in.) Relief valve spring free length and load
Limit: 0.355 mm (0.0140 in.) Check free length and load of relief valve spring as
shown in figure. If any of measurement is smaller than
specification, replace relief valve spring.
4 1
Relief valve spring free length and load
Standard Limit
59.7 mm
Free length —
(2.35 in.)
Load at spring 21.5 – 24.7 N
20.0 N (2.0 kgf,
length (2.2 – 2.5 kgf,
4.5 lbf)
52.0 mm (2.05 in.) 4.8 – 5.6 lbf)
3 2
ILKC0P150021-01
Side clearance
Using straightedge (1) and feeler gauge (2), measure
side clearance.
If side clearance is out of specification, replace timing
chain cover (3) or inner rotor (5) and outer rotor (4) as
set.
Side clearance for oil pump inner rotor
Standard: 0.03 – 0.08 mm (0.0012 – 0.0031 in.)
Limit: 0.10 mm (0.0039 in.) I2RH01150023-01
Specifications
AENNTA0E1507001 (09(t)
NOTE
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Engine oil drain plug 35 3.6 26.0 (T1E001)
Oil filter 14 1.4 10.5 (T1E002)
Engine under cover lid screw 3.0 0.31 2.5 (T1E003)
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Oil pressure switch 13 1.3 9.5 (T1E004)
Oil filter stand 18 1.8 13.5 (T1E005)
Oil pan baffle plate stud bolt 11 1.1 8.5 (T1E006)
Oil pan baffle plate bolt 11 1.1 8.5 (T1E007)
Oil pump strainer bolt 11 1.1 8.5 (T1E008)
Oil pump strainer nut 11 1.1 8.5 (T1E009)
Oil pan No.1 bolt* 11 1.1 8.5 (T1E010)
Oil pan No.2 bolt* 11 1.1 8.5 (T1E011)
Oil pump rotor plate bolt 11 1.1 8.5 (T1E012)
Reference:
“Oil Pan and Oil Pump Strainer Components”
“Oil Pump Assembly Components”

AENNTA0E1508001 (11(m)
Sealant SUZUKI Bond No.1217G P/No.: 99000–31260 (M1E002)
Thread lock cement Thread Lock Cement Super 1322 P/No.: 99000–32150 (M1E001)
NOTE
“Oil Pan and Oil Pump Strainer Components”
“Oil Pump Assembly Components”
Special Tool
AENNTA0E1508002 (11(s)
09915M47341 09915M47350
Oil filter wrench socket Oil filter stand remover
(L1E003) / (L1E004) / (L1E006) / (L1E007)
(L1E005)
09915M77311 09915M78211
Oil pressure gauge Oil pressure gauge
attachment
(L1E001) (L1E002)
1F-1 Engine Cooling System:
Engine Cooling System

Engine
Precautions
Precautions for Cooling System
AENNTA0E1600001 (01(01)
! 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.
General Description
Cooling System Description Coolant table
AENNTA0E1601001 (03(01)
The cooling system consists of the radiator, coolant °C –14.5
Freezing temperature
reservoir, water pump, cooling fan and thermostat. The °F 5.9
radiator is of a tube-and-fin type. Antifreeze / Anti-corrosion
% 30
coolant concentration
Coolant Description Coolant capacity
AENNTA0E1601002 (03(01)
The coolant recovery system is a standard system, Engine, radiator and heater: 3.7 liters (7.82/6.51 US/
which allows part of coolant to flow from the radiator into Imp pt.)
the coolant reservoir when it expands by heat. When the Reservoir: 0.5 liters (1.06/0.88 US/Imp pt.)
cooling system cools down, the coolant in the coolant Total: 4.2 liters (8.88/7.39 US/Imp pt.)
reservoir is drawn back into the radiator.
The cooling system has been filled with a SUZUKI long Cooling Fan Operation Description
AENNTA0E1601003 (03(01)
life coolant (coolant color: Yellow) that is a 30/70 mixture
Radiator cooling fan motor is controlled by ECM as
of ethylene glycol antifreeze and deionized water. This
follows.
coolant solution provides freezing protection to –14.5 °C
(5.9 °F).
Coolant Temperature
• This 30/70 mixture coolant also provides protection
against corrosion and loss of coolant from boiling.
[A]
Keep cooling system filled with this coolant even
where freezing temperatures are not expected.
[B]
• When replenishing the system due to loss of coolant,
the same ethylene glycol base coolant should be used [C]
in order to ensure the same level of protection against
freezing and corrosion. 95 97 100 102 (°C)
203.0 206.6 212.0 215.6 (°F)
NOTICE IFRA0A161001-01
[A]: High speed [C]: OFF

Using alcohol or methanol base coolant or
[B]: Low speed
plain water alone may cause damage to the
cooling system.
Use the specified coolant.
Engine Cooling System: 1F-2
A/C Refrigerant Pressure and Vehicle Speed (In

Compressor ON) [A]
Low speed
A/C compressor is ON, and one of the following [B]
condition is met.
[C]
• Until vehicle speed exceeds 30km/h (19 mile/h), after
0.6 1.1 1.2 1.5 (MPa) [D]
vehicle speed becomes lower than 20 km/h (12 mile/ 6.1 11.2 12.2 15.3 (kgf/cm2)
h). 87 160 174 217 (psi)
IL2R0A160002-01
• Until A/C refrigerant pressure becomes lower than 0.6
[A]: High speed [C]: OFF
MPa (6.1 kgf/cm2, 87 psi), after A/C refrigerant
[B]: Low speed [D]: A/C refrigerant pressure
pressure exceeds 1.1 MPa (11.2 kgf/cm2, 160 psi).
High speed: Other

Until A/C refrigerant pressure is lower than 1.2 MPa Cooling fan operates at high speed if malfunction related
(12.2 kgf/cm2, 174 psi), after A/C refrigerant pressure is to ECT sensor is detected.
more than 1.5 MPa (15.3 kgf/cm2, 218 psi).

Coolant Circulation
AENNTA0E1602001 (10(03)
[A]
4
3 5
8 9
6
7 10
2
[B]
4
3 5
8 9
6
7 10
2
IMTA0A160001-02
[A]: Engine is cool (thermostat closed) 2. Engine 5. Heater inlet hose 8. EGR cooler
[B]: Engine is normal at operating temperature (thermostat open) 3. Heater outlet hose 6. Thermostat 9. Radiator outlet hose
1. Water pump 4. Heater core 7. Radiator inlet hose 10. Radiator
Radiator Cooling Fan Control System Circuit Diagram

AENNTA0E1602002 (10(01)
+BB +B 5
1
BLU LT GRN E01-2
GRY BLU
2 3 GRN E01-27
L+
BLU GRN H+ BLU
L-
GRY PNK 4 BLK LT GRN
H-
5V
6
BLU C01-20
GRY C01-4
[A] C01 E01
[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49
IMTA0A160040-01
[A]: ECM connector (View: [a]) 2. Radiator cooling fan relay No.2 4. Radiator cooling fan motor 6. ECT sensor
1. Radiator cooling fan relay No.1 3. Radiator cooling fan relay No.3 5. ECM

Engine Cooling Symptom Diagnosis
AENNTA0E1604001 (06(04)
Engine overheats (Radiator fan operates)

• Broken accessory drive belt Replace broken accessory drive belt. (Accessory Drive Belt
• Not enough coolant Check coolant level and add if necessary. (Coolant Level
Check)
• Faulty thermostat Check thermostat assembly. (Thermostat Removal and
Installation)
• Faulty water pump Replace water pump. (Water Pump Removal and
Installation)
• Dirty or bent radiator fins Clean or repair. (Radiator On-Vehicle Inspection and
Cleaning)
• Coolant leakage on cooling system Check cooling system for leakage. (Engine Cooling System
Inspection)
• Clogged radiator Replace radiator. (Radiator Removal and Installation)
• Faulty radiator cap Check radiator cap. (Engine Cooling System Inspection)
• Dragging brakes Check brake. (Brake Symptom Diagnosis) in Section 4A
• Poorly charged battery Check battery. (Battery Inspection) in Section 1J

• Poor electricity generated by generator Check generator. (Generator Test) in Section 1J
• Faulty ECT sensor Check ECT sensor. (ECT Sensor Inspection) in Section 1C
• Faulty radiator cooling fan motor Check radiator cooling fan motor. (Radiator Cooling Fan
Assembly On-Vehicle Inspection)
• Faulty ECM Check ECM and its circuit. (Inspection of ECM and Its
Circuits) in Section 1A
• Faulty radiator cooling fan relay Check radiator cooling fan relay. (Radiator Cooling Fan
Relay Inspection)
• Faulty wiring or grounding Repair wiring.
• Too many optional electric devices Remove electrical devices.
Engine overheats (Radiator fan does not operate)

• Blown fuse Check fuse.
• Faulty radiator cooling fan relay Check radiator cooling fan relay. (Radiator Cooling Fan
Relay Inspection)
Assembly On-Vehicle Inspection)
• Faulty ECM Check ECM and its circuit. (Inspection of ECM and Its
Radiator Cooling Fan System Check

AENNTA0E1604002 (06(01)
Circuit Diagram
+BB +B 5
1
BLU LT GRN E01-2
GRY BLU B1
A1
E1 D1 E1
D1 2 3 GRN E01-27
L+
BLU GRN H+ BLU
L-
GRY PNK 4 BLK LT GRN
A2 B2 H- C1 C2
5V
A3 6
BLU C01-20
GRY C01-4
[A] C01 E01
[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49
IMTA0A160041-01
[A]: ECM connector (View: [a]) D1: Radiator cooling fan relay No.2 and No.3 power supply circuit (coil side)
A1: Radiator cooling fan relay No.1 power supply circuit (switch side) E1: Radiator cooling fan relay No.2 and No.3 drive circuit
A2: Radiator cooling fan relay No.2 power supply circuit (switch side) 1. Radiator cooling fan relay No.1
A3: Radiator cooling fan relay No.3 power supply circuit (switch side) 2. Radiator cooling fan relay No.2
B1: Radiator cooling fan motor drive circuit (low speed) 3. Radiator cooling fan relay No.3
B2: Radiator cooling fan motor drive circuit (high speed) 4. Radiator cooling fan motor
C1: Radiator cooling fan motor ground circuit 5. ECM
C2: Radiator cooling fan relay No.3 ground circuit 6. ECT sensor
Troubleshooting
NOTE
• For details of engine cooling fan operation, refer to “Cooling Fan Operation Description”.
• Before beginning troubleshooting, read “Precautions for Engine” in Section 1.
• When measuring circuit voltage, resistance and/or pulse signal of ECM, refer to “Inspection of ECM
and Its Circuits” in Section 1A.
Step 1 DTC check

1) Connect SUZUKI scan tool to DLC. (Suzuki SDT-II Connection and Disconnection) in Section 0A
2) Set ignition “ON” and check DTC. (DTC Check) in Section 1A
Is there DTC(s)?
Yes Go to applicable DTC troubleshooting and recheck DTC.

No Go to Step 2.
Step 2 Radiator cooling fan low-speed operation control check

1) Check radiator cooling fan control for low-speed operation. (Radiator Cooling Fan Assembly On-Vehicle
Inspection)
Is check result OK?
Yes Go to Step 3.
No Go to Step 4.
Step 3 Radiator cooling fan high-speed operation control check

1) Check radiator cooling fan control for high-speed operation. (Radiator Cooling Fan Assembly On-Vehicle
Inspection)
Is check result OK?
Yes Radiator cooling fan control system is in good condition.

No Go to Step 8.
Step 4 Radiator cooling fan relay No.1 power supply 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?
Yes Go to Step 5.
No Repair “A1” circuit.

1) Check radiator cooling fan relay No.1. (Radiator Cooling Fan Relay Inspection)
Is check result OK?
Yes Go to Step 6.
Step 6 Radiator cooling fan motor drive circuit (low speed) check
1) Set ignition “OFF” and disconnect ECM connector.
2) Disconnect radiator cooling fan motor connector.
3) Check for proper connection to radiator cooling fan motor at each terminal.
4) If OK, check the following points.
• Resistance of “B1” circuit: 1 Ω or less
Is check result OK?
Yes Go to Step 7.
No Repair “B1” circuit.
Step 7 Radiator cooling fan motor ground circuit check

1) Measure resistance between “C1” circuit and ground.
Is resistance 1 Ω or less?
Yes Go to Step 16.

No Repair “C1” circuit.
3) If OK, measure voltage between “A2” circuit and ground.
Is it 10 – 14 V?
Yes Go to Step 9.

Is check result OK?
Yes Go to Step 10.

Step 10 Radiator cooling fan motor drive circuit (high speed) check
1) Set ignition “OFF” and disconnect radiator cooling fan motor connector.
2) Check for proper connection to radiator cooling motor at each terminal.
• Resistance of “B2” circuit: 1 Ω or less
Is check result OK?
Yes Go to Step 11.

No Repair “B2” circuit.
• Resistance of “A3” circuit: 1 Ω or less
Is check result OK?
Yes Go to Step 12.


Is check result OK?
Yes Go to Step 13.

Step 13 Radiator cooling fan relay No.3 ground circuit check

1) Measure resistance between “C2” circuit and ground.
Yes Go to Step 14.

No Repair “C2” circuit.
Step 14 Radiator cooling fan relay No.2 and No.3 power supply circuit (coil side)
1) Set ignition “OFF” and remove radiator cooling fan relay No.1, No.2 and No.3 from individual circuit fuse
box No.1.
• Resistance of “D1” circuit: 1 Ω or less
• Resistance between “D1” circuit and ground: infinity
• Voltage of “D1” circuit: approx. 0 V
Is check result OK?
Yes Go to Step 15.

No Repair “D1” circuit.
Step 15 Radiator cooling fan relay No.2 and No.3 drive circuit
1) Set ignition “OFF” and disconnect ECM connector.
2) Check for proper connection to ECM connector.
• Resistance of “E1” circuit: 1 Ω or less
• Resistance between “E1” circuit and ground: infinity
• Voltage of “E1” circuit: approx. 0 V (When ignition is “ON”)
Is check result OK?
Yes Go to Step 16.

No Repair “E1” circuit.
Step 16 Radiator cooling fan motor check

1) Check radiator cooling fan motor.
Is check result OK?
Yes Replace ECM and recheck radiator cooling fan system.

No Replace radiator cooling fan motor. (Radiator Cooling Fan Disassembly and Reassembly)
Repair Instructions
Cooling System Components
AENNTA0E1606001 (12(01)
(a)
(a) 1
3
2 25 (h)
4
(f)
24 1207F
(f)
17
18
5 (a)
(a) 14 19
20 (g)
6 21 22
7 (b)
23
13 (f)
6 [a]
(f)
17
[a] 12 17 [b]
(f)
26
16
[b]
4 9 11 (a)
8
30
28
(c) 10 15
27
29
29
(e)
(d)
IMTA0A160002-03
1. Radiator support upper bracket 14. Radiator inlet hose 27. Heater inlet hose
2. Radiator cap 15. Radiator outlet hose 28. Heater outlet hose
3. Radiator 16. Water inlet pipe 29. To heater core
4. Heat insulator 17. To cylinder block 30. To intake manifold
5. Reservoir 18. Thermostat cap : 11 Nm (1.1 kgf-m, 8.5 lbf-ft)
6. To vehicle body 19. Thermostat : 1.0 Nm (0.10 kgf-m, 1.0 lbf-ft)
: For installation, refer to “Thermostat Removal and Installation”
“Thermostat Removal and Installation”.
7. Drain plug 20. ECT sensor : 2.5 Nm (0.25 kgf-m, 2.0 lbf-ft)
8. Radiator cooling fan shroud 21. Thermostat case : 6.3 Nm (0.64 kgf-m, 5.0 lbf-ft)
9. Radiator cooling fan motor 22. Gasket : 3.9 Nm (0.40 kgf-m, 3.0 lbf-ft)
10. Radiator cooling fan 23. To cylinder head : 25 Nm (2.5 kgf-m, 18.5 lbf-ft)
11. EGR cooler water inlet hose 24. Water pump : 12 Nm (1.3 kgf-m, 9.0 lbf-ft)
: Apply sealant 99000-31250
12. EGR cooler 25. Water pump pulley : 20 Nm (2.0 kgf-m, 15.0 lbf-ft)
13. EGR cooler water outlet hose 26. O-ring : Do not reuse.
Coolant Level Check Cooling system holding pressure

AENNTA0E1606002 (08(03) 123 kPa (1.3 kgf/cm2, 17.8 psi, 1.23 bar)
Before performing the following procedure, observe
“Precautions for Cooling System”. 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
IMTA0A160004-02
If proper quality antifreeze is used, there is
no need to add extra rust inhibitors or other b) Check that cooling system holds the pressure.
additives that claim to improve system. They If cooling system does not hold applied pressure,
may be harmful to proper operation of check cooling system for leakage.
system, and are unnecessary expense. 5) Check radiator cap according to the following
procedure.
a) Attach pressure tester (1) to radiator cap (2), and
then apply specified pressure.
4
Radiator cap valve opening pressure
2
93 – 123 kPa (0.9 – 1.3 kgf/cm2, 13.5 – 17.8 psi,
0.93 – 1.23 bar)
1 2
1
IMTA0A160003-01
Engine Cooling System Inspection

AENNTA0E1606003 (08(03) IFRA0A161006-01
b) If radiator cap valve opening pressure is out of
“Precautions for Cooling System”.
specification, replace radiator cap.
1) Check cooling system for leakage or damage.
6) Detach pressure tester and rinse off spilled coolant.
2) Remove radiator cap.
7) Install radiator cap on radiator.
3) Check coolant for proper level and freeze protection.
4) Check cooling system for coolant leakage according Cooling System Draining
to the following procedure. AENNTA0E1606004 (08(01)
a) Attach pressure tester (1) to radiator, and then
“Precautions for Cooling System”.
apply specified pressure to cooling system.

2) Remove radiator cap.
3) Drain coolant from drain plug (1). 2
4) After draining coolant, tighten drain plug to specified

torque.
Tightening torque
Drain plug (a): 1.0 N·m (0.10 kgf-m, 1.0 lbf-ft)
1
IMTA0A160007-01
3) Fill radiator with coolant up to bottom of radiator filler

neck (1) and install radiator cap (2). (Coolant
Description)
1, (a)
IMTA0A160005-01
5) Remove reservoir (1). 1
6) Drain coolant from reservoir.

7) Install reservoir, and tighten reservoir bolt (2) to
specified torque.
Tightening torque I8G001160015-01
Reservoir bolt (a): 11 N·m (1.1 kgf-m, 8.5 lbf-ft) 4) Run engine at idle speed until radiator fan motor is
operated.
2, (a) 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.
System Inspection)
1
IMTA0A160006-01
Cooling System Hose Removal and Installation

AENNTA0E1606006 (08(01)
Cooling System Refilling
AENNTA0E1606005 (08(01) Reference: “Cooling System Components”
“Precautions for Cooling System”. Removal
1) Fill reservoir (1) with coolant up to “FULL” mark (2). 1) Drain coolant. (Cooling System Draining)
2) Install reservoir cap (3) on reservoir. 2) Loosen clamp on the hose to be removed and pull
hose end off.
Installation
• If there is matchmark on each of hose and pipe, install
the hose aligning matchmark on hose with matchmark
on pipe.
• Install each clamp in proper position.
• Tighten bolts and nuts to specified torque, if removed.
(Cooling System Components)
• Refill cooling system with coolant. (Cooling System 7) Remove water inlet pipe bolt (1) and thermostat case
Refilling) nut (2).
• Check cooling system for leakage. (Engine Cooling 8) Remove water inlet pipe (3) and O-ring (4) from
System Inspection) cylinder block.
Water Inlet Pipe Removal and Installation

AENNTA0E1606007 (08(01)
Reference: “Cooling System Components”
2
Removal 4
1) Drain coolant. (Cooling System Draining)

2) Disconnect radiator outlet hose (1) from water inlet
pipe (2).
1 3
2
IMTA0A160008-01
3
3) Remove intake manifold. (Intake Manifold Removal IMTA0A160011-02

4) Disconnect heater outlet hose (1) and EGR cooler Installation
water outlet hose (2) from water inlet pipe (3). Reverse removal procedure noting the following points.
• Replace O-ring (1) with new one.
• Tighten water inlet pipe bolt (2) and thermostat case
nut (3) to specified torque.
Tightening torque
Water inlet pipe bolt (a): 11 N·m (1.1 kgf-m, 8.5
lbf-ft)
Thermostat case nut (b): 25 N·m (2.5 kgf-m, 18.5
lbf-ft)
2 3 1
IMTA0A160009-01
5) Disconnect radiator inlet hose (1) from thermostat 3, (b)

cap (2), if necessary. 1
6) Disconnect EGR cooler water inlet hose (3) from
thermostat case (4), if necessary.
2 4
2, (a)
1 3
IMTA0A160010-02
IMTA0A160012-01

the hose aligning matchmark on hose with matchmark 3 4 2
on pipe.
• Install intake manifold, referring to “Intake Manifold
Removal and Installation” in Section 1D.
• Refill cooling system with coolant. (Cooling System
Refilling)
• Check cooling system for leakage. (Engine Cooling
System Inspection)
1
Thermostat Removal and Installation IMTA0A160015-01
AENNTA0E1606008 (08(01)
Removal • Tighten thermostat cap bolts (1) to specified torque.
1) Drain coolant. (Cooling System Draining) Tightening torque
2) Disconnect radiator inlet hose (1) from thermostat Thermostat cap bolt (a): 11 N·m (1.1 kgf-m, 8.5
cap (2). lbf-ft)
3) Remove thermostat cap bolts (3), and then remove 1, (a)
thermostat cap.
IMTA0A160032-01

2
IMTA0A160013-01
on pipe.
4) Remove thermostat (1) from thermostat case (2). • Install each clamp in proper position.
2 Refilling)
System Inspection)
Thermostat Inspection
AENNTA0E1606009 (08(03)
Reference: “Thermostat Removal and Installation”
Check the following points.
If check result is not OK, replace thermostat.
(Thermostat Removal and Installation)
1 • Check that air bleed valve (1) is clean.
IMTA0A160014-01
• Check that valve seat (2) is free from foreign material
Installation that would prevent valve from seating tight.
Reference: “Thermostat Inspection” • Check thermostat seal (3) for breakage, deterioration
Reverse removal procedure noting the following points. or any other damage.
• Install thermostat (1) to thermostat case (2) by
aligning air bleed valve (3) of thermostat with mark (4)
of thermostat case.
1 2 3 2 3
IJW60P160007-01
• Check thermostat operation as follows.

a. Immerse thermostat (1) in water, and heat water
1
gradually. IMTA0A160018-02
b. Check that wax pellet starts to open at specific 4) Disconnect EGR cooler water inlet hose (1) and
temperature. heater inlet hose (2) from thermostat case (3).
Temperature at which valve starts to open (lift 5) Remove thermostat case bolt (4) and nuts (5).
0.05 mm (0.002 in))
5
86.5 – 89.5 °C (187.7 – 193.1 °F)
Temperature at which valve becomes fully
1 2
open
100 °C (212 °F)
Valve lift
More than 8 mm (0.31 in) at 100 °C (212 °F)
3 5 3 4
IMTA0A160019-01
6) Remove water inlet pipe. (Water Inlet Pipe Removal

1
and Installation)
7) Remove engine harness protector bracket and
2 EVAP canister purge valve. (EVAP Canister Purge
Valve Removal and Installation) in Section 1B
8) Remove thermostat case (1) from cylinder head (2).
I8T401162018-01
2
2. Heater 3. Thermometer
Thermostat Case Removal and Installation

AENNTA0E1606010 (08(01)
Reference: “Cooling System Components”
Removal
1) Drain coolant. (Cooling System Draining)
2) Disconnect radiator inlet hose (1) from thermostat
1
cap (2). IMTA0A160020-02
3) Disconnect ECT sensor connector (3). 9) Remove gasket (1) from thermostat case (2) or
cylinder head.
10) Remove ECT sensor (3) from thermostat case, if
necessary.
11) Remove thermostat cap (4) and thermostat (5) from
thermostat case, if necessary.

3 Refilling)
2 4 System Inspection)
1
Radiator Cooling Fan Assembly On-Vehicle
Inspection
AENNTA0E1606011 (08(03)
5 Radiator Cooling Fan Operation
IMTA0A160021-01
Installation
Reverse removal procedure noting the following points. 2) Set ignition “ON” and clear DTC. (DTC Clearance) in
Section 1A
• Install thermostat (1) and thermostat cap (2), referring
to “Thermostat Removal and Installation”, if removed. 3) Select “Radiator Fan” function in “Active Test”.
• Install ECT sensor (3), referring to “ECT Sensor 4) Check radiator cooling fan operation at low and high
Removal and Installation” in Section 1C, if removed. modes.
If any abnormality is found, check cooling fan control
• Replace gasket (4) with new one. system. (Radiator Cooling Fan System Check)
3 Radiator cooling fan operation
Select mode Radiator cooling fan motor
2 Off OFF
4
Low mode Low speed
High mode High speed
Radiator Cooling Fan Motor

IMTA0A160022-01 1) Disconnect radiator cooling fan motor connector (1).
• Install engine harness protector bracket and EVAP
canister purge valve, referring to “EVAP Canister
Purge Valve Removal and Installation” in Section 1B.
• Install water inlet pipe, referring to “Water Inlet Pipe
• Tighten thermostat case bolt (1) and nuts (2) to
specified torque.
Tightening torque
Thermostat case bolt (a): 25 N·m (2.5 kgf-m, 18.5
lbf-ft)
1
Thermostat case nut (b): 25 N·m (2.5 kgf-m, 18.5 IMTA0A160016-02
lbf-ft) 2) Using service wire, connect radiator cooling fan
motor connector and battery as shown in figure.
2, (b)
3) Check that radiator cooling fan motors rotate
smoothly and properly.
If any abnormality is found, replace radiator cooling
fan motor.
Reference: Fan motor specified current at 12 V
Low speed: 6.5 – 10.5 A
High speed: 10.1 – 15.1 A
2, (b) 1, (a)
IMTA0A160024-01

on pipe.
Installation
[A] [B] Reverse removal procedure noting the following points.
• Tighten reservoir bolt (1) to specified torque.
Tightening torque
Reservoir bolt (a): 11 N·m (1.1 kgf-m, 8.5 lbf-ft)
IMTA0A160017-01
[A]: Low speed [B]: High speed

1,
(a)
Radiator Cooling Fan Relay Inspection
AENNTA0E1606012 (08(03)
IMTA0A160025-03
Radiator Cooling Fan Assembly Removal and • If there is matchmark on each of hose and pipe, install
Installation the hose aligning matchmark on hose with matchmark
AENNTA0E1606013 (08(01) on pipe.
Reference: “Radiator Cooling Fan Assembly On-Vehicle
Inspection”
Reference: “Precautions for Electrical System Work” • Refill cooling system with coolant. (Cooling System
Refilling)
Removal • Check cooling system for leakage. (Engine Cooling
1) Drain coolant. (Cooling System Draining) System Inspection)
2) Disconnect radiator cooling fan motor connector (1).
Radiator Cooling Fan Disassembly and
Reassembly
AENNTA0E1606014 (08(02)
Reference: “Radiator Cooling Fan Assembly Removal
and Installation”
Disassembly
1) Remove radiator cooling fan (1) from radiator cooling
fan motor (2).
2) Remove radiator cooling fan motor from radiator
cooling fan shroud (3).
1
IMTA0A160016-02 3) Remove heat insulator (4) from radiator cooling fan
3) Disconnect radiator inlet hose from radiator. (Cooling shroud, if necessary.
System Hose Removal and Installation)
2
4) Remove reservoir bolt (1) and then remove reservoir
(2).
3
5) Unlock hook (3).
6) Remove radiator cooling fan assembly (4) from 1
radiator.
4
2 4
3 3
IMTA0A160038-02
1 Reassembly
Reverse disassembly procedure noting the following
point.
IMTA0A160043-01
• Tighten radiator cooling fan nut (1), radiator cooling 4) Remove front end upper cover, front end lower cover
fan motor screws (2) and heat insulator screw (3) to and front bumper lower absorber. (Front End Upper
specified torque. Cover, Front Bumper Lower Absorber, Front End
Lower Cover, Front Bumper Member and Front
Tightening torque
Lower Crossmember Removal and Installation) in
Radiator cooling fan nut (a): 6.3 N·m (0.64 kgf-m,
Section 9H
5.0 lbf-ft)
Radiator cooling fan motor screw (b): 3.9 N·m ( 5) Drain coolant. (Cooling System Draining)
0.40 kgf-m, 3.0 lbf-ft) 6) Disconnect radiator cooling fan motor connector (1).
Heat insulator screw (c): 2.5 N·m (0.25 kgf-m, 2.0
lbf-ft)
3, (c)
1, (a)
2, (b)
1
IMTA0A160016-02
IMTA0A160039-02 7) Disconnect radiator inlet hose and radiator outlet

hose from radiator. (Cooling System Hose Removal
Radiator On-Vehicle Inspection and Cleaning and Installation)
AENNTA0E1606015 (08(03)
Inspection 8) Detach condenser assembly (1) as follows.
Check radiator for leakage or damage. Straighten bent a) Remove condenser bolts. (Condenser Assembly
fins, if any. Removal and Installation) in Section 7B
b) With liquid pipe (2) and discharge hose (3)
Cleaning connected to condenser assembly, detach
Clean frontal area of radiator cores. condenser assembly from radiator (4).
c) Suspend the detached condenser assembly to
the vehicle body using strings (5) etc.
NOTICE
When condenser assembly is detached,
discharge hose and liquid hose could be
damaged receiving weight of condenser
assembly.
Suspend detached condenser assembly to
I2RH01160014-01
vehicle body while condenser assembly is
detached.
Radiator Removal and Installation
AENNTA0E1606016 (08(01)
Reference: “Radiator On-Vehicle Inspection and 3 5
Cleaning”
Removal
2) Remove engine side undercover at each of right and
left sides. (Front End Upper Cover, Front Bumper
Lower Absorber, Front End Lower Cover, Front 2 4 1
IMTA0A160026-01
Bumper Member and Front Lower Crossmember
Removal and Installation) in Section 9H 9) Support front lower crossmember (1) with jack (2).
3) Remove front bumper. (Front Bumper and Radiator 10) Remove front lower crossmember bolts (3).
Grille Removal and Installation) in Section 9H
11) Lower the jack, and then remove radiator (4)

together with front lower crossmember from vehicle
3
body. 2
12) Remove radiator from front lower crossmember.
IMTA0A160029-01
Installation
Reference: “Water Pump Inspection”
1) Apply sealant to mating surface of water pump as
1 2 4
shown in figure.
NOTICE
After having applied sealant, coolant leak is
3 3 Install within 2 minutes after applying
IMTA0A160028-01 sealant.
Installation “A”: Sealant 99000–31250 (SUZUKI Bond
Reverse removal procedure noting the following points. No.1207F)
“A”
on pipe.
• Tighten front lower crossmember bolts to specified
torque. (Front End Upper Cover, Front Bumper Lower “a”
Absorber, Front End Lower Cover, Front Bumper
“b”
Member and Front Lower Crossmember Removal and
Installation) in Section 9H “A”
• Refill cooling system with coolant. (Cooling System I7V20A161015-01
Refilling) “a”: 3 mm (0.12 in.) “b”: 2 mm (0.08 in.)

System Inspection) 2) Install water pump (1) to cylinder block.
3) Install generator adjusting arm (2) to water pump.
Water Pump Removal and Installation 4) Tighten water pump bolts (3) and nuts (4) to
AENNTA0E1606017 (08(01)
specified torque.
Removal
1) Drain coolant. (Cooling System Draining) Tightening torque
Water pump bolt (a): 25 N·m (2.5 kgf-m, 18.5 lbf-
ft)
Water pump nut (b): 25 N·m (2.5 kgf-m, 18.5 lbf-
3) Remove water pump pulley (1). ft)
4) Remove generator adjusting arm (2).
5) Remove water pump (3) from cylinder block.
1
2
4, (b)
3, (a)
IMTA0A160030-01
5) Install water pump pulley (1) to water pump (2).

6) Tighten water pump pulley bolts (3) to specified 9) Refill cooling system with coolant. (Cooling System
torque. Refilling)
Tightening torque 10) Check cooling system for leakage. (Engine Cooling
Water pump pulley bolt (c): 20 N·m (2.0 kgf-m, System Inspection)
15.0 lbf-ft)
Water Pump Inspection
7) Tighten generator upper bolt (4) to specified torque. AENNTA0E1606018 (08(03)
(Generator Removal and Installation) in Section 1J Reference: “Water Pump Removal and Installation”
Rotate water pump by hand to check for smooth
operation. If pump does not rotate smoothly or makes
2
abnormal noise, replace it.
3, (c)
IMTA0A160031-01

I2RH0B160019-01
Specifications
AENNTA0E1607001 (09(t)
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Drain plug 1.0 0.10 1.0 (T1F001)
Reservoir bolt 11 1.1 8.5 (T1F002) / (T1F008)
Water inlet pipe bolt 11 1.1 8.5 (T1F003)
Thermostat case nut 25 2.5 18.5 (T1F004) / (T1F007)
Thermostat cap bolt 11 1.1 8.5 (T1F005)
Thermostat case bolt 25 2.5 18.5 (T1F006)
Radiator cooling fan nut 6.3 0.64 5.0 (T1F009)
Radiator cooling fan motor screw 3.9 0.40 3.0 (T1F010)
Heat insulator screw 2.5 0.25 2.0 (T1F011)
Water pump bolt 25 2.5 18.5 (T1F012)
Water pump nut 25 2.5 18.5 (T1F013)
Water pump pulley bolt 20 2.0 15.0 (T1F014)
Reference:
“Cooling System Components”

AENNTA0E1608001 (11(m)
Sealant SUZUKI Bond No.1207F P/No.: 99000–31250 (M1F001)
NOTE
“Cooling System Components”
Fuel System: 1G-1
Fuel System
Engine
Precautions
Precautions for Fuel System Service • Since fuel hose connections vary with the
AENNTA0E1700001 (01(01) pipe type, connect and clamp each hose
! WARNING using the correct method for each specific
connection. (Fuel Hose Disconnection and
Service operation of any type performed on
Reconnection)
the fuel system involves a risk of fire and
After connecting a hose, check that there
personal injury if proper precautions are not
is no twist or kink in the hose.
taken.
Take the following precautions whenever • When installing a fuel injector or a fuel
working on the fuel system. feed pipe, lubricate its O-rings with
gasoline.
• Disconnect the negative (–) cable at the
battery. • Handle the fuel tank carefully. Do not allow
it to touch sharp edges or hot surfaces. Do
• Do not smoke. Put up no smoking signs
not drop it. If the tank is dropped, the tank
around the work area.
and all components on and in it should be
• Have CO2 fire extinguishers handy. replaced because they may have been
• Perform service operations only in a well- damaged.
ventilated area away from any open flames • When any pit and/or crack is found in fuel
such as gas water heaters. tank, never repair the tank but always
• Wear safety glasses. replace it with a new fuel tank.
• Remove the fuel filler cap from the fuel • As fuel tank is made of plastic, when
filler neck to relieve the fuel tank of fuel solvent such as grease and sealant is
vapor pressure, and then reinstall the cap. allowed to contact fuel tank, some
• Before loosening or disconnecting the fuel chemical reaction may occur, causing fuel
feed line, relieve the fuel system of fuel tank to be swollen, hardened or deformed,
pressure by following “Fuel Pressure resulting in fuel leakage from fuel tank.
Relief Procedure”. Do not allow solvent such as grease or
sealant to contact fuel tank. In addition,
• When disconnecting a fitting on the fuel
wipe off any solvent such as grease or
line, cover the fitting with a shop cloth to
sealant when it contacts tank, without
soak up the small amount of fuel that may
delay.
flow out from the disconnected fuel line.
Put the used cloth in an approved
container. NOTICE
• Never run the engine with the fuel pump If a leaded or low-lead fuel is used for this
relay disconnected when the engine and engine, the engine itself and the emission
exhaust system are hot. control system will be damaged.
Use only unleaded fuel for this engine.
General Description
Fuel System Description The fuel delivery system consists of the fuel tank, fuel
AENNTA0E1701001 (03(01) pump assembly (with fuel filter, fuel level sensor and fuel
The main components of the fuel system are fuel tank,
pressure regulator), delivery pipe, injectors and fuel feed
fuel pump assembly (with fuel filter, fuel level sensor and
line.
fuel pressure regulator), fuel feed line and fuel vapor
The fuel in the fuel tank is pumped up by the fuel pump,
line.
sent into fuel filter beside the tank and delivery pipe and
For the details of fuel flow, refer to “Fuel Delivery System
injected by the fuel injectors.
Diagram”.
As the fuel pump assembly is equipped with built-in fuel
filter and fuel pressure regulator, the fuel is filtered and
Fuel Delivery System Description its pressure is regulated before being sent to the feed
AENNTA0E1701002 (03(01)
pipe.
The excess fuel at fuel pressure regulation process is
returned back into the fuel tank.
1G-2 Fuel System:
Also, fuel vapor generated in fuel tank is led through the DUALJET System Description
fuel vapor line into the EVAP canister. AENNTA0E1701004 (03(01)
“DUALJET” system employs the dual injection system
For system diagram, refer to “Fuel Delivery System
that has two fuel injectors per cylinder. The two injectors
Diagram”.
inject fuel simultaneously to each cylinder respectively.
The injectors that are located close to the combustion
Fuel Pump Description chamber allow fuel to be injected in extremely fine mist,
AENNTA0E1701003 (03(01)
The fuel pump (1) is an in-tank type electric pump. improving the combustion efficiency.
Incorporated in the pump assembly are;
fuel filter (2), fuel pressure regulator (3) and fuel level
sensor (4).
1
4
8 7 6 5 4 3 2 1
IMTA0A170001-01
1. Fuel injector No.1-1 5. Fuel injector No.3-1

2
2 3. Fuel injector No.2-1 7. Fuel injector No.4-1
IGJA0A172001-01

Fuel Delivery System Diagram
AENNTA0E1702001 (10(03)
10
9
13
5 12
11
2 7 8
1
IMKC0A170004-01
1. Fuel tank 5. Fuel injector 9. Fuel vapor line 13. Fuel cut valve
2. Fuel pump assembly 6. Fuel feed line 10. Intake manifold
3. Fuel pressure regulator 7. Fuel filter 11. EVAP canister
4. Fuel delivery pipe 8. Fuel level sensor 12. EVAP canister purge valve
Fuel Injector Control System Circuit Diagram

AENNTA0E1702002 (10(01)
Fuel System: 1G-3
12
A1 1 B1
C01-31 PNK BLU 9
A2 2 B2
C01-36 BRN BLU
A3 3 B3
C01-11 WHT BLU
A4 4 B4
C01-23 GRY BLU
A5 5 B5
C01-10 RED BLU
A6 6 B6
C01-32 BEG BLU
A7 7 B7
C01-12 GRN BLU
A8 8 B8
C01-24 LT GRN BLU
11
E01-1 WHT 10
[A] C01 E01
[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49
IKRA0A173008-01
[A]: ECM connector (View: [a]) B2. Fuel injector No.1-2 power supply circuit 4. Fuel injector No.2-2
A1. Fuel injector No.1-1 drive circuit B3. Fuel injector No.2-1 power supply circuit 5. Fuel injector No.3-1
A5. Fuel injector No.3-1 drive circuit B7. Fuel injector No.4-1 power supply circuit 9. To main relay
A6. Fuel injector No.3-2 drive circuit B8. Fuel injector No.4-2 power supply circuit 10. To ignition power supply
A7. Fuel injector No.4-1 drive circuit 1. Fuel injector No.1-1 11. “IG” fuse
A8. Fuel injector No.4-2 drive circuit 2. Fuel injector No.1-2 12. ECM
B1. Fuel injector No.1-1 power supply circuit 3. Fuel injector No.2-1
Fuel Pump Control System Circuit Diagram

AENNTA0E1702003 (10(01)
3
+B
B1 A1
1
E01-24 RED BLU
2
BLK P PNK BLU
C1 B2 A2
[A] C01 E01
[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49
IMTA0A170060-02
1G-4 Fuel System:
[A]: ECM connector (View: [a]) B1: Fuel pump relay drive circuit 1. Fuel pump relay
A1: Fuel pump relay power supply circuit (coil side) B2: Fuel pump power supply circuit 2. Fuel pump
A2: Fuel pump relay power supply circuit (switch side) C1: Fuel pump ground circuit 3. ECM

Fuel System Inspection
AENNTA0E1704001 (06(01)
Step 1 Fuel pump sound check

1) Check fuel pump function hearing the sound. (Fuel Pump On-Vehicle Inspection)
Is check result OK?
Yes Go to Step 2.
No Check fuel pump circuit. (Fuel Pump and Its Circuit Check)
Step 2 Fuel hose pressure check

1) Check fuel pump function sensing the pressure at fuel feed hose. (Fuel Pump On-Vehicle Inspection)
Is check result OK?
Yes Go to Step 5.
No Go to Step 3.
Step 3 Fuel pressure check

1) Check fuel pressure. (Fuel Pressure Check)
Is check result OK?
Yes Go to Step 5.
No Go to Step 4.
Step 4 Fuel line check

1) Check the following items.
• Check fuel pipe, fuel hose and fuel joint for fuel leakage. (Fuel Leakage Check Procedure)
• Check fuel pipe, fuel hose and fuel line joint for damage or deformation. (Fuel Line On-Vehicle
Inspection)
Is check result OK?
Yes Fuel system is in good condition.

No Repair defective part.
Step 5 Power balance test

1) Check power balance. (Power Balance Test)
Is check result OK?

No Go to Step 6.
Step 6 Fuel injector circuit check

1) Check fuel injector circuit. (Fuel Injector Circuit Check)
Is check result OK?

Fuel System: 1G-5
Yes Go to Step 7.

1) Check fuel injector. (Fuel Injector Inspection)
Is check result OK?
No Replace fuel injector. (Fuel Injector Removal and Installation)
Power Balance Test 5) Using SUZUKI scan tool, select “Fuel Injector” in
AENNTA0E1704002 (06(01) “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 an 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 (Fuel Injector Circuit Check)
• Fuel injector (Fuel Injector Inspection)
1) Set the vehicle in the following conditions. • Spark plug (Spark Plug Inspection) in Section 1H
• For 5M/T model, place gear shift lever in “Neutral”. • Ignition coil circuit (Ignition System Check) in
• For AGS model, place select lever in N range. Section 1H
• Apply parking brake. • Ignition coil (Ignition Coil Assembly Inspection) in
• Block drive wheels. Section 1H
2) Connect SUZUKI scan tool to DLC. (Suzuki SDT-II • Engine compression (Compression Check) in
Connection and Disconnection) in Section 0A Section 1D
3) Clear DTC. (DTC Clearance) in Section 1A 8) Clear DTC, after completing service work. (DTC
4) Warm up engine to normal operating temperature. Clearance) in Section 1A
Fuel Injector Circuit Check

AENNTA0E1704003 (06(01)
1G-6 Fuel System:
Circuit Diagram
9 +B
A1 1 B1
C01-31 PNK BLU
A2 2 B2
C01-36 BRN BLU
A3 3 B3
C01-11 WHT BLU
A4 4 B4
C01-23 GRY BLU
A5 5 B5
C01-10 RED BLU
A6 6 B6
C01-32 BEG BLU
A7 7 B7
C01-12 GRN BLU
A8 8 B8
C01-24 LT GRN BLU
[A] C01 E01
[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49
ILKC0P170083-02
[A]: ECM connector (View: [a]) B1. Fuel injector No.1-1 power supply circuit 2. Fuel injector No.1-2
A7. Fuel injector No.4-1 drive circuit B8. Fuel injector No.4-2 power supply circuit 9. ECM
A8. Fuel injector No.4-2 drive circuit 1. Fuel injector No.1-1
Troubleshooting
Step 1 Fuel injector check for operating sound

1) Remove air cleaner assembly, if necessary. (Air Cleaner Assembly Removal and Installation) in Section
1D
2) Using sound scope, check each injector for operating sound at engine running or cranking.
Do all injectors make operating sound?
Yes Fuel injectors circuit is in good condition.

No Go to Step 2.
Step 2 Fuel injector resistance check

1) With ignition “OFF”, disconnect connectors from fuel injectors.
2) Check for proper terminal connection to fuel injector connectors.
3) If connections are OK, check all fuel injectors for resistance. (Fuel Injector On-Vehicle Inspection)
Fuel System: 1G-7
Is check result OK?
Yes Go to Step 3.
Step 3 Fuel injector insulation resistance check

1) Check that resistance between each fuel injector terminal and ground is infinity.
Is check result OK?
Yes Go to Step 4.
Step 4 Fuel injector power supply circuit check

2) Check that voltage between each of “B1” – “B8” and ground is battery voltage.
Is check result OK?
Yes Go to Step 5.
No Repair fuel injector power supply circuit.
Step 5 Fuel injector drive circuit check

1) With ignition “OFF”, disconnect “C01” and “E01” connectors from ECM.
2) Check for proper terminal connection to “C01” and “E01” connectors.
• Resistance of “A1” – “A8”: less than 1 Ω
• Resistance between each of “A1” – “A8” circuit and ground: infinity
• Resistance between each of “A1” – “A8” circuit terminal and other terminal at ECM connector: infinity
• Voltage of “A1” – “A8” circuits: approx. 0 V (when ignition is “ON”)
Is check result OK?
Yes Go to Step 6.
No Repair fuel injector drive circuit.

1) Check fuel injector. (Fuel Injector Inspection)
Is check result OK?
Yes Replace ECM and recheck fuel injector operation. (ECM Removal and Installation) in Section 1C
Fuel Pump and Its Circuit Check

AENNTA0E1704004 (06(01)
1G-8 Fuel System:
Circuit Diagram
3
+B
B1 A1
1
E01-24 RED BLU
2
BLK P PNK BLU
C1 B2 A2
[A] C01 E01
[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49
IMTA0A170060-02
[A]: ECM connector (View: [a]) B1: Fuel pump relay drive circuit 1. Fuel pump relay
A1: Fuel pump relay power supply circuit (coil side) B2: Fuel pump power supply circuit 2. Fuel pump
A2: Fuel pump relay power supply circuit (switch side) C1: Fuel pump ground circuit 3. ECM
Troubleshooting
Step 1 Fuel pump sound check

1) Check fuel pump function hearing the sound. (Fuel Pump On-Vehicle Inspection)
Is check result OK?
Yes Fuel pump circuit is in good condition. Reinstall fuel filler cap.
No Go to Step 2.
Step 2 Fuel pump relay power supply circuit check

2) Remove fuel pump relay from individual circuit fuse box No.1.
3) Check for proper terminal connection to fuel pump relay connector.
4) If OK, set ignition “ON”.
5) Check that voltage between each of “A1” and “A2” and ground is battery voltage.
Is check result OK?
Yes Go to Step 3.
No Repair fuel pump relay power supply circuit.
Step 3 Fuel pump relay check

1) Check fuel pump relay. (Control Relay Inspection) in Section 10B
Is check result OK?
Yes Go to Step 4.
No Replace fuel pump relay.
Step 4 Fuel pump relay drive circuit check

Fuel System: 1G-9
2) Disconnect “C01” and “E01” connectors from ECM.

3) Check for proper terminal connection to “C01” and “E01” connectors.
Is check result OK?
Yes Go to Step 5.
No Repair fuel pump relay drive circuit.
Step 5 Fuel pump relay drive circuit signal check

2) Connect “C01” and “E01” connectors to ECM.
3) Using service wire, connect fuel pump relay.
4) Check that voltage between “B1” and ground is approx. 0 V for 2 seconds after the ignition is “ON”.
Is check result OK?
Yes Go to Step 6.
No Replace ECM and recheck fuel pump operation. (ECM Removal and Installation) in Section 1C
Step 6 Fuel pump power supply circuit check 1

1) Check that ignition is “OFF”.
2) Remove fuel tank. (Fuel Tank Removal and Installation)
3) Disconnect fuel pump connector.
4) Check that resistance between “B2” and ground is infinity.
Is check result OK?
Yes Go to Step 7.
No Repair fuel pump power supply circuit.
Step 7 Fuel pump power supply circuit check 2

1) Connect service wire between “B1” and ground.
3) Check that voltage between “B2” and ground is battery voltage.
Is check result OK?
Yes Go to Step 8.
No Repair fuel pump power supply circuit.
Step 8 Fuel pump ground circuit check

2) Check that resistance between “B3” and ground is less than 1 Ω.
Is check result OK?
Yes Replace fuel pump. (Fuel Pump Assembly Removal and Installation)
No Repair fuel pump ground circuit.
1G-10 Fuel System:
Fuel Pressure Check

AENNTA0E1704005 (06(01)
System Diagram
Special tool
(A): 09912M58442
(B): 09912M58432
(C): 09912M58490
1
(A)
(B)
(C) 3
IMKC0A170001-01
1. Fuel injector 2. Fuel delivery pipe 3. Fuel pump assembly
Troubleshooting
NOTE
Before using the following flow chart, 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 1 Was “Fuel Pump and Its Circuit Check” performed?
Yes Go to Step 2.
No Go to “Fuel Pump and Its Circuit Check”.
Step 2 Fuel pressure check 1

1) Check fuel pressure. (Fuel Pressure Basic Check)
Is check result OK?
Yes Go to Step 3.
No Go to Step 5.
Step 3 Fuel pressure check 2

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?
Yes Go to Step 4.
No Fuel pressure regulator is in faulty condition. Replace fuel pump assembly. (Fuel Pump Assembly

1) Check fuel pipe and joint for fuel leakage, damage or deformation.
Is check result OK?

Fuel System: 1G-11


1) Check fuel pipe and joint for damage or deformation.
Is check result OK?
Yes Clogged fuel filter, faulty fuel pump, faulty fuel pressure regulator or fuel leakage from pipe
connection in fuel tank.
Fuel Pressure Basic Check If measured pressure is out of specification, refer to

AENNTA0E1704006 (06(01) “Fuel Pressure Check” and check each possible
defective part. Replace if found defective.
“Precautions for Fuel System Service”.
6) Relieve fuel pressure. (Fuel Pressure Relief
1) Relieve fuel pressure from fuel feed line. (Fuel
Procedure)
Pressure Relief Procedure)
7) Remove special tools from fuel feed hose and fuel
2) Disconnect fuel feed hose (1) from fuel feed pipe
feed pipe (body side).
(body side) (2).
8) Connect fuel feed hose to fuel feed pipe (body side)
3) Connect special tools and hose between fuel feed
and clamp it securely. (Fuel Hose Disconnection and
hose and fuel feed pipe (body side) as shown in
Reconnection)
figure, and clamp hoses securely to check that no
leakage occurs during checking. 9) With engine stopped, set ignition “ON” and check for
fuel leakage. (Fuel Leakage Check Procedure)
Special tool
(A): 09912M58442 Fuel Cut Operation Inspection
(B): 09912M58432 AENNTA0E1704007 (06(01)
(C): 09912M58490 1) Set the vehicle in the following conditions.
(B) (A)
1 (C) • For AGS model, place select lever in N range.
3) While listening to sound of fuel injector (1) using
sound scope (2) or the like, increase engine speed
to higher than 3,000 rpm.
2
IMTA0A170002-01
4) Check that battery voltage is 11 V or more.

5) Measure fuel pressure as follows.
a) Set ignition “ON” to operate fuel pump.
b) After 2 seconds, set ignition “OFF”.
c) Repeat Step a) – b) 3 or 4 times and then check
fuel pressure.
1
IMTA0A170003-02
Fuel pressure specification
With fuel pump operating and engine 4) Check that fuel injector operation sound stops when
stopped: 375 – 385 kPa (3.8 – 3.9 kgf/cm2, throttle valve is closed instantly and it resumes when
54.4 – 55.8 psi) engine speed decreases to 2,000 rpm.
1G-12 Fuel System:
Repair Instructions
Fuel System Components
AENNTA0E1706001 (12(01)
(a)
1 5
2
7
3
6 8 8
2 4
8
8
8
10
(e) 23
11
12
8
22
13
8 18
8
14
20
(d)
15
19 (c) 21 (c)
16
17
(b)
IMTA0A170004-02
Fuel System: 1G-13
1. Fuel delivery pipe 11. Fuel pump assembly 21. Fuel filler side clamp
: For installation, refer to “Fuel Hose
Disconnection and Reconnection”.
2. O-ring (fuel Injector) 12. O-ring (fuel pump) 22. Fuel filler neck
: Apply thin coat of fuel to install.
3. Fuel injector 13. Pad 23. Fuel filler cap
: For installation, refer to “Fuel Injector Removal and
Installation”.
4. Fuel injector clip 14. Fuel tank : 25 Nm (2.5 kgf-m, 18.5 lbf-ft)
: For installation, refer to “Fuel Injector Removal and
Installation”.
5. Fuel feed hose 15. Heat insulator : 14 Nm (1.4 kgf-m, 10.5 lbf-ft)
: For installation, refer to “Fuel Hose Disconnection
and Reconnection”.
6. To intake manifold 16. Fuel tank baffle plate : 2.0 Nm (0.20 kgf-m, 1.5 lbf-ft)
: For removal and installation, refer to
“Fuel Tank Removal and Installation”.
7. Fuel feed pipe (body side) 17. Fuel tank belt : 5.5 Nm (0.56 kgf-m, 4.0 lbf-ft)
8. To vehicle body 18. Breather hose : 3.0 Nm (0.31 kgf-m, 2.5 lbf-ft)
: For installation, refer to “Fuel Hose
Disconnection and Reconnection”.
9. Fuel feed pipe (fuel pump side) 19. Fuel tank side clamp : Do not reuse.
: For disconnect and connect of quick joint, refer to : For installation, refer to “Fuel Hose
the followings. Disconnection and Reconnection”.
• “Fuel Pipe Removal and Installation”
• “Fuel Pump Assembly Removal and Installation”
10. Fuel pump lock nut 20. Fuel tank filler hose
: For removal and installation, refer to “Fuel Pump : For removal and installation, “Fuel Hose
Assembly Removal and Installation”. Disconnection and Reconnection”.
Fuel Hose Disconnection and Reconnection

AENNTA0E1706002 (08(01) 1
“Precautions for Fuel System Service”. “a”
NOTE
2
For disconnect and connect of quick joint,
ICV00P170012-01
refer to the followings.
• “Fuel Pipe Removal and Installation” 3) Hoist vehicle. (Vehicle Lifting Points) in Section 0A
• “Fuel Pump Assembly Removal and 4) Turn filler and breather hose clamp (1) in arrow
Installation” direction.
Disconnection 5) Loosen fuel tank side clamp (2) and fuel filler side
Fuel tank filler hose and breather hose clamp (3).
1) Remove fuel filler cap. 6) Disconnect fuel tank filler hose (4) from fuel tank and
fuel filler neck.
2) Insert hose of hand operated pump into fuel tank
through fuel filler neck (1), and then pump out fuel in 3 1
space “a” shown in figure.
! 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.
Store the fuel in a sealed metal container.
NOTICE
The hose of the hand-operated pump could 2 4
IMTA0A170005-01
damage the fuel tank inlet valve (2) if
7) Remove breather hose (1) from clamp (2) of fuel
excessive force is applied when inserting or
tank.
removing it from the fuel tank.
Do not apply excessive force when inserting 8) Release clamps (3) and disconnect breather hose
or removing the hose of the hand-operated from fuel tank and fuel filler neck.
pump.
1G-14 Fuel System:
NOTE 2) Remove air cleaner assembly. (Air Cleaner

Lower fuel tank a little referring to “Fuel Tank Assembly Removal and Installation) in Section 1D
Removal and Installation”, if necessary. 3) Disconnect fuel feed hose (1) from clamp (2).
4) Release clamps (3) and disconnect fuel feed hose
from fuel delivery pipe and fuel feed pipe (body
3
side).
3
1 2 3
1 2
IMTA0A170007-01
IMTA0A170006-01
Fuel feed hose
Reconnection
Fuel tank filler hose and breather hose
• Install fuel tank filler hose and breather hose at the specified angles and dimensions shown in figure.
• Tighten fuel tank side clamp (7) and fuel filler side clamp (8) to specified torque.
Tightening torque
Fuel tank side clamp (a): 2.0 N·m (0.20 kgf-m, 1.5 lbf-ft)
Fuel filler side clamp (b): 2.0 N·m (0.20 kgf-m, 1.5 lbf-ft)
[u] [u] 3 2 4
“a”
“b” “f”
1 2 3 [l]
“b” “g”
“a”
[l] [d]
[d] 4
4
6
8, (b)
5
7, (a)
“a” [u] 8 4
“c” “f”
1 7 6 5 “h” [l]
[l]
5 “d” “d”
“e” “i”
[d]
IMTA0A170008-01
Fuel System: 1G-15
[d]: Vehicle downward “d”: 20 mm (0.79 in.) 1. Fuel tank

[l]: Vehicle leftward “e”: 0 – 8 mm (0 – 0.31 in.) 2. Clamp
[u]: Vehicle upward “f”: 0° ± 22.5° 3. Breather hose
“a”: 0 mm (0 in.) “g”: 45° ± 22.5° 4. Fuel filler neck
“b”: 3 – 7 mm (0.12 – 0.27 in.) “h”: 10° 5. Fuel tank filler hose
: For marking positions. : Install with the fuel tank side marking upward.
“c”: 5 – 10 mm (0.20 – 0.39 in.) “i”: 67.5° ± 22.5° 6. Marking
Fuel feed hose

Reverse removal procedure noting the following points. 3 “a” 2 1
• Align match marks (1) of fuel feed hose (2) and fuel
feed pipe (body side) (3).
2 3 “b”
3 “a” 2 1
2
1
“b”
3
3 “a” 2 1
IMTA0A170009-01
• Install with the fuel delivery pipe (1) side mark (2) of
fuel feed hose (3) upward.
“b”
3
ILKC0P170014-01
“a” 3 – 7 mm (0.12 – 0.27 in.)

“b” 0 mm (0 in.)
3 2
1 3. Stopper, protective tube or fuel delivery pipe
• Install clamps (1) at the specified angles shown in

figure.
• Install with mark (2) of fuel feed hose (3) upward, and
align its mark and clamp (4) position.
IMTA0A170010-01
3 2 4
• Install fuel feed hose (1) and clamps (2) at the
specified dimensions shown in figure.
3 4 1
[u] 1 [u] 1 [f]
[l] [f]
[l]
IMTA0A170011-01
[f]: Vehicle forward [u]: Vehicle upward

[l]: Vehicle leftward
1G-16 Fuel System:
Fuel Pressure Relief Procedure Fuel Line On-Vehicle Inspection

AENNTA0E1706003 (08(01) AENNTA0E1706005 (08(03)
Reference: “Precautions for Electrical System Work” 1) Visually check the following items.
If check result is not OK, replace defective parts.
NOTICE
• Evidence of fuel leakage.
Performing this procedure when the engine
is still hot can damage the catalyst. • Crack, deterioration and/or damage of fuel feed
Wait until the engine has cooled down before hose (1).
performing this procedure. • Bent and/or damage of fuel feed pipe (body side)
(2).
NOTE 2) Check that all clamps (3) is clamped securely.
Clear DTCs, if any DTC is detected. (DTC If check result is not OK, replace defective parts.
Clearance) in Section 1A In engine compartment
1 2
1) Check that engine is cold.
3) Remove fuel pump relay (1) from individual circuit
fuse box No.1 (2).
4) Remove fuel filler cap to release fuel vapor pressure 3
IMTA0A170016-02
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 Front floor side
seconds each time to dissipate fuel pressure in lines. 1
Fuel connections are now safe for servicing.
6) After servicing, install fuel pump relay to individual
circuit fuse box No.1 and install individual circuit fuse
box No.1 cover.
2
IMTA0A170017-01
Rear floor side

1
1 2
IMTA0A170012-01
Fuel Leakage Check Procedure

AENNTA0E1706004 (08(03)
After performing any service on fuel system, check that
there are no fuel leakage as follows.
1) Set ignition “ON” for 3 seconds (to operate fuel
pump) and then to “OFF”. Repeat this cycle of
operation 3 or 4 times. 2
IMTA0A170018-01
Fuel pressure should now be established in fuel
system and felt by hand on fuel feed hose. 3) Check that quick joint (1) of fuel feed pipe (fuel pump
side) (2) is securely connected to fuel feed pipe
2) Check that there is no fuel leakage from any part of
(body side) (3).
fuel system.
Fuel System: 1G-17
1
2 2
1 1
3 3
IMTA0A170020-01 IMTA0A170021-01
5) Mark (1) the location of clamps (2) on fuel feed pipe

Fuel Pipe Removal and Installation (body side) (3), so that the clamps can be reinstalled
AENNTA0E1706006 (08(01)
to the original position.
Reference: “Fuel Pressure Relief Procedure”
Reference: “Fuel System Components” 6) Remove clamps from vehicle body and fuel feed
Before performing the following procedure, observe pipe (body side) etc.
“Precautions for Fuel System Service”. 7) Remove fuel feed pipe (body side).
Front floor side
NOTICE
2
Fuel feed pipe pipe (body side) may be bent
or damaged if you are not careful when
unclamping them.
Properly support fuel feed pipe (body side)
when removing clamps.
1
2 3
Removal
2) Disconnect fuel feed hose (1) from fuel feed pipe
3
(body side) (2). IMTA0A170022-02
3) Remove fuel feed pipe (body side) from clamp (3).

Rear floor side
1 2
2
1
2 3
3 3
IMTA0A170016-02 IMTA0A170024-02
4) Disconnect quick joint (1) of fuel feed pipe (fuel

pump side) (2) from fuel feed pipe (body side) (3) as Installation
follows. 1) Install clamps (2) to marked (1) position on fuel feed
a) Remove mud, dust and/or foreign material pipe (body side) (3).
between fuel feed pipe (body side) and quick If clamp is deformed or has bent or broken claws,
joint by blowing compressed air. replace it with new one.
b) Release lock pin (4) in arrow direction as shown 2) Install fuel feed pipe (body side) together with
in figure, and disconnect quick joint. clamps to vehicle.
1G-18 Fuel System:
Front floor side

4 2
2
3 2
1
2 3
1
3
3 IMTA0A170026-01
IMTA0A170022-02
7) With engine stopped, set ignition “ON” and check for
Rear floor side
2 Fuel Injector On-Vehicle Inspection
AENNTA0E1706007 (08(03)
NOTE
1
• Operation check can be confirmed using
2 3 “Fuel Injector” function in “Active Test”
mode on Suzuki SDT-II.
• After inspection, install injector
connectors referring to “Fuel Injector
3
IMTA0A170024-02 Removal and Installation”.
3) Connect quick joint (1) of fuel feed pipe (fuel pump • Remove air cleaner assembly, if necessary.
side) (2) to fuel feed pipe (body side) (3) as follows. (Air Cleaner Assembly Removal and
a) Clean the outside surface of fuel feed pipe (body
side) where quick joint is to be installed.
Fuel Injector Operating Sound Check
b) Insert quick joint to fuel feed pipe (body side) Using sound scope (2) or the like, check operating
until they lock securely (a click is heard). sound of fuel injector (1) when engine is running or
c) Push lock pin (4) to its original position. cranking.
d) Check that quick joint is not disconnected by Cycle of operating sound should vary according to
hand. engine speed.
If no sound or unusual sound is heard, check fuel
4
injector circuit (wire or connector) or fuel injector. (Fuel
Injector Circuit Check)
3 2
1
2
1
3
IMTA0A170025-01
4) Align mark (1) on fuel feed pipe (body side) (2) to

center of clamp (3).
5) Install fuel feed pipe (body side) to clamp.
6) Refer to “Fuel Hose Disconnection and 1
IMTA0A170003-02
Reconnection”, and then connect fuel feed hose (4)
to fuel feed pipe (body side).
Fuel Injector Resistance Check
Disconnect connector (1) from fuel injector (2), connect
ohmmeter between terminals of fuel injector and check
resistance.
Fuel System: 1G-19
If resistance is out of reference value greatly, replace

fuel injector. 3
Reference resistance of fuel injector

11.6 – 12.4 Ω at 20 °C (68 °F)
1 4 1
IMTA0A170029-01
7) Remove fuel delivery pipe bolts (1), and then remove

fuel injectors (2) together with fuel delivery pipe (3).
1 2 1
IMTA0A170027-01
Fuel Injector Insulation Resistance Check

Disconnect connector (1) from fuel injector (2), connect
ohmmeter between each fuel injector terminal and 3
ground and check resistance.
If resistance is other than infinity, replace fuel injector.
2 2
IMTA0A170032-01
8) Remove fuel injector (2) from fuel delivery pipe (1)

as follows.
a) Expand fuel injector clip (3) in arrow “1”
directions to unhook it, and then remove it in
arrow “2” direction.
b) Remove fuel injector.
1 2 1
IMTA0A170028-01
Fuel Injector Removal and Installation

AENNTA0E1706008 (08(01) “1”
Reference: “Fuel Injector On-Vehicle Inspection”
Reference: “Precautions for Electrical System Work” “1”

Removal 2 “2”
1) Relieve fuel pressure. (Fuel Pressure Relief 3
Procedure) ILKC0P170047-01

Installation
Reference: “Fuel Injector Inspection”
3) Disconnect fuel injector connectors (1).
4) Disconnect engine harness clamps (2). NOTICE
5) Remove engine harness protector bolts (3). Failure to take the following precautions may
6) Disconnect fuel feed hose (4) from fuel delivery pipe affect O-ring and cause leakage of high
(5). pressure fuel.
• Replace O-ring in clean condition.
• Do not reuse O-ring once removed.
1G-20 Fuel System:
• To avoid damaging injector, do not use

metal tool for removal of O-ring. 3
• Check injector groove for cleanliness

before fitting O-ring. [b] [a]
• Fit new O-ring with a minimum stretch. 2
• After fitting O-ring, check for proper

seating and cleanliness.
NOTE
Outside diameter of O-ring is different 1
ILKC0P170049-01
between nozzle side and delivery pipe side.
Install O-ring with small outside diameter to 2) Install fuel delivery pipe together with injectors to
nozzle side and O-ring with large outside cylinder head as follows.
diameter to delivery pipe side. a) Apply thin coat of fuel to fuel injectors (1) nozzle
side O-rings (2).
1) Install fuel injectors to fuel delivery pipe as follows.
a) Install new O-rings (1) to fuel injector (2).
2
1 1
IMTA0A170061-01
b) Install fuel injectors (1) together with fuel delivery

pipe to cylinder head (2), until stays (3) of fuel
IFKA0P170014-01 delivery pipe come in contact with boss (4) of
b) Align [a] and [b] shown in the figure with fuel cylinder head.
injector (2), and then install fuel injector clip (1) to
3
fuel injector.
[a]
1
1
[b]
2 4
2 IMTA0A170033-01
ILKC0P170048-01
c) Tighten fuel delivery pipe bolts (1) to specified
c) Apply thin coat of fuel to fuel delivery pipe side torque.
O-ring (2) of fuel injector (1).
Tightening torque
d) Align [a] shown in the figure with fuel delivery
Fuel delivery pipe bolt (a): 25 N·m (2.5 kgf-
pipe (3), insert fuel injector to fuel delivery pipe
m, 18.5 lbf-ft)
until [b] fits.
Fuel System: 1G-21
Tightening torque
1, (a) Engine harness protector bolts (a): 10 N·m (1.0
kgf-m, 7.5 lbf-ft)
4, (a)
IMTA0A170035-01
d) Check that fuel injectors (1) can be rotated

smoothly (2). 3
If check result is not OK, probable cause is
1
incorrect installation of O-ring (3). In such a case, IMTA0A170037-01
replace the O-ring with new one again. 7) Install air cleaner assembly. (Air Cleaner Assembly
1
3 fuel leakage. (Fuel Leakage Check Procedure)
Fuel Injector Inspection

AENNTA0E1706009 (08(03)
3 Reference: “Fuel Injector Removal and Installation”
! WARNING
2 There is an increased risk of personal injury

IFKA0P170043-01
and fire if the following procedure is
3) Connect fuel injector connectors as follows. performed without taking proper precautions.
• Connect black connector (1) (and black harness Put fuel injectors as far away from the battery
tube) to No. 1 -1, No. 2 -1, No. 3 -1, and No. 4 -1 as possible when connecting / disconnecting
fuel injectors (2). the test lead to / from the battery.
• Connect gray connector (3) (and blue harness
tube) to No. 1 -2, No. 2 -2, No. 3 -2, and No. 4 -2 1) Remove fuel injector. (Fuel Injector Removal and
fuel injectors (4). Installation)
2) Set special tools as follows.
[a]
4
Special tool
2
(A): 09912M58421
(B): 09912M57610
(C): 09912M97110
3
(D): 09912M97120
1
a) Install special tool (A) and special tool (C) to fuel
injector (1).
b) Connect special tool (D) to fuel injector.
IMTA0A170036-01
c) Install special tool (B) to special tool (A).
[a]: Crankshaft pulley side d) Connect fuel feed hose to special tool (A).
4) Connect fuel feed hose (1) to fuel delivery pipe (2).

5) Connect engine harness clamps(3).
6) Tighten engine harness protector bolts (4) to
specified torque.
1G-22 Fuel System:
c) Connect “4” terminal and “5” terminal of relay

(B) connector (3) using service wire (4).
NOTICE
If the service wire is connected between the
wrong terminals, the ECM, wire harness, etc.
(A) (C)
may be damaged.
Connect the service wire to the correct
terminals.
(D)
4 1
3
3 2 1
1 4
(C) 3
3 2 1
IDP70P171030-01 4 4
3) Install suitable vinyl tube (1) onto fuel injector nozzle 2
IMTA0A170038-01
to prevent fuel from splashing out during injection.
d) Set ignition “ON”.
4) Put graduated cylinder (2) under fuel injector.
7) Apply battery voltage to fuel injector for 15 sec. and
5) Connect one of terminal of special tool (D) to battery
measure injected fuel volume with graduated
positive (+) terminal.
cylinder. Test each fuel injector two or three times.
Special tool If injected volume is out of reference value greatly,
(D): 09930M86310 replace fuel injector.
NOTE
Fuel pump operates for 30 seconds when
SUZUKI scan tool (Suzuki SDT-II) is used,
(D) measure injected fuel volume within 30
seconds.
Reference injected fuel volume

27.2 – 28.8 cm3/15 sec. (0.057/0.048 – 0.061/0.051
US/Imp pt/15 sec.)
1
IDP70P171031-01
6) Operate fuel pump and apply fuel pressure to fuel

injector as follows:
Using SUZUKI scan tool:
a) Connect SUZUKI scan tool to DLC. (Suzuki
SDT-II Connection and Disconnection) in Section
0A
b) Set ignition “ON”, and clear DTC. (DTC
Clearance) in Section 1A
c) Select “Fuel Pump” under “Active Test” mode on IDP70P171032-01
scan tool, and operate fuel pump on. 8) Check fuel leakage from injector nozzle.
Without using SUZUKI scan tool: Do not operate fuel injector for this check (but fuel
a) Set ignition “OFF”. pump should be at work).
b) Remove fuel pump relay (1) from individual If fuel leaks (1) more than the following specification,
circuit fuse box No.1 (2). replace fuel injector.
Fuel System: 1G-23
Fuel leakage Before performing the following procedure, observe

Less than 1 drop/min. “Precautions for Fuel System Service”.
Removal
2) Refer to “Fuel Hose Disconnection and
Reconnection”, and then disconnect fuel tank filler
hose (1) and breather hose (2) from fuel filler neck
(3).
3) Remove air suction hose (4) from fuel filler neck.
1
1 3 2
IDP70P171033-01
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. 4
IMTA0A170048-02
10) Carry out Step 2) – 9) on each fuel injector. 4) Release lock pin and disconnect quick joint of fuel
11) After checking, remove special tools from fuel feed pipe (fuel pump side) (1) from fuel feed pipe
injector and fuel feed hose. (body side) (2). (Fuel Pipe Removal and Installation)
12) Install fuel injectors to cylinder head. (Fuel Injector 5) Disconnect quick joint (3) of EVAP pipe (canister to
Removal and Installation) pipe) (4) from EVAP pipe (5) as follows.
13) Install fuel pump relay to individual circuit fuse box a) Remove mud, dust and/or foreign material
No.1, if removed. between EVAP pipe and quick joint by blowing
14) With engine stopped, set ignition “ON” and check for compressed air.
fuel leakage. (Fuel Leakage Check Procedure) b) Disconnect quick joint using special tool.
Special tool
Fuel Filler Cap Inspection (A): 09919M47020
AENNTA0E1706010 (08(03)
NOTICE
Failure to use correct cap can result in EVAP 2
5
leakage.
If cap requires replacement, use a cap with
genuine SUZUKI parts.
Remove cap (1), and check gasket for even filler neck
imprint, deterioration or any damage. If gasket (2) is
defective, replace cap.
3
5
4 4 1
2
(A)
IMTA0A170039-01
1 6) Remove heat insulator (1), if necessary.

7) Remove muffler. (Exhaust System Components) in
I9W10P170020-01
Section 1K
8) Support fuel tank (2) with jack (3) and remove fuel
Fuel Tank Removal and Installation tank bolts (4).
AENNTA0E1706011 (08(01)
1G-24 Fuel System:
a) Hang hook (1) of fuel tank belt to flange (2)of fuel

1 4 tank.
b) Insert hook (4) of fuel tank to hole (3) of fuel tank
4 belt.
1 2
3
4 3 4
IMTA0A170040-01
9) Lower fuel tank (1) a little to disconnect fuel pump

4
connector (2). ILKC0P170060-01
10) Lower and remove the fuel tank from vehicle. 2) If removed, install fuel tank baffle plate (1) as follows.
2
a) Install fuel tank baffle plate in numerical order
(“1” – “2”).
“1”
“2”
1
1
IMTA0A170041-01
IMTA0A170043-01
11) Remove fuel tank filler hose and breather hose from
b) Install fuel pump. (Fuel Pump Assembly
fuel tank, if necessary. (Fuel Hose Disconnection
and Reconnection)
12) Remove EVAP canister, if necessary. (EVAP
Reconnection”, and then install fuel tank filler hose
Canister Removal and Installation) in Section 1B
and breather hose to fuel tank, if removed.
13) If necessary, remove fuel tank baffle plate as follows.
4) Install EVAP canister, if removed. (EVAP Canister
a) Remove fuel pump. (Fuel Pump Assembly Removal and Installation) in Section 1B
5) Raise fuel tank (1) part way up with jack (2) and
b) Drain fuel from fuel tank. connect fuel pump connector (3).
c) Remove fuel tank baffle plate (1) in numerical 6) Raise fuel tank to original position.
order (“1” – “2”).
7) Install fuel tank to vehicle body, and tighten new fuel
tank bolts (4) to specified torque.
NOTICE
The fuel tank bolts are pre-coated with
“2” friction stabilizer. If the bolts are reused, they
may work loose.
“1”
Use the new fuel tank bolts.
Tightening torque
1
Fuel tank bolt (a): 14 N·m (1.4 kgf-m, 10.5 lbf-ft)
IMTA0A170042-01
8) If removed, install heat insulator (5) to fuel tank.
14) Remove fuel tank belt, if necessary.
Installation
Reference: “Fuel Tank Inspection”
Reference: “Fuel Tank Flushing Procedure”
1) If removed, install fuel tank belt as follows.
Fuel System: 1G-25
3 1 3 2
4
5 4, (a) IMTA0A170048-02
4, (a)
Fuel Tank Inspection

AENNTA0E1706012 (08(03)
1 Reference: “Fuel Tank Removal and Installation”
• Check fuel tank for crack, deformation or damage.
If faulty condition is found, replace fuel tank.
• Check fuel pump O-ring for fuel leakage.
4, (a) 2 4, (a) If faulty condition is found, replace O-ring and fuel
IMTA0A170044-01
pump lock nut.
9) Connect fuel feed pipe (fuel pump side) (1) to fuel
feed pipe (body side) (2) and push lock pin. (Fuel
Pipe Removal and Installation) Fuel Tank Flushing Procedure
AENNTA0E1706013 (08(03)
10) Connect EVAP pipe (canister to pipe) (3) to EVAP Reference: “Fuel Tank Removal and Installation”
pipe (4).
! WARNING
NOTE
This flushing procedure cannot remove all
• Clean the outside surface of the pipe fuel vapors in the fuel tank completely, so
where each quick joint is to be installed. using a flame or electric heater to dry the fuel
• Push the pipe into the joint until the joint tank will increase the risk of an explosion
lock clicks, and then check that the pipe is which may cause human injury.
connected securely. Do not use a flame and/or electric heater to
dry the fuel tank.
2 Before performing the following procedure, observe

4
1) Remove fuel tank. (Fuel Tank Removal and
Installation)
2) Remove all hoses, pipes and fuel pump assembly
from fuel tank.
• Fuel tank filler hose and breather hose (Fuel Hose
Disconnection and Reconnection)
• Fuel pump assembly (Fuel Pump Assembly
3 1 Removal and Installation)
IMTA0A170059-01
3) Drain all remaining fuel from tank.
Reconnection”, and then connect fuel tank filler hose 4) Place fuel tank to flushing area.
(1) and breather hose (2) to fuel filler neck (3). 5) Fill tank with warm water or tap water, agitate water
12) Connect air suction hose (4) to fuel filler neck. vigorously, and drain water out of tank.
Repeat this process until inside of tank is clean.
6) Completely flush out remaining water.
7) Dry fuel tank assembly thoroughly in a place free of
direct sunlight.
1G-26 Fuel System:
Fuel Pump On-Vehicle Inspection Removal

AENNTA0E1706014 (08(03)
NOTE 1) Remove fuel tank from vehicle. (Fuel Tank Removal
and Installation)
Fuel pressure regulator is an integral part of
2) Disconnect quick joint (1) of fuel feed pipe (fuel
fuel pump assembly. Fuel pressure regulator
pump side) (2) from fuel pump assembly (3) using
cannot be individually checked.
special tool.
1) Remove fuel filler cap and set ignition “ON”. Fuel Special tool
pump operation sound should be heard from fuel (A): 09919M47020
filler for about 2 seconds. Reinstall fuel filler cap.
If check result is not as specified, go to “Fuel Pump 2
and Its Circuit Check”.
2
1 (A)
3
IMTA0A170049-02
3) Remove fuel pump lock nut (1) from fuel tank (2)
IMTA0A170046-01 using special tool.
2) Set ignition “OFF” and leave it over 10 minutes as it
NOTICE
is.
If fuel pump lock nut is left removed for a
3) Fuel pressure should be felt at fuel feed hose (1) for
long time, the screw part on fuel tank side
about 2 seconds after setting ignition “ON”.
deforms and it might be difficult to tighten
If fuel pressure is not felt, go to “Fuel Pressure
the lock nut.
Check”.
• After removing fuel pump lock nut, install it
1 as soon as possible.
• If immediate installation is impossible,
temporarily tighten fuel pump lock nut.
Special tool
(A): 09941M51013
IMTA0A170047-01
(A)
Fuel Pump Assembly Removal and Installation

AENNTA0E1706015 (08(01)
Reference: “Fuel Pump On-Vehicle Inspection”
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.
Do not remove each of the fuel pump
assembly components except the fuel level 2 1
sensor. If any faulty condition is found, IMTA0A170050-01
replace the fuel pump assembly with a new 4) Remove fuel pump assembly from fuel tank.
one.
Fuel System: 1G-27
Installation
NOTICE
3 1
Removed fuel pump lock nut cannot assure
adequate sealing. If the fuel pump lock nut is
reused, it may cause fuel leakage. 2
Never reuse the fuel pump lock nut.
NOTE
• Clean the outside surface of the pipe 1
where each quick joint is to be installed. 2

IMTA0A170054-01
• Push the pipe into the joint until the joint
lock clicks, and then check that the pipe is 3. O-ring
connected securely.
c) In the state of Step b), tighten new fuel pump
1) Clean mating surfaces of fuel pump assembly and lock nut (1) by hand.
fuel tank.
NOTE
2) Install new O-ring (1) to fuel tank (2).
Tighten lock nut while pressing straight on it
1 so that it will not tilt.
2 1
3
4
2
IMTA0A170051-01 2
3) Install fuel pump assembly to fuel tank as follows.
IMTA0A170055-01
a) Align arrow mark (1) on fuel pump assembly (2)
2. Fuel tank 3. Fuel pump assembly 4. O-ring
with cutout (3) of fuel tank (4).
2 d) Using special tool, tighten fuel pump lock nut (1)

1 4 until triangle mark (2) of fuel pump lock nut and
indexes mark (3) of fuel tank (4) are aligned.
NOTE
Marks are aligned when fuel pump lock nut is
tightened by approx. 1 rotations.
Special tool
(A): 09941M51013
3
IMTA0A170052-01
b) Push fuel pump assembly (1) down by hand until

fuel pump assembly comes into contact with fuel
tank (2) as shown in figure.
1G-28 Fuel System:
1 2
(A)
4
IMTA0A170057-01
Installation
Reference: “Fuel Level Sensor Inspection”
4 1 Reverse removal procedure.
IMTA0A170056-01
Fuel Level Sensor Inspection

Fuel Pump Inspection AENNTA0E1706018 (08(03)
AENNTA0E1706016 (08(03) Reference: “Fuel Level Sensor Removal and Installation”
Reference: “Fuel Pump Assembly Removal and Check resistance between terminals “1” and “2” at each
Installation” float position in the “a”, “b” and “c”.
• Check fuel pump assembly for damage. If check result is not as specified, replace fuel level
• Check fuel suction filter for contamination. sensor.
If contaminated, replace or clean the filter and check NOTE
fuel tank inside for presence of dirt.
• Check in the order of “a”, “b” and “c”.
Fuel Level Sensor Removal and Installation • Measure the each float position at the
AENNTA0E1706017 (08(01)
position (1) shown in the figure.
NOTICE
• Check the float position and resistance of
Failure to take proper precautions when “a” and “c” with insulator (2) in contact
removing or installing the fuel level sensor with each stopper (3).
can result in damage.
To prevent failure of the fuel level sensor, be Fuel level sensor specifications
careful not to touch the resistor plate (1) or Float Position Resistance (Ω)
deform the arm (2) when performing the “a” 147.3 mm (5.799 in.) 40 ± 2.0
service operations described below. “b” 96.8 mm (3.811 in.) 160 ± 10.0
“c” 25.5 mm (1.004 in.) 280 ± 3.3
IMKC0A170003-01
Removal
1) Remove fuel pump assembly from fuel tank. (Fuel
Pump Assembly Removal and Installation)
2) Disconnect fuel level sensor connector (1).
3) Release lock (2), and remove fuel level sensor (3)
from fuel pump (4) by sliding it in arrow direction as
shown in figure.
Fuel System: 1G-29
2 1
4 3
1
2
“a”
“b”
3
“c”
IMTA0A170058-01
Specifications
AENNTA0E1707001 (09(t)
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Fuel tank side clamp 2.0 0.20 1.5 (T1G001)
Fuel filler side clamp 2.0 0.20 1.5 (T1G002)
Fuel delivery pipe bolt 25 2.5 18.5 (T1G003)
Engine harness protector bolts 10 1.0 7.5 (T1G004)
Fuel tank bolt 14 1.4 10.5 (T1G005)
Reference:
“Fuel System Components”

Special Tool
AENNTA0E1708001 (11(s)
09912M57610 09912M58421
Injector checking tool plate Checking tool set
(L1G008) 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(L1G007)
1G-30 Fuel System:
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).(L1G002) / (L1G005) 58413).(L1G001) / (L1G004)
09912M58490 09912M97110
3-way joint & hose Checking tool attachment
(L1G003) / (L1G006) (L1G009)
09912M97120 09919M47020
Injector test harness Quick joint remover
(L1G010) (L1G012) / (L1G013)
09930M86310 09941M51013
Injector test harness Lock ring wrench
(L1G011) (L1G014) / (L1G015)
Ignition System: 1H-1
Ignition System
Engine
General Description
Ignition System Construction
AENNTA0E1801001 (03(01)
The ignition system is of an electronic ignition type which consists of the following components.
• ECM
It monitors the engine and vehicle conditions through the signals from the sensors, determines the most suitable
ignition timing and duration and sends a signal to the ignition coil assembly.
• Ignition coil assembly
One ignition coil assembly is provided for each cylinder.
The ignition coil assembly turns on and off the current to the primary coil according to the signal from ECM. When
the current flow to the primary coil is turned off, a high voltage is induced in the secondary coil.
• Spark plugs
• CMP sensor and CKP sensor
Using signals from these sensors, ECM identifies the specific cylinder whose piston is in the compression stroke,
detects the crank angle and adjusts initial ignition timing automatically.
• TP sensor, ECT sensor, MAP sensor, MAF sensor with 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 Circuit Diagram
AENNTA0E1802001 (10(01)
1H-2 Ignition System:
IG1
WHT
1
2 12
5 5V
6 5V
YEL C01-44
GRN C01-33
3
4
7 5V
8 5V
PNK C01-34
BEG C01-35
+B 5V
9
PPL C01-30
5V
10
YEL C01-40
5V
11
PNK C01-39
GRY
[A] C01 E01
[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49
ILKC0P180001-02
[A]: ECM connector (View: [a]) 3. Ignition coil assembly No.3 6. Spark plug No.2 9. Intake CMP sensor 12. ECM
1. Ignition coil assembly No.1 4. Ignition coil assembly No.4 7. Spark plug No.3 10. Exhaust CMP sensor
2. Ignition coil assembly No.2 5. Spark plug No.1 8. Spark plug No.4 11. CKP sensor
Component Location
Ignition System Component Location • Ignition coil assembly No.4
AENNTA0E1803001 (04(01)
For the following parts, refer to “Electronic Control • CKP sensor
System Component Location” in Section 1A. • Intake CMP sensor
• Ignition coil assembly No.1 • Exhaust CMP sensor
• Ignition coil assembly No.2 • Knock sensor
• Ignition coil assembly No.3 • ECM
• DLC

Ignition System Check

AENNTA0E1804001 (06(01)
Circuit Diagram
IG1 10
9
WHT A1
A2
1
2 B1 11
B2 5 5V
6
C1 5V
C2 YEL C01-44
GRN C01-33
WHT A3
A4 3
4 B3
B4 7 5V
8
C3 5V
C4 PNK C01-34
BEG C01-35
[A] C01 E01
[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49
ILKC0P180002-01
[A]: ECM connector (View: [a]) B4. Ignition coil assembly No.4 drive circuit 4. Ignition coil assembly No.4
A1. Ignition coil assembly No.1 power supply circuit C1. Ignition coil assembly No.1 ground circuit 5. Spark plug No.1
B1. Ignition coil assembly No.1 drive circuit 1. Ignition coil assembly No.1 9. “IG” fuse
B2. Ignition coil assembly No.2 drive circuit 2. Ignition coil assembly No.2 10. To each electronic units
B3. Ignition coil assembly No.3 drive circuit 3. Ignition coil assembly No.3 11. ECM
Troubleshooting
Yes Go to Step 2.
No Go to “Engine and Emission Control System Check” in Section 1A.
Step 2 Ignition spark test 1

1) Perform ignition spark test. (Ignition Spark Test)
Is test result OK?
Yes Go to Step 3.
No Go to Step 4.
Step 3 Ignition timing check

1) Check ignition timing. (Ignition Timing Inspection)
Is check result OK?
Yes Ignition system is in good condition.

Step 4 Confirmation of malfunctioning cylinder

1) Check cylinder(s) that failed in ignition spark test.
Did all cylinders fail in ignition spark test?
Yes Go to Step 7.
No Go to Step 5.

1) Replace spark plug of each malfunctioning cylinder with normal cylinder’s one.
Is test result OK?
Yes Replace spark plug. (Spark Plug Removal and Installation)

No Go to Step 6.

1) Replace ignition coil of each malfunctioning cylinder with normal cylinder’s one.
Is test result OK?
Yes Replace ignition coil. (Ignition Coil Assembly Removal and Installation)
No Go to Step 7.
Step 7 Ignition coil assembly power supply and ground circuit check
2) Remove “IG” fuse.
3) Disconnect connector of all electronic units protected by “IG” fuse, referring to “Fuses and the Protected
Parts” in Section 9A.
4) Check for proper terminal connection to Ignition coil connectors.
• Resistance of “A1”, “A2”, “A3”, “A4”, “C1”, “C2”, “C3” and “C4” circuits: less than 1 Ω
• Resistance between each of “A1”, “A2”, “A3” and “A4” circuits and ground: infinity
• Resistance of “C1”, “C2”, “C3” and “C4” circuits and ground: less than 1 Ω
• Resistance between “A1”, “A2”, “A3” and “A4” circuits terminal and other terminal at Ignition coil
connector: infinity
• Resistance between “C1”, “C2”, “C3” and “C4” circuits terminal and other terminal at Ignition coil
connector: infinity
• Voltage of“A1”, “A2”, “A3” and “A4” circuits: approx. 0 V (When ignition is “ON”)
Is check result OK?
Yes Go to Step 8.
Step 8 Ignition coil assembly drive circuit check

1) Set ignition “OFF”, and then disconnect ECM connector.
2) Check for proper terminal connection to ECM connector.

• 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
• Voltage of “B1”, “B2”, “B3” and “B4” circuits: 0 to 1 V (When ignition is “ON”)
Is check result OK?
Yes Replace ECM and recheck ignition spark. (ECM Removal and Installation) in Section 1C
Ignition Spark Test 4) Disconnect all fuel injector connectors. (Fuel Injector
AENNTA0E1804002 (06(01) Removal and Installation) in Section 1G
5) Connect ignition coil connector (1) to ignition coil
! WARNING assembly (2).
6) Connect spark plug (3) to ignition coil assembly, and
If this test is performed without
ground spark plug.
disconnecting the injector connectors, a
spark from a plug may ignite fuel vapor 2 1
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.
NOTE
After ignition spark test, install injector
connectors referring to “Fuel Injector
Removal and Installation” in Section 1G.
3
1) Remove spark plugs. (Spark Plug Removal and IMTA0A180001-01
Installation) 7) Crank engine and check if each spark plug sparks.

2) Check spark plugs. (Spark Plug Inspection) If no spark is emitted, check the related parts.
(Ignition System Check)
Repair Instructions
Spark Plug Removal and Installation
AENNTA0E1806001 (08(01) 1
Removal
1) Remove ignition coil assemblies. (Ignition Coil
2) Remove spark plugs (1) from cylinder head.
IMTA0A180002-01
Installation
Reference: “Spark Plug Inspection”

• Tighten spark plugs (1) to specified torque.
“a”
Tightening torque
Spark plug (a): 18 N·m (1.8 kgf-m, 13.5 lbf-ft)
1, (a)
I8T401182005-01
IMTA0A180003-01
Ignition Coil Assembly Removal and Installation
AENNTA0E1806003 (08(01)
Spark Plug Inspection Reference: “Precautions for Electrical System Work”
AENNTA0E1806002 (08(03)
Reference: “Spark Plug Removal and Installation”
Removal
NOTICE 1) Remove air cleaner assembly. (Air Cleaner
The iridium spark plug has a slender center Assembly Removal and Installation) in Section 1D
electrode that is made of a material sensitive 2) Disconnect ignition coil connectors (1).
to mechanical forces. It may be damaged if 3) Remove ignition coil bolts (2) and then pull out
handled carelessly. ignition coil assemblies (3).
Do not touch the center electrode of an
iridium spark plug. Avoid cleaning it or 1
adjusting its electrode gap.
Check spark plug for:

• Electrode wear 3 3 3 3
• Carbon deposits
• Insulator damage
• Spark plug air gap
Check spark plug air gap “a” using special tool (wire type
plug gap gauge). 2
IMTA0A180004-01
If out of specification of the air gap or any other
abnormality is found with iridium spark plug, replace it
Installation
with new plug.
Reference: “Ignition Coil Assembly Inspection”
Special tool Reverse removal procedure.
(A): 09930M77410
Spark plug air gap “a” Ignition Coil Assembly Inspection
AENNTA0E1806004 (08(03)
: 1.0 – 1.1 mm (0.040 to 0.043 in.) Reference: “Ignition Coil Assembly Removal and
Spark plug type Installation”
NGK: ILZKR6F11 (Iridium) Check ignition coil assembly for the following points:
• Damage
• Deterioration
• Corrosion on terminals
If check result is not OK, replace ignition coil assembly.
Ignition Timing Inspection

AENNTA0E1806005 (08(03)
NOTE
• Ignition timing is not adjustable. If ignition
timing is not as specified, check
IHSB0A181001-01
components related to ignition system.
• For identification of each ignition coil If check result is not as specified, check the following
assembly, refer to “Ignition System points.
Component Location”. • CKP sensor: (CKP Sensor Inspection) in Section
1C
• CKP sensor plate: (Sensor Plate Inspection) in
• For 5M/T model, place gear shift lever in “Neutral”. Section 1D
• For AGS model, place select lever in N range. • Intake CMP sensor: (CMP Sensor On- Vehicle
• Apply parking brake. Inspection) in Section 1C
• Block drive wheels. • Exhaust CMP sensor: (CMP Sensor On- Vehicle
2) Connect SUZUKI scan tool to DLC. (Suzuki SDT-II Inspection) in Section 1C
Connection and Disconnection) in Section 0A • CMP sensor rotor teeth of camshaft: (Camshaft
3) Start engine and warm it up to normal operating Inspection) in Section 1D
temperature. • MAP sensor (MAP Sensor Inspection) in Section
4) Check that all electrical loads except ignition system 1C
are switched off. • IAT sensor (MAF Sensor with IAT Sensor
5) Check that idle speed is within specification. (Idle Inspection) in Section 1C
Speed Inspection) in Section 1A • Knock sensor (Knock Sensor On-Vehicle
6) Select “Ignition Advance” under “Data List” mode on Inspection) in Section 1C
SUZUKI scan tool. • TP sensor: (Electric Throttle Body Assembly On-
7) With engine idling, check that ignition timing is about Vehicle Inspection) in Section 1C
–10 to 10° BTDC. (Constant variation within a few • APP sensor: (APP Sensor Inspection) in Section
degrees from –10 to 10° BTDC indicates no 1C
abnormality but proves operation of ignition timing • ECT sensor (ECT Sensor Inspection) in Section
control system.) 1C
Initial ignition timing • Battery voltage (Generator Test) in Section 1J
: –10 to 10° BTDC (at specified idle speed) • Crankshaft pulley key, key groove of crankshaft
Also, check that increasing engine speed advances pulley and crankshaft
ignition timing. • ECM and its circuit: (Inspection of ECM and Its
Specifications
AENNTA0E1807001 (09(t)
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Spark plug 18 1.8 13.5 (T1H001)
Reference:

Special Tool
AENNTA0E1808001 (11(s)
09930M77410
Plug gap gauge
(L1H001)
1I-1 Starting System:
Starting System
Engine
Precautions
Precautions for Replacing Starting Motor
AENNTA0E1900001 (01(01)
Perform “Saving / Writing of Starter Drive Count” in Section 10I, if starting motor is replaced.
General Description
Cranking System Description
AENNTA0E1901001 (03(01)
Cranking Circuit
The cranking circuit consists of the battery, starting motor, starting motor control relay, BCM (keyless push start
model), ignition switch (ignition switch model) or engine switch (keyless push start model), CPP No.1 switch (5M/T
model) or TCM (AGS model) and related electrical wiring.
Starting Motor Circuit

In the circuit shown in “Cranking System Circuit Diagram”, 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.

Cranking System Circuit Diagram
AENNTA0E1902001 (10(01)
WHT 11
[A] [B]
5 8
2
1 6
BLU
LT BLU 9
WHT 7
[C]
GRN 12 YEL
3 4 10 [D] 13
PNK GRN GRN BLK
RED YEL
14
E01-11
15
E01-36 GRY BRN
RED YEL
IMTA0A190010-01
Starting System: 1I-2
[A]: Ignition switch model 1. Battery 5. J/B 9. BCM 13. CPP No.1 switch
[B]: Keyless push start model 2. Main fuse box 6. “KEY2” fuse 10. Starting motor control relay 14. ECM
[C]: AGS model 3. Relay box 7. Ignition switch 11. Starting motor 15. “ST2” relay
[D]: 5M/T model 4. “ST” fuse 8. Engine switch 12. Starting motor control relay drive circuit (integrated in TCM)

Cranking System Symptom Diagnosis
AENNTA0E1904001 (06(04)
Possible symptoms of starting system trouble are as follows:
• Starting motor does not run (or runs slowly).
• Starting motor runs but fails to crank engine.
• Starting motor does not stop.
• Abnormal noise is heard.
Proper diagnosis must be made to determine in which of the battery, wiring harness, starting motor (including
magnetic switch) and engine the cause of each trouble lies.
Before removing the starting motor, check the following items to identify most possible cause of trouble.
1) Condition of trouble
2) Tightness of battery terminals (including ground cable connection on engine) and starting motor terminals
3) Discharge of battery
4) Mounting of starting motor
Starting motor not running (No operating sound of magnetic switch)

• Malfunction of CPP No.1 switch (5M/T model) Check CPP No.1 switch. (CPP No.1 Switch Inspection and
Adjustment) in Section 5C
• Malfunction of shift selector (AGS model) Check shift selector. (Shift Selector Inspection) in Section
5D
• Battery voltage is too low Check battery. (Battery Inspection) in Section 1J
• Impossible charging due to deteriorated battery Replace battery. (Battery Removal and Installation) in
Section 1J
• Poor battery terminal connection Check terminal connection or replace battery. (Battery
• Poor ground cable connection Tighten ground cable.
• Blown fuse Replace fuse and check its circuit.
• Faulty magnetic switch Check magnetic switch. (Starting Motor Inspection)
• Poor magnetic switch lead wire connector
connection Check connector connection. (Starting Motor Removal and
Installation)
• Open circuit in pull-in coil Check pull-in coil circuit. (Starting Motor Inspection)
• Defective brushes and/or brush springs Check brushes and brush springs. (Starting Motor
Inspection)
• Poor sliding of plunger and/or pinion Check plunger and pinion. (Starting Motor Inspection)
• Faulty starting motor control relay Check starting motor control relay. (Starting Motor Control
Relay Inspection)
• Faulty keyless push start system (keyless push
start model) Check keyless push start system. (Keyless Start System
Symptom Diagnosis) in Section 10E
• Faulty ignition switch (ignition switch model) Check ignition switch. (Ignition Switch Inspection (Ignition
Switch Model)) in Section 6B
• Malfunction of TCM (AGS model) Check TCM. (Starting Motor Control Relay Circuit Check) in
Section 5D
• Malfunction of ECM Check ECM. (Inspection of ECM and Its Circuits) in Section
1A
Starting motor not running (Operating sound of magnetic switch heard)

• Battery voltage is too low Check battery. (Battery Inspection) in Section 1J
Section 1J
• Poor ground terminal connection Tighten ground cable.
Inspection)
• Defective brush holder Check brush holder. (Starting Motor Inspection)
• Burnt commutator Check commutator. (Starting Motor Inspection)
• Short circuit between commutator and armature Check commutator. (Starting Motor Inspection)
• Poor starting motor cable connection Check starting motor cable connection. (Starting Motor
• Open circuit between battery and magnetic switch Repair circuit.
• Worn teeth of ring gear Replace flywheel. (Flywheel Removal and Installation) in
Section 1D
• Obstructed crankshaft rotation Repair engine assembly.
Starting motor running but too slow (small torque)

• Low battery voltage Check battery. (Battery Inspection) in Section 1J
Section 1J
• Short circuit between commutator and armature Check commutator. (Starting Motor Inspection)
• Burnt commutator Check commutator. (Starting Motor Inspection)
Inspection)
• Defective brush holder Check brush holder. (Starting Motor Inspection)
• Defective rear bracket bushing Check rear bracket bushing. (Starting Motor Inspection)
Starting motor running, but not cranking engine

• Worn pinion tip Replace overrunning clutch. (Starting Motor Components)
• Poor sliding of overrunning clutch Check overrunning clutch. (Starting Motor Inspection)
• Slipping overrunning clutch Replace overrunning clutch. (Starting Motor Components)
Section 1D
• Obstructed crankshaft rotation Repair engine assembly.
Starting motor does not stop (cranking sound is heard)

• Poor return of magnetic switch (plunger) Check magnetic switch. (Starting Motor Inspection)
• Starting motor control relay stays on Check starting motor control relay. (Starting Motor Control
Relay Inspection)
• Poor return of ignition switch from “START”
position (ignition switch model) Check ignition switch. (Ignition Switch Inspection (Ignition
Switch Model)) in Section 6B
• Short circuit between battery (+) cable and
magnetic switch lead wire Repair circuit.
• Short circuit between battery and starting motor

control relay coil side power supply lead wire Repair circuit.
Starting motor does not stop (Free rotating sound is heard)

• Welded contact point in magnetic switch Replace magnetic switch. (Starting Motor Components)
• Poor return of magnetic switch Replace magnetic switch. (Starting Motor Components)
Noise
• Abnormally worn bushing Replace bushing. (Starting Motor Components)
• Worn teeth of pinion Replace overrunning clutch. (Starting Motor Components)
Section 1D
Repair Instructions
Starting Motor Control Relay Inspection
AENNTA0E1906001 (08(03)
Starting Motor Removal and Installation

AENNTA0E1906002 (08(01)
Removal
1 2
and Engine Under Side Cover Removal and IMTA0A190002-02
3) Disconnect magnetic switch lead wire (1) from Installation
starting motor (2). Reference: “Starting Motor Inspection”
4) Remove starting motor cable nut (3), and then Reverse removal procedure noting the following point.
disconnect starting motor cable (4) from starting • Perform “Saving / Writing of Starter Drive Count” in
motor. Section 10I, if starting motor is replaced.
• Tighten starting starting motor cable nut (1) to
4 3
specified torque.
Tightening torque
Starting motor cable nut (a): 11 N·m (1.1 kgf-m,
8.5 lbf-ft)
1, (a)
2 1
IMTA0A190001-01
5) Remove starting motor mounting bolts (1), and then

remove starting motor (2).
IMTA0A190003-02
Starting Motor Components

AENNTA0E1906003 (12(01)
(a) 3
A
2
(d)
A
4
A 1
(b)
8
(c) A
IMTA0A190004-01
1. Armature housing 5. Armature : 11 Nm (1.1 kgf-m, 8.5 lbf-ft) : Apply grease to sliding surface of each part.
2. Drive lever assembly 6. Yoke : 6.1 Nm (0.62 kgf-m, 4.5 lbf-ft)
3. Magnetic switch 7. Brush assembly : 3.4 Nm (0.35 kgf-m, 2.5 lbf-ft)
4. Overrunning clutch assembly 8. End housing : 5.9 Nm (0.60 kgf-m, 4.5 lbf-ft)
Starting Motor Disassembly and Reassembly 2) Remove nut (1) and disconnect lead wire (2) from
AENNTA0E1906004 (08(02) magnetic switch (3).
Disassembly
Reference: “Starting Motor Removal and Installation” 3
Reference: “Starting Motor Components”
1) Before disassembly, draw matchmarks (1) and (2) as
shown in figure to assure proper alignment when 2
reassembled.
1
1
I8C50A190004-01
2 3) Remove screws (4) and pull out magnetic switch (1)

from starting motor assembly.
4) Remove spring (2) and plunger (3) from magnetic
switch body.
IGAA0A192004-01
IGAA0A192008-01
1 2 3 8) Remove end housing (1) from yoke (2).
IGAA0A192005-01
5) Remove bolts (1) and separate yoke from armature

housing (2).
2
2
1
IGAA0A192009-01
9) Remove armature (1) from yoke (2) and brush

assembly (3).
1 3
IGAA0A192006-01
6) Remove seal rubber (1) and plate (2).
2
I9P60A191031-01
10) Remove brush springs (2) and yoke side brushes (1)
from brush assembly (3).
2
3
1
2
IGAA0A192007-01
7) Remove overrunning clutch assembly (1) together

with drive lever (2).
I9P60A191033-01
Reassembly
Reference: “Starting Motor Inspection”
1) Apply grease to end housing bushing.

“A”: Grease 99000–25480 (ECSTAR Grease A)
“A”
1
IGAA0A192010-01
2) Install yoke side brushes (1) and brush springs (2) to

brush assembly (3). 2 , (a)
IGAA0A192012-02
2 5) Apply grease to drive lever (2) and insert

3 overrunning clutch assembly (1) into armature
1
housing with drive lever positioned as shown in
figure.
I9P60A191033-01
3) Install armature (1) to yoke (2) and to brush

assembly (3) while pushing 4 brushes (4) outward.
IGAA0A192013-01
6) Install plate (2) and seal rubber (1) to armature

3 housing.
4
IGAA0A192011-01
4) Install end housing (1) to brush holder and tighten

brush holder screws (2) to specified torque. IGAA0A192007-01
Tightening torque 7) Apply grease to armature (1).

Brush holder screw (a): 3.4 N·m (0.35 kgf-m, 2.5 “A”: Grease 99000–25480 (ECSTAR Grease A)
lbf-ft)
Tightening torque
Magnetic switch screw (a): 5.9 N·m (0.60 kgf-m,
4.5 lbf-ft)
5, (a)
4
“A”
I9P60A191045-02
8) Install yoke, armature, brush assembly and end 1 2 3

housing (1) to armature housing (2) while aligning
matchmarks (3) drawn before disassembly.
9) Tighten end housing bolts (4) to specified torque.
Tightening torque IGAA0A192015-01
End housing bolt (a): 6.1 N·m (0.62 kgf-m, 4.5 13) Connect lead wire (1) to terminal “M” and tighten
lbf-ft) lead wire nut (2) to specified torque.
Tightening torque
2
Lead wire nut (a): 11 N·m (1.1 kgf-m, 8.5 lbf-ft)
2, (a)
IGAA0A192016-01
1 4, (a) 14) Check magnetic switch for operation. (Starting Motor

IGAA0A192014-01 Inspection)
10) Apply grease to plunger.
“A”: Grease 99000–25480 (ECSTAR Grease A) Starting Motor Inspection
AENNTA0E1906005 (08(03)
Reference: “Starting Motor Removal and Installation”
Reference: “Starting Motor Disassembly and
Reassembly”
Starting Motor Operation Check
! CAUTION
Sparks resulting from a short circuit between
the positive (+) and negative (–) terminals
during connections to the battery may cause
burns.
Be careful not to short circuit the positive (+)
I8C50B190021-01 and negative (–) cables, and connect them
11) Install magnetic switch (1), spring (2) and plunger (3) only to the correct terminals.
to armature housing (4) while aligning matchmarks
drawn before removal.
12) Tighten screws (5) to specified torque.
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.
Pull-in test
1) Disconnect lead wire (1) from “M” terminal (2).
2
2) Connect battery (-) terminal to “M” terminal and
armature housing (3) using service wire. 1
3) Connect battery (+) terminal to “S” terminal (4), and

then check that plunger and pinion move outward. IMTA0A190007-01
If plunger and pinion do not move, replace magnetic
switch. No-load performance test
4 ! CAUTION
2 1 If the cable used for the test is not adequately
thick, the cable may become extremely hot
due to large current flowing through it and
you could get burned.
Use a cable (1) with thickness equal to or
larger than the cable used between the
vehicle’s battery and the starter.
3
1) Fix starting motor with vice or the like.
2) Connect battery (+) terminal and ammeter to “B”
IMTA0A190005-01 terminal (2) as shown in figure.
3) Connect “S” terminal (3) to “B” terminal using service
Hold-in test
wire (4), and then check that starting motor rotates
1) From the state of “Pull-in test” with plunger and smoothly and steadily with pinion moving out.
pinion in outward, disconnect service wire (1) from
4) Check that ammeter indicates specified current.
“M” terminal (2).
If check result is not as specified, repair or replace
2) Check that plunger and pinion remain in outward. starting motor.
If plunger and pinion return inward, replace magnetic
switch. Specified current (No-load performance test)
90 A MAX. at 11 V
4
2
1
1 3
IMTA0A190006-01
Plunger and pinion return test IMTA0A190008-01
1) From the state of “Hold-in test” with plunger and

Plunger
pinion in outward, disconnect service wire (1) from
Check plunger for wear.
armature housing (2).
If check result is not OK, replace magnetic switch.
2) Check that plunger and pinion return inward.
If plunger and pinion do not return, replace magnetic
switch.
1
I2RH01190008-01
IKFA0B194016-01
Magnetic Switch
Check that plunger quickly returns to its original position End Housing Bushing
when plunger is pushed in with a finger and released. Check end housing bushing for wear or damage.
If check result is not OK, replace magnetic switch. If check result is not OK, replace bushing.
IMTA0A190009-01
Brush
• Check brushes for wear.
I2RH01190009-01
Measure length of each brush.
Pull-in coil open circuit test If length is less than the limit, replace brush assembly.
Check for continuity between magnetic switch “S” Brush length
terminal (1) and “M” terminal (2). Standard (initial length): 15.5 mm (0.61 in.)
If there is no continuity, replace magnetic switch. Limit (brush length fully worn): 4.5 mm (0.18 in.)
1
IKFA0B194015-01
Hold-in coil open circuit test I2RH01190013-01

Check for continuity between magnetic switch “S” • After installing brushes into their holders, check that
terminal (1) and coil case. movement of brushes is smooth.
If there is no continuity, replace magnetic switch.
Spring
Check brush springs for wear, damage or other
abnormal conditions.
If check result is not OK, replace brush assembly.
Brush spring tension
Standard: 17.5 – 23.6 N (1.8 – 2.4 kgf, 4.0 – 5.3 lbf)
Limit: 6.9 N (0.70 kgf, 1.55 lbf)
Brush Holder
• Check brush holder for brush movement problems,
distortion, and dirt on sliding surface.
If check result is not OK, clean or replace brush
holder.
• Check for continuity between insulated brush (positive
(+) side) and grounded brush (negative (–) side).
If there is continuity, replace brush holder.
I2RH01190016-01
3. Magnetic stand
• Check commutator for wear and measure diameter of

commutator.
If diameter of commutator is lower than the limit,
replace armature.
Commutator outside diameter
I9P60A191044-01 Standard: 26.5 mm (1.04 in.)
Limit: 25.5 mm (1.01 in.)
Armature
• Check commutator for dirt or burn.
If check result is not OK, correct commutator with
sandpaper (1) or lathe.
I2RH01190017-01
• Check commutator (1) for insulator (2) depth.

If insulator depth is lower than the limit, replace
armature.
I7RW01190005-02
Commutator insulator depth “a”
1. Sandpaper of #300 – 400 Standard: 0.5 – 1.0 mm (0.02 – 0.03 in.)
Limit: 0 mm (0 in.)
• Check commutator for uneven wear with armature (1)
supported on V-blocks (2) using dial gauge (4).
If dial gauge deflection exceeds the limit, repair
commutator or replace armature.
Commutator out of round
Standard: 0.008 mm (0.0003 in.) MAX.
Limit: —
Pinion and Overrunning Clutch

If check result is not OK, replace pinion and overrunning
clutch.
• Check pinion for wear, damage or other abnormal
conditions.
• Check that clutch locks when turned in normal rotation
direction [a] and rotates freely when turned in reverse
direction [b].
I3RH0A190005-01
[A]: Correct [B]: Incorrect
• Check insulation between commutator and armature

core. IAP70P190007-01
If there is continuity, replace armature. • Check spline teeth for wear or damage.
• Check pinion for smooth movement.
I2RH01190023-01
I2RH01190019-01
Armature Housing Bushing
• Check for continuity between segments.
Check bushing or needle bearing for wear and damage.
If there is no continuity at any test point, replace
If check result is not OK, replace bushing.
armature.
I2RH01190024-01
I2RH01190020-01
Specifications
Cranking System Specifications
AENNTA0E1907001 (09(01)
Voltage 12 V
Output 1.0 kW
Rating 30 seconds
Direction of rotation Clockwise as viewed from pinion side
Number of pinion teeth 10

Performance Voltage Current Torque Revolution speed
No-load characteristic 11 V 90 A MAX — 2,730 rpm MIN
11 Nm (1.1 kgf-m, 8.0
Loaded characteristic 7.5 V 300 A 700 rpm MIN
lbf-ft) MIN
At around 20 °C
16 Nm (1.6 kgf-m, 11.5
(68 °F) Locked characteristic 4V 510 A MAX —
lbf-ft) MIN
Magnetic switch
8 volts MAX
operating voltage

AENNTA0E1907002 (09(t)
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Starting motor cable nut 11 1.1 8.5 (T1I001)
Brush holder screw 3.4 0.35 2.5 (T1I002)
End housing bolt 6.1 0.62 4.5 (T1I003)
Magnetic switch screw 5.9 0.60 4.5 (T1I004)
Lead wire nut 11 1.1 8.5 (T1I005)
Reference:
“Starting Motor Components”

AENNTA0E1908001 (11(m)
Grease ECSTAR Grease A P/No.: 99000–25480 (M1I001) / (M1I002) /
(M1I003) / (M1I004)
NOTE
“Starting Motor Components”
Charging System: 1J-1
Charging System
Engine
Precautions
Precautions for Handling Battery
AENNTA0E1A00001 (01(01) 1
! WARNING
handling the battery may cause severe
personal injury.
• Never expose the battery to an open flame
3
or electric spark. A battery generates
highly flammable and explosive hydrogen
gas.
• Battery fluid (electrolyte) is a corrosive 2
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 IJCA0A1A1036-01
a large quantity of water.
• Keep the battery out of reach of children. 1) The battery is a very reliable component, but needs
periodical attentions.
NOTICE • Keep battery carrier clean.
• Battery electrolyte lowers the level during • Prevent rust formation on the terminal posts.
normal use and continuous use of battery • Keep electrolyte up to the upper level uniformly in
with the electrolyte under the lower level all cells (if cell caps are equipped).
will extremely deteriorate the battery. • When keeping battery on vehicle over a long
For battery with removable filler plugs (1) period, follow instructions given below.
or vent caps and visible level lines, always
– Weekly, start the engine and run it until it
take the following precautions.
reaches normal operating temperature with
– Do not continue to use the battery with engine speed of 2,000 to 3,000 rpm. Check that
the electrolyte under the lower level (2). all electric switches are turned off before storing
– Add distilled water up to the upper level the vehicle.
(3) if the level is below the midpoint of – Recharge the battery twice a month to prevent
upper and lower levels. it from discharging excessively. This is
– Wash away spilled electrolyte after especially important when ambient temperature
fitting filler plugs or vent caps. is low.
• Overfilled electrolyte exceeding the upper The battery discharges even when it is not
level may overspill while the vehicle is used, while vehicles are stored. Battery
running and it may cause damage to the electrolyte can freeze and battery case can
parts near the battery. crack in cold ambient condition if the battery is
Add distilled water up to the upper level. not properly charged.
2) Keep the battery cable connections clean.
The cable connections, particularly at the positive (+)
terminal post, tend to corrode. The corrosion or rust
on the mating faces of conductors resists the flow of
current.
Clean the terminals and fittings periodically to
ensure good metal-to-metal contact, and grease the
connections after each cleaning to protect them
against rusting.
3) Periodically check the state of charge of the battery.
The simplest way to tell the state of charge is to carry
out a hydrometer test. The hydrometer is an
instrument for measuring the specific gravity of the
1J-2 Charging System:
battery electrolyte. The specific gravity of the Precautions for Replacing Battery
electrolyte is indicative of the state of charge. AENNTA0E1A00002 (01(01)
Use SUZUKI genuine battery specific for ENG A-STOP
(Battery Inspection)
system. (Charging System Specifications)
General Description
Battery Description Electrolyte Freezing
AENNTA0E1A01001 (03(01) The freezing point of electrolyte depends on its specific
The battery has three major functions in the electrical
gravity. Since freezing may ruin a battery, it should be
system.
protected against freezing by keeping it in a fully
• It is a source of electrical energy for cranking the charged condition. If the battery freezes accidentally, it
engine. should not be charged until it will unfreeze.
• It acts as a voltage stabilizer for the electrical system.
• It can, for a limited time, provide energy when the Sulfation
electrical load exceeds the output of generator. If the battery is left for a long period in discharged
condition, the lead sulfate becomes converted into a
Carrier and Hold-Down hard, crystalline substance, which will not easily turn
The battery carrier should be in good condition so that it back to the active material again during the subsequent
supports the battery securely and keeps it level. Before recharging. “Sulfation” means the result as well as the
installing the battery, check that the battery carrier and process of that reaction. Such a battery can be revived
hold-down clamp are clean and free from corrosion and by very slow charging and may be restored to usable
that there is no foreign material in the carrier. condition but its capacity will be lower than before.
To prevent the battery from shaking in its carrier, the
hold-down clamp nuts should be tightened enough but
not over-tightened.
Generator Description
AENNTA0E1A01002 (03(01)
The generator is of a small and high performance type with an IC regulator incorporated. The internal components are
connected electrically as shown in figure.
LIN is used for communication between generator and ECM.
The generator features are as follows:
• Solid state regulator is mounted inside the generator.
• All regulator components are enclosed into a solid mold.
• The IC regulator along with the brush holder assembly is attached to the rear end frame.
• The IC regulator uses integrated circuits and controls the voltage produced by the generator, and the voltage setting
cannot be adjusted.
• The generator rotor bearings contain enough grease to eliminate the need for periodic lubrication. Two brushes
carry current through the two slip rings to the field coil mounted on the rotor, and under normal conditions they will
provide long period of attention-free service.
• The stator windings are assembled on the inside of a laminated core that forms part of the generator frame.
1
B
6
3 4
9
10
11 7 8
2
10
LIN 12
IMTA0A1A0005-01
1. Generator 4. Diode 7. Battery 10. CAN driver

2. IC regulator 5. Field coil (rotor coil) 8. Electric load 11. ECM
3. Stator coil 6. Charge warning light 9. Combination meter 12. Electric load current sensor with battery temperature sensor
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)

Battery Inspection
AENNTA0E1A04001 (06(01)
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. (Generator Symptom Diagnosis)
• 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.
Generator Symptom Diagnosis

AENNTA0E1A04002 (06(04)
Trouble in charging system will show up as one or more of the following conditions.
Charge Warning Light Operation
Charge warning light does not light with ignition “ON” and engine off
• Blown fuse Replace fuse.
• Faulty combination meter Replace combination meter. (Combination Meter Removal
and Installation) in Section 9C
• Faulty ECM Check ECM. (Inspection of ECM and Its Circuits) in Section
1A
• Faulty CAN communication line Repair or replace CAN communication line. (CAN DTC
(Lost Communication and Communication Bus Off) Table):
CAN in Section 10H
• Faulty wiring Repair wiring.
• Faulty IC regulator or field coil Repair or replace generator. (Generator Disassembly and
Reassembly)
Charge warning light does not go out with engine running (battery requires frequent recharging)
• Loose or worn drive belt of generator Adjust or replace drive belt of generator. (Accessory Drive
Belt Inspection)
• Faulty combination meter Replace combination meter. (Combination Meter Removal
• Faulty ECM Check ECM. (Inspection of ECM and Its Circuits) in Section
1A
• Faulty IC regulator or generator Repair or replace generator. (Generator Disassembly and
Reassembly)
• Faulty wiring Repair wiring.
Battery Charge Failure
Undercharged battery
• Loose or worn drive belt of generator Adjust or replace drive belt of generator. (Accessory Drive
Belt Inspection)
• Loose or corroded battery terminal Tighten battery terminal or replace battery. (Battery
• Faulty rectifier, rotor and/or IC regulator Repair or replace generator. (Generator Disassembly and
Reassembly)
Overcharged battery
• Faulty IC regulator Repair or replace generator. (Generator Disassembly and

Reassembly)
Noise
Noisy generator
• Loose mounting bolts Tighten mounting bolts. (Generator Removal and
Installation)
• Dirty, worn and/or faulty bearings Repair or replace generator. (Generator Disassembly and
Reassembly)
• Faulty rotor, diode and/or stator Repair or replace generator. (Generator Disassembly and
Reassembly)
Generator Test
AENNTA0E1A04003 (06(01)
This condition, as evidenced by slow cranking or low
specific gravity, can be caused by one or more of the
following conditions even though warning light operates
normally.
• Check that undercharged condition has not been
caused by accessories being left on for an extended
period.
• Check drive belt of generator for wear and tension.
(Accessory Drive Belt Inspection)
I9P60A1A1018-01
• If battery defect is suspected, refer to “Battery
1. Generator 6. Switch
Description”.
4. Battery 7. “B” terminal
• Check wiring for defects. Check all connections for
tightness and cleanliness, battery cable connections 5) Run engine around 2,000 rpm and read meters.
at battery, generator, starting motor and ignition
• If voltage is higher than standard value, check
ground cable.
ground circuit of brushes. (Generator Inspection)
If brushes are not grounded, replace brush holder
No-Load Check
assembly.
NOTE • If voltage is lower than standard value, check
Use fully charged battery. rotor, stator and rectifier. (Generator Inspection)
Specification (No-load check)
1) Check for DTC. Current: 10 A
If there is any DTC, perform troubleshooting for Regulated voltage: 10.3 – 16.3 V at 25 °C (77 °F)
applicable DTC and then clear DTC.
• DTC check: (DTC Check) in Section 1A Load Check
• Troubleshooting: (DTC Table) in Section 1A
NOTE
• DTC clearance: (DTC Clearance) in Section 1A
Use fully charged battery.
2) Turn off all electrical loads (5).
3) Connect voltmeter (3) and ammeter (2) as shown in 1) Connect ammeter in the same way as “No-Load
figure. Check”.
4) Start engine and warm it up to normal operating 2) Run engine around 2,000 rpm and turn on the
temperature. following electrical loads.
• Headlight (high beam)
• Rear defogger
• 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
Repair Instructions
Jump-Starting in Case of Emergency • For AGS model, place select lever in N range.
AENNTA0E1A06001 (08(03)
With Booster Battery • Apply parking brake.
NOTICE
Trying to start a M/T vehicle equipped with a 3) Turn off lights and all other electrical loads.
catalytic converter by pushing or towing it
4) For battery with cell caps, check electrolyte level. If it
may cause damage to the emission control
is below low level line, add distilled water.
system and/or other components.
Do not start a M/T vehicle by pushing or 5) Attach end of one jumper cable to positive (+)
towing it. terminal of booster battery and other end of the
same cable to positive (+) terminal of discharged
NOTE battery (use 12-volt battery only to jump-start
engine).
Engine is started with the hood open in case
of jump-starting with a discharged or 6) Attach one end of the remaining negative (–) cable to
deteriorated lead-acid battery etc., or the negative (–) terminal of booster battery, and the
hood is opened while the engine is running, other end to a solid engine ground (such as exhaust
ECM inhibits engine auto stop and auto manifold) at least 45 cm (18 in.) away from battery of
restart control until the ignition is set “OFF”. vehicle being started.
7) Start engine of vehicle with booster battery and turn
Both booster and discharged battery should be treated off its electrical loads. Then try to start engine of
carefully when using jumper cables. Follow the vehicle with discharged battery.
procedure outlined as follows, being careful not to cause 8) Disconnect jumper cables in the exact reverse order.
sparks.
With Charging Equipment
! WARNING
NOTICE
Failure to take proper precautions when jump
starting a vehicle may result in serious Using 24-volt charging equipment to jump-
personal injury and/or damage to electronic start the engine will cause serious damage to
components of either the vehicle with a dead electric and electronic system components.
battery or the vehicle used for jump starting. Use only 12-volt charging equipment to
• Never expose the battery to open flame or jump-start the engine.
electric spark. A battery generates highly
flammable and explosive hydrogen gas. Battery Removal and Installation
AENNTA0E1A06002 (08(01)
• Remove rings, watches and other jewelry.
Wear approved eye protector.
• Battery fluid is a corrosive acid. Do not Removal
allow it to contact eyes, skin, fabrics or
painted surfaces of the vehicle. If the fluid
contacts any of them, immediately and 2) Disconnect negative (–) cable (1) at battery (2).
thoroughly flush the affected area with 3) Disconnect positive (+) cable (3) at battery.
water. 4) Remove battery band (4).
• To avoid a danger of short circuit, do not 5) Remove battery and battery cover (5).
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.
• Keep the battery out of the reach of
children.

• Tighten battery cable nuts (2) to specified torque.

4 1 2
Tightening torque
Battery cable nut (b): 5.0 N·m (0.51 kgf-m, 4.0 lbf-
ft)
2. (b)
5
IMTA0A1A0001-01
6) If necessary, remove battery tray (1) as follows. 2, (b)

a) Disconnect harness clamps (2) and harness
protectors (3) from battery tray.
1, (a)
b) Remove battery tray bolts (4) and nut (5). IMTA0A1A0004-01
c) Remove battery tray.

Accessory Drive Belt Inspection
AENNTA0E1A06003 (08(03)
2 3 5
NOTE
3
Check accessory drive belt when engine is
cool.
1) Check accessory drive belt (1) for crack, tear,

deformation, wear or dirt.
If any defect is found replace it. (Accessory Drive
Belt Removal and Installation)
2 2) Check engine is cold.
4 1 3) Remove engine under side cover of right side.
IMTA0A1A0002-02 (Engine Under Cover and Engine Under Side Cover
Installation
4) Check that slit (3) on accessory drive belt auto
tensioner (2) is within width “a” of protrusion (4).
• Use new battery tray bolts (1) and battery tray nut (2),
if removed. 3
• Tighten new battery tray bolts and nut to specified 1
torque, if removed. 4
Tightening torque
Battery tray bolt (a): 13 N·m (1.3 kgf-m, 9.5 lbf-ft)
Battery tray nut (b): 13 N·m (1.3 kgf-m, 9.5 lbf-ft)
2
2, (b)
“a”
ILKC0P1A1011-01
If check result is not as specified, replace accessory

drive belt and recheck that the slit is within the width
“a”. (Accessory Drive Belt Removal and Installation)
If new accessory drive belt is installed and the slit
position is not as specified, replace accessory drive
belt auto tensioner. (Accessory Drive Belt Auto
1, (a)
IMTA0A1A0003-02
Accessory Drive Belt Removal and Installation
• Tighten battery band nuts (1) to specified torque. AENNTA0E1A06004 (08(01)
Tightening torque
Battery band nut (a): 3.3 N·m (0.34 kgf-m, 2.5 lbf-
ft)
NOTICE
6) Remove accessory drive belt (4).
compressing the accessory drive belt auto
tensioner can cause damage to the tensioner. 3
4
• Compress the tensioner very slowly using
hexagonal socket (special tool) with ring
wrench.
• Do not apply more than 130 Nm (13.3 kgf-
m, 96.0 lbf-ft) when compressing the
tensioner.
• Do not apply more force when the
tensioner stops at full stroke.
1 2
IMTA0A1A0009-01
Removal
7) Detach special tool and ring wrench from accessory
drive belt auto tensioner.
Installation
1) Put accessory drive belt (1) on crankshaft pulley,
water pump pulley and generator pulley fitting belt
3) Attach special tool and adjustable wrench (1) to ribs to pulley grooves correctly.
hexagonal section (3) of accessory drive belt auto
2) Attach special tool and adjustable wrench (2) to
tensioner (2).
hexagonal section (4) of accessory drive belt auto
Special tool tensioner (3).
(A): 09919M16020
Special tool
(A): 09919M16020
3
2 1 4
(A)
3
(A)
IMTA0A1A0007-01
4) Turn moving part (1) of accessory drive belt auto IMTA0A1A0010-01

tensioner counterclockwise, and then hole (2) of
3) Turn moving part (1) of accessory drive belt auto
moving part is aligned with hole (3) of stationary part.
tensioner counterclockwise (2), and then pull out pin
(3).
4) Slowly return the moving parts of the accessory drive
belt auto tensioner clockwise (4).
1
3
1
2 3
IMTA0A1A0008-01
5) Insert pin (3) to hole (1) of moving part and hole (2) 4
2
of stationary part, and then fix the moving part.
NOTE IMTA0A1A0011-01
5) Detach special tool and ring wrench from accessory

• Recommended pin diameter: 5 mm (0.2 in.)
drive belt auto tensioner.
• Keep the pin installed until accessory drive
6) Turn crankshaft clockwise 720°.
belt is installed.
7) Check that all of belt ribs are fitted into all of pulley
grooves. 3 1
8) Start engine for 2 to 3 seconds to stabilize the belt

tension, and stop engine.
9) Check the state of the belt. (Accessory Drive Belt
Inspection)
10) Install compressor drive belt. (Compressor Drive Belt 2
11) Install engine under side cover of right side. (Engine
ILKC0P1A1013-01
Generator Removal and Installation 10) Take out generator through a space between the
AENNTA0E1A06005 (08(01) suspension frame and the vehicle body.
11) Remove generator adjusting arm, if necessary.
(Water Pump Removal and Installation) in Section
Removal
1F
and Engine Under Side Cover Removal and Installation
Installation) in Section 9H Reverse removal procedure noting the following points.
2) Remove engine under side cover of right side. • Install generator adjusting arm refer to “Water Pump
(Engine Under Cover and Engine Under Side Cover Removal and Installation” in Section 1F, if removed.
• Tighten generator upper bolt (1) and lower bolt (2) as
3) Remove compressor drive belt. (Compressor Drive follows.
a. Put generator (3) on cylinder block and tighten
4) Remove accessory drive belt. (Accessory Drive Belt generator lower bolt temporarily.
b. Tighten generator upper bolt to specified torque.
5) Remove accessory drive belt auto tensioner.
(Accessory Drive Belt Auto Tensioner Removal and Tightening torque
Installation) Generator upper bolt (a): 30 N·m (3.1 kgf-m,
22.5 lbf-ft)
6) Remove exhaust pipe. (Exhaust System
Components) in Section 1K c. Tighten generator lower bolt to 30 Nm (3.1 kgf-m,
7) Remove nut (1) and disconnect “B” terminal wire (3) 22.5 lbf-ft) and check that bush (4) in generator
from generator (2). bracket is in contact with cylinder block.
8) Disconnect generator connector (4) from generator. d. loosen generator lower bolt.
e. Tighten generator lower bolt to specified torque.
3 1 2
Tightening torque
Generator lower bolt (b): 48 N·m (4.9 kgf-m,
35.5 lbf-ft)
3 1, (a)
ILKC0P1A1012-01 2, (b)
9) Remove generator upper bolt (1) and lower bolt (2),

and then remove generator (3) from engine.
4
ILKC0P1A1014-01
• Insert lugs (2) of “B” terminal wire (1) into groove (3),
and then tighten “B” terminal nut (4) to specified
torque.
Tightening torque Installation

“B” terminal nut (a): 7.9 N·m (0.81 kgf-m, 6.0 lbf- Reference: “Accessory Drive Belt Auto Tensioner
ft) Inspection”
• Tighten auto tensioner lower bolt and timing chain
cover No.1 bolt to specified torque.
4, (a)
1 Tightening torque
2
Auto tensioner lower bolt (a): 25 N·m (2.5 kgf-m,
18.5 lbf-ft)
3 Timing chain cover No.1 bolt (b): 25 N·m (2.5 kgf-
m, 18.5 lbf-ft)
ILKC0P1A1015-01
Accessory Drive Belt Auto Tensioner Removal

2,(b)
and Installation
AENNTA0E1A06006 (08(01)
NOTE
• Keep the retaining pin installed as it is until
the tensioner is installed.
• New accessory drive belt auto tensioner
(1) is supplied in compressed position held 1,(a) 3
with a pin (2). Keep the pin installed until IFKA0P1A1008-01
the tensioner is installed. • Install accessory drive belt, refer to “Accessory Drive
Belt Removal and Installation”.
1 Accessory Drive Belt Auto Tensioner Inspection

AENNTA0E1A06007 (08(03)
Reference: “Accessory Drive Belt Auto Tensioner
2
If check result is not OK, replace accessory drive belt
auto tensioner (1).
• Check pulley (2) of accessory drive belt auto
ILKC0P1A1016-01
tensioner for wear and smooth rotation.
Removal • Check damage on accessory drive belt auto
tensioner.
(Engine Under Cover and Engine Under Side Cover 1 2
3) Remove auto tensioner lower bolt (1) and timing
chain cover No.1 bolt (2) and then remove accessory
drive belt auto tensioner (3). IFKA0P1A1009-01
Generator Components
AENNTA0E1A06008 (12(01)
1 (a)
2
(b)
4
5
10
(c)
(e)
(d)
IFKA0P1A1010-01
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 : 4.6Nm (0.47 kgf-m, 3.5 lbf-ft)
Generator Disassembly and Reassembly 2) Remove rear end cover bolts (1) and remove rear
AENNTA0E1A06009 (08(02) end cover (2) from stator assembly.
Reference: “Generator Removal and Installation”
Reference: “Generator Components” 3) Remove bushing (3) from “B” terminal.
Disassembly
1) To facilitate reinstallation, provide matchmarks (1) on 3
drive end frame (2) and stator assembly (3) as
shown.
1
2 1
IE3J0P1A0007-01
4) Remove brush holder assembly (1) from stator

assembly.
3
IFRA0A1A1019-01
3 2
ICV00P1A0011-01
8) Remove stator assembly from rotor by tapping stator

assembly evenly using plastic hammer.
IE3J0P1A0008-01
9) If necessary, remove bearing retainer screws and
5) Fix shaft using 6-point socket wrench (1) and bearing retainer (1), and then remove bearing (2)
remove pulley nut, and then remove the pulley (2) from drive end frame (3) using special tool.
from the shaft.
! CAUTION
NOTICE
The shaft end is not hard enough and the end If drive end frame is heated, may be hot
may be damaged if it is held using a 12-point enough to cause burns.
socket wrench. Wear safety gloves.
Use 6-point socket wrench to hold the shaft.
NOTE
If necessary, when removing bearing heat
drive end frame to a temperature of 80 – 100
°C (176 – 212 °F) so that it will not be
distorted.
Special tool
(A): 09924M74510
I9D30P1A0010-01
6) Remove stator assembly bolts (1).
I8C50B1A0004-01
1
1
(A)
IE3J0P1A0009-01
7) Remove stator assembly (3) and rotor from drive end

IFKA0P1A1011-01
frame (2) by tapping shaft (1) lightly using plastic
hammer.
Reassembly
Reference: “Generator Inspection”
1) Using special tool, install new bearing to drive end 4) Install drive end frame (2) to stator assembly (1).
frame, if removed.
Check the bearing for smooth rotation, after NOTE
installation. When installing the drive end frame to the
stator assembly, align matchmark (3)
NOTICE provided before disassembly.
When installing the bearing, the bearing and
the drive end frame may become damaged if
1 2
pressing any section other than the outer
race.
Press the outer race of the bearing when
installing it.
Special tool
(A): 09913M76010
IHD10P1A1005-01
(A)
5) Tighten stator assembly bolts (1) to specified torque.
Tightening torque
Stator assembly bolt (a): 5.9 N·m (0.60 kgf-m,
4.5 lbf-ft)
ICV00P1A0021-01
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, 1, (a)
2.0 lbf-ft) 1, (a)
IMTA0A1A0006-01
6) Install pulley (1), fix shaft using 6-point socket

2
wrench (2), and then tighten pulley nut (3) to
(a)
specified torque.
1
IFRA0A1A1026-01 NOTICE
3) Install rotor (1) to stator assembly (2).
The shaft end is not hard enough and the end
may be damaged if it is held using a 12-point
socket wrench.
Use 6-point socket wrench to hold the shaft.
Tightening torque
Pulley nut (a): 133 N·m (13.6 kgf-m, 98.5 lbf-ft)
1
2
IEL10A1A1011-01
9) 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
IMTA0A1A0013-02
7) Install brush holder assembly (1) using the following

procedure:
a) Push brushes (2) in arrow direction.
3, (a)
b) Hold brushes in compressed position, by
inserting a pin (4) into stopper hole (3).
2
NOTE
Recommended pin diameter: About 1.0 mm
(0.04 in.)
IMTA0A1A0012-01
[A]
2 Generator Inspection
AENNTA0E1A06010 (08(03)
4
Reference: “Generator Disassembly and Reassembly”
Rotor
1
1) Using ohmmeter (1), check for continuity between
3 slip rings (2) of rotor.
ILKC0P1A1017-01
If there is no continuity, replace rotor assembly.
[A]: Rotor side
Standard resistance between slip rings of rotor
c) Install brush holder assembly (1) to stator 1.85 – 2.25 Ω
assembly (2), and then tighten brush holder
assembly screws (3) to specified torque. 2
Tightening torque
1
Brush holder assembly screw (a): 1.8 N·m (
0.18 kgf-m, 1.5 lbf-ft)
d) Remove pin (4) from brush holder assembly.
I8G0011A0010-01
2
3, (a)
2) Using ohmmeter (1), check that there is no continuity
between slip ring (2) and rotor core (3).
[A]
4 If there is continuity, replace rotor assembly.
ILKC0P1A1018-01
[A]: Rotor side

I8G0011A0011-01
8) Install bushing (1) to “B” terminal. 3) Check slip rings and blades for damage.
If any abnormality is found, replace rotor assembly. there is no conduction if a voltage higher
than that in the positive direction is
Bearing displayed.
Check bearing for smooth rotation.
If any abnormality is found, replace bearing.
1
NOTE 1
Bearing (1) shown in figure is combined with
rotor (2) and check it as it is. A1 A4
A4
If any abnormality is found, replace rotor.
A2 A5
A1
A3 A3 A6
2
A6
2 1
A2
A5
2
IJ3J0Q1A0002-01
ICV00P1A0016-01
Brush
Check each brush (1) for wear by measuring its length
Stator as shown.
• Using ohmmeter, check continuity between each of If brush has worn down to service limit, replace brush
stator coil terminals (A1 / A2 / A3). holder assembly.
If there is no continuity, replace stator assembly.
Exposed brush length “a”
• Using ohmmeter, check continuity between each of Standard: 10.5 mm (0.41 in.)
stator coil terminals (A1 / A2 / A3) and corresponding Limit: 1.5 mm (0.06 in.)
terminals (A4 / A5 / A6).
If there is no continuity, replace stator assembly.
• Using diode range of circuit tester, check continuity 1
between “B” terminal (1) and stator coil terminals (A4 /
A5 / A6), and ground (2) and stator coil terminals (A4 / “a”
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.
IE3J0P1A0017-01
NOTE
Rectifier
• For diode test, refer to the instruction
manual of circuit tester. NOTE
• In conducting inspection in the reverse Rectifiers are combined with stator assembly
direction, since the display voltage is and inspection for individual rectifier is not
affected by the power supply performance possible.
of the circuit tester, it is determined that
Refer to “Stator”for checking the stator assembly.
Specifications
Charging System Specifications
AENNTA0E1A07001 (09(01)
Battery
Battery type
: M42
Battery specification
: CCA 330 A (JIS) (38 Ah/20 HR) 12 V
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

AENNTA0E1A07002 (09(t)
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Battery tray bolt 13 1.3 9.5 (T1J001)
Battery tray nut 13 1.3 9.5 (T1J002)
Battery band nut 3.3 0.34 2.5 (T1J003)
Battery cable nut 5.0 0.51 4.0 (T1J004)
Generator upper bolt 30 3.1 22.5 (T1J005)
Generator lower bolt 48 4.9 35.5 (T1J006)
“B” terminal nut 7.9 0.81 6.0 (T1J007)
Auto tensioner lower bolt 25 2.5 18.5 (T1J008)
Timing chain cover No.1 bolt 25 2.5 18.5 (T1J009)
Bearing retainer screw 2.3 0.23 2.0 (T1J010)
Stator assembly bolt 5.9 0.60 4.5 (T1J011)
Pulley nut 133 13.6 98.5 (T1J012)
Brush holder assembly screw 1.8 0.18 1.5 (T1J013)
Rear end cover bolt 4.6 0.47 3.5 (T1J014)
Reference:
“Generator Components”

Special Tool
AENNTA0E1A08001 (11(s)
09913M76010 09919M16020
Bearing installer Socket (17 mm)
(L1J004) (L1J001) / (L1J002)
09924M74510
Bearing and oil seal handle
(L1J003)
Exhaust System: 1K-1
Exhaust System
Engine
Precautions
Precautions
AENNTA0E1B00001 (01(01)
! 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.
NOTICE
Applying a shock to the exhaust manifold 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 something.
General Description
Exhaust System Description
AENNTA0E1B01001 (03(01)
The exhaust system consists of an exhaust manifold, a three-way catalytic converter (TWC) in the exhaust manifold,
exhaust pipe, 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.

Exhaust System Check
AENNTA0E1B04001 (06(01)
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. (Exhaust System Components)
• 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.
Repair Instructions
Exhaust System Components
AENNTA0E1B06001 (12(01)
1K-2 Exhaust System:
(a)
(a)
1 (a)
5 (c)
7
(b)
(e)
6 (c) 15
9 8 13 14
8
10
11 (d)
21
(f)
19
12 (e)
20
19
16
(f)
14
18
17
IMTA0A1B0001-02
1. Exhaust manifold cover 11. Exhaust manifold stiffener bolt 21. Mounting No.3
: For tightening order, refer to “Exhaust Manifold Removal and Installation”.
2. Exhaust manifold 12. Exhaust manifold stiffener nut : 11 Nm (1.1 kgf-m, 8.5 lbf-ft)
: For tightening order, refer to “Exhaust Manifold Removal and Installation”.
3. Exhaust manifold gasket 13. To EGR pipe : 60 Nm (6.1 kgf-m, 44.5 lbf-ft)
4. To cylinder head cover 14. Seal ring : 45 Nm (4.6 kgf-m, 33.5 lbf-ft)
5. HO2S-1 15. Exhaust pipe : 35 Nm (3.6 kgf-m, 26.0 lbf-ft)
6. HO2S-2 16. Muffler : 25 Nm (2.5 kgf-m, 18.5 lbf-ft)
7. To cylinder block 17. Mounting No.1 : 43 Nm (4.4 kgf-m, 32.0 lbf-ft)
: For installation, refer to “Exhaust Pipe and Muffler Removal and
Installation”
8. To oil pan 18. To front suspension frame : Do not reuse.
9. Exhaust manifold stiffener No.1 19. To vehicle body
10. Exhaust manifold stiffener No.2 20. Mounting No.2
: For installation, refer to “Exhaust Pipe and Muffler Removal and
Installation”
Exhaust Manifold Removal and Installation Removal

AENNTA0E1B06002 (08(01)
Reference: “Exhaust System Components” 1) Hoist vehicle. (Vehicle Lifting Points) in Section 0A
Exhaust System: 1K-3
2) Remove engine under cover. (Engine Under Cover b. Temporarily tighten until a each part comes
and Engine Under Side Cover Removal and contact face to face exhaust manifold stiffener
Installation) in Section 9H bolts (3) and exhaust manifold stiffener nuts (4) in
3) Disconnect HO2S-1 and HO2S-2 connectors and numerical order (“1” – “4”).
clamps. (HO2S Removal and Installation) in Section
3, “1”
1C 1 3, “3”
4) Remove HO2S-1 and HO2S-2 from exhaust
manifold, if necessary. (HO2S Removal and
5) Remove exhaust pipe from exhaust manifold.
(Exhaust System Components)
6) Remove EGR pipe from exhaust manifold. (EGR
Cooler Removal and Installation) in Section 1B
7) Remove exhaust manifold stiffener No.1 (1) and
exhaust manifold stiffener No.2 (2) from exhaust 4, “2” 4, “4” 2
IMTA0A1B0005-01
manifold.
c. Tighten exhaust manifold stiffener bolts (1) and
exhaust manifold stiffener nuts (2) in numerical
order (“1” – “4”) to specified torque.
1, “3”
1, “4”
1 2
IMTA0A1B0002-01
8) Remove exhaust manifold cover (1) from exhaust

manifold (2).
9) Remove exhaust manifold bolts (3) and nuts (4). 2, “1” 2, “2”
IMTA0A1B0006-02
10) Remove exhaust manifold and its gasket (5) from
cylinder head. • Install EGR pipe referring to “EGR Cooler Removal
and Installation” in Section 1B.
1 • Install HO2S-1 and HO2S-2 referring to “HO2S
5 Removal and Installation” in Section 1C, if removed.
2
• Run engine and check for exhaust gas leakage.
Exhaust Manifold Inspection

AENNTA0E1B06003 (08(03)
Using straightedge and feeler gauge, check gasket
surface for distortion.
If flatness exceeds its limit, repair it.
If repair is not possible, replace exhaust manifold.
3 4 3 4 Distortion of exhaust manifold [a] – [e]
IMTA0A1B0004-01
Limit: 0.3 mm (0.012 in.)
Installation Distortion of exhaust manifold [f] – [i]
Reverse removal procedure noting the following points. Limit: 0.7 mm (0.028 in.)
• Use new gasket and new seal ring.
[b] [c] [d] [e]
• Tighten bolts and nuts to specified torque referring to
“Exhaust System Components”. [h] [f]
• Install exhaust manifold stiffener No.1 (1) and No.2 (2)

as follows. [i]
[g]
a. Install exhaust manifold stiffener No.1 and No.2.

[a]
IMTA0A1B0007-01
1K-4 Exhaust System:
Exhaust Pipe and Muffler Removal and • Install mounting No.2 (1) positioning its cavity (2)
Installation forward-backward direction.
AENNTA0E1B06004 (08(01)
Reference: “Exhaust System Components” 1
For replacement of exhaust pipe and muffler, refer to
“Exhaust System Components” and the following points. [b]
• Use new gasket and new seal ring.
[f]
• Tighten bolts and nuts to specified torque referring to
“Exhaust System Components”. 2
• Install mounting No.1 (1) positioning its weight (2)

downward.
IMTA0A1B0009-02
[f]: Forward [b]: Backward
1
• Run engine and check for exhaust gas leakage.
[d]
IMTA0A1B0008-02
[d]: Downward
Specifications
AENNTA0E1B07001 (09(t)
Reference:
“Exhaust System Components”
Section 2
Suspension
CONTENTS
Precautions .................................................2-1 Special Tools and Equipment ...........................2B-17

Special Tool ......................................................2B-17 2
Precautions............................................................. 2-1
Precautions for Suspension .................................. 2-1
Rear Suspension ..................................... 2C-1
Suspension General Diagnosis.............. 2A-1 Precautions...........................................................2C-1
Diagnostic Information and Procedures............2A-1 Precautions for Handling of Rear Shock
Suspension, Wheel and Tire Symptom Absorber............................................................2C-1
Diagnosis .......................................................... 2A-1 General Description .............................................2C-1
Repair Instructions ..............................................2A-5 Rear Suspension Description..............................2C-1
Suspension System Check ................................. 2A-5 Repair Instructions ..............................................2C-1
Rear Wheel Alignment Inspection.......................2C-1
Front Suspension .................................... 2B-1 Rear Suspension Components ...........................2C-2
Precautions...........................................................2B-1 Rear Shock Absorber Removal and
Precautions for Handling of Front Strut............... 2B-1 Installation .........................................................2C-3
General Description .............................................2B-1 Rear Shock Absorber Inspection ........................2C-6
Front Suspension Description ............................. 2B-1 Rear Coil Spring and Spring Seat Removal
Front Wheel Alignment Description..................... 2B-1 and Installation ..................................................2C-6
Rear Coil Spring and Spring Seat Check............2C-9
Repair Instructions ..............................................2B-1
Rear Axle Removal and Installation ....................2C-9
Front Wheel Alignment Inspection and
Rear Axle Check ...............................................2C-11
Adjustment ........................................................ 2B-2
Rear Suspension Fastener Inspection ..............2C-11
Front Strut Assembly Components ..................... 2B-3
Front Strut Assembly Removal and Specifications.....................................................2C-11
Installation......................................................... 2B-4 Tightening Torque Specifications......................2C-11
Front Strut Assembly Disassembly and
Reassembly ...................................................... 2B-6
Wheels and Tires ..................................... 2D-1
Front Strut Inspection.......................................... 2B-8 Precautions...........................................................2D-1
Coil Spring, Strut Bearing and Strut Support Precautions for Servicing Wheel and Tire...........2D-1
Check................................................................ 2B-8 General Description .............................................2D-1
Suspension Arm Components ............................ 2B-8 Tire Description ...................................................2D-1
Suspension Arm Removal and Installation ......... 2B-8 Replacement Tire Description.............................2D-1
Suspension Arm Check .................................... 2B-10 Wheel Description ...............................................2D-1
Front Suspension Frame and Stabilizer Bar Replacement Wheel Description.........................2D-2
Components.................................................... 2B-11 Matched Tire and Wheel Description (for
Front Suspension Frame, Stabilizer Bar and Vehicle Equipped with Steel Wheel) .................2D-2
Bushing Removal and Installation................... 2B-12 Tire Placard Description......................................2D-2
Front Suspension Frame Check ....................... 2B-15 Repair Instructions ..............................................2D-2
Front Stabilizer Bar Removal and Installation ... 2B-15 Wheel (with Tire) Removal and Installation.........2D-2
Front Stabilizer Bar, Bushing and Joint Check .. 2B-16 Tire Inspection.....................................................2D-3
Front Suspension Fastener Check ................... 2B-16 Wheel Inspection.................................................2D-3
Specifications.....................................................2B-16 Tire Rotation........................................................2D-4
Tightening Torque Specifications...................... 2B-16 Specifications.......................................................2D-4
Tightening Torque Specifications........................2D-4
2-1 Precautions:
Precautions
Suspension
Precautions
Precautions for Suspension
AENNTA0E2000001 (01(01)
General Precautions
Refer to “General Precautions” in Section 00.

Refer to “Precautions for Electrical Circuit Service” in Section 00.
Caution for Fastener

Refer to “Caution for Fastener” in Section 00.
Caution for Suspension

Refer to “Caution for Suspension” in Section 00.
Warning for Wheel and Tire

Refer to “Warning for Wheel and Tire” in Section 00.
Warning for Brake

Refer to “Warning for Brake” in Section 00.
Warning for Air Bag


Refer to “Caution for Vehicles Equipped with DCM” in Section 00.
Suspension General Diagnosis: 2A-1
Suspension General Diagnosis

Suspension

Suspension, Wheel and Tire Symptom Diagnosis
AENNTA0E2104001 (06(04)
Vehicle pulls to one side (leads)

• Mismatched or unevenly worn tires Replace tires. (Wheel (with Tire) Removal and Installation)
in Section 2D
• Tires not adequately inflated Adjust tire pressure.
• Broken or sagging coil springs Replace coil springs.
• Front: (Front Strut Assembly Disassembly and
Reassembly) in Section 2B
• Rear: (Rear Coil Spring and Spring Seat Removal and
• Abnormal lateral force created by radial tire Replace tire. (Wheel (with Tire) Removal and Installation) in
Section 2D
• Disturbed wheel alignment Check and adjust wheel alignment. (Front Wheel Alignment
Inspection and Adjustment) in Section 2B
• Brake dragging in one wheel Adjust or repair brake. (Brake Symptom Diagnosis) in
Section 4A
• Loose, bent or broken front or rear suspension
parts Tighten or replace related suspension parts. (Suspension
System Check)
Excessive tire wear

• Wheel out of balance Adjust balance or replace tire.
• Faulty shock absorber Replace shock absorber.
• Rear: (Rear Shock Absorber Removal and Installation) in
Section 2C
• Hard driving Replace tires. (Wheel (with Tire) Removal and Installation)
in Section 2D
• Overloaded vehicle Replace tires. (Wheel (with Tire) Removal and Installation)
in Section 2D
• Not rotated tires Replace or rotate tires.
• Worn or loose wheel bearing Replace wheel hub assembly.
• Front: (Front Wheel Hub Assembly and Steering Knuckle
• Rear: (Rear Wheel Hub Assembly Removal and
Installation): Rear in Section 3A
• Wheel or tire wobbles Replace wheel or tire. (Wheel (with Tire) Removal and
• Tires not adequately inflated Adjust tire pressure.
2A-2 Suspension General Diagnosis:
Wheel tramp
• Blister or bump on tire Replace tire. (Wheel (with Tire) Removal and Installation) in
Section 2D
• Improper shock absorber action Replace shock absorber.
• Rear: (Rear Shock Absorber Removal and Installation) in
Section 2C
Shimmy, shake or vibration

• Loose wheel bearings Replace wheel hub assembly.
• Worn tie-rod ends Replace tie-rod ends. (Tie-Rod End Removal and
• Worn suspension arm joints Replace suspension arm. (Suspension Arm Removal and
• Excessive tire or wheel run-out Repair or replace wheel and/or tire. (Wheel (with Tire)
• Blister or bump on tire Replace tire. (Wheel (with Tire) Removal and Installation) in
Section 2D
• Excessive radial runout of tire / wheel assembly Replace tire or wheel. (Wheel (with Tire) Removal and
• Loose or worn steering linkage Check steering system.
• Steering wheel: (Steering Wheel Play Check) in Section
6C
• Steering shaft joint: (Steering Shaft Joint On-Vehicle
Inspection) in Section 6B
• Pinion shaft: (Pinion Shaft Rotation Torque Inspection) in
Section 6B
• Tie-rod ends: (Tie-Rod End Inspection) in Section 6B
• Loose steering gear case bolts Tighten steering gear case bolts. (Steering Gear Case
Abnormal noise
• Damaged front strut assembly (shock absorber) or
mountings Repair or replace front strut assembly (shock absorber) or
mountings. (Front Strut Assembly Disassembly and
• Damaged rear shock absorber or mountings Replace rear shock absorber or mountings. (Rear Shock
Absorber Removal and Installation) in Section 2C
• Worn or sticky tie-rod ends Replace tie-rod ends. (Tie-Rod End Removal and
• Worn or damaged suspension arm joints Replace suspension arm. (Suspension Arm Removal and
• Worn or sticky tie-rod ball joints Replace tie-rod. (Tie-Rod / Rack Boot Removal and
• Worn or sticky drive shaft joints Replace drive shaft joints. (Front Drive Shaft Assembly
• Worn suspension arm front bushings Replace suspension arm front bushings. (Suspension Arm
• Worn suspension arm rear bushings Replace suspension arm. (Suspension Arm Removal and
• Loose stabilizer bar Tighten bolts or nuts and/or replace bushings. (Front
Suspension Frame, Stabilizer Bar and Bushing Removal
• Loose wheel nuts Tighten wheel nuts. (Wheel (with Tire) Removal and
• Loose suspension bolts or nuts Tighten suspension bolts or nuts.
• Front: (Front Suspension Fastener Check) in Section 2B
• Rear: (Rear Suspension Fastener Inspection) in Section
2C
• Broken or damaged wheel bearings Replace wheel hub assembly.
• Broken coil springs Replace coil springs.
• Front: (Front Strut Assembly Removal and Installation) in
Section 2B
• Poorly lubricated or worn strut bearings Replace strut bearings. (Front Strut Assembly Disassembly
and Reassembly) in Section 2B
• Steering system malfunction Check and correct malfunction. (Steering Symptom
Diagnosis) in Section 6A
• Deteriorated rear axle bushings Replace rear axle. (Rear Axle Removal and Installation) in
Section 2C
Too low or uneven trim heights
NOTE
See NOTE *1.

• Overloaded vehicle Check loading.
• Incorrect coil springs Replace coil springs.
• Poorly inflated tires Adjust tire pressure.
Too soft ride

• Faulty front strut assembly (shock absorber) Replace front strut assembly (shock absorber). (Front Strut
Assembly Disassembly and Reassembly) in Section 2B
2A-4 Suspension General Diagnosis:
• Faulty rear shock absorber Replace rear shock absorber. (Rear Shock Absorber
Suspension bottoms
• Faulty rear shock absorber Replace rear shock absorber. (Rear Shock Absorber
• Incorrect, broken or sagging coil springs Replace coil springs.
Body leans or sways in corners

• Loose stabilizer bar Tighten stabilizer bar bolts or nuts, or replace bushings.
(Front Suspension Frame and Stabilizer Bar Components)
in Section 2B
• Faulty front strut assembly (shock absorber) or
mounting Replace front strut assembly (shock absorber) or tighten
mounting. (Front Strut Assembly Disassembly and
• Faulty rear shock absorber or mountings Replace rear shock absorber or mountings. (Rear Shock
Absorber Removal and Installation) in Section 2C
Cupped tires
• Faulty front strut assembly Replace front strut assembly. (Front Strut Assembly
Disassembly and Reassembly) in Section 2B
• Worn wheel bearings Replace wheel hub assembly.
• Excessive tire or wheel run-out Repair or replace tire and/or wheel. (Wheel (with Tire)
• Worn suspension arm joints Replace suspension arm. (Suspension Arm Removal and
NOTE
*1: Right-to-left trim height (“h”) difference should be within 15 mm (0.6 in.) with curb weight. (The
same applies to both front and rear suspensions.)
I8C50A210002-01
Repair Instructions
Suspension System Check
AENNTA0E2106001 (08(03)
Hoist vehicle and check the following parts. Retighten,
repair or replace defective part with new one if
necessary.
Front Suspension
• Front suspension frame: (Front Suspension Frame
Check) in Section 2B
• Suspension arm: (Suspension Arm Check) in Section
2B
• Front strut assembly: (Front Strut Inspection) in
Section 2B
• Coil spring, strut bearing and strut support: (Coil
Spring, Strut Bearing and Strut Support Check) in IMTA0A210001-01
Section 2B
• Front stabilizer bar and joint: (Front Stabilizer Bar,
Bushing and Joint Check) in Section 2B
IMTA0A210002-01
Rear Suspension
• Rear axle: (Rear Axle Check) in Section 2C
• Rear shock absorber: (Rear Shock Absorber
• Rear coil spring: (Rear Coil Spring and Spring Seat
Check) in Section 2C
2B-1 Front Suspension:
Front Suspension
Suspension
Precautions
Precautions for Handling of Front Strut • Wear eye protection when drilling a gas
AENNTA0E2200001 (01(01) release hole. Although the gas itself is
! WARNING harmless, metal chips produced by the
drilling can injure your eyes.
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. 1 2
• 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
IDL10A220001-01
cylinder.
General Description
Front Suspension Description
AENNTA0E2201001 (03(01)
• Front suspension employs a McPherson strut type
combined with suspension frame (1).
• The suspension frame supports steering gear case 6
assembly (2), engine rear torque rod (3) and
suspension arms (4), to reduce vehicle vibration.
• Front strut assembly consists of a sealed cylindrical
5
strut (5) filled with high-pressure gas and a coil spring
(6).
7
• The front suspension also includes stabilizer bar (7),
to improve anti-rolling performance of vehicle. 2
1 3
IGSD0A220001-01
Front Wheel Alignment Description

AENNTA0E2201002 (03(01)
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 Suspension: 2B-2
Front Wheel Alignment Inspection and

Adjustment [f]
AENNTA0E2206001 (08(03)
Preparation
Perform the following items before checking and “a”
adjusting front wheel alignment.
• Check each tire as follows.
– Check that tire is of specified size. Replace tire with
correct one if necessary.
– 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. “b”
I7V10A220002-02
– Check that tire is of the same brand as the other
[f]: Forward
tires. Replace tire with one of correct brands if
necessary.
Toe Adjustment
• Check that wheel bearing is not damaged. Replace
wheel hub assembly if defective. NOTICE
• Check wheel (with tire) for deflection. If necessary, The rack boot may break if it is twisted.
repair or replace. Check that the rack boot does not get twisted
• Check if each suspension part is installed properly. If during adjustment of front wheel alignment.
faulty condition is found, repair or replace.
• Check that each suspension part is free from bend, NOTE
dent, wear or damage. Never adjust only right or left tie-rod, adjust
• Place vehicle in non-loaded state on level surface. both tie-rods by the same amount.
• Set steering wheel in straight ahead position.
1) Loosen tie-rod end lock nuts.
• Bounce vehicle up and down several times to stabilize
2) Tighten or loosen right and left tie-rods by the same
suspension.
amount to adjust toe to specification.
• Check that ground clearance at the right and left is
3) Check that length “a” on right tie-rod is equal to that
almost the same.
on left tie-rod. If they are not equal, readjust toe.
Toe Inspection
Measure toe using toe-in gauge (1) or total wheel “a”
alignment tester.
If toe is out of specification, adjust it at tie-rod.
Total toe–in (Using total wheel alignment tester)
Front:
• Standard value: IN 0° 06’
• Minimum value: OUT 0° 10’
• Maximum value: IN 0° 22’ IGSB0A220002-01
Total toe–in “b” – “a” (Using toe–in gauge) 4) Tighten tie-rod end lock nuts to specified torque.
Front: (Steering Gear Case Assembly Components) in
• Standard value: IN 1 mm (0.04 in) Section 6B
• Minimum value: OUT 2 mm (0.08 in)
• Maximum value: IN 4 mm (0.2 in) Reference Information
Side slip
When checked using side slip tester, side slip should be
within the following specification.
NOTE
The side slip is only applicable for regulation
required countries.
I6RS0C220007-01
Side slip (On one person)

Front: OUT 5 to IN 5 mm/m (OUT 0.2 to IN 0.2 in./3.4
[k]
ft.) [A]
2
If side slip deviates from specification greatly, front wheel

alignment may be out of specification. “c”
[t]
Camber, Caster and Kingpin Inclination Angle

Inspection
Check camber, caster and kingpin inclination angle [s]
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.
“d” 1
• Strut assembly components
• Suspension arms and bushings
“a”
• Front suspension frame
[B]
• Front wheel hubs, steering knuckles and wheel “b”
bearings
• Vehicle body
[f]
“d”
2
IGRA0A220001-01
[A]: Camber and kingpin [t]: Center line of wheel

inclination angle (Front view)
I7RS0A220003-01 [B]: Caster (Side view) “d”: 90°
Camber “a” [f]: Forward 1. Suspension arm joint

[k]: Center line of kingpin 2. Strut support
Front:
[s]: Vehicle body center
• Standard value: 0° 12’
• Minimum value: –0° 48’
Steering Angle Inspection and Adjustment
• Maximum value: 1° 12’
When tie-rod or tie-rod end is replaced, check toe and
Caster “b” then also steering angle using turning radius gauge. If
Front: measured value is not as specified, check and adjust
• Standard value: 4° 40’ toe.
• Minimum value: 2° 40’
Steering angle
Inside:
Kingpin inclination angle “c” • Standard value: 40° 54’
Front (Reference): 12° 28’ • Minimum value: 38° 54’
NOTE
Steering angle
Camber, caster and kingpin inclination angle
Outside (Reference): 33° 42’
are not adjustable. If they are out of
specification, repair vehicle body or replace
related part.
Front Strut Assembly Components

AENNTA0E2206002 (12(01)
16
6
15 (a)
5 10
14 (a)
1
13 (b) 7
3
11
12
[f]
IMTA0A220023-01
[f]: Forward 7. Strut bearing 14. Strut support lower nut

1. Front strut 8. Strut bearing plate 15. Strut support upper nut
2. Coil spring lower seat 9. Strut support 16. Strut rod cap
3. Coil spring 10. Rebound stopper : 50 Nm (5.1 kgf-m, 37.0 lbf-ft)
4. Bump stopper 11. Steering knuckle : 90 Nm (9.2 kgf-m, 66.5 lbf-ft)
: Install in correct direction. (Front Strut
Assembly Disassembly and Reassembly)
5. Strut dust cover 12. Strut bracket bolt : Do not reuse.
: Insert from vehicle front side.
6. Coil spring upper seat 13. Strut bracket nut
Front Strut Assembly Removal and Installation NOTE

AENNTA0E2206003 (08(01)
Reference: “Front Strut Assembly Components” When servicing strut assembly components,
loosen strut support upper nut a little before
NOTE removing strut assembly. This will facilitate
Pulling steering knuckle outward with drive service work. Note that the nut must not be
shaft fixed to steering knuckle could cause removed at this point.
drive shaft to be removed from transaxle.
Do not pull steering knuckle outward.
If drive shaft is removed, replace drive shaft
circlip with new one.
Removal
1) Remove strut rod cap (1).
1 3
IMTA0A220002-01 INTA0A220004-01
2) Hoist vehicle, allowing front suspension to be free of 7) Remove strut bracket nuts (1) and bolts (2).
vehicle weight.
3) Remove front wheel. (Wheel (with Tire) Removal
4) Remove stabilizer joint nut (2) while holding stud
using hexagon wrench (1), remove stabilizer upper
joint (3) from front strut bracket (4).
2
1
2
3
IMTA0A220005-01
8) Remove strut support upper nut (1) and rebound

stopper (2), and then remove front strut assembly
4 1 from vehicle.
IL2R0A220016-01 NOTE
5) Remove front brake hose bolt (1), and then Hold strut assembly by hand so that it will
disconnect brake hose (2) from front strut bracket not fall off.
(3).
1
IA1J0P220004-01
1
2
Installation
Reference: “Front Strut Assembly Components”
IMTA0A220003-01
Reference: “Front Strut Inspection”
6) Disconnect grommets (1), and then disconnect front NOTICE
wheel speed sensor harness (3) from front strut (2).
The following nuts are pre-coated with
friction stabilizer. If these nuts are reused,
they may work loose.
Never reuse the following nuts.
• Strut bracket nut
• Strut support upper nut

• Insert strut bracket bolts (1) in the direction shown in
figure. 2, (a)
1
1
IK2R0P220024-01
3. Torque wrench
• Tighten wheel nuts to specified torque.(Wheel (with

[f] Tire) Removal and Installation) in Section 2D
• Lower hoist and bounce vehicle up and down several
IMTA0A220006-01
times to stabilize suspension, and then tighten new
[f]: Forward strut support upper nut (1) to specified torque.
• Tighten front brake hose strut bolt (1) and new strut Tightening torque
bracket nuts (2) to specified torque. Strut support upper nut (a): 50 N·m (5.1 kgf-m,
37.0 lbf-ft)
NOTE
1, (a)
Do not twist brake hose and front wheel
speed sensor harness when installing them.
Tightening torque
Front brake hose strut bolt (a): 26 N·m (2.7 kgf-
m, 19.5 lbf-ft)
Strut bracket nut (b): 90 N·m (9.2 kgf-m, 66.5 lbf-
ft)
IE3J0P220015-01
• Check front wheel alignment. (Front Wheel Alignment

Inspection and Adjustment)
Front Strut Assembly Disassembly and

Reassembly
AENNTA0E2206004 (08(02)
Reference: “Front Strut Assembly Removal and
Installation”
2, (b)
1, (a) ! WARNING
compressing the coil spring can result in
IMTA0A220007-01 severe personal injury.
• Tighten stabilizer joint nut (2) to specified torque while • Attach the spring compressors to the
holding stud using hexagon wrench (1). positions that allow compressing the
spring evenly.
Tightening torque
Stabilizer joint nut (a): 50 N·m (5.1 kgf-m, 37.0 lbf- • Do not use an impact wrench when
ft) compressing the coil spring.
• When using commercially available spring
compressors, follow the manufacturer’s
instructions described in the manual
attached to the spring compressors.
Disassembly (A): 09943M25010

1) Attach special tool to coil spring as shown. Screw in
“a”
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
length of compressed coil spring when it is
compressed. [u] [l] (A)
Special tool
(A): 09943M25010
(A) I9P60A220009-02
1 [u]: Upper side (large diameter) [l]: Lower side (small diameter)
3) Install compressed coil spring (1) to front strut (2) by

fitting coil spring end (3) with protrusion of coil spring
lower seat (4) as shown in figure.
NOTE
I9P60A220008-02 Coil spring end should not ride on step in coil
2) While keeping coil spring compressed using special spring lower seat.
tool, remove strut support lower nut (1) using
hexagon wrench (2) as shown in figure.
2
1
4
2
IFRA0A220031-01
“a” 3
3) Disassemble front strut assembly. (Front Strut IMTA0A220008-01
Assembly Components)
“a”: 10 mm (0.39 in.) or less
Reassembly
4) Install bump stopper (2) directing slit side (1)
Reference: “Front Strut Inspection”
upward, and then Install dust cover (3) over three
Reference: “Coil Spring, Strut Bearing and Strut Support
claws (5) of front strut (4).
Check”
1) Install coil spring lower seat (2) to front strut by fitting
its protrusions (1) into holes (3) in front strut.
3
1
1
3
2 2
4
IDL10A220004-01 5
IMTA0A220009-01
2) Compress coil spring using special tool (spring
compressor) evenly until total length “a” becomes 5) Pull strut rod (3) as far up as possible and use care
the same length as recorded in disassembly. not to allow it to retract into strut.
6) Install coil spring upper seat.
Special tool
7) Install strut bearing, strut bearing plate, strut support If conditions of front struts are in doubt, compare
and strut support lower nut in this sequence. (Front them with known-good vehicle or front strut.
Strut Assembly Components)
8) Then tighten strut support lower nut (1) to specified Coil Spring, Strut Bearing and Strut Support
torque while holding stud using hexagon wrench (2). Check
AENNTA0E2206006 (08(03)
Tightening torque Reference: “Front Strut Assembly Disassembly and
Strut support lower nut (a): 50 N·m (5.1 kgf-m, Reassembly”
37.0 lbf-ft) • 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
2 crack, deformation and damage.
3 • Check strut bearing for wear, abnormal noise and
1, (a) damage.
If check result is not OK, replace defective parts with
new ones.
Suspension Arm Components

AENNTA0E2206007 (12(01)
IAP70P220021-02
9) Remove special tool (spring compressor) from coil

spring. Then check that coil spring end does not ride
on protrusion of spring lower seat.
1
Front Strut Inspection
AENNTA0E2206005 (08(03)
Reference: “Front Strut Assembly Disassembly and
Reassembly”
5 (a)
• Check each front strut for oil leakage, damage or
deformation. If check result is not OK, replace front 2
4 (a)
strut as an assembly, as it is not repairable.
3 (b)
[f]
INTA0A220006-01
[f]: Forward
1. Suspension arm
2. Clip
3. Suspension arm joint nut
4. Suspension arm front bushing bolt
:For tightening procedure, refer to “Suspension Arm Removal and
Installation”.
5. Front suspension frame No.2 bolt
:For tightening procedure, refer to “Suspension Arm Removal and
Installation”.
: 95 Nm (9.7 kgf-m, 70.0 lbf-ft)
: 55 Nm (5.6 kgf-m, 40.5 lbf-ft)
I4RS0A220014-01
: Do not reuse.
• Check front strut function as follows. If check result is
not OK, replace front strut as an assembly, as it is not Suspension Arm Removal and Installation
repairable. AENNTA0E2206008 (08(01)
a. Check and adjust tire pressures as specified. Reference: “Suspension Arm Components”
b. Bounce vehicle body up and down 3 or 4 times NOTICE
continuously by pushing front end of vehicle side
body to check front strut. • Unless you pay adequate attention when
Also, note how many times vehicle body rebounds removing the suspension arm joint from
to stop after force application. the steering knuckle, the dust cover of the
suspension arm joint may be damaged by
c. Repeat the same procedure to the other front strut
the puller.
to check that both struts equally function.
When you remove the suspension arm

joint from the steering knuckle, be careful
not to damage the dust cover of the
suspension arm joint.
Removal
3
1) Hoist vehicle and remove front wheel. (Wheel (with
Tire) Removal and Installation) in Section 2D
2) Remove engine undercovers. (Engine Under Cover 1 2
3) Remove clip (1), and then loosen suspension arm
joint nut (2) until nut end becomes flush with stud
end of suspension arm joint. IMTA0A220012-02
Installation
Reference: “Suspension Arm Check”
NOTICE
The following bolts are pre-coated with
friction stabilizer. If these bolts are reused,
1 they may work loose.
Never reuse the following bolts.
• Suspension arm front bushing bolt
2
• Front suspension frame No.2 bolt
1) Install suspension arm (3) and tighten new

IMTA0A220011-01
suspension arm front bushing bolt (1) and new front
suspension frame No.2 bolt (2) temporarily by hand.
4) Disconnect suspension arm joint (3) from steering
knuckle (2) using ball joint puller (1).
! CAUTION
Ball joint puller may fall off when suspension
arm joint is disconnected and cause an
injury. 3
Suspend the ball joint puller from the vehicle
body using a rope to prevent the puller from
1 2
falling off.
2
IMTA0A220012-02
2) Connect suspension arm joint to steering knuckle

and then tighten new suspension arm joint nut (1) to
specified torque.
1 NOTE
3
If grease is stuck on taper surface of
IL2R0A220005-01 suspension arm joint and knuckle, remove it
5) Remove suspension arm joint nut. before connecting these parts.
6) Remove suspension arm front bushing bolt (1) and Tightening torque
front suspension frame No.2 bolt (2), and then Suspension arm joint nut (a): 55 N·m (5.6 kgf-m,
remove suspension arm (3). 40.5 lbf-ft)
3) Insert clip (2) to suspension arm joint.
Bushing
2 Check suspension arm front bushing (2) for damage,
wear and deterioration. Replace suspension arm if
check result is not OK.
1, (a) Check suspension arm rear bushing (3) for damage,
wear and deterioration. Replace suspension arm if
check result is not OK.
IL2R0A220015-01
4) Install front wheel and tighten wheel nuts to specified

torque. (Wheel (with Tire) Removal and Installation)
in Section 2D 1
5) Lower hoist and bounce vehicle up and down
several times to stabilize suspension.
6) Tighten new suspension arm front bushing bolt (1)
and front suspension frame No.2 bolt (2) to specified
torque. 2
Tightening torque
Suspension arm front bushing bolt (a): 95 N·m ( IGSB0A220015-01
9.7 kgf-m, 70.0 lbf-ft)

Front suspension frame No.2 bolt (b): 95 N·m ( Joint
9.7 kgf-m, 70.0 lbf-ft) 1) Remove front wheel. (Wheel (with Tire) Removal
2) Using washers (2) and nuts (3) other than the wheel
nuts, fix front brake disc (1) diagonally.
NOTICE
If the wheel nut is used to fix the front brake
disc, the tapered end of the wheel nut may be
2, (b)
damaged.
1, (a)
Do not use wheel nut for the brake disc
fixation in this step.
IMTA0A220013-01
7) Hoist vehicle again, and then install engine 2

undercover. (Engine Under Cover and Engine Under
Side Cover Removal and Installation) in Section 9H
3
8) Lower hoist.
Alignment Inspection and Adjustment)
Suspension Arm Check IA1J0P020018-01

AENNTA0E2206009 (08(03)
Reference: “Suspension Arm Removal and Installation” 3) Using magnetic stand (1), set dial gauge (2) on front
brake disc.
Arm NOTE
Check body of suspension arm (1) for damage and
deterioration. Replace suspension arm if check result is Apply measuring tip of dial gauge
not OK. perpendicular to bottom center surface of
ball joint as much as possible.
4) Set pointer to 0 (zero) by turning dial (3).

5) Push suspension arm up at near ball joint by hand If surface is found rusted, replace suspension arm.
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
then read dial gauge.
6) Reversing direction of force, pull suspension arm 2
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
state for 2 to 3 seconds, and then read dial gauge.
7) Check total “a” of readings in Steps 5) – 6), amount 1
of looseness.
If measured looseness exceeds specified range,
replace suspension arm.
ICP50A220002-01
Amount of looseness in suspension arm ball 10) Move top end of suspension arm joint dust cover
joint back to original position.
“a”: less than 0.2 mm (0.008 in.) 11) Check suspension arm joint dust cover (1) for crack
and damage.
If it is cracked or damaged, replace suspension arm.
3 “a”
0
90 10
ICP50A220003-01
20
80
12) Detach suspension arm ball joint from steering
70
30 knuckle. (Suspension Arm Removal and Installation)
1
2
40 13) Check that suspension arm ball joint stud (1) moves
60
50 without sticking. If not, replace suspension arm.
1
IA1J0P020019-01
8) Lightly push suspension arm joint dust cover (1) with

fingers to check whether there is water inside.
If water is found to come out, replace suspension
arm.
ICP70A220001-01
1
14) Connect suspension arm ball joint to steering
knuckle. (Suspension Arm Removal and Installation)
15) Remove nuts and washers holding the front brake
disc.
ICP50A220001-01
16) Install front wheel and tighten wheel nuts to specified
torque. (Wheel (with Tire) Removal and Installation)
9) Push top end (1) of suspension arm joint dust cover
in Section 2D
down to check for rust on ball stud’s surface (2) in
contact with suspension arm joint dust cover.
Front Suspension Frame and Stabilizer Bar Components

AENNTA0E2206010 (12(01)
(a)
(b)
(b)
9
12 (c)
8
[f]
11 (d)
10 (d)
INTA0A220005-01
[f]: Forward 6. Stabilizer joint 12. Front suspension frame rear bolt
: For tightening procedure, refer to
“Front Stabilizer Bar Removal and
Installation”.
1. Front suspension frame 7. Suspension arm : 23 Nm(2.3 kgf-m, 17.0 lbf-ft)
2. Torque rod cover 8. Engine rear torque rod : 50 Nm(5.1 kgf-m, 37.0 lbf-ft)
3. Stabilizer bar 9. Clip : 75 Nm (7.6 kgf-m, 55.5 lbf-ft)
: For installing direction of stabilizer bar, refer to
“Front Stabilizer Bar Removal and Installation”.
4. Stabilizer mounting bracket 10. Front suspension frame No.1 bolt : 95 Nm(9.7 kgf-m, 70.0 lbf-ft)
: For tightening procedure, refer to “Front
Stabilizer Bar Removal and Installation”.
5. Stabilizer bar bushing 11. Front suspension frame No.2 bolt : Do not reuse.
: For installing direction of stabilizer bar bushing, : For tightening procedure, refer to “Front
refer to “Front Stabilizer Bar Removal and Stabilizer Bar Removal and Installation”.
Installation”.
Front Suspension Frame, Stabilizer Bar and Check that the weight of the front
Bushing Removal and Installation suspension frame is supported at the
AENNTA0E2206011 (08(01) frame’s center and that the frame is well
Reference: “Front Suspension Frame and Stabilizer Bar balanced on the support.
Components”
• Touching a hot exhaust system component
! CAUTION will cause a burn.
Do not perform any service work on the
• If the front suspension frame is not stably exhaust system until the exhaust system is
supported on a transmission jack or other cool.
supporting equipment during its removal
and installation, the frame could drop and Removal
cause personal injury. 1) Disconnect steering lower shaft from pinion shaft.
(Steering Lower Shaft Removal and Installation) in
Section 6B
2) Hoist vehicle and remove front wheels. (Wheel (with

Tire) Removal and Installation) in Section 2D 1 2
3) Remove engine undercover. (Engine Under Cover

4) Disconnect muffler mounting No.1 from front
suspension frame. (Exhaust System Components) in
Section 1K
5) Disconnect tie-rod ends from steering knuckle. (Tie-
Rod End Removal and Installation) in Section 6B IMTA0A220019-01
6) Disconnect suspension arm joint from steering 10) Remove front suspension frame No.1 bolts and No.2
knuckle. (Suspension Arm Removal and Installation) bolts (1) and front suspension frame rear bolts (2),
7) Remove stabilizer joint nuts (2) while holding stud and then lower transmission jack to remove
using hexagon wrench (1), disconnect stabilizer joint suspension frame (3) together with stabilizer bar,
(4) from stabilizer bar (3). torque rod, torque rod cover and steering gear case
from vehicle body.
4
1
3
1 1
3
3
1 1
2 2
2 IMTA0A220016-01
IFKA0P220012-01 11) Remove steering gear case assembly from front

8) Remove engine rear torque rod bolt (1). suspension frame. (Steering Gear Case Assembly
12) Remove stabilizer bar from front suspension frame.
(Front Stabilizer Bar Removal and Installation)
13) Remove suspension arm. (Suspension Arm
14) Remove torque rod cover from front suspension
frame. (Front Suspension Frame and Stabilizer Bar
Components)
1
15) Remove engine rear torque rod from front
2 suspension frame. (Engine Mounting Components)
in Section 1D
Installation
IMTA0A220022-01 Reference: “Front Suspension Frame Check”
2. Engine rear torque rod Reference: “Front Stabilizer Bar, Bushing and Joint
Check”
9) Support front suspension frame (1) using
NOTICE
transmission jack (2).
• The front suspension frame No.1 bolts,
front suspension frame No.2 bolts, front
suspension frame rear bolts and steering
gear case bolts are pre-coated with friction
stabilizer. If these bolts are reused, they
may work loose.
Never reuse the front suspension frame 7) Tighten new front suspension frame rear bolts (2)
No.1 bolts, front suspension frame No.2 and new front suspension frame No.2 bolts (3) and
bolts, front suspension frame rear bolts new front suspension frame No.1 bolts (4) to front
and steering gear case bolts. suspension frame (1) temporarily.
• Once steering gear cover use, the packing 8) Tighten front suspension frame No.2 bolts to
part transforms. If this cover is reused, specified torque.
water may enter into gearbox.
Tightening torque
Never reuse the steering gear cover.
Front suspension frame No.2 bolt (a): 95 N·m (
1) Install engine rear torque rod to front suspension 9.7 kgf-m, 70.0 lbf-ft)
frame. (Engine Mounting Components) in Section 9) Tighten front suspension frame No.1 bolts and front
1D suspension frame rear bolts to specified torque.
2) Install torque rod cover (1) and clips (2) to front Tightening torque
suspension frame (3) as shown in figure. Front suspension frame No.1 bolt (b): 95 N·m (
9.7 kgf-m, 70.0 lbf-ft)
Front suspension frame rear bolt (c): 75 N·m (
7.6 kgf-m, 55.5 lbf-ft)
4, (b) 4, (b)
1
2 2
3 3, (a) 3, (a)
1
[f] 2, (c) 2, (c)

3
IMTA0A220018-01
10) Lower transmission jack.

IMTA0A220017-01
11) Install engine rear torque rod bolt (1) and then
[f]: Forward tighten it to specified torque. (Engine Mounting
Components) in Section 1D
3) Install suspension arm to front suspension frame,
and then tighten new suspension arm front bushing
bolts temporarily by hand. (Suspension Arm
4) Install stabilizer bar to front suspension frame. (Front
Stabilizer Bar Removal and Installation)
5) Install steering gear case assembly to front
suspension frame. (Steering Gear Case Assembly
Removal and Installation) in Section 6B 1
6) Put front suspension frame (1) on transmission jack 2

(2) and raise jack.
1 2
IMTA0A220022-01
2. Engine rear torque rod
12) Connect stabilizer joint to stabilizer bar. (Front Strut

13) Tighten stabilizer joint lower nuts (2) to specified
torque while holding stud using hexagon wrench (1).
IMTA0A220019-01
Tightening torque
Stabilizer joint nut (a): 50 N·m (5.1 kgf-m, 37.0
lbf-ft)
2, (a)
IMTA0A220020-01
1
3 Front Stabilizer Bar Removal and Installation
ILKC0P220013-01 AENNTA0E2206013 (08(01)
Reference: “Front Suspension Frame and Stabilizer Bar
3. Torque wrench
Components”
14) Connect suspension arm joint to steering knuckle. Removal
(Suspension Arm Removal and Installation)
1) Remove front suspension frame. (Front Suspension
15) Connect tie-rod ends to steering knuckle. (Tie-Rod Frame, Stabilizer Bar and Bushing Removal and
End Removal and Installation) in Section 6B Installation)
16) Install muffler mounting No.1 to front suspension 2) Remove stabilizer bar mounting bracket bolts (1),
frame. (Exhaust System Components) in Section 1K and remove stabilizer mounting brackets (2),
17) Lower hoist and bounce vehicle up and down stabilizer bar bushings (3) and stabilizer bar (4).
several times to stabilize suspension, and then
tighten suspension arm front bushing bolts to 1
specified torque. (Suspension Arm Removal and
Installation)
18) Hoist vehicle again, and then install engine 2
undercover. (Engine Under Cover and Engine Under
Side Cover Removal and Installation) in Section 9H 3
19) Install front wheels and tighten wheel nuts to
specified torque. (Wheel (with Tire) Removal and
20) Lower hoist.
21) Connect steering lower shaft to pinion shaft.
(Steering Lower Shaft Removal and Installation) in 4
ILKC0P220014-01
Section 6B
22) Check front wheel alignment. (Front Wheel Installation
Alignment Inspection and Adjustment)
1) Install front stabilizer bar (1), bushings (2) and
mounting brackets (3) to front suspension frame as
Front Suspension Frame Check follows.
AENNTA0E2206012 (08(03)
Reference: “Front Suspension Frame, Stabilizer Bar and a) Position stabilizer bar with identification painting
Bushing Removal and Installation” (4) facing up at center side.
Check front suspension frame for crack, deformation b) Position stabilizer bar bushing with its slit (5)
and damage. Replace front suspension frame if check facing frontward and its end closely fit against
result is not OK. (Front Suspension Frame Dimensions) rings (6) of stabilizer bar.
in Section 9K
2) Install front suspension frame. (Front Suspension

3 Frame, Stabilizer Bar and Bushing Removal and
2 Installation)
6 Alignment Inspection and Adjustment)
5 Front Stabilizer Bar, Bushing and Joint Check

AENNTA0E2206014 (08(03)
Stabilizer Bar
2 Check stabilizer bar for damage and deformation.
4 3
Replace stabilizer bar if check result is not OK.
1
[f] Stabilizer Bar Bushing
5
Check stabilizer bar bushing for damage and
INTA0A220003-01 deterioration. Replace stabilizer bar bushing if check
[f]: Forward result is not OK.
c) Tighten stabilizer bar mounting bracket bolts (1) Stabilizer Joint

to specified torque. • Check ball stud for smooth movement.
Tightening torque • Check ball stud for looseness.
Stabilizer bar mounting bracket bolt (a): 23 • Check dust cover for damage and crack.
N·m (2.3 kgf-m, 17.0 lbf-ft) • Check rod for damage and deformation.
1, (a)
NOTE
Stabilizer joint cannot be disassembled.
If check result is not OK, replace stabilizer joint

assembly.
Front Suspension Fastener Check

AENNTA0E2206015 (08(03)
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”
IFKA0P220018-01 • “Suspension Arm Components”
• “Front Suspension Frame and Stabilizer Bar
Components”
Specifications
AENNTA0E2207001 (09(t)
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Front brake hose strut bolt 26 2.7 19.5 (T2B001)
Strut bracket nut 90 9.2 66.5 (T2B002)
Stabilizer joint nut 50 5.1 37.0 (T2B003) / (T2B012)
Strut support upper nut 50 5.1 37.0 (T2B004)
Strut support lower nut 50 5.1 37.0 (T2B005)
Suspension arm joint nut 55 5.6 40.5 (T2B006)
Suspension arm front bushing bolt 95 9.7 70.0 (T2B007)
Front suspension frame No.2 bolt 95 9.7 70.0 (T2B008) / (T2B009)
Front suspension frame No.1 bolt 95 9.7 70.0 (T2B010)
Front suspension frame rear bolt 75 7.6 55.5 (T2B011)
Stabilizer bar mounting bracket bolt 23 2.3 17.0 (T2B013)
Reference:
“Front Strut Assembly Components”
“Suspension Arm Components”
“Front Suspension Frame and Stabilizer Bar Components”

Special Tool
AENNTA0E2208001 (11(s)
09943M25010
Spring compressor
(L2B001) / (L2B002)
Rear Suspension: 2C-1
Rear Suspension
Suspension
Precautions
Precautions for Handling of Rear Shock Absorber
AENNTA0E2300001 (01(01)
! WARNING
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 rear shock absorber.
• Do not put it into fire.
• Do not store a rear shock absorber where it gets hot.
• Before disposing of a rear 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
AENNTA0E2301001 (03(01)
Rear suspension is a torsion beam type having rear axle connected with torsion beam.
Repair Instructions
Rear Wheel Alignment Inspection
AENNTA0E2306001 (08(03)
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.
2C-2 Rear Suspension:
Inspection
Measure toe and camber using toe-in gauge (1) or total wheel alignment tester. (Front Wheel Alignment Inspection
and Adjustment) in Section 2B
NOTE
Rear toe and camber are not adjustable. If they are out of specification, replace reference part.
Total toe–in (Using total wheel alignment tester)

Rear:
• Standard value: IN 0° 23’
• Minimum value: OUT 0° 03’
• Maximum value: IN 0° 48’
Total toe–in “b” – “a” (Using toe–in gauge)
Rear:
• Standard value: IN 4 mm (0.2 in)
• Minimum value: OUT 1 mm (0.04 in)
• Maximum value: IN 9 mm (0.4 in)
I6RS0C220007-01
[f]
“a”
“b”
I7V10A220002-02
[f]: Forward
Camber
Rear:
• Standard value: – 1° 00’
• Minimum value: – 2° 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
Rear Suspension Components

AENNTA0E2306002 (12(01)
(c)
5
8
4
(b)
b)
1 2
(a)
IMTA0A230001-01
1. Rear axle 5. Rear shock absorber upper washer : 100 Nm (10.2 kgf-m, 74.0 lbf-
ft)
2. Rear shock absorber 6. Rear spring upper seat : 90 Nm (9.2 kgf-m, 66.5 lbf-ft)
3. Rear shock absorber upper No.2 bushing 7. Rear coil spring : 28 Nm (2.9 kgf-m, 21.0 lbf-ft)
: Install in correct direction. (Rear Shock Absorber Removal : Install in correct direction. (Rear Coil
and Installation) Spring and Spring Seat Removal and
Installation)
4. Rear shock absorber upper No.1 bushing 8. Rear spring lower seat : Do not reuse.
: Install in correct direction. (Rear Shock Absorber Removal
and Installation)
Removal
Rear Shock Absorber Removal and Installation 1) Hoist vehicle and remove rear wheel. (Wheel (with
AENNTA0E2306003 (08(01)
Reference: “Rear Suspension Components”
2) Support rear axle using floor jack (1) to prevent it
NOTICE from lowering.
• 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.
• Failure to take the following precautions
may damage the removed part or its
contact surface with the remover.
– When using a remover, use a resin
remover. 1
– Cover around the part and its contact
surface with the remover to prevent any
IMTA0A230002-01
damage using masking tape or waste
3) Remove rear shock absorber lower bolt (1).
cloth before removing the part.
IMTA0A230003-01 IMTA0A230005-01
4) Remove quarter lower trim cap (1) inserting the 6) Remove upper nut (1), rear shock absorber upper
remover in hatched area. washer (2) and rear shock absorber No.1 bushing
(3).
A B
C D 2
1 A A
IMTA0A230006-01
7) Remove rear shock absorber (1) and rear shock

C absorber No.2 bushing (2).
B
D D
1
IMTA0A230004-01
: Inserting position of resin remover
5) Remove rear shock absorber cap (1).
IMTA0A230007-01
Installation
Reference: “Rear Shock Absorber Inspection”
NOTICE
• The rear shock absorber upper nut is a
self-locking nut. If this nut is reused, it may
work loose.
Never reuse the rear shock absorber upper

nut.
• The rear shock absorber lower bolt is pre- 3
2
coated with friction stabilizer. If this bolt is 1
reused, it may work loose.
Never reuse the rear shock absorber lower
5
bolt.
1) Install rear shock absorber upper No.2 bushing (2) 4

and rear shock absorber (1).
3
3
2
2
INTA0A230005-01
4. Rear shock absorber upper 5. Body panel

1 No.2 bushing
3) Tighten new rear shock absorber lower bolt (1)

temporarily.
INTA0A230004-01
3. Body panel
2) Install rear shock absorber upper No.1 bushing (1)

and rear shock absorber upper washer (2), and then
tighten new rear shock absorber upper nut (3)
temporarily.
1
IMTA0A230003-01
4) Remove floor jack from rear axle.

5) Install rear wheel. (Wheel (with Tire) Removal and
several times to stabilize suspension.
7) Tighten rear shock absorber upper nut (1) and lower
bolt (2) to specified torque.
Tightening torque
Rear shock absorber upper nut (a): 28 N·m (2.9
kgf-m, 21.0 lbf-ft)
Rear shock absorber lower bolt (b): 90 N·m (9.2
kgf-m, 66.5 lbf-ft)
[A]
1, (a)
IMTA0A230011-01
[B]
10) Check rear wheel alignment. (Rear Wheel Alignment
Inspection)
Rear Shock Absorber Inspection

AENNTA0E2306004 (08(03)
Reference: “Rear Shock Absorber Removal and
Installation”
• Check rear shock absorber for deformation or
damage.
• Check rear shock absorber upper bushings for wear
or damage.
2, (b)
• Check rear shock absorber for evidence of oil
leakage.
• Check rear shock absorber for deterioration.
IMTA0A230010-01
If check result is not OK, replace rear shock absorber
[A]: Luggage compartment side [B]: Wheel housing side with new one.
8) Install rear shock absorber cap (1).

Rear Coil Spring and Spring Seat Removal and
Installation
AENNTA0E2306005 (08(01)
Reference: “Rear Suspension Components”
Removal
NOTICE
• Lowering the rear axle too much may
1
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.
IMTA0A230005-01
1) Hoist vehicle and remove rear wheels. (Wheel (with
9) Install quarter lower trim cap (1). Tire) Removal and Installation) in Section 2D
2) Paint identification mark (2) to lower side of rear coil
spring (1).
2
IMTA0A230012-01 IMTA0A230014-01
3) Support both ends of rear axle (1) using two floor

jacks (2) to prevent it from lowering. Installation
Reference: “Rear Coil Spring and Spring Seat Check”
NOTICE
The rear shock absorber lower bolt is pre-
coated with friction stabilizer. If this bolt is
reused, it may work loose.
Never reuse the rear shock absorber lower
bolt.
1) Install rear spring upper seat (1) to vehicle body.

2 1
2
IAP70P230004-01
4) Remove rear shock absorber lower bolt (1).

5) Lower rear axle gradually for removing rear coil
spring (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. 1
Limit lowering the rear axle to the minimum
distance necessary.
IMTA0A230015-01
6) Remove rear coil spring. 2) Install rear spring lower seat (1) to rear axle. At this
time, fit hooks (2) of rear spring lower seat into holes
(3) in rear axle.
2
2
1
2
IMTA0A230013-01
7) Remove rear spring upper seat (1) from vehicle body

and remove rear spring lower seat (2) from rear axle. IMTA0A230016-01
3) Facing identification mark (1) downward, install rear

coil spring (2). At this time, contact rear coil spring
end (3) with protrusion (4) of rear spring lower seat
as shown in figure.
NOTICE
Adjusting the position of coil spring bottom
end after it is already installed may damage
the rear spring lower seat. 2
Before installing the coil spring, adjust the
bottom end position so that it is within the 1
specified range.
NOTE
To avoid abnormal noise from rear [A] [B]
suspension, position spring seats and
springs correctly.
3
3
2 2
4 4
[f]
“a”
IMTA0A230017-01
[f]: Forward [B]: Right side

[A]: Left side “a”: 0 - 10 mm
4) Jack up rear axle, and then connect rear shock

absorber lower end to rear axle on both right and left
sides.
5) Install new rear shock absorber lower bolt (1) and
tighten bolt temporarily by hand.
NOTICE
• Brake fluid is extremely damaging to
painted surfaces.
If brake fluid contacts a painted surface,
immediately wipe it off and flush the
surface with water thoroughly.
Removal
1) Hoist vehicle and remove rear wheels. (Wheel (with
1
2) Remove rear fender linings. (Rear Bumper Removal
and Installation) in Section 9H
3) Remove rear brake backing plate for each of right
IMTA0A230003-01
and left rear wheels. (Brake Backing Plate Removal
6) Remove floor jack from rear axle. and Installation) in Section 4C
7) Install rear wheel. (Wheel (with Tire) Removal and 4) Remove rear wheel speed sensors from rear axle.
Installation) in Section 2D (Rear Wheel Speed Sensor Removal and
8) Lower hoist and bounce vehicle up and down Installation) in Section 4F
several times to stabilize suspension. 5) Remove parking brake cable bracket bolts (1) from
9) Tighten rear shock absorber lower bolt (1) to rear axle (3), and then disconnect parking brake
specified torque. cables (2) from rear axle.
Tightening torque
Rear shock absorber lower bolt (a): 90 N·m (9.2
2
kgf-m, 66.5 lbf-ft)
1, (a) IMTA0A230019-01
6) Remove E-rings (1), and then disconnect brake pipe

clamps (2).
IMTA0A230018-01 7) Disconnect brake pipes (3) and brake hoses (4) from
10) Check rear wheel alignment. (Rear Wheel Alignment rear axle.
Inspection)
1
Rear Coil Spring and Spring Seat Check
AENNTA0E2306006 (08(03) 2
Reference: “Rear Coil Spring and Spring Seat Removal 4
and Installation” 3
• 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

AENNTA0E2306007 (08(01) INTA0A230001-01
Reference: “Rear Suspension Components” 8) Remove rear shock absorbers and rear coil springs.
• Rear shock absorber: (Rear Shock Absorber • Rear brake assembly: (Rear Brake Components)
• Rear coil spring: (Rear Coil Spring and Spring • Rear wheel hub assembly: (Rear Wheel Hub
Seat Removal and Installation) Assembly Removal and Installation): Rear in
9) Remove rear wheel hub assembly. (Rear Wheel Hub Section 3A
Assembly Removal and Installation): Rear in Section 4) Install rear shock absorbers and rear coil springs,
3A and tighten new rear shock absorber upper nuts and
10) Using a rope, hold rear brake assembly. new lower bolts temporarily by hand.
11) Remove right and left rear axle bolts (2), and then • Rear shock absorber: (Rear Shock Absorber
remove rear axle from vehicle by lowering the jacks Removal and Installation)
(1) gradually. • Rear coil spring: (Rear Coil Spring and Spring
Seat Removal and Installation)
5) Connect brake pipes (3) and brake hoses (4) to rear
axle.
6) Connect brake pipe clamps (2), and then install E-
rings (1).
2 1
2
4
IMTA0A230021-01
Installation
Reference: “Rear Axle Check”
NOTICE
INTA0A230001-01
The rear axle bolts are pre-coated with
friction stabilizer. If these bolts are reused, 7) Connect parking brake cables (2) to rear axle (3),
they may work loose. and then tighten parking brake cable bracket bolts
Never reuse the rear axle bolts. (1) to specified torque. (Parking Brake Cable
1) Place rear axle on floor jacks (1) and align its front
ends with mounting positions on vehicle body.
2
2) Insert new right and left rear axle bolts (2) and
tighten them temporarily.
2
3
IMTA0A230019-01
8) Install wheel speed sensors to rear axle. (Rear

Wheel Speed Sensor Removal and Installation) in
1 Section 4F
9) Bleed brake system. (Air Bleeding of Brake System)
IMTA0A230021-01
in Section 4A
3) Install rear brake assemblies and rear wheel hub
10) Adjust parking brake. (Parking Brake Adjustment) in
assemblies.
Section 4D
11) Install rear wheels. (Wheel (with Tire) Removal and 18) Check rear wheel alignment. (Rear Wheel Alignment
Installation) in Section 2D Inspection)
several times to stabilize suspension. Rear Axle Check
AENNTA0E2306008 (08(03)
13) Tighten rear axle bolts (1) to specified torque. Reference: “Rear Axle Removal and Installation”
Tightening torque • Check rear axle (1) for deformation and damage.
Rear axle bolt (a): 100 N·m (10.2 kgf-m, 74.0 lbf- • Check rear axle bushings (2) for crack, deformation
ft) and damage. If check result is not OK, replace rear
axle with new one. (Rear Axle Removal and
Installation)
1
1, (a)
IMTA0A230024-01
14) Install rear fender linings. (Rear Bumper Removal

and Installation) in Section 9H IMTA0A230025-01
15) Tighten rear shock absorber upper nuts and lower

bolts to specified torque. (Rear Shock Absorber Rear Suspension Fastener Inspection
AENNTA0E2306009 (08(03)
Check fastening suspension bolts and nuts for tightness.
16) Check that rear brakes are free from dragging and Tighten loose fastener to specified torque, if any. (Rear
proper braking is obtained. Suspension Components)
17) Check all installed parts for brake fluid leakage.
Specifications
AENNTA0E2307001 (09(t)
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Rear shock absorber upper nut 28 2.9 21.0 (T2C001)
Rear shock absorber lower bolt 90 9.2 66.5 (T2C002) / (T2C003)
Rear axle bolt 100 10.2 74.0 (T2C004)
Reference:
“Rear Suspension Components”
2D-1 Wheels and Tires:
Wheels and Tires

Suspension
Precautions
Precautions for Servicing Wheel and Tire
AENNTA0E2400001 (01(01)
! 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 Correct tire pressures and driving habits have an
AENNTA0E2401001 (03(01) important influence on tire life. Hard cornering,
This vehicle is equipped with tubeless tires of the
excessively rapid acceleration, and unnecessary hard
following specifications.
braking increase tire wear.
Tire specification
Ground: 185/65 R15 88H or 195/55 R16 87H Replacement Tire Description
Spare: 185/65R15 88H AENNTA0E2401002 (03(01)
Replacement tires should be of the same size, load
NOTE range and construction as those originally installed on
the vehicle refer to the “Tire Placard”. Using tires of any
• Tire inflation pressure should be checked other size or type may affect ride, handling,
when tires are cool. speedometer / odometer calibration, vehicle ground
• The tire inflation pressure will change due clearance and tire or snow chain clearance to the body
to changes in atmospheric pressure and and chassis.
temperature as well as in temperature of It is recommended that new tires be installed in pairs on
tire itself when driving. It is important to the same axle. If replacing only one tire is unavoidable, it
check and adjust the tire pressures when should be paired with the tire of the best tread condition
the tires are cold. Tires that appear to be at to equalize tire-road friction during braking.
the specified pressure when checked after The tire inflation pressure is indicated in kilo-pascal
driving (when the tires are warm) will have (kPa) while it is also indicated in kgf/cm2 and psi on the
pressure below the specification when the “Tire Placard”. Metric tire gauges are available from tool
tires cool down. Also, tires that are inflated suppliers. The table below shows unit conversion for
to the specified pressure in a warm garage commonly used inflation pressures.
may have pressure below the specification kPa kgf/cm2 psi
when the vehicle is driven outside in very Conversion: 160 1.6 23
cold temperature. If the tire pressure is 1 psi = 6.895 kPa 180 1.8 26
adjusted in a place warmer than the 1 kgf/cm2 = 98.066 kPa 200 2.0 29
outside, add 1.2 kPa (0.01 kgf/cm2, 0.17 psi, 220 2.2 32
0.01 bar) to the recommended cold tire 240 2.4 35
inflation pressure for every 1 °C (1.8 °F) 260 2.6 38
increase in the temperature of the 280 2.8 41
adjustment place compared to the outside 300 3.0 44
air temperature. 320 3.2 47
• Specified tire inflation pressure is 340 3.4 50
indicated on the “Tire Placard” or in the
vehicle’s Owner’s Manual.
Wheel Description
The tires are designed to operate satisfactorily with AENNTA0E2401003 (03(01)
loads up to the full rated load capacity when inflated to
the recommended inflation pressure.
Wheels and Tires: 2D-2
Wheel Maintenance The “low spot” of the wheel is originally marked by paint
Wheels must be replaced if they have any of the dot on the wheel rim-flange. When assembling, the
following conditions: bends, dents, excessive lateral or wheel rims’ paint dot (1) should be aligned with the tires’
radial runout, air leakage through welds, elongated bolt paint dot (2) as shown in figure.
holes, failure of lug nuts to stay tight, heavy rust. Wheels Whenever a tire is dismounted from its wheel, it should
with great runout will cause objectionable vibrations. be remounted so that the tire and wheel are matched. If
the tire’s paint dot cannot be located, a line should be
Wheel specification
scribed on the tire and wheel before dismounting to
Ground: 15 X 5 1/2J inset 45 or 16 x 6J inset 50
assure that it is remounted in the same position.
Spare: 15 X 5 1/2J inset 45
Replacement Wheel Description

AENNTA0E2401004 (03(01)
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.
Matched Tire and Wheel Description (for

Vehicle Equipped with Steel Wheel)
AENNTA0E2401005 (03(01)
Tires and wheels are match mounted at the assembly IYSQ01240005-01
plant.
This means that the radially stiffest part of the tire, or
“high spot”, is matched to the smallest radius or “low Tire Placard Description
AENNTA0E2401006 (03(01)
spot” of the wheel. The “Tire Placard” is located on the driver’s side door
This is done to provide the smoothest possible ride. lock pillar and should be referred to for tire information.
The “high spot” of the tire is originally marked by paint The placard lists the tire size, rim size and cold tire
dot on the outboard sidewall. This paint dot will pressure.
eventually wash off the tire.
Repair Instructions
Wheel (with Tire) Removal and Installation 2) Hoist vehicle.
AENNTA0E2406001 (08(01)
Removal 3) Remove wheel with tire.
NOTICE Installation
Using heat to loosen a tight wheel bolt for To avoid bending wheel or brake disc, wheel nuts must
removal may shorten the life of the wheel and be tightened in sequence and to proper torque as
damage the wheel bearings. shown.
Never use heat to loosen a wheel bolt for NOTICE
removal.
Installing wheels without good metal-to-metal
1) Loosen wheel nuts by approximately 180°. contact at mounting surfaces can cause
wheel nuts to loosen, which can later allow
wheel to come off while vehicle is moving.
Before installing wheels, remove any build-
up of corrosion on wheel mounting surface
and brake disc mounting surface by scraping
and wire brushing.
Tightening order
“1” – “2” – “3” – “4”
Tightening torque
Wheel nut* (a): 100 N·m (10.2 kgf-m, 74.0 lbf-ft)
I7V10A240001-01
Wear Indicator
Originally installed tires have built-in tread wear
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)
I8C50A240002-01
Tire Inspection
AENNTA0E2406002 (08(03)
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.
• Uneven wear between both sides of tread on the
same tire. I2RH01240005-01
• Both front tires wear unevenly.

• Both rear tires wear unevenly. Wheel Inspection
AENNTA0E2406003 (08(03)
• Abnormal wear such as cupping or flat spotting is Wheels must be replaced if they are bent, dented, have
noted. excessive lateral or radial runout, air leakage through
Wheel alignment should be checked if one of the welds, have elongated nut holes, if wheel nuts do not
following conditions is noted. stay tight, or if they are heavily rusted. Wheels with
• Front tires wear unevenly. greater runout than shown in the figure may cause
objectionable vibrations.
• Uneven wear between both sides of tread on the
To measure the wheel runout, it is necessary to use
same front tire.
accurate dial indicator.
• Front tire treads show scuffs with “feather” edges on The wheel should be installed to the wheel balancer or
one side of tread ribs or blocks. the like for proper measurement.
Take measurements of both lateral runout and radial
runout at inside 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.
Wheel runout
Lateral runout Radial runout
limit “a” limit “b”
0.90 mm 0.70 mm
Steel wheel
(0.040 in.) (0.030 in.)
0.30 mm 0.30 mm
Aluminum wheel
(0.010 in.) (0.010 in.)
I3RH0A240002-01
[A]: Hard cornering, under inflation or non-rotated tires

[B]: Incorrect wheel alignment, use of tires of different types or wheel
heavy acceleration
Wheels and Tires: 2D-4
“a”
“b”
INTA0A240001-01
Tire Rotation
AENNTA0E2406004 (08(03)
To equalize tire wear, rotate tires periodically as shown
in figure.
NOTICE
While performing tire rotation, ensure that all IBP80A240001-04
tires being rotated are of same specification. [f]: Vehicle forward [B]: 4-tire rotation
If spare tire is of different specification than [A]: 5-tire rotation
ground tires, perform 4-tire rotation.
Specifications
AENNTA0E2407001 (09(t)
NOTE
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Wheel nut* 100 10.2 74.0 (T2D001)
Reference:
Section 3
Driveline / Axle
CONTENTS
Precautions .................................................3-1 Front Wheel Hub Assembly and Steering

Precautions............................................................. 3-1 Knuckle Components ........................................3A-7
Precautions for Driveline / Axle ............................. 3-1 Front Wheel Bearing Check ................................3A-8
Front Wheel Hub Assembly and Steering
Drive Shaft / Axle ..................................... 3A-1 Knuckle Removal and Installation .....................3A-9
Front .........................................................................3A-1 Specifications.....................................................3A-11 3
General Description .............................................3A-1 Tightening Torque Specifications......................3A-11
Front Drive Shaft Construction............................ 3A-1 Special Tools and Equipment ...........................3A-11
Diagnostic Information and Procedures............3A-1 Recommended Service Material .......................3A-11
Front Drive Shaft Symptom Diagnosis ................ 3A-1 Special Tool ......................................................3A-11
Repair Instructions ..............................................3A-1 Rear ........................................................................3A-12
Front Drive Shaft Components ........................... 3A-1 Repair Instructions ............................................3A-12
Front Drive Shaft Assembly On-Vehicle Rear Axle Components .....................................3A-12
Inspection.......................................................... 3A-2 Rear Wheel Bearing Check...............................3A-12
Front Drive Shaft Assembly Removal and Rear Wheel Hub Assembly Removal and
Installation......................................................... 3A-2 Installation .......................................................3A-13
Front Drive Shaft Disassembly and Specifications.....................................................3A-14
Reassembly ...................................................... 3A-3 Tightening Torque Specifications......................3A-14
3-1 Precautions:
Precautions
Driveline / Axle
Precautions
Precautions for Driveline / Axle
AENNTA0E3000001 (01(01)
General Precautions

Warning for Air Bag


Drive Shaft / Axle: Front 3A-1
Drive Shaft / Axle

Driveline / Axle
Front
General Description
Front Drive Shaft Construction
AENNTA0E3111001 (03(01)
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.

Front Drive Shaft Symptom Diagnosis
AENNTA0E3114001 (06(04)
Abnormal noise
• Wear or breakage of drive shaft joint Replace. (Front Drive Shaft Assembly Removal and
Installation): Front
• Wear or breakage of the wheel bearing Replace. (Front Wheel Hub Assembly and Steering Knuckle
Removal and Installation): Front
Repair Instructions
Front Drive Shaft Components
AENNTA0E3116001 (12(01)
1 2
4
3
5
7
12
7
10
8
7 11 (a)
IMTA0A311004-01
3A-2 Drive Shaft / Axle: Front
1. Circlip 8. Damper (right side drive shaft only)

2. Differential side joint housing 9. Wheel side boot
: Apply brown grease in the service kit to differential side joint : Apply black grease in the service kit to wheel side boot.
housing.
3. Snap ring 10. Wheel side joint assembly
: Never disassemble.
: Apply black grease in the service kit to wheel side joint
assembly.
4. Tripod joint 11. Drive shaft nut
: Never disassemble. : After tightening nut to specified torque, caulk nut securely.
: Apply brown grease in the service kit to tripod joint.
5. Boot band (big) 12. Boot insert
6. Differential side boot : 175 Nm (17.8 kgf-m, 129.0 lbf-ft)
: Apply brown grease in the service kit to differential side boot.
7. Boot band (small) : Do not reuse.
Front Drive Shaft Assembly On-Vehicle • ESP® model: (Front Wheel Speed Sensor
Inspection Removal and Installation) in Section 4F
AENNTA0E3116002 (08(03)
6) Disconnect suspension arm joint from steering
• Check boots for breakage, leakage, tear or knuckle. (Suspension Arm Removal and Installation)
deterioration. in Section 2B
• Check boot bands for looseness, crack or damage. 7) Disconnect tie-rod end from steering knuckle. (Tie-
• Check drive shafts for crack or damage. Rod End Removal and Installation) in Section 6B
• Check wheel side joint for smooth rotation and no 8) Support transaxle with transmission jack.
rattle. 9) Remove engine rear torque rod bracket. (Engine
• Check differential side joint for smooth rotation. Mounting Components) in Section 1D
Replace if any abnormalities are found. 10) Pull out drive shaft joint (1) from transaxle using tire
lever (2) or the like and remove drive shaft assembly.
Front Drive Shaft Assembly Removal and
Installation NOTE
AENNTA0E3116003 (08(01)
Turning drive shaft while pulling out drive
Reference: “Front Drive Shaft Components”: Front
shaft joint may facilitate release of the circlip
Reference: “Front Drive Shaft Assembly On-Vehicle
fitting of joint spline.
Inspection”: Front
Removal Left side

1
2) Release caulking (1) from drive shaft nut and
remove drive shaft nut (2) with brake pedal
depressed.
2 2
IMTA0A311001-01
IBP80A311002-01
3) Remove engine undercover.

4) Drain transaxle oil.
• M/T model: (Manual Transaxle Oil Change) in
Section 5B
• AGS model: (Auto Gear Shift Transaxle Oil
5) Remove wheel speed sensor from steering knuckle.
• Non-ESP® model: (Front Wheel Speed Sensor
Right side Never reuse the drive shaft nut.
Tightening torque
Drive shaft nut (a): 175 N·m (17.8 kgf-m, 129.0 lbf-
ft)
• Caulk drive shaft nut as shown.
2
IFRA0A311020-01
Installation 2
NOTICE
Failure to take proper precautions when 1,(a)
installing the drive shaft may result in IBP80A311004-01
damage to or breakage of the drive shaft 2. Caulking part

assembly.
• Before inserting drive shaft (1), check that • Install front wheel. (Wheel (with Tire) Removal and
there is no foreign material around Installation) in Section 2D
encoder (2) on wheel bearing. • Fill transaxle with transaxle oil as specified.
– M/T model: (Manual Transaxle Oil Change) in
Section 5B
• Check front wheel alignment. (Front Wheel Alignment
Front Drive Shaft Disassembly and Reassembly

AENNTA0E3116004 (08(02)
2
Reference: “Front Drive Shaft Components”: Front
Reference: “Front Drive Shaft Assembly Removal and
1
Installation”: Front
IGSD0A311002-01
Disassembly
• Be careful not to damage the oil seals and
boots when installing the drive shaft. NOTICE
• Insert joints only by hand. Never hit joint Disassembly of the wheel side joint or the
boots with a hammer. tripod joint can cause performance
• Check that the differential side joint is fully problems.
inserted and the circlip is seated in If anything abnormal (damage, noise, etc.) is
position. found with either of these joints, replace the
joint as an assembly.
• Use new differential side joint circlip. Differential side joint
• Tighten tie-rod end nut to specified torque. (Tie-Rod 1) Using nose pliers (1), disengage hooks of boot big
End Removal and Installation) in Section 6B band (2) and remove band.
• Tighten suspension arm joint nut to specified torque.
(Suspension Arm Removal and Installation) in Section
2B
• 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.
I9P60A311005-01
6) Using flat-bladed screwdriver (1) or the like, release

caulking (2) of boot small band (3). Remove boot
IEL10A311006-01 small band.
2) Remove differential side joint housing from tripod
joint.
3) Remove boot insert (1) from differential side joint
housing (2). 2
1
2
I8V101311031-01
7) Pull out differential side boot from shaft.

8) For right side drive shaft, use flat-bladed screwdriver
(1) or the like, release caulking (2) of damper band
1 (3).
IEL10A311019-01
4) Wipe off grease from shaft and use snap ring pliers
(2) to remove snap ring (1).
2
1
IFFA0A311003-01
9) Remove damper from shaft.
Wheel side joint

1) Using flat-bladed screwdriver (1) or the like, release
caulking (2) of boot small band (3) and big band (4).
I7RW01311003-01
5) Remove tripod joint (1) using 3-arm puller (2). NOTE

Use nippers to cut boot band if it is of a
NOTICE welded type.
Except for the housing, washing the tripod Take care not to damage boot while cutting
joint parts with a washing solution may cause band.
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.
Wheel side joint

4
1) Wash disassembled parts (except boots). After
2 washing parts, air-dry them completely.
3 2) Clean boots with shop cloth.
3) Apply grease in the service kit to wheel side joint.
Grease specification for front drive shaft wheel
2
side joint
1 Grease color Grease amount
70 – 80 g
Black
(2.47 – 2.82 oz)
IFFA0A311002-01
2) Pull out wheel side boot from shaft. 4) Install wheel side boot on shaft.
5) Insert flat-bladed screwdriver or the like into boot (1)
Reassembly
and allow air to enter boot so that air pressure in
Judging from abnormality noted before disassembly and
boot becomes the same as atmospheric pressure at
what is found through visual check of component parts
boot fixing position.
after disassembly, prepare replacing parts and proceed
to reassembly. 1
Check that wheel side joint assembly (1) and housing of
tripod joint (2) are washed thoroughly and air-dried.
NOTICE
Joints may not perform as designed if proper
cleaning and lubrication precautions are not
taken. IFRA0A311007-01
• Do not wash boots with solvents such as 6) Place new boot big band (1) and small band (2) onto
gasoline or kerosene. Washing boots with boot.
these solvents causes deterioration of the
1
boots.
• Lubricate joints with the specified amount
of the specified grease. Follow the
instructions below to identify the specified
grease and specified amount for each
joint.
IMTA0A311005-01
7) Fasten boot bands (1) using special tool as shown in

figure.
I9P60A311027-01
NOTICE
[A]: Wheel side [B]: Differential side
Squeezing or distorting the boot will reduce
its durability.
Do not force air out of the boot by squeezing Differential side joint
or distorting it when fastening it with boot 1) Wash disassembled parts (except boots). After
bands. washing parts, air-dry them completely.
Boot band fastening distance 2) Clean boots with shop cloth.
“a”: less than 1.5 mm (0.06 in.) 3) Install boot insert on differential side joint housing.
Special tool 4) Install differential side boot on shaft.
(A): 09943M57011 5) 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).
“a” Special tool
(A): 09925M98221
1
3
(A)
IFRA0A311008-01
8) Install damper to specified position on right side I8G001311014-01
drive shaft as shown in figure.

Drive shaft damper installing position
“a”: 207 – 213 mm (8.15 – 8.27 in.)
[A]
“a”
I8C50A311007-01
6) Apply grease “A” in the service kit to tripod joint and

1
IGSD0A311003-01 joint housing (1).
[A]: Wheel side 1. Damper band Grease specification for front drive shaft
differential side joint
9) For right side drive shaft, fasten new damper band Grease color Grease amount
(1) as shown in figure. 110 – 120 g
Brown
Damper band fastening distance (3.88 – 4.23 oz)
“a”: less than 1.5 mm (0.06 in.)
Special tool
(A): 09943M57011
“a”
I4RS0B310003-01
7) Fit boot (1) to grooves of shaft and differential side

1 joint housing (2).
8) Insert flat-bladed screwdriver or the like into boot (1)
(A) and allow air to enter boot so that air pressure in
IAV10A311009-01 boot becomes the same as atmospheric pressure at
boot fixing position.
Drive shaft boot fixing position (distance Band Method

between differential side joint end and boot small Small band b
end)
“a”: 150.6 – 156.6 mm (5.929 – 6.165 in.) • Method a:
Fasten boot band (1) by pinching hooks (2) with
1 2 special tool and engage hooks (3) as shown in
figure.
Special tool
(A): 09943M57021
(A)
“a”
IFRA0A311010-01
IDL10A311007-01
9) Place new boot big band (1) and small band (2) onto
boot. 3 2
I8C50A311034-01
1 2
• Method b:
Fasten boot band (1) using special tool as shown
in figure.
Boot band fastening distance
“a”: less than 1.5 mm (0.06 in.)
Special tool
(B): 09943M57011
IMTA0A311006-01
10) Fasten boot bands using special tool as shown in

figure.
“a”
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 1
bands.
(B)
Install each boot band using the appropriate IDL10A311008-01
method referring to the following table

Band Method
Big band a
Front Wheel Hub Assembly and Steering Knuckle Components

AENNTA0E3116005 (12(01)
2
1 (a)
[f]
6 (b)
5
IMTA0A311007-01
[f]: Vehicle forward 4. Brake disc dust cover : 70 Nm (7.1 kgf-m, 52.0 lbf-ft)
1. Drive shaft nut 5. Steering knuckle : Do not reuse.
: After tightening nut to specified torque,
caulk nut securely.
2. Front wheel hub assembly 6. Wheel hub mounting bolt
3. Hub bolt : 175 Nm (17.8 kgf-m, 129.0 lbf-ft)
Front Wheel Bearing Check

AENNTA0E3116006 (08(03)
2) Remove front brake disc. (Front Brake Disc Removal
If check result is not as specified, replace wheel hub
assembly.
3) Check thrust play of front wheel bearing as follows. If
measured value exceeds the limit, replace front
wheel hub assembly.
a) Apply measuring tip of dial gauge (1) to flat- 1
surface of front wheel hub assembly (2).
NOTE
Apply measuring tip of dial gauge 2
IKW00P311010-01
perpendicular to flat-surface of front wheel
hub assembly as much as possible. 4) Install front brake disc. (Front Brake Disc Removal
b) Gripping hub at the top and bottom, apply push 5) Install front wheel. (Wheel (with Tire) Removal and
pull force to the front wheel hub assembly. Installation) in Section 2D
Front wheel bearing thrust play 6) Check wheel bearing noise and smooth wheel
Limit: 0.05 mm (0.002 in.) rotation by rotating wheel.
If check result is not OK, replace wheel hub 6) Disconnect suspension arm joint from steering
assembly. (Front Wheel Hub Assembly and Steering knuckle. (Suspension Arm Removal and Installation)
Knuckle Removal and Installation): Front in Section 2B
7) Remove strut bracket nuts and bolts. (Front Strut
8) Remove steering knuckle (1), front wheel hub
assembly (2), brake disc dust cover (3) all together
from strut bracket (4).
4 1
I3RM0A230050-01
Front Wheel Hub Assembly and Steering

Knuckle Removal and Installation
AENNTA0E3116007 (08(01)
Reference: “Front Wheel Hub Assembly and Steering 2
Knuckle Components”: Front
NOTICE 3
IMTA0A311008-01
• If the steering knuckle is removed and
9) Remove wheel hub housing bolts (1), and remove
installed without care, the front brake disc
front wheel hub assembly (2) and brake disc dust
dust cover may damage the dust cover of
cover (3) from steering knuckle (4).
the suspension arm joint.
When removing and installing the steering 2
knuckle assembly, do not damage the 3
suspension arm joint dust cover.
4
• If front wheel speed sensor receives large
shock, the sensor could be damaged.
Do not drop or expose the sensor to large
shock. Any front wheel speed sensor that
has received large shock should be
replaced.
• If front wheel speed sensor is brought
closer to magnetic force, the sensor could
1
become inoperative. [f]
IMTA0A311009-01
Do not bring the sensor closer to magnetic
force. [f]: Vehicle forward
Removal 10) Remove hub bolts (1) with copper hammer or

1) Hoist vehicle and remove front wheel. (Wheel (with hydraulic press, if necessary.
NOTICE
2) Remove drive shaft nut. (Front Drive Shaft Assembly
Removal and Installation): Front Removing the hub bolts will break the
serrations on the hub bolts.
3) Remove front wheel speed sensor. Avoid removing the hub bolts unless their
• Non-ESP® model: (Front Wheel Speed Sensor replacement is absolutely necessary. If the
Removal and Installation) in Section 4E hub bolts are removed, never reuse the bolts.
• ESP® model: (Front Wheel Speed Sensor Removal Replace them with new bolts.
4) Remove brake disc. (Front Brake Disc Removal and
5) Disconnect tie-rod end from steering knuckle. (Tie-
Rod End Removal and Installation) in Section 6B
2
1
4, (a)
[f]
IFRA0A311015-01
IMTA0A311010-01
[f]: Vehicle forward

Installation
1) Insert new hub bolts (1) in hub holes, if removed. 3) Install steering knuckle (1) with brake disc dust cover
Rotate each hub bolt slowly to assure that serrations (2) and front wheel hub assembly (3) to strut bracket
are aligned with those made by original bolt and then (4).
press-fit one by one.
4 1
3
[f]
IFRA0A311016-01
2
2) Install brake disc dust cover (1) and front wheel hub IMTA0A311011-01
assembly (2) to steering knuckle (3) and tighten new [f]: Vehicle forward
wheel hub housing bolts (4) to specified torque.
4) Install strut bracket bolts and nuts. (Front Strut
NOTICE
The wheel hub housing bolts are pre-coated 5) Connect steering knuckle to suspension arm.
with friction stabilizer. If the bolts are reused, (Suspension Arm Removal and Installation) in
they may work loose. Section 2B
Use new wheel hub housing bolts.
6) Connect tie-rod end to steering knuckle. (Tie-Rod
Tightening torque End Removal and Installation) in Section 6B
Wheel hub housing bolt (a): 70 N·m (7.1 kgf-m, 7) Install brake disc and brake caliper. (Front Brake
52.0 lbf-ft) Disc Removal and Installation) in Section 4B
8) Install front wheel speed sensor.
• Non-ESP® model: (Front Wheel Speed Sensor
• ESP® model: (Front Wheel Speed Sensor
9) Tighten new drive shaft nut to specified torque.
(Front Drive Shaft Assembly Removal and
Installation): Front
10) Install front wheel. (Wheel (with Tire) Removal and
Alignment Inspection and Adjustment) in Section 2B
Specifications
AENNTA0E3117001 (09(t)
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Drive shaft nut 175 17.8 129.0 (T3A101)
Wheel hub housing bolt 70 7.1 52.0 (T3A102)
Reference:
“Front Drive Shaft Components”: Front
“Front Wheel Hub Assembly and Steering Knuckle Components”: Front

AENNTA0E3118001 (11(m)
NOTE
“Front Drive Shaft Components”: Front
Special Tool
AENNTA0E3118002 (11(s)
09925M98221 09943M57011
Bearing installer Band compressor
(L3A103) (L3A101) / (L3A102) /
(L3A105)
09943M57021
Low-profile clamp pliers
(L3A104)
3A-12 Drive Shaft / Axle: Rear
Rear
Repair Instructions
Rear Axle Components
AENNTA0E3126001 (12(01)
[f]
3 4
6 (a)
IGSD0A312001-01
[f]: Vehicle forward 3. Rear drum brake assembly 6. Rear hub mounting bolt
1. Rear axle 4. Rear wheel hub assembly : 77 Nm (7.9 kgf-m, 57.0 lbf-ft)
2. Rear brake drum 5. Hub bolt : Do not reuse.
Rear Wheel Bearing Check

AENNTA0E3126002 (08(03)
1) Hoist vehicle and remove rear wheel. (Wheel (with
2) Remove rear brake drum. (Rear Brake Drum
3) Check thrust play of rear wheel bearing as follows.
a) Apply measuring tip of dial gauge (1) 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.
1
b) Gripping hub, apply push pull force to the hub.
IKW00P312005-01
Rear wheel bearing thrust play 4) Install rear brake drum. (Rear Brake Drum Removal
Limit: 0.05 mm (0.002 in.) and Installation) in Section 4C
Drive Shaft / Axle: Rear 3A-13
6) 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 hub
assembly. (Rear Wheel Hub Assembly Removal and
Installation): Rear 3
2
IFRA0A312003-01
6) Remove rear wheel speed sensor from rear wheel

I3RM0A230050-01 hub assembly.
• Non-ESP® model: (Rear Wheel Speed Sensor
Rear Wheel Hub Assembly Removal and Removal and Installation) in Section 4E
Installation • ESP® model: (Rear Wheel Speed Sensor
AENNTA0E3126003 (08(01)
Removal Removal and Installation) in Section 4F
1) Hoist vehicle and remove rear wheel. (Wheel (with 7) Remove hub bolts (1) with copper hammer or
Tire) Removal and Installation) in Section 2D hydraulic press, if necessary.
2) Remove rear brake drum. (Rear Brake Drum NOTICE
Removing the hub bolts will break the
3) Disconnect rear wheel speed sensor connector (1) serrations on the hub bolts.
and detach rear wheel speed sensor clip (2) from Avoid removing the hub bolts unless their
rear axle. replacement is absolutely necessary. If the
hub bolts are removed, never reuse the bolts.
Replace them with new bolts.
1
2
IGSD0A312002-02
4) Remove rear hub mounting bolts (1), and then

remove rear wheel hub assembly (2).
5) Using a rope, hold rear brake assembly (3) with IBP80A312004-01
brake pipe connected.

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.
3A-14 Drive Shaft / Axle: Rear
1
1
[f]
IBP80A312005-01
2) Install rear wheel speed sensor to rear wheel hub 3, (a)

assembly. 2
• Non-ESP® model: (Rear Wheel Speed Sensor
Removal and Installation) in Section 4E IFRA0A312004-01
• ESP model: (Rear Wheel Speed Sensor Removal [f]: Forward

3) Install rear wheel hub assembly (1) and tighten new 4) Connect rear wheel speed sensor connector (1) and
rear hub mounting bolts (3) to specified torque. For clip (2)
ABS model, locate socket (2) installed with the
speed sensor in step 2) to the lower side.
Tightening torque
Hub mounting bolt (a): 77 N·m (7.9 kgf-m, 57.0
lbf-ft)
1
2
IGSD0A312002-02
5) Install rear brake drum. (Rear Brake Drum Removal

7) Check rear wheel alignment. (Rear Wheel Alignment
Specifications
AENNTA0E3127001 (09(t)
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Hub mounting bolt 77 7.9 57.0 (T3A203)
Reference:
“Rear Axle Components”: Rear
Section 4
Brakes
CONTENTS
Precautions .................................................4-1 Brake Booster Pressure Sensor Inspection

Precautions............................................................. 4-1 (ESP® Model) .................................................4A-27
Precautions for Brakes.......................................... 4-1 Specifications.....................................................4A-29
Tightening Torque Specifications......................4A-29
Brake Control System and Diagnosis ... 4A-1 Special Tools and Equipment ...........................4A-29
Precautions...........................................................4A-1 Recommended Service Material .......................4A-29
Precautions for Brake Service ............................ 4A-1 Special Tool ......................................................4A-30
Brake System Description................................... 4A-1 Front Brakes ............................................ 4B-1
Brake Pedal Leg Protection Mechanism General Description .............................................4B-1 4
Construction ...................................................... 4A-2 Front Brake Description ......................................4B-1
Diagnostic Information and Procedures............4A-2 Repair Instructions ..............................................4B-1
Brake Symptom Diagnosis.................................. 4A-2 Front Brake Components ....................................4B-1
Repair Instructions ..............................................4A-5 Front Brake Pad On-Vehicle Inspection..............4B-3
Brake Fluid Level Inspection ............................... 4A-5 Front Brake Pad Removal and Installation..........4B-3
Brake Fluid Level Switch Inspection ................... 4A-6 Front Brake Pad Inspection.................................4B-4
Brake Fluid Replacement.................................... 4A-6 Front Brake Disc Removal and Installation .........4B-5
Air Bleeding of Brake System ............................. 4A-7 Front Brake Disc Inspection ................................4B-6
Brake Pedal Components ................................... 4A-8 Front Brake Caliper Removal and Installation.....4B-6
Brake Pedal Assembly Removal and Front Brake Caliper Disassembly and
Installation......................................................... 4A-9 Reassembly ......................................................4B-7
Brake Pedal Free Height Inspection ................. 4A-10 Front Brake Caliper Inspection............................4B-9
Brake Pedal Play Inspection ............................. 4A-11 Specifications.....................................................4B-10
Excessive Pedal Travel Inspection ................... 4A-11 Tightening Torque Specifications......................4B-10
Brake Light Switch ON-Vehicle Inspection........ 4A-11 Special Tools and Equipment ...........................4B-10
Brake Light Switch Removal and Installation .... 4A-12 Recommended Service Material .......................4B-10
Brake Light Switch Inspection ........................... 4A-12
Brake Flexible Hose and Pipe Components ..... 4A-13 Rear Brakes.............................................. 4C-1
Brake Flexible Hose and Pipe Removal and General Description .............................................4C-1
Installation....................................................... 4A-16 Rear Brake Description .......................................4C-1
Brake Flexible Hose and Pipe Inspection ......... 4A-16 Repair Instructions ..............................................4C-1
Brake Master Cylinder Components ................. 4A-16 Rear Brake Components.....................................4C-1
Brake Master Cylinder Assembly On-Vehicle Rear Brake Shoe On-Vehicle Inspection ............4C-2
Inspection........................................................ 4A-17 Rear Brake Drum Removal and Installation........4C-2
Brake Master Cylinder Assembly Removal Rear Brake Drum and Shoe Inspection ..............4C-2
and Installation................................................ 4A-17 Rear Brake Shoe Removal and Installation ........4C-3
Brake Master Cylinder Reservoir Removal Rear Brake Adjuster and Brake Shoe Lever
and Installation................................................ 4A-19 Check ................................................................4C-4
Brake Master Cylinder Assembly Inspection..... 4A-20 Wheel Cylinder Removal and Installation ...........4C-4
Brake Booster Components .............................. 4A-21 Wheel Cylinder Inspection ..................................4C-5
Brake Booster Function Check ......................... 4A-22 Brake Backing Plate Removal and Installation ....4C-5
Brake Booster Removal and Installation ........... 4A-23 Specifications.......................................................4C-5
Brake Booster Inspection .................................. 4A-26 Tightening Torque Specifications........................4C-5
Brake Booster Switch Inspection (ABS Model) .. 4A-26 Special Tools and Equipment .............................4C-6
Recommended Service Material .........................4C-6 DTC U0073-88 ..................................................4E-33

Special Tool ........................................................4C-6 DTC U0100-87 ..................................................4E-33
ABS Control Module Power Supply and
Parking Brake .......................................... 4D-1 Ground Circuit Check......................................4E-33
General Description .............................................4D-1 Repair Instructions ............................................4E-35
Parking Brake Description...................................4D-1 ABS Hydraulic Unit Operation Check................4E-35
Repair Instructions ..............................................4D-1 ABS Hydraulic Unit / Control Module
Parking Brake Components ................................4D-1 Assembly Components ...................................4E-36
Parking Brake Inspection ....................................4D-1 ABS Hydraulic Unit / Control Module
Parking Brake Adjustment...................................4D-2 Assembly On-Vehicle Inspection ....................4E-38
Parking Brake Cable Removal and ABS Hydraulic Unit / Control Module
Installation .........................................................4D-2 Assembly Removal and Installation ................4E-38
Parking Brake Lever Removal and Installation ....4D-2 Front and Rear Wheel Speed Sensor On-
Parking Brake Switch Inspection.........................4D-3 Vehicle Inspection ...........................................4E-40
Specifications.......................................................4D-3 Front Wheel Speed Sensor Removal and
Tightening Torque Specifications........................4D-3 Installation .......................................................4E-40
Rear Wheel Speed Sensor Removal and
ABS............................................................4E-1 Installation .......................................................4E-41
Precautions........................................................... 4E-1 Front and Rear Wheel Speed Sensor
Precautions for Diagnosing Trouble.................... 4E-1 Inspection........................................................4E-42
General Description ............................................. 4E-1 Front Wheel Speed Sensor Encoder Removal
ABS Description .................................................. 4E-1 and Installation ................................................4E-42
OBD System Description .................................... 4E-2 Rear Wheel Speed Sensor Encoder Removal
Warning Light Description ................................... 4E-2 and Installation ................................................4E-42
DLC Description .................................................. 4E-3 Front and Rear Wheel Speed Sensor
CAN Communication System Description........... 4E-3 Encoder Inspection .........................................4E-42
Schematic and Routing Diagram........................ 4E-3 Specifications .....................................................4E-42
ABS Diagram ...................................................... 4E-3 Tightening Torque Specifications......................4E-42
ABS Input / Output Diagram................................ 4E-4 Special Tools and Equipment ...........................4E-43
ABS Circuit Diagram ........................................... 4E-5 Special Tool ......................................................4E-43
Component Location ........................................... 4E-7
ABS Component Location................................... 4E-7
Electronic Stability Program ...................4F-1
Precautions........................................................... 4F-1
Diagnostic Information and Procedures............ 4E-9
Precautions for ESP® ......................................... 4F-1
ABS Check........................................................ 4E-10
Precautions for Diagnosing Trouble.................... 4F-1
Visual Inspection ............................................... 4E-12
Test with Speedometer Tester or Other
ABS Symptom Diagnosis .................................. 4E-12
Equipment ......................................................... 4F-1
Warning Light Check......................................... 4E-13
DTC Check........................................................ 4E-14 General Description ............................................. 4F-1
DTC Clearance ................................................. 4E-15 ABS Description .................................................. 4F-1
DTC Table......................................................... 4E-15 ESP® Description ............................................... 4F-2
Fail-Safe Table.................................................. 4E-18 ESP® Component Description............................ 4F-3
Scan Tool Data ................................................. 4E-23 OBD System Description .................................... 4F-4
ABS Warning Light Does Not Come ON after Warning / Indicator Light Description .................. 4F-5
Setting Ignition “ON” ....................................... 4E-24 Description of Sensor Calibrating Condition ....... 4F-6
ABS Warning Light Comes ON Steady............. 4E-25 DLC Description .................................................. 4F-6
Brake System Warning Light (Red) Does Not CAN Communication System Description........... 4F-6
Come ON after Setting Ignition “ON” .............. 4E-26 Schematic and Routing Diagram ........................ 4F-6
Brake System Warning Light (Red) Comes ESP® System Diagram....................................... 4F-6
ON Steady ...................................................... 4E-26 ESP® Input / Output Diagram ............................. 4F-7
DTC C1121-01 / C1121-92 / C1125-01 / ESP® Circuit Diagram......................................... 4F-7
C1125-92 / C1131-01 / C1131-92 / C1133- Component Location ........................................... 4F-9
62 / C1135-01 / C1135-92 .............................. 4E-28 ESP® Component Location ................................ 4F-9
DTC C1141-07 / C1142-07 / C1145-07 / Diagnostic Information and Procedures .......... 4F-12
C1146-07 / C1151-07 / C1152-07 / C1155- ESP® System Check ........................................ 4F-12
07 / C1156-07 / C1163-07 .............................. 4E-30 Visual Inspection ............................................... 4F-14
DTC C1157-1C ................................................. 4E-31 ESP® Symptom Diagnosis ............................... 4F-14
DTC C1161-07 .................................................. 4E-32 Warning Light Check......................................... 4F-15
DTC C1162-00 .................................................. 4E-32 DTC Check........................................................ 4F-17
DTC C1171-49 .................................................. 4E-33 DTC Clearance ................................................. 4F-17
DTC Table......................................................... 4F-18 DTC U0100-87 / U0101-87 / U0126-87 /

Fail-Safe Table.................................................. 4F-21 U0140-87 / U1082-87...................................... 4F-58
Scan Tool Data ................................................. 4F-25 DTC U0402-81 .................................................. 4F-58
Scan Tool Active Test Table ............................. 4F-28 DTC U1410-81 .................................................. 4F-59
ESP® Warning Light Does Not Come ON ESP® Control Module Power Supply and
after Setting Ignition “ON” ............................... 4F-28 Ground Circuit Check...................................... 4F-59
ESP® Warning Light Comes ON Steady .......... 4F-29 Repair Instructions ............................................ 4F-61
ABS Warning Light Does Not Come ON after ESP® Hydraulic Unit Operation Check ............. 4F-61
Setting Ignition “ON” ....................................... 4F-29 Sensor Calibration............................................. 4F-62
ABS Warning Light Comes ON Steady............. 4F-30 ESP® OFF Function ......................................... 4F-63
Brake System Warning Light (Red) Does Not ESP® Hydraulic Unit / Control Module
Come ON after Setting Ignition “ON” .............. 4F-31 Assembly Components ................................... 4F-64
Brake System Warning Light (Red) Comes ESP® Hydraulic Unit / Control Module
ON Steady ...................................................... 4F-31 Assembly On-Vehicle Inspection .................... 4F-65
DTC C1115-92 / C1117-92 / C1123-92 ............ 4F-33 ESP® Hydraulic Unit / Control Module
DTC C1116-62 .................................................. 4F-34 Assembly Removal and Installation ................ 4F-66
DTC C111C-00 ................................................. 4F-36 Front and Rear Wheel Speed Sensor On-
DTC C1121-01 / C1121-92 / C1125-01 / Vehicle Inspection ........................................... 4F-68
C1125-92 / C1131-01 / C1131-92 / C1133- Front Wheel Speed Sensor Removal and
62 / C1135-01 / C1135-92 .............................. 4F-36 Installation ....................................................... 4F-68
DTC C1124-09 .................................................. 4F-39 Rear Wheel Speed Sensor Removal and
DTC C1127-29 .................................................. 4F-41 Installation ....................................................... 4F-68
DTC C1128-92 .................................................. 4F-42 Front and Rear Wheel Speed Sensor
DTC C112A-00 ................................................. 4F-43 Inspection........................................................ 4F-68
DTC C112B-92 ................................................. 4F-44 Front Wheel Speed Sensor Encoder Removal
DTC C1137-1C ................................................. 4F-46 and Installation ................................................ 4F-68
DTC C1137-82 .................................................. 4F-47 Rear Wheel Speed Sensor Encoder Removal
DTC C1138-76 .................................................. 4F-48 and Installation ................................................ 4F-68
DTC C1139-49 / C1171-49 ............................... 4F-49 Front and Rear Wheel Speed Sensor
DTC C1141-07 / C1142-07 / C1143-07 / Encoder Inspection ......................................... 4F-68
C1144-07 / C1145-07 / C1146-07 / C1151- Brake Master Cylinder Pressure Sensor On-
07 / C1152-07 / C1153-07 / C1154-07 / Vehicle Inspection ........................................... 4F-68
C1155-07 / C1156-07 / C1163-07................... 4F-50 Steering Angle Sensor On-Vehicle Inspection .. 4F-69
DTC C1147-62 / C1148-62 ............................... 4F-50 Steering Angle Sensor Removal and
DTC C114A-29 ................................................. 4F-51 Installation ....................................................... 4F-70
DTC C114B-29 ................................................. 4F-53 Steering Angle Sensor Inspection..................... 4F-70
DTC C1157-1C ................................................. 4F-54 ESP® OFF Switch Removal and Installation .... 4F-70
DTC C1161-07 .................................................. 4F-55 ESP® OFF Switch Inspection ........................... 4F-71
DTC C1162-00 .................................................. 4F-55 Specifications..................................................... 4F-71
DTC C1169-00 .................................................. 4F-56 Tightening Torque Specifications...................... 4F-71
DTC C1174-54 / C1175-54 ............................... 4F-56 Special Tools and Equipment ........................... 4F-72
DTC C1190-82 / C1194-81 / U0401-81 ............ 4F-57 Special Tool ...................................................... 4F-72
DTC U0073-88 .................................................. 4F-58
4-1 Precautions:
Precautions
Brakes
Precautions
Precautions for Brakes
AENNTA0E4000001 (01(01)
General Precautions


Warning for Wheel and Tire

Refer to “Warning for Wheel and Tire” in Section 00.
Warning for Brake

Refer to “Warning for Brake” in Section 00.
Precautions for Vehicle Equipped with ESP® System

Refer to “Precautions for Vehicle Equipped with ESP® System” in Section 00.
Warning for Air Bag

Reassembling Note for Wiring Harness

Observe “Reassembling Note for Wiring Harness” in Section 9A whenever installing wiring harness.
Otherwise, electrical trouble may occur.

Brake Control System and Diagnosis: 4A-1
Brake Control System and Diagnosis

Brakes
Precautions
Precautions for Brake Service
AENNTA0E4100001 (01(01)
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.
General Description
Brake System Description
AENNTA0E4101001 (03(01)
When the 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.
2
1
4
7
3
[f] 5 6
IMTA0A410056-01
4A-2 Brake Control System and Diagnosis:
[f]: Forward 3. Primary side 6. Parking brake lever

1. Brake booster 4. Secondary side 7. Parking brake cable
2. Brake master cylinder 5. ESP® hydraulic unit / control module assembly
Brake Pedal Leg Protection Mechanism Construction

AENNTA0E4101002 (03(01)
Should a frontal crash occur, the engine pushes the dash panel toward the interior and the brake pedal bracket (5) is
also pushed rearward. In this case, the brake pedal lever (3) comes off from the brake pedal (1), to prevent the brake
pedal from moving rearward.
[A] [B]
5 5
2 2
3
3
4
4
1
1
ILKC0PF40007-01
[A]: Before crash 2. Brake booster

[B]: After crash 4. Cylinder push rod clevis

Brake Symptom Diagnosis
AENNTA0E4104001 (06(04)
Not enough braking force

• Brake fluid leakage from brake lines Locate leaking point and repair. (Brake Flexible Hose and
Pipe Inspection)
• Brake disc or pads stained with fluid, grease or
other oil Clean or replace.
• Front brake disc: (Front Brake Disc Removal and
• Front brake pad: (Front Brake Pad Removal and
• Overheated brakes Determine cause and repair.
• Poor contact of shoes on brake drum Repair for proper contact. (Rear Brake Drum and Shoe
• Brake drum and/or shoe stained with oil or wet with
water Clean or replace.
• Rear brake drum: (Rear Brake Drum Removal and
• Rear brake shoe: (Rear Brake Shoe Removal and
• Badly worn brake pad and/or shoe Replace.

• Defective wheel cylinders Repair or replace. (Wheel Cylinder Removal and
• Malfunctioning brake caliper assembly Repair or replace. (Front Brake Caliper Removal and
• Air in system Bleed brake system. (Air Bleeding of Brake System)
• Brake booster internal failure Replace brake booster. (Brake Booster Removal and
Installation)
• Inadequate negative pressure for brake booster Check engine condition and vacuum hose.
• Malfunctioning ESP® Check system and replace if necessary. (ESP® System
Check) in Section 4F
• Malfunctioning master cylinder Repair or replace. (Brake Master Cylinder Assembly
Vehicle pulls to one side (Brakes not working uniformly)

• Pad, disc, shoe and/or drum are wet with water or
stained with oil in some brakes Clean or replace.
• Drum-to-shoe clearance out of adjustment in some
brake (Malfunctioning auto adjusting mechanism) Check for inoperative auto adjusting mechanism. (Rear
Brake Adjuster and Brake Shoe Lever Check) in Section 4C
• Disc and/or drum are out of round in some brakes Replace.
• Tires are inflated unequally Inflate equally.
• Malfunction in wheel cylinders Repair or replace. (Wheel Cylinder Removal and
• Disturbed front wheel alignment Adjust as specified. (Front Wheel Alignment Inspection and
Adjustment) in Section 2B
• Unmatched tires on the same axle Tires with approximately the same amount of tread should
be used on the same axle.
• Restricted brake pipes or hoses Check for damage and replace pipes and/or hoses if
necessary. (Brake Flexible Hose and Pipe Inspection)
• Malfunctioning brake caliper assembly Check for stuck or sluggish pistons and proper lubrication of
caliper slide pin. (Front Brake Caliper Inspection) in Section
4B
• Loose suspension parts Check all suspension mountings. (Suspension System
Check) in Section 2A
• Loose brake calipers Check and tighten bolts to specified torque. (Front Brake
Caliper Removal and Installation) in Section 4B
Noise (High pitched squeak without brake applied)

• Contact of wear indicator to brake disc Replace brake pad. (Front Brake Pad Removal and
• Worn rear brake shoe Replace brake shoe. (Rear Brake Shoe Removal and
Excessive pedal travel (Pedal stroke too large)

• Brake fluid leakage Locate leaking point and repair. (Brake Flexible Hose and
Pipe Inspection)
• Air in system (soft / spongy pedal) Bleed brake system. (Air Bleeding of Brake System)
• Rear brake system not adjusted (malfunctioning
auto adjusting mechanism) Repair auto adjusting mechanism.
Adjust rear brakes. (Parking Brake Adjustment) in Section
4D
• Bent brake shoes Replace brake shoes. (Rear Brake Shoe Removal and
• Malfunctioning master cylinder Repair or replace. (Brake Master Cylinder Assembly
Brake locked
• Malfunctioning ESP® Check system and replace if necessary. (ESP® System
Dragging brakes (A very light drag is present in all brakes immediately after pedal is released)
• Master cylinder pistons not returning correctly Replace brake master cylinder. (Brake Master Cylinder
• Restricted brake pipes or hoses Check for damage and replace pipes and/or hoses if
necessary. (Brake Flexible Hose and Pipe Inspection)
• Incorrect parking brake adjustment on rear brakes Check and adjust to correct specifications.(Parking Brake
Adjustment) in Section 4D
• Weakened or broken return springs in brake Replace. (Rear Brake Shoe Removal and Installation) in
Section 4C
• Sluggish parking brake cables or linkage Repair or replace. (Parking Brake Cable Removal and
• Wheel cylinder or brake caliper piston sticking Repair if necessary.
• Front brake caliper piston: (Front Brake Caliper
Disassembly and Reassembly) in Section 4B
• Rear brake wheel cylinder: (Wheel Cylinder Removal and
• Badly worn piston seal in brake caliper Replace piston seal. (Front Brake Caliper Disassembly and
• Improper brake pedal free height Check brake pedal free height. (Brake Pedal Free Height
Inspection)
® Check system and replace if necessary. (ESP® System
• Malfunctioning ESP
Pedal pulsation (Pedal pulsates when depressed for braking)


• Damaged or loose front and/or rear wheel
bearings Replace front wheel bearing and/or rear wheel hub
assembly.
• Distorted steering knuckle or rear wheel hub
assembly Replace.
• Knuckle: (Front Wheel Hub Assembly and Steering
Knuckle Removal and Installation): Front in Section 3A
• Rear wheel hub: (Rear Wheel Hub Assembly Removal
and Installation): Rear in Section 3A
• Excessive disc lateral runout Check per instructions. If not as specified, replace or
machine disc. (Front Brake Disc Inspection) in Section 4B
• Rear drums out of round Check runout.
Repair or replace drum if necessary. (Rear Brake Shoe
Braking noise
• Glazed brake pad and/or brake shoe Repair or replace brake pad and/or brake shoe.
• Worn or distorted brake shoe Replace brake shoe. (Rear Brake Shoe Removal and
• Loose front and/or rear wheel bearings Replace front wheel bearing and/or rear wheel hub
assembly.
• Distorted backing plates or loose mounting bolts Replace or retighten securing bolts. (Brake Backing Plate
• Contact of wear indicator to brake disc Replace brake pads. (Front Brake Pad Removal and
• Poorly lubricated contact surfaces of rear brake
shoe and backing plate. Apply grease to contact surfaces of rear brake shoe and
backing plate.
Repair Instructions
Brake Fluid Level Inspection
AENNTA0E4106001 (08(03)
• 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 (red) comes on during driving or brake fluid level on brake master
cylinder reservoir is at “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.
If brake fluid contacts painted surfaces,

Brake Fluid Level Switch Inspection immediately wipe it off and flush the
AENNTA0E4106002 (08(03) surfaces with water thoroughly.
Disconnect brake fluid level switch connector (1), check
continuity between terminals of brake fluid level switch
(2). If check result is not as specified, replace reservoir. NOTE
Brake fluid level switch specification • When replacing brake fluid, start with the
MAX position (float up): No continuity brake closest to the brake master cylinder.
MIN position (float down): Continuity exists • To prevent air from getting into reservoir,
be careful not to let the reservoir be short
of fluid while operating brake pedal.
1) Using a dropper or the like, extract some brake fluid

2 from reservoir (1) of brake master cylinder.
1
IMTA0A410028-01
Brake Fluid Replacement

AENNTA0E4106003 (08(01)
NOTICE IMTA0A410026-01
2) Add new brake fluid to reservoir of brake master

• Using improper or contaminated brake
cylinder.
fluid can cause brake system failure. Using
shock absorber fluid or any other fluid that Brake fluid specification
contains mineral oil for the brake fluid will : Refer to reservoir cap of brake master cylinder
cause the rubber parts in the brake or Owner’s Manual.
hydraulic system to swell or distort. If
3) Remove bleeder plug cap on brake caliper. Attach a
water is mixed in the brake fluid, the
vinyl tube (1) to bleeder plug, and insert the other
boiling point will be lowered.
end into container (2).
– 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.
painted surfaces.
I2RH01410015-01
4) Depress brake pedal several times with bleeder plug

loosened. [f]
5) If new brake fluid starts coming out, tighten bleeder

plug to specified torque. 1 3
• Front: (Front Brake Components) in Section 4B
• Rear: (Rear Brake Components) in Section 4C
6) Perform Step 3) – 5) for remaining wheels as well.
7) If necessary, bleed brake system. (Air Bleeding of
Brake System)
Air Bleeding of Brake System

AENNTA0E4106004 (08(03)
NOTICE
2 4
• Using improper or contaminated brake
IMTA0A410058-01
fluid can cause brake system failure. Using
shock absorber fluid or any other fluid that [f]: Forward 3. Rear right wheel cylinder
1. Front right brake caliper 4. Rear left wheel cylinder
contains mineral oil for the brake fluid will
2. Front left brake caliper
cause the rubber parts in the brake
hydraulic system to swell or distort. If
1) Fill brake master cylinder reservoir with new brake
water is mixed in the brake fluid, the
fluid and keep the reservoir at least one-half full of
boiling point will be lowered.
fluid during bleeding operation.
– Use only the specified brake fluid from a
sealed container. Brake fluid specification
Refer to reservoir cap (1) of brake master
– Do not use a container that has been
cylinder or Owner’s Manual.
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 1
moisture.
painted surfaces.
surfaces with water thoroughly.
• If ESP® hydraulic unit operation check is
performed when air is trapped in brake
line, air may be taken in hydraulic unit. To
prevent this, bleed brake system before IMTA0A410030-01
performing hydraulic unit operation check. 2) Remove bleeder plug cap. Attach a vinyl tube (1) to
bleeder plug, and insert the other end into container
Hydraulic brake system must be bled whenever air (2).
enters the system.
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.
NOTE
Perform bleeding operation starting from the
brake farthest from brake master cylinder
I2RH01410015-01
and then at the brake on the same brake line.
Do the same on the other brake line. 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 • Rear: (Rear Brake Components) in Section 4C
released, retighten bleeder plug.
5) Repeat this operation until air is completely removed
from hydraulic line.
I2RH01410017-01
7) Attach bleeder plug cap.

8) After completing bleeding operation, apply fluid
I2RH01410016-01
pressure to brake lines and check for leakage.
6) When air bubbles disappear from fluid flowing into
container, depress and hold brake pedal and tighten 9) Replenish reservoir with new fluid up to specified
bleeder plug. level. (Brake Fluid Level Inspection)
• Front: (Front Brake Components) in Section 4B 10) Check brake pedal stroke. If the stroke is so large,
repeat entire procedure of bleeding.
Brake Pedal Components

AENNTA0E4106005 (12(01)
4 (a)
5 6
3 (a)
IMTA0A410033-03
1. Brake pedal: Do not 4. Brake pedal bracket nut: For 7. Accelerator pedal: For installation, refer to “Accelerator Pedal
disassemble. tightening order, refer to “Brake Assembly (Incorporating APP Sensor) Removal and Installation” in
Pedal Assembly Removal and Section 1C.
Installation”.
2. Pedal pad 5. Brake light switch 8. Accelerator pedal assembly nut: For installation, refer to “Accelerator
Pedal Assembly (Incorporating APP Sensor) Removal and
Installation” in Section 1C.
3. Brake booster nut: For 6. Bushing : 13 Nm (1.3 kgf-m, 9.5 lbf-ft)
tightening order, refer to
“Brake Pedal Assembly
3) Disconnect brake light switch connector (1) and

Brake Pedal Assembly Removal and Installation harness clip (2), remove main harness (3) from
AENNTA0E4106006 (08(01) brake pedal assembly (4).
NOTICE
The brake pedal assembly will lose their
original performance if they are
3
disassembled and reassembled.
If any faulty condition is found with the brake 2
pedal assembly, replace the part rather than
trying to disassemble and repair it. 1
Removal
1) Remove steering column hole cover. (Instrument 4
Panel Removal and Installation) in Section 9C
2) Remove steering column lower cover. (Steering IMTA0A410036-01
Wheel and Column Components) in Section 6B 4) Remove accelerator pedal assembly. (Accelerator
Pedal Assembly (Incorporating APP Sensor)
5) Remove clip (2) and clevis pin (3) from clevis (1).
2,“2”,(b)
3
1 1,“1”,(a)
1,“1”,(a)
IMTA0A410039-01
ILKC0P410010-02 • Install clevis pin (1) and new clip (2).
6) Remove brake pedal bracket nut (1) and brake
booster nuts (2), and remove brake pedal assembly
(3).
1
2
ILKC0P410009-04
2
2
• Check brake pedal free height and play.
– Brake pedal free height: (Brake Pedal Free Height
IMTA0A410038-01
Inspection)
7) Remove pedal pad, if necessary. (Brake Pedal
– Brake pedal play: (Brake Pedal Play Inspection)
Components)
• Check that brake system operates properly.
8) Remove brake light switch, if necessary. (Brake Light
Switch Removal and Installation) • Adjust brake light switch, if necessary. (Brake Light
Switch Removal and Installation)
Installation
Reference: “Brake Booster Removal and Installation” Brake Pedal Free Height Inspection
AENNTA0E4106007 (08(03)
NOTE
• Tighten brake booster nuts (1) and brake pedal
The brake pedal to carpet clearance must be
bracket nut (2) in numerical order (“1” – “2”) to
measured between the specified points that
specified torque.
vary with steering wheel position and
Tightening torque transaxle type. Select the appropriate
Brake booster nut (a): 13 N·m (1.3 kgf-m, 9.5 lbf- measuring point (1) according to the figure
ft) below.
Brake pedal bracket nut (b): 13 N·m (1.3 kgf-m,
9.5 lbf-ft) [A] [B]
1 1
IFRA0A410011-01
[A]: M/T model [B]: AGS model

Check brake pedal free height. If it is not within

specification, check and adjust the following items. [A] [B]
• Brake booster for installation.

• Length of brake booster push rod.
Brake pedal free height “a” from carpet
AGS model: 108 – 128 mm (4.25 – 5.04 in.)
1 1
M/T model: 109 – 129 mm (4.29 – 5.08 in.)
IFRA0A410011-01
[A]: M/T model [B]: AGS model
1) Start engine.
2) Depress brake pedal a few times.
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
“a”
less than specification, check the following points.
• Air in brake system. (Air Bleeding of Brake
1
System)
I8G001410006-01 • Brake fluid leakage
1. Carpet • Length of brake booster push rod. (Brake Booster
Inspection)
Brake Pedal Play Inspection Brake pedal to carpet clearance “a”
AENNTA0E4106008 (08(03)
With engine stopped, depress brake pedal several When pedal is depressed at 300 N (30.6 kgf, 67.4
times. lbf): Over 53 mm (2.1 in.)
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. (Brake Booster Inspection)
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.
Brake pedal play “a”
: 1 – 8 mm (0.04 – 0.31 in.)
“a”
IBP80A410011-01
Brake Light Switch ON-Vehicle Inspection

AENNTA0E4106010 (08(03)
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”
I3RH0A410010-01 “a”: 6.4 – 15 mm (0.25 – 0.59 in.)
Excessive Pedal Travel Inspection

AENNTA0E4106009 (08(03)
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.
“a”
IAP70B410015-01
“a”
Brake Light Switch Removal and Installation
AENNTA0E4106011 (08(01)
Reference: “Precautions for Electrical System Work” ILKC0P410013-02
Removal
Brake Light Switch Inspection
1) Disconnect brake light switch connector. AENNTA0E4106012 (08(03)
2) Remove brake light switch (1) by turning it Reference: “Precautions for Electrical System Work”
counterclockwise viewed from above by approx. 45°. Reference: “Brake Light Switch Removal and
Installation”
NOTE
2 Reference voltage of each measurement is as
follows.
• Hi: Higher than battery voltage –0.5 V
1
3
• Lo: Lower than 0.5 V
1) Connect battery positive (+) terminal to terminal “1”

and negative (–) terminal to terminal “3” as shown.
2) Measure the terminal voltage at each shaft condition.
I8G001410007-01
Brake light switch voltage
2. Brake pedal bracket 3. Bushing
Terminal Shaft condition Voltage
Free [A] Hi
2
Pushed [B] Lo
Installation
While keeping brake pedal (2) in unloaded condition,
and then install brake light switch (1) pressing it to pedal
bracket so that the switch stroke becomes 0 (zero) and
turning it clockwise viewed from above by approx. 45°.
NOTE
5 4 3 2 1
While installing brake light switch turning it
clockwise, the switch body rises from the
pedal bracket.
This movement automatically creates
specified clearance “a” between switch
screw end and the pedal bracket.
IFRA0B410010-01
Clearance “a”: 1.0 to 2.0 mm (0.04 to 0.07 in.)
[A] [B]
IFRA0B410011-01
3) Connect battery positive (+) terminal to terminal “5”

and negative (-) terminal to terminal “3” as shown.
4) Measure the terminal voltage at each shaft condition.

If check result is not as specified, replace brake light
switch.
Brake light switch voltage
Terminal Shaft condition Voltage
Free [A] Lo 5 4 3 2 1
4
Pushed [B] Hi
IFRA0B410012-01
[A] [B]
IFRA0B410011-01
Brake Flexible Hose and Pipe Components

AENNTA0E4106013 (12(01)
Front
[a] 15
13
(c) 15
3
(a)
15
4
6
15 15
15
7
14 [c] 5 (a) 12
[R]
(d) [L]
9 (a)
15
11 15
[A]: [b] 8 10
(a)
[a] (a)
[B]: (b) 3 (e)
1
13
4 (c)
(d)
14
8
[b] [c] 5
9 6
(a)
3
3
4 9
5
8 6 4
[A]: (a)
2 [B]: (b)
IMTA0A410040-02
[L]: To [L] in “Rear” 6. Right pipe between ABS / ESP® hydraulic 15. Clamp
unit / control module assembly and front
brake flexible hose
[R]: To [R] in “Rear” 7. Front brake flexible hose : 16 Nm (1.6 kgf-m, 12.0 lbf-ft)
[A]: ABS model 8. Left pipe between ABS / ESP® hydraulic unit : 21 Nm (2.1 kgf-m, 15.5 lbf-ft)
/ control module assembly and brake 4-way
joint
[B]: ESP® model 9. Right pipe between ABS / ESP® hydraulic : 26 Nm (2.7 kgf-m, 19.5 lbf-ft)
unit / control module assembly and brake 4-
way joint
1. Brake master cylinder 10. Brake 4-way joint : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
2. ABS / ESP® hydraulic unit / control module 11. Left pipe between brake 4-way joint and : 11 Nm (1.1 kgf-m, 8.5 lbf-ft)
assembly rear brake flexible hose
3. Pipe between master cylinder primary and 12. Right pipe between brake 4-way joint and : Do not reuse.
ABS / ESP® hydraulic unit / control module rear brake flexible hose
assembly
4. Pipe between master cylinder secondary 13. E-ring
and ABS / ESP® hydraulic unit / control
module assembly
5. Left pipe between ABS / ESP® hydraulic unit 14. Flexible hose gasket
/ control module assembly and front brake
flexible hose
Rear
(a)
5
6
3
(a)
(a) 6
7 7
7 7 4
7
(a)
7 6
(a)
(a)
7
7
2
1 7
[R]
7
[L]
IMTA0A410041-01
[L]: To [L] in “Front” 4. Left pipe between rear brake flexible hose and wheel cylinder
[R]: To [R] in “Front” 5. Right pipe between rear brake flexible hose and wheel cylinder
1. Left pipe between brake 4-way joint and rear brake flexible hose 6. E-ring
2. Right pipe between brake 4-way joint and rear brake flexible hose 7. Clamp
3. Rear brake flexible hose : 16 Nm (1.6 kgf-m, 12.0 lbf-ft)
Brake Flexible Hose and Pipe Removal and Installation

AENNTA0E4106014 (08(01)
Reference: “Brake Flexible Hose and Pipe Components”
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. (Wheel (with Tire) Removal and Installation) in Section 2D
NOTE
This operation is not necessary when removing pipes connected 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. (Brake Fluid Replacement)
4) Remove brake flexible hose or pipe using special tool.
Special tool
: 09950M78220
Installation
Reference: “Brake Flexible Hose and Pipe Inspection” Brake Flexible Hose and Pipe Inspection
Reverse removal procedure noting the following points. AENNTA0E4106015 (08(03)
Reference: “Brake Flexible Hose and Pipe Removal and
• Tighten flare nuts to specified torque referring to
Installation”
“Brake Flexible Hose and Pipe Components”.
• Install all removed clamps properly. (Brake Flexible Flexible Hose
Hose and Pipe Components) Check the following points. If check result is not OK,
• Check that steering wheel is in straight-forward replace brake flexible hose.
position and flexible hoses are not twisted or kinked. • Connection for leakage and other damage
• Check that flexible hose is not in contact with any part • Blister, crack and other damage
of suspension when steering wheel is turned fully right
and left. Pipe
• Bleed brake system. (Air Bleeding of Brake System) Check brake pipe for damage, crack, dents and
• Check that brake system operates properly and there corrosion. If check result is not OK, replace pipe.
is no fluid leakage.
Brake Master Cylinder Components

AENNTA0E4106016 (12(01)
[A] 7
6
5 FLD
(a)
IMTA0A410002-01
[A]: M/T model 4. O-ring 8. Reservoir cap

1. Brake master cylinder 5. Grommet
9. Reservoir filter
: Do not disassemble. : Apply brake fluid.
2. Reservoir 6. Clutch reservoir hose : 18 Nm (1.8 kgf-m, 13.5 lbf-ft)
3. Spring pin 7. Hose clamp : Do not reuse.
• If brake master cylinder is tilted, the piston

Brake Master Cylinder Assembly On-Vehicle may slip off.
Inspection Do not tilt it facing the piston downward.
AENNTA0E4106017 (08(03) • Brake fluid is extremely damaging to
Check brake master cylinder for crack, damage and painted surfaces.
brake fluid leakage. If check result is not OK, replace If brake fluid contacts painted surfaces,
brake master cylinder. immediately wipe it off and flush the
Brake Master Cylinder Assembly Removal and
Installation
AENNTA0E4106018 (08(01) Removal
Reference: “Brake Master Cylinder Components” 1) Remove air cleaner assembly. (Air Cleaner
Reference: “Brake Master Cylinder Assembly On- Assembly Removal and Installation) in Section 1D
Vehicle Inspection” 2) Clean external surface of brake master cylinder (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
and repair it.
1 2
IMTA0A410003-01 IMTA0A410009-01
3) Drain brake fluid in reservoir. 7) Remove brake master cylinder fixing nuts (1) and
4) Disconnect brake fluid level switch connector (1). brake master cylinder (2) from brake booster.
IMTA0A410006-01 IMTA0A410013-01
5) Loosen flare nuts (1) with special tool and 8) Remove O-ring (1) from brake master cylinder.
disconnect brake pipes (3) from brake master
cylinder (2).
Special tool
: 09950M78220
1
IMTA0A410014-01
3
Installation
Reference: “Brake Master Cylinder Assembly
Inspection”
3 Reverse removal procedure noting the following points.
2
• Install new O-ring (1) to brake master cylinder
IMTA0A410007-01 assembly.
6) For M/T model, loosen hose clamp (1) and then
disconnect clutch reservoir hose (2) from reservoir
(3).
1 1
(A)
IMTA0A410014-01 IMTA0A410015-01
• Tighten new brake master cylinder fixing nuts to 4) Remove reservoir (1) and grommets (2).
specified torque.
Tightening torque 1
Brake master cylinder fixing nut: 13 N·m (1.3 kgf-
m, 9.5 lbf-ft)
• Connect brake pipes to brake master cylinder and
tighten flare nuts to specified torque.
Tightening torque
Brake pipe flare nut (ABS model): 16 N·m (1.6
kgf-m, 12.0 lbf-ft)
2
Brake pipe flare nut (ESP® model): 21 N·m (2.1
kgf-m, 15.5 lbf-ft)
• For M/T model, bleed clutch system. (Air Bleeding of
Clutch System) in Section 5C
• Bleed brake system. (Air Bleeding of Brake System)
• Check installed parts for brake fluid leakage. IMTA0A410017-01
• Check brake pedal for play. (Brake Pedal Play
Inspection) Installation
• Check brake pedal travel. (Excessive Pedal Travel 1) Lubricate new grommets with the same brake fluid
Inspection) as the one to fill reservoir before fitting grommets
• Check that brake system operates properly without into master cylinder.
fluid leakage. 2) Install reservoir (1) and grommets (2) to brake
master cylinder.
Brake Master Cylinder Reservoir Removal and
Installation 1
AENNTA0E4106019 (08(01)
Reference: “Brake Master Cylinder Components”
NOTICE
Brake fluid is extremely damaging to painted
surfaces.
2
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. (Brake Master Cylinder IMTA0A410017-01
Assembly Removal and Installation) 3) Insert new spring pin (2) from chamfered end (1) of
3) Remove spring pin (1) using special tool. brake master cylinder using special tool until both
right and left ends are the same length “a”.
Special tool
(A): 09922M85811 Special tool
(A): 09922M85811
(A) 1
“a” “a”
IFJA0P410021-01
4) Install brake master cylinder with reservoir to brake

(B)
booster. (Brake Master Cylinder Assembly Removal
and Installation)
Brake Master Cylinder Assembly Inspection

AENNTA0E4106020 (08(03)
Reference: “Brake Master Cylinder Assembly Removal (A)
and Installation” IMTA0A410018-01
3) Repeat Step 1) – 2) for secondary port (1) as well.

NOTE
After inspection of brake master cylinder
assembly, install it to the vehicle and check
the following points.
• Fluid leakage
• Brake pedal play and travel
– Brake pedal play (Brake Pedal Play
Inspection)
– Brake pedal travel (Excessive Pedal
Travel Inspection)
No-Load Inspection 1
1) Fit special tools to primary port (1) as shown below.
NOTE IMTA0A410021-01
If the vehicle is not equipped with ESP®,

special tool (B) is unused for this inspection. Air Tightness Inspection
1) With brake master cylinder assembly (1) fixed in vise
Special tool (3) as shown below, fit special tools to primary port
(A): 09918M78230 (2).
(B): 09952M48010
NOTE
2) Apply pressure to brake master cylinder assembly
with special tool (A) and check that pressure does • When using vise, put clean cloth between
not build up in cylinder. brake master cylinder and vise so as not to
If pressure builds up, brake master cylinder cause damage to brake master cylinder.
assembly is defective and must be replaced. • If the vehicle is not equipped with ESP®,
special tool (B) is unused for this
inspection.
Special tool
(A): 09918M78230
(B): 09952M48010
2) Using special tool (A), apply pressure of 50 kPa (0.5 3) Repeat Step 1) – 2) for secondary port (1).
kgf/cm2, 7.25 psi, 0.5 bar) to brake master cylinder
assembly.
If above pressure does not build up, brake master
cylinder assembly is defective and must be replaced.
2 1
IMTA0A410021-01
(B)
“a”
(A)
IMTA0A410022-01
“a”: 50 mm (2.0 in.)
Brake Booster Components

AENNTA0E4106021 (12(01)
5
(b) 11
10 6
3
(c)
[A] [B] 4
2 7
1
(a) 9
(a)
12
13
IMTA0A410023-03
[A]: ABS model 6. Clip 13. To intake manifold

[B]: ESP® model 7. Vacuum hose No.1 : 11 Nm (1.1 kgf-m, 8.5 lbf-ft)
1. Brake booster switch 8. Vacuum hose No.2 : 13 Nm (1.3 kgf-m, 9.5 lbf-ft)
2. Brake booster pressure sensor 9. Vacuum pipe : 25 Nm (2.5 kgf-m, 18.5 lbf-ft)
3. Brake booster piston rod 10. Brake booster : Do not reuse.
4. Gasket 11. Clevis
5. Clevis pin 12. Stud cover
Brake Booster Function Check Air Tightness Check

AENNTA0E4106022 (08(03) 1) Start engine.
NOTE
2) Stop engine after running for 1 to 2 minutes.
Check that no air is in hydraulic line before
this check.
3) Depress brake pedal several times with the same 2) Start engine while depressing brake pedal. If pedal
force as in ordinary braking to see how pedal travel travel increases a little, brake booster operation is
changes. Brake booster is air tight if pedal travel satisfactory. No change in pedal travel indicates
decreases every time the pedal is depressed. malfunction of brake booster.
I2RH01410005-01 I2RH01410008-01
1. 1st 2. 2nd 3. 3rd

Air Tightness Check under Loaded Condition
4) If pedal travel does not change, brake booster is 1) With engine running, depress brake pedal. Then
defective in air tightness. stop engine while holding brake pedal depressed.
NOTE
If faulty condition is found, check vacuum
lines and sealing parts, and replace the faulty
part. After this, repeat the entire test.
I2RH01410009-01
H: Hold
2) Hold brake pedal depressed for 30 seconds. If pedal

height does not change, brake booster is in good
I2RH01410006-01 condition. If pedal height changes, brake booster is
1. 1st, 2nd, 3rd not in good condition.
Operation Check
1) With engine stopped, depress brake pedal several
times with the same force and check that pedal
travel does not change.
I2RH01410010-01
H: Hold T: 30 seconds
Brake Booster Removal and Installation

AENNTA0E4106023 (08(01)
I2RH01410007-01 Reference: “Brake Booster Components”
NOTICE
Do not disassembly brake booster assembly.
Disassembly and reassembly will spoil its
3
original performance.
If faulty condition is observed, replace brake
booster assembly with new one.
Removal
1
2) Remove brake master cylinder. (Brake Master
Cylinder Assembly Removal and Installation)
3) Disconnect the following parts.
• ABS model: brake booster switch connector (1) 2
• ESP® model: brake booster pressure sensor
connector (2)
IMTA0A410059-01
5) Remove steering column hole cover. (Instrument

6) Remove clip (2) and clevis pin (3) from clevis (1).
3
1
1
ILKC0P410010-02
7) Remove brake booster nuts (1).
2
IMTA0A410043-07
4) Loosen hose clamp (1) and then disconnect vacuum

hose (3) from brake booster (2).
1
IMTA0A410044-01
8) Remove suction pipe. (A/C System Major

Components) in Section 7B
9) Disconnect clutch fluid pipe from clamp. (Clutch
Fluid Pipe and Hose Components) in Section 5C
10) Disconnect the following brake pipe clamp from dash
panel. (Brake Flexible Hose and Pipe Components)
• Pipe between master cylinder primary and ABS /

ESP® hydraulic unit / control module assembly
• Pipe between master cylinder secondary and ABS
/ ESP® hydraulic unit / control module assembly
11) Remove brake booster (2) and gasket from dash
panel (1).
IMTA0A410045-01
5) Tighten brake booster nuts (1) and brake pedal

bracket nut (2) in numerical order (“1” – “2”) to
specified torque.
Tightening torque
Brake booster nut (a): 13 N·m (1.3 kgf-m, 9.5 lbf-
ft)
2 Brake pedal bracket nut (b): 13 N·m (1.3 kgf-m,
9.5 lbf-ft)
IMTA0A410055-03
2,“2”,(b)
12) Remove brake vacuum hose, if necessary. (Brake
Booster Components)
Installation
Reference: “Brake Booster Inspection”
1) Install brake vacuum hose, if removed. (Brake
Booster Components)
2) Install new gasket to brake booster (2), and then
install brake booster to dash panel (1).
1,“1”,(a)
1,“1”,(a)
IMTA0A410039-01
1 6) Connect clevis to brake pedal arm with clevis pin (1)

and new clip (2).
2 1
IMTA0A410055-03
3) Remove steering column lower cover. (Steering

Wheel and Column Components) in Section 6B ILKC0P410009-04
4) Loosen brake pedal bracket nut (1). 7) Install steering column lower cover. (Steering Wheel
and Column Components) in Section 6B
8) Install steering column hole cover. (Instrument Panel
9) Connect the following brake pipe clamp to dash 14) Install brake master cylinder to brake booster. (Brake
panel. (Brake Flexible Hose and Pipe Components) Master Cylinder Assembly Removal and Installation)
• Pipe between master cylinder primary and ABS / 15) Install intake manifold. (Intake Manifold Removal and
ESP® hydraulic unit / control module assembly Installation) in Section 1D
• Pipe between master cylinder secondary and ABS 16) Bleed brake system. (Air Bleeding of Brake System)
/ ESP® hydraulic unit / control module assembly 17) Check installed parts for brake fluid leakage.
10) Connect clutch fluid pipe to clamp. (Clutch Fluid Pipe 18) Check brake pedal for play. (Brake Pedal Play
and Hose Components) in Section 5C Inspection)
11) Install suction pipe. (A/C System Major 19) Check brake pedal travel. (Excessive Pedal Travel
Components) in Section 7B Inspection)
12) Connect vacuum hose (3) to brake booster (2) and 20) Check that brake system operates properly without
then install hose clamp (1). brake fluid leakage.
Brake Booster Inspection

AENNTA0E4106024 (08(03)
3 Reference: “Brake Booster Removal and Installation”
NOTICE
Do not disassembly brake booster assembly.
Disassembly and reassembly will spoil its
1 original performance.
booster assembly with new one.
• Check brake booster for damage.

• Check brake booster for operation referring to
“Operation Check” under “Brake Booster Function
2
Check”.
• Check boot for damage and deterioration.
IMTA0A410059-01 • Check push rod length.
13) Connect the following parts. If check result is not as specified, adjust distance
• ABS model: brake booster switch connector (1) between booster installation surface (without including
• ESP® model: brake booster pressure sensor packing) and the center of clevis pin hole to standard
connector (2) value “a” and tighten push rod nut (1) to specified
torque.
Push rod length
“a”: 114.5 – 115.5 mm (4.508 – 4.547 in.)
Tightening torque
Push rod nut (a): 26 N·m (2.7 kgf-m, 19.5 lbf-ft)
IGRA0A410007-01
Brake Booster Switch Inspection (ABS Model)

AENNTA0E4106025 (08(03)
Reference: “Precautions for Electrical Circuit Service”
2
IMTA0A410043-07
! CAUTION Negative pressure Scan tool display

38.7 kPa (0.4 kgf/cm2, 5.61 psi) Value Hi
Do not remove brake booster switch.
Removal and reinstallation will spoil its Using Circuit Tester
original performance.
1) Disconnect connector from brake booster switch (1).
booster assembly with new one. 2) Disconnect vacuum hose from brake booster (2).
3) Connect special tool (A) to brake booster.
Special tool
1) Disconnect vacuum hose from brake booster (2). (A): 09917M47020
2) Connect special tool (A) to brake booster.
3
Special tool
(A): 09917M47020 (A)
(A)
2 IMTA0A410046-01
3. Adapter included in special tool

1
IMTA0A410046-01
4) Apply vacuum to brake booster (1) by special tool
and check for continuity between switch terminal and
1. Brake booster switch 3. Adapter included in special tool
ground at each specified negative pressure in the
following table.
3) 3)Connect SUZUKI scan tool to DLC (1).
5) If the tester reading is not as shown in the table,
Special tool replace brake booster assembly with new one.
: SUZUKI scan tool (Suzuki SDT-II)
Brake booster switch reference value
(A)
Negative pressure Scan tool display
30.7 kPa (0.3 kgf/cm2, 4.45 psi) Continuity exists
38.7 kPa (0.4 kgf/cm2, 5.61 psi) No continuity
3
1
IMTA0A140005-01
4) Set ignition “ON”, and select “Brake Booster Vacuum

Condition” in “Data list” mode under “ECM” on
SUZUKI scan tool. 2
1
5) Check data displayed on SUZUKI scan tool at each
negative pressure specified. If the data displayed is
not as shown in the table, replace brake booster IMTA0A410048-02
assembly with new one. 2. Brake booster switch 3. Circuit tester
Brake booster switch reference value Brake Booster Pressure Sensor Inspection
Negative pressure Scan tool display (ESP® Model)
30.7 kPa (0.3 kgf/cm2, 4.45 psi) Value Lo AENNTA0E4106026 (08(03)
Reference: “Precautions for Electrical System Work” Using Circuit Tester

Reference: “Precautions for Electrical Circuit Service” 1) Remove brake booster with brake master cylinder
assembly (1). (Brake Booster Removal and
! CAUTION
Installation)
• If excessive vacuum is applied, the brake 2) Check brake booster pressure sensor output voltage
booster pressure sensor may be damaged. as follows.
Do not exceed a vacuum of –90 kPa (–0.9 If check result is not as specified, replace brake
kgf/cm2, –13.0 psi, –0.9 bar). booster.
• Do not remove brake booster sensor.
NOTICE
Removal and reinstallation will spoil its
original performance. Specified input voltage of this brake booster
If faulty condition is observed, replace pressure sensor is between 4.8 and 5.2 V.
brake booster assembly with new one. Therefore, arrangement of three 1.5 V dry
batteries (4.5 V) is not enough, and four 1.5 V
Using SUZUKI Scan Tool dry batteries (6 V) exceeds the limit which
may affect the sensor.
Use four 1.2 V chargeable batteries for this
check.
2) Set ignition “ON”, and select “Brake Booster
Pressure Sensor” in “Data list” mode on SUZUKI a) Arrange four 1.2 V chargeable batteries (3) in
scan tool. series and check that total voltage is 4.8 – 5.2 V.
3) Check parameter displayed on SUZUKI scan tool at b) Connect special tool, voltmeter (4) and batteries
each negative pressure specified. Refer to “Scan to brake booster and brake booster pressure
Tool Data” in Section 4F. sensor (2) as shown in figure and set the tool in
If the parameter is not as shown in the table, check “VACUUM” mode.
the following points.
• Brake booster pressure sensor (1) and grommet NOTE
(2) for installation Before using special tool (vacuum pump
• Grommet damage gauge), read its Operator’s Manual to know
how to use it.
• Wiring and connection
• Brake vacuum hose (3) Special tool
• Brake booster pressure sensor: (Using Circuit (A): 09917M47020
Tester) c) Check that voltage varies gradually when
• Brake booster (4): (Brake Booster Inspection) negative pressure is gradually applied with
special tool.
3
Vacuum sensor reference voltage
Negative pressure 0 kPa (0.0 kgf/cm2, 0.0 psi,
0.0 bar): Approx. 0.5 V
Negative pressure –70 kPa (–0.7 kgf/cm2, –
10.2 psi, –0.7 bar): Approx. 2.3 V
2 4
IMTA0A410052-01
(A)
1 2 3
IMTA0A410054-02
5. Adaptor included in special tool
Specifications
AENNTA0E4107001 (09(t)
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Brake booster nut 13 1.3 9.5 (T4A001) / (T4A006)
Brake pedal bracket nut 13 1.3 9.5 (T4A002) / (T4A007)
Brake master cylinder fixing nut 13 1.3 9.5 (T4A003)
Brake pipe flare nut (ABS model) 16 1.6 12.0 (T4A004)
Brake pipe flare nut (ESP® model) 21 2.1 15.5 (T4A005)
Push rod nut 26 2.7 19.5 (T4A008)
Reference:
“Brake Pedal Components”
“Brake Flexible Hose and Pipe Components”
“Brake Master Cylinder Components”
“Brake Booster Components”

AENNTA0E4108001 (11(m)
NOTE
“Brake Master Cylinder Components”
Special Tool
AENNTA0E4108002 (11(s)
09917M47020 09918M78230
Vacuum pump gauge set Master cylinder leakage
tester
(L4A009) / (L4A011) / (L4A005) / (L4A007)
(L4A012)
09922M85811 09950M78220
Spring pin remover (4.5 mm) Flare nut wrench (10 x 12
mm)
(L4A003) / (L4A004) (L4A001) / (L4A002)
09952M48010 SUZUKI scan tool (Suzuki

SDT-II)
Master cylinder attachment —
adapter
(L4A006) / (L4A008) (L4A010)
Front Brakes: 4B-1
Front Brakes
Brakes
General Description
Front Brake Description
AENNTA0E4201001 (03(01)
Front brake system is of a ventilated disc brake type.
Repair Instructions
Front Brake Components
AENNTA0E4206001 (12(01)
4B-2 Front Brakes:
19
17
18
16
13 (c)
15
(d) (a)
14
1
(b)
5 3
12
11
10
9
7
8
9
ILSD0A420001-02
Front Brakes: 4B-3
1. Front brake caliper 9. Shim 17. Front brake disc dust cover
: If brake pads are replaced, use new shim included
in supply parts.
2. Front brake caliper carrier 10. Piston boot 18. Front wheel hub
: Apply small amount of rubber grease included in
piston seal set of supply parts or specified brake fluid.
3. Pin boot 11. Piston seal 19. Steering knuckle
: Apply small amount of rubber grease included in
piston seal set of supply parts or specified brake fluid.
4. Slide pin without bush 12. Brake piston : 27 Nm (2.8 kgf-m, 20.0 lbf-ft)
: Apply rubber grease included in pin : Apply small amount of rubber grease included in
boot set of supply parts. piston seal set of supply parts or specified brake fluid.
5. Slide pin with bush 13. Bleeder plug : 85 Nm (8.7 kgf-m, 63.0 lbf-ft)
: Apply rubber grease included in pin
boot set of supply parts.
6. Pad spring 14. Flexible hose gasket : 8.5 Nm (0.86 kgf-m, 6.2 lbf-ft)
7. Inner brake pad 15. Front brake flexible hose : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
8. Outer brake pad 16. Front brake disc : Do not reuse.
Front Brake Pad On-Vehicle Inspection • Avoid depressing the brake pedal during
AENNTA0E4206002 (08(03) the front brake pad removal procedure to
Check pad linings (1) periodically according to
prevent the brake piston from being forced
maintenance schedule and whenever wheels are
out of the cylinder.
removed (for tire rotation or other reason). Check lining
thickness of outside and inside pads.
NOTE
If lining is worn and its thickness (“a” in figure) is less
than the limit, all pads must be replaced at the same • Check for leakage of brake fluid when
time. removing front brake pads and repair front
brake caliper if leakage is found.
Front brake pad thickness (lining thickness) “a”
Standard: 10 mm (0.39 in.) • Replace all brake pads at the same time
Limit: 1.5 mm (0.06 in.) even if only one pad is defective.
Removal
Reference: “Front Brake Pad On-Vehicle Inspection”
2) Remove front brake caliper pin bolts (1).
I2RH01420001-01
Front Brake Pad Removal and Installation IA1J0P420002-01

AENNTA0E4206003 (08(01)
Reference: “Front Brake Components” 3) Remove front brake caliper (1) from front brake
caliper carrier (2).
NOTICE
Failure to take proper precautions during NOTICE
front brake caliper removal may cause If the removed front brake caliper (1) is left
damage to the front brake flexible hose and/ hung by the front brake flexible hose (6), the
or the brake piston. front brake flexible hose may be damaged
• Be careful not to damage the front brake due to the tension caused by the caliper’s
flexible hose during front brake pad weight.
removal. Hang a removed front brake caliper with a
wire hook (4) or the like to relieve the front
brake flexible hose of the tension.
4B-4 Front Brakes:
4) Remove front brake pads (3) and pad springs (5)

from front brake caliper carrier (2).
4
5
3
6
5
2
IFRA0B420002-01
1 2 NOTE
ILSD0A420002-02 Install inner pad at vehicle center side of
caliper carrier with its wear indicator (1)
Installation positioned upside.
Reference: “Front Brake Disc Inspection”
Reference: “Front Brake Caliper Inspection”
1) Install pad springs (1) to front brake caliper carrier
(2).
IBP80A420003-01
2) Fit shims (1) to front brake pads (2).

ILSD0A420006-02
[A] [B]
4) Install front brake caliper to front brake caliper carrier
2 and tighten caliper pin bolts (1) to specified torque.
2
Tightening torque
Front brake caliper pin bolt (a): 27 N·m (2.8 kgf-
m, 20.0 lbf-ft)
1
1
ILSD0A420005-02
[A]: Inside [B]: Outside
3) Install front brake pads (1) with shims to front brake 1,(a)
caliper carrier (2) as shown in figure.
IBP80A420007-01
5) Install front wheel. (Wheel (with Tire) Removal and

6) Check that brake system operates properly.
Front Brake Pad Inspection

AENNTA0E4206004 (08(03)
Brake Pad
Reference: “Front Brake Caliper Inspection”
Front Brakes: 4B-5
NOTICE
If the front brake pad lining is polished with 1
sandpaper, abrading particles will be
embedded in the lining and will damage the
front brake disc.
Do not polish pad lining with sandpaper.
2
Replace the front brake pad with a new one.
NOTE
• Check for leakage of brake fluid when
removing front brake pads and repair front I9P60A420030-01
brake caliper if leakage is found. 3) Pull off front brake disc (2) by M8 bolts (1).
• Replace all brake pads at the same time
even if only one pad is defective.
Check thickness of each front brake pad lining. If any

lining is thinner than limit or is excessively worn on one
side, replace all front brake pads.
Front brake pad thickness (lining thickness) “a”
Standard: 10 mm (0.39 in.)
Limit: 1.5 mm (0.06 in.)
“a”
2
IFRA0A420002-01
Installation
Reference: “Front Brake Disc Inspection”
NOTICE
IDAA0A420036-01 If the front brake flexible hose is twisted, the
hose will be damaged.
Front Brake Disc Removal and Installation If the front brake flexible hose is twisted,
AENNTA0E4206005 (08(01)
Reference: “Front Brake Components” reinstall front brake caliper being careful not
to let front brake flexible hose get twisted.
NOTICE
1) Install front brake disc to front wheel hub.
Failure to take proper precautions during
front brake caliper removal may cause 2) Install front brake caliper to steering knuckle and
damage to the front brake flexible hose and/ tighten front brake caliper carrier bolts (1) to
or the brake piston. specified torque.
• Hang removed front brake caliper with a Tightening torque
wire hook or the like not to twist the front Front brake caliper carrier bolt (a): 85 N·m (8.7
brake flexible hose during front brake kgf-m, 63.0 lbf-ft)
caliper removal.
• Avoid depressing the brake pedal during 1, (a)
the brake disc removal procedure to
prevent the brake piston from being forced
out of the cylinder.
Removal
2) Remove front brake caliper carrier bolts (1) and
remove front brake caliper (2) from steering knuckle.
IFRA0A420003-01
4B-6 Front Brakes:
3) Install front wheel. (Wheel (with Tire) Removal and NOTICE

Installation) in Section 2D Failure to take proper precautions during
4) Check that brake system operates properly. front brake caliper removal may cause
damage to the front brake flexible hose and/
Front Brake Disc Inspection or the brake piston.
AENNTA0E4206006 (08(03)
Reference: “Front Brake Disc Removal and Installation” • Be careful not to damage the brake front
brake flexible hose during front brake
Front Brake Disc caliper removal.
• Using magnetic stand (1), set dial gauge (2) with prod • Avoid depressing the brake pedal during
positioned about 10 mm (0.39 in.) inward from the front brake caliper removal procedure
periphery of disc, measure deflection of disc. If it to prevent the brake piston from being
exceeds the limit, correct or replace the front brake forced out of the cylinder.
disc.
Removal
Front brake disc deflection 1) Hoist vehicle and remove front wheel. (Wheel (with
Limit: 0.10 mm (0.004 in.) Tire) Removal and Installation) in Section 2D
1
2) Place a container below caliper to catch brake fluid.
3) Remove flexible hose joint bolt (1) from front brake
caliper (2).
2
1
IFRA0A420004-01 2
• Using micrometer, measure thickness of front brake
disc. If it is less than limit, replace front brake disc.
Front brake disc thickness “a”
Standard: 20.0 mm (0.78 in.) IDL10A420002-01
Limit: 18.0 mm (0.70 in.) 4) Remove front brake caliper pin bolts (1).
5) Remove front brake caliper (2) from front brake
“a”
2
1
IAP70A420011-01
3
Front Brake Caliper Removal and Installation IA1J0P420011-01
AENNTA0E4206007 (08(01)
Reference: “Front Brake Components”
Installation
! WARNING Reference: “Front Brake Caliper Inspection”
Removing front brake flexible hose gasket NOTICE

cannot assure adequate sealing. If the gasket If the front brake flexible hose is twisted, the
is reused, brake fluid may leak, which could hose will be damaged.
result in an accident. If the front brake flexible hose is twisted,
Always use new flexible hose gasket when reinstall front brake caliper being careful not
reinstalling the flexible hose. to let front brake flexible hose get twisted.
Front Brakes: 4B-7
1) Install front brake caliper to front brake caliper Disassembly

carrier. Caliper
Tighten front brake caliper pin bolts (1) to specified 1) Clean surfaces around caliper with brake cleaner
torque. before disassembly.
Tightening torque 2) Remove brake piston by blowing air into the hole for
Front brake caliper pin bolt (a): 27 N·m (2.8 kgf- front brake flexible hose joint bolt.
m, 20.0 lbf-ft)
! CAUTION
If you place your fingers in front of the piston
when you push it out with compressed air,
1, (a)
you may hurt your fingers.
Do not place your fingers in front of the
piston when removing it using compressed
air.
NOTICE
Using compressed air that is under high
pressure can force the disc brake piston
IDL10A420003-02 quickly out of the cylinder and damage the
2) Connect brake flexible hose (1) with new flexible piston.
hose gaskets (2) to caliper as shown in figure. Use a moderate air pressure to push the
Tighten flexible hose joint bolt (3) to specified torque. piston out of the cylinder slowly. In addition,
place a cloth (1) in front of the piston to
Tightening torque prevent it from being damaged.
Front brake flexible hose joint bolt (a): 23 N·m (
2.3 kgf-m, 17.0 lbf-ft)
NOTICE
Check that drive wheels are in straight ahead
position while installing brake flexible hose.
Do not twist brake flexible hose while
installation.
1
I2RH01420011-01
3) Remove piston boot (1) and bleeder plug (2) from

brake caliper (3).
3, (a) 1
2
2
3
IGSD0A420001-01
3) Fill reservoir with brake fluid and bleed brake

system. (Air Bleeding of Brake System) in Section
4A
4) Check that there is no leakage of the brake fluid.
5) Install front wheel. (Wheel (with Tire) Removal and 1
IDL10A420005-01
6) Check that brake system operates properly. 4) Remove piston seal (1) from cylinder of front brake
caliper (3) using flat-bladed screwdriver (2) or the
Front Brake Caliper Disassembly and like.
Reassembly
AENNTA0E4206008 (08(02)
Reference: “Front Brake Components”
4B-8 Front Brakes:
NOTICE
If the inside surface of the cylinder (bore Caliper
wall) and outside surface of piston are 1) Perform the following steps before installing brake
damaged, brake fluid leakage may result. piston to front brake caliper.
Be extremely careful not to damage the a) Check entire periphery of brake piston and inside
inside surface of the cylinder and outside surface of cylinder for rust, corrosion and any
surface of piston when removing the piston other damage. If check result is not OK, replace
seal. brake piston and/or front brake caliper.
b) After applying rubber grease included in piston
3 seal set of supply parts or specified brake fluid to
new piston seal (1), fit the seal into groove in
1 cylinder taking care not to twist the seal.
Brake fluid specification
Refer to reservoir cap of brake master
cylinder or Owner’s Manual.
1
2
I9P60A420026-01
Slide pin
Remove slide pins (1) and pin boots (2) from front brake
1
I2RH01420017-01
c) Apply rubber grease included in piston seal set

2 of supply parts or specified brake fluid to new
3
cylinder boot (1). And then install it onto brake
piston as shown.
[B] [A]
IDAA0A420025-01
Reassembly
! WARNING
I9P60A420019-01
Failure to take proper precautions when [A]: Caliper cylinder side [B]: Brake pad side
assembling the brake caliper can result in
brake system failure, which could lead to an 2) Fit piston boot (1) with piston into boot groove in
accident. cylinder by hand as shown below.
• 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
cylinder boot to the cylinder, apply rubber
grease included in the piston seal set or
brake fluid to them. IAP70A420017-01
• Fit a new piston seal securely into the 3) Insert brake piston (1) into cylinder by hand and fit
groove of the cylinder checking that it is cylinder boot (2) in boot groove on brake piston.
not twisted.
Front Brakes: 4B-9
NOTE c) Apply rubber grease included in pin boot set of

Check that boot is securely fitted in boot supply parts to slide pin (1).
grooves in piston and cylinder.
IAW101420005-01
2) Install slide pin without bush (1) into upper side and
slide pin with bush (2) into lower side of front brake
caliper carrier (3) as shown.
3
IAP70A420018-01
4) To check that piston boot (2) is fitted in its groove in

cylinder properly, pull piston (1) a little outward
[A]
without moving it fully out. 1
IDAA0A420032-01
[A]: Upward
Front Brake Caliper Inspection

AENNTA0E4206009 (08(03)
IAP70A420019-01 NOTE
5) Insert piston into cylinder by hand. Perform this inspection in the following
6) Install bleeder plug to front brake caliper and tighten cases.
it to specified torque. • When replacing front brake pads with new
Tightening torque ones.
Bleeder plug: 8.5 N·m (0.86 kgf-m, 6.2 lbf-ft) • When checking thickness of front brake
pads.
Slide pin • Before reassembling front brake caliper.
1) Check the following points before installing slide pins
to front brake caliper carrier. Caliper Body and Carrier
a) Check slide pins for rust, corrosion and other Check brake caliper body and carrier for deformation,
damage. Replace slide pin if defective. crack, damage and rust. Replace front brake caliper and
carrier if defective.
b) Install pin boots to front brake caliper carrier (2)
with their ends directed as shown below.
Cylinder Boot
1
Check cylinder boot (1) for break and crack. Replace
cylinder boot if defective.
IDL10A420006-01
I8RW01420003-01
4B-10 Front Brakes:
Slide Pin
Before installing caliper to carrier (2), check slide pins (1)
for smooth thrust movement.
ILSD0A420010-01
Specifications
AENNTA0E4207001 (09(t)
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Front brake caliper pin bolt 27 2.8 20.0 (T4B001) / (T4B003)
Front brake caliper carrier bolt 85 8.7 63.0 (T4B002)
Front brake flexible hose joint bolt 23 2.3 17.0 (T4B004)
Bleeder plug 8.5 0.86 6.2 (T4B005)
Reference:
“Front Brake Components”

AENNTA0E4208001 (11(m)
NOTE
“Front Brake Components”
Rear Brakes: 4C-1
Rear Brakes
Brakes
General Description
Rear Brake Description
AENNTA0E4301001 (03(01)
The rear brake is of a leading-trailing drum type.
Repair Instructions
Rear Brake Components
AENNTA0E4306001 (12(01)
13 (d)
17
(c)
16 (b)
9
10 15
14
(c)
7
11
5 4
8 6
12
(a)
3
6
2
8
ILSD0A430001-01
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 (7.8 kgf-m, 56.8 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)
4C-2 Rear Brakes:
4. Brake adjuster (strut) 12. Parking brake cable : 11 Nm (1.1 kgf-m, 8.1 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 : Do not reuse.
7. Shoe set pin 15. Rear axle
8. Shoe hold down retainer 16. Bleeder plug
Installation
Rear Brake Shoe On-Vehicle Inspection Reference: “Rear Brake Drum and Shoe Inspection”
AENNTA0E4306002 (08(03)
1) Check that inside of rear brake drum and rear brake
Amount of brake shoe wear can be checked as follows.
shoes are free from dirt and oil.
1) Hoist vehicle.
2) Check outer diameter “a” of brake shoes. If it is out
2) Remove rubber cover (plug) (1) from brake backing of the specified range below, adjust it by turning
plate. adjuster (1).
3) Through hole in backing plate, visually check for Brake shoes outer diameter “a” = measured brake
thickness “a” of brake shoe lining (2). If brake shoe drum inside diameter – 0.5 to 1.0 mm (0.02 to 0.04
lining is found significantly worn, check rear brake in.)
shoe lining thickness as follows.
a) Remove rear brake drum. (Rear Brake Drum “a”
b) Check rear brake shoe lining thickness referring
to “Rear Brake Shoe” under “Rear Brake Drum
and Shoe Inspection”.
Rear brake shoe lining thickness “a”
Standard: 4.2 mm (0.16 in.)
Limit: 1.0 mm (0.04 in.)
1
IBP80A430002-01
3) Install rear brake drum to rear wheel hub assembly.

4) Adjust parking brake cable referring to “Parking
Brake Adjustment” in Section 4D.
5) Install rear wheel referring to “Wheel (with Tire)
Removal and Installation” in Section 2D.
1 6) Check that brake drum does not drag and brake
I4RS0B430004-01 provides proper braking. Perform brake test (foot
brake and parking brake).
Rear Brake Drum Removal and Installation
AENNTA0E4306003 (08(01) Rear Brake Drum and Shoe Inspection
Removal AENNTA0E4306004 (08(03)
Reference: “Rear Brake Shoe On-Vehicle Inspection” Reference: “Rear Brake Drum Removal and Installation”
1) Hoist vehicle and remove rear wheel. (Wheel (with
Tire) Removal and Installation) in Section 2D Rear Brake Drum
2) Release parking brake. • Check rear brake drum for damage, deformation and
cracks. If check result is not OK, replace brake drum
3) Remove rear brake drum (2) by screwing M8 bolts
with new one.
(1) evenly.
• Check brake drum for wear.
If drum inner diameter exceeds the limit or uneven or
2 stepped wear is excessive, replace brake drum with
new one.
Rear brake drum inner diameter “a”
Standard: 200 mm (7.87 in.)
Limit: 202 mm (7.95 in.)
1
IFRA0A430001-02
Rear Brakes: 4C-3
“a”
ILSD0A430002-01
I9P60A431006-01
3) Remove shoe return springs, brake shoes and brake
Rear Brake Shoe adjuster.
• Check surface of lining (1) for hardening, excessive 4) Disconnect brake shoe lever (1) from parking brake
wear, peel-off and oil. cable (2).
• Measure brake shoe thickness “a” (not including
backing plate) at least three points (2). 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: 4.2 mm (0.16 in.)
Limit: 1.0 mm (0.04 in.)
2
1
2 IBP80A430004-01
Installation
“a”
1 Reference: “Rear Brake Drum and Shoe Inspection”
I9P60A431014-01
• Before installing brake shoes to brake backing plate,
2. Inspection point
clean brake backing plate and apply grease “A”.
“A”: Heat-resistant brake grease
Rear Brake Shoe Removal and Installation
AENNTA0E4306005 (08(01)
Reference: “Rear Brake Components”
NOTE
Replace both right and left brake shoes as a
“A” “A”
set.
Removal
1) Remove rear brake drum. (Rear Brake Drum
Removal and Installation) I9P60A431009-02
2) Pushing and turning shoe hold down retainer (1), • Connect brake shoe lever to parking brake cable
remove shoe hold down retainer, shoe set pin (2) securely.
and hold down spring (3) at both sides. • Install rear brake drum. (Rear Brake Drum Removal
and Installation)
4C-4 Rear Brakes:
• Adjust parking brake cable. (Parking Brake

Adjustment) in Section 4D 1
• Check that brake drum is free from dragging and
check that brake system operates properly.
Rear Brake Adjuster and Brake Shoe Lever

Check
AENNTA0E4306006 (08(03)
Reference: “Rear Brake Shoe Removal and Installation”
• 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
weakening.
I9P60A431010-01
• Check for smooth movement of brake shoe lever (2)
along shoe rim. 3) Remove wheel cylinder mounting bolts. Disconnect
If check result is not OK, repair or replace brake adjuster brake pipe from wheel cylinder and put bleeder plug
and/or brake shoe lever. cap (1) onto pipe to prevent fluid from spilling.
1
2
IBP80A430005-01
Wheel Cylinder Removal and Installation I9P60A431011-01

AENNTA0E4306007 (08(01)
Installation
NOTICE Reference: “Wheel Cylinder Inspection”
Brake fluid is extremely damaging to painted Reverse removal procedure noting the following points.
surfaces. If brake fluid contacts any painted • Install wheel cylinder to brake backing plate (1), and
surface, immediately wipe it off and flush the then connect brake pipe (2) to wheel cylinder.
surface with water thoroughly. • Tighten wheel cylinder mounting bolts (3) and rear
brake pipe flare nut (4) to specified torque.
Removal
1) Remove rear brake shoes. (Rear Brake Shoe Tightening torque
Removal and Installation) Wheel cylinder mounting bolt (a): 10 N·m (1.0 kgf-
m, 7.5 lbf-ft)
2) Loosen brake pipe flare nut (1) but limit loosening to
Rear brake pipe flare nut (b): 16 N·m (1.6 kgf-m,
on extent in which fluid does not leak.
12.0 lbf-ft)
Special tool
: 09950M78220
Rear Brakes: 4C-5
2) Remove parking brake cable cap nut (1) and parking

3, (a) 1 brake cable (2) from brake backing plate.
3, (a)
4, (b)
IFRA0A430004-02
3) Remove rear wheel hub assembly. (Rear Wheel Hub

Assembly Removal and Installation): Rear in Section
IFRA0A430003-01
3A
• Install rear brake drum. (Rear Brake Drum Removal
4) Remove brake backing plate.
and Installation)
• Bleed brake system. (Air Bleeding of Brake System) Installation
in Section 4A Reverse removal procedure noting the following points.
• Adjust parking brake cable. (Parking Brake • Install brake backing plate and rear wheel hub
Adjustment) in Section 4D assembly. (Rear Wheel Hub Assembly Removal and
• Check that brake drum is free from dragging and Installation): Rear in Section 3A
check that brake system operates properly. • Install parking brake cable (1) to brake backing plate.
• Tighten parking brake cable cap nut (2) to specified
Wheel Cylinder Inspection torque.
AENNTA0E4306008 (08(03)
Reference: “Wheel Cylinder Removal and Installation” Tightening torque
• Check wheel cylinder for fluid leakage and boots for Parking brake cable cap nut (a): 11 N·m (1.1 kgf-
breakage, crack and damage. If check result is not m, 8.1 lbf-ft)
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. 1
2, (a)
IFRA0A430005-02
• Install rear brake drum. (Rear Brake Drum Removal

I7V20A430004-02 and Installation)
• Bleed brake system. (Air Bleeding of Brake System)
Brake Backing Plate Removal and Installation in Section 4A
AENNTA0E4306009 (08(01)
• Adjust parking brake cable. (Parking Brake
Inspection) in Section 4D
Removal • Check that brake drum is free from dragging and
check that brake system operates properly.
1) Remove wheel cylinder. (Wheel Cylinder Removal
and Installation)
Specifications
AENNTA0E4307001 (09(t)
4C-6 Rear Brakes:
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Wheel cylinder mounting bolt 10 1.0 7.5 (T4C001)
Rear brake pipe flare nut 16 1.6 12.0 (T4C002)
Parking brake cable cap nut 11 1.1 8.1 (T4C003)
Reference:
“Rear Brake Components”

AENNTA0E4308001 (11(m)
Heat-resistant brake — — (M4C001)
grease
NOTE
“Rear Brake Components”
Special Tool
AENNTA0E4308002 (11(s)
09950M78220
Flare nut wrench (10 x 12
mm)
(L4C001)
Parking Brake: 4D-1
Parking Brake
Brakes
General Description
Parking Brake Description
AENNTA0E4401001 (03(01)
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
AENNTA0E4406001 (12(01)
(b)
(b)
(b)
(b) (b)
4
(a)
1 (b)
2
5
2 4
(b)
3
6
(b)
IMTA0A440002-01
1. Parking brake lever 4. Parking brake cable : 26 Nm (2.7 kgf-m, 19.5 lbf-ft)
2. Equalizer 5. Brake shoe lever : 11 Nm (1.1 kgf-m, 8.5 lbf-ft)
3. Parking brake cable end (equalizer side) 6. Parking brake cable end (shoe lever side)
• With parking brake lever pulled up, check the

Parking Brake Inspection following items. If check result is not OK, adjust or
AENNTA0E4406002 (08(03) replace parking brake cable.
NOTE
a. Operation of parking brake lever is smooth.
Check the following conditions before b. Rear wheels are locked firmly.
parking brake inspection and adjustment.
c. Operate parking brake lever with force of 200 N
• No air is trapped in brake system. (20.4 kgf, 45.0 lbf) as shown, counting number of
• Brake pedal travel is proper. clicks ratchet notches generate.
• Rear brake shoes are not worn beyond
NOTE
limit.
One click sound corresponds to one notch.
4D-2 Parking Brake:
Parking brake stroke “a”

When lever pulled up at 200 N (20.4 kgf, 45.0
lbf): 4 to 9 notches
1
2
“a”
IGSD0A440002-02
7) After completion of adjustment, check that brake

drum is not dragging.
Parking Brake Cable Removal and Installation

I7V20A440002-01 AENNTA0E4406004 (08(01)
• Release parking brake lever and check that brake Reference: “Precautions for Electrical System Work”
warning light turns off. Then check that brake warning
light turns on within 1 notch when parking brake lever Removal
is pulled up. If check result is not OK, check and, if 1) Disconnect parking brake cable from brake shoe
necessary, repair the following items. lever. (Rear Brake Drum Removal and Installation) in
Section 4C
NOTE
2) Remove floor console rear box. (Center Console
• Warning light should be checked when Box Removal and Installation) in Section 9H
ignition is “ON”. 3) Remove heat insulator. (Exhaust System
• Check that ABS warning light is turned off. Components) in Section 1K
4) Disconnect parking brake cable from vehicle.
a. Remaining amount of brake fluid (Brake Fluid (Parking Brake Components)
Level Inspection) in Section 4A
b. Brake fluid switch (attached to brake master NOTE
cylinder reservoir) (Brake Fluid Level Switch If necessary to remove both right and left
Inspection) in Section 4A parking brake cables, repeat above steps.
c. Parking brake switch (Parking Brake Switch
Inspection)
Installation
Parking Brake Adjustment
AENNTA0E4406003 (08(03) • Install clamps properly. (Parking Brake Components)
• Tighten each bolt to specified torque. (Parking Brake
1) Remove floor console rear box. (Center Console Components)
Box Removal and Installation) in Section 9H
• Check that parking brake cable end is installed to
2) Release parking brake. equalizer and brake shoe lever securely.
3) Loosen parking brake adjusting nut (1) until parking • Adjust parking brake cable. (Parking Brake
brake cable becomes free of tension. Adjustment)
4) Start engine and depress brake pedal more than 15 • After completion of the installation and adjustment of
times with about 150 N (15.3 kgf, 33.7 lbf) to obtain parking brake lever stroke, check that brake system
proper drum-to-shoe clearance. operates properly.
5) Stop engine and adjust parking brake lever stroke to
specified value with adjusting nut (1). Parking Brake Lever Removal and Installation
AENNTA0E4406005 (08(01)
6) Check equalizer (2) inclination angle. If angle is not
as specified, check parking brake cable and rear
brake shoe linings. (Rear Brake Drum and Shoe
Removal
1) Place gear shift lever in “1st” (M/T model) or shift
Equalizer inclination angle selector in “D” range (AGS model), and block drive
“a”: within 15 degrees wheels.
Parking Brake: 4D-3
2) Remove floor console rear box. (Center Console

Box Removal and Installation) in Section 9H
3) Disconnect parking brake switch connector from
parking brake lever.
4) Loosen parking brake cable adjusting nut (1).
1, (a)
1, (a)
IMTA0A440006-01
2) Connect parking brake cable to equalizer, and then

adjust parking brake cable. (Parking Brake
Adjustment)
3) Connect parking brake switch connector to parking
IMTA0A440004-01 brake lever.
5) Disconnect parking brake cables from equalizer. 4) Check that brake system operates properly.
6) Remove parking brake lever bolts (1) and then 5) Install floor console rear box. (Center Console Box
remove parking brake lever (2) together with Removal and Installation) in Section 9H
equalizer (3).
Parking Brake Switch Inspection
AENNTA0E4406006 (08(03)
Check for continuity between parking brake switch
terminal and vehicle body ground as shown in figure. If
2 check result is not as specified, replace parking brake
3
lever assembly.
Parking brake switch specification
Parking brake released: No continuity
Parking brake lever pulled up: Continuity exists
1
1
IMTA0A440005-01
Installation
1) Tighten parking brake lever bolts (1) to specified
torque.
Tightening torque
Parking brake lever bolt (a): 26 N·m (2.7 kgf-m, 1
19.5 lbf-ft)
I9P60A440007-02
1. Parking brake switch 2. Parking brake lever
Specifications
AENNTA0E4407001 (09(t)
4D-4 Parking Brake:
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Parking brake lever bolt 26 2.7 19.5 (T4D001)
Reference:
“Parking Brake Components”
ABS: 4E-1
ABS
Brakes
Precautions
Precautions for Diagnosing Trouble • When disconnecting ABS control module connector
AENNTA0E4500001 (01(01) (1), pull down the lock lever (2) of connector.
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”.
assembly and pull up the lock lever (2) 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.
– The vehicle is driven with brake dragging. [A] [D]
– The vehicle is stuck in mud, sand, etc.
– Wheel spins while driving. 2
[C]
– Wheels are rotated while the vehicle is jacked up. [B]
1
• Follow trouble diagnosis procedure described in “ABS IFRA0A450022-02
Check”. If trouble diagnosis procedure is not followed [A]: Pull down to unlock [C]: Connect
properly, incorrect diagnosis may result. (If incorrect [B]: Disconnect [D]: Pull up to lock
procedure is performed, other DTC may be stored in
the ABS hydraulic unit / control module assembly.)
General Description
ABS Description motor (2), reservoirs (6) and check valves (7). It
AENNTA0E4501001 (03(01) activates inlet and outlet solenoid valves by the
The ABS (Anti-lock Brake System) controls the fluid
signals from ABS hydraulic unit / control module
pressure applied to the caliper or wheel cylinder of each
assembly and controls the brake fluid pressure
brake from the master cylinder so that each wheel is not
applied on each wheel brake. (The following figure
locked even when hard braking is applied.
shows the circuit for one wheel, with inlet and outlet
This ABS is equipped with EBD (Electronic Brake force
solenoid valves in OFF positions.)
Distributions) function.
While brake pedal is depressed not so hard as to
1
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. 7
If the EBD control is deactivated, the brake system
warning light (red) lights to inform the driver of 7
3 2
abnormality.
4
7 5
ABS Hydraulic Unit / Control Module Assembly
• ABS hydraulic unit / control module assembly detects
wheel slip by the signal from wheel speed sensor of 8
6
each wheel and sends control signals to the hydraulic
unit.
ABS hydraulic unit / control module assembly also IFRA0B460028-01
monitors system conditions and stops the function of 1. Master cylinder 8. Caliper or wheel cylinder
ABS and lights the ABS warning light in case it judges
that the system is faulty. The hydraulic pressure control is performed in 3 modes:
• ABS hydraulic unit is composed of inlet solenoid pressure increase, pressure keeping and pressure
valves (4) (normally-opened valves), outlet solenoid reduction.
valves (5) (normally-closed valves), pumps (3), pump
4E-2 ABS:
• In the pressure increase mode, inlet and outlet • When no abnormality is detected (the system is in
solenoid valves are turned OFF, and the brake fluid good condition), these lights turn OFF after 2
pressure applied from the master cylinder to the seconds. However, when parking brake is applied,
caliper or wheel cylinder is increased. brake system warning light (red) remains ON.
• In the pressure keeping mode, the inlet solenoid valve • When an abnormality in the system is detected, ABS
is turned ON, and the brake fluid pressure in the warning light and/or brake system warning light (red)
caliper or wheel cylinder is kept constant. are turned ON and DTC is stored in ABS hydraulic
• In the pressure reduction mode, inlet and outlet unit / control module assembly.
solenoid valves are turned ON, and the brake fluid
[A]
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.
Wheel Speed Sensor

All wheel speeds are detected by the Magnetic
Resistive Effect element type wheel speed sensor (1)
and encoder (2). The wheel speed sensor is fixed to 2 1
each front steering knuckle and rear wheel hub
assembly.
The encoder consists of a permanent magnet which has [B]
south poles and north poles. As it is located on the wheel
hub it turns along with the wheel.
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.
IMTA0A450002-05
N 4
[A]: Segment display type [B]: Color dot display type
S
2 N
Fail-Safe Mode
S 1 3 If ABS hydraulic unit / control module assembly stores a
N DTC, ABS hydraulic unit / control module assembly
S stops ABS and/or EBD function corresponding to the
faulty area. It is possible to check the stopped function(s)
I8C50B450012-03 by the warning lights in combination meter. (Warning
3. Integrated circuit 4. Magnetic field lines Light Description)
Warning Light Description

AENNTA0E4501003 (03(01)
OBD System Description There are two warning lights controlled by ABS hydraulic
AENNTA0E4501002 (03(01)
ABS control module is built in ABS hydraulic unit / unit / control module assembly in combination meter.
control module assembly and has the following They give warning to driver by changing their modes:
functions. light ON / blinking / light OFF.
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 (1) and/or brake system warning light (red)
(2) are turned ON to inform the driver of the abnormality.
• When ignition is set “ON”, ABS warning light and
brake system warning light (red) turn on for 2 seconds
to check its circuit.
ABS: 4E-3
[A]
2 1
[B]
IMTA0A450002-05
[A]: Segment display type 1. ABS warning light

[B]: Color dot display type 2. Brake system warning light (red)
Condition and Operation of Warning Light

Warning light Condition and operation
ABS warning light If ABS has abnormality, the light turns “ON”.
Brake system warning light (red) • If EBD control is deactivated by ABS failure the light turns “ON”.
• 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
AENNTA0E4501004 (03(01)
Refer to “DLC Description” in Section 1A.
CAN Communication System Description

AENNTA0E4501005 (03(01)
Refer to “Communication System Description”: CAN in Section 10H.

ABS Diagram
AENNTA0E4502001 (10(03)
4E-4 ABS:
8
8
6
5
1 2
4
3
8
8
9 10 11
IFRA0A450025-01
1. ABS hydraulic unit / control module assembly 5. Other control modules (if equipped) 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 Input / Output Diagram

AENNTA0E4502002 (10(01)
ABS: 4E-5
INPUT OUTPUT
ABS hydraulic unit / control module assembly
Battery power supply Solenoid valve power

supply driver
Right-front inlet solenoid valve
Right-front outlet solenoid valve
Left-front inlet solenoid valve
Left-front outlet solenoid valve

Wheel speed sensor (Right-Front)
Solenoid valve Right-rear inlet solenoid valve
Wheel speed sensor (Left-Front) driver
Right-rear outlet solenoid valve
CPU
Wheel speed sensor (Right-Rear)
Left-rear inlet solenoid valve
Wheel speed sensor (Left-Rear)
Left-rear outlet solenoid valve
Pump motor Pump motor

driver
BCM (M/T–keyless push start model)
ECM
ECM
· Engine speed signal CAN driver · Wheel speed signal (Right or Left - front or rear)
· Brake light switch signal
BCM
BCM · Wheel speed signal (Right or Left - front or rear)
· Parking brake switch signal
Combination meter
Central gateway control module · Warning light signal (ABS/EBD)
: CAN communication DLC
Central gateway control module

IMTA0A450023-02
ABS Circuit Diagram

AENNTA0E4502003 (10(01)
4E-6 ABS:
4
24
RED
25
WHT
5
[C]
6
26
1
27
7 2
19
28
BRN E09-5
E09-1
E09-26
[B]
11 21
7 22
2
M
5
26 BLU 3
1 LT GRN
10 5
29 20
1 PNK YEL
BLK LT BLU
8 [D]
PPL E09-28
12
[A] E09 13
1
26
3 RED E09-3
28 15 2 7
4 WHT E09-15
29 16
5
30 17
6
31 18 GRN E09-20
7 15 23
32 19 BLK E09-34
8
33 20 E09-17
9 16 GRN
34 21 GRY E09-30
10
35 22 14
11 BRN E09-8
36 23 17
12 YEL E09-19
37 24
13
38 25 LT BLU E09-18
14 18
PNK E09-6
27
2
BLK E09-2
[a]
BLK E09-27
: 30 : 5V : 12V
IMTA0A450003-05
[A]: ABS hydraulic unit / control module assembly connector (View: [a]) 9. Brake light 21. Pump motor relay
[B]: Ignition switch model 10. Brake light switch 22. Pump motor
ABS: 4E-7
[C]: Keyless push start model 11. Steering angle sensor 23. Solenoid valve circuit
[D]: M/T–keyless push start model 12. Brake fluid level switch 24. “ABS MOT” fuse
1. From battery 13. Parking brake switch 25. “ABS SOL” fuse
2. To other control modules by CAN 14. Wheel speed sensor driver 26. “IG1 SIG” fuse
3. To ECM 15. Left-front wheel speed sensor 27. “DOME 2” fuse
4. Relay box 16. Right-front wheel speed sensor 28. “ABS” fuse
5. J/B 17. Left-rear wheel speed sensor 29. “STOP” fuse
6. Lighting and turn signal switch 18. Right-rear wheel speed sensor 30. Ground
7. CAN driver 19. ABS hydraulic unit / control module assembly
8. BCM 20. CPU
Terminal Wire color Circuit

1 WHT Solenoid valve power supply circuit
2 BLK ABS control module ground circuit
3 RED CAN communication line (high)
5 BRN Ignition power supply circuit
6 PNK Right-rear wheel speed sensor signal circuit
8 BRN Left-rear wheel speed sensor power supply circuit
15 WHT CAN communication line (low)
17 GRN Right-front wheel speed sensor power supply circuit
18 LT BLU Right-rear wheel speed sensor power supply circuit
19 YEL Left-rear wheel speed sensor signal circuit
20 GRN Left-front wheel speed sensor power supply circuit
26 RED Pump motor power supply circuit
27 BLK ABS control module ground circuit
28 PPL Vehicle speed output circuit
30 GRY Right-front wheel speed sensor signal circuit
34 BLK Left-front wheel speed sensor signal circuit
Component Location
ABS Component Location
AENNTA0E4503001 (04(01)
4E-8 ABS:
Engine compartment and exterior
10
9
2
4
7
8
5 6
IMTA0A450004-03
ABS: 4E-9
1. ABS hydraulic unit / control 5. Front wheel speed sensor 9. “ABS SOL” fuse
module assembly
2. ECM 6. Front wheel hub assembly incorporating front wheel 10. “ABS MOT” fuse
speed sensor encoder
3. Brake booster switch 7. Rear wheel speed sensor
4. Relay box 8. Rear wheel hub assembly incorporating rear wheel
Around instrument panel
5 4 5 4
3 3
[A] [B]
9
8
[C] [D]
11
12
1 2
10 13 8
IMTA0A450005-04
[A]: Segment display type 3. Combination meter 9. Brake light switch

[B]: Color dot display type 4. ABS warning light 10. “IG1 SIG” fuse
[C]: Non-auto-on headlight model 5. Brake system warning light (red) 11. “DOME2” fuse
[D]: Auto-on headlight model 6. P/S control module / motor assembly 12. “ABS” fuse
1. Steering angle sensor 7. BCM 13. “STOP” fuse
2. Lighting and turn signal switch 8. J/B

4E-10 ABS:
ABS Check
AENNTA0E4504001 (06(01)
Refer to the description after the following general flow for details of each step.
Step 1 Malfunction analysis (Step 1: Malfunction Analysis)

1) Perform “Customer complaint analysis”.
2) Perform “Problem symptom confirmation”.
3) Perform “DTC check, record and clearance” and recheck DTC.
Is the same DTC detected again after performing DTC clearance?
Yes Check and repair referring to applicable DTC troubleshooting, and then go to Step 6.
No Go to Step 2.

1) Perform “Step 2: Visual Inspection”.

No Go to Step 3.
Step 3 Road test

1) Perform “Step 3: Road Test”.
Is malfunction detected?

No Go to Step 4.
Step 4 Brake diagnosis

1) Check and repair brake system. (Step 4: Brakes Diagnosis)

No Go to Step 5.

1) Check for intermittent problems. (Step 5: Intermittent Problem)
Yes Repair or replace defective part, then go to Step 6.

No Go to Step 6.

1) Perform “Step 6: Final Confirmation Test”.
Yes Go to Step 4.
No End.
Step 1: Malfunction Analysis

Customer complaint analysis
Record details of the problem (failure, complaint) and how it occurred as described by the customer.
ABS: 4E-11
For this purpose, use of such a questionnaire form shown below table will facilitate collecting information required for
proper analysis and diagnosis.
Customer's name: Model: VIN:
Date of issue: Date of Reg: Date of problem: Mileage:
● ABS warning light abnormal: fails to turn on / fails to turn off

● Brake system warning light (red) abnormal
: fails to turn on / fails to turn off
● Abnormal noise while vehicle is running: from motor, from valve,
other___________________
● Wheel is locked at braking:

● Wheel skids at turning:
Problem Symptoms ● Pump motor does not stop (running):
● Braking does not work:
● Other:
● Continuous / Intermittent ( times a day, a month) /

Frequency of occurrence other______________
● Vehicle at stop & ignition “ON”:

● When starting: at initial start only / at every start / other ________________
Vehicle speed: while accelerating / while decelerating / while stopping /
while turning / while running at constant speed /
Conditions for other___________________
Occurrence of Problem ● Road surface condition: paved road / rough road / snow-covered road /
other______________________
● Chain equipment:
● Weather: fair / cloudy / rainy / snowy /other___________________

Environmental Condition ● Temperature: °C ( °F)
● First check: No DTC / DTC ( )
Diagnostic Trouble Code ● Second check after test drive: No DTC / DTC ( )
IMTA0A450024-01
Problem symptom confirmation When DTC which is recorded at DTC check procedure is
If symptom in “Customer Questionnaire” is found or detected again after performing DTC clearance, go to
reproduced in the vehicle, check that the symptom is “DTC Check” to perform the diagnosis.
problem or not. (This step should be done with the When DTC which is recorded at DTC check procedure is
customer if possible.) Check warning light related to not detected anymore after performing DTC clearance,
brake system referring to “Brake System Warning Light ABS control module does not perform the system
(Red) Check” and “ABS Warning Light Check” under diagnosis, or temporary abnormality may occur,
“Warning Light Check”. therefore go to “Step 3: Road Test” to proceed to the
diagnosis.
DTC check, record and clearance
Perform “DTC Check” procedure, record it and then Step 2: Visual Inspection
clear it. (DTC Clearance) As a preliminary step, perform visual check of the items
Recheck DTC. (DTC Check) that support proper function of the ABS. (Visual
Inspection)
4E-12 ABS:
Step 3: Road Test Step 5: Intermittent Problem

Perform Road Test as follows to check if each warning Check parts that are prone to cause intermittent trouble
light lights up. (e.g. wire harness, connector), referring to “Intermittent
1) Drive at 40 km/h (25 mph) for over two minutes. Connection and Poor Contact Inspection” in Section 00
and the related circuit of which DTC is recorded in Step 1
2) Turn right and left at over 10 km/h (6 mph) for over a
– 5.
second by turning steering wheel over 45 degrees.
3) Drive at 60 km/h (37 mph) for over three seconds. Step 6: Final Confirmation Test
4) Stop the vehicle using foot brake from driving at 60 Check that the problem symptom is not observed any
km/h (37 mph). more and ABS is free from any abnormal condition. If
what has been repaired is related to malfunction DTC,
Step 4: Brakes Diagnosis clear the DTC referring to “DTC Clearance”, perform
Check the parts or system suspected as a possible road test and confirm that the DTC is not indicated.
cause referring to “Brake System Description” in Section
4A and based on symptoms appearing on the vehicle
(symptoms observed through Step 1 – 3). Repair faulty
parts or replace them, if necessary).
Visual Inspection
AENNTA0E4504002 (06(01)
Battery Fluid level, leakage “Battery Description” in Section 1J
Connectors of electric “Intermittent Connection and Poor Contact Inspection” in
Disconnection, friction
wire harness Section 00
Fuses Burning —
Brake fluid Level, leakage “Brake Fluid Level Inspection” in Section 4A
ABS warning light Operation
Brake system warning Operation “Warning Light Check”
light (red)
ABS Symptom Diagnosis

AENNTA0E4504003 (06(04)
ABS warning light remains lit for more than 2 seconds after setting ignition “ON”
• Malfunctioning ABS function Perform ABS check. (ABS Check)
• Malfunctioning ABS warning light circuit Check ABS warning light circuit. (ABS Warning Light
Comes ON Steady)
ABS warning light does not turn ON after setting ignition “ON”
• Malfunctioning ABS function Perform ABS check. (ABS Check)
• Malfunctioning CAN communication system
function Check CAN communication system. (CAN Communication
Check): CAN in Section 10H
• Malfunctioning ABS warning light circuit Check ABS warning light circuit. (ABS Warning Light Does
Not Come ON after Setting Ignition “ON”)
ABS warning light blinks

• Improper air bleed from ABS hydraulic unit /
control module assembly Perform ABS hydraulic unit operation check. (ABS
Hydraulic Unit Operation Check)
Brake system warning light (red) remains lit for more than 2 seconds after setting ignition “ON”
• Parking brake applied Release parking brake and check that brake system
warning light (red) turns OFF.
ABS: 4E-13
• Insufficient amount of brake fluid Check brake fluid level. (Brake Fluid Level Inspection) in
Section 4A
• Faulty parking brake switch circuit and/or brake
fluid level switch circuit Check BCM and its circuit. (Inspection of BCM and Its
Circuits) in Section 10B
• Faulty parking brake switch and/or brake fluid level
switch Check parking brake switch and/or brake fluid level switch.
• Parking brake switch: (Parking Brake Switch Inspection)
in Section 4D
• Brake fluid level switch: (Brake Fluid Level Switch
• Malfunctioning EBD control Perform ABS check. (ABS Check)
• Faulty ABS control module power supply and
ground circuit Check ABS control module power supply and ground
circuits. (ABS Control Module Power Supply and Ground
Circuit Check)
• Malfunctioning CAN communication system Check CAN communication system. (CAN Communication
• Faulty BCM Check BCM and its circuit. (Inspection of BCM and Its
• Faulty ABS control module Replace ABS control module. (ABS Hydraulic Unit / Control
Module Assembly Removal and Installation)
• Malfunctioning brake system warning light (red)
circuit Check brake system warning light (red) circuit. (Brake
System Warning Light (Red) Comes ON Steady)
Brake system warning light (red) does not turn ON after setting ignition “ON”
• Malfunctioning EBD control Perform ABS check. (ABS Check)
System Warning Light (Red) Does Not Come ON after
Setting Ignition “ON”)
Warning Light Check

AENNTA0E4504004 (06(01)
ABS Warning Light
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””. If ABS
warning light remains ON and no DTC is stored in
ABS control module, go to “ABS Warning Light
Comes ON Steady”.
4E-14 ABS:
[A] [A]
1 1
[B] [B]
IMTA0A450006-02 IMTA0A450007-03
[A]: Segment display type [B]: Color dot display type [A]: Segment display type [B]: Color dot display type
Brake System Warning Light (Red) 5) Release parking brake lever and check that brake
system warning light (red) goes OFF. If brake system
NOTE warning light (red) remains ON and no DTC is stored
Perform this check on a level place. in ABS control module, go to “Brake System Warning
Light (Red) Comes ON Steady”.
1) Check brake fluid level. (Brake Fluid Level
Inspection) in Section 4A DTC Check
2) Pull parking brake lever. AENNTA0E4504005 (06(01)
3) Set ignition “ON”. 1) Connect SUZUKI scan tool to DLC. (Suzuki SDT-II
4) Check that brake system warning light (red) (1)
comes ON. If brake system warning light (red) never 2) Check DTC and follow the instructions displayed on
lights up, go to “Brake System Warning Light (Red) SUZUKI scan tool.
Does Not Come ON after Setting Ignition “ON””. Refer to Operator's Manual of SUZUKI scan tool for
further details.
NOTE
and ABS control module is not possible,
perform the following checks:
• Check communication condition between
PC and VCI using SUZUKI scan tool
function.
circuit.
• Check CAN communication circuit and
connectors between DLC and central
“Diagnosis flow: [a]” in “Troubleshooting”
of “Troubleshooting for Lost
Communication”: CAN in Section 10H.)
cable.
ABS: 4E-15
• Check CAN communication system. – Check CAN communication circuit and

(“Control Module Communication Bus Off” connectors between DLC and central
is detected in any control module.) gateway control module. (Refer to
(Troubleshooting for Communication Bus “Diagnosis flow: [a]” in
Off): CAN in Section 10H “Troubleshooting” of “Troubleshooting
• Check central gateway control module for Lost Communication”: CAN in
power supply circuit and ground circuit. Section 10H.)
(Inspection of Central Gateway Control – Check DLC cable. If necessary, check
Module and Its Circuits): CAN (Central DLC cable by substituting a known-good
Gateway) in Section 10H DLC cable.
• Check ABS control module power circuit – Check CAN communication system.
and ground circuit. (ABS Control Module (“Control Module Communication Bus
Power Supply and Ground Circuit Check) Off” is detected in any control module.)
(Troubleshooting for Communication
3) Disconnect SUZUKI scan tool from DLC. (Suzuki Bus Off): CAN in Section 10H
SDT-II Connection and Disconnection) in Section 0A – Check central gateway control module
DTC Clearance (Inspection of Central Gateway Control
AENNTA0E4504006 (06(01)
Module and Its Circuits): CAN (Central
1) Connect SUZUKI scan tool to DLC. (Suzuki SDT-II Gateway) in Section 10H
– Check ABS control module power circuit
2) Check DTC and follow the instructions displayed on and ground circuit. (ABS Control Module
SUZUKI scan tool. Power Supply and Ground Circuit
Refer to Operator's Manual of SUZUKI scan tool for Check)
further details.
NOTE current trouble is present. Solve the
trouble and check that the system is in
• If communication between SUZUKI scan normal condition referring to “Fail-safe
tool and ABS control module is not condition” under “Fail-Safe Table”. Clear
possible, perform the following checks: DTCs after changing current DTCs to
– Check communication condition history DTCs.
tool function. 3) Disconnect SUZUKI scan tool from DLC. (Suzuki
– Check DLC power circuit and ground SDT-II Connection and Disconnection) in Section 0A
circuit.
DTC Table
AENNTA0E4504007 (06(01)
NOTE
• Perform “ABS Check” before diagnosing DTC.
• Skipping “ABS Check” may show a false result.
• *: Whether ABS warning light or brake system warning light (red) lights up or not depends on DTC
detecting condition.
Brake
ABS system
DTC DTC name DTC detecting condition warning warning
light light
(red)
C1121-01 (DTC Right-Front Wheel Speed Sensor Wheel speed sensor signal is out of
C1121-01 / C1121- Circuit Voltage specified range.
92 / C1125-01 /
C1125-92 / C1131- Lights up OFF
01 / C1131-92 /
C1133-62 / C1135-
01 / C1135-92)
4E-16 ABS:
Brake
ABS system
light light
(red)
C1121-92 (DTC Right-Front Wheel Speed Sensor or Abnormal wheel speed sensor signal
C1121-01 / C1121- Encoder Signal Performance is detected continuously.
92 / C1125-01 /
01 / C1131-92 /
C1133-62 / C1135-
01 / C1135-92)
C1125-01 (DTC Left-Front Wheel Speed Sensor Wheel speed sensor signal is out of
92 / C1125-01 /
01 / C1131-92 /
C1133-62 / C1135-
01 / C1135-92)
C1125-92 (DTC Left-Front Wheel Speed Sensor or Abnormal wheel speed sensor signal
92 / C1125-01 /
01 / C1131-92 /
C1133-62 / C1135-
01 / C1135-92)
C1131-01 (DTC Right-Rear Wheel Speed Sensor Wheel speed sensor signal is out of
92 / C1125-01 /
01 / C1131-92 /
C1133-62 / C1135-
01 / C1135-92)
C1131-92 (DTC Right-Rear Wheel Speed Sensor or Abnormal wheel speed sensor signal
92 / C1125-01 /
01 / C1131-92 /
C1133-62 / C1135-
01 / C1135-92)
C1133-62 (DTC Wheel Speed Sensor Deviation Abnormal wheel speed sensor signal
C1121-01 / C1121- is detected continuously at two or
92 / C1125-01 / more wheel speed sensors.
C1125-92 / C1131- ABS control is activated for more
* *
01 / C1131-92 / than specified time.
C1133-62 / C1135- Wheel speed sensor driver power
01 / C1135-92) supply voltage is out of specified
range.
C1135-01 (DTC Left-Rear Wheel Speed Sensor Wheel speed sensor signal is out of
92 / C1125-01 /
01 / C1131-92 /
C1133-62 / C1135-
01 / C1135-92)
ABS: 4E-17
Brake
ABS system
light light
(red)
C1135-92 (DTC Left-Rear Wheel Speed Sensor or Abnormal wheel speed sensor signal
92 / C1125-01 /
01 / C1131-92 /
C1133-62 / C1135-
01 / C1135-92)
C1141-07 (DTC Right-Front Inlet Solenoid Valve Solenoid output and solenoid monitor
C1141-07 / C1142- Circuit Correlation data disagree.
07 / C1145-07 /
C1146-07 / C1151- Lights up Lights up
07 / C1152-07 /
C1155-07 / C1156-
07 / C1163-07)
C1142-07 (DTC Right-Front Outlet Solenoid Valve Solenoid output and solenoid monitor
07 / C1145-07 /
07 / C1152-07 /
C1155-07 / C1156-
07 / C1163-07)
C1145-07 (DTC Left-Front Inlet Solenoid Valve Circuit Solenoid output and solenoid monitor
C1141-07 / C1142- Correlation data disagree.
07 / C1145-07 /
07 / C1152-07 /
C1155-07 / C1156-
07 / C1163-07)
C1146-07 (DTC Left-Front Outlet Solenoid Valve Solenoid output and solenoid monitor
07 / C1145-07 /
07 / C1152-07 /
C1155-07 / C1156-
07 / C1163-07)
C1151-07 (DTC Right-Rear Inlet Solenoid Valve Solenoid output and solenoid monitor
07 / C1145-07 /
07 / C1152-07 /
C1155-07 / C1156-
07 / C1163-07)
C1152-07 (DTC Right-Rear Outlet Solenoid Valve Solenoid output and solenoid monitor
07 / C1145-07 /
07 / C1152-07 /
C1155-07 / C1156-
07 / C1163-07)
4E-18 ABS:
Brake
ABS system
light light
(red)
C1155-07 (DTC Left-Rear Inlet Solenoid Valve Circuit Solenoid output and solenoid monitor
C1141-07 / C1142- Correlation data disagree.
07 / C1145-07 /
07 / C1152-07 /
C1155-07 / C1156-
07 / C1163-07)
C1156-07 (DTC Left-Rear Outlet Solenoid Valve Solenoid output and solenoid monitor
07 / C1145-07 /
07 / C1152-07 /
C1155-07 / C1156-
07 / C1163-07)
C1157-1C (DTC Power Supply Voltage ABS control module power supply
C1157-1C) voltage is higher than specified
value. * *
ABS control module power supply
voltage is lower than specified value.
C1161-07 (DTC Pump Motor Circuit Performance Pump motor power supply voltage is
C1161-07) out of specified range.
Pump motor is activated although
Lights up OFF
pump motor control relay is OFF.
Pump motor is not activated although
pump motor control relay is ON.
C1162-00 (DTC Solenoid Valve Continuous Operation Solenoid valve is activated for more
C1162-00) Failure than specified time using active test Lights up Lights up
of SUZUKI scan tool.
C1163-07 (DTC Solenoid Valve Power Supply Driver Solenoid valve power supply relay
C1141-07 / C1142- Circuit Performance output is “ON”, although monitored
07 / C1145-07 / output is “OFF”.
C1146-07 / C1151- Solenoid valve power supply relay Lights up Lights up
07 / C1152-07 / output is “OFF”, although monitored
C1155-07 / C1156- output is “ON”.
07 / C1163-07)
C1171-49 (DTC ABS Control Module Internal Failure ABS control module internal failure is
Lights up Lights up
C1171-49) detected.
U0073-88 (DTC Control Module Communication Bus Impossible to receive and transmit
OFF OFF
U0073-88) Off CAN data.
U0100-87 (DTC Lost Communication With ECM ECM message data is missing from
OFF OFF
U0100-87) CAN communication.
Fail-Safe Table
AENNTA0E4504008 (06(01)
When any of the following DTCs is detected, ABS control module enters 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 (red).
– When ABS warning light lights up, ABS control is deactivated.
– When brake system warning light (red) lights up, EBD control is deactivated.
ABS: 4E-19
Fail-safe
DTC operation Fail-safe cancel condition
ABS EBD
C1121-01 (DTC When ABS control module judges the system to be normal, after switching ignition from
C1121-01 / “OFF” to “ON”.
C1121-92 /
C1125-01 /
C1125-92 /
– ○
C1131-01 /
C1131-92 /
C1133-62 /
C1135-01 /
C1135-92)
C1121-92 (DTC When ABS control module judges the system to be normal and “Road Test” under
C1121-01 / “ABS Check” is performed after switching ignition from “OFF” to “ON”.
C1121-92 /
C1125-01 /
C1125-92 /
– ○
C1131-01 /
C1131-92 /
C1133-62 /
C1135-01 /
C1135-92)
C1121-01 / “OFF” to “ON”.
C1121-92 /
C1125-01 /
C1125-92 /
– ○
C1131-01 /
C1131-92 /
C1133-62 /
C1135-01 /
C1135-92)
C1121-92 /
C1125-01 /
C1125-92 /
– ○
C1131-01 /
C1131-92 /
C1133-62 /
C1135-01 /
C1135-92)
C1121-01 / “OFF” to “ON”.
C1121-92 /
C1125-01 /
C1125-92 /
– ○
C1131-01 /
C1131-92 /
C1133-62 /
C1135-01 /
C1135-92)
4E-20 ABS:
Fail-safe
ABS EBD
C1121-92 /
C1125-01 /
C1125-92 /
– ○
C1131-01 /
C1131-92 /
C1133-62 /
C1135-01 /
C1135-92)
C1121-01 / “OFF” to “ON”.
C1121-92 /
C1125-01 /
C1125-92 /
* *
C1131-01 /
C1131-92 /
C1133-62 /
C1135-01 /
C1135-92)
C1121-01 / “OFF” to “ON”.
C1121-92 /
C1125-01 /
C1125-92 /
– ○
C1131-01 /
C1131-92 /
C1133-62 /
C1135-01 /
C1135-92)
C1121-92 /
C1125-01 /
C1125-92 /
– ○
C1131-01 /
C1131-92 /
C1133-62 /
C1135-01 /
C1135-92)
ABS: 4E-21
Fail-safe
ABS EBD
C1141-07 / “OFF” to “ON”.
C1142-07 /
C1145-07 /
C1146-07 /
– –
C1151-07 /
C1152-07 /
C1155-07 /
C1156-07 /
C1163-07)
C1142-07 (DTC
C1141-07 /
C1142-07 /
C1145-07 /
C1146-07 /
– –
C1151-07 /
C1152-07 /
C1155-07 /
C1156-07 /
C1163-07)
C1145-07 (DTC
C1141-07 /
C1142-07 /
C1145-07 /
C1146-07 /
– –
C1151-07 /
C1152-07 /
C1155-07 /
C1156-07 /
C1163-07)
C1146-07 (DTC
C1141-07 /
C1142-07 /
C1145-07 /
C1146-07 /
– –
C1151-07 /
C1152-07 /
C1155-07 /
C1156-07 /
C1163-07)
4E-22 ABS:
Fail-safe
ABS EBD
C1141-07 / “OFF” to “ON”.
C1142-07 /
C1145-07 /
C1146-07 /
– –
C1151-07 /
C1152-07 /
C1155-07 /
C1156-07 /
C1163-07)
C1152-07 (DTC
C1141-07 /
C1142-07 /
C1145-07 /
C1146-07 /
– –
C1151-07 /
C1152-07 /
C1155-07 /
C1156-07 /
C1163-07)
C1141-07 / “OFF” to “ON”.
C1142-07 /
C1145-07 /
C1146-07 /
– –
C1151-07 /
C1152-07 /
C1155-07 /
C1156-07 /
C1163-07)
C1156-07 (DTC
C1141-07 /
C1142-07 /
C1145-07 /
C1146-07 /
– –
C1151-07 /
C1152-07 /
C1155-07 /
C1156-07 /
C1163-07)
C1157-1C (DTC • When ABS control module judges the system to be normal.
C1157-1C) * * • When ABS control module judges the system to be normal and “Road Test” under
“ABS Check” is performed after switching ignition from “OFF” to “ON”.
– –
C1161-07) “ABS Check” is performed after switching ignition from “OFF” to “ON”.
– –
C1162-00) “ABS Check” is performed after switching ignition from “OFF” to “ON”.
C1142-07 /
C1145-07 /
C1146-07 /
– –
C1151-07 /
C1152-07 /
C1155-07 /
C1156-07 /
C1163-07)
ABS: 4E-23
Fail-safe
ABS EBD
– –
C1171-49) “OFF” to “ON”.
U0073-88 (DTC When ABS control module judges the system to be normal, after switching ignition from
○ ○
U0073-88) “OFF” to “ON”.
U0100-87 (DTC When ABS control module judges the system to be normal, after switching ignition from
○ ○
U0100-87) “OFF” to “ON”.
Scan Tool Data

AENNTA0E4504009 (06(01)
ABS Control Module
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 CAN communication circuit and connectors between DLC and central gateway control
• 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
• Check central gateway control module power circuit and ground circuit. (Inspection of Central
Gateway Control Module and Its Circuits): CAN (Central Gateway) in Section 10H
• Check ABS control module power circuit and ground circuit. (ABS Control Module Power Supply
and Ground Circuit Check)
Scan tool data Vehicle condition Condition / Reference value

RF Wheel Speed (RF
Wheel Speed, LF Wheel
Speed, RR Wheel Speed At stop (Stationary vehicle) 0 km/h (0 mph)
and LR Wheel Speed (km/
h, MPH))
LF Wheel Speed (RF
h, MPH))
RR Wheel Speed (RF
h, MPH))
LR Wheel Speed (RF
h, MPH))
Ignition “ON” (Engine stopped) 10.0 – 14.0 V
Voltage (V))
4E-24 ABS:

Pump Motor Driver (Pump Inactive (Pump motor not working) 0.0 V
Motor Driver (V)) Active (Pump motor working) 13.0 – 15.0 V
Brake Switch (Brake Depressed brake pedal ON
Switch (ON, OFF)) Released brake pedal OFF
ABS control (ABS Control Operating ON
(ON / OFF)) Not operating OFF
Set ignition “ON” 0 rpm
Specified idle speed: (Scan Tool
Speed (rpm)) Engine: Idle speed with no load after warning up
Data) in Section 1A
Hill Descent Control (Hill
Descent Control (Not Not supported Without
supported))
Hill Hold Control (Hill Hold Equipped with hill hold control function With
Control (With / Without)) Not equipped with hill hold control function Without
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 Control (ON / OFF): This informs whether ABS control is operating or not.
Engine Speed (rpm): This parameter indicates engine speed sent from ECM through CAN.
Hill Descent Control (Not supported): This parameter is indicated all the time without change.
Hill Hold Control (With / Without): This informs whether vehicle is equipped with hill hold control function or not.
ABS Warning Light Does Not Come ON after Setting Ignition “ON”
AENNTA0E4504010 (06(03)
Circuit Description
Operation (ON/OFF) of ABS warning light is controlled by ABS control module through light driver module in
combination meter.
If ABS system is in good condition, ABS control module turns ON ABS warning light with ignition “ON”, keeps the light
ON for 2 seconds and then turns it OFF. If ABS control is deactivated by ABS system 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 1 Warning light check

Do other indicator lights light up within 2 seconds after setting ignition “ON”?
Yes Go to Step 2.
No Go to Step 3.
Step 2 DTC check

2) Connect scan tool to DLC.
4) Check DTC related to CAN communication.

ABS: 4E-25
No Replace combination meter and recheck warning light operation. If ABS warning light does not
come ON, replace ABS hydraulic unit / control module assembly and recheck warning light
operation.
• Combination meter: (Combination Meter Removal and Installation) in Section 9C
• ABS hydraulic unit / control module assembly: (ABS Hydraulic Unit / Control Module Assembly
On-Vehicle Inspection)
Step 3 Fuse check
Is “MTR” fuse in good condition?
Yes Go to Step 4.
No Replace “MTR” fuse and check for short circuit to ground.
Step 4 CAN communication circuit check

1) Check CAN communication circuit between ABS control module and combination meter.
(Troubleshooting for Communication Bus Off): CAN in Section 10H
Is check result OK?
Yes Go to Step 5.
Step 5 Combination meter power supply and ground circuit check

1) Check combination meter power supply and ground circuits. (Inspection of Combination Meter and Its
Circuit) in Section 9C
Is check result OK?
Yes Replace combination meter and recheck warning light operation. If ABS warning light does not
come ON, replace ABS hydraulic unit / control module assembly and recheck warning light
operation.
On-Vehicle Inspection)
ABS Warning Light Comes ON Steady

AENNTA0E4504011 (06(03)
System Description
Refer to “System Description” under “ABS Warning Light Does Not Come ON after Setting Ignition “ON””.
Troubleshooting
Step 1 ABS control module connector check

1) Check for proper connection to ABS control module connector.
Is connection in good condition?
Yes Go to Step 2.
No Connect connector securely.
Step 2 DTC check

1) Perform “DTC Check”.
4E-26 ABS:

No Go to Step 3.
Step 3 ABS control module power supply and ground circuit check
1) Check ABS control module power supply circuit and ground circuits. (ABS Control Module Power Supply
Is check result OK?
Yes Go to Step 4.
Step 4 Combination meter check

1) Replace combination meter. (Combination Meter Removal and Installation) in Section 9C
Does ABS warning light stay on?
Yes Replace ABS hydraulic unit / control module assembly and recheck warning light operation. (ABS
Hydraulic Unit / Control Module Assembly Removal and Installation)
No End.
Brake System Warning Light (Red) Does Not Come ON after Setting Ignition “ON”
AENNTA0E4504012 (06(03)
System Description
Refer to “System Description” under “Brake System Warning Light (Red) Comes ON Steady”.
Troubleshooting

Yes Go to “ABS Warning Light Comes ON Steady”.

No Replace combination meter and recheck warning light operation. If brake system warning light
(red) does not come ON, replace ABS hydraulic unit / control module assembly and recheck
warning light operation.
Brake System Warning Light (Red) Comes ON Steady

AENNTA0E4504013 (06(03)
Circuit Description
Brake system warning light (red) is controlled by ABS control module and BCM through light driver module in
combination meter.
If ABS system is in good condition, ABS control module turns ON brake system warning light (red) when ignition is set
“ON”, keeps it ON for 2 seconds and then turns it OFF.
Brake system warning light (red) is turned ON continuously in the following conditions.
• EBD control is deactivated by ABS system failure.
• Parking brake lever is pulled up.
• Brake fluid level is lower than minimum level.
ABS: 4E-27
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.
Troubleshooting
Step 1 ABS control module connector check

1) Check for proper connection to ABS control module connector.
Yes Go to Step 2.
Step 2 Parking brake and brake fluid level check

• Parking brake is completely released.
• Brake fluid level is above minimum level. (Brake Fluid Level Inspection) in Section 4A
Is check result OK?
Yes Go to Step 3.
No Release parking brake and check brake fluid level. (Brake Fluid Level Inspection) in Section 4A
Step 3 ABS warning light operation check

Yes Perform “ABS Warning Light Comes ON Steady”.

No Go to Step 4.
Step 4 Parking brake switch signal circuit and brake fluid level switch signal circuit check
1) Check parking brake switch signal circuit and brake fluid level switch signal circuit. (Inspection of BCM
and Its Circuits) in Section 10B
Is check result OK?
Yes Go to Step 5.

4) Perform “DTC Check”:
Is DTC U0073-88 detected?
Yes Go to “Troubleshooting for Communication Bus Off”: CAN in Section 10H.

No Go to Step 6.
Step 6 DTC check for BCM

1) Check BCM for DTC. (DTC Check) in Section 10B
4E-28 ABS:

No Go to Step 7.

Does brake system warning light (red) stay on?
Yes Replace ABS hydraulic unit / control module assembly and recheck warning light operation. (ABS
No End.
DTC C1121-01 / C1121-92 / C1125-01 / C1125-92 / C1131-01 / C1131-92 / C1133-62 / C1135-01 / C1135-
92
AENNTA0E4504014 (06(02)
C1121-01 / C1125-01 / C1131-01 / C1135-01: Right-Front / Left-Front / • Wheel speed sensor circuit
Right-Rear / Left-Rear Wheel Speed Sensor Circuit Voltage • Wheel speed sensor
Wheel speed sensor signal is out of specified range.
• Wheel speed sensor encoder
C1121-92 / C1125-92 / C1131-92 / C1135-92: Right-Front / Left-Front /
Right-Rear / Left-Rear Wheel Speed Sensor or Encoder Signal • ABS control module
Performance
Abnormal wheel speed sensor signal is detected continuously.
C1133-62: Wheel Speed Sensor Deviation
• Abnormal wheel speed sensor signal is detected continuously at two
or more wheel speed sensors.
• ABS control is activated for more than specified time.
• Wheel speed sensor driver power supply voltage is out of specified
range.
NOTE
When vehicle is 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 (DTC Clearance) and
check whether any abnormality exists or not by performing road test as described in Step 3 of “ABS
Check”.
• Vehicle is driven with parking brake lever pulled.
• Wheel spins while driving.
• Wheel(s) is rotated while vehicle is jacked up.
ABS: 4E-29
Circuit Diagram
5 [A] E09
12V 1
26
A1
3
GRN E09-20 28 15
1 4
BLK E09-34
29 16
B1 5
30 17
6
A2 31 18
7
GRN E09-17 32 19
2 8
GRY E09-30 33 20
B2 9
34 21
6 10
A3 35 22
11
BRN E09-8 36 23
3 12
YEL E09-19 37 24
B3 13
38 25
14
A4 27
LT BLU E09-18 2
4
PNK E09-6
B4
[a]
IMTA0A450008-05
[A]: ABS control module connector (View: [a]) B1: Left-front wheel speed sensor signal circuit 2. Right-front wheel speed sensor
A1: Left-front wheel speed sensor power supply circuit B2: Right-front wheel speed sensor signal circuit 3. Left-rear wheel speed sensor
A2: Right-front wheel speed sensor power supply circuit B3: Left-rear wheel speed sensor signal circuit 4. Right-rear wheel speed sensor
A3: Left-rear wheel speed sensor power supply circuit B4: Right-rear wheel speed sensor signal circuit 5. ABS control module
A4: Right-rear wheel speed sensor power supply circuit 1. Left-front wheel speed sensor 6. Wheel speed sensor driver
NOTE
• DTC C1057 is not detected.

2) Drive vehicle at 20 km/h or higher for more than 1 min.
3) Stop vehicle and turn ignition switch to “OFF” position.
DTC Troubleshooting
Step 1 Was “ABS Check” performed?
Yes Go to Step 2.
No Go to “ABS Check”.
Step 2 Tire pressure check

1) Check that tire pressure is at specified value.
Is check result OK?
Yes Go to Step 3.
No Adjust tire pressure or replace tire and recheck DTC.
Step 3 Wheel speed sensor power supply circuit and signal circuit check
4E-30 ABS:
2) Disconnect “E09” and each of wheel speed sensor connectors.

3) Check for proper connection to “E09” and each of wheel speed sensor connectors.
• Resistance of “A1”, “A2”, “A3”, “A4”, “B1”, “B2”, “B3” and “B4” circuits: less than 1 Ω
• Resistance between each of “A1”, “A2”, “A3”, “A4”, “B1”, “B2”, “B3” and “B4” circuits and ground:
infinity
• Resistance between each terminal of “A1” – “B1”, “A2” – “B2”, “A3” – “B3” and “A4” – “B4” circuits and
each terminal of “E09” connector: infinity
• Voltage of “A1”, “A2”, “A3”, “A4”, “B1”, “B2”, “B3” and “B4” circuits: approx. 0 V (When ignition is “ON”)
Is check result OK?
Yes Go to Step 4.
No Repair or replace defective wire harness and recheck DTC.
Step 4 Wheel speed sensor signal check

1) Check applicable wheel speed sensor for output voltage and waveform. (Front and Rear Wheel Speed
Sensor On-Vehicle Inspection)
Is check result OK?
Yes Replace ABS hydraulic unit / control module assembly and recheck DTC. (ABS Hydraulic Unit /
Control Module Assembly Removal and Installation)
No Go to Step 5.
Step 5 Wheel speed sensor check

1) Check applicable wheel speed sensor. (Front and Rear Wheel Speed Sensor Inspection)
Is check result OK?
Yes Go to Step 6.
No Clean, repair or replace wheel speed sensor and recheck DTC.
• Front wheel speed sensor: (Front Wheel Speed Sensor Removal and Installation)
• Rear wheel speed sensor: (Rear Wheel Speed Sensor Removal and Installation)
Step 6 Wheel speed sensor encoder check

1) Check applicable wheel speed sensor encoder. (Front and Rear Wheel Speed Sensor Encoder
Inspection)
Is check result OK?
No Clean, repair or replace wheel speed sensor encoder and recheck DTC.
• Front wheel speed sensor encoder: (Front Wheel Speed Sensor Encoder Removal and
Installation)
• Rear wheel speed sensor encoder: (Rear Wheel Speed Sensor Encoder Removal and
Installation)
DTC C1141-07 / C1142-07 / C1145-07 / C1146-07 / C1151-07 / C1152-07 / C1155-07 / C1156-07 / C1163-
07
AENNTA0E4504015 (06(02)
ABS: 4E-31

C1141-07 / C1145-07 / C1151-07 / C1155-07: Right-Front / Left-Front / • ABS control module circuit
Right-Rear / Left-Rear Inlet Solenoid Valve Circuit Correlation • ABS control module
Right-Rear / Left-Rear Outlet Solenoid Valve Circuit Correlation
Solenoid output and solenoid monitor data disagree.
C1163-07: 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”.
DTC Troubleshooting
Step 1 Was “ABS System Check” performed?
Yes Go to Step 2.
Step 2 Solenoid valve power supply and ABS control module ground circuit check
1) Check solenoid valve power supply and ground circuits. (ABS Control Module Power Supply and Ground
Circuit Check)
Is check result OK?
DTC C1157-1C
AENNTA0E4504016 (06(02)
C1157-1C: Power Supply Voltage • ABS control module circuit
• Pump motor power supply voltage is out of specified • ABS control module
range. • Charging system
• Solenoid valve power supply voltage is out of specified
range.
DTC Troubleshooting
Yes Go to Step 2.
Step 2 ABS control module circuit check

1) Check ABS control module circuit. (ABS Control Module Power Supply and Ground Circuit Check)
Is check result OK?
Yes Go to Step 3.
4E-32 ABS:

Is check result OK?
No Repair or replace defective parts and recheck DTC.
DTC C1161-07
AENNTA0E4504017 (06(02)
C1161-07: Pump Motor Circuit Performance • ABS control module circuit
• Pump motor power supply voltage is lower than specified value. • ABS control module
• When pump motor is activated, a malfunction in pump motor is
detected.
• Power supply from CPU to pump motor and pump motor relay monitor
data disagree.

2) Drive vehicle at 40 km/h (25 mile/h) or higher for more than 1 min.
DTC Troubleshooting
Yes Go to Step 2.
Step 2 Pump motor power supply circuit and ground circuit check
1) Check pump motor power supply circuit and ground circuits. (ABS Control Module Power Supply and
Ground Circuit Check)
Is check result OK?
DTC C1162-00
AENNTA0E4504018 (06(02)
C1162-00: 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
Yes Go to Step 2.
ABS: 4E-33
Step 2 DTC check

1) Clear DTC(s). (DTC Clearance)
3) Leave vehicle for 5 minutes or more, for cooling down of ABS system.
Is DTC C1162-00 detected?
No End.
DTC C1171-49
AENNTA0E4504019 (06(02)
C1171-49: ABS Control Module Internal Failure ABS control module
ABS control module internal failure is detected.
DTC Troubleshooting
Yes Go to Step 2.
Step 2 DTC check

Is other DTC(s) than C1171-49 detected?
Yes Go to applicable DTC troubleshooting.

No Replace ABS hydraulic unit / control module assembly and recheck DTC. (ABS Hydraulic Unit /
DTC U0073-88
AENNTA0E4504020 (06(02)
DTC U0100-87
AENNTA0E4504021 (06(02)
Refer to “Troubleshooting for Lost Communication”: CAN in Section 10H.
ABS Control Module Power Supply and Ground Circuit Check

AENNTA0E4504022 (06(01)
4E-34 ABS:
Circuit Diagram
[A] E09
4
1
2 26
7 B1
3
1 RED E09-26 5 28 15
4
8 29 16
WHT E09-1 6 5
30 17
C1 6
31 18
7
32 19
8
3 33 20
10 9
9 5V 34 21
10
1 BRN E09-5 12V 35 22
11
36 23
A1 12
37 24
13
D1 38 25
14
BLK E09-2 27
2
BLK E09-27
D2
[a]
IMTA0A450009-02
[A]: ABS control module connector (View: [a]) 1. From battery 7. “ABS MOT” fuse
A1: Ignition power supply circuit 2. Relay box 8. “ABS SOL” fuse
B1: Pump motor power supply circuit 3. J/B 9. “ABS” fuse
C1: Solenoid valve power supply circuit 4. ABS control module 10. IG11 relay
D1: ABS control module ground circuit 1 5. To pump motor relay
D2: ABS control module ground circuit 2 6. To solenoid valve power supply circuit
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 1 Fuse check
Are “ABS MOT” fuse, “ABS SOL” fuse and “ABS” fuse in good condition?
Yes Go to Step 2.
No Replace fuse and check for short circuit to ground.
Step 2 Ignition power supply circuit check

2) Disconnect “E09” connector.
3) Check for proper terminal connection to “E09” connector.
Is check result OK?
Yes Go to Step 3.
Step 3 Pump motor and solenoid valve power supply circuit check
ABS: 4E-35

• Voltage between “B1” circuit and ground is battery voltage.
• Voltage between “C1” circuit and ground is battery voltage.
Is check result OK?
Yes Go to Step 4.
Step 4 ABS control module ground circuit check

2) Check that resistance between each of “D1” and “D2” circuits and ground is less than 1 Ω.
Is check result OK?
Yes ABS control module power supply and ground circuits are in good condition.
Repair Instructions
ABS Hydraulic Unit Operation Check • Check DLC power circuit and ground
AENNTA0E4506001 (08(03) circuit.
NOTE
• A false diagnosis may result if operation connectors between DLC and central
check of the ABS hydraulic unit is gateway control module. (Refer to
performed without satisfying all of the “Diagnosis flow: [a]” in “Troubleshooting”
specified condition below. of “Troubleshooting for Lost
Check that all the following conditions are Communication”: CAN in Section 10H.)
met before performing operation check of • Check DLC cable. If necessary, check DLC
the ABS hydraulic unit. cable by substituting a known-good DLC
– Battery voltage is 12 V or more. cable.
– No air is trapped in the brake system. • Check CAN communication system.
– Brakes do not drag. (“Control Module Communication Bus Off”
– No DTC is stored in ABS hydraulic unit / is detected in any control module.)
control module. (Troubleshooting for Communication Bus
Off): CAN in Section 10H
• Operation check must be performed by 2
persons. • Check central gateway control module
• Lighting or blinking of warning light stops (Inspection of Central Gateway Control
when ignition is set “ON” after completing Module and Its Circuits): CAN (Central
ABS hydraulic unit operation check. Gateway) in Section 10H
1) Connect SUZUKI scan tool to DLC. (Suzuki SDT-II • Check ESP® control module power circuit
Connection and Disconnection) in Section 0A and ground circuit. (ABS Control Module
Power Supply and Ground Circuit Check)
2) Check DTC and follow the instructions displayed on
SUZUKI scan tool. 3) Hoist vehicle until tire can be rotated.
Refer to Operator's Manual of SUZUKI scan tool for
further details. 4) Set transmission to neutral and release parking
brake.
NOTE 5) Set ignition “ON”, and select “Depressurization
If communication between SUZUKI scan tool check” in “Hydraulic control test” under “Utility” mode
and ESP® control module is not possible, of SUZUKI scan tool.
perform the following checks: Refer to Operator’s Manual of SUZUKI scan tool for
further details.
PC and VCI using SUZUKI scan tool 6) Perform the following check with help of another
function. person.
4E-36 ABS:
• Depressurization check 7) Check all 4-wheels respectively.

Step on brake pedal and then select testing wheel 8) Check that ABS warning light is turned off after
by SUZUKI scan tool and the wheel should be switching ignition from “OFF” to “ON”. Check for
turned by another person’s hand. At this time, DTC and repair problem if lights are still lit.
check whether the wheel rotates freely due to
9) If any faulty condition is found in Step 6) – 7), replace
brake depressurization.
ABS hydraulic unit / control module assembly.
NOTE 10) After completing the check, check that ignition is
Depressurization by SUZUKI scan tool is “OFF” and then disconnect SUZUKI scan tool from
available for 0.5 seconds. DLC. (Suzuki SDT-II Connection and Disconnection)
in Section 0A
I8G001460007-01
ABS Hydraulic Unit / Control Module Assembly Components

AENNTA0E4506002 (12(01)
ABS: 4E-37
(a)
(a)
(a)
(b)
(b)
4
(a)
(c)
(c)
IMTA0A450010-01
4E-38 ABS:
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. Mount damper 7. To Left-front brake : 9.0 Nm (0.92 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)
ABS Hydraulic Unit / Control Module Assembly – Use care not to allow dust to enter ABS
On-Vehicle Inspection hydraulic unit / control module.
AENNTA0E4506003 (08(03)
– Do not place ABS hydraulic unit / control
Check the following points. Repair or replace defective
module on its side or upside down.
parts.
– Do not give an impact to hydraulic unit.
• Check ABS hydraulic unit / control module assembly
(1) for dents, crack, deformation and leakage. • Brake fluid is extremely damaging to
painted surfaces. If brake fluid contacts
• Check actuator bracket (2) and its mounting surface
painted surfaces, immediately wipe it off
for dents, crack and deformation.
and flush the surfaces with water
• Check ABS hydraulic unit / control module assembly thoroughly.
nuts and actuator bracket bolts for looseness.
• The bracket of the ABS hydraulic unit /
• Check ABS control module connector (ABS control control module assembly may have some
module side and harness side) and its connector lock burrs at the edge and may damage or
mechanism for damage or crack. deform the bushing, resulting in abnormal
• Check connector terminals for bend, corrosion or rust. 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.
1
Removal
1) Remove battery and battery tray. (Battery Removal
2) Disconnect ABS control module connector (3) by
pushing the lock button (1), and then pulling down
the lock lever (2).
2
IMTA0A450011-01
3
1
ABS Hydraulic Unit / Control Module Assembly
Removal and Installation
AENNTA0E4506004 (08(01)
[a]
Reference: “Precautions for Electrical System Work” 2
Reference: “ABS Hydraulic Unit / Control Module

Assembly Components”
Reference: “ABS Hydraulic Unit / Control Module
Assembly On-Vehicle Inspection” ILKC0P460032-01
[a]: Pull down to unlock

NOTICE
• Performing the following prohibited 3) Disconnect battery cable of bracket (1) from actuator
operations will affect the original bracket (2).
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.
ABS: 4E-39
7) Remove actuator mount nuts (1) and actuator

bracket (2) from ABS hydraulic unit / control module
assembly.
IMTA0A450014-01 1 1
4) Disconnect clutch fluid pipe of clamp (1) from
actuator bracket (2). 2
IMTA0A450015-01
Installation
• Install actuator bracket (1) to ABS hydraulic unit /
control module assembly, and tighten actuator mount
2 nuts (2) to specified torque.
Tightening torque
Actuator mount nut (a): 9.0 N·m (0.92 kgf-m, 7.0
lbf-ft)
1
IMTA0A450013-01
5) Loosen flare nuts (1) using special tool and

disconnect brake pipes from ABS hydraulic unit /
control module assembly (2).
NOTE
Put bleeder plug cap or the like onto pipe to
prevent fluid from spilling. 2, (a) 2, (a)
Special tool 1
(A): 09950M78220 IMTA0A450016-02
6) Remove actuator bracket nuts (3), remove ABS • Tighten brake pipe flare nuts (1) and actuator bracket
hydraulic unit / control module assembly with nuts (2) to specified torque.
actuator bracket (4). Tightening torque
Brake pipe flare nut (a): 16 N·m (1.6 kgf-m, 12.0
lbf-ft)
1 Actuator bracket nut (b): 26 N·m (2.7 kgf-m, 19.5
1 4
lbf-ft)
1
3
IMTA0A450012-01
4E-40 ABS:
[a]
1
1, (a)
1, (a)
[A]
1, (a) 2, (b)
3
2, (b)
IAP70A460014-02
IMTA0A450017-01
[A]: Wheel speed sensor connector (View: [a])
• Install ABS hydraulic unit correctly, preventing the
2. Resistance (100 Ω)
mount damper from deformation and crushing.
3. Power supply (12 V)
• Bleed brake system. (Brake Fluid Replacement) in
Section 4A 5) Measure voltage at both ends of resistance without
• Check for leakage of brake fluid and perform ABS wheel rotation. If check result is not as specified,
hydraulic unit operation check. (ABS Hydraulic Unit check sensor, mating encoder and their installation
Operation Check) conditions.
NOTE Voltage at resistance (100 Ω) without wheel
rotation
• If perform depressurization check while air 600 to 800 mV or 1200 to 1600 mV
was trapped in the brake system, air will
enter the inside of ABS hydraulic unit. 6) Measure voltage at both ends of resistance with
rotating wheel. Check that high (1) and low (2)
• Check for proper operation of hydraulic
voltages are as specified. Check that waveform is
unit and proper installation of brake
not disordered.
system after completing sensor calibration
referring to ABS hydraulic unit operation Voltage at resistance (100 Ω) with wheel rotating
check. Low voltage: 600 to 800 mV
High voltage: 1200 to 1600 mV
Front and Rear Wheel Speed Sensor On-Vehicle
Inspection
AENNTA0E4506005 (08(03)
NOTICE
Incorrect voltage or mis-connection will
damage the wheel speed sensor.
Check that the power supply voltage and test
connections are both correct before
connecting battery.
IAP70A460015-01
Output Voltage Inspection

1) Disconnect negative (–) cable at battery. Front Wheel Speed Sensor Removal and
2) Hoist vehicle until tire can be rotated. Installation
AENNTA0E4506006 (08(01)
3) Disconnect wheel speed sensor connector (1). Reference: “Precautions for Electrical System Work”
4) Set up measuring devices as shown in figure. Reference: “Front and Rear Wheel Speed Sensor On-
Vehicle Inspection”
Removal
2) Hoist vehicle a little and remove wheel. (Wheel (with
ABS: 4E-41
3) Remove front fender lining. (Front Fender • Check that no iron powder attaches to sensing area of
Components) in Section 9J wheel speed sensor (1).
4) Remove clips (1) and grommets (2), and disconnect • Tighten front wheel speed sensor bolt (2) to specified
front wheel speed sensor connector (3). torque.
Right side
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
1 speed sensor and steering knuckle (3).
3 [A] [B]
1 2,(a) 1 2,(a)
1 3 3
I9W10P460009-02
[A]: OK [B]: NG
IMTA0A450018-01
• Install wheel. (Wheel (with Tire) Removal and

Left side
Rear Wheel Speed Sensor Removal and

1 Installation
AENNTA0E4506007 (08(01)
3 Reference: “Front and Rear Wheel Speed Sensor On-
Vehicle Inspection”
1
Removal
2) Hoist vehicle a little and remove wheel.
3) Remove clip and disconnect rear wheel speed
IMTA0A450019-01
sensor connector (1).
5) Remove front wheel speed sensor bolt (1). 4) Remove clips (2).
6) Remove front wheel speed sensor (2) from steering
knuckle.
2
2
1
1
IMTA0A450021-02
5) Remove rear wheel speed sensor bolt (1).

IMTA0A450020-01 6) Remove rear wheel speed sensor (2) from rear
wheel hub assembly.
Installation
Reference: “Front and Rear Wheel Speed Sensor
Inspection”
Reverse removal procedures noting the following points.
4E-42 ABS:
Reference: “Front Wheel Speed Sensor Removal and

Installation”
Reference: “Rear Wheel Speed Sensor Removal and
Installation”
Replace or clean wheel speed sensor if sensing area of
1
front and rear wheel speed sensor(s) is damaged or
covered with iron powder.
Front Wheel Speed Sensor Encoder Removal

2
and Installation
AENNTA0E4506009 (08(01)
NOTE
Front wheel speed sensor encoder is
included in front wheel hub assembly. If front
IMTA0A450022-01
wheel speed sensor encoder needs to be
Installation replaced, replace front wheel hub assembly.
Reference: “Front and Rear Wheel Speed Sensor
For removal and installation of front wheel speed sensor
Inspection”
encoder (included in front wheel hub assembly), refer to
Reverse removal procedures noting the following points.
“Front Wheel Hub Assembly and Steering Knuckle
• Check that no iron powder attaches to sensing area of Removal and Installation”: Front in Section 3A.
wheel speed sensor (2).
• Tighten wheel speed sensor bolt (1) to specified Rear Wheel Speed Sensor Encoder Removal
torque. and Installation
AENNTA0E4506010 (08(01)
NOTICE NOTE
When installing rear wheel speed sensor, Rear wheel speed sensor encoder is included
damaged O-ring may cause water to enter in rear wheel hub assembly. If rear wheel
into bearing. speed sensor encoder needs to be replaced,
Be careful not to damage O-ring when replace rear wheel hub assembly.
installing rear wheel speed sensor.
For removal and installation of rear wheel speed sensor
Tightening torque encoder (included in rear wheel hub assembly), refer to
Rear wheel speed sensor bolt (a): 11 N·m (1.1 “Rear Wheel Hub Assembly Removal and Installation”:
kgf-m, 8.5 lbf-ft) Rear in Section 3A.
• Check that there is no space between rear wheel
speed sensor and rear wheel hub assembly (3). Front and Rear Wheel Speed Sensor Encoder
Inspection
AENNTA0E4506011 (08(03)
[A] [B] Reference: “Front Wheel Speed Sensor Encoder
2 1,(a) 2 1,(a)
3 3 Removal and Installation”
Reference: “Rear Wheel Speed Sensor Encoder
NOTE
I9P60A460033-01
Wheel speed sensor encoder is united to
[A]: OK [B]: NG
wheel hub assembly. Replace wheel hub
assembly if wheel speed sensor encoder
• Install wheel. (Wheel (with Tire) Removal and needs to be replaced.
Check front and rear wheel speed sensor encoders for
Front and Rear Wheel Speed Sensor Inspection crack, damage, or deformation.
AENNTA0E4506008 (08(03) Replace wheel hub assembly if defective.
Specifications
AENNTA0E4507001 (09(t)
ABS: 4E-43
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Actuator mount nut 9.0 0.92 7.0 (T4E001)
Brake pipe flare nut 16 1.6 12.0 (T4E002)
Actuator bracket nut 26 2.7 19.5 (T4E003)
Front wheel speed sensor bolt 11 1.1 8.5 (T4E004)
Rear wheel speed sensor bolt 11 1.1 8.5 (T4E005)
Reference:
“ABS Hydraulic Unit / Control Module Assembly Components”

Special Tool
AENNTA0E4508001 (11(s)
09950M78220
Flare nut wrench (10 x 12
mm)
(L4E001)
4F-1 Electronic Stability Program:
Electronic Stability Program

Brakes
Precautions
Precautions for ESP® When connecting the connector, set the connector in
AENNTA0E4600001 (01(01) position on ESP® hydraulic unit / control module
When disconnecting ESP® control module connector,
assembly and pull up the lock lever (2) until it locks.
disconnect the negative (–) cable at battery since the
battery voltage is constantly applied to ESP® hydraulic

AENNTA0E4600002 (01(01)
To check that the trouble diagnosis is done accurately [A] [D]
and smoothly, observe the following and follow “ESP®
System Check”.
2
• Before using SUZUKI scan tool, read its Operator’s [C]
Manual to know how to use it. [B]
1
IFRA0A450022-02
• If the vehicle was operated in any of the following
conditions, ABS warning light and ESP® warning light [A]: Pull down to unlock [C]: Connect
[B]: Disconnect [D]: Pull up to lock
may light momentarily but this does not indicate any
fault in ESP® system.
• Communication of ESP® control module and other
– The vehicle is driven with parking brake applied. control module is established by CAN.
– The vehicle is driven with brake dragging. Therefore, read “Precautions for Installing Mobile
– The vehicle is stuck in mud, sand, etc. Communication Equipment” in Section 00 before
– Wheel spins while driving. inspection and handling CAN communication line.
– Wheels are rotated while the vehicle is jacked up.
Test with Speedometer Tester or Other
• Follow trouble diagnosis procedure described in
Equipment
“ESP® System Check”. If trouble diagnosis procedure AENNTA0E4600003 (01(01)
is not followed properly, incorrect diagnosis may NOTE
result. (If incorrect procedure is performed, other DTC Before performing speedometer test or other
may be stored in the ESP® hydraulic unit / control tests using speedometer tester or chassis
module assembly.) dynamometer, traction control system of
• When disconnecting ESP® control module connector ESP® must be deactivated by ESP® OFF
(1), pull down the lock lever (2) of connector. switch or using SUZUKI scan tool.
General Description
ABS Description While brake pedal is depressed not so hard as to
AENNTA0E4601001 (03(01) activate ABS control, brake force is proportionally
ABS
distributed between front and rear brakes to prevent rear
• The ABS (Anti-lock Brake System) controls the fluid wheels from being locked too early for better stability of
pressure applied to the caliper or wheel cylinder from the vehicle.
the master cylinder so that each wheel is not locked If the EBD control is deactivated, the brake system
even when hard braking is applied. warning light (red) lights to inform the driver of
• ABS control module detects wheel slip by the signal abnormality.
from wheel speed sensor of each wheel and sends
control signals to the hydraulic unit. ESP® Hydraulic Unit / Control Module Assembly
ABS control module also monitors system conditions • ESP® hydraulic unit / control module assembly
and stops the function of ABS and lights the ABS detects wheel slip by the signal from wheel speed
warning light in case it judges that the system is faulty. sensor of each wheel and sends control signals to the
hydraulic unit. ESP® hydraulic unit / control module
EBD assembly also monitors system conditions and stops
This ABS is equipped with EBD (Electronic Brake force the function of ABS and lights the ABS warning light in
Distributions) function. case it judges that the system is faulty.
Electronic Stability Program: 4F-2
• ESP® hydraulic unit is composed of inlet solenoid

valves (4) (normally-opened valves), outlet solenoid [A] [B]
valves (5) (normally-closed valves), pumps (3), pump 1

motor (2), reservoirs (6) and check valves (7). It 2
activates the inlet and outlet solenoid valves by the
signals from ESP® 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.) 1
2
IGJA0A450018-01
1
[A]: Front side [B]: Rear side
ESP® Description
7 AENNTA0E4601002 (03(01)
4
NOTE
3 2
7 ESP® is registered trademark of Daimler AG.
7 ESP® (Electronic Stability Program) is an auxiliary

function to enable the vehicle to stabilize while the
vehicle is running, stopping or turning.
6 5 ESP® consists of the following functions.
8
ABS
I7V20A450003-01 Refer to “ABS Description”.
1. Master cylinder 8. Caliper or wheel cylinder
EBD
The hydraulic pressure control is performed in 3 modes: Refer to “ABS Description”.
pressure increase, pressure keeping and pressure
reduction. Engine Torque-Up Control
• In the pressure increase mode, inlet and outlet This function controls the engine torque to release lock-
solenoid valves are turned OFF, and the brake fluid up of the driving wheel(s) to maintain vehicle stability
pressure applied from the master cylinder to the and steering when the lock-up occurs while engine brake
caliper or wheel cylinder is increased. is functioning with accelerator pedal released.
When ESP® hydraulic unit / control module detects the
• In the pressure keeping mode, the inlet solenoid valve lock-up, the control module computes target minimum
is turned ON, and the brake fluid pressure in the slip and target engine torque according to the vehicle
caliper or wheel cylinder is kept constant. speed based on the engine speed signal and engine
• In the pressure reduction mode, inlet and outlet torque signal from ECM, and demands engine torque up
solenoid valves are turned ON, and the brake fluid to ECM.
pressure applied to the caliper or wheel cylinder is
released to the reservoir. Thus the brake pressure Traction Control
applied to the wheel likely to be locked is reduced. This function controls the engine and brakes to prevent
The brake fluid temporarily stored in the reservoir is the driving wheels from spinning at the time of starting
pumped back to the master cylinder. and accelerating. Particularly, this function is helpful for
safe driving on muddy or icy roads. When ESP®
Wheel Speed Sensor hydraulic unit / control module assembly detects wheel
All wheel speeds are detected by the magnetic resistive spinning using information from the yaw rate / G sensor
effect element type wheel speed sensor (1) and encoder assembly and wheel speed sensors, it lowers the engine
(2). The wheel speed sensor is fixed to each steering torque by reducing throttle opening and retarding the
knuckle and rear wheel hub assembly. ignition timing. At the same time, brake is applied to the
The encoder consists of a permanent magnet which has spinning wheel so that the engine torque can be
south poles and north poles. As it is located on the wheel transmitted to the other wheel.
hub it turns along with the wheel.
The wheel speed sensor feeds pulse signals in Stability Control
proportion to the wheel speed to ESP®control module, This function maintains the vehicle stability by controlling
which then calculates the wheel speed based on such the engine and brakes to prevent the vehicle from
signal information. oversteering or understeering while turning.
When understeering occurs, this function lowers the Hill Hold Control
engine torque and applies brake to the inner rear wheel This function prevents occurrence of creeping down
to prevent the vehicle from moving outward. When which may occur when the driver shifts from the brake
oversteering occurs, this function applies brake to the pedal depression to the accelerator pedal operation to
outer front wheel to prevent the vehicle from moving restart moving forward the vehicle stopped on an up-
inward. slope. The ESP® control module activates each solenoid
in the hydraulic unit to keep the brake pressure to each
Hydraulic Brake Assist Control brake caliper or wheel cylinder, which is applied by brake
This function controls brake fluid pressure to satisfy the pedal depression.
pressure range for activation of ABS. When ESP® The vehicle remains stationary at the position for 2
hydraulic unit / control module detects hard braking seconds without operation of the accelerator pedal.
sensing variation of signal from brake master cylinder Operating the accelerator pedal within 2 seconds
pressure sensor, pump motor in ESP® hydraulic unit / releases the brake pressure.
control module functions to add brake pressure to the
pressure generated by driver’s brake operation for
activation of ABS.
ESP® Component Description

AENNTA0E4601003 (03(01)
ESP® hydraulic unit / control module assembly is composed of the following components. Regarding location, refer to
“ESP® Component Location”.
ESP® Hydraulic Unit / Control Module

The ESP® control module receives signals from each wheel speed sensor, ESP® OFF switch, brake master cylinder
pressure sensor (7) and steering angle sensor. Based on these signals, the ESP® control module judges the vehicle
conditions and controls the brake hydraulic pressure by combining the ON/OFF operation of the solenoid valves in the
hydraulic unit and the pump motor operation.
The hydraulic unit contains an inlet solenoid valve (8) and an outlet solenoid valve (9) for each wheel as well as a cut
solenoid valve (10) and a low pressure solenoid valve (11) for each hydraulic circuit. Also, a brake master cylinder
pressure sensor, pump motor (6), etc. are included. The hydraulic pressure control is performed in 3 modes: pressure
increase, pressure keeping and pressure reduction.
• Pump motor:
The pump motor turns on and applies pressure to each brake when braking is activated in the traction control and
stability control state. In the pressure reduction mode, the pump motor returns the brake fluid in the reservoir (12) to
the brake master cylinder (1).
• Brake master cylinder pressure sensor:
This sensor detects the brake hydraulic pressure in the primary piping when brakes are applied in the normal
condition. Also, it detects the pump motor driving state when a brake is applied in the traction control and stability
control state.
• Inlet solenoid valve:
When the ABS, traction control and stability control functions are working, this valve is activated in the pressure
keeping and pressure reduction modes to close the fluid passage, thereby restricting increase of the hydraulic
pressure applied to the brake caliper or wheel cylinder.
• Outlet solenoid valve:
When the ABS, traction control and stability control functions are working, this valve is activated in the pressure
reduction mode to open the fluid passage, thereby lowering the hydraulic pressure in the brake caliper or wheel
cylinder.
• Cut solenoid valve:
When brake application is commanded while the traction control and stability control functions are working, this
valve is activated to close the fluid passage to apply the hydraulic pressure generated by the pump motor to the
brake caliper or wheel cylinder.
• Low pressure solenoid valve:
When brake application is commanded while the traction control and stability control functions are working, this
valve is activated to open the fluid passage from the master cylinder to the pump motor.
• Yaw rate / G sensor:
The yaw rate / G sensor incorporated in ESP® control module detects yaw rate and acceleration of gravity on the
vehicle.
11 10 10 11
8 8 8 8
12 12
9 9 9 9
4 3 2 5
INTA0A460006-02
2. Brake caliper (left-front) 4. Wheel cylinder (left-rear)

3. Brake caliper (right-front) 5. Wheel cylinder (right-rear)
Steering Angle Sensor ESP® control module is built in ESP® hydraulic unit /
The steering angle sensor is a unit including a lighting control module assembly and has the following
and turn signal switch and mounted to the steering functions.
column.
Detecting the angle as the steering wheel is turned, it Self-Diagnosis Function
sends that information to the ESP® hydraulic unit / ESP® hydraulic unit / control module assembly monitor
control module assembly. input and output signal. When ESP® hydraulic unit /
control module assembly detects any malfunction, ABS
ESP® OFF Switch warning light (1), brake system warning light (red) (2),
This switch is of a momentary contact type, and is ESP® warning light (3), and/or ESP® OFF light (4) are
located at the switch bezel of the instrument panel. turned ON to inform the driver of the abnormality.
When the ESP® OFF switch is pressed for about 3 • When ignition is set “ON”, ABS warning light, brake
seconds, the ESP® hydraulic unit / control module system warning light (red), ESP® warning light and
assembly stops the traction control and stability control ESP® OFF light turn ON for 2 seconds to check its
functions. The ESP® OFF light in the combination meter circuit.
lights and informs driver that these functions are
• When no abnormality is detected (the system is in
inactive. When the ESP® OFF switch is pressed again
good condition), these lights turn OFF after 2
momentarily, the ESP® hydraulic unit / control module
seconds. However, when parking brake is applied,
assembly resumes these functions.
brake system warning light (red) remains ON.
Wheel Speed Sensor • When an abnormality in the system is detected, ABS
Refer to “Wheel speed sensor” under “ABS Description”. warning light, brake system warning light (red), ESP®
warning light and/or ESP® OFF light are turned ON
and DTC is stored in ESP® hydraulic unit / control
AENNTA0E4601004 (03(01) module assembly.
Fail-Safe Mode
[A] If ESP® hydraulic unit / control module assembly stores a
DTC, ESP® hydraulic unit / control module assembly
stops ABS, EBD, traction control function, stability
control function, etc. corresponding to the faulty area. It
is possible to check the stopped function(s) by the
warning / indicator lights in combination meter. (Warning
/ Indicator Light Description)
2 1 3 4
[B]
IMTA0A460002-05
Warning / Indicator Light Description

AENNTA0E4601005 (03(01)
There are three warning and one indicator lights controlled by ESP® hydraulic unit / control module assembly in
combination meter. They give warning and indication to driver by changing their modes: light ON / blinking / light OFF.
[A]
2 1 3 4
[B]
IMTA0A460002-05
[A]: Segment display type 2. Brake system warning light

(red)
[B]: Color dot display type 3. ESP® warning light
1. ABS warning light 4. ESP® OFF light
Condition and Operation of Warning Light and Indicator Light

Warning light / Indicator light Condition and operation
ABS warning light If ABS control is deactivated by ESP® system failure, the light turns “ON”.
Warning light / Indicator light Condition and operation

• If EBD control is deactivated by ESP® system failure, the light turns “ON” with
ABS warning light.
Brake system warning light (red)
• 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”.
• If traction control and stability control are deactivated by ESP® system failure,
ESP® warning light the light turns “ON”.
• If traction control and/or stability control is activated, the light blinks.
ESP® OFF light turns “ON” to indicate that ESP® hydraulic unit / control module
ESP® OFF light
assembly stops traction control and stability control functions.
Description of Sensor Calibrating Condition

AENNTA0E4601006 (03(01)
When the following conditions are met, sensor calibration should be performed since the original calibration data are
deleted.
Sensor to be calibrated Condition requiring calibration
• Lighting and turn signal switch is replaced.
Steering angle sensor
• ESP® hydraulic unit / control module assembly is replaced.
Yaw rate / G sensor assembly ESP® hydraulic unit / control module assembly is replaced or removed.
Perform sensor calibration according to “Sensor Calibration”.
DLC Description CAN Communication System Description

AENNTA0E4601007 (03(01) AENNTA0E4601008 (03(01)
Refer to “DLC Description” in Section 1A. Refer to “Communication System Description”: CAN in
Section 10H.

ESP® System Diagram
AENNTA0E4602001 (10(03)
10 10
6
5
11
12
1
2
9
8 4
3
10 10
13 14 15
IL2R0A460002-01
1. ESP® hydraulic unit / control module assembly 6. Combination meter 11. ESP® OFF switch
2. ESP® control module 7. Brake light switch 12. Brake booster pressure sensor
3. Hydraulic unit 8. Brake master cylinder pressure sensor 13. Electronic signal
4. ECM 9. Yaw rate / G sensor 14. CAN signal
5. Other control modules (if equipped) and steering 10. Wheel speed sensor 15. Hydraulic circuit
angle sensor
ESP® Input / Output Diagram

AENNTA0E4602002 (10(01)
INPUT ESP® hydraulic unit / control module assembly OUTPUT
Battery power supply

Solenoid valve power supply driver
Brake master cylinder pressure

sensor Right-front inlet solenoid valve
Right-front outlet solenoid valve

Yaw rate / G sensor
Left-front inlet solenoid valve
Wheel speed sensor (Right-front) Left-front outlet solenoid valve
Right-rear inlet solenoid valve

Wheel speed sensor (Left-front)
Solenoid valve Right-rear outlet solenoid valve
Wheel speed sensor (Right-rear)
driver
Left-rear inlet solenoid valve
Wheel speed sensor (Left-rear)
Left-rear outlet solenoid valve
Brake booster pressure sensor Low pressure solenoid valve No.1
(if equipped) CPU
Low pressure solenoid valve No.2
ESP® OFF switch
Cut solenoid valve No.1
Back up light switch (if equipped)
Cut solenoid valve No.2
Pump motor Pump motor

driver
BCM BCM
TCM (if equipped) CAN driver TCM (if equipped)
ECM ECM
Combination meter Combination meter
Steering angle sensor P/S control module

(non-auto-on headlight model)
Steering angle sensor (non-auto-on headlight model)

Lighting and turn signal switch
(auto-on headlight model)
Lighting and turn signal switch
: CAN communication
IMTA0A460003-03
ESP® Circuit Diagram

AENNTA0E4602003 (10(01)
4
31
RED
32
WHT
5
[C]
6
33
1
34
7 2
25
35
BRN E09-5
E09-1
[B] E09-26
11
28
7 2
29
M
5
33 BLU 3
1 LT GRN
10 5
36
1 PNK YEL
27
17 26
BLK LT BLU
8
9
PPL E09-28
RED E09-3
12 2 7
WHT E09-15
13 GRN E09-20
18
BLK E09-34
GRN E09-17
19
GRY E09-30 24
BRN E09-8
[A] E09 20
YEL E09-19
LT BLU E09-18
1 21
26 PNK E09-6
3
28 15
4 GRY E09-31
29 16
5 14
30 17 BLU E09-13
6
31 18 PNK E09-9
7 30
32 19
8 15
33 20
9 WHT E09-36
34 21
10
35 22
11 [D] 5
36 23
12 37 22
37 24 1 YEL BRN E09-38
13
38 25 BRN
14
23
27
RED
2
[D] 16
PPL E09-32
[a]
BLK E09-2
BLK E09-27
: 38 : 5V : 12V
INTA0A460011-03
[A]: ESP® hydraulic unit / control module 11. Steering angle sensor 25. ESP® hydraulic unit / control module
assembly connector (View: [a]) assembly
[B]: Ignition switch model 12. Brake fluid level switch 26. CPU
[C]: Keyless push start model 13. Parking brake switch 27. Brake master cylinder pressure sensor
[D]: M/T model 14. Brake booster pressure sensor 28. Pump motor relay
1. From battery 15. ESP® OFF switch 29. Pump motor
2. To other control modules by CAN 16. CPP No.2 switch 30. Solenoid valve circuit
3. To ECM 17. Yaw rate / G sensor 31. “ABS MOT” fuse
4. Relay box 18. Left-front wheel speed sensor 32. “ABS SOL” fuse
5. J/B 19. Right-front wheel speed sensor 33. “IG1 SIG” fuse
6. Lighting and turn signal switch 20. Left-rear wheel speed sensor 34. “DOME 2” fuse
7. CAN driver 21. Right-rear wheel speed sensor 35. “ABS” fuse
8. BCM 22. Back up light switch 36. “STOP” fuse
9. Brake light 23. Back up light 37. “BACK” fuse
10. Brake light switch 24. Wheel speed sensor driver 38. Ground
Terminal Wire color Circuit

1 WHT Solenoid valve power supply circuit
2 BLK ESP® control module ground circuit
3 RED CAN communication line (high)
5 BRN Ignition power supply circuit
6 PNK Right-rear wheel speed sensor signal circuit
8 BRN Left-rear wheel speed sensor power supply circuit
9 PNK Brake booster pressure sensor ground circuit
13 BLU Brake booster pressure sensor signal circuit
15 WHT CAN communication line (low)
17 GRN Right-front wheel speed sensor power supply circuit
18 LT BLU Right-rear wheel speed sensor power supply circuit
19 YEL Left-rear wheel speed sensor signal circuit
20 GRN Left-front wheel speed sensor power supply circuit
26 RED Pump motor power supply circuit
27 BLK ESP® control module ground circuit
28 PPL Vehicle speed output circuit
30 GRY Right-front wheel speed sensor signal circuit
31 GRY Brake booster pressure sensor power supply circuit
32 PPL CPP No.2 switch signal circuit
34 BLK Left-front wheel speed sensor signal circuit
36 WHT ESP® OFF switch signal circuit
38 RED Back up light switch signal circuit
Component Location
ESP® Component Location
AENNTA0E4603001 (04(01)
Engine compartment and exterior
11
10
2
5
[A]: 3
8
9
6 7
IMTA0A460005-01
[A]: 5AGS model 4. Brake booster pressure sensor 8. Rear wheel speed sensor
1. ESP® hydraulic unit / control 5. Relay box 9. Rear wheel hub assembly incorporating rear wheel
module assembly speed sensor encoder
2. ECM 6. Front wheel speed sensor 10. “ABS SOL” fuse
3. TCM 7. Front wheel hub assembly incorporating front wheel 11. “ABS MOT” fuse
4 5 6 7 4 5 6 7
3 3
[A] [B]
11
10 [E]: 12
[C] [D]
14
15
1 2
13 16 10
IMTA0A460006-03
[A]: Segment display type 3. Combination meter 10. J/B

[B]: Color dot display type 4. Brake system warning light (red) 11. Brake light switch
[C]: Non-auto-on headlight model 5. ABS warning light 12. CPP No.2 switch
[D]: Auto-on headlight model 6. ESP® warning light 13. “IG1 SIG” fuse
[E]: M/T model 7. ESP® OFF light 14. “DOME2” fuse
1. Steering angle sensor 8. P/S control module / motor assembly 15. “ABS” fuse
2. Lighting and turn signal switch 9. BCM 16. “STOP” fuse

ESP® System Check
AENNTA0E4604001 (06(01)
Refer to the description after the following general flow for details of each step.
Step 1 Malfunction analysis (Step 1: Malfunction Analysis)

1) Perform “Customer complaint analysis”.
2) Perform “Problem symptom confirmation”.
3) Perform “DTC check, record and clearance” and recheck DTC.
Is the same DTC detected again after performing DTC clearance?
Yes Check and repair referring to applicable DTC troubleshooting, and then go to Step 6.
No Go to Step 2.

1) Perform “Step 2: Visual Inspection”.

No Go to Step 3.
Step 3 Road test

1) Perform “Step 3: Road Test”.

No Go to Step 4.
Step 4 Brake diagnosis

1) Check and repair brake system. (Step 4: Brake Diagnosis)

No Go to Step 5.

1) Check for intermittent problems. (Step 5: Intermittent Problem Check)

No Go to Step 6.

Yes Go to Step 4.
No End.
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 will facilitate collecting information for proper analysis
and diagnosis.
Customer's name: Model: VIN:
● ESP® warning light abnormal: fails to turn on / fails to turn off

● ABS warning light abnormal: fails to turn on / fails to turn off
● Brake system warning light (red) abnormal
: fails to turn on / fails to turn off
● Abnormal noise while vehicle is running: from motor, from valve,
other___________________
● Wheel is locked at braking:
Problem Symptoms ● Wheel skids at turning:
● Pump motor does not stop (running):
● Braking does not work:
● Other:
● Continuous / Intermittent ( times a day, a month) /

Frequency of occurrence other______________
● Vehicle at stop & ignition “ON”:

● When starting: at initial start only / at every start / other ________________
Vehicle speed: while accelerating / while decelerating / while stopping /
while turning / while running at constant speed /
Conditions for other___________________
Occurrence of Problem ● Road surface condition: paved road / rough road / snow-covered road /
other______________________
● Chain equipment:
● Weather: fair / cloudy / rainy / snowy /other___________________

Environmental Condition ● Temperature: °C ( °F)
● First check: No DTC / DTC ( )
Diagnostic Trouble Code ● Second check after test drive: No DTC / DTC ( )
IMTA0A460026-01
Problem symptom confirmation DTC check, record and clearance

If symptom in “Customer Questionnaire” is found or Perform “DTC Check” procedure, record it and then
reproduced in the vehicle, check that the symptom is clear it. (DTC Clearance)
problem or not. (This step should be done with the Recheck DTC. (DTC Check)
customer if possible.) Check warning light related to When DTC which is recorded at DTC check procedure is
brake system referring to “Brake System Warning Light detected again after performing DTC clearance, go to
(Red) Check”, “ABS Warning Light Check” and “ESP® “DTC Check” to perform the diagnosis.
Warning Light Check” under “Warning Light Check”. When DTC which is recorded at DTC check procedure is
not detected anymore after performing DTC clearance,
ESP® control module does not perform the system
diagnosis, or temporary abnormality may occur,

therefore go to “Step 3: Road Test” to perform the Perform Road Test as follows to check if each warning
diagnosis. light lights up.
1) Drive at 40 km/h (25 mph) for over two minutes.
Step 2: Visual Inspection 2) Turn right and left at over 10 km/h (6 mph) for over a
As a preliminary step, perform visual check of the items second by turning steering wheel over 45 degrees.
that support proper function of the ESP® system. (Visual
3) Drive at 60 km/h (37 mph) for over three seconds.
Inspection)
4) Stop the vehicle using foot brake from driving at 60
Step 3: Road Test km/h (37 mph).
! WARNING Step 4: Brake Diagnosis

Check the parts or system suspected as a possible
If you do not select a suitable route and take cause referring to “Brake System Description” in Section
proper precautions when performing a road 4A and based on symptoms appearing on the vehicle
test, an accident can occur. (symptoms observed through Step 1 – 3)). Repair faulty
• Select a level road with no traffic to parts or replace them, if necessary.
minimize the risk of accident.
• Perform the test extremely carefully. Step 5: Intermittent Problem Check
• Perform the road test with 2 persons, a Check parts that are prone to cause intermittent trouble
driver and a tester. (e.g. wire harness, connector), referring to “Intermittent
Connection and Poor Contact Inspection” in Section 00
and the related circuit of which DTC is recorded in Step 1
NOTE
– 5.
The ESP® control module monitors signals
from each wheel speed sensor, yaw rate/ G Step 6: Final Confirmation Test
senor and steering angle sensor (lighting and Check that the problem symptom is not observed any
turn signal switch assembly) while running more and ESP® is free from any abnormal conditions. If
vehicle. It is necessary to perform road test what has been repaired is related to malfunction DTC,
when detecting malfunction(s) related DTCs clear the DTC referring to “DTC Clearance”, perform
of above sensor(s) and canceling fail-safe. road test and check that the DTC is not indicated.
Visual Inspection
AENNTA0E4604002 (06(01)
• Battery – Fluid level, leakage “Battery Description” in Section 1J
• Connectors of electric wire harness – “Intermittent Connection and Poor Contact Inspection” in
Disconnection, friction Section 00
• Fuses – Burning —
• Brake fluid – Fluid level, leakage “Brake Fluid Level Inspection” in Section 4A
• ABS warning light – Operation
• Brake system warning light (red) – Operation “Warning Light Check”
• ESP® warning light – Operation
• Other parts that can be checked visually —
ESP® Symptom Diagnosis

AENNTA0E4604003 (06(04)
ESP® warning light remains lit for more than 2 seconds after setting ignition “ON”
• Malfunctioning ESP® function Perform ESP® system check. (ESP® System Check)
® warning light circuit Check ESP® warning light circuit. (ESP® Warning Light
• Malfunctioning ESP
Comes ON Steady)
ABS warning light remains lit for more than 2 seconds after setting ignition “ON”
• Malfunctioning ABS warning light circuit Check ABS warning light circuit. (ABS Warning Light
Comes ON Steady)
ABS and/or ESP® warning light does not turn ON after setting ignition “ON”
• Malfunctioning CAN communication system
function Check CAN communication system. (CAN Communication
®
• Malfunctioning ESP warning light circuit Check ESP® warning light circuit. (ESP® Warning Light
Does Not Come ON after Setting Ignition “ON”)
• Malfunctioning ABS warning light circuit Check ABS warning light circuit. (ABS Warning Light Does
Not Come ON after Setting Ignition “ON”)
ABS warning light blinks

• Brake system is not filled with brake fluid Fill brake system with brake fluid.
Brake system warning light (red) remains lit for more than 2 seconds after setting ignition “ON”
• Parking brake applied Release parking brake and check that brake system
warning light (red) turns OFF.
• Insufficient amount of brake fluid Check brake fluid level. (Brake Fluid Level Inspection) in
Section 4A
• Faulty parking brake switch circuit and/or brake
fluid level switch circuit Check BCM and its circuit. (Inspection of BCM and Its
• Faulty parking brake switch and/or brake fluid level
switch Check parking brake switch and/or brake fluid level switch.
• Parking brake switch: (Parking Brake Switch Inspection)
in Section 4D
• Brake fluid level switch: (Brake Fluid Level Switch
• Faulty ESP® control module power supply and
ground circuits Check ESP® control module power supply and ground
circuits. (ESP® Control Module Power Supply and Ground
Circuit Check)
• Faulty BCM Check BCM and its circuit. (Inspection of BCM and Its
• Faulty ESP® control module Replace ESP® control module. (ESP® Hydraulic Unit /
System Warning Light (Red) Comes ON Steady)
Brake system warning light (red) does not turn ON after setting ignition “ON”
System Warning Light (Red) Does Not Come ON after
Setting Ignition “ON”)
Warning Light Check

AENNTA0E4604004 (06(01)
ESP® Warning Light Check

[A]
2) Check that ESP® warning light (1) comes ON for
about 2 seconds and then goes OFF.
If ESP® warning light never lights up, go to “ESP®
Warning Light Does Not Come ON after Setting
Ignition “ON””. If ESP® warning light remains ON and
no DTC is stored in ESP® control module, go to
“ESP® Warning Light Comes ON Steady”.
[A] 1
[B]
IMTA0A450006-02
[B]
Brake System Warning Light (Red)
NOTE
Perform this check on a level place.
1) Check brake fluid level. (Brake Fluid Level

IMTA0A460007-02
2) Pull parking brake lever.
ABS Warning Light 4) Check that brake system warning light (red) (1)
1) Set ignition “ON”. comes ON. If brake system warning light (red) never
2) Check that ABS warning light (1) comes ON for lights up, go to “Brake System Warning Light (Red)
about 2 seconds and then goes OFF. If ABS warning Does Not Come ON after Setting Ignition “ON””.
light never lights up, go to “ABS Warning Light Does
Not Come ON after Setting Ignition “ON””. If ABS
warning light remains ON and no DTC is stored in
ESP® control module, go to “ABS Warning Light
Comes ON Steady”.
• Check CAN communication system.

[A] (“Control Module Communication Bus Off”
is detected in any control module.)
(Troubleshooting for Communication Bus
Off): CAN in Section 10H
• Check central gateway control module
(Inspection of Central Gateway Control
Gateway) in Section 10H
1 • Check ESP® control module power circuit
and ground circuit. (ESP® Control Module
Power Supply and Ground Circuit Check)
[B]
3) Disconnect SUZUKI scan tool from DLC. (Suzuki

DTC Clearance
AENNTA0E4604006 (06(01)
IMTA0A450007-03
SUZUKI scan tool.
further details.
5) Release parking brake lever and check that brake
system warning light (red) goes OFF. If brake system NOTE
warning light (red) remains ON and no DTC is stored
in ESP® control module, go to “Brake System • If communication between SUZUKI scan
Warning Light (Red) Comes ON Steady”. tool and ESP® control module is not
possible, perform the following checks:
DTC Check – Check communication condition
AENNTA0E4604005 (06(01) between PC and VCI using SUZUKI scan
1) Connect SUZUKI scan tool to DLC. Refer to “Suzuki tool function.
SDT-II Connection and Disconnection” in Section – Check DLC power circuit and ground
0A. circuit.
2) Check DTC and follow the instructions displayed on – Check CAN communication circuit and
SUZUKI scan tool. connectors between DLC and central
Refer to Operator's Manual of SUZUKI scan tool for gateway control module. (Refer to
further details. “Diagnosis flow: [a]” in
NOTE “Troubleshooting” of “Troubleshooting
for Lost Communication”: CAN in
If communication between SUZUKI scan tool Section 10H.)
and ESP® control module is not possible,
DLC cable by substituting a known-good
• Check communication condition between DLC cable.
function.
(“Control Module Communication Bus
• Check DLC power circuit and ground Off” is detected in any control module.)
circuit. (Troubleshooting for Communication
• Check CAN communication circuit and Bus Off): CAN in Section 10H
connectors between DLC and central – Check central gateway control module
gateway control module. (Refer to power supply circuit and ground circuit.
“Diagnosis flow: [a]” in “Troubleshooting” (Inspection of Central Gateway Control
of “Troubleshooting for Lost Module and Its Circuits): CAN (Central
Communication”: CAN in Section 10H.) Gateway) in Section 10H
cable.
– Check ESP® control module power normal condition referring to “Fail-safe

circuit and ground circuit. (ESP® condition” under “Fail-Safe Table”. Clear
Control Module Power Supply and DTCs after changing current DTCs to
Ground Circuit Check) history DTCs.
current trouble is present. Solve the 3) Disconnect SUZUKI scan tool from DLC. (Suzuki
trouble and check that the system is in SDT-II Connection and Disconnection) in Section 0A
DTC Table
AENNTA0E4604007 (06(01)
NOTE
• If you do not perform “ESP® System Check” before starting the diagnosis, the diagnosis will show a
false result.
Perform “ESP® System Check” before starting the diagnosis.
• *1: Whether ABS warning light, brake system warning light (red) or ESP® warning light lights up or
not depends on DTC detecting condition.
• *2: DTC is cleared automatically when sensor is calibrated.
• *3: In case that both DTC C1124-09 and C1175-54 are detected at the same time, go to DTC C1124-09
troubleshooting.
Brake
ABS system ESP®
DTC DTC name warning warning warning
light light light
(red)
C1115-92 (DTC C1115-92 / C1117- Longitudinal G Sensor in Yaw Rate / G Sensor Lights
OFF OFF
92 / C1123-92) Assembly Failure up
C1116-62 (DTC C1116-62) Brake Light Switch Circuit Performance Lights
OFF OFF
up
C1117-92 (DTC C1115-92 / C1117- Lateral G Sensor Circuit Performance Lights
OFF OFF
92 / C1123-92) up
C111C-00 (DTC C111C-00) Vehicle Variant Data Mismatched Lights
OFF OFF
up
C1121-01 (DTC C1121-01 / Right-Front Wheel Speed Sensor Circuit Voltage
C1121-92 / C1125-01 / C1125-92 / Lights
Lights up OFF
C1131-01 / C1131-92 / C1133-62 / up
C1135-01 / C1135-92)
C1121-92 (DTC C1121-01 / Right-Front Wheel Speed Sensor or Encoder Signal
C1121-92 / C1125-01 / C1125-92 / Performance Lights
Lights up OFF
C1131-01 / C1131-92 / C1133-62 / up
C1135-01 / C1135-92)
C1123-92 (DTC C1115-92 / Yaw Rate Sensor Circuit Performance Lights
OFF OFF
C1117-92 / C1123-92) up
C1124-09 *3 (DTC C1124-09) Steering Angle Sensor Circuit Performance Lights
OFF OFF
up
C1125-01 (DTC C1121-01 / Left-Front Wheel Speed Sensor Circuit Voltage
C1121-92 / C1125-01 / C1125-92 / Lights
Lights up OFF
C1131-01 / C1131-92 / C1133-62 / up
C1135-01 / C1135-92)
C1125-92 (DTC C1121-01 / Left-Front Wheel Speed Sensor or Encoder Signal
Lights up OFF
C1131-01 / C1131-92 / C1133-62 / up
C1135-01 / C1135-92)
C1127-29 (DTC C1127-29) ESP® OFF Switch Circuit Failure OFF OFF OFF
C1128-92 (DTC C1128-92) Master Cylinder Pressure Sensor Circuit Voltage Lights
OFF OFF
up
C112A-00 (DTC C112A-00) ABS Control Continuous Operation Lights
Lights up Lights up
up
Brake
ABS system ESP®
light light light
(red)
C112B-92 (DTC C112B-92) Brake Booster Pressure Sensor System Malfunction Lights
OFF OFF
up
C1131-01 (DTC C1121-01 / Right-Rear Wheel Speed Sensor Circuit Voltage
C1121-92 / C1125-01 / C1125-92 / Lights
Lights up OFF
C1131-01 / C1131-92 / C1133-62 / up
C1135-01 / C1135-92)
C1131-92 (DTC C1121-01 / Right-Rear Wheel Speed Sensor or Encoder Signal
Lights up OFF
C1131-01 / C1131-92 / C1133-62 / up
C1135-01 / C1135-92)
C1133-62 (DTC C1121-01 / Wheel Speed Sensor Deviation
C1121-92 / C1125-01 / C1125-92 / Lights
*1 *1
C1131-01 / C1131-92 / C1133-62 / up
C1135-01 / C1135-92)
C1135-01 (DTC C1121-01 / Left-Rear Wheel Speed Sensor Circuit Voltage
C1121-92 / C1125-01 / C1125-92 / Lights
Lights up OFF
C1131-01 / C1131-92 / C1133-62 / up
C1135-01 / C1135-92)
C1135-92 (DTC C1121-01 / Left-Rear Wheel Speed Sensor or Encoder Signal
Lights up OFF
C1131-01 / C1131-92 / C1133-62 / up
C1135-01 / C1135-92)
C1137-1C (DTC C1137-1C) Steering Angle Sensor Power Supply Voltage Lights
OFF OFF
up
C1137-82 (DTC C1137-82) Steering Angle Sensor Detects Rolling Counter Lights
OFF OFF
Failure up
C1138-76 (DTC C1138-76) Steering Angle Sensor Offset Failure Lights
OFF OFF
up
C1139-49 (DTC C1139-49 / Yaw Rate / G Sensor Assembly Internal Failure Lights
OFF OFF
C1171-49) up
C1141-07 (DTC C1141-07 / Right-Front Inlet Solenoid Valve Circuit Correlation
C1142-07 / C1143-07 / C1144-07 /
Lights
C1145-07 / C1146-07 / C1151-07 / Lights up Lights up
up
C1152-07 / C1153-07 / C1154-07 /
C1155-07 / C1156-07 / C1163-07)
C1142-07 (DTC C1141-07 / Right-Front Outlet Solenoid Valve Circuit Correlation
C1142-07 / C1143-07 / C1144-07 /
Lights
up
C1152-07 / C1153-07 / C1154-07 /
C1155-07 / C1156-07 / C1163-07)
C1143-07 (DTC C1141-07 / Cut Solenoid No.1 Valve Circuit Correlation
C1142-07 / C1143-07 / C1144-07 /
Lights
up
C1152-07 / C1153-07 / C1154-07 /
C1155-07 / C1156-07 / C1163-07)
C1144-07 (DTC C1141-07 / Cut Solenoid No.2 Valve Circuit Correlation
C1142-07 / C1143-07 / C1144-07 /
Lights
up
C1152-07 / C1153-07 / C1154-07 /
C1155-07 / C1156-07 / C1163-07)
C1145-07 (DTC C1141-07 / Left-Front Inlet Solenoid Valve Circuit Correlation
C1142-07 / C1143-07 / C1144-07 /
Lights
up
C1152-07 / C1153-07 / C1154-07 /
C1155-07 / C1156-07 / C1163-07)
Brake
ABS system ESP®
light light light
(red)
C1146-07 (DTC C1141-07 / Left-Front Outlet Solenoid Valve Circuit Correlation
C1142-07 / C1143-07 / C1144-07 /
Lights
up
C1152-07 / C1153-07 / C1154-07 /
C1155-07 / C1156-07 / C1163-07)
C1147-62 (DTC C1147-62 / Both-Front Wheel Speed Sensor or Encoder Signal Lights
Lights up OFF
C1148-62) Performance up
C1148-62 (DTC C1147-62 / Both-Rear Wheel Speed Sensor or Encoder Signal Lights
Lights up OFF
C1148-62) Performance up
C114A-29 (DTC C114A-29) Clutch Pedal Position No.2 Switch System Lights
OFF OFF
Malfunction up
C114B-29 (DTC C114B-29) Back Up Light Switch System Malfunction Lights
OFF OFF
up
C1151-07 (DTC C1141-07 / Right-Rear Inlet Solenoid Valve Circuit Correlation
C1142-07 / C1143-07 / C1144-07 /
Lights
up
C1152-07 / C1153-07 / C1154-07 /
C1155-07 / C1156-07 / C1163-07)
C1152-07 (DTC C1141-07 / Right-Rear Outlet Solenoid Valve Circuit Correlation
C1142-07 / C1143-07 / C1144-07 /
Lights
up
C1152-07 / C1153-07 / C1154-07 /
C1155-07 / C1156-07 / C1163-07)
C1153-07 (DTC C1141-07 / Low Pressure Solenoid No.1 Valve Circuit
C1142-07 / C1143-07 / C1144-07 / Correlation
Lights
up
C1152-07 / C1153-07 / C1154-07 /
C1155-07 / C1156-07 / C1163-07)
C1154-07 (DTC C1141-07 / Low Pressure Solenoid No.2 Valve Circuit
C1142-07 / C1143-07 / C1144-07 / Correlation
Lights
up
C1152-07 / C1153-07 / C1154-07 /
C1155-07 / C1156-07 / C1163-07)
C1155-07 (DTC C1141-07 / Left-Rear Inlet Solenoid Valve Circuit Correlation
C1142-07 / C1143-07 / C1144-07 /
Lights
up
C1152-07 / C1153-07 / C1154-07 /
C1155-07 / C1156-07 / C1163-07)
C1156-07 (DTC C1141-07 / Left-Rear Outlet Solenoid Valve Circuit Correlation
C1142-07 / C1143-07 / C1144-07 /
Lights
up
C1152-07 / C1153-07 / C1154-07 /
C1155-07 / C1156-07 / C1163-07)
C1157-1C (DTC C1157-1C) Power Supply Voltage Lights
*1 *1
up
C1161-07 (DTC C1161-07) Pump Motor Circuit Performance Lights
Lights up Lights up
up
C1162-00 (DTC C1162-00) Solenoid Valve Continuous Operation Failure Lights
Lights up Lights up
up
C1163-07 (DTC C1141-07 / Solenoid Valve Power Supply Driver Circuit
C1142-07 / C1143-07 / C1144-07 / Performance
Lights
up
C1152-07 / C1153-07 / C1154-07 /
C1155-07 / C1156-07 / C1163-07)
Brake
ABS system ESP®
light light light
(red)
C1169-00 (DTC C1169-00) Steering Angle Sensor Specification Unregistered Lights
OFF OFF
up
C1171-49 (DTC C1139-49 / ESP® Control Module Internal Failure Lights
Lights up Lights up
C1171-49) up
C1174-54 *2 (DTC C1174-54 / G Sensor Calibration Lights
OFF OFF
C1175-54) up
C1175-54 *2, *3 (DTC C1174-54 / Steering Angle Sensor Calibration Lights
OFF OFF
C1175-54) up
C1190-82 (DTC C1190-82 / ECM Detect Rolling Counter Failure from ESP® Lights
OFF OFF
C1194-81 / U0401-81) Control Module up
C1194-81 (DTC C1190-82 / Torque Request Reject Status Lights
OFF OFF
C1194-81 / U0401-81) up
U0073-88 (DTC U0073-88) Control Module Communication Bus Off Lights
OFF OFF
up
U0100-87 (DTC U0100-87 / Lost Communication With ECM
Lights
U0101-87 / U0126-87 / U0140-87 / OFF OFF
up
U1082-87)
U0101-87 (DTC U0100-87 / Lost Communication With TCM
Lights
U0101-87 / U0126-87 / U0140-87 / OFF OFF
up
U1082-87)
U0126-87 (DTC U0100-87 / Lost Communication With Steering Angle Sensor
Lights
U0101-87 / U0126-87 / U0140-87 / Module OFF OFF
up
U1082-87)
U0140-87 (DTC U0100-87 / Lost Communication With Body Control Module
Lights
U0101-87 / U0126-87 / U0140-87 / OFF OFF
up
U1082-87)
U0401-81 (DTC C1190-82 / Invalid Data Received From ECM Lights
OFF OFF
C1194-81 / U0401-81) up
U0402-81 (DTC U0402-81) Invalid Data Received From TCM Lights
OFF OFF
up
U1082-87 (DTC U0100-87 / Lost Communication With ENG A-STOP Control
Lights
U0101-87 / U0126-87 / U0140-87 / Module OFF OFF
up
U1082-87)
U1410-81 (DTC U1410-81) Invalid Data Received From ENG A-STOP Control Lights
OFF OFF
Module up
Fail-Safe Table
AENNTA0E4604008 (06(01)
When any of the following DTCs is detected, ESP® control module changes the control to the fail-safe mode and ABS,
EBD, traction control and stability control functions are deactivated until ESP® control module judges the system is
normal.
NOTE
• O: Activated
• –: Deactivated
• *1: Whether ESP® system 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, brake system warning light (red) or
ESP® warning light.
– When ABS warning light lights up, ABS control is deactivated.
– When brake system warning light (red) lights up, EBD control is deactivated.
– When ESP® warning light lights up, traction control and stability control are deactivated.
Fail-safe operation
Traction
DTC control / Hill hold Fail-safe cancel condition
ABS EBD
Stability control
control
C1115-92 (DTC C1115-92 / C1117-
○ ○ – –
92 / C1123-92)
C1116-62 (DTC C1116-62) ○ ○ – –
C1117-92 (DTC C1115-92 / C1117- When ESP® control module judges
○ ○ – –
92 / C1123-92) the system to be normal, after
C111C-00 (DTC C111C-00) ○ ○ – – switching ignition from “OFF” to
C1121-01 (DTC C1121-01 / C1121- “ON”.
92 / C1125-01 / C1125-92 / C1131-
– ○ – –
01 / C1131-92 / C1133-62 / C1135-
01 / C1135-92)
92 / C1125-01 / C1125-92 / C1131- the system to be normal and “Road
01 / C1131-92 / C1133-62 / C1135- – ○ – – Test” under “ESP® System Check”
01 / C1135-92) is performed after switching
ignition from “OFF” to “ON”.
C1123-92 (DTC C1115-92 / C1117-
○ ○ – –
92 / C1123-92)
When ESP® control module judges
C1124-09 (DTC C1124-09) ○ ○ – ○
the system to be normal, after
C1125-01 (DTC C1121-01 / C1121-
switching ignition from “OFF” to
92 / C1125-01 / C1125-92 / C1131-
– ○ – – “ON”.
01 / C1131-92 / C1133-62 / C1135-
01 / C1135-92)
C1127-29 (DTC C1127-29) ○ ○ ○ ○ When ESP® control module judges
C1128-92 (DTC C1128-92) the system to be normal, after
○ ○ – – switching ignition from “OFF” to
“ON”.
C112A-00 (DTC C112A-00) When ESP® control module judges
– – – –
the system to be normal.
C112B-92 (DTC C112B-92) ○ ○ – ○
C1131-01 (DTC C1121-01 / C1121-
92 / C1125-01 / C1125-92 / C1131-
– ○ – – switching ignition from “OFF” to
01 / C1131-92 / C1133-62 / C1135-
“ON”.
01 / C1135-92)
C1133-62 (DTC C1121-01 / C1121-
92 / C1125-01 / C1125-92 / C1131-
*1 *1 – –
01 / C1131-92 / C1133-62 / C1135- When ESP® control module judges
01 / C1135-92) the system to be normal, after
C1135-01 (DTC C1121-01 / C1121- switching ignition from “OFF” to
92 / C1125-01 / C1125-92 / C1131- “ON”.
– ○ – –
01 / C1131-92 / C1133-62 / C1135-
01 / C1135-92)
Fail-safe operation
Traction
ABS EBD
Stability control
control
C1137-1C (DTC C1137-1C) When ESP® control module judges
○ ○ – ○
the system to be normal.
C1137-82 (DTC C1137-82) ○ ○ – ○ When ESP® control module judges
C1138-76 (DTC C1138-76) ○ ○ – ○ the system to be normal, after
C1139-49 (DTC C1139-49 / C1171- switching ignition from “OFF” to
○ ○ – –
49) “ON”.
C1141-07 (DTC C1141-07 / C1142-
07 / C1143-07 / C1144-07 / C1145-
07 / C1146-07 / C1151-07 / C1152- – – – –
07 / C1153-07 / C1154-07 / C1155-
07 / C1156-07 / C1163-07)
C1142-07 (DTC C1141-07 / C1142-
07 / C1143-07 / C1144-07 / C1145-
07 / C1146-07 / C1151-07 / C1152- – – – –
07 / C1153-07 / C1154-07 / C1155-
“ON”.
07 / C1156-07 / C1163-07)
C1143-07 (DTC C1141-07 / C1142-
07 / C1143-07 / C1144-07 / C1145-
07 / C1146-07 / C1151-07 / C1152- – – – –
07 / C1153-07 / C1154-07 / C1155-
07 / C1156-07 / C1163-07)
C1144-07 (DTC C1141-07 / C1142-
07 / C1143-07 / C1144-07 / C1145-
07 / C1146-07 / C1151-07 / C1152- – – – –
07 / C1153-07 / C1154-07 / C1155-
07 / C1156-07 / C1163-07)
C1145-07 (DTC C1141-07 / C1142-
07 / C1143-07 / C1144-07 / C1145-
07 / C1146-07 / C1151-07 / C1152- – – – –
07 / C1153-07 / C1154-07 / C1155-
“ON”.
07 / C1156-07 / C1163-07)
C1146-07 (DTC C1141-07 / C1142-
07 / C1143-07 / C1144-07 / C1145-
07 / C1146-07 / C1151-07 / C1152- – – – –
07 / C1153-07 / C1154-07 / C1155-
07 / C1156-07 / C1163-07)
– ○ – –
62) the system to be normal and “Road
C1148-62 (DTC C1147-62 / C1148- Test” under “ESP® System Check”
62) – ○ – – is performed after switching
C114A-29 (DTC C114A-29) ○ ○ – – When ESP® control module judges
C114B-29 (DTC C114B-29) ○ ○ – – the system to be normal.
Fail-safe operation
Traction
ABS EBD
Stability control
control
C1151-07 (DTC C1141-07 / C1142-
07 / C1143-07 / C1144-07 / C1145-
07 / C1146-07 / C1151-07 / C1152- – – – –
07 / C1153-07 / C1154-07 / C1155-
07 / C1156-07 / C1163-07)
C1152-07 (DTC C1141-07 / C1142-
07 / C1143-07 / C1144-07 / C1145-
07 / C1146-07 / C1151-07 / C1152- – – – –
07 / C1153-07 / C1154-07 / C1155-
“ON”.
07 / C1156-07 / C1163-07)
C1153-07 (DTC C1141-07 / C1142-
07 / C1143-07 / C1144-07 / C1145-
07 / C1146-07 / C1151-07 / C1152- – – – –
07 / C1153-07 / C1154-07 / C1155-
07 / C1156-07 / C1163-07)
C1154-07 (DTC C1141-07 / C1142-
07 / C1143-07 / C1144-07 / C1145-
07 / C1146-07 / C1151-07 / C1152- – – – –
07 / C1153-07 / C1154-07 / C1155-
07 / C1156-07 / C1163-07)
C1155-07 (DTC C1141-07 / C1142-
07 / C1143-07 / C1144-07 / C1145-
07 / C1146-07 / C1151-07 / C1152- – – – –
07 / C1153-07 / C1154-07 / C1155-
“ON”.
07 / C1156-07 / C1163-07)
C1156-07 (DTC C1141-07 / C1142-
07 / C1143-07 / C1144-07 / C1145-
07 / C1146-07 / C1151-07 / C1152- – – – –
07 / C1153-07 / C1154-07 / C1155-
07 / C1156-07 / C1163-07)
C1157-1C (DTC C1157-1C) When ESP® control module judges
*1 *1 – –
“ON”.
C1161-07 (DTC C1161-07) When ESP® control module judges
the system to be normal and “Road
– ○ – – Test” under “ESP® System Check”
is performed after switching
C1162-00 (DTC C1162-00) – – – –
07 / C1143-07 / C1144-07 / C1145- the system to be normal, after
07 / C1146-07 / C1151-07 / C1152- – – – – switching ignition from “OFF” to
07 / C1153-07 / C1154-07 / C1155- “ON”.
07 / C1156-07 / C1163-07)
C1169-00 (DTC C1169-00) When new Lighting and turn signal
○ ○ – ○
switch is installed.
Fail-safe operation
Traction
ABS EBD
Stability control
control
C1171-49 (DTC C1139-49 / C1171-
– – – –
49)
C1174-54 (DTC C1174-54 / C1175-
○ ○ – –
54)
C1175-54 (DTC C1174-54 / C1175-
○ ○ – ○
54)
C1190-82 (DTC C1190-82 / C1194-
○ ○ – –
81 / U0401-81)
C1194-81 (DTC C1190-82 / C1194-
○ ○ – –
81 / U0401-81)
U0073-88 (DTC U0073-88) ○ ○ – –
U0100-87 (DTC U0100-87 /
U0101-87 / U0126-87 / U0140-87 / ○ ○ – –
“ON”.
U1082-87)
U0101-87 (DTC U0100-87 /
U0101-87 / U0126-87 / U0140-87 / ○ ○ – –
U1082-87)
U0126-87 (DTC U0100-87 /
U0101-87 / U0126-87 / U0140-87 / ○ ○ – ○
U1082-87)
U0140-87 (DTC U0100-87 /
U0101-87 / U0126-87 / U0140-87 / ○ ○ – –
U1082-87)
U0401-81 (DTC C1190-82 /
○ ○ – –
C1194-81 / U0401-81)
U0402-81 (DTC U0402-81) ○ ○ – –
U1082-87 (DTC U0100-87 /
U0101-87 / U0126-87 / U0140-87 / ○ ○ – –
“ON”.
U1082-87)
U1410-81 (DTC U1410-81) ○ ○ – –
Scan Tool Data

AENNTA0E4604009 (06(01)
ESP® Control Module
NOTE
If communication between SUZUKI scan tool and ESP® 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 CAN communication circuit and connectors between DLC and central gateway control
• 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
• Check central gateway control module power supply circuit and ground circuit. (Inspection of
• Check ESP® control module power circuit and ground circuit. (ESP® Control Module Power Supply

RF Wheel Speed (RF Wheel
Speed, LF Wheel Speed, RR
At stop (Stationary vehicle) 0 km/h (0 MPH)
Wheel Speed and LR Wheel
Speed (km/h / MPH))
LF Wheel Speed (RF Wheel
Speed (km/h / MPH))
RR Wheel Speed (RF Wheel
Speed (km/h / MPH))
LR Wheel Speed (RF Wheel
Speed (km/h / MPH))
Parking (Ignition: “ON”, on level surface) 0 ±0.1 G
G sensor (G Sensor (G)) Accelerating 0 ±0.1 G or more
Decelerating 0 ±0.1 G or less
Ignition: “ON” (Engine stopped) 10.0 – 14.0 V
Voltage (V))
Pump Motor Driver (Pump Inactive (Pump motor not working) 0.0 V
Motor Driver (V)) Active (Pump motor working) 13.0 – 15.0 V
Steering Angle Offset (Steering
Steering angle is being compensated -14 to 14°
Angle Offset (°))
When brake pedal is depressed 3 or more times with
Brake Booster Pressure 0 kPa
engine stopped.
Sensor (Brake Booster
Engine: Idle speed Brake pedal: Released 60 to 80 kPa
Pressure Sensor (kPa))
Engine: Idle speed Brake pedal: Fully depressed 50 to 70 kPa
Master Cyl Press (Master Cyl Brake pedal: Depressed Over 0 ±0.9 MPa
Press (MPa)) Brake pedal: Released 0 ±0.9 MPa
Parking (Ignition: “ON”, on level surface) 0 ±0.1 G
G Sensor (Lateral) (G Sensor
Right turning 0 ±0.1 G or more
(Lateral) (G))
Left turning 0 ±0.1 G or less
Parking (Ignition: “ON”, on level surface) 0 ±4 deg/s
Yaw Rate Sensor (Yaw Rate
Right turning 0 ±5 deg/s or more
Sensor (Deg/s))
Left turning 0 ±5 deg/s or less
Engine: Idle speed with no load after warning up
Engine Speed (Engine Speed
• Radiator cooling fan: Stopped 600 – 700 rpm
(rpm))
• Select lever: “N” range
Front wheels in straight ahead position 0 ±3°
Steering Angle Sensor
Rotate steering wheel once clockwise -360° ±3°
(Steering Angle Sensor (°))
Rotate steering wheel once counterclockwise 360° ±3°
Hill Hold Control State (Hill Hill hold control: Operating ON
Hold Control State (ON / OFF)) Other than above condition OFF
Brake Switch (Brake Switch Brake pedal: Depressed ON
(ON / OFF)) Brake pedal: Released OFF
ABS Control (ABS Control (ON Operating ON
/ OFF)) Not operating OFF
Stability Control (Stability Operating ON
Control (ON / OFF)) Not operating OFF
TCS Control (Brake) (TCS Active brake applied to wheel ON
Control (Brake) (ON / OFF)) Other than above condition OFF
TCS Control (Engine) (TCS Engine torque control: Operating ON
Control (Engine) (ON / OFF)) Other than above condition OFF

ESP® OFF SW State (ESP® ESP® OFF switch: Released OFF
OFF SW State (ON / OFF)) ESP® OFF switch: Pushed ON
Hill Descent Control(Hill
Descent Control (Not Not supported Without
supported))
Hill Hold Control (Hill Hold Equipped with hill hold control function With
Control (With / Without)) Not equipped with hill hold control function Without
IPC Communication State (IPC Equipped with correct steering angle sensor normal
Communication State (normal /
Other than above condition abnormal
abnormal))
Internal Steering Angle Not supported —
When steering angle sensor is working normally. No Failure
Steering Angle Sensor When steering angle sensor is malfunctioning
Temporarily Failed
Status(Steering Angle Sensor temporarily.
Status) When steering angle sensor is malfunctioning all the
Permanently Failed
time.
Scan Tool Data Definition Engine Speed (rpm)

RF Wheel Speed, LF Wheel Speed, RR Wheel Speed This parameter indicates engine speed sent from ECM
and LR Wheel Speed (km/h / MPH) through CAN.
Wheel speed is ESP® control module internal parameter.
It is computed by reference pulses from the wheel speed Steering Angle Sensor (°)
sensor. Steering wheel rotation angle is measured by lighting
and turn signal switch and output to ESP® control
G Sensor (G) module by CAN communication signal.
Acceleration and deceleration are measured by yaw rate
/ G sensor in ESP® control module. Hill Hold Control State (ON / OFF)
This informs whether hill hold control is operating or not.
Battery Voltage (V)
Battery voltage is an analog input signal read by ESP® Brake Switch (ON / OFF)
control module. ESP® control module functions may be These switch signals inform ESP® control module
stopped if battery voltage falls below or rises above whether brake pedal is depressed or not.
programmed thresholds.
ABS Control (ON / OFF)
Pump Motor Driver (V) This informs whether ABS control is operating or not.
This parameter indicates operational condition of pump
motor driver (transistor). Stability Control (ON / OFF)
This parameter informs whether active brake is
Steering Angle Offset (°) operating or not when vehicle is oversteering or
This value is calculated based on steering angle understeering.
computed in ESP® control module and steering angle
signal from steering angle sensor. TCS Control (Brake) (ON / OFF)
This informs whether active brake is operating or not
Brake Booster Pressure Sensor (kPa) when vehicle is accelerating.
This parameter indicates negative pressure value in
brake booster. TCS Control (Engine) (ON / OFF)
This informs whether engine torque control is operating
Master Cyl Press (MPa) or not when vehicle is accelerating.
This indicates brake fluid pressure from brake master
cylinder. ESP® OFF SW State (ON / OFF)
This indicates state of ESP® OFF switch.
G Sensor (Lateral) (G)
Lateral acceleration is measured by yaw rate / G sensor Pump Motor Relay (ON / OFF)
in ESP® control module. This parameter indicates the operational condition of
pump motor relay.
Yaw Rate Sensor (Deg/s)
Yaw rate is measured by yaw rate / G sensor in ESP® Hill Descent Control (Not supported)
control module. This parameter is indicated all the time without change.
Hill Hold Control (With / Without) Steering Angle Sensor Status

This informs whether vehicle is equipped with hill hold This parameter indicates the state of Steering Angle
control function or not. Sensor.
IPC Communication State (normal / abnormal)

This informs whether steering angle sensor is equipped
for ESP® or not.
Scan Tool Active Test Table

AENNTA0E4604010 (06(01)
SUZUKI scan tool includes output test function which can force operation of the following relays of systems controlled
by ESP® control module. When a malfunction is found in system controlled by ESP® control module, execute output
test to facilitate judgment of whether the malfunction is on the input or output side of ESP® control module.
For details of SUZUKI scan tool, refer to its Operator’s Manual.
Brake Light Relay
ESP® Warning Light Does Not Come ON after Setting Ignition “ON”
AENNTA0E4604011 (06(03)
System Description
Operation (ON/OFF) of ESP® warning light is controlled by ESP® control module through light driver module in
combination meter.
If ESP® system is in good condition, ESP® control module turns ON ESP® warning light with ignition “ON”, keeps the
light ON for 2 seconds and then turns it OFF. If traction control and stability control are deactivated by ESP® system
failure, ESP® warning light is turned ON continuously by ESP® control module. Also, the light is turned ON
continuously by light driver module when the connector of ESP® control module connector is disconnected.
Troubleshooting

Yes Go to Step 2.
No Go to Step 3.
Step 2 DTC check

4) Check DTC related to CAN communication. (DTC Check)
Yes Go to Troubleshooting for applicable DTC.

No Go to Step3.
Step 3 Fuse check
Yes Go to Step 4.

1) Check CAN communication circuit between ESP® control module and combination meter referring to
“Troubleshooting for Communication Bus Off”: CAN in Section 10H.
Is check result OK?
Yes Go to Step 5.

Is check result OK?
Yes Replace combination meter and recheck warning light operation. (Combination Meter Removal
and Installation) in Section 9C If ESP® warning light does not come ON, replace ESP® hydraulic
unit / control module assembly and recheck warning light operation. (ESP® Hydraulic Unit / Control
ESP® Warning Light Comes ON Steady

AENNTA0E4604012 (06(03)
System Description
Refer to “System Description” under “ESP® Warning Light Does Not Come ON after Setting Ignition “ON””.
Troubleshooting
Step 1 ESP® control module connector check

1) Check for proper connection to ESP® control module connector.
Yes Go to Step 2.
Step 2 DTC check


No Go to Step 3.
Step 3 ESP® control module power supply and ground circuit check
1) Check ESP® control module power supply and ground circuits. (ESP® Control Module Power Supply
Is check result OK?
and Installation) in Section 9C If ESP® warning light is turned ON continuously, replace ESP®
hydraulic unit / control module assembly and recheck warning light operation. (ESP® Hydraulic
Unit / Control Module Assembly Removal and Installation)
ABS Warning Light Does Not Come ON after Setting Ignition “ON”
AENNTA0E4604013 (06(03)
System Description
Operation (ON/OFF) of ABS warning light is controlled by ESP® control module through light driver module in
combination meter.
If ESP® system is in good condition, ESP® control module turns ON ABS warning light with ignition “ON”, keeps the
light ON for 2 seconds and then turns it OFF. If ABS control is deactivated by ESP® system failure, ABS warning light
is turned ON continuously by ESP® control module. Also, the light is turned ON continuously by light driver module
when the connector of ESP® control module is disconnected.
Troubleshooting

Yes Go to Step 2.
No Go to Step 3.
Step 2 DTC check

4) Check DTC related to CAN communication.

No Go to Step 3.
Step 3 Fuse check
Yes Go to Step 4.

1) Check CAN communication circuit between ESP® control module and combination meter referring to
“Troubleshooting for Communication Bus Off”: CAN in Section 10H.
Is check result OK?
Yes Go to Step 5.

Is check result OK?
and Installation) in Section 9C If ABS warning light does not come ON, replace ESP® hydraulic unit
/ control module assembly and recheck warning light operation. (ESP® Hydraulic Unit / Control
ABS Warning Light Comes ON Steady

AENNTA0E4604014 (06(03)
System Description
Refer to “System Description” under “ABS Warning Light Does Not Come ON after Setting Ignition “ON””.
Troubleshooting

Yes Go to Step 2.
Step 2 DTC check


No Go to Step 3.
Step 3 ESP® control module power supply and ground circuit check
1) Check ESP® control module power supply and ground circuits. (ESP® Control Module Power Supply
Is check result OK?
and Installation) in Section 9C If ABS warning light is turned ON continuously, replace ESP®
Brake System Warning Light (Red) Does Not Come ON after Setting Ignition “ON”
AENNTA0E4604015 (06(03)
System Description
Refer to “System Description” under “Brake System Warning Light (Red) Comes ON Steady”.
Troubleshooting

Yes Go to “ESP® Warning Light Comes ON Steady”.

No Replace combination meter and recheck warning light operation. (Combination Meter Removal
and Installation) in Section 9C If brake system warning light (red) does not come ON, replace ESP®
Brake System Warning Light (Red) Comes ON Steady

AENNTA0E4604016 (06(03)
System Description
Brake system warning light (red) is controlled by ESP® control module and BCM through light driver module in
combination meter.
If ESP® system is in good condition, ESP® control module turns ON brake system warning light (red) when ignition is
set “ON”, keeps it ON for 2 seconds and then turns it OFF.
Brake system warning light (red) is turned ON continuously in the following conditions.
• EBD control is deactivated by ESP® system 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 ESP® control module is
disconnected.
Troubleshooting

Yes Go to Step 2.
Step 2 Parking brake and brake fluid level check

• Parking brake is completely released.
• Brake fluid level is above minimum level. (Brake Fluid Level Inspection) in Section 4A
Is check result OK?
Yes Go to Step 3.
No Release parking brake and check brake fluid level. (Brake Fluid Level Inspection) in Section 4A
Step 3 ABS warning light operation check

Yes Perform “ABS Warning Light Comes ON Steady”.

No Go to Step 4.
Step 4 Parking brake switch signal circuit and brake fluid level switch signal circuit check
1) Check parking brake switch signal circuit and brake fluid level switch signal circuit. (Inspection of BCM
and Its Circuits) in Section 10B
Is check result OK?
Yes Go to Step 5.

4) Perform “DTC Check”:


No Go to Step 6.

1) Check BCM for DTC. (DTC Check) in Section 10B

No Replace combination meter and recheck warning light operation. (Combination Meter Removal
and Installation) in Section 9C If brake system warning light (red) is turned ON continuously,
replace ESP® hydraulic unit / control module assembly and recheck warning light operation.
(ESP® Hydraulic Unit / Control Module Assembly Removal and Installation)
DTC C1115-92 / C1117-92 / C1123-92

AENNTA0E4604017 (06(02)
C1115-92: Longitudinal G Sensor in Yaw Rate / G Sensor Assembly Failure • ESP® control module
• Longitudinal G sensor signal is out of specified range. • Actuator bracket
• Longitudinal G sensor signal does not change although vehicle is accelerating or • Actuator mount damper
decelerating.
C1117-92: Lateral G Sensor Circuit Performance
• Lateral G sensor signal is out of specified range.
• Lateral G sensor signal does not change although vehicle is turning right or left.
C1123-92: Yaw Rate Sensor Circuit Performance
• Yaw rate sensor signal is out of specified range.
• Although vehicle is in a stop, yaw rate sensor signal is more than specified value.
DTC Troubleshooting
Step 1 Was “ESP® System Check” performed?
Yes Go to Step 2.
No Go to “ESP® System Check”.
Step 2 ESP® control module and actuator bracket check

1) Check ESP® hydraulic unit / control module assembly, actuator bracket and actuator mount damper.
(ESP® Hydraulic Unit / Control Module Assembly On-Vehicle Inspection)
Is check result OK?
Yes Go to Step 3.
No Adjust ESP® hydraulic unit / control module assembly installation condition and recheck DTC.
Step 3 DTC check

Is other DTC(s) than C1115-92, C1117-92 and C1123-92 detected?

No Replace ESP® hydraulic unit / control module assembly and recheck DTC. (ESP® Hydraulic Unit /
DTC C1116-62
AENNTA0E4604018 (06(02)
C1116-62: Brake Light Switch Circuit Performance • Brake light switch circuit
• Brake light switch ON signal is detected for more than specified time • Brake light switch
while vehicle running with accelerator pedal depressed. • J/B
• Brake light switch ON signal is not detected although brake master • ECM
cylinder pressure sensor signal is more than specified value.
• ESP® control module
• CAN communication circuit
Circuit Diagram
3 [A] E09
8 1
1 GRN E181-5 26
E181-2 YEL 7 3
9 28 15
4
1 BLU E181-1 29 16
5
A1 30 17
6
E181-4 E181-3 31 18
7
32 19
BLK 8
33 20
9
34 21
A2 10
5 4 35 22
11
BLU 36 23
12
37 24
E01-28 RED E09-3 13
38 25
E01-44 6 6 14
27
E01-29 WHT E09-15
2
[a]
[B] E181 [D] E01
1 2 3 4 5 1 2 3 4 5 6 7 8 9 10 11 12
[C] E323
13 14 15 16 17 18 19 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 37 38 39 40 41 42 43 44 45 46 47 48
49 50 51 52 53 54 55 56
IMTA0A460022-02
[A]: ESP control module connector (View: [a])

®
A2: Brake light switch signal circuit 5. ECM
[B]: Brake light switch connector (View: [a]) 1. From battery 6. CAN driver
[C]: J/B connector (View: [a]) 2. Brake light switch 7. To brake light
[D]: ECM connector (View: [a]) 3. J/B 8. “IG1 SIG” fuse
A1: Brake light switch power supply circuit 4. ESP® control module 9. “STOP” fuse
DTC Troubleshooting
Yes Go to Step 2.
Step 2 DTC check

Is DTC U0073-88 and/or U0100-87 detected?

No Go to Step 3.
Step 3 Brake light switch power supply circuit check

1) When ignition is “OFF”, disconnect brake light switch connector.
2) Check for proper terminal connection to brake light switch connector.
Is check result OK?
Yes Go to Step 4.

2) Disconnect ECM and “E323” connectors.
3) Check for proper terminal connection to ECM and “E323” connectors.
• Resistance between each of “A2” circuit and ground: infinity
• Resistance between each of “A2” circuit terminal and each terminal at “E323” connector: infinity
• Resistance between each of “A2” circuit and battery positive (+) cable: infinity
• Resistance between each of “A2” circuit and each fuse in J/B: infinity
Is check result OK?
Yes Go to Step 5.
Step 5 Brake light switch check

1) Check brake light switch. (Brake Light Switch Inspection) in Section 4A
Is check result OK?
Yes Go to Step 6.
No Replace brake light switch and recheck DTC. (Brake Light Switch Removal and Installation) in
Section 4A
Step 6 J/B check

1) Connect brake light switch and ECM connectors.
2) When ignition is “ON” and “OFF”, check voltage of “A2” circuit and ground circuit.
• When brake light switch is “OFF”: approx. 0 to 1 V
• When brake light switch is “ON”: approx. battery voltage
Is check result OK?

Yes Go to Step 7.
No Replace J/B and recheck DTC.
Step 7 ECM check

1) Check ECM. (Inspection of ECM and Its Circuits) in Section 1A
Is check result OK?
Yes Replace ESP® hydraulic unit / control module assembly and recheck DTC. (ESP® Hydraulic Unit /
DTC C111C-00
AENNTA0E4604019 (06(02)
C111C-00: Vehicle Variant Data Mismatched • ECM
Inconsistency between vehicle variant data stored in ESP® control • ESP® control module
module and vehicle information signal transmitted via CAN
communication.
DTC Troubleshooting
Yes Go to Step 2.
Step 2 ECM specification check

1) Check ECM part number of the vehicle in service.
Is a correct ECM used for the vehicle in service?
Yes Go to Step 3.
No Replace ECM with a correct one and recheck DTC. (ECM Removal and Installation) in Section 1C
Step 3 ESP® control module specification check

1) Check ESP® control module part number of the vehicle in service.
Is a correct ESP® control module used for the vehicle in service?
No Replace ESP® hydraulic unit / control module assembly with the correct one and recheck DTC.
DTC C1121-01 / C1121-92 / C1125-01 / C1125-92 / C1131-01 / C1131-92 / C1133-62 / C1135-01 / C1135-
92
AENNTA0E4604020 (06(02)

C1121-01 / C1125-01 / C1131-01 / C1135-01: Right-Front / Left-Front / • Wheel speed sensor circuit
Right-Rear / Left-Rear Wheel Speed Sensor Circuit Voltage • Wheel speed sensor
Wheel speed sensor signal is out of specified range.
• Wheel speed sensor encoder
Right-Rear / Left-Rear Wheel Speed Sensor or Encoder Signal • ESP® control module
Performance
Abnormal wheel speed sensor signal is detected continuously.
C1133-62: Wheel Speed Sensor Deviation
• Abnormal wheel speed sensor signal is detected continuously at two
or more wheel speed sensors.
• ABS control is activated for more than specified time.
• Wheel speed sensor driver power supply voltage is out of specified
range.
NOTE
When vehicle was placed in any of the following conditions, one of these DTCs may be set although
sensor is in good condition. If such possibility is suspected, clear DTC once (DTC Clearance) and
check whether any abnormality exists or not by performing road test as described in Step 3 of “ESP®
System Check”.
• Vehicle is driven with parking brake applied.
• Vehicle is driven with brake dragging.
• Vehicle is stuck in mud, sand, etc.
• Wheel spins while driving.
• Wheel(s) is rotated while vehicle is jacked up.
Circuit Diagram
[A] E09
5
1
26
A1
3
GRN E09-20 28 15
1 4
BLK E09-34
29 16
B1 5
30 17
6
A2 31 18
7
GRN E09-17 32 19
2 8
GRY E09-30 33 20
B2 9
6 34 21
10
A3 35 22
11
BRN E09-8 36 23
3 12
YEL E09-19 37 24
B3 13
38 25
14
A4 27
LT BLU E09-18 2
4
PNK E09-6
B4
[a]
INTA0A460012-02
[A]: ESP® control module connector (View: [a]) B1: Left-front wheel speed sensor signal circuit 2. Right-front wheel speed sensor
A1: Left-front wheel speed sensor power supply circuit B2: Right-front wheel speed sensor signal circuit 3. Left-rear wheel speed sensor
A2: Right-front wheel speed sensor power supply circuit B3: Left-rear wheel speed sensor signal circuit 4. Right-rear wheel speed sensor
A3: Left-rear wheel speed sensor power supply circuit B4: Right-rear wheel speed sensor signal circuit 5. ESP® control module
A4: Right-rear wheel speed sensor power supply circuit 1. Left-front wheel speed sensor 6. Wheel speed sensor driver
! WARNING
accident can occur.
NOTE
• The ESP® control module monitors signals from each wheel speed sensor, yaw rate/ G senor and
steering angle sensor (lighting and turn signal switch assembly) while running vehicle. It is
necessary to perform road test when detecting malfunction(s) related DTCs of above sensor(s) and
canceling fail-safe.
– DTC C1157-1C is not detected.

2) Drive vehicle at 20 km/h (12 mile/h) or more for 1 minute or more.
3) Stop vehicle and set ignition “OFF”.
DTC Troubleshooting
Yes Go to Step 2.
Step 2 Tire pressure check

1) Check that tire pressure is at specified value.
Is check result OK?
Yes Go to Step 3.
No Adjust tire pressure or replace tire and recheck DTC. (Wheel (with Tire) Removal and Installation)
in Section 2D
Step 3 Wheel speed sensor power supply circuit and signal circuit check
2) Disconnect “E09” and each of wheel speed sensor connectors.
3) Check for proper terminal connection to “E09” and each of wheel speed sensor connectors.
• Resistance of “A1”, “A2”, “A3”, “A4”, “B1”, “B2”, “B3” and “B4” circuits: less than 1 Ω
• Resistance between each of “A1”, “A2”, “A3”, “A4”, “B1”, “B2”, “B3” and “B4” circuits and ground:
infinity
• Resistance between each terminal of “A1” – “B1”, “A2” – “B2”, “A3” – “B3” and “A4” – “B4” circuits and
each terminal of “E09” connector: infinity
• Voltage of “A1”, “A2”, “A3”, “A4”, “B1”, “B2”, “B3” and “B4” circuits: approx. 0 V (When ignition is “ON”)
Is check result OK?
Yes Go to Step 4.
Step 4 Wheel speed sensor signal check

1) Check applicable wheel speed sensor for output voltage and waveform. (Front and Rear Wheel Speed
Sensor On-Vehicle Inspection)
Is check result OK?
No Go to Step 5.
Step 5 Wheel speed sensor check

1) Check applicable wheel speed sensor. (Front and Rear Wheel Speed Sensor Inspection)
Is check result OK?
Yes Go to Step 6.
No Clean, repair or replace wheel speed sensor and recheck DTC.
• Front wheel speed sensor: (Front Wheel Speed Sensor Removal and Installation)
• Rear wheel speed sensor: (Rear Wheel Speed Sensor Removal and Installation)
Step 6 Wheel speed sensor encoder check

1) Check applicable wheel speed sensor encoder. (Front and Rear Wheel Speed Sensor Encoder
Inspection)
Is check result OK?
No Clean, repair or replace wheel speed sensor encoder and recheck DTC.
• Front wheel speed sensor encoder: (Front Wheel Speed Sensor Encoder Removal and
Installation)
• Rear wheel speed sensor encoder: (Rear Wheel Speed Sensor Encoder Removal and
Installation)
DTC C1124-09
AENNTA0E4604021 (06(02)
C1124-09: Steering Angle Sensor Circuit Performance • Steering angle sensor
• CPU in lighting and turn signal switch detects internal • Lighting and turn signal switch
defect. • ESP® control module
• Steering angle sensor signal is out of specified range.
• Steering angle sensor signal does not change although
vehicle is turning right or left.
DTC Troubleshooting
! WARNING
accident can occur.
NOTE
• Detection of both DTC C1124-09 and/or C1138-76 and C1175-54 means internal malfunction of
steering angle sensor.
Replace lighting and turn signal switch. (Lighting and Turn Signal Switch Removal and Installation)
in Section 9B
Yes Go to Step 2.
Step 2 DTC check

Is DTC U0073-88 and/or U0126-87 detected?

No Go to Step 3.
Step 3 DTC check
Are both DTC C1124-09 and C1175-54 detected?
Yes Replace lighting and turn signal switch. (Lighting and Turn Signal Switch Removal and Installation)
in Section 9B
No Go to Step 4.
Step 4 DTC check
Is DTC C1124-09 detected alone?
Yes Go to Step 5.
No Go to Step 8.
Step 5 Scan tool parameter check 1

1) Check “Steering Angle Offset” using “Data list” mode on SUZUKI scan tool. (Scan Tool Data)
Is steering angle offset -14 to 14°?
Yes Go to Step 8.
No Go to Step 6.
Step 6 Steering wheel straightness check

1) Run vehicle straight ahead and check that steering wheel is in straight position.
Is steering wheel positioned straight?
Yes Go to Step 8.
No Reposition steering wheel and check the straightness running vehicle again, and then go to Step 7.

1) Drive at 40 km/h (25 mph) for about five minutes.

Does numerical value of steering angle offset become closer to 0 (zero) about 4° compared with the value in
Step 2 and is ESP® warning light in off state?
Yes End.
No Go to Step 8.
Step 8 Steering angle sensor on-vehicle inspection

1) Check steering angle sensor. (Steering Angle Sensor On-Vehicle Inspection)
Is check result OK?
Yes Go to Step 9.
No Replace lighting and turn signal switch and recheck DTC. (Lighting and Turn Signal Switch
Step 9 Steering angle sensor inspection

1) Check steering angle sensor. (Steering Angle Sensor Inspection)
Is check result OK?
DTC C1127-29
AENNTA0E4604022 (06(02)
C1127-29: ESP® OFF Switch Circuit Failure • ESP® OFF switch circuit
ESP® OFF switch remains “ON” for more than specified • ESP® OFF switch
time.
Circuit Diagram
[A] E09
1
26
3
28 15
4
29 16
5
30 17
6
31 18
2 7
32 19
8
33 20
12V 9
A1 34 21
1 10
35 22
BLK WHT E09-36 11
36 23
12
37 24
13
38 25
14
27
2
[a]
IMTA0A460009-01
[A]: ESP® control module connector (View: [a]) 1. ESP® OFF switch
A1: ESP® OFF switch signal circuit 2. ESP® control module
DTC Troubleshooting
Yes Go to Step 2.
Step 2 ESP® OFF switch circuit check

2) Disconnect “E09” and ESP® OFF switch connectors.
3) Check for proper terminal connection to “E09” and ESP® OFF switch connectors.
4) If connections are OK, check that resistance between “A1” circuit and ground is infinity.
Is check result OK?
Yes Go to Step 3.
Step 3 ESP® OFF switch check

1) Check ESP® OFF switch. (ESP® OFF Switch Inspection)
Is check result OK?
No Replace ESP® OFF switch and recheck DTC. (ESP® OFF Switch Inspection)
DTC C1128-92
AENNTA0E4604023 (06(02)

C1128-92: Master Cylinder Pressure Sensor Circuit Voltage • Brake system
Brake master cylinder pressure sensor signal is out of specified range. • ESP® control module
DTC Troubleshooting
Yes Go to Step 2.
Step 2 DTC check

Is DTC C1157-1C detected?

No Go to Step 3.
Step 3 Brake master cylinder pressure sensor check

1) Check brake master cylinder pressure sensor. (Brake Master Cylinder Pressure Sensor On-Vehicle
Inspection)
Is check result OK?
Yes Go to Step 4.
Step 4 Brake system check

• Leakage of brake fluid or air in the hydraulic brake system.
• Too large front brake pad-to-disc clearance.
• Too large rear brake drum-to-shoe clearance.
Is check result OK?
No Repair, replace or adjust brake system.
DTC C112A-00
AENNTA0E4604024 (06(02)
C112A-00: ABS Control Continuous Operation ESP® control module
ABS control is activated on all wheels continuously.
NOTE
When DTC C112A-00 is detected, ESP® control module turns off ESP® warning light and ABS warning
light after prohibiting the control, but the DTC will remain as the present DTC during the current
ignition cycle.
When the ignition is turned “ON” after being turned “OFF”, DTC C112A-00 is stored in the ESP® control
module as history DTC.
DTC Troubleshooting
Yes Go to Step 2.
Step 2 DTC check

Is other DTC(s) than C112A-00 detected?

No Go to Step 3.
Step 3 DTC check

Is DTC C112A-00 still detected?
No End.
DTC C112B-92
AENNTA0E4604025 (06(02)
C112B-92: Brake Booster Pressure Sensor System • Brake booster pressure sensor circuit
Malfunction • Brake booster pressure sensor
• The change of the brake booster pressure sensor signal value • ESP® control module
during braking is abnormally small.
• Brake booster pressure sensor signal is out of specified range.
Circuit Diagram
[A] E09
1
26
3
28 15
2 4
29 16
5
30 17
5V 6
31 18
1 A1 7
32 19
GRY E09-31 8
A2 33 20
9
BLU E09-13 34 21
A3 10
35 22
PNK E09-9 11
36 23
12
37 24
13
38 25
14
27
2
[a]
IMTA0A460010-01
[A]: ESP® control module connector (View: [a]) A2: Brake booster pressure sensor signal circuit 1. Brake booster pressure sensor
A1: Brake booster pressure sensor power supply circuit A3: Brake booster pressure sensor ground circuit 2. ESP® control module
DTC Troubleshooting
Yes Go to Step 2.
Step 2 Brake booster pressure sensor power supply circuit check

1) With ignition “OFF”, disconnect brake booster pressure sensor connector.
2) Check for proper terminal connection to brake booster pressure sensor connector.
4) Check that voltage between “A1” and “A3” circuit is approx. 5 V.
Is check result OK?
Yes Go to Step 4.
No Go to Step 3.
Step 3 Brake booster pressure sensor ground circuit check

1) Check that voltage between “A1” circuit and ground is approx. 5 V.
Is check result OK?
Yes Repair or replace “A3” circuit. If DTC C112B-92 is still detected, replace ESP® hydraulic unit /
control module assembly and recheck DTC. (ESP® Hydraulic Unit / Control Module Assembly
No Repair or replace “A1” circuit. If DTC C112B-92 is still detected, replace ESP® hydraulic unit /
control module assembly and recheck DTC. (ESP® Hydraulic Unit / Control Module Assembly
Step 4 Brake booster pressure sensor signal circuit check

1) With ignition “OFF”, disconnect “E09” connector.
• Resistance between “A2” circuit terminal and other terminal at “E09” connector: infinity
Is check result OK?
Yes Go to Step 5.
Step 5 Brake booster pressure sensor check

1) Check brake booster pressure sensor. (Brake Booster Pressure Sensor Inspection (ESP® Model)) in
Section 4A
Is check result OK?
No Replace brake booster assembly and recheck DTC.(Brake Booster Removal and Installation) in
Section 4A
DTC C1137-1C
AENNTA0E4604026 (06(02)
C1137-1C: Steering Angle Sensor Power Supply • Steering angle sensor circuit
Voltage • Steering angle sensor
Steering angle sensor power supply voltage is out of
• Lighting and turn signal switch circuit
specified range.
• Lighting and turn signal switch
DTC Troubleshooting
Yes Go to Step 2
Step 2 DTC check

Is other DTC(s) than C1137-1C, C1137-82 and C1157-1C detected?

No Go to Step 3.
Step 3 DTC check for lighting and turn signal switch

1) Check lighting and turn signal switch for DTC. (DTC Check) in Section 9B

No Go to Step 4.

1) Connect lighting and turn signal switch connector.
Is check result OK?
No Replace lighting and turn signal switch and recheck DTC.(Lighting and Turn Signal Switch
DTC C1137-82
AENNTA0E4604027 (06(02)
C1137-82: Steering Angle Sensor Detect Rolling Counter Failure • CAN communication circuit
Lighting and turn signal switch detects invalid CAN data from ESP® • Steering angle sensor circuit
control module.
• Steering angle sensor
• Lighting and turn signal switch circuit

DTC Troubleshooting
Yes Go to Step 2.
Step 2 DTC check

Is other DTC(s) than C1137-82 detected?

No Go to Step 3.

1) Check CAN communication circuit between ESP® control module and lighting and turn signal switch
referring to “Troubleshooting for Communication Bus Off”: CAN in Section 10H.
Is check result OK?
Yes Replace lighting and turn signal switch and recheck DTC. (Lighting and Turn Signal Switch
Removal and Installation) in Section 9B If DTC C1137-82 is still detected, replace ESP® hydraulic
unit / control module assembly and recheck DTC. (ESP® Hydraulic Unit / Control Module
DTC C1138-76
AENNTA0E4604028 (06(02)
C1138-76: Steering Angle Sensor Offset Failure • Steering angle sensor circuit
The offset value of the steering angle sensor is out of specified range. • Steering angle sensor
circuit
DTC Troubleshooting
! WARNING
accident can occur.
NOTE
• Detection of both DTC C1124-09 and/or C1138-76 and C1175-54 means internal malfunction of
steering angle sensor.
Replace lighting and turn signal switch. (Lighting and Turn Signal Switch Removal and Installation)
in Section 9B
Yes Go to Step 2.
Step 2 DTC check

Is other DTC(s) than U0073-88 and/or U0126-87 detected?

No Go to Step 3.

Is steering angle offset -14 to 14°?
Yes Go to Step 6.
No Go to Step 4.
Step 4 Steering wheel straightness check

1) Run vehicle straight ahead and check that steering wheel is in straight position.
Is steering wheel positioned straight?
Yes Go to Step 6.
No Reposition steering wheel and check the straightness running vehicle again, and then go to Step 5.

1) Drive at 40 km/h (25 mph) for about five minutes.
2) Connect scan tool to DLC. (Suzuki SDT-II Connection and Disconnection) in Section 0A
Does numerical value of steering angle offset become closer to 0 (zero) about 4° compared with the value in
Step 3 and is ESP® warning light in off state?
Yes End.
No Go to Step 6.

Is check result OK?
Yes Go to Step 7.
Step 7 Steering angle sensor inspection

1) Check steering angle sensor. (Steering Angle Sensor Inspection)
Is check result OK?
DTC C1139-49 / C1171-49

AENNTA0E4604029 (06(02)
C1139-49: Yaw Rate / G Sensor Assembly Internal Failure ESP® control module
Yaw rate / G sensor internal failure is detected.
C1171-49: ESP® Control Module Internal Failure
ESP® control module internal failure is detected.
DTC Troubleshooting
Yes Go to Step 2.
Step 2 DTC check

Is other DTC(s) than C1139-49 and C1171-49 detected?

DTC C1141-07 / C1142-07 / C1143-07 / C1144-07 / C1145-07 / C1146-07 / C1151-07 / C1152-07 / C1153-
07 / C1154-07 / C1155-07 / C1156-07 / C1163-07
AENNTA0E4604030 (06(02)
C1141-07 / C1145-07 / C1151-07 / C1155-07: Right-Front / Left-Front / Right- • ESP® control module circuit
Rear / Left-Rear Inlet Solenoid Valve Circuit Correlation • ESP® control module
C1142-07 / C1146-07 / C1152-07 / C1156-07: Right-Front / Left-Front / Right-
Rear / Left-Rear Outlet Solenoid Valve Circuit Correlation
C1143-07 / C1144-07: Cut Solenoid No.1 / No.2 Valve Circuit Correlation
C1153-07 / C1154-07: Low Pressure Solenoid No.1 / No.2 Valve Circuit
Correlation
Electrical failure of solenoid valve.
C1163-07: 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”.
DTC Troubleshooting
Yes Go to Step 2.
Step 2 Solenoid valve power supply and ESP® control module ground circuit check
1) Check solenoid valve power supply and ground circuits. (ESP® Control Module Power Supply and
Is check result OK?
DTC C1147-62 / C1148-62

AENNTA0E4604031 (06(02)
C1147-62: Both-Front Wheel Speed Sensor or • Steering angle sensor
Encoder Signal Performance • Lighting and turn signal switch
Yaw rate value calculated by the front wheel speed
• Wheel speed sensor
sensors does not match with target yaw rate value.
C1148-62: Both-Rear Wheel Speed Sensor or Encoder • Wheel speed sensor circuit
Signal Performance • Wheel speed sensor encoder
Yaw rate value calculated by the rear wheel speed • ESP® control module
sensors does not match with target yaw rate value.
DTC Troubleshooting
Yes Go to Step 2.
Step 2 DTC check

Is other DTC(s) than C1147-62 or C1148-62 detected?

No Go to Step 3.

Is check result OK?
Yes Check applicable wheel speed sensor, wheel speed sensor encoder and/or wheel speed sensor
circuit and recheck DTC. (DTC C1121-01 / C1121-92 / C1125-01 / C1125-92 / C1131-01 / C1131-
92 / C1133-62 / C1135-01 / C1135-92)
No Replace Lighting and turn signal switch and recheck DTC.(Lighting and Turn Signal Switch
Removal and Installation) in Section 9B If DTC C 1148 -62 is still detected, replace ESP® hydraulic
unit/control module assembly and recheck DTC. (ESP® Hydraulic Unit / Control Module Assembly
DTC C114A-29
AENNTA0E4604032 (06(02)
C114A-29: Clutch Pedal Position No.2 Switch System • CPP No.2 switch circuit
Malfunction • CPP No.2 switch
CPP No.2 switch signal is out of specified range.
Circuit Diagram
[A] E09
1
26
3
28 15
4
29 16
5
30 17
6
2 31 18
7
32 19
8
12V 33 20
9
A2 A1 34 21
1 10
PPL E09-32 35 22
11
36 23
BLK 12
37 24
13
38 25
14
27
2
[a]
IMTA0A460024-03
[A]: ESP® control module connector (View: [a]) A2: CPP No.2 switch ground circuit 2. ESP® control module
A1: CPP No.2 switch signal circuit 1. CPP No.2 switch
DTC Troubleshooting
Yes Go to Step 2.
Step 2 CPP No.2 switch signal circuit check

1) With ignition “OFF”, disconnect CPP No.2 switch connector.
2) Check for proper connection to CPP No.2 switch connector.
Is check result OK?
Yes Go to Step 3.
Step 3 CPP No.2 switch ground circuit check

2) Check that resistance between “A2” circuit and ground is less than 1 Ω.
Is check result OK?
Yes Go to Step 4.
Step 4 CPP No.2 switch check

1) Check CPP No.2 switch. (CPP No.2 Switch Inspection and Adjustment) in Section 5C
Is check result OK?

No Replace CPP No.2 switch. (CPP No.2 Switch Removal and Installation) in Section 5C
DTC C114B-29
AENNTA0E4604033 (06(02)
C114B-29: Back Up Light Switch System Malfunction • Back up light switch circuit
Reverse signal is out of specified range. • Back up light switch
Circuit Diagram
[A] E09
1 1
26
A1 4 3
3
2 E323-10 YEL 5 28 15
4
29 16
5
30 17
A2 6
E323-23 BRN BRN E09-38 31 18
7
32 19
6 8
33 20
9
L314-33 RED 34 21
10
35 22
11
36 23
12
37 24
G271-45 RED 7 13
38 25
14
[B] E323 27
2
1 2 3 4 5 6
[a]
7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33 34 35 36 37
IMTA0A460025-02
[A]: ESP® control module connector (View: [a]) 1. J/B 5. ESP® control module
[B]: J/B connector (View: [a]) 2. Ignition power supply 6. Back up light
A1: Back up light switch power supply circuit 3. “BACK” fuse 7. To navigation (if equipped)
A2: Back up light switch signal circuit 4. Back up light switch
DTC Troubleshooting
Yes Go to Step 2.
Step 2 Back up light switch power supply circuit check

1) With ignition “OFF”, disconnect back up light switch connector.
2) Check for proper connection to back up light switch connector.
Is check result OK?
Yes Go to Step 3.
Step 3 Back up light switch signal circuit check

2) Disconnect “E336” and “E09” connectors.
3) Check for proper connection to “E336” and “E09” connectors.
• Resistance between “A2” circuit terminal and other terminal at back up light switch, “E336” and “E09”
connectors: infinity
Is check result OK?
Yes Go to Step 4.
Step 4 Back up light switch check

1) Check back up light switch. (Back Up Light Switch Inspection) in Section 5B
Is check result OK?
No Replace back up light switch. (Back Up Light Switch Removal and Installation) in Section 5B
DTC C1157-1C
AENNTA0E4604034 (06(02)
C1157-1C: Power Supply Voltage • ESP® control module circuit
• Pump motor power supply voltage is out of specified • ESP® control module
range. • Charging system
• Solenoid valve power supply voltage is out of specified
range.
DTC Troubleshooting
Yes Go to Step 2.
Step 2 ESP® control module circuit check

1) Check ESP® control module circuit. (ESP® Control Module Power Supply and Ground Circuit Check)
Is check result OK?
Yes Go to Step 3.

Is check result OK?

No Repair or replace defective parts and recheck DTC.
DTC C1161-07
AENNTA0E4604035 (06(02)
C1161-07: Pump Motor Circuit Performance • ESP® control module circuit
• Pump motor power supply voltage is lower than specified value. • ESP® control module
• When pump motor is activated, a malfunction in pump motor is detected.
• Power supply from CPU to pump motor and pump motor relay monitor
data disagree.
DTC Troubleshooting
Yes Go to Step 2.
Step 2 Pump motor power supply circuit and ground circuit check
1) Check pump motor power supply circuit and ground circuits. (ESP® Control Module Power Supply and
Is check result OK?
DTC C1162-00
AENNTA0E4604036 (06(02)
C1162-00: Solenoid Valve Continuous Operation Failure ESP® control module
Solenoid valve is activated for more than specified time using active
test of SUZUKI scan tool.
DTC Troubleshooting
Step 1 DTC check

3) Leave vehicle for 5 minutes or more, for cooling down of ESP® system.
Yes Replace ESP® hydraulic unit / control module assembly and recheck DTC.(ESP® Hydraulic Unit /
No End.
DTC C1169-00
AENNTA0E4604037 (06(02)
C1169-00: Steering Angle Sensor Specification • Steering angle sensor
Unregistered • Lighting and turn signal switch
ESP® control module detects that steering angle sensor
which has been used in other vehicle is installed.
DTC Troubleshooting
Step 1 DTC check

1) Replace lighting and turn signal switch. (Lighting and Turn Signal Switch Removal and Installation) in
Section 9B
No End.
DTC C1174-54 / C1175-54

AENNTA0E4604038 (06(02)
C1174-54: G Sensor Calibration • Yaw rate / G sensor calibration is incomplete
Yaw rate / G sensor calibration is not completed. • ESP® control module
C1175-54: Steering Angle Sensor Calibration • Steering angle sensor
Steering angle sensor calibration is not completed. • Lighting and turn signal switch
• Steering angle sensor calibration is incomplete
DTC Troubleshooting
NOTE
Detection of both DTC C1124-09 and C1175-54 means internal malfunction of steering angle sensor.
Replace lighting and turn signal switch. (Steering Angle Sensor Removal and Installation)
Yes Go to Step 2.
Step 2 DTC check

Is other DTC(s) than C1174-54 and C1175-54 detected?

No Go to Step 3.
Step 3 Sensor calibration

1) Calibrate all sensors. (Sensor Calibration)

Is DTC C1174-54 and/or C1175-54 still detected?
Yes • DTC C1174-54: Replace ESP® hydraulic unit / control module assembly and recheck DTC.
• DTC C1175-54: Replace lighting and turn signal switch and recheck DTC. (Lighting and Turn
Signal Switch Removal and Installation) in Section 9B If DTC C1175-54 is still detected, replace
ESP® hydraulic unit / control module assembly and recheck DTC. (ESP® Hydraulic Unit /
No End.
DTC C1190-82 / C1194-81 / U0401-81

AENNTA0E4604039 (06(02)
C1190-82: ECM Detect Rolling Counter Failure From • CAN communication circuit
ESP® Control Module • Engine control system
ECM detected invalid CAN data which ESP® control
• ECM
module transmitted.
C1194-81: Torque Request Reject Status • ESP® control module
ECM does not receive torque request signal from ESP®
control module.
U0401-81: Invalid Data Received From ECM
ESP® control module detects abnormality of CAN
communication data from ECM.
DTC Troubleshooting
Yes Go to Step 2.
Step 2 DTC check

Is other DTC(s) than C1190-82, C1194-81 or U0401-81 detected?

No Go to Step 3.
Step 3 DTC check for ECM

1) Check ECM for DTC. (DTC Check) in Section 1A
Is DTC U0073 or U0121 detected?

No Go to Step 4.

1) Check CAN communication circuit between ECM and ESP® control module. (Troubleshooting for Lost
Communication): CAN in Section 10H
Is check result OK?

Yes Replace ECM and recheck DTC. (ECM Removal and Installation) in Section 1C If DTC C1190-82,
C1194-81 or U0401-81 is still detected, replace ESP® hydraulic unit / control module assembly and
recheck DTC. (ESP® Hydraulic Unit / Control Module Assembly Removal and Installation)
DTC U0073-88 DTC U0100-87 / U0101-87 / U0126-87 / U0140-87

AENNTA0E4604040 (06(02)
/ U1082-87
AENNTA0E4604041 (06(02)
Refer to “Troubleshooting for Communication Bus Off”: Reference: “Precautions for Electrical System Work”
CAN in Section 10H. Refer to “Troubleshooting for Lost Communication”:
CAN in Section 10H.
DTC U0402-81
AENNTA0E4604042 (06(02)
U0402-81: Invalid Data Received From TCM • CAN communication circuit
DTC concerned with TCM is detected. • CVT system
• TCM
DTC Troubleshooting
Yes Go to Step 2.
Step 2 DTC check

Is other DTC(s) than U0402-81 detected?

No Go to Step 3.
Step 3 DTC check for TCM

1) Check TCM for DTC. (DTC Check) in Section 5D

No Go to Step 4.

1) Check CAN communication circuit between TCM and ESP® control module. (Troubleshooting for Lost
Is check result OK?
Yes Replace TCM and recheck DTC. (TCM Removal and Installation) in Section 5D If DTC U0402-81
is still detected, replace ESP® hydraulic unit / control module assembly and recheck DTC. (ESP®
DTC U1410-81
AENNTA0E4604043 (06(02)
U1410-81: Invalid Data Received From ENG A-STOP Control • CAN communication circuit
Module • ENG A-STOP system
ESP® control module received invalid CAN data from ECM.
• ECM
DTC Troubleshooting
Yes Go to Step 2.
Step 2 DTC check

Is other DTC(s) than U1410-81 detected?

No Go to Step 3.

1) Check ECM for DTC. (DTC Check) in Section 1A
Is any DTC(s) detected?

No Go to Step 4.

1) Check CAN communication circuit between ECM and ESP® control module. (Troubleshooting for Lost
Is check result OK?
Yes Replace ECM and recheck DTC. (ECM Removal and Installation) in Section 1C If DTC U1410-81
is still detected, replace ESP® hydraulic unit / control module assembly and recheck DTC. (ESP®
ESP® Control Module Power Supply and Ground Circuit Check

AENNTA0E4604044 (06(01)
Circuit Diagram
[A] E09
4
1
2 26
7 B1
3
1 RED E09-26 5 28 15
4
8 29 16
WHT E09-1 6 5
30 17
C1 6
31 18
7
32 19
8
3 33 20
10 9
9 34 21
10
1 BRN E09-5 35 22
11
36 23
A1 12
37 24
13
D1 38 25
14
BLK E09-2 27
2
BLK E09-27
D2
[a]
INTA0A460014-01
[A]: ESP® control module connector (View: [a]) 1. From battery 7. “ABS MOT” fuse
A1: Ignition power supply circuit 2. Relay box 8. “ABS SOL” fuse
B1: Pump motor power supply circuit 3. J/B 9. “ABS” fuse
C1: Solenoid valve power supply circuit 4. ESP® control module 10. IG11 relay
D1: ESP® control module ground circuit 1 5. To pump motor relay
D2: ESP® control module ground circuit 2 6. To solenoid valve power supply circuit
Circuit Description
When the ignition is set “ON”, power is supplied to ESP® control module. Then power is supplied to pump motor and
solenoid valve in other line by the switching function in ESP® control module.
Troubleshooting
Step 1 Fuse check
Are “ABS MOT” fuse, “ABS SOL” fuse and “ABS” fuse in good condition?
Yes Go to Step 2.

2) Disconnect “E09” and connector.
Is check result OK?
Yes Go to Step 3.
Step 3 Pump motor and solenoid valve power supply circuit check

• Voltage between “B1” circuit and ground is battery voltage.
• Voltage between “C1” circuit and ground is battery voltage.
Is check result OK?
Yes Go to Step 4.
Step 4 ESP® control module ground circuit check

2) Check that resistance between each of “D1” and “D2” circuits and ground is less than 1 Ω.
Is check result OK?
Yes ESP® control module power supply and ground circuit are in good condition.
Repair Instructions
ESP® Hydraulic Unit Operation Check NOTE
AENNTA0E4606001 (08(03)
NOTE If communication between SUZUKI scan tool
• A false diagnosis may result if operation perform the following checks:
check of the ESP® hydraulic unit is • Check communication condition between
performed without satisfying all of the
specified conditions below.
function.
Check that all the following conditions are
met before performing operation check of • Check DLC power circuit and ground
the ESP® hydraulic unit. circuit.
– Battery voltage is 12 V or more. • Check CAN communication circuit and
– No air is trapped in the brake system.
– Brakes do not drag. “Diagnosis flow: [a]” in “Troubleshooting”
– No DTC is stored in ESP® hydraulic unit / of “Troubleshooting for Lost
control module. Communication”: CAN in Section 10H.)
• Operation check must be performed by 2 • Check DLC cable. If necessary, check DLC
persons. cable by substituting a known-good DLC
• DTC C1174-54 and C1175-54 are detected, cable.
and ESP® warning light light up when ESP® • Check CAN communication system.
hydraulic unit / control module assembly (“Control Module Communication Bus Off”
(hydraulic unit) is replaced. Perform ESP® is detected in any control module.)
hydraulic unit operation check after sensor (Troubleshooting for Communication Bus
calibration. (Sensor Calibration) Off): CAN in Section 10H
• Lighting or blinking of warning light stops • Check central gateway control module
when ignition is set “ON” after completing power supply circuit and ground circuit.
ESP® hydraulic unit operation check. (Inspection of Central Gateway Control
1) Connect SUZUKI scan tool to DLC. (Suzuki SDT-II Gateway) in Section 10H
Connection and Disconnection) in Section 0A • Check ESP® control module power supply
2) Check DTC and follow the instructions displayed on circuit and ground circuit. (ESP® Control
SUZUKI scan tool. Module Power Supply and Ground Circuit
Refer to Operator's Manual of SUZUKI scan tool for Check)
further details.
3) Hoist vehicle until tire can be rotated.
5) Shift select lever to N range and release parking • ESP® hydraulic unit / control module
brake. assembly has reference values for master
6) Select “Depressurization check” / “Pressurization cylinder pressure sensor and yaw rate / G
check” in “Hydraulic control test” under “Utility” mode sensor stored. Also steering angle sensor
of SUZUKI scan tool. has its own reference point stored.
Refer to Operator’s Manual of SUZUKI scan tool for Traction control and stability control are
further details. performed according to the variation of
these sensors from their reference points.
7) Perform the following checks with help of another
If a reference value is lost or shifted due to
person.
the following maintenance, calibration is
• Depressurization check needed.
Step on brake pedal and then select testing wheel
Sensor Condition requiring calibration
by SUZUKI scan tool and the wheel should be
• Replacement of lighting and turn
turned by another person’s hand. At this time,
signal switch (C1175-54).
check whether the wheel rotates freely due to Steering angle
brake depressurization. sensor • Replacement of ESP® hydraulic unit
/ control module assembly (C1175-
• Pressurization check
54).
Step off brake pedal and then select testing wheel
Replacement or removal of ESP®
by SUZUKI scan tool and the wheel should be Yaw rate / G
hydraulic unit / control module
turned by another person’s hand. At this time, sensor
assembly (C1174-54).
check whether the wheel is locked due to brake
pressurization. • All sensors are calibrated at once when
NOTE calibration is performed.
Pressurization / Depressurization by SUZUKI 1) Park vehicle on level surface, apply parking brake,
scan tool is available for 0.5 seconds. set steering wheel in straight ahead position, stop
engine and release brake pedal.
NOTE
Keep condition of Step 1) until sensor
calibration is completed, in order to calibrate
sensor correctly.

I8G001460007-01 3) Check DTC and follow the instructions displayed on
8) Check all 4 wheels respectively. SUZUKI scan tool.
9) Check that ABS warning light and ESP® warning
further details.
light are turned off after switching ignition from “OFF”
to “ON”. Check for DTC and repair problem if lights NOTE
are still lit.
10) If any faulty condition is found in Step 6) – 7), replace and ESP® control module is not possible,
ESP® hydraulic unit /control module assembly. perform the following checks:
(ESP® Hydraulic Unit / Control Module Assembly
11) After completing the check, check that ignition is function.
“OFF” and then disconnect SUZUKI scan tool from
DLC. (Suzuki SDT-II Connection and Disconnection)
circuit.
in Section 0A
Sensor Calibration
AENNTA0E4606002 (08(03) gateway control module. (Refer to
NOTE “Diagnosis flow: [a]” in “Troubleshooting”
• If any DTC other than C1174-54 and C1175- Communication”: CAN in Section 10H.)
54 is detected, repair the cause of the
detected DTC first. • Check DLC cable. If necessary, check DLC
cable.
• Check CAN communication system. • Check CAN communication circuit and

(“Control Module Communication Bus Off” connectors between DLC and central
is detected in any control module.) gateway control module. (Refer to
(Troubleshooting for Communication Bus “Diagnosis flow: [a]” in “Troubleshooting”
Off): CAN in Section 10H of “Troubleshooting for Lost
• Check central gateway control module Communication”: CAN in Section 10H.)
power supply circuit and ground circuit. • Check DLC cable. If necessary, check DLC
(Inspection of Central Gateway Control cable by substituting a known-good DLC
Module and Its Circuits): CAN (Central cable.
Gateway) in Section 10H • Check CAN communication system.
• Check ESP® control module power supply (“Control Module Communication Bus Off”
circuit and ground circuit. (ESP® Control is detected in any control module.)
Module Power Supply and Ground Circuit (Troubleshooting for Communication Bus
Check) Off): CAN in Section 10H
4) Set ignition “ON” and check that no DTC is detected power supply circuit and ground circuit.
except C1174-54 and C1175-54. If any DTC is (Inspection of Central Gateway Control
detected, repair or replace trouble area. Module and Its Circuits): CAN (Central
5) Select menu “Sensor Calibration” under “Utility” Gateway) in Section 10H
mode of SUZUKI scan tool and calibrate sensor with • Check ESP® control module power supply
ignition “ON”. Refer to Operator’s Manual of SUZUKI circuit and ground circuit. (ESP® Control
scan tool for further details. Module Power Supply and Ground Circuit
6) After completing the calibration, check DTC(s) is not Check)
stored in ESP® hydraulic unit / control module
assembly. 3) Set ignition “ON”, select “ESP® Function Setting”
7) Check that ignition is “OFF” and then disconnect under “Utility” mode and “Deactivation” to disable the
SUZUKI scan tool from DLC. (Suzuki SDT-II ESP® function. Refer to Operator’s Manual of
Connection and Disconnection) in Section 0A SUZUKI scan tool for further details. In this state
ESP® warning light (1) and ESP® OFF light (2) come
ON and “message” is displayed on the information
ESP® OFF Function
AENNTA0E4606003 (08(03) display (Color dot display type) (3) and ESP®
NOTE function is disabled (ESP® OFF function starts) for
speedometer test or other tests which require
• Disabling ESP® function is available only
rotating a wheel.
to perform maintenances and inspections.
Upon completion of them, it is necessary
to enable ESP® function by setting ignition
switch “OFF”.
• If Suzuki SDT-II is not working, cancel
traction control by operating ESP® OFF SW
as a substitute. ABS/EBD control can be
activated in maintenance mode.

SUZUKI scan tool.
further details.
NOTE
function.
circuit.
4) After completion of necessary maintenances or

[A] inspections, set ignition “OFF” and disconnect
SUZUKI scan tool. (Suzuki SDT-II Connection and
Disconnection) in Section 0A
5) Set ignition “ON” again and check that ESP® warning
light and ESP® OFF light come ON for 2 seconds as
an initial check function and then go OFF. This
represents normal condition of ESP® function.
2 1
[B]
3
IMTA0A460023-02
ESP® Hydraulic Unit / Control Module Assembly Components

AENNTA0E4606004 (12(01)
5
8
(a)
(a)
1
(c)
4
3
(b)
(c)
(d)
(d)
IMTA0A460012-01
1. ESP® hydraulic unit / control module assembly 5. To Right-front brake : 16 Nm (1.6 kgf-m, 12.0 lbf-ft)
2. Actuator bracket 6. To Left-front brake : 21 Nm (2.1 kgf-m, 15.5 lbf-ft)
3. To master cylinder primary 7. To Right-rear brake : 9.0 Nm (0.92 kgf-m, 7.0 lbf-ft)
4. To master cylinder secondary 8. To Left-rear brake : 26 Nm (2.7 kgf-m, 19.5 lbf-ft)
ESP® Hydraulic Unit / Control Module • Check actuator bracket (2), actuator mount damper
Assembly On-Vehicle Inspection and its mounting surface for dents, crack and
AENNTA0E4606005 (08(03) deformation.
Check the following points. Repair or replace defective
• Check actuator mount bolts and actuator bracket nuts
parts.
for looseness.
• Check ESP® hydraulic unit / control module assembly
(1) for dents, crack, deformation and leakage.
• Check ESP® control module connector (ESP® control Be careful not to scratch bushings with the
module side and harness side) and its connector lock burr of the bracket when removing /
mechanism for damage or crack. installing the ESP® hydraulic unit / control
• Check connector terminals for bend, corrosion or rust. module assembly from / to the bracket.
Removal
1
2) Disconnect ESP® control module connector (3) by
pushing the lock button (1), and then pulling down
the lock lever (2).
2 3
1
IMTA0A460013-01 2 [a]
ESP® Hydraulic Unit / Control Module

Assembly Removal and Installation
AENNTA0E4606006 (08(01) ILKC0P460032-01
[a]: Pull down to unlock
Reference: “ESP® Hydraulic Unit / Control Module
Assembly Components”
Reference: “ESP® Hydraulic Unit / Control Module 3) For 5 M/T model, disconnect battery cable of bracket
Assembly On-Vehicle Inspection” (1) from actuator bracket (2).
NOTICE
• Performing the following prohibited
operations will affect the original
performance of ESP® hydraulic unit /
control module assembly.
– Do not disassemble the ESP® hydraulic
– Do not loosen the blind plug.
2 1
– Do not remove the motor.
– Regarding ESP® hydraulic unit / control
module assembly removal and
installation, check specified torque and IMTA0A460014-01
do not use impact tool. 4) For 5 M/T model, disconnect clutch fluid pipe of
– Do not allow dust to enter ESP® clamp (1) from actuator bracket (2).
hydraulic unit / control module.
– Do not place ESP® hydraulic unit /
control module on its side or upside
down.
– Do not give an impact to hydraulic unit.
painted surfaces. If brake fluid contacts
painted surfaces, immediately wipe it off
and flush the surfaces with water
2
thoroughly.
• The bracket of the ESP® hydraulic unit /
control module assembly may have some
burrs at the edge and may damage or 1
deform the bushing, resulting in abnormal IMTA0A460015-01
operation of the ESP® system.

5) Loosen flare nuts (1) using special tool and Installation

disconnect brake pipes from ESP® hydraulic unit / Reverse removal procedure noting the following points.
control module assembly (2). • Install actuator bracket (1) to ESP® hydraulic unit /
control module assembly, and tighten actuator mount
NOTE
nuts (2) to specified torque.
Put bleeder plug cap or the like onto pipe to
prevent fluid from spilling. Tightening torque
Actuator mount nut (a): 9.0 N·m (0.92 kgf-m, 7.0
Special tool lbf-ft)
: 09950M78220
2, (a)
6) Remove actuator bracket nuts (3), remove ESP®
hydraulic unit / control module assembly with
actuator bracket (4).
NOTICE
remove ESP® hydraulic unit / control module
assembly can cause damage to mount 1
dampers, yaw rate / G sensor malfunction
and can lead to poor ESP® hydraulic unit /
control module assembly operation.
2, (a)
• Do not damage mount dampers in stud 2, (a)
end and actuator bracket. IMTA0A460018-02
• Tighten brake pipe flare nuts (M10) (1), brake pipe

flare nuts (M12) (2) and actuator bracket nuts (3) to
specified torque.
1
1 4 NOTICE
Failure to install brake pipe to the proper port
will affect the original performance of ESP®
hydraulic unit / control module assembly.
1 3
Install brake pipes to each proper port
correctly.
2 Tightening torque
Brake pipe flare nut (M10) (a): 16 N·m (1.6 kgf-m,
12.0 lbf-ft)
Brake pipe flare nut (M12) (b): 21 N·m (2.1 kgf-m,
3
15.5 lbf-ft)
IMTA0A460016-01
Actuator bracket nut (c): 26 N·m (2.7 kgf-m, 19.5
7) Remove actuator mount nuts (1) and actuator
lbf-ft)
bracket (2) from ESP hydraulic unit / control module
assembly.
1, (a)
1
1, (a)
2, (b) 3, (c)
3, (c)
1 IMTA0A460019-01
1
IMTA0A460017-01 • Install ESP® hydraulic unit correctly, preventing the
mount damper from deformation and crushing.
• Bleed brake system. (Brake Fluid Replacement) in Rear Wheel Speed Sensor Encoder Removal
Section 4A and Installation
AENNTA0E4606012 (08(01)
• After checking for leakage of brake fluid, perform
Refer to “Rear Wheel Speed Sensor Encoder Removal
necessary operation referring to sensor calibration
and Installation” in Section 4E.
and ESP® hydraulic unit operation check.
– Sensor calibration (ESP® Hydraulic Unit Operation
Front and Rear Wheel Speed Sensor Encoder
Check)
Inspection
– ESP® hydraulic unit operation check (ESP® AENNTA0E4606013 (08(03)
Hydraulic Unit Operation Check) Refer to “Front and Rear Wheel Speed Sensor Encoder
Inspection” in Section 4E.
NOTE
• If perform depressurization check while air Brake Master Cylinder Pressure Sensor On-
was trapped in the brake system, air will Vehicle Inspection
AENNTA0E4606014 (08(03)
enter the inside of ESP® hydraulic unit.
1) Check basic brake system other than ESP®.
• DTC C1174-54, C1175-54 will be detected, (Precautions for Brake Service) in Section 4A
and brake system warning light (red), ESP®
warning light and ABS warning light light 2) Connect SUZUKI scan tool to DLC. (Suzuki SDT-II
up when ESP® hydraulic unit / control Connection and Disconnection) in Section 0A
module assembly is replaced. Perform 3) Check DTC and follow the instructions displayed on
sensor calibration. SUZUKI scan tool.
• Check for proper operation of hydraulic Refer to Operator's Manual of SUZUKI scan tool for
unit and proper installation of brake further details.
system after completing sensor calibration NOTE
referring to ESP® hydraulic unit operation
check. If communication between SUZUKI scan tool
Front and Rear Wheel Speed Sensor On-Vehicle • Check communication condition between
Inspection PC and VCI using SUZUKI scan tool
AENNTA0E4606007 (08(03)
Refer to “Front and Rear Wheel Speed Sensor On- function.
Vehicle Inspection” in Section 4E. • Check DLC power circuit and ground
circuit.
Front Wheel Speed Sensor Removal and • Check CAN communication circuit and
Installation connectors between DLC and central
AENNTA0E4606008 (08(01) gateway control module. (Refer to
Reference: “Precautions for Electrical System Work” “Diagnosis flow: [a]” in “Troubleshooting”
Refer to “Front Wheel Speed Sensor Removal and of “Troubleshooting for Lost
Installation” in Section 4E. Communication”: CAN in Section 10H.)
Rear Wheel Speed Sensor Removal and cable by substituting a known-good DLC
Installation cable.
AENNTA0E4606009 (08(01)
Reference: “Precautions for Electrical System Work” • Check CAN communication system.
Refer to “Rear Wheel Speed Sensor Removal and (“Control Module Communication Bus Off”
Installation” in Section 4E. is detected in any control module.)
Front and Rear Wheel Speed Sensor Inspection Off): CAN in Section 10H
AENNTA0E4606010 (08(03) • Check central gateway control module
Refer to “Front and Rear Wheel Speed Sensor
Inspection” in Section 4E.
Front Wheel Speed Sensor Encoder Removal • Check ESP® control module power circuit
and Installation and ground circuit. (ESP® Control Module
AENNTA0E4606011 (08(01)
Refer to “Front Wheel Speed Sensor Encoder Removal Power Supply and Ground Circuit Check)
and Installation” in Section 4E.
4) Set ignition “ON” and select “Data List” of SUZUKI
scan tool.
Refer to Operator’s Manual of SUZUKI scan tool for NOTE

further details. Before each inspection, confirm steering
5) Check “Master Cyl Press” under “Data List” of angle sensor (lighting & turn signal switch
SUZUKI scan tool with brake pedal released. assembly) calibration is completed.
If check result is not as specified, replace ESP® If calibration is incomplete, calibrate sensor.
hydraulic unit / control module assembly. (Sensor Calibration)
Master cylinder pressure specification
Brake pedal released: 0 ± 0.9 MPa (0 ± 9.2 kgf/
cm2, 0 ± 131 psi)
6) Hoist vehicle and remove right-side front wheel. SUZUKI scan tool.
(Wheel (with Tire) Removal and Installation) in Refer to Operator's Manual of SUZUKI scan tool for
Section 2D further details.
7) Remove bleeder plug from right-side front caliper
and install special tool to right-side front caliper. NOTE
Special tool
(A): 09956M02311
function.
circuit.
(A) gateway control module. (Refer to
“Diagnosis flow: [a]” in “Troubleshooting”
IL2R0A460019-01
8) With brake pedal depressed up to special tool gauge
reading 10 MPa (102.0 kgf/cm2, 1450 psi), check
“Master Cyl Press” under “Data List” of SUZUKI scan
cable.
tool.
If check result displayed on SUZUKI scan tool is not • Check CAN communication system.
as specified, replace ESP® hydraulic unit / control (“Control Module Communication Bus Off”
module assembly. is detected in any control module.)
Master cylinder pressure specification Off): CAN in Section 10H
Brake pedal depressed 10 MPa (102.0 kgf/cm2,
1450 psi): 10 ± 1.2 MPa (102.0 ± 12.2 kgf/cm2,
1450 ± 174 psi)
9) After completing the check, set ignition “OFF” and Module and Its Circuits): CAN (Central
disconnect SUZUKI scan tool from DLC. (Suzuki Gateway) in Section 10H
SDT-II Connection and Disconnection) in Section 0A • Check ESP® control module power circuit
10) Remove special tool, tighten bleeder plug and bleed and ground circuit. (ESP® Control Module
brake system. (Air Bleeding of Brake System) in Power Supply and Ground Circuit Check)
Section 4A
Tightening torque scan tool.
Bleeder plug: 8.5 N·m (0.87 kgf-m, 6.5 lbf-ft) Refer to Operator’s Manual of SUZUKI scan tool for
11) Check brake fluid level in master cylinder reservoir. further details.
(Brake Fluid Level Inspection) in Section 4A 4) Check “Steering Angle Sensor” under “Data List” of
12) Install right-side front wheel. (Wheel (with Tire) SUZUKI scan tool in the following steering wheel
Removal and Installation) in Section 2D conditions.
• Front wheels are in straight ahead position.
Steering Angle Sensor On-Vehicle Inspection • Rotate steering wheel once clockwise from
AENNTA0E4606015 (08(03)
straight ahead position.
• Rotate steering wheel once counterclockwise • Check sensor connectors (sensor side and harness
from straight ahead position. side) and sensor connector lock mechanism for
Replace lighting and turn signal switch if check result damage.
is not as specified. • Check connector terminals for bend, corrosion or rust.
Steering angle specification Replace steering angle sensor (1) (non-auto-on
headlight model) or lighting and turn signal switch (2)
Vehicle condition Steering angle
(auto-on headlight model) if defective.
Front wheels in straight
0 ± 3°
ahead position 1
Rotate steering wheel once
-360 ± 3°
clockwise
360 ± 3°
counterclockwise
IA1J0P460026-01
I6JB01460032-01
5) After completing the check, set ignition “OFF” and

disconnect SUZUKI scan tool from DLC. (Suzuki
IF3J0P460009-01
Steering Angle Sensor Removal and Installation

AENNTA0E4606016 (08(01)
ESP® OFF Switch Removal and Installation
Reference: “Precautions for Electrical System Work” AENNTA0E4606018 (08(01)
Reference: “Steering Angle Sensor On-Vehicle Reference: “Precautions for Electrical System Work”
Inspection”
Removal
NOTE
For auto-on headlight model, steering angle Panel Removal and Installation) in Section 9C
sensor is included in lighting and turn signal
2) Remove instrument panel switch bezel (3) from
switch.
instrument panel. (Instrument Panel Disassembly
If steering angle sensor needs to be replaced,
and Reassembly) in Section 9C
replace lighting and turn signal switch.
3) Disconnect ESP® OFF switch connector.
For non-auto-on headlight model, refer to “Steering 4) Remove ESP® OFF switch (2) from instrument panel
Angle Sensor Removal and Installation” in Section 6B. switch bezel while holding claws (1) pressed in arrow
directions.
Steering Angle Sensor Inspection
AENNTA0E4606017 (08(03)
Reference: “Steering Angle Sensor Removal and
Installation”
NOTE
For auto-on headlight model, steering angle
sensor is included in lighting and turn signal
switch.
If steering angle sensor needs to be replaced,
replace lighting and turn signal switch.
• Check sensor for dents, crack or deformation.

Without push start model ESP® OFF Switch Inspection

AENNTA0E4606019 (08(03)
Reference: “ESP® OFF Switch Removal and
Installation”
Check ESP® OFF switch (1) for continuity between
terminals at each switch position.
If check result is not as specified, replace ESP® OFF
switch.
3 NOTE
1
For checking diode circuit, select diode

range of circuit tester.
2
INTA0A460009-01
6 5 4 3 2 1
With push start model “6” “5”
“1” “2”
1
3
1
[B]
6 1 5 2
[A]
[C]
2
INTA0A460010-01
[D]
IK2R0P460018-02
Installation
Reference: “ESP® OFF Switch Inspection” [A]: Switch position [C]: OFF
Reverse removal procedure. [B]: Terminal [D]: ON
Specifications
AENNTA0E4607001 (09(t)
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Actuator mount nut 9.0 0.92 7.0 (T4F001)
Brake pipe flare nut (M10) 16 1.6 12.0 (T4F002)
Brake pipe flare nut (M12) 21 2.1 15.5 (T4F003)
Actuator bracket nut 26 2.7 19.5 (T4F004)
Bleeder plug 8.5 0.87 6.5 (T4F005)
Reference:
“ESP® Hydraulic Unit / Control Module Assembly Components”

Special Tool
AENNTA0E4608001 (11(s)
09950M78220 09956M02311
Flare nut wrench (10 x 12 Brake pressure gauge
mm)
(L4F001) (L4F002)
Section 5
Transmission / Transaxle
CONTENTS
Precautions .................................................5-1 Differential Components....................................5B-35

Precautions............................................................. 5-1 Differential Disassembly and Reassembly........5B-35
Precautions for Transmission / Transaxle............. 5-1 Specifications.....................................................5B-37
Tightening Torque Specifications......................5B-37
Manual Transmission/Transaxle ............ 5B-1 Special Tools and Equipment ...........................5B-38
General Description .............................................5B-1 Recommended Service Material .......................5B-38
Manual Transaxle Construction .......................... 5B-1 Special Tool ......................................................5B-38
Diagnostic Information and Procedures............5B-4
Manual Transaxle Symptom Diagnosis............... 5B-4 Clutch ....................................................... 5C-1
Repair Instructions ..............................................5B-6 General Description .............................................5C-1
Manual Transaxle Oil Level Check ..................... 5B-6 Clutch Construction.............................................5C-1
Manual Transaxle Oil Change ............................ 5B-7 Diagnostic Information and Procedures ............5C-1
Differential Side Oil Seal Replacement ............... 5B-7 Clutch System Symptom Diagnosis ....................5C-1
Gear Shift Control Lever and Cable Repair Instructions ..............................................5C-3 5
Components...................................................... 5B-8 CPP No.1 Switch Removal and Installation ........5C-3
Gear Shift Control Lever and Cable Removal CPP No.1 Switch Inspection and Adjustment .....5C-3
and Installation.................................................. 5B-8 CPP No.2 Switch Removal and Installation ........5C-4
Gear Select Control Cable Adjustment ............. 5B-10 CPP No.2 Switch Inspection and Adjustment .....5C-4
Back Up Light Switch Removal and Clutch Pedal Inspection ......................................5C-5
Installation....................................................... 5B-11 Clutch Fluid Level Inspection ..............................5C-5
Back Up Light Switch Inspection....................... 5B-11 Air Bleeding of Clutch System.............................5C-5
Neutral Position Switch On-Vehicle Clutch Fluid Pipe and Hose Components ...........5C-6
Inspection........................................................ 5B-11 Clutch Fluid Pipe Removal and Installation.........5C-7
Neutral Position Switch Removal and Clutch Fluid Pipe and Hose Inspection ...............5C-8
Installation....................................................... 5B-12 Clutch Master Cylinder Removal and
Manual Transaxle Unit Components................. 5B-12 Installation .........................................................5C-8
Manual Transaxle Unit Dismounting and Clutch Master Cylinder Inspection ......................5C-8
Remounting..................................................... 5B-12 Clutch Operating Cylinder Removal and
Gear Shift and Select Shaft Assembly Installation .........................................................5C-8
Components.................................................... 5B-14 Clutch Operating Cylinder Inspection..................5C-9
Gear Shift and Select Shaft Assembly Clutch Pedal Assembly Components..................5C-9
Removal and Installation................................. 5B-14 Clutch Pedal Assembly Removal and
Manual Transaxle Assembly Components........ 5B-15 Installation .......................................................5C-10
Manual Transaxle Assembly Disassembly Clutch Cover and Clutch Disc Components......5C-10
and Reassembly ............................................. 5B-17 Clutch Cover and Clutch Disc Removal and
Transaxle Left Case Disassembly and Installation .......................................................5C-11
Reassembly .................................................... 5B-21 Clutch Cover and Clutch Disc Inspection..........5C-12
Transaxle Right Case Disassembly and Clutch Release System Removal and
Reassembly .................................................... 5B-23 Installation .......................................................5C-13
Input Shaft Components ................................... 5B-25 Clutch Release System Inspection ...................5C-14
Input Shaft Disassembly and Reassembly........ 5B-25 Specifications.....................................................5C-15
Countershaft Components ................................ 5B-29 Tightening Torque Specifications......................5C-15
Countershaft Disassembly and Reassembly .... 5B-30 Special Tools and Equipment ...........................5C-15
Gear Shift Shaft Components ........................... 5B-34 Recommended Service Material .......................5C-15
Gear Shift Shaft and Fork Inspection ................ 5B-35
Special Tool ......................................................5C-15 DTC P1844 .......................................................5D-62

DTC P184A .......................................................5D-63
Automated Manual Transaxle ................ 5D-1 DTC P184B / P184C / P184D ...........................5D-64
Precautions...........................................................5D-1 DTC P184E / P184F / P1854 / P1855...............5D-66
Precautions for Diagnosing Trouble....................5D-1 DTC P1850 / P1851 / P1888 / P1889 ...............5D-67
General Description .............................................5D-1 DTC P1852 / P1853 ..........................................5D-68
Auto Gear Shift Description.................................5D-1 DTC P185C.......................................................5D-68
Function of Auto Gear Shift Control System DTC P185E / P185F .........................................5D-70
Component .......................................................5D-9 DTC P1884 .......................................................5D-70
Automatic Gear Shift Table .................................5D-9 DTC P1885 .......................................................5D-72
Auto Gear Shift Control System Description .....5D-10 DTC P1886 .......................................................5D-73
Auto Gear Shift Diagnosis General DTC P188A / P188B / P188F............................5D-73
Description ......................................................5D-12 DTC P188C.......................................................5D-75
On-Board Diagnostic System Description.........5D-12 DTC P188D / P188E .........................................5D-77
CAN Communication System Description.........5D-12 DTC P1902 .......................................................5D-79
Schematic and Routing Diagram......................5D-12 DTC P1903 / P1904 ..........................................5D-81
TCM Circuit Diagram.........................................5D-12 DTC P1905 .......................................................5D-82
Electronic Shift Control Input / Output DTC P1906 / P1907 / P1908 / P190A...............5D-84
Diagram ..........................................................5D-13 DTC P1909 / P190B..........................................5D-86
Component Location .........................................5D-14 DTC P190C.......................................................5D-87
Auto Gear Shift System Component Location ..5D-14 DTC P190D.......................................................5D-89
DTC P190E .......................................................5D-89
Diagnostic Information and Procedures..........5D-16
DTC P190F .......................................................5D-90
Auto Gear Shift System Check .........................5D-16
DTC P1980 .......................................................5D-91
Visual Inspection ...............................................5D-20
DTC P1981 .......................................................5D-91
MIL Check .........................................................5D-20
DTC P1984 .......................................................5D-92
Auto Gear Shift Warning Light Check ...............5D-20
DTC P1986 / P1987 ..........................................5D-93
DTC Check........................................................5D-21
DTC P2712 .......................................................5D-94
DTC Clearance .................................................5D-21
DTC P2789 .......................................................5D-95
DTC Table.........................................................5D-22
DTC U0073 .......................................................5D-96
Fail-Safe Table..................................................5D-27
DTC U0100 / U0121 / U0140 / U0155 ..............5D-96
Scan Tool Data .................................................5D-34
TCM Power Supply and Ground Circuit Check ..5D-96
Auto Gear Shift Symptom Diagnosis.................5D-40
Inspection of TCM and Its Circuits ....................5D-97
MIL Does Not Come ON with Ignition “ON”
and Engine Stopped (but Engine Can Be Repair Instructions ..........................................5D-100
Started) ...........................................................5D-41 TCM and Clutch Initialization ..........................5D-100
MIL Remains ON after Engine Starts................5D-41 Auto Gear Shift Actuator Oil Level Check .......5D-102
Auto Gear Shift Warning Light Does Not Auto Gear Shift Transaxle Oil Level Check.....5D-102
Come ON at Ignition “ON” and Engine Auto Gear Shift Transaxle Oil Change............5D-103
Stopped...........................................................5D-41 Differential Side Oil Seal Replacement ...........5D-103
Auto Gear Shift Warning Light Remains ON Shift Selector Components .............................5D-104
after Engine Starts ..........................................5D-42 Shift Selector Removal and Installation ..........5D-104
Starting Motor Control Relay Circuit Check ......5D-42 Shift Selector Disassembly and Reassembly..5D-105
DTC P0070 .......................................................5D-43 Shift Selector Inspection .................................5D-107
DTC P0560 / P0562 / P1711.............................5D-44 Auto Gear Shift Actuator Unit Removal and
DTC P0572 / P0573 ..........................................5D-46 Installation .....................................................5D-108
DTC P0602 .......................................................5D-48 Auto Gear Shift Oil Reservoir Tank Removal
DTC P0604 / P060A / P062F / P1702 / P1704 and Installation ..............................................5D-112
/ P1982 / P1983 ..............................................5D-48 Auto Gear Shift Electric Motor Removal and
DTC P0615 .......................................................5D-49 Installation .....................................................5D-114
DTC P0715 / P0716 ..........................................5D-51 TCM Removal and Installation ........................5D-116
DTC P0720 / P0721 ..........................................5D-52 Clutch Actuator Piston Assembly Removal
DTC P0805 .......................................................5D-55 and Installation ..............................................5D-117
DTC P0840 / P0841 ..........................................5D-55 Gear Shift and Select Shaft Assembly
DTC P0904 / P0914 ..........................................5D-56 Components..................................................5D-121
DTC P080A / P185A / P185B ...........................5D-57 Gear Shift and Select Shaft Assembly
DTC P0944 .......................................................5D-58 Removal and Installation...............................5D-121
DTC P0945 .......................................................5D-59 Clutch Speed Sensor Removal and
DTC P1706 .......................................................5D-60 Installation .....................................................5D-122
DTC P1707 / P1985 ..........................................5D-61 Clutch Speed Sensor Inspection.....................5D-122
VSS Removal and Installation.........................5D-123
VSS Inspection ...............................................5D-123 Gear Shift Shaft and Fork Inspection ..............5D-146
Starting Motor Control Relay and Back Up Differential Components..................................5D-146
Light Relay Inspection...................................5D-124 Differential Disassembly and Reassembly......5D-146
Auto Gear Shift Unit Components...................5D-124 Speed Sensor Ring Inspection........................5D-149
Auto Gear Shift Unit Dismounting and Clutch Cover and Clutch Disc Components....5D-149
Remounting...................................................5D-124 Clutch Cover and Clutch Disc Removal and
Auto Gear Shift Components ..........................5D-126 Installation .....................................................5D-150
Auto Gear Shift Disassembly and Clutch Cover and Clutch Disc Inspection........5D-151
Reassembly ..................................................5D-128 Clutch Release System Component Removal
Transaxle Left Case Disassembly and and Installation ..............................................5D-151
Reassembly ..................................................5D-132 Clutch Release System Component
Transaxle Right Case Disassembly and Inspection......................................................5D-153
Reassembly ..................................................5D-134 Specifications...................................................5D-154
Input Shaft Components .................................5D-136 Tightening Torque Specifications....................5D-154
Input Shaft Disassembly and Reassembly......5D-137 Special Tools and Equipment .........................5D-155
Countershaft Components ..............................5D-141 Recommended Service Material .....................5D-155
Countershaft Disassembly and Reassembly ..5D-141 Special Tool ....................................................5D-155
Gear Shift Shaft Components .........................5D-145
5-1 Precautions:
Precautions
Precautions
Precautions for Transmission / Transaxle
AENNTA0E5000001 (01(01)
General Precautions


Warning for Air Bag



Manual Transmission/Transaxle: 5B-1
Manual Transmission/Transaxle
General Description
Manual Transaxle Construction
AENNTA0E5201001 (03(01)
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.
IFRA0B522001-02
5B-2 Manual Transmission/Transaxle:
1. 5th speed sleeve & hub 8. Reverse idler gear 15. Countershaft 2nd gear
2. Input shaft 5th gear 9. Input shaft 16. Low speed synchronizer sleeve & hub
3. Input shaft 4th gear 10. Right case 17. Countershaft 1st gear
4. High speed synchronizer sleeve & 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. Reverse gear shaft 14. Countershaft 3rd gear
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
4
4
3
11
5
9
6
5
7
9 10
IDLA0A520002-01
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 and 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] [f]
[e]
[e]
[d] [d]
[c]
[c]
[b] [b]
[a]
[a]
IDLA0A520004-01
[c]: 3rd [e]: 1st

[d]: 4th [f]: 2nd
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 Transaxle Symptom Diagnosis
AENNTA0E5204001 (06(04)
Gears slipping out of mesh

• Worn shift shaft Replace shift shaft.
• Low speed gear shift shaft: (Manual Transaxle Assembly
Disassembly and Reassembly)
• High speed gear shift shaft: (Manual Transaxle Assembly
• 5th & reverse gear shift shaft: (Manual Transaxle
• Worn shift shaft or synchronizer sleeve Replace shift shaft or synchronizer sleeve.
• Low speed gear shift shaft: (Manual Transaxle Assembly
• Low speed synchronizer sleeve: (Countershaft

• High speed synchronizer sleeve: (Input Shaft
• 5th speed synchronizer sleeve: (Input Shaft Disassembly
and Reassembly)
• Worn bearings on input shaft or countershaft Replace input shaft bearing or countershaft bearing.
• Input shaft bearing: (Input Shaft Disassembly and
Reassembly)
• Countershaft bearing: (Countershaft Disassembly and
Reassembly)
• Worn chamfered tooth on sleeve and gear Replace synchronizer sleeve and gear.
• Countershaft 1st gear and 2nd gear: (Countershaft
• Input shaft 3rd gear and 4th gear: (Input Shaft
• Input shaft 5th gear: (Input Shaft Disassembly and
Reassembly)
and Reassembly)
Hard shifting
• Insufficient lubricant Add manual transaxle oil. (Manual Transaxle Oil Change)
• Improper clutch pedal free travel Replace clutch pedal arm or clutch master cylinder.
• Clutch pedal arm: (Clutch Pedal Assembly Removal and
• Clutch master cylinder: (Clutch Master Cylinder Removal
• Distorted or broken clutch disc Replace clutch disc. (Clutch Cover and Clutch Disc
• Damaged clutch pressure plate Replace clutch cover. (Clutch Cover and Clutch Disc
• Worn synchronizer ring Replace synchronizer ring.
• Low speed synchronizer ring: (Countershaft Disassembly
and Reassembly)
• High speed synchronizer ring: (Input Shaft Disassembly
and Reassembly)
• 5th speed synchronizer ring: (Input Shaft Disassembly
and Reassembly)
• Worn chamfered tooth on sleeve and gear Replace synchronizer sleeve and gear.
Reassembly)

and Reassembly)
• Worn gear shift control shaft joint bushing Replace shift and select shaft assembly. (Gear Shift and
Select Shaft Assembly Removal and Installation)
• Distorted shift shaft • Low speed gear shift shaft: (Manual Transaxle Assembly
• Broken gear shift / select control cables Replace gear shift and select cable. (Gear Shift Control
Lever and Cable Removal and Installation)
Noise
• Insufficient lubricant Add manual transaxle oil. (Manual Transaxle Oil Change)
• Damaged or worn bearing(s) Replace input shaft bearing or countershaft bearing.
• Input shaft bearing: (Input Shaft Disassembly and
Reassembly)
• Countershaft bearing: (Countershaft Disassembly and
Reassembly)
• Damaged or worn gear(s) Replace gear.
Reassembly)
• Damaged or worn synchronizer parts Replace synchronizer parts.
• Low speed synchronizer parts: (Countershaft
• High speed synchronizer parts: (Input Shaft Disassembly
and Reassembly)
• 5th speed synchronizer parts: (Input Shaft Disassembly
and Reassembly)
Repair Instructions
Manual Transaxle Oil Level Check If oil is excessively dirty or insufficient, change oil or
AENNTA0E5206001 (08(03) add specified oil up to plug hole. (Manual Transaxle
1) Hoist vehicle horizontally. Oil Change)
2) Remove engine under cover and left side engine
Special tool
under side cover. (Engine Under Cover and Engine
(A): 09922M36310
Under Side Cover Removal and Installation) in
Section 9H 6) Apply sealant to thread of level / filler plug, and then
3) Check manual transaxle for oil leakage. tighten it to specified torque.
Repair leaky point, if any. “A”: Sealant 99000–31260 (SUZUKI Bond
4) Remove oil level / filler plug (1). No.1217G)
5) Check oil contamination and check that oil level (2) is Tightening torque
lower end of oil level / filler plug hole using special Transaxle oil level / filler plug (a): 21 N·m (2.1
tool. kgf-m, 15.5 lbf-ft)
Viscosity chart
75W
C - 30 - 20 - 10 0 10 20 30 40
F - 22 -4 14 32 50 68 86 104
[a]
IFFA0B521002-01
1, (a), “A”
[a]: Temperature
8) Check oil level. (Manual Transaxle Oil Level Check)

9) Apply sealant to thread of level / filler plug, and then
tighten it to specified torque.
IFRA0B522002-01
No.1217G)
Tightening torque
2
Transaxle oil level / filler plug (b): 21 N·m (2.1
kgf-m, 15.5 lbf-ft)
(A)
IKRC0A520001-01
Manual Transaxle Oil Change 2, (b), “A”

AENNTA0E5206002 (08(01)
1) Hoist vehicle horizontally.
2) Remove engine under cover and left side engine
under side cover. (Engine Under Cover and Engine
Under Side Cover Removal and Installation) in 1, (a), “A”
Section 9H IFRA0B522003-01
3) Check manual transaxle for oil leakage.
Repair leaky point, if any. Differential Side Oil Seal Replacement
AENNTA0E5206003 (08(01)
4) Remove oil level / filler plug (2).
1) Drain transaxle oil. (Manual Transaxle Oil Change)
5) Remove drain plug (1) and drain oil.
2) Remove front drive shafts. (Front Drive Shaft
6) Apply sealant to thread of drain plug, and tighten it to
Assembly Removal and Installation): Front in
specified torque.
Section 3A
“A”: Sealant 99000–31260 (SUZUKI Bond 3) Remove oil seals (1) using special tool.
No.1217G)
Special tool
Tightening torque (A): 09913M50121
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 (A)

: SUZUKI GEAR OIL 99000–22B27–036 1
I9P60A522004-01
: API GL-4 (For SAE classification, refer to
viscosity.) 4) Install new oil seal (1) to specified position using
special tool.
Manual transaxle oil capacity
Reference: 1.5 liters (3.17/2.64 US/Imp. pt)
NOTE
1, “A”
• When installing oil seal, face its spring
side inward.
• Check that oil seal is installed horizontally
to surface of case after installing oil seal.
(B) (B)
Special tool (A) (A)
(A): 09944M88220
(B): 09924M74510
Distance from case end face to left oil seal
“a”: 1.0 – 2.0 mm (0.04 – 0.07 in.)
Distance from case end face to right oil seal
“b”: –0.5 – 0.5 mm (–0.02 – 0.01 in.)
“a” “b”
5) Apply grease to oil seal lip. Then, check drive shaft IFRA0A521007-01
where oil seal contacts and check its smoothness. 6) Insert front drive shafts. (Front Drive Shaft Assembly
7) Add transaxle oil. (Manual Transaxle Oil Change)
Gear Shift Control Lever and Cable Components

AENNTA0E5206004 (12(01)
1
A
(b)
3
(d)
(a)
(c)
IMTA0A520001-01
1. Gear shift control lever knob 5. Cable bracket : 10 Nm (0.1 kgf-m, 7.5 lbf-ft)
: For removal refer to “Gear Shift Control Lever
and Cable Removal and Installation”.
2. Gear shift control cable 6. Shift control lever boot : 5.5 Nm (0.56 kgf-m, 4.0 lbf-ft)
: Apply grease 99000-25480 to cable end.
3. Gear select control cable : 21 Nm (2.1 kgf-m, 15.5 lbf-ft) : Do not reuse.
: Apply grease 99000-25480 to cable end.
4. Gear shift control lever assembly : 13 Nm (1.3 kgf-m, 9.5 lbf-ft)
AENNTA0E5206005 (08(01)
Gear Shift Control Lever and Cable Removal
and Installation
Reference: “Gear Shift Control Lever and Cable

Components”
(A)
! CAUTION 2
Touching a hot exhaust system component

will cause a burn.
Do not perform any service work on the 1
select cable until the exhaust system is cool.
Removal
1) Disable air bag system.
• 4-channel air bag model: (Disabling Air Bag
System): 4-Channel in Section 8B
2) Remove floor console rear box and floor console
front covers. (Center Console Box Removal and
IMTA0A520012-01
3) For keyless push start model, remove rear vent No.2
duct. (Rear Ventilation Duct Removal and Installation 9) Disconnect end (1) of gear select control cable from
(If Equipped)) in Section 7B pivot of gear shift control lever assembly (2).
4) Remove floor console cover front bracket. (Center
Console Box Removal and Installation) in Section 9H
5) Rotate gear shift control lever knob counterclockwise
to remove it, if necessary.
6) Remove shift control lever boot, if necessary.
7) Remove SDM.
• 4-channel air bag model: (SDM Removal and
Installation): 4-Channel in Section 8B
• 8-channel air bag model: (SDM Removal and
Installation): 8-Channel in Section 8B 1 2
IMTA0A520004-02
8) Disconnect cable end (2) of gear shift control cable
from pivot of gear shift control lever assembly (1) as 10) Disconnect gear shift and select control cables (1)
follows. from gear shift control lever assembly while pulling
a) Insert special tool between gear shift control quick joints (2) in arrow direction as shown in figure.
lever assembly and cable end.
Special tool
(A): 09922M75230 2
b) Pry cable end away pushing special tool in arrow

direction.
IMTA0A520005-01
11) Remove gear shift control lever nuts (1) and remove
gear shift control lever assembly from floor panel.
• Enable air bag system.

– 4-channel air bag model: (Enabling Air Bag
– 8-channel air bag model: (Enabling Air Bag
1 1
Gear Select Control Cable Adjustment
AENNTA0E5206006 (08(03)
1) Release lock plate (1) which restricts moving of
cable end holder (2).
2) Push cable end holder out from adjuster (4) using
IMTA0A520006-01
appropriate tool (3) to disengage cable.
12) Disconnect cable end of gear shift and gear select
control cables (2) from pivot of gear shift and select
shaft assembly (1) as follows.
a) Insert special tool between gear shift and select
shaft assembly and cable end.
Special tool
(A): 09922M75230
b) Pry cable end away pushing special tool in arrow
direction.
(A)
1
IJHB0A522008-01
13) Disconnect gear shift and gear select control cables

from transaxle while puling up quick joint (1) in arrow I4RS0A520004-01
direction. 3) Apply grease to pivot (2) of gear shift control lever,

14) Remove cable grommet bolts (2) and cable nuts (3), and then install adjuster (1) into pivot of gear shift
and then remove gear shift and gear select control control lever securely.
cables from floor panel. “A”: Grease 99000–25480 (ECSTAR Grease A)
1
2
1 2
1 3
IFRA0A521009-02
2, “A”
1
Installation IMTA0A520009-01
Reverse removal procedure noting the following points. 4) Push cable end holder (1) in direction [a].
• Tighten each bolt and nut to specified torque. (Gear
Shift Control Lever and Cable Components) NOTE
• Adjust gear select control cable. (Gear Select Control Do not apply force to adjuster in cable
Cable Adjustment) operation direction [b].
Installation
Reference: “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)
[b]
1 2, (a)
[a] 1
I3RH0A520006-01
IMTA0A520010-01
2) Connect back up light switch connector.
5) Slide lock plate (1) in direction [a], until it gets over
the claw (2) of cable end holder.
Back Up Light Switch Inspection
AENNTA0E5206008 (08(03)
Reference: “Back Up Light Switch Removal and
Installation”
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
1 2
[a]
1
IMTA0A520011-01
Back Up Light Switch Removal and Installation

AENNTA0E5206007 (08(01)
I4RS0A520011-01
Removal
1) Disconnect back up light switch connector (1). Neutral Position Switch On-Vehicle Inspection
AENNTA0E5206009 (08(03)
2) Remove back up light switch (2). Reference: “Precautions for Electrical System Work”
Check neutral position switch (1) function using
ohmmeter.
Replace neutral position switch if defective.
Neutral position switch specification
Neutral position: Continuity exists
1 Other than neutral position: No continuity
IFRA0A521010-01
2) Disconnect neutral position switch connector.

3) Remove neutral position switch (1).
1
1
IFRA0B522013-01
IFRA0B522012-01
Neutral Position Switch Removal and

Installation Installation
AENNTA0E5206010 (08(01) Reverse removal procedure noting the following points.
• Install new neutral position switch.
Reference: “Neutral Position Switch On-Vehicle
Inspection” • Tighten neutral position switch to specified torque.
Tightening torque
Removal Neutral position switch: 23 N·m (2.3 kgf-m, 17.0
1) Remove battery and battery tray. (Battery Removal lbf-ft)
Manual Transaxle Unit Components

AENNTA0E5206011 (12(01)
(a)
(a)
1
(b)
(a)
IFRA0B522004-01
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)
Manual Transaxle Unit Dismounting and Dismounting

Remounting 1) Remove battery and battery tray. (Battery Removal
AENNTA0E5206012 (08(01)
2) Disconnect back up light switch connector and
release wiring harness clamps.
3) Disconnect gear shift and gear select control cables • Do not use a hammer when installing the
from transaxle. (Gear Shift Control Lever and Cable drive shaft joint into the differential gear.
Removal and Installation) Hitting the drive shaft joint with a hammer
4) Remove engine undercovers. will damage the joint.
5) Disconnect ground cable (1) and ground cable • Install manual transaxle to engine according to the
clamp. following procedure.
a. Apply grease to input shaft, if necessary. (Clutch
Cover and Clutch Disc Removal and Installation)
in Section 5C
b. Check that the dowel pins (1) are installed on the
engine assembly as shown in figure.
1 1
IFRA0A521013-01
6) Drain transaxle oil. (Manual Transaxle Oil Change)

7) Remove exhaust pipe. (Exhaust Pipe and Muffler
8) Remove drive shaft assembly. (Front Drive Shaft
Section 3A
9) Remove starting motor. (Starting Motor Removal and 1
Installation) in Section 1I
10) Remove clutch fluid pipe from clutch operating ILSB0B521002-01
cylinder. (Clutch Fluid Pipe Removal and Installation)
c. Align manual transaxle with engine horizontally
in Section 5C
using transmission jack.
11) Loosen bolts and nuts fastening engine.
d. Align the spline of input shaft with the spline hole
12) Open hood as wide as possible and hold it using of clutch disc.
rope.
e. Install manual transaxle to engine.
13) Support engine referring to “Engine Assembly
Removal and Installation” in Section 1D. NOTICE
14) Remove engine left mounting, engine rear torque rod Follow the following points when installing
and engine rear torque rod bracket. (Engine manual transaxle to engine.
Mounting Components) in Section 1D Otherwise, clutch disc may be damaged and
15) Support manual transaxle with transmission jack. clutch may not disengage normally.
16) Remove bolts and nut fastening engine and manual • Do not excessively shake manual
transaxle and then detach manual transaxle from transaxle when installing it to engine.
engine. • Do not strongly contact input shaft to the
spline hole of clutch disc.
Remounting
Reverse dismounting procedure noting the following NOTE
points.
• In case of hard fitting, rotate input shaft
NOTICE slightly to align spline of input shaft with
the spline hole of clutch disc.
remounting manual transaxle can cause • Confirm that there is not gap between
damage to parts. engine assembly and manual transaxle.
• When installing the manual transaxle, be
careful not to let the drive shaft scratch the
oil seal. – Transaxle to engine bolt: (Manual Transaxle Unit
Oil leakage may occur if the oil seal lip is Components)
scratched by the drive shaft. – Front drive shaft: (Front Drive Shaft Assembly
– Starting motor: (Starting Motor Removal and

Installation) in Section 1I (a)
– Engine left mounting: (Engine Mounting

– Engine rear torque rod: (Engine Mounting (a)
– Engine rear torque rod bracket: (Engine Mounting
– Exhaust pipe: (Exhaust Pipe and Muffler Removal
and Installation) in Section 1K
• Positioning ground cable to specified angle as shown,
tighten engine harness ground bolt (1) to specified
torque.
Position range for ground cable 1
“a”: 45°
Tightening torque IFRA0A521014-01
Ground cable bolt (a): 25 N·m (2.5 kgf-m, 18.5 lbf-
1. Gear shift and select shaft : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
ft) assembly
Gear Shift and Select Shaft Assembly Removal

and Installation
AENNTA0E5206014 (08(01)
“a” Reference: “Gear Shift and Select Shaft Assembly
Components”
“a”
1, (a) Removal
2) Disconnect gear shift and gear select control cables
from transaxle. (Gear Shift Control Lever and Cable
IGSB0A522008-01
• Set each clamp for wiring securely.
3) Remove gear shift guide case bolts (1) and gear shift
• Add transaxle oil. (Manual Transaxle Oil Change)
& select shaft assembly (2).
• Bleed clutch system. (Air Bleeding of Clutch System)
in Section 5C
• Connect battery and check function of engine, clutch
and transaxle.
Gear Shift and Select Shaft Assembly

Components
AENNTA0E5206013 (12(01) 1
1
IFRA0A521015-01
Installation
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 2) Tighten gear shift and select shaft assembly bolts (1)
shown in figure. to specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond Tightening torque
No.1217G) Gear shift and select shaft assembly bolt (a): 23
N·m (2.3 kgf-m, 17.0 lbf-ft)
Sealant amount for transaxle left case
“a”: 1.5 mm (0.059 in.)
1, (a)
1, (a)
“a”
“A”
“A” “a” IFRA0A521016-01
3) Connect gear shift and gear select control cables to

IDLA0A520029-01
transaxle. (Gear Shift Control Lever and Cable
c) Install gear shift and select shaft assembly to left Removal and Installation)
case. 4) Install battery and battery tray. (Battery Removal and
Manual Transaxle Assembly Components

AENNTA0E5206015 (12(01)
(a) 28 (b)
29
OIL
19
21 1217G (d)
3 1217G
16
2 1217G
35 (a)
20 A
23
(c)
OIL
19 (a)
18 33
30
34 25
26
32
32 27
(a)
(a)
5
15
18
4
17
(c)
13
14
20 A
31
1 (c)
9 6
22 1217G (d) 10
12
24
11 A
7
(a)
8
IMTA0A520002-02
1. Transaxle right case 22. Oil drain plug

2. Transaxle left case 23. Transaxle case plug
: Apply sealant 99000-31260 to mating surface of left case and
gear shift and select shaft assembly.
3. Gear shift and select shaft assembly 24. Gasket
: For details, refer to “Gear Shift and Select Shaft Assembly
: Apply sealant 99000-31260 to mating surface of gear shift
and select shaft assembly and left case.
4. Input shaft and countershaft assembly 25. Breather plug
: For details, refer to “Manual Transaxle Assembly
5. Differential assembly 26. Breather hose
: For details, refer to “Differential Components”.
6. Reverse gear shaft 27. Breather union
7. Washer 28. Back up light switch
8. Reverse idle gear 29. Back up light switch bracket
9. Reverse gear shift lever 30. Hook
10. Reverse gear shift locating ball assembly 31. Countershaft right bearing outer race
11. Input shaft oil seal 32. Outer race
: Apply grease 99000-25480 to oil seal lip.
12. Countershaft oil channel 33. Differential side shim
: For adjustment, refer to “Transaxle Left Case Disassembly
and Reassembly”.
13. Bearing stopper plate 34. Cap
14. Input shaft oil channel 35. Neutral position switch
15. Magnet : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
16. Oil gutter : 19 Nm (1.9 kgf-m, 14.0 lbf-ft)
17. Countershaft circlip : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
19. O-ring : Apply transaxle oil.
20. Oil seal : Do not reuse.

21. Oil level / filler plug
Manual Transaxle Assembly Disassembly and

Reassembly
AENNTA0E5206016 (08(02)
Reference: “Manual Transaxle Unit Dismounting and
Remounting”
Reference: “Manual Transaxle Unit Components”
1
Disassembly
1) Remove gear shift and select shaft assembly. (Gear
Shift and Select Shaft Assembly Removal and
Installation) 1
2) Remove reverse gear shaft bolt (1) with gasket.
IFRA0B522006-01
4) Remove transaxle case plug (1) with flat-bladed

screwdriver (2) or the like.
IDLA0A520034-01
3) Remove transaxle case bolts (1).

7) Remove reverse gear shaft (3), washer (4) and

reverse idler gear (5).
1
2
IDL70A540047-01
IDLA0A520036-01
5) While expanding countershaft circlip (1) to unhook it
from bearing groove, remove transaxle left case (2) 8) Remove magnet from right case.
from right case using special tool. 9) Tapping input shaft end with plastic hammer, push it
out as assembly from case a little, and then take out
NOTE input shaft assembly (1), countershaft assembly (2),
When removing transaxle left case, circlip 5th and reverse gear shift shaft (3), high speed gear
comes out with left case and bearing remains shift shaft (4) and low speed gear shift shaft (5).
at countershaft side.
Special tool
4
(A): 09912M34510
5
3
3
1 2
IDLA0A520037-01
1 10) Remove differential assembly from transaxle right

case.
IDL70A540048-01
Reassembly
Reference: “Transaxle Right Case Disassembly and
2 Reassembly”
Reference: “Transaxle Left Case Disassembly and
(A)
Reassembly”
Reference: “Input Shaft Disassembly and Reassembly”
Reference: “Countershaft Disassembly and
Reassembly”
Reference: “Differential Disassembly and Reassembly”
Reference: “Gear Shift Shaft and Fork Inspection”
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
gear shift shaft (4) and low speed gear shift shaft (5)
IDL70A540049-01
all together, and then install them into transaxle right
3. Countershaft left bearing case so as not to damage oil seal by input shaft
spline.
6) Remove reverse gear shift lever bolts (1) and
reverse gear shift lever (2).
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
3
5
1 2
2
IDLA0A520037-01
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
IGJA0A540070-01
specified torque while pushing reverse gear shift
lever in arrow direction. 7) Align matchmark (1) of reverse idler gear assembly
with matchmark (2) of transaxle right case.
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
new ones whenever they are removed.
2
Tightening torque
Reverse gear shift lever bolt (a): 10 N·m (1.0 kgf-
m, 7.5 lbf-ft)
1
IFRA0A521020-01
8) Install magnet (1) to right case and input shaft oil

1
(A) channel (2) to input shaft.
2, (a)
IGJA0A540069-01
6) Install reverse idler gear (1), washer (2) and reverse

gear shaft (3).
1
1
IDL70A540057-01
IDLA0A520040-01
9) Clean mating surfaces of both right and left cases, 12) Tighten transaxle case bolts (1) to specified torque.
and apply sealant to transaxle right case (1) as Tightening torque
shown in figure. Transaxle case bolt (a): 23 N·m (2.3 kgf-m, 17.0
“A”: Sealant 99000–31260 (SUZUKI Bond lbf-ft)
No.1217G)
Sealant amount for transaxle right case
“a”: 1.5 mm (0.059 in.)
“a”
1, (a)
“A” “a”
1 “A”
1, (a)
IFRA0B522007-01
IFRA0A521021-01
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 NOTICE
temporarily.
The reverse gear shaft bolt is pre-coated with
11) Turn manual transaxle upside down so that adhesive. If the bolt is reused, it may work
countershaft bearing fits in left case and circlip fits in loose. Replace the reverse gear shaft bolt
bearing groove. with new one whenever it is removed.
NOTICE
Tightening torque
Fitting failure of circlip into bearing groove Reverse gear shaft bolt (a): 23 N·m (2.3 kgf-m,
causes noise or breakage of countershaft 17.0 lbf-ft)
related parts because of wrong positioning of
countershaft.
Fit circlip into bearing groove.
2
1
1, (a)
IDLA0A520043-01 ILSB0B522002-01
14) Install new transaxle case plug (1) using special tool. 3) Remove differential side bearing outer race (1) using
special tools, and then remove shim.
Special tool
(B): 09924M74510 (A): 09942M15511
(B): 09944M96013
(B)
(C): 09921M26010
(A) (C)
(A)
(B)
IDL70A540060-02
1
15) Install gear shift and select shaft assembly. (Gear IGSB0A522013-01
Installation) Reassembly
1) Install new circlip and oil gutter (1), if removed.
Transaxle Left Case Disassembly and
Reassembly NOTE
AENNTA0E5206017 (08(02)
Reference: “Manual Transaxle Assembly Disassembly When installing oil gutter, fit its claws into
and Reassembly” holes of transaxle left case securely.
Reference: “Manual Transaxle Assembly Components”
Disassembly
1) Remove differential side oil seal from transaxle left
case, if necessary. (Differential Side Oil Seal
Replacement)
2) Remove circlip (1) and oil gutter (2), if necessary.
1
ILSB0B522003-01
2) Install new differential side oil seal to transaxle left

case, if removed. (Differential Side Oil Seal 1
Replacement)
3) Calculate clearance “c” for selection of applicable
differential side shim as follows.
a) Install differential side bearing outer race to
transaxle right case. (Transaxle Right Case
b) Install differential assembly (2) to transaxle right
case (1).
c) Install differential side bearing outer race of “b”
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 1
turn differential assembly 10 times or more.
IGSB0A521027-01
3 g) Calculate clearance “c” by the following formula.

1 2
Clearance “c” = depth “b” – distance “a”
“c”
“b” “a”
IGSB0A521025-01
e) Measure distance “a” from mating surface of

transaxle right case (1) to differential side IGSB0A521028-01
bearing outer race (2). 4) Select shim closest to calculated shim thickness
from the following available sizes.
Available shim thickness
“a” 2
Calculated shim thickness Applicable shim
0.491 – 0.530 mm
0.66 mm (0.0260 in.)
(0.01933 – 0.02087 in.)
0.531 – 0.570 mm
0.70 mm (0.0276 in.)
1 (0.02091 – 0.02244 in.)
0.571 – 0.610 mm
0.74 mm (0.0291 in.)
(0.02248 – 0.02402 in.)
0.611 – 0.650 mm
0.78 mm (0.0307 in.)
(0.02406 – 0.02559 in.)
0.651 – 0.690 mm
IGSB0A521026-01 0.82 mm (0.0323 in.)
(0.02563 – 0.02717 in.)
f) Measure depth “b” from mating surface of 0.691 – 0.730 mm
transaxle left case (1) to installation position of 0.86 mm (0.0339 in.)
(0.02720 – 0.02874 in.)
differential side bearing outer race. 0.731 – 0.770 mm
0.90 mm (0.0354 in.)
(0.02878 – 0.03031 in.)
0.771 – 0.810 mm
0.94 mm (0.0370 in.)
(0.03035 – 0.03189 in.)
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.)
(0.03350 – 0.03504 in.)
Calculated shim thickness Applicable shim Transaxle Right Case Disassembly and
0.891 – 0.930 mm Reassembly
1.06 mm (0.0417 in.) AENNTA0E5206018 (08(02)
(0.03508 – 0.03661 in.)
Reference: “Manual Transaxle Assembly Disassembly
0.931 – 0.970 mm
1.10 mm (0.0433 in.) and Reassembly”
(0.03665 – 0.03819 in.)
Reference: “Manual Transaxle Assembly Components”
0.971 – 1.010 mm
1.14 mm (0.0449 in.)
(0.03823 – 0.03976 in.)
Disassembly
1.011 – 1.050 mm
1.18 mm (0.0465 in.) 1) Remove differential side oil seal from transaxle right
(0.03980 – 0.04134 in.)
1.051 – 1.090 mm case, if necessary. (Differential Side Oil Seal
1.22 mm (0.0480 in.) Replacement)
(0.04138 – 0.04291 in.)
1.091 – 1.130 mm 2) Remove differential side bearing outer race (1) using
1.26 mm (0.0496 in.)
(0.04295 – 0.04449 in.) special tool, if necessary.
1.131 – 1.170 mm
1.30 mm (0.0512 in.) Special tool
(0.04453 – 0.04606 in.)
(A): 09925M16510
1.171 – 1.210 mm
1.34 mm (0.0528 in.)
(0.04610 – 0.04764 in.)
1.211 – 1.250 mm
1.38 mm (0.0543 in.)
(0.04768 – 0.04921 in.) (A)
1.251 – 1.290 mm
1.42 mm (0.0559 in.)
(0.04925 – 0.05079 in.)
5) Install differential side shim(s) (1).

1
1
IGJA0A520029-01
3) Remove input shaft oil seal (1) using special tool, if

necessary.
Special tool
(A): 09913M50121
IGJA0A520027-01
6) Install countershaft right bearing outer race (1) using (A)
special tool and hammer.

Special tool
(A): 09913M85210
(A)
1
IDLA0A520045-01
1
4) Remove bearing stopper plate (1), countershaft right
bearing outer race (2) and countershaft oil channel
(3), if necessary.
IGJA0A520028-01
3
4
3
2
1
IDLA0A520046-01
2
5) Remove reverse gear shift locating ball assembly
(1), if necessary.
1
IDLA0A520049-01
3) Install bearing stopper plate (1) and tighten new

1
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.
IDLA0A520047-01
Tightening torque
Bearing stopper plate bolt (a): 10 N·m (1.0 kgf-
Reassembly
m, 7.5 lbf-ft)
1) Install new input shaft oil seal (1) facing its spring
side upward up to bottom of transaxle right case
hole, if removed. Use special tool and hammer for
installation and apply grease to oil seal lip.
Special tool
(A): 09926M37610M003
(B): 09913M80113
(B)
1 2, (a)
IDLA0A520050-01
4) Install differential side bearing outer race (1) using

(A)
special tool, if removed.
Special tool
(A): 09913M85210
1, “A”
IDLA0A520048-01
2) Install countershaft oil channel (1) and countershaft

right bearing outer race (2), if removed.
NOTE
Install countershaft oil channel aligning its
ridge (3) with ridge (4) of transaxle right case.
6) Install new differential side oil seal to transaxle right

case, if removed. (Differential Side Oil Seal
Replacement)
(A)
IGSD0A521040-01
5) Install reverse gear shift locating ball assembly, if

removed.
Input Shaft Components

AENNTA0E5206019 (12(01)
8
6
5
OIL
3
7
OIL
1 4
OIL
2
OIL
15 17
8
OIL
12
16
11
14
13
9
OIL
3
OIL
3
OIL
10
IGSB0A522016-01
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
: For assembly, refer to “Input Shaft
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
: For assembly, refer to “Input Shaft
7. High speed synchronizer key 14. 5th gear synchronizer washer
Input Shaft Disassembly and Reassembly

AENNTA0E5206020 (08(02)

and Reassembly” 4
Reference: “Input Shaft Components” 1
3
Disassembly
! CAUTION
Using an inappropriate hydraulic press or
bearing puller could cause personal injury.
2
Use the hydraulic press and bearing puller
which are capable of safely bearing a load of
at least 5 tons (11,000 lbs).
IDL70A540072-02
NOTICE 4. Metal stick
Supporting the gear on the concave side of

4) Remove 5th gear needle bearing from input shaft.
the bearing puller can cause damage to the
gear. Support the gear on the flat side of the 5) Remove 5th gear spacer according to the following
bearing puller. procedure.
a) Engage high speed synchronizer sleeve with 4th
1) Remove input shaft right bearing (2) and left bearing gear.
(4) from input shaft (1) using bearing puller (3) and b) Push down input shaft (1) a little using bearing
hydraulic press. puller (2) and hydraulic press.
5
1
2
4
3 3
IDL70A540070-01 2
5. Metal stick
2) Remove circlip (1) using snap ring pliers (2).
IKRC0A520004-01
c) Remove 5th gear spacer (1) using bearing puller

(2) and hydraulic press.
IDL70A540071-01
3) Remove 5th gear synchronizer sleeve & hub

1
assembly (1), 5th gear synchronizer levers, 5th gear
synchronizer washer, 5th gear synchronizer ring and
2
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

gear needle bearing from input shaft.
2
1
“a”
1
IDLA0A520052-01
IDL70A540075-02 3) To ensure lubrication of input shaft (1), blow air into

8) Remove high speed synchronizer sleeve & hub oil holes (2) as shown in figure and check that they
assembly (1) and 3rd gear (2) from input shaft (4) are free from any obstruction.
using bearing puller (3) and hydraulic press.
2
1
4
2
2 IDL70A540078-02
3 4) Install right bearing (1) to input shaft (2) using special

tool and hydraulic press.
Special tool
(A): 09913M80113
IDL70A540076-01
9) Remove 3rd gear needle bearing from input shaft. (A)
10) Disassemble synchronizer sleeve & hub assembly.

1
Reassembly
2
1) Clean all components thoroughly, check them for
any abnormality and replace them with new ones if
necessary.
2) Check clearance “a” between synchronizer ring (2)
and gear (1) and replace with new one, if necessary.
Also, check gear teeth for damage.
Clearance “a” between synchronizer ring and IDL70A540079-01
gear (3rd, 4th and 5th) 5) Fit high speed synchronizer sleeve (1) to hub (2) and
Standard: 0.40 – 1.10 mm (0.016 – 0.043 in.) 3 keys (3) as shown in figure.
Service limit: 0.40 mm (0.016 in.)
NOTE
No specific direction is assigned to high
speed synchronizer sleeve or each key but it
is assigned as sleeve & hub assembly.
Synchronizer key installation position Special tool

(A): 09913M84510
3
(A)
2 1
2
3
4
1
IDL70A540082-01
11) Install 5th gear needle bearing and apply transaxle

1 oil to it, and then install 5th gear and synchronizer
ring.
12) Assemble 5th gear synchronizer sleeve (1), 5th gear
2 synchronizer hub (2), 5th gear synchronizer levers
IDL70A540080-03
(3), 5th gear synchronizer washer (4) and 5th speed
6) Install 3rd gear needle bearing and apply transaxle synchronizer ring (5) as follows.
oil to it, and then install 3rd gear (1) and 3rd gear
1
synchronizer ring (2) to input shaft.
7) Install high speed synchronizer sleeve & hub
assembly (3) using special tool and hydraulic press. 3
NOTE
5
• While press-fitting sleeve & hub assembly,
check that synchronizer ring keys (4) are 2
aligned with key slots (5) in sleeve & hub
assembly. 4
• Check free rotation of 3rd gear after press-
IFRA0A521025-01
fitting sleeve & hub assembly.
a) Install 5th gear synchronizer hub (1) to 5th gear
Special tool synchronizer sleeve (2) in specified direction as
(A): 09913M84510 shown in figure.
(A)
[a] [c]
[b] 3
2
[a]
2 [b]
5
IGSB0A522017-01
[a]: Chamfered side [b]: Long boss side

1 [a]: Stepped side
4
IDL70A540081-02 b) Apply transaxle oil to 5th gear synchronizer
[a]: 3rd gear side [b]: Long flange levers.
c) Fit 5th gear synchronizer levers (1) to 5th gear
8) Install new circlip with flat face upper side. synchronizer hub (2) by aligning protrusion (3) of
9) Install 4th gear needle bearing (2) and apply 5th gear synchronizer levers with groove of 5th
transaxle oil to it, and then install synchronizer ring gear synchronizer hub.
(4) and 4th gear (3).
10) Install 5th gear spacer (1) using special tool and
hydraulic press.
14) Select new circlip (1) that makes thrust clearance “a”
3
of 5th gear synchronizer hub 0.1 mm (0.004 in) or
less and install it.
1
3
Available circlip thickness
Clearance “b” Circlip thickness
2
2.000 – 2.049 mm
2.00 mm (0.0787 in.)
(0.0787 – 0.0807 in.)
2.050 – 2.099 mm
2.05 mm (0.0807 in.)
(0.0807 – 0.0826 in.)
2.100 – 2.149 mm
IFRA0A521027-01 2.10 mm (0.0827 in.)
(0.0827 – 0.0846 in.)
d) Install 5th gear synchronizer washer (2) and 5th 2.150 – 2.199 mm
gear synchronizer ring (1) to 5th gear 2.15 mm (0.0846 in.)
(0.0846 – 0.0866 in.)
synchronizer hub (3) in specified direction as 2.200 – 2.249 mm
shown in figure. 2.20 mm (0.0866 in.)
(0.0866 – 0.0885 in.)
2.250 – 2.300 mm
1 2.25 mm (0.0886 in.)
(0.0886 – 0.0906 in.)
2 1
“a” “b”
3
IFRA0A521028-01
13) Install 5th gear synchronizer sleeve & hub assembly

(1) using special tool and hydraulic press.
NOTE IFRA0A521030-01
Check free rotation of 5th gear after press- 15) Press-fit left bearing (1) using special tool and
fitting sleeve & hub assembly. hydraulic press.
Special tool Special tool

(A): 09913M80113 (A): 09944M66060
(A)
(A)
1
[a]
IKRC0A520005-01
IDL70A540086-01
[a]: 5th gear side
Countershaft Components
AENNTA0E5206021 (12(01)
OIL
7
6
9
4
OIL
8
OIL
2
15
5
3 14 1
1
OIL
13
1
12
OIL
7
10
11
1
IGSB0A522019-01
1. Circlip 7. Needle bearing 13. Countershaft 1st gear

2. Countershaft left bearing 8. Countershaft 2nd gear 14. Countershaft
: For assembly, refer to “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 NOTICE

AENNTA0E5206022 (08(02)
Reference: “Manual Transaxle Assembly Disassembly Supporting the gear on the concave side of
and Reassembly” the bearing puller can cause damage to the
Reference: “Countershaft Components” gear. Support the gear on the flat side of the
bearing puller.
Disassembly
! CAUTION
2
IDL70A540088-02
2) Remove left bearing (1) using bearing puller (2) and 7) Remove 2nd gear synchronizer ring and 2nd gear
hydraulic press. needle bearing.
1
3
1
2
2
IDL70A540093-02
IDL70A540089-01
9) Apply bearing puller (3) to 1st gear (2) and remove
3. Metal stick
low speed synchronizer sleeve & hub assembly (1),
1st gear synchronizer ring and 1st gear using
hydraulic press.
2 1
1 2
IDL70A540090-02 IDL70A540094-01
4) Apply bearing puller (3) to 4th gear (2) and remove 10) Remove 1st gear needle bearing.
5th gear (1) together with 4th gear using hydraulic 11) Remove circlip (1) using snap ring pliers (2).
press.
2
IDL70A540095-02
IDL70A540091-01 12) Grind portion “a” of right bearing inner race (1) using
5) Remove 3rd and 4th gear spacer. grinder (2) as shown.
6) Apply bearing puller (3) to 2nd gear (2) and remove NOTICE
3rd gear (1) together with 2nd gear using hydraulic
The shaft (3) will be damaged if the bearing is
press.
ground too much. Limit the amount of
grinding to the minimum amount if
necessary.
1
2
IDL70A540092-01
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.
1
2
2
3
“a”
1
3
1
IDL70A540096-01
13) Break the thinnest portion of bearing inner race (2)

IDL70A540099-02
with a chisel (1) and remove bearing inner race.
4) Install right bearing inner race (1) using special tool
and hydraulic press.
1 Special tool
(A): 09913M80113
(A)
2
IDL70A540097-01
Reassembly
IDL70A540098-01
necessary. 5) Install new circlip with flat face upper side.
2) Check clearance “a” between synchronizer ring (2) 6) Fit low speed synchronizer sleeve (1) to hub (2) and
and gear (1) and replace with new one, if necessary. 3 keys (3) as shown in figure.
NOTE
Clearance “a” between synchronizer ring and
• No specific direction is assigned to low
gear (1st and 2nd)
speed synchronizer hub or each key, but it
Standard: 0.40 – 1.10 mm (0.016 – 0.043 in.)
• When fitting synchronizer hub into sleeve,
raise the sleeve and check that the hub
comes off with the self-weight.
“a”
1
IDLA0A520052-01
(A)
3
1
2
[b]
1
[a]
IDL70A540102-01
1 [a]: 2nd gear side [b]: Long flange
2 12) Install 3rd and 4th gear spacer (1) and then install
IDL70A540100-03 4th gear (2) using special tool and hydraulic press.
7) Install 1st gear needle bearing and apply transaxle Special tool
oil to it, and then install 1st gear (1) and 1st gear (A): 09925M18011
synchronizer ring to countershaft.
8) Install low speed synchronizer sleeve & hub (A)
assembly (2) using special tool and hydraulic press.
2
NOTE
1
check that synchronizer ring keys (3) are
[b]
assembly. [a]
• Check free rotation of 1st gear after press-

fitting sleeve & hub assembly.
Special tool IDL70A540103-01

(A): 09940M51711
[a]: 3rd and 4th gear spacer side [b]: Long flange
(A)
13) Install 5th gear (1) using special tool and hydraulic
press.
2 Special tool
[a] (A): 09925M18011
4
(A)
3 1
1
IDL70A540101-02 [b]
[a]: 1st gear side [a]
9) Install new circlip with flat face upper side.

10) Install 2nd gear needle bearing and apply transaxle
oil to it, and then install 2nd gear synchronizer ring
IDL70A540104-01
and 2nd gear to countershaft.
[a]: 4th gear side [b]: Long flange
11) Install 3rd gear (1) using special tool and hydraulic
press.
14) Select new circlip (1) that makes thrust clearance “a”
Special tool of 5th gear 0.1 mm (0.004 in) or less and install it.
(A): 09925M18011
Available circlip thickness 15) Install left bearing (1) using special tool and
Clearance “b” Circlip thickness hydraulic press.
2.150 – 2.199 mm Special tool
2.15 mm (0.0846 in.)
(0.0846 – 0.0866 in.) (A): 09913M80113
2.200 – 2.249 mm
2.20 mm (0.0866 in.)
(0.0866 – 0.0885 in.)
2.250 – 2.299 mm (A)
2.25 mm (0.0886 in.) [b]
(0.0886 – 0.0905 in.)
2.300 – 2.349 mm 1
2.30 mm (0.0906 in.)
(0.0906 – 0.0925 in.)
2.350 – 2.399 mm
2.35 mm (0.0925 in.) [a]
(0.0925 – 0.0944 in.)
2.400 – 2.450 mm
2.40 mm (0.0945 in.)
(0.0945 – 0.0965 in.)
IDL70A540106-01
1
[a]: 5th gear side [b]: Gloves
2
“a” “b”
IDL70A540105-01
2. Countershaft 4. 4th gear

3. 5th gear
Gear Shift Shaft Components

AENNTA0E5206023 (12(01)
(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

AENNTA0E5206024 (08(03)
and Reassembly”
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 (0.0020 – 0.0157 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.
Differential Components
AENNTA0E5206025 (12(01)
5
2 3 4
1
2
11
1
3 10
7
4
5
9 (a)
8
6
IGSA0P520017-01
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 NOTE

AENNTA0E5206026 (08(02)
Reference: “Manual Transaxle Assembly Disassembly Keep a thick hosiery cloth or soft PU strips
and Reassembly” between the jaws of the bench vice and the
Reference: “Differential Components” teeth of the final gear to protect the final gear
teeth.
Disassembly
2) Remove final gear bolts (1) and then remove final
1) Support the final gear with soft jawed vise. gear (2) from differential case (3).
NOTE Reassembly
Support the differential case so that it Judging from abnormality noted before disassembly and
doesn’t fall down when removing the final what is found through visual check of component parts
gear bolts. after disassembly, prepare replacing parts and proceed
to reassembly. Check that all parts are clean.
1) Install differential pinions, differential side gears (1),
washers and pinion shaft to differential case (2) and
measure thrust play of differential side gear at each
3 side as follows. If measured value is out of
2
specification, select suitable side gear washer (3)
from the following available sizes, install it and check
again.
1 Special tool
(A): 09900M20607
(B): 09900M20701
1 (C): 09952M06010
a) Hold differential assembly with soft jawed vise
ILSA0P521012-01 and apply measuring tip or face of dial gauge to
3) Remove left side bearing (1) using special tool, side gear as shown in figure.
bearing puller (2) and hydraulic press. b) Move side gear up and down by hand and read
Special tool dial gauge.
(A): 09913M75821 Differential side gear thrust play
0.03 – 0.31 mm (0.0012 – 0.0122 in.)
(A) [A]
(A)
2
1
3
1 4 (B)
2
(C)
1
IFRA0B522009-01
2
4) Remove right side bearing in the same manner as in
Step 3).
[B] (A)
5) Remove differential pinion shaft pin (1) using special
tool and hammer, and then disassemble component
2
parts.
Special tool
4
(A): 09922M85811 1
(B)
3
(A)
2
1
1 IDL70A540111-02
[A]: Right side 4. Spring washer

[B]: Left side
Available side gear washer thickness

Thickness mm (in.) Thickness mm (in.)
0.60 mm (0.0236 in.) 0.85 mm (0.0335 in.)
IKRC0A520006-01
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.)
2) Install new differential pinion shaft pin (1) from left Special tool
side until depth “a” becomes 4.70 – 5.70 mm (0.185 (A): 09924M74510
– 0.224 in.) as shown using special tool. (B): 09951M16060
(C): 09913M85230
Special tool
(A): 09922M85811
(A)
(A)
(B)
“a” 1
(C)
IDL70A540112-02
IFRA0B522011-01
3) Install right side bearing (1) using special tool and 5) Support differential case with soft jawed vise and
hydraulic press. install final gear (1) directing its discrimination
Special tool groove (2) upward, and then tighten new final gear
(A): 09924M74510 bolts to specified torque.
(B): 09951M16060 Tightening torque
Final gear bolt (a): 100 N·m (10.2 kgf-m, 74.0 lbf-
ft)
(A) 1
(B)
(a)
1
IFRA0B522010-01
IDL70A540116-01
4) Install left side bearing (1) using special tool and
hydraulic press.
Specifications
AENNTA0E5207001 (09(t)
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Transaxle oil level / filler plug 21 2.1 15.5 (T5B001) / (T5B003)
Transaxle oil drain plug 21 2.1 15.5 (T5B002)
Back up light switch 19 1.9 14.0 (T5B004)
Neutral position switch 23 2.3 17.0 (T5B005)
Ground cable bolt 25 2.5 18.5 (T5B006)
Gear shift and select shaft assembly bolt 23 2.3 17.0 (T5B007)
Reverse gear shift lever bolt 10 1.0 7.5 (T5B008)
Transaxle case bolt 23 2.3 17.0 (T5B009)
Reverse gear shaft bolt 23 2.3 17.0 (T5B010)
Bearing stopper plate bolt 10 1.0 7.5 (T5B011)
Final gear bolt 100 10.2 74.0 (T5B012)
Reference:
“Gear Shift Control Lever and Cable Components”
“Manual Transaxle Unit Components”
“Gear Shift and Select Shaft Assembly Components”
“Manual Transaxle Assembly Components”
“Gear Shift Shaft Components”
“Differential Components”

AENNTA0E5208001 (11(m)
Grease ECSTAR Grease A P/No.: 99000–25480 (M5B004) / (M5B005) /
(M5B008)
Sealant SUZUKI Bond No.1217G P/No.: 99000–31260 (M5B001) / (M5B002) /
(M5B003) / (M5B006) /
(M5B007)
NOTE
“Gear Shift Control Lever and Cable Components”
“Manual Transaxle Assembly Components”
“Input Shaft Components”
“Countershaft Components”
Special Tool
AENNTA0E5208002 (11(s)
09900M20607 09900M20701
Dial gauge Magnetic stand
(L5B033) (L5B034)
09912M34510 09913M50121
Case separator Oil seal remover
(L5B007) (L5B002) / (L5B016)
09913M75821 09913M80113
Bearing installer attachment Bearing installer
(L5B031) (L5B018) / (L5B020) /
(L5B023) / (L5B025) /
(L5B030)
09913M84510 09913M85210
Bearing installer Bearing installer
(L5B021) / (L5B022) (L5B014) / (L5B019)
09913M85230 09921M26010
Bearing remover tool Bearing outer race remover
collar
(L5B041) (L5B013)
09922M28111 09922M36310
Reverse gear shift lever Oil level gauge
positioner
(L5B008) (L5B001)
09922M75230 09922M85811
Gear shift cable remover Spring pin remover (4.5 mm)
(L5B005) / (L5B006) (L5B032) / (L5B036)
09924M74510 09924M74590
Bearing and oil seal handle Input shaft oil seal installer
attachment
(L5B004) / (L5B010) / (L5B009)
(L5B037) / (L5B039)
09925M16510 09925M18011
Oil seal installer Transmission gear, bush
and bearing installer
(L5B015) (L5B027) / (L5B028) /
(L5B029)
09926M37610M003 09940M51711
Bearing remover attachment Bearing installer
(L5B017) (L5B026)
09942M15511 09944M66060
Sliding hammer Bearing installer
(L5B011) (L5B024)
09944M88220 09944M96013
Oil seal installer Bearing outer race remover
(L5B003) (L5B012)
09951M16060 09952M06010
Control arm bush remover Dial gauge plate No.1
(L5B038) / (L5B040) (L5B035)
Clutch: 5C-1
Clutch
General Description
Clutch Construction
AENNTA0E5301001 (03(01)
The clutch is a diaphragm spring clutch of a dry single
disc type. The diaphragm spring is of a tapering-finger
type, which is a solid ring in the outer diameter part, with
a series of tapered fingers pointing inward.
The disc, carrying torsional coil springs, is positioned on
the transaxle input shaft with an involute spline fit.
The clutch cover is secured to the flywheel, and carries
the diaphragm spring in such a way that the peripheral
edge part of the spring pushes on the pressure plate
against the flywheel (with the disc in between), when the
clutch release bearing 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, the drive
straps (connecting clutch cover and pressure plate) pull
the pressure plate away from the flywheel, thereby
interrupting the flow of drive from flywheel through clutch
disc to transaxle input shaft. Clutch fluid is supplied from
brake fluid reservoir. Clutch fluid level can be checked by
brake fluid level of brake fluid reservoir.
I7V20A531001-01
1. Crankshaft 6. Diaphragm spring

2. Flywheel 7. Clutch release bearing
3. Clutch disc 8. Input shaft
4. Pressure plate 9. Clutch release shaft
5. Clutch cover

Clutch System Symptom Diagnosis
AENNTA0E5304001 (06(04)
Slipping
• Improper clutch pedal free travel Replace clutch pedal arm and/or clutch master cylinder.
Installation)
and Installation)
• Worn or oily clutch disc facing Replace clutch disc. (Clutch Cover and Clutch Disc
• Warped disc, pressure plate or flywheel surface Replace clutch disc, cover or flywheel.
• Clutch disc and cover: (Clutch Cover and Clutch Disc
• Flywheel: (Flywheel Removal and Installation) in Section
1D
• Weakened diaphragm spring Replace clutch cover. (Clutch Cover and Clutch Disc
• Master cylinder piston or seal cup not returning Replace clutch master cylinder. (Clutch Master Cylinder
5C-2 Clutch:
Dragging clutch
• Improper clutch pedal free travel Replace clutch pedal arm and/or clutch master cylinder.
Installation)
and Installation)
• Weakened diaphragm spring or worn spring tip Replace clutch cover. (Clutch Cover and Clutch Disc
• Rusted input shaft spline Lubricate input shaft spline.
• Damaged or worn spline of transaxle input shaft Replace input shaft. (Input Shaft Disassembly and
• Excessively wobbly clutch disc Replace clutch disc. (Clutch Cover and Clutch Disc
• Broken clutch facing or dirty clutch facing with oil Replace clutch disc. (Clutch Cover and Clutch Disc
• Fluid leakage Repair or replace clutch system.
Clutch vibration
• Glazed (glass-like) clutch facings Repair or replace clutch disc. (Clutch Cover and Clutch Disc
• Dirty clutch facing with oil Replace clutch disc. (Clutch Cover and Clutch Disc
• Release bearing does not slide smoothly Replace clutch release bearing or related parts. (Clutch
Release System Removal and Installation)
• Wobbly clutch disc or poor facing contact Replace clutch disc. (Clutch Cover and Clutch Disc
• Weakened torsion springs in clutch disc Replace clutch disc. (Clutch Cover and Clutch Disc
• Clutch disc rivets loose Replace clutch disc. (Clutch Cover and Clutch Disc
• Distorted pressure plate or flywheel surface Replace clutch cover or flywheel.
• Clutch disc and cover: (Clutch Cover and Clutch Disc
• Flywheel: (Flywheel Removal and Installation) in Section
1D
• Weakened engine mounting or loosened engine
mounting bolt(s) / nut(s) Replace engine mounting or retighten engine mounting
bolts / nuts. (Engine Mounting Components) in Section 1D
Noisy clutch
• Worn or broken clutch release bearing Replace clutch release bearing. (Clutch Release System
• Input shaft right bearing worn down Replace input shaft right bearing. (Input Shaft Disassembly
and Reassembly) in Section 5B
• Excessive rattle of clutch disc hub Replace clutch disc. (Clutch Cover and Clutch Disc
• Cracked clutch disc Replace clutch disc. (Clutch Cover and Clutch Disc
• Rattle of pressure plate and diaphragm spring Replace clutch cover. (Clutch Cover and Clutch Disc
Grabbing clutch
Clutch: 5C-3
• Clutch disc facings soaked with oil Replace clutch disc. (Clutch Cover and Clutch Disc
• Clutch disc facing excessively worn Replace clutch disc. (Clutch Cover and Clutch Disc
• Rivet heads protrude from clutch disc facing
surface Replace clutch disc. (Clutch Cover and Clutch Disc
• Weakened torsion springs Replace clutch disc. (Clutch Cover and Clutch Disc
Repair Instructions
CPP No.1 Switch Removal and Installation Inspection
AENNTA0E5306001 (08(01) Measure resistance between terminals under each
condition below. If check result is not as specified,
replace switch.
Removal
1) Remove steering column. (Steering Column CPP No.1 switch resistance
Removal and Installation) in Section 6B When switch shaft is pushed [A]: Continuity exists
When switch shaft is free [B]: No continuity
2) Disconnect connector of CPP No.1 switch (1).
3) Remove CPP No.1 switch from clutch pedal bracket.
I5JB0AA10009-01
Adjustment
1) With clutch pedal (1) depressed, adjust CPP No.1
switch (2) position so that clearance “a” between end
of thread and clutch pedal arm is within specification.
Clearance between end of thread and clutch
IMTA0A530001-01 pedal arm
“a”: 3.0 – 4.0 mm (0.118 – 0.157 in.)
Installation
2) Tighten CPP No.1 switch lock nut (3) to specified
1) Install CPP No.1 switch to clutch pedal bracket. torque.
2) Adjust switch position. (CPP No.1 Switch Inspection
and Adjustment) Tightening torque
CPP No.1 switch lock nut (a): 7.5 N·m (0.76 kgf-
3) Connect connector to CPP No.1 switch securely. m, 5.5 lbf-ft)
4) Install steering column. (Steering Column Removal
CPP No.1 Switch Inspection and Adjustment

AENNTA0E5306002 (08(03)
Reference: “CPP No.1 Switch Removal and Installation”
5C-4 Clutch:

3, (a)
2
CPP No.2 Switch Inspection and Adjustment
2 AENNTA0E5306004 (08(03)
Reference: “CPP No.2 Switch Removal and Installation”
“a”
Inspection
Measure resistance between terminals under each
condition below. If check result is not as specified,
replace switch.
CPP No.2 switch resistance
When switch shaft is pushed [A]: No continuity
When switch shaft is free [B]: Continuity exists
1
IMTA0A530002-01
CPP No.2 Switch Removal and Installation

AENNTA0E5306003 (08(01)
Removal
1) Remove steering column. (Steering Column
2) Disconnect connector of CPP No.2 switch (1). I5JB0AA10009-01
3) Remove CPP No.2 switch from clutch pedal bracket.

Adjustment
1) With clutch pedal (1) pulled toward driver’s seat,
1 adjust CPP No.2 switch (2) position so that
clearance “a” between end of thread and clutch
pedal arm is within specification.
Clearance between end of thread and clutch
pedal arm
“a”: 1.0 – 2.0 mm (0.039 – 0.078 in.)
2) Tighten CPP No.2 switch lock nut (3) to specified
torque.
Tightening torque
CPP No.2 switch lock nut (a): 7.5 N·m (0.76 kgf-
m, 5.5 lbf-ft)
IMTA0A530003-01
Installation
1) Install CPP No.2 switch to clutch pedal bracket.
2) Adjust switch position. (CPP No.2 Switch Inspection
and Adjustment)
3) Connect connector to CPP No.2 switch securely.
Clutch: 5C-5
Clutch Release Margin
! WARNING
3, (a)
2 Failure to take proper precautions when
“a” 2
checking clutch release margin can cause
the vehicle to start suddenly and severe
personal injury.
• Pull up parking brake fully.
• Block wheels.
1) Pull up parking brake fully and block wheels.

2) Start engine and keep engine at idle with neutral
gear position.
3) Without clutch pedal depressed, slightly push the
1 shift lever to reverse position until transaxle emits
gear contact noise. Do not shift the lever to reverse
position.
4) With emitting gear contact noise, be slow to depress
IMTA0A530005-01 clutch pedal, and at gear contact noise died position
(release point) stop depressing.
Clutch Pedal Inspection 5) Measure distance between release point (4) and full
AENNTA0E5306005 (08(03)
stroke point (5) on clutch pedal which is shown by “b”
Clutch Pedal Height
in the figure.
Measure distance between free position (1) and fully
If “b” is not within specification, it is possible that air
depressed position (2) on clutch pedal which is shown
is trapped in this system. If suspected so, bleed air.
by “a” in figure. If clutch pedal height is out of
(Air Bleeding of Clutch System)
specification, replace pedal arm and/or clutch master
Upon completion of above inspection, start engine
cylinder (3).
and check clutch for proper operation.
Clutch pedal height
Clutch release margin
“a”: 135 mm (5.31 in.)
“b”: 25 – 40 mm (0.99 – 1.57 in.)
2
1 3
3
4 1
2
“a”
“a” “b”
5
IKRC0A530001-01
IKRC0A530002-01
Clutch Pedal Free Travel

Clutch Fluid Level Inspection
Depress clutch pedal (1), stop it when clutch resistance AENNTA0E5306006 (08(03)
is felt, and measure how much pedal has moved (clutch 1) Check clutch system for crack, damage and fluid
pedal free travel) as represented by “a” in the figure. leakage.
If “a” is not within specification, check pedal arm (2) and If any defect is found, repair or replace.
master cylinder (3) and replace defective part.
2) Check fluid level. (Brake Fluid Level Inspection) in
Clutch pedal free travel “a” Section 4A
: MAX. 10 mm (0.39 in.)
Clutch fluid specification
: Refer to brake fluid reservoir cap.
Air Bleeding of Clutch System

AENNTA0E5306007 (08(03)
5C-6 Clutch:
NOTICE
3
painted surfaces.
• If the clutch pedal is pumped continuously 1
to bleed the clutch system, the oil seal of
the operating cylinder may be damaged,
resulting in fluid leakage. 2
After releasing the clutch pedal, wait at
least 1 second before depressing it again.
Bleed hydraulic clutch system of air as follows whenever

air enters hydraulic clutch system.
1) Fill master cylinder reservoir with brake fluid and
keep the reservoir at least one-half full of fluid during IFRA0B530001-02
bleeding operation. 4) When fluid pressure in cylinder is completely

released, retighten bleeder plug.
Clutch fluid specification
: Refer to brake fluid reservoir cap. 5) Repeat this operation until there are no more air
bubbles in hydraulic line.
2) Remove bleeder plug cap. Attach a vinyl tube (1) to
6) When air bubbles disappear from fluid flowing into
bleeder plug, and insert the other end into container
container, depress and hold clutch pedal, and tighten
(2).
bleeder plug until the lock clicks.
3) Depress clutch pedal several times, and then while
7) Attach bleeder plug cap.
holding it depressed, loosen bleeder plug (3) about
one-half a turn. 8) After completing bleeding operation, apply fluid
pressure to clutch line and check for leakage.
9) Replenish master cylinder reservoir with fluid up to
specified level.
10) Check clutch pedal for operation. If spongy condition
is felt, repeat entire procedure of bleeding.
Clutch Fluid Pipe and Hose Components

AENNTA0E5306008 (12(01)
Clutch: 5C-7
3
4
1 Si
6 2
(a)
6
5
IMTA0A530006-01
1. Clutch master cylinder 4. Brake master cylinder reservoir : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
: Apply grease 99000-25100 to push rod tip.
2. Clutch fluid pipe 5. Clutch operating cylinder
3. Clutch reservoir hose 6. Clamp
Clutch Fluid Pipe Removal and Installation 6) Disconnect clutch fluid pipe (3) in arrow direction [a]
AENNTA0E5306009 (08(01) while pulling clamp (1) of clutch master cylinder (2)
NOTICE
in arrow direction [b].
Brake fluid is extremely damaging to painted
surfaces.
immediately wipe it off and flush the surfaces
with water thoroughly.
[a] 1
Removal
1) Remove dust and dirt from each joint of pipe to be
2
disconnected and clean around brake master [b]
cylinder reservoir cap.
2 1 3
3) Remove ECM. (ECM Removal and Installation) in
Section 1C IMTA0A530007-01
4) Take out fluid from brake master cylinder reservoir 7) Disconnect clutch fluid pipe (3) in arrow direction [a]
with syringe or the like. while pushing clamp (1) of clutch operating cylinder
5) Remove engine left mounting bracket. (Engine (2) in arrow direction [b].
Mounting Components) in Section 1D
5C-8 Clutch:
2
[a]
1
3 [b]
1
IMTA0A530013-01
IMTA0A530008-02
4) Remove clutch pedal assembly. (Clutch Pedal
Installation
Reverse removal procedure noting the following points. 5) Remove clutch master cylinder.
• Install each clamp securely.
Installation
• After installation, check clutch pedal free travel. Reverse removal procedure noting the following point.
(Clutch Pedal Inspection)
• Apply grease to push rod tip.
• After installation, bleed air from clutch system. (Air
Bleeding of Clutch System) “A”: Grease 99000–25100 (SUZUKI Silicone
Grease)
• Check fluid leakage.
• Add fluid to MAX level of reservoir.
“A”
Clutch Fluid Pipe and Hose Inspection
AENNTA0E5306010 (08(03)
Reference: “Clutch Fluid Pipe Removal and Installation”
Check clutch fluid pipe and hose for damage, abrasions
and leakage. If check result is not OK, replace clutch
fluid pipe and hose.
Clutch Master Cylinder Removal and IGSB0A530019-01
Installation
AENNTA0E5306011 (08(01)
Clutch Master Cylinder Inspection
NOTICE AENNTA0E5306012 (08(03)
Brake fluid is extremely damaging to painted Reference: “Clutch Master Cylinder Removal and
surfaces. Installation”
If brake fluid contacts painted surfaces, Check clutch master cylinder for damage and leakage.
immediately wipe it off and flush the surfaces Replace clutch master cylinder if defective. (Clutch
with water thoroughly. Master Cylinder Removal and Installation)
Removal Clutch Operating Cylinder Removal and

1) Clean around brake master cylinder reservoir cap Installation
AENNTA0E5306013 (08(01)
and take out fluid from brake master cylinder
NOTICE
reservoir with syringe or the like.
2) Disconnect clutch fluid pipe from clutch master • Brake fluid is extremely damaging to
cylinder. (Clutch Fluid Pipe Removal and Installation) painted surfaces.
3) Disconnect clutch reservoir hose (1).
• If clutch operating cylinder is
disassembled, it may not operate normally.
Do not disassemble clutch operating
cylinder.
Clutch: 5C-9
Removal Tightening torque

1) Disconnect clutch fluid pipe from clutch operating Clutch operating cylinder bolt (a): 23 N·m (2.3
cylinder. (Clutch Fluid Pipe Removal and Installation) kgf-m, 17.0 lbf-ft)
2) Remove clutch operating cylinder bolts (1) and then
remove clutch operating cylinder (2).
1, (a)
2 IMTA0A530010-01
• Install clamp securely.

IMTA0A530009-01 • After installation, bleed air clutch system. (Air
Bleeding of Clutch System)
Installation • After installation, check clutch pedal free travel.
Reverse removal procedure noting the following points. (Clutch Pedal Inspection)
• Tighten clutch operating cylinder bolts (1) to specified
torque. Clutch Operating Cylinder Inspection
AENNTA0E5306014 (08(03)
Check clutch fluid leakage.
If malfunction is found, replace clutch operating cylinder.
Clutch Pedal Assembly Components

AENNTA0E5306015 (12(01)
10 (b)
8
9
(c)
(c)
(a)
6
1 10 (b)
2 E
10 (b) 2 E
Si 5
6
7 E 4
IMTA0A530014-02
5C-10 Clutch:
1. Clutch pedal bracket 6. Cushion : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)

2. Pedal boss bushing 7. Spring : 13 Nm (1.3 kgf-m, 9.5 lbf-ft)
: Apply grease 99000-25450 to all surfaces : Apply grease 99000-25450 to all surface
of bushings. of spring.
3. Clutch pedal shaft spacer 8. CPP No.1 switch : 7.5 Nm (0.76 kgf-m, 5.5 lbf-ft)
4. Clutch pedal 9. CPP No.2 switch
: Apply grease 99000-25100 to all surface
of pin.
5. Clutch pedal pad 10. Clutch pedal nut
: For tightening order, refer to “Clutch Pedal
Assembly Removal and Installation”.
Clutch Pedal Assembly Removal and 10) Remove CPP No.2 switch, if necessary. (CPP No.2
Installation Switch Removal and Installation)
AENNTA0E5306016 (08(01)
Reference: “Precautions for Electrical System Work” Installation
Removal
• Tighten clutch pedal nut in (1) numerical order (“1” –
1) Remove steering column. (Steering Column “2”) to specified torque.
2) Remove HVAC unit. (HVAC Unit Removal and Tightening torque
Installation) in Section 7B Clutch pedal nut (a): 13 N·m (1.3 kgf-m, 9.5 lbf-ft)
3) Disconnect CPP No.1 switch connector. • Tighten clutch master cylinder bolts (2) to specified
4) Disconnect CPP No.2 switch connector. torque.
5) Remove push rod (5) from clutch pedal. (Clutch Tightening torque
Master Cylinder Removal and Installation) Clutch master cylinder bolt (b): 23 N·m (2.3 kgf-
6) Disconnect harness clamp (1). m, 17.0 lbf-ft)
7) Remove clutch master cylinder bolts (2). • Apply grease to push rod tip.
8) Remove clutch pedal nuts (3), and then remove “A”: Grease 99000–25100 (SUZUKI Silicone
clutch pedal assembly (4). Grease)
1, “2”, (a)
3
5
1 “A”
4 2
2, (b)
3
3
IFRA0B530007-01 1, “1”, (a) 1, “1”, (a)
IGSB0A530017-01
9) Remove CPP No.1 switch, if necessary. (CPP No.1
Switch Removal and Installation)
Clutch Cover and Clutch Disc Components

AENNTA0E5306017 (12(01)
Clutch: 5C-11
(a)
10
4 A
5 A
9
1
8
6
7 A
3 (a)
IKRC0A530003-01
1. Clutch cover 5. Clutch release shaft No.2 bushing 9. Pin

: Apply grease 99000-25480 to clutch
release shaft No.2 bushing inside.
2. Clutch disc 6. Clutch release shaft 10. Release arm
: Apply grease 99000-25480 to the end of
clutch release shaft arm.
3. Clutch cover bolt 7. Clutch release shaft No.1 bushing : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
: For tightening order, refer to “Clutch Cover : Apply grease 99000-25480 to clutch
and Clutch Disc Removal and Installation”. release shaft No.1 bushing inside.
4. Clutch release shaft seal 8. Clutch release bearing : Do not reuse.
: Apply grease 99000-25480 to clutch
release shaft seal lip.
Clutch Cover and Clutch Disc Removal and Installation

Installation Reference: “Clutch Cover and Clutch Disc Inspection”
AENNTA0E5306018 (08(01)
Reference: “Clutch Cover and Clutch Disc Components” NOTE
Before assembling, check the following
Removal items.
1) Dismount manual transaxle. (Manual Transaxle Unit • Contact surfaces of flywheel, pressure
Dismounting and Remounting) in Section 5B plate and clutch disc are clean and dry.
2) Hold flywheel with special tool and remove clutch • Old grease and dust are removed from
cover (1) and clutch disc. input shaft and clutch disc hub spline.
Special tool
(A): 09924M17811 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 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 strap plate rivet (2).
I7V20A532013-01
5C-12 Clutch:
NOTE
For centering of clutch disc spline, tighten
clutch cover bolts while pushing clutch disc
with special tool.
Special tool
(A): 09924M17811
(B): 09923M36320
Tightening torque
Clutch cover bolt (a): 5.0 Nm → 23 Nm (0.51 1, “A”
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- IKRC0A530004-01
ft) 6) Join manual transaxle with engine. (Manual
Transaxle Unit Dismounting and Remounting) in
4, “4”, (a)
Section 5B
3, “2”, (b)
Clutch Cover and Clutch Disc Inspection
1 AENNTA0E5306019 (08(03)
Reference: “Clutch Cover and Clutch Disc Removal and
3, “1”, (b) Installation”
(B)
Clutch Disc
4, “5”, (a) At clutch cover side of clutch disc, measure depth “a” of
2
rivet head depression, i.e. distance between rivet head
(A) and facing surface.
If depression is found to have reached service limit at
any of rivet holes, replace clutch disc.
Rivet head depth “a”
4, “6”, (a) Standard: 1.0 mm (0.04 in.)
Limit: 0.2 mm (0.0079 in.)
3, “3”, (b)
IKRC0A530006-01
4) Measure each diaphragm spring height.

If diaphragm spring height uniformity is out of
specification, remove and reinstall clutch cover.
Diaphragm spring height uniformity
0.6 mm (0.024 in.) or less
5) Slightly apply grease (0.1 g (0.04 oz)) to spline (1) of
I4RS0B540166-03
input shaft.
NOTICE Clutch Cover

When a large quantity of grease is applied, Check clutch cover as follows.
grease may be scattered to clutch disc. • Check diaphragm spring (1) for abnormal wear or
When grease is applied, reduce quantity as damage.
much as possible. • Check pressure plate (2) for wear or heat spots.
NOTE
When replacing clutch disc with new one, it
is not necessary to apply grease to input
shaft.
“A”: Grease 99000–25210 (SUZUKI Super

Grease I)
I3RM0A530015-01
Clutch: 5C-13
Clutch Release System Removal and

Installation
AENNTA0E5306020 (08(01)
Reference: “Clutch Cover and Clutch Disc Components”
Removal
1) Remove release arm by removing its bolt.
2) Remove clutch release bearing by turning release
shaft.
3) Remove clutch release shaft No.2 bushing and
release shaft seal as follows. IYSY01531016-01
a) Drive out clutch release shaft No.2 bushing and b) Connect special tools to tap (1) and pull out No.1
release shaft seal (1) together using special tool bushing.
(A) and hammer, and then remove release shaft
Special tool
seal.
(B): 09923M46020
Special tool (C): 09930M30104
(A): 09922M46010
IYSY01531017-01
Installation
Reference: “Clutch Release System Inspection”
(A)
1) Press-fit a new clutch release shaft No.1 bushing
using special tools and hammer, and then apply
grease to bushing inside.
IFRA0B530010-01 “A”: Grease 99000–25480 (ECSTAR Grease A)

b) Pry out clutch release shaft No.2 bushing (1) Special tool
using pliers. (A): 09943M88211
(B): 09923M46030
IFRA0B530011-01
4) Remove clutch release shaft No.1 bushing as

follows, if necessary.
I3RM0A530016-01
a) Install tap (M16 X 1.5) (1) to clutch release shaft
2) Apply grease to clutch release shaft No.2 bushing
No.1 bushing.
(1) inside and press-fit it using the same special tool
used for removal.
Special tool
(A): 09922M46010
5C-14 Clutch:
3) Apply grease to release shaft seal (2) lip, and then

install it with special tool facing its lip downward
(inside) until it is flush with case surface.
1
“A”: Grease 99000–25480 (ECSTAR Grease A) “A”
Special tool 3
(B): 09925M98221
4) Caulk seal at [a] using caulking tool and hammer.
2, “A”
ILSA0P540016-01
7) Set release arm (1) to release shaft (2) putting punch

mark (3) of release arm to punch mark (4) of release
shaft as shown in figure. Then tighten release arm
bolt to specified torque.
Tightening torque
Release arm bolt (a): 23 N·m (2.3 kgf-m, 17.0 lbf-
ft)
3
1
4
(a)
I8C50A530012-01 2
5) Clean the following parts. IFRA0B530013-01
• Arm part of release shaft (1).

• Inner circumference of release bearing (2). Clutch Release System Inspection
AENNTA0E5306021 (08(03)
• Release bearing sliding part of transaxle right Reference: “Clutch Release System Removal and
case (3). Installation”
6) Apply grease to the following parts and then set
release bearing. Clutch Release Bearing
Check clutch release bearing (1) for smooth rotation. If
NOTE any abnormality is found, replace it.
When replacing release bearing with new NOTICE
one, it is not necessary to apply grease to
release bearing. If the clutch release bearing is washed, the
grease contained within the clutch release
• Arm part of release shaft. bearing may be washed away, causing the
• Inner circumference of release bearing. bearing to seize up.
Do not wash the clutch release bearing.
• Release bearing sliding part of transaxle right
case.
I7V20A531009-01
Clutch: 5C-15
Clutch Release Shaft

Check clutch release shaft and its pin for deflection or
damage.
If any abnormality is found, replace it.
I3RM0A530021-01
Specifications
AENNTA0E5307001 (09(t)
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
CPP No.1 switch lock nut 7.5 0.76 5.5 (T5C001)
CPP No.2 switch lock nut 7.5 0.76 5.5 (T5C002)
Clutch operating cylinder bolt 23 2.3 17.0 (T5C003)
Clutch pedal nut 13 1.3 9.5 (T5C004)
Clutch master cylinder bolt 23 2.3 17.0 (T5C005)
Clutch cover bolt 5.0 Nm → 23 Nm (0.51 kgf-m → 2.3 kgf- (T5C006)
m, 4.0 lbf-ft → 17.0 lbf-ft)
Clutch cover bolt 23 2.3 17.0 (T5C007)
Release arm bolt 23 2.3 17.0 (T5C008)
Reference:
“Clutch Fluid Pipe and Hose Components”
“Clutch Pedal Assembly Components”
“Clutch Cover and Clutch Disc Components”

AENNTA0E5308001 (11(m)
Grease SUZUKI Silicone Grease P/No.: 99000–25100 (M5C001) / (M5C002)
SUZUKI Super Grease I P/No.: 99000–25210 (M5C003)
ECSTAR Grease A P/No.: 99000–25480 (M5C004) / (M5C005) /
(M5C006) / (M5C007)
NOTE
“Clutch Fluid Pipe and Hose Components”
“Clutch Pedal Assembly Components”
Special Tool
AENNTA0E5308002 (11(s)
5C-16 Clutch:
09922M46010 09923M36320
Clutch bushing remover Clutch center guide (15 mm)
(L5C004) / (L5C009) (L5C003)
09923M46020 09923M46030
Joint pipe Joint pipe
(L5C005) (L5C008)
09924M17811 09925M98221
Flywheel holder Bearing installer
(L5C001) / (L5C002) (L5C010)
09930M30104 09943M88211
Sliding shaft Pinion bearing installer
(L5C006) (L5C007)
Automated Manual Transaxle: 5D-1
Automated Manual Transaxle

Precautions
AENNTA0E5400001 (01(01)
• Before using scan tool, read its Owner’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”.
• After replacing or reinstalling any one of the following parts, perform “TCM and Clutch Initialization”.
– Auto gear shift (AGS) actuator unit or AGS actuator related parts.
– 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)
• 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 or AGS related part which is filled
with the fluid will be required.
• Read “Precautions for Electrical Circuit Service” in Section 00 before inspection and observe what is written there.
• Communication of ECM and TCM and other control modules are established by CAN. Therefore, handle CAN
communication line with care referring to “Precautions for Electrical Circuit Service” in Section 00.
General Description
Auto Gear Shift Description
AENNTA0E5401001 (03(01)
• 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.
5D-2 Automated Manual Transaxle:
IGJC0A541002-01
Auto Gear Shift Actuator Unit Construction
NOTE
The component parts of the auto gear shift actuator unit shown below are for explanation. However,
disassembling of all these component parts are 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)
• Shift actuator (15)
• Engage 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
5 14
6 [a]
22
21
20
19
13
17
18
15
9 15 16
[a]
10
11
8
28
27
26
25
24
23
7 3 2
IMTA0A540001-01
23. Clutch actuator circlip 26. Clutch actuator spring

24. Clutch actuator plug with O-ring 27. Spring guide
25. Clutch actuator piston sub-assembly 28. Clutch actuator oil seal
Auto gear shift actuator hydraulic circuit
IMTA0A540032-01
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 engage piston and shift position sensor, and the engage 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 unit 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.
19 18
17
16
15
14
12 11
13
6
10
4 3 2 1
5
7
8
IGSD0A541047-01
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 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. (Auto Gear
Shift System Component Location)
• Auto gear shift can be driven in D (drive) mode and M (manual) mode.
• Operation of shift selector from D to R (reverse) or R to D is not effective if brake pedal is not pressed:
- Gear stays in neutral if engine is on at this moment.
- Gear does not change if the engine is off & ignition is on 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.
• 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.
– During a stop, if driver's door is open with gearshift lever in 'R', 'D' or 'M' position without depressing brake pedal
and accelerator pedal for some time.
– 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 engage piston (2) in the shift
actuator and select piston (3) in the select actuator. The engage 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).
[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
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
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 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]
IMTA0A540002-01
Function of Auto Gear Shift Control System Component

AENNTA0E5401002 (03(01)
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.
Engage piston Moves gear shift and select shaft assembly according to shift solenoid
valves 1 and 2.
Select piston Moves gear shift and select shaft assembly according to select solenoid
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.
TCM • Controls gear shift and clutch operation.
• Diagnoses auto gear shift control system components.
Gear shift and select shaft assembly Transmits movement of engage piston and select piston in auto gear shift
actuator unit to gear shift shaft.
Automatic Gear Shift Table

AENNTA0E5401003 (03(01)
Automatic gear shift schedule is shown in the following table. Road test the vehicle on a flat road in D range.
Throttle Vehicle speed

Shift Remark
opening (%) (km/h (mile/h))
1st → 2nd 25 to 53 (16 to 33)
2nd → 3rd 60 to 95 (37 to 59)
80 to 100
3rd → 4th 98 to 137 (61 to 85)
4th → 5th 166 to 186 (103 to 116)
1st → 2nd 15 to 43 (9 to 27)
There is no sudden change in accelerator
2nd → 3rd 36 to 74 (22 to 46)
UP shift 40 to 70 opening.
3rd → 4th 48 to 109 (30 to 68)
Hard brake is not being applied.
4th → 5th 61 to 147 (38 to 91)
1st → 2nd 10 to 30 (6 to 19)
2nd → 3rd 21 to 41 (13 to 25)
10 to 30
3rd → 4th 30 to 50 (19 to 31)
4th → 5th 43 to 63 (27 to 39)
5th → 4th 111 to 165 (69 to 103)
4th → 3rd 63 to 114 (39 to 71)
80 to 100
3rd → 2nd 26 to 65 (16 to 40)
2nd → 1st 4 to 25 (2 to 16)
5th → 4th 38 to 98 (24 to 61)
There is no sudden change in accelerator
4th → 3rd 26 to 53 (16 to 33)
DOWN shift 40 to 70 opening.
3rd → 2nd 18 to 28 (11 to 17)
Hard brake is not being applied.
2nd → 1st 3 to 13 (2 to 8)
5th → 4th 38 to 48 (24 to 30)
4th → 3rd 26 to 36 (16 to 22)
10 to 30
3rd → 2nd 18 to 28 (11 to 17)
2nd → 1st 3 to 13 (2 to 8)
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 Learning function

AENNTA0E5401004 (01(02) Assembled parts in the transaxle such as shift forks,
When the driver's door is opened regardless of ignition
gears, etc. and gear shift and select shaft assembly
ON / OFF, electric oil pump is driven to raise the
change engagement positions of the respective gears
hydraulic pressure if it is judged that the pressure
caused by aging and manufacturing tolerance. In order
accumulated in the accumulator is lower than the
to compensate these factors and keep the smooth
specified value according to the signal from the pressure
shifting, TCM provides the following gear position
sensor. Through this pressure rising, smooth operation
learning functions.
of the shift / select and clutch actuator is realized right
after the ignition ON. • Shift actuator position at engaged condition in each
gear (1 ↔ 2 speed, 3 ↔ 4 speed and 5 ↔ R speed).
Cranking Control • Shift actuator position in neutral.
The starting motor control relay operates only at the time • Select actuator position at selected condition in each
the brake pedal is depressed (stop light switch: ON) and speed range (1 ↔ 2 speed, 3 ↔ 4 speed and 5 ↔ R
the shift selector is in N range. Therefore, unintended speed).
starting out is prevented. Further, if ignition switch is
turned to start position without depressing the brake D (Drive) mode control
pedal, the brake request indicator in the combination When the shift selector is in D range, shift solenoid No.
meter is lit and the warning buzzer sounds to urge the 1, No. 2 and select solenoid are controlled for optimal
driver to depress the brake pedal. gear change. The solenoid valves are controlled based
on the programmed gear shift timing and adjusting it by
Shift Control judging driving conditions according to the throttle
TCM controls the shift solenoid No. 1, No. 2 and the opening informed from ECM.
select solenoid for optimal gear shift corresponding to
the engine torque based on information of accelerator M (Manual) mode control
opening, engine speed and torque. 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 exceeds the specified value, unnecessary shift change
information display in the combination meter. is avoided. As a result, the engine brake can be used on
Since the M (manual) mode is selected by driver’s the down-hill slope and suitable gear position is
intention, the gear position is fixed in “M”. Therefore, maintained on the up-hill slope.
change to the D (drive) mode is not performed
automatically. Coast down control when brake is applied
When coasting of the vehicle is judged based on the
NOTE brake signal and vehicle deceleration (calculated from
Even if the TCM receives the shift request, if the vehicle speed signal), this control changes the
the condition such as throttle opening, normal gear position to the gear position for the
engine speed and vehicle speed deviate from coasting. Consequently, at hard braking, down shift is
the specified range, the shift may not be executed at a higher vehicle speed than the normal
executed in some cases. down shift vehicle speed and is over during deceleration.
In this way, time lag at the time of re-acceleration
Up shift (without this control, down shift takes place after the
During M (manual) mode control, TCM executes shift up accelerator pedal is depressed) is eliminated for smooth
when shifting up is operated by shift selector. However, if acceleration.
the clutch rotational speed after shifting is less than the
specified value, the up-shifting is canceled in order to Clutch Control
prevent the engine stall. TCM controls the clutch solenoid based on clutch
Down shift engagement characteristic programmed in advance and
During the M (manual) mode control, if the shift selector judging the vehicle running conditions and the operation
is operated to shift down, TCM executes shift down. state of the driver using the accelerator opening
However, if the clutch rotational speed after shifting is information from the ECM and the vehicle speed signal.
over the specified value, shift down is canceled for the
engine protection. Learning function
The clutch disc changes engagement point and torque
Kickdown control (in D (drive) mode) transmission characteristic caused by aging and
When the accelerator pedal is depressed more than the temperature of the disc. For smooth clutch engagement
specified value, TCM judges that the vehicle is in at the gear change compensating the characteristic
acceleration state and performs a down shift to improve changes, TCM has the learning function for the following
acceleration performance. factors.
• Clutch engagement point: The point where the clutch
Under speed control (in D (drive) mode and M disk and the flywheel are fully engaged.
(manual) mode)
If the vehicle is running at low speed with a high gear • Clutch torque transmission point: The point where the
position like 4th gear or 5th gear, TCM executes a down clutch disc and the flywheel begin to contact and the
shift judging that driving torque is insufficient receiving engine torque starts to be transmitted to the
information such as the gear position and the engine transmission.
speed. This prevents engine stall. However, when down • Clutch torque characteristic: Index corresponding to
shifting in M (manual) mode, the gear position is fixed wear and temperature of the clutch disc.
even if the vehicle speed increases. • Clutch end stroke: The point where the clutch disc and
the flywheel are completely disengaged.
Shift hold control when accelerator (throttle) is
quickly closed Vehicle start control
When the accelerator is closed during acceleration and For the vehicle start, shift solenoid No. 1, No. 2 and
the accelerator is depressed again, up shift is executed clutch solenoid are duty controlled on the basis of
usually because the gear change point for accelerator accelerator opening. And, to realize smooth start, the
0% opening is used as a reference value. However, this shift speed and the engagement speed of the clutch are
shift hold control prevents unnecessary up shift holding adjusted in response to the vehicle acceleration and
the gear in the position when the accelerator pedal is deceleration.
released. In this way, the engine brake can be used
effectively and acceleration after that will be done Creep control
smoothly. For creep function, shift solenoid No. 1, No. 2 and the
clutch solenoid are duty controlled by the TCM when the
Shift hold control using estimated gradient of slope accelerator is closed and shift selector is in D, M or R
While the vehicle is running, the gradient of the road range. In this condition, the vehicle can run at the set
surface is constantly estimated based on the engine speed.
torque information from ECM and the vehicle speed
signal. When it is judged that the estimated slope
Clutch protection control • It is possible to communicate with TCM through data

When estimated temperature of the clutch disc reaches link connector (DLC) (3) using SUZUKI scan tool (4).
about 260 °C (500 °F), TCM sounds warning buzzer and (Diagnostic information can be checked and cleared
blinks transmission warning light to warn the driver. This using SUZUKI scan tool.)
prevents the clutch temperature from rising to the
temperature at which the clutch generates odor due to
[A]
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 300 °C (572 °F), 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
1 2
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
[B]
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 4
removed or replaced, the learned values are deviated.
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 initialization, refer to “TCM and
Clutch Initialization”.
Auto Gear Shift Diagnosis General Description

AENNTA0E5401005 (03(01)
TCM has an On-Board Diagnosis System which detects 3
a malfunction in this system. IMTA0A540003-01
When diagnosing a trouble in transaxle control including [A]: Segment display type [B]: Color dot display type
this system, be sure to have full understanding of “On-
Board Diagnostic System Description” and each item in Warm-Up Cycle
“Precautions for Diagnosing Trouble” and execute A warm-up cycle means sufficient vehicle operation such
diagnosis according to “Auto Gear Shift System Check” that the coolant temperature has risen by at least 22 °C
to obtain correct result smoothly. (40 °F) from engine starting and reaches a minimum
temperature of 70 °C (160 °F).
On-Board Diagnostic System Description
AENNTA0E5401006 (03(01) Driving Cycle
TCM has the following functions. A “Driving Cycle” consists of engine startup, driving
• When TCM detects a malfunction in auto gear shift mode where a malfunction would be detected if present,
control system, TCM turns on malfunction indicator and engine shutoff.
lamp (MIL) (1) and/or auto gear shift warning light (2)
and stores DTC in TCM memory.

AENNTA0E5401007 (03(01)
Refer to “Communication System Description”: CAN in Section 10H for CAN communication system description.

TCM Circuit Diagram
AENNTA0E5402001 (10(01)
10
WHT 11 22
1
GRY C15-11
23
2 LT BLU C15-22
39
3 YEL C15-20
24
4 BLU C15-18
5 PPL C15-16
6 WHT C15-14 C15-3 BEG 25 26
27
7 RED C15-13
[C] 28
8 GRN C15-9
C15-1 BLU 40 41
9 BRN C15-17
C15-2 BRN YEL
BLK C15-4
29
30
RED C15-7 C15-23 PNK

13 12 [B]
WHT C15-10 31
32 36 42
14
15 C15-25 PPL
37
43 44
C15-28 LT GRN
16
45
C15-26 WHT
17 46
C15-24 GRY
IG2 [A]
IG1 33
18
ST
[B] 47
19 C15-19 PNK 31 34
38
C15-21 GRN
48
20
[B]
21 31 27 35 49
: 50 : 51
IMTA0A540005-01
[A]: Ignition switch model 12. CAN driver 26. To main relay 40. “STOP” fuse
[B]: Keyless push start model 13. To control modules connected by CAN 27. ECM 41. “B/U” fuse
[C]: Cruise control model 14. Valve body 28. Brake light switch 42. “BACK” fuse
1. Shift selector 15. Shift position sensor 29. Brake light 43. “IG1 SIG” fuse
2. Hall sensor M1 16. Select position sensor 30. Driver side front door switch 44. “IGN” fuse
3. Hall sensor M2 17. Pressure sensor 31. BCM 45. “T/M” fuse
4. Hall sensor M3 18. Shift solenoid valve 1 32. Back up light 46. “T/M PUMP” fuse
5. Hall sensor M4 19. Shift solenoid valve 2 33. Ignition switch 47. “ST” fuse
6. Hall sensor M5 20. Clutch solenoid valve 34. Engine switch 48. Main fuse box
7. Hall sensor H1 21. Select solenoid valve 35. Starting motor 49. Battery
8. Hall sensor H2 22. Electric motor 36. Back up light relay 50. Engine ground
9. Hall sensor H3 23. Clutch position sensor (auto gear shift 37. IG11 relay 51. Body ground
actuator unit)
10. Auto gear shift actuator unit 24. Clutch speed sensor 38. Starting motor control relay
11. TCM 25. VSS 39. “T/M2” fuse
Electronic Shift Control Input / Output Diagram

AENNTA0E5402002 (10(01)
INPUT OUTPUT
Auto gear shift actuator unit
Pressure sensor TCM Valve body

Shift position sensor Gear shift control

Select position sensor
Shift timing control
Select solenoid valve
Clutch position sensor
Reverse control Clutch solenoid valve
VSS
Electric motor
Clutch control
Clutch speed sensor
Brake light switch signal Starting motor control Starting motor control relay
Brake switch signal Back up light

Protective function
- Oil pump high temp. control
Ignition “START” signal Shift selector power supply
Shift selector
CAN communication function
- Lever position sensor M1 signal
Fail-safe function
- Lever position sensor H1 signal Self diagnosis
- Lever position sensor H2 signal
- Lever position sensor H3 signal ECM
Warning function
ECM BCM
BCM ESP® control module
ESP® control module Combination meter
Signal on CAN
communincation line
IMTA0A540006-01
Component Location
Auto Gear Shift System Component Location
AENNTA0E5403001 (04(01)
Around engine compartment
5 6
9
9
11
12
8
13
14 13 10
7
IMTA0A540027-01
1. Driver side front door switch 6. TCM 11. Select solenoid valve
2. Relay box 7. Clutch speed sensor 12. Clutch solenoid valve
3. Back up light relay 8. VSS 13. Shift solenoid valve 1 and shift solenoid valve 2
4. Starting motor control relay 9. Valve body (auto gear shift actuator unit) 14. Pressure sensor
5. Auto gear shift actuator unit 10. Electric motor
6 5 4 6 5 4
[A] 3 [B] 3
IMTA0A540028-01
[A]: Color dot display type 2. Brake light switch 5. Depress brake pedal indicator
[B]: Segment display type 3. Combination meter 6. MIL
1. Shift selector 4. Auto gear shift warning light

Auto Gear Shift System Check
AENNTA0E5404001 (06(01)

1) Perform customer complaint analysis. (Step 1. Customer Complaint Analysis)
Yes Go to Step 2.
Step 2 DTC / freeze frame data check, record and clearance

1) Check for DTC. (Step 2. DTC / Freeze Frame Data Check, Record and Clearance)
Yes Print DTC and freeze frame data or write them down and clear them referring to “DTC Clearance”.
Then go to Step 3.
No Go to Step 4.

1) Perform visual inspection. (Step 3 and 4. Visual Inspection)
Yes Repair or replace defective part. Then go to Step 11.

No Go to Step 5.

1) Perform visual inspection. (Step 3 and 4. Visual Inspection)
Yes Repair or replace defective part. Then go to Step 11.

No Go to Step 8.

1) Check trouble symptom. (Step 5. Trouble Symptom Confirmation)
Yes Go to Step 6.
No Go to Step 7.
Step 6 Rechecking and record of DTC / freeze frame data

1) Recheck for and freeze frame data. (Step 6 and 7. Rechecking and Record of DTC and Freeze Frame
Data)
Yes Go to Step 9.
No Go to Step 8.
Step 7 Rechecking and record of DTC / freeze frame data

1) Recheck for DTC and freeze frame data. (Step 6 and 7. Rechecking and Record of DTC and Freeze
Frame Data)
Yes Go to Step 9.
No Go to Step 10.
Step 8 Auto gear shift symptom diagnosis

1) Check auto gear shift symptom diagnosis. (Step 8. Auto Gear Shift Symptom Diagnosis)
Yes Go to Step 11.

No Check and repair defective part. Then go to Step 11.

1) Perform troubleshooting for applicable DTC. (Step 9. Troubleshooting for DTC)
Yes Go to Step 11.

No Check and repair defective part. Then go to Step 11.
Step 10 Check for intermittent problems

1) Check for intermittent problems. (Step 10. Intermittent Problem Check)
Yes Repair or replace defective part(s). Then go to Step 11.

No Go to Step 11.

2) Perform final confirmation test. (Step 11. Final Confirmation Test)
Yes Go to Step 6.
No End.
Step 1. Customer Complaint Analysis

Record details of the problem (failure, complaint) and how it occurred as described by customer.
For this purpose, use of such an inspection from will facilitate collecting information required for proper analysis and
diagnosis.
NOTE
The form is a standard sample. It should be modified according to characteristic of each market.
User name: Model: VIN:

PROBLEM SYMPTOMS
Vehicle does not move (R, D, M)
No upshift ( 1st to 2nd 2nd to 3rd 3rd to 4th 4th to 5th)
No downshift ( 5th to 4th 4th to 3rd 3rd to 2nd 2nd to 1st )
Shift lever cannot be operated ( N → D D → N N → R R → N D→M M → D)
Noise ( Motor Gear Clutch Other )
Automatic shift point too high or too low
Excessive gear change shock (1st / 2nd / 3rd / 4th / 5th / Reverse)
No kickdown
Clutch slipping
Others
VEHICLE / ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS

Environmental Condition
Fair Cloudy Rain Always Others
Weather
( F/ C) Hot Warm Cool Cold Always
Temperature
Always Sometimes ( times / day, month) Only once Under certain condition
Frequency
Urban Suburb Highway Mountainous Uphill Downhill Tarmacadam
Road
Gravel Other
Vehicle Condition
Engine & Cold Warming-up phase Warmed up
transmission Engine speed ( rpm)
condition Throttle opening ( Idle Approx. % Full)
At stop During driving ( Accelerating Decelerating Braking)
Vehicle condition Right-hand turn Left-hand turn Vehicle speed ( km/h / mile/h)
Other
Auto gear shift Always ON Sometimes ON Always OFF

warning light Good condition
Blink Always ON Sometimes ON Always OFF
MIL
Good condition
First check: No DTC DTC ( )
DTC
Second check: No DTC DTC ( )
IGSD0A541004-01
Step 2. DTC / Freeze Frame Data Check, Record and Step 5. Trouble Symptom Confirmation
Clearance Recheck DTC according to “DTC Confirmation
First, check DTC (current DTC). (DTC Check) Procedure” described in each DTC troubleshooting.
If DTC is indicated, print DTC and freeze frame data or
write them down and then clear them. (DTC Clearance) Step 6 and 7. Rechecking and Record of DTC and
Freeze Frame Data
Step 3 and 4. Visual Inspection Refer to “DTC Check” for checking procedure.
As a preliminary step, perform visual check of the items
that support proper function of the engine and auto gear Step 8. Auto Gear Shift Symptom Diagnosis
shift referring to “Visual Inspection”. Check the parts of the system suspected as a possible
cause referring to “Auto Gear Shift Symptom Diagnosis”.
Step 9. Troubleshooting for DTC Step 11. Final Confirmation Test

Perform applicable DTC troubleshooting and repair or Check that the problem symptom has gone and the
replace faulty parts. vehicle is free from any abnormal conditions. If what has
been repaired is related to DTC, clear DTC once,
Step 10. Intermittent Problem Check perform DTC confirmation procedure and check that no
Check parts related to detected DTC (e.g. wire harness, DTC is indicated.
connector, etc.). (Intermittent Connection and Poor
Contact Inspection) in Section 00
Visual Inspection
AENNTA0E5404002 (06(01)
Inspection item Referring
• Auto gear shift actuator----- oil level, oil leakage, corrosion on • “Auto Gear Shift Actuator Oil Level Check”
the electric motor screw, clutch actuator cable and anchor • “Auto Gear Shift Transaxle Oil Change”
position
• “Auto Gear Shift Electric Motor Removal and
Installation”
• “Auto Gear Shift Actuator Unit Removal and
Installation”
• Engine mountings ----- play, looseness, damage “Engine Assembly Removal and Installation” in
Section 1D
• Suspension ----- play, looseness “Suspension, Wheel and Tire Symptom Diagnosis”
in Section 2A
• Drive shafts ----- damage “Front Drive Shaft Symptom Diagnosis”: Front in
Section 3A
• Battery ----- indicator condition, corrosion of terminal “Battery Inspection” in Section 1J
• Connectors of electric wire harness and ground connection “Auto Gear Shift System Component Location”
check----- 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 “Auto Gear Shift Warning Light Check”
• Malfunction indicator lamp ----- Operation “MIL Check”
• Charge warning light ----- Operation “Generator Symptom Diagnosis” in Section 1J
• Other parts that can be checked visually
MIL Check
AENNTA0E5404003 (06(01) [A]
Refer to “MIL Check” in Section 1A.
Auto Gear Shift Warning Light Check

AENNTA0E5404004 (06(01)
2) Check that auto gear shift warning light (1) lights for
about 2 sec. and then goes OFF. If anything faulty is 1
found, refer to “Auto Gear Shift Warning Light Does
Not Come ON at Ignition “ON” and Engine Stopped”
or “Auto Gear Shift Warning Light Remains ON after [B]
Engine Starts”.
IMTA0A540007-01

DTC Check NOTE

AENNTA0E5404005 (06(01)
1) Connect SUZUKI scan tool to DLC. Refer to “Suzuki • A communication error may occur due to
SDT-II Connection and Disconnection” in Section temporary overlap of communication load.
0A. If communication error occurs, wait about
SUZUKI scan tool. • If communication between SUZUKI scan
Refer to Operator's Manual of SUZUKI scan tool for tool and TCM is not possible, perform the
further details. following checks:
– Check communication condition
NOTE between PC and VCI using SUZUKI scan
• A communication error may occur due to tool function.
temporary overlap of communication load. – Check DLC power circuit and ground
If communication error occurs, wait about circuit.
10 seconds and try the operation again. – Check DLC cable. If necessary, check
• If communication between SUZUKI scan DLC cable by substituting a known-good
tool and TCM is not possible, perform the DLC cable.
following checks: – Check CAN communication circuit and
– Check communication condition connectors between DLC and central
between PC and VCI using SUZUKI scan gateway control module. (Refer to
tool function. “Diagnosis flow: [a]” in
– Check DLC power circuit and ground “Troubleshooting” of “Troubleshooting
circuit. for Lost Communication”: CAN in
Section 10H.)
DLC cable by substituting a known-good – Check CAN communication system.
DLC cable. (Troubleshooting for Communication
Bus Off): CAN in Section 10H
– Check CAN communication circuit and
connectors between DLC and central – Check central gateway control module
gateway control module. (Refer to power supply circuit and ground circuit.
“Diagnosis flow: [a]” in (Inspection of Central Gateway Control
“Troubleshooting” of “Troubleshooting Module and Its Circuits): CAN (Central
for Lost Communication”: CAN in Gateway) in Section 10H
Section 10H.) – Check TCM power circuit and ground
– Check CAN communication system. circuit. (TCM Power Supply and Ground
(Troubleshooting for Communication Circuit Check)
3) Disconnect SUZUKI scan tool from DLC. Refer to
– Check central gateway control module “Suzuki SDT-II Connection and Disconnection” in
power supply circuit and ground circuit. Section 0A.
Module and Its Circuits): CAN (Central NOTE
Gateway) in Section 10H Confirmed DTC and freeze frame data stored
– Check TCM power circuit and ground in TCM memory are also cleared in the
circuit. (TCM Power Supply and Ground following cases. Be careful not to clear them
Circuit Check) before recording them.
• When the same malfunction (DTC) is not
detected again for 40 engine warm-up
“Suzuki SDT-II Connection and Disconnection” in
cycles.
Section 0A.
• Even though the pending and confirmed
DTCs are cleared, the permanent DTC will
DTC Clearance
AENNTA0E5404006 (06(01) not be cleared.
1) Connect SUZUKI scan tool to DLC. Refer to “Suzuki
SDT-II Connection and Disconnection” in Section
0A.
2) Clear DTC and follow the instructions displayed on
SUZUKI scan tool.
further details.
DTC Table
AENNTA0E5404007 (06(01)
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 “On-Board Diagnostic System Description”.
• Two or more DTCs of P188A, P188B, P188C, P188D, P188E or P188F could be detected
simultaneously.
DTC
Auto gear shift
warning light
logic
P0070
( ) (DTC Ambient Air Temperature Sensor Circuit 1 D/C Lights up Off
P0070)
P0560
(DTC P0560 /
System Voltage 1 D/C Lights up Off
P0562 /
P1711)
P0562
(DTC P0560 /
System Voltage Low 1 D/C Lights up Off
P0562 /
P1711)
P0572
( ) (DTC
Brake Switch “A” Circuit Low 1 D/C Lights up Off
P0572 /
P0573)
P0573
( ) (DTC
Brake Switch “A” Circuit High 1 D/C Lights up Off
P0572 /
P0573)
P0602
Control Module Programming Error 1 D/C Off Off
(DTC P0602)
P0604 (DTC
P0604 / P060A
/ P062F / Internal Control Module Random Access Memory
1 D/C Lights up Off
P1702 / P1704 (RAM) Error
/ P1982 /
P1983)
P060A
(DTC P0604 /
P060A / P062F Internal Control Module Monitoring Processor
1 D/C Lights up Off
/ P1702 / Performance
P1704 / P1982
/ P1983)
P0615
( ) (DTC Starter Relay Circuit 1 D/C Lights up Off
P0615)
P062F
(DTC P0604 /
P060A / P062F
Internal Control Module EEPROM Error 1 D/C Lights up Off
/ P1702 /
P1704 / P1982
/ P1983)
P0715
(DTC P0715 / Input / Turbine Speed Sensor “A” Circuit 1 D/C Lights up Off
P0716)
DTC
Auto gear shift
warning light
logic
P0716
Input / Turbine Speed Sensor “A” Circuit Range /
(DTC P0715 / 1 D/C Lights up Off
Performance
P0716)
P0720
(DTC P0720 / Output Speed Sensor Circuit 1 D/C Lights up Lights up
P0721)
P0721
(DTC P0720 / Output Speed Sensor Circuit Range / Performance 1 D/C Lights up Lights up
P0721)
P0805
Clutch Position Sensor Circuit 1 D/C Lights up Off
(DTC P0805)
P080A
( ) (DTC
Clutch Position Not Learned 1 D/C Lights up Off
P080A / P185A
/ P185B)
P0840
(DTC P0840 / Transmission Fluid Pressure Sensor / Switch “A” Circuit 1 D/C Lights up Off
P0841)
P0841
Transmission Fluid Pressure Sensor / Switch “A” Circuit
Range / Performance
P0841)
P0904
(DTC P0904 / Gate Select Position Circuit 1 D/C Lights up Off
P0914)
P0914
(DTC P0904 / Gear Shift Position Circuit 1 D/C Lights up Lights up
P0914)
P0944
Hydraulic Pressure Unit Loss of Pressure 1 D/C Lights up Off
(DTC P0944)
P0945
Hydraulic Pump Relay Circuit / Open 1 D/C Lights up Off
(DTC P0945)
P1702
(DTC P0604 /
P060A / P062F
Internal Control Module Memory Check Sum Error 1 D/C Lights up Off
/ P1702 /
P1704 / P1982
/ P1983)
P1704
(DTC P0604 /
P060A / P062F
Internal Control Module Memory EEPROM Error 1 D/C Lights up Off
/ P1702 /
P1704 / P1982
/ P1983)
P1706
( ) (DTC Torque Request Communication Error From TCM 1 D/C Off Off
P1706)
P1707
( ) (DTC
Torque Reduction Error From ECM 1 D/C Off Off
P1707 /
P1985)
P1711
(DTC P0560 /
TCM Power Input Low Voltage 1 D/C Lights up Off
P0562 /
P1711)
P1844
( ) (DTC Grid Position Not Learned 1 D/C Lights up Off
P1844)
DTC
Auto gear shift
warning light
logic
P184A
Pump Off failed 1 D/C Lights up Off
(DTC P184A)
P184B
(DTC P184B /
Solenoid Driver “A” Circuit Range / Performance 1 D/C Lights up Off
P184C /
P184D)
P184C
(DTC P184B / Solenoid Driver “A” Feedback Signal Range /
1 D/C Lights up Off
P184C / Performance
P184D)
P184D
(DTC P184B /
Solenoid Driver “B” Circuit Range / Performance 1 D/C Lights up Off
P184C /
P184D)
P184E
(DTC P184E /
TCM Internal Supply Voltage “B” Circuit 1 D/C Lights up Off
P184F / P1854
/ P1855)
P184F
( ) (DTC
P184E / P184F TCM Internal Supply Voltage “C” Circuit 1 D/C Lights up Off
/ P1854 /
P1855)
P1850
(DTC P1850 /
Gear Shift Odd Actuator Circuit 1 D/C Lights up Off
P1851 / P1888
/ P1889)
P1851
(DTC P1850 /
Gear Shift Even Actuator Circuit 1 D/C Lights up Off
P1851 / P1888
/ P1889)
P1852
(DTC P1852 / Sensor Power Supply “A” 1 D/C Lights up Off
P1853)
P1853
(DTC P1852 / Sensor Power Supply “B” 1 D/C Lights up Off
P1853)
P1854
(DTC P184E /
TCM Internal Supply Voltage “A” Low 1 D/C Lights up Off
P184F / P1854
/ P1855)
P1855
(DTC P184E /
TCM Internal Supply Voltage “A” High 1 D/C Lights up Off
P184F / P1854
/ P1855)
P185A
( ) (DTC
Clutch End Stroke Position Selftune 1 D/C Lights up Off
P080A / P185A
/ P185B)
P185B
( ) (DTC
Clutch Stroke Selftune 1 D/C Lights up Off
P080A / P185A
/ P185B)
P185C
Hydraulic Pump Relay Circuit 1 D/C Lights up Off
(DTC P185C)
DTC
Auto gear shift
warning light
logic
P185E
(DTC P185E / TCM Safety Function Failure 1 D/C Lights up Off
P185F)
P185F
(DTC P185E / TCM Safety Integrity Function Failure 1 D/C Lights up Off
P185F)
P1884
( ) (DTC Reverse Lamp Control Circuit 1 D/C Lights up Off
P1884)
P1885
( ) (DTC Door Switch Circuit 1 D/C Lights up Off
P1885)
P1886
Dual port RAM check 1 D/C Lights up Off
(DTC P1886)
P1888
(DTC P1850 /
Clutch Actuator Circuit 1 D/C Lights up Off
P1851 / P1888
/ P1889)
P1889
(DTC P1850 /
Gate Select Actuator Circuit 1 D/C Lights up Off
P1851 / P1888
/ P1889)
P188A
(DTC P188A /
Transmission Range Sensor Circuit fault type “A” 1 D/C Lights up Off
P188B /
P188F)
P188B
(DTC P188A /
Transmission Range Sensor Circuit fault type “B” 1 D/C Lights up Off
P188B /
P188F)
P188C
Transmission Range Sensor Circuit fault type “C” 1 D/C Lights up Off
(DTC P188C)
P188D
(DTC P188D / Transmission Range Sensor Circuit fault type “D” 1 D/C Lights up Off
P188E)
P188E
(DTC P188D / Transmission Range Sensor Circuit fault type “E” 1 D/C Lights up Off
P188E)
P188F
(DTC P188A /
Transmission Range Sensor Circuit fault type “F” 1 D/C Lights up Off
P188B /
P188F)
P1902
Transmission Range Sensor Supply Circuit 1 D/C Lights up Off
(DTC P1902)
P1903
(DTC P1903 / Clutch Not Opening Before Gear Shifting 1 D/C Lights up Off
P1904)
P1904
(DTC P1903 / Clutch Closing During Engage 1 D/C Lights up Off
P1904)
P1905
Clutch Control Error 1 D/C Lights up Off
(DTC P1905)
P1906
(DTC P1906 /
Gear Box Disengage Failed 1 D/C Lights up Off
P1907 / P1908
/ P190A)
DTC
Auto gear shift
warning light
logic
P1907
(DTC P1906 /
Gear Box Shift Failed 1 D/C Lights up Lights up
P1907 / P1908
/ P190A)
P1908
(DTC P1906 /
Gear Box Engage Failed 1 D/C Lights up Lights up
P1907 / P1908
/ P190A)
P1909
(DTC P1909 / Gear Box Unintended Gear Disengage 1 D/C Lights up Lights up
P190B)
P190A
(DTC P1906 /
Gear Box Shift Locked 1 D/C Lights up Lights up
P1907 / P1908
/ P190A)
P190B
(DTC P1909 / Gear Box Unintended Gear Engage 1 D/C Lights up Off
P190B)
P190C
Gear shift Endless 1 D/C Lights up Lights up
(DTC P190C)
P190D
Clutch Overspeed 1 D/C Lights up Off
(DTC P190D)
P190E
Pump Overheating 1 D/C Lights up Off
(DTC P190E)
P190F
( ) (DTC Accumulator Failed 1 D/C Lights up Off
P190F)
P1980
( ) (DTC System Misuse 1 D/C Off Off
P1980)
P1981
( ) (DTC CAN Invalid Data of Engine Torque 1 D/C Off Off
P1981)
P1982
(DTC P0604 /
P060A / P062F
Internal Control Module EEPROM Error (Application) 1 D/C Lights up Off
/ P1702 /
P1704 / P1982
/ P1983)
P1983 (DTC
P0604 / P060A
/ P062F / Internal Control Module Monitoring Processor Output
1 D/C Lights up Off
P1702 / P1704 Failure
/ P1982 /
P1983)
P1984
TCM Safety Input Preprocessing Failure 1 D/C Lights up Off
(DTC P1984)
P1985
( ) (DTC
Torque Up Error From ECM 1 D/C Off Off
P1707 /
P1985)
P1986 ( )
Vehicle equipment information self- learning not
completed
P1987)
P1987 ( )
(DTC P1986 / Vehicle equipment information not matched 1 D/C Lights up Off
P1987)
DTC
Auto gear shift
warning light
logic
P2712
Hydraulic Power Unit Leakage 1 D/C Lights up Off
(DTC P2712)
P2789
( ) (DTC Clutch “A” Adaptive Learning at Limit 1 D/C Lights up Off
P2789)
U0073
Control Module Communication Bus Off 1 D/C Lights up Off
(DTC U0073)
U0100
(DTC U0100 /
Lost Communication With ECM 1 D/C Lights up Off
U0121 / U0140
/ U0155)
U0121
(DTC U0100 /
Lost Communication With ABS/ESP® Control Module 1 D/C Lights up Off
U0121 / U0140
/ U0155)
U0140
( ) (DTC
U0100 / U0121 Lost Communication With Body Control Module 1 D/C Lights up Off
/ U0140 /
U0155)
U0155 (DTC
U0100 / U0121 Lost Communication With Instrument Panel Cluster
1 D/C Lights up Off
/ U0140 / (IPC) Control Module
U0155)
Fail-Safe Table
AENNTA0E5404008 (06(01)
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 (DTC Ambient Air Temperature
ambient temperature is 20 °C (68 Normal condition is recovered.
P0070) Sensor Circuit
°F).
TCM shifts gear to neutral if the
following conditions are met while
engine is running.
P0560 (DTC
P0560 / P0562 System Voltage • Vehicle is stopped. Normal condition is recovered.
/ P1711) • Accelerator pedal is released.
• Gear is engaged.
• Brake pedal is released.
P0562 (DTC
Auto gear shift actuator unit cannot
P0560 / P0562 System Voltage Low Normal condition is recovered.
shift gear to other than neutral.
/ P1711)
P0572 (DTC
Brake Switch “A” Circuit • TCM inhibits creep control.
P0572 /
Low
P0573) • TCM substitutes brake switch Normal condition is recovered.
P0573 (DTC (control signal) for brake light
Brake Switch “A” Circuit
P0572 / switch (brake light signal).
High
P0573)
P0602 (DTC Control Module Reprogramming of TCM is correctly
TCM stops gear shift control.
P0602) Programming Error executed.

P0604 (DTC
P0604 / P060A
Internal Control Module • TCM stops gear shift control.
/ P062F /
Random Access Memory Normal condition is recovered.
P1702 / P1704 • TCM stops cranking.
(RAM) Error
/ P1982 /
P1983)
P060A (DTC
P0604 / P060A • TCM stops engine.
Internal Control Module
/ P062F /
Monitoring Processor • TCM stops gear shift control. Normal condition is recovered.
P1702 / P1704
Performance • TCM disengages clutch.
/ P1982 /
P1983)
P0615 (DTC TCM controls shifts gear position to Normal condition is recovered or
Starter Relay Circuit
P0615) neutral when cranking. ignition is set to “ON”.
P062F (DTC
P0604 / P060A • Auto gear shift is controlled in
/ P062F / Internal Control Module default mode. Normal condition is recovered.
P1702 / P1704 EEPROM Error
/ P1982 / • TCM shifts gear to neutral.
P1983)
P0715 (DTC • When only clutch speed sensor is
Input / Turbine Speed
P0715 / malfunctioning.
Sensor “A” Circuit
P0716) – TCM substitutes VSS signal or
engine speed sensor signal for
clutch speed by calculation.
• When VSS, engine speed sensor
or APP sensor is malfunctioning.
Normal condition is recovered.
P0716 (DTC Input / Turbine Speed – TCM stops gear shift control.
P0715 / Sensor “A” Circuit Range / – TCM controls gear shift to
P0716) Performance neutral when vehicle is
stopping, starting or creeping.
– TCM substitutes engine speed
sensor signal or VSS signal for
clutch speed by calculation.
P0720 (DTC • When only VSS is
Output Speed Sensor Normal condition is recovered or
P0720 / malfunctioning.
Circuit ignition is set to “ON”.
P0721) – 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.
P0721 (DTC Output Speed Sensor • When clutch speed sensor,
P0720 / Circuit Range / engine speed sensor or APP Normal condition is recovered.
P0721) 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.

• TCM stops gear shift control.
• TCM releases clutch when
vehicle is stopping, starting or
creeping.
• TCM stops creep control.
• TCM stops cranking.
P0805 (DTC Clutch Position Sensor • TCM stops engine if the following Normal condition is recovered.
P0805) 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 (DTC
Clutch Position Not TCM restricts gear shift control
P080A / P185A Normal condition is recovered.
Learned except N, R and 1st gear.
/ P185B)
P0840 (DTC Transmission Fluid • TCM stops creep control.
P0840 / Pressure Sensor / Switch • TCM shifts gear to neutral if the
P0841) “A” Circuit following conditions are met.
– Vehicle is stopped.
Transmission Fluid Normal condition is recovered.
P0841 (DTC – Accelerator pedal is released.
Pressure Sensor / Switch
P0840 / – Gear is engaged.
“A” Circuit Range /
P0841)
Performance – Brake pedal is not depressed
for more than specified time.
P0904 (DTC • TCM stops cranking.
Gate Select Position
P0904 / • TCM stops starting / creeping Normal condition is recovered.
Circuit
P0914) control when selector lever is
shifted from D to R or R to D.
P0914 (DTC
P0904 / Gear Shift Position Circuit TCM restricts gear shift control. Normal condition is recovered.
P0914)
P0944 (DTC Hydraulic Pressure Unit • TCM controls gear shift to neutral Oil pressure is higher than specified
P0944) Loss of Pressure when vehicle is stopping, starting value.
or creeping.
TCM stops gear shift request to
P0945 (DTC Hydraulic Pump Relay
gears other than neutral when oil Normal condition is recovered.
P0945) Circuit / Open
pressure is not enough.
P1702 (DTC
P0604 / P060A
/ P062F / Internal Control Module • TCM stops gear shift control.
P1702 / P1704 Memory Check Sum Error • TCM stops cranking.
/ P1982 /
P1983)
P1704 (DTC
P0604 / P060A
/ P062F / Internal Control Module • TCM controls gear shift to neutral
P1702 / P1704 Memory EEPROM Error when vehicle is stopping.
/ P1982 /
P1983)
Torque Request
P1706 (DTC
Communication Error — —
P1706)
From TCM

P1707 (DTC
Torque Reduction Error
P1707 / — —
From ECM
P1985)
P1711 (DTC • TCM restricts gear shifting.
TCM Power Input Low
P0560 / P0562 Normal condition is recovered.
Voltage • TCM restricts oil pump operation.
/ P1711)
• TCM stops vehicle start control.
P1844 (DTC
Grid Position Not Learned • TCM stops creep control. Normal condition is recovered.
P1844)
TCM turns OFF oil pump for a
P184A (DTC specified period of time and turns
Pump Off failed Ignition is set to “ON”.
P184A) ON when oil pressure becomes
lower than specified value.
• TCM stops engine if the following
conditions are met.
P184B (DTC
P184B / Solenoid Driver “A” Circuit
specified value. Normal condition is recovered.
P184C / Range / Performance
P184D) – Engine speed is lower than
specified value.
conditions are met.
P184C (DTC
Solenoid Driver “A” – Vehicle speed is lower than
P184B / Normal condition is recovered or
Feedback Signal Range / specified value.
P184C / ignition is set to “ON”.
Performance – Engine speed is lower than
P184D)
specified value.
P184D (DTC
P184B / Solenoid Driver “B” Circuit
TCM stops gear shift control. Normal condition is recovered.
P184C / Range / Performance
P184D)
conditions are met.
P184E (DTC
P184E / P184F TCM Internal Supply
/ P1854 / Voltage “B” Circuit
P1855) – Engine speed is lower than
specified value.
P184F (DTC
— —
/ P1854 / Voltage “C” Circuit
P1855)

P1850 (DTC
P1850 / P1851 Gear Shift Odd Actuator
/ P1888 / Circuit • TCM stops gear shift control.
P1889)
• TCM stops vehicle start after Normal condition is recovered.
P1851 (DTC
P1850 / P1851 Gear Shift Even Actuator stopping vehicle.
/ P1888 / Circuit
P1889)
conditions are met.
specified value.
P1852 (DTC specified value.
P1852 / Sensor Power Supply “A” Normal condition is recovered.
P1853) – Accelerator pedal is depressed
• TCM releases clutch when
vehicle is stopping, starting or
creeping.
P1853 (DTC • TCM stops vehicle start control.
P1852 / Sensor Power Supply “B” • TCM stops cranking. Normal condition is recovered.
P1853)
• TCM stops engine when selector
lever is shifted from D to R or R to
D.
conditions are met.
P1854 (DTC
/ P1854 / Voltage “A” Low
specified value.
P1855 (DTC
— —
/ P1854 / Voltage “A” High
P1855)
P185A (DTC
Clutch End Stroke Position
P080A / P185A — —
Selftune
/ P185B)
P185B (DTC
P080A / P185A Clutch Stroke Selftune TCM stops cranking. Normal condition is recovered.
/ P185B)
P185C (DTC Hydraulic Pump Relay
— —
P185C) Circuit
P185E (DTC • TCM stops engine.
TCM Safety Function
P185E / • TCM stops gear shift control. Ignition is set to “OFF”.
Failure
P185F) • TCM disengages clutch.

P185F (DTC • TCM stops gear shift control.
TCM Safety Integrity
P185E / • TCM disengages clutch. —
Function Failure
P185F) • TCM stops CAN communication.
P1884 (DTC Reverse Lamp Control
— —
P1884) Circuit
P1885 (DTC
Door Switch Circuit TCM stops creep control. Normal condition is recovered.
P1885)
• TCM stops gear shift control
except neutral.
P1886 (DTC • TCM controls gear position to
Dual port RAM check neutral after vehicle stopping. Normal condition is recovered.
P1886)
conditions are met.
P1888 (DTC
P1850 / P1851
Clutch Actuator Circuit specified value. Normal condition is recovered.
/ P1888 /
specified value.
P1889 (DTC
P1850 / P1851 Gate Select Actuator • TCM stops gear shift control.
/ P1888 / Circuit • TCM shifts gear to neutral.
P1889)
P188A (DTC Transmission Range
P188A / P188B Sensor Circuit fault type
/ P188F) “A”
P188B (DTC Transmission Range
/ P188F) “B”
• TCM cancels manual gear shift. After recovering normal condition,
Transmission Range
P188C (DTC • TCM controls gear position to the following steps are performed.
Sensor Circuit fault type
P188C) neutral at vehicle low speed.
“C” 1. Ignition is set to “ON”.
P188D (DTC Transmission Range • TCM stops creep control. 2. Gear is shifted to R, N, D and M
P188D / Sensor Circuit fault type • TCM stops vehicle start control. holding each gear position for
P188E) “D” more than 1 second.
P188E (DTC Transmission Range
P188D / Sensor Circuit fault type
P188E) “E”
P188F (DTC Transmission Range
/ P188F) “F”
P1902 (DTC Transmission Range
— —
P1902) Sensor Supply Circuit
P1903 (DTC
Clutch Not Opening Before Gear is shifted by shift selector lever
P1903 / TCM stops gear shift control.
Gear Shifting normally.
P1904)
• TCM controls gear shift to
P1904 (DTC neutral.
Clutch Closing During
P1903 / Ignition is set to “ON”.
Engage • TCM stops gear shift until gear is
P1904)
shifted to neutral.

conditions are met.
P1905 (DTC
Clutch Control Error specified value. Ignition is set to “ON”.
P1905)
specified value.
P1906 (DTC
P1906 / P1907 Gear Box Disengage Gear is shifted by shift selector lever
TCM stops gear shift control.
/ P1908 / Failed normally.
P190A)
P1907 (DTC
P1906 / P1907 • TCM stops gear shift request.
Gear Box Shift Failed Ignition is set to “ON”.
/ P1908 / • TCM shifts gear to neutral.
P190A)
P1908 (DTC
P1906 / P1907
Gear Box Engage Failed TCM stops gear shift request. Ignition is set to “ON”.
/ P1908 /
P190A)
P1909 (DTC TCM controls gear position to
Gear Box Unintended
P1909 / neutral, and then gear shift to any Ignition is set to “ON”.
Gear Disengage
P190B) gear becomes possible.
P190A (DTC If TCM fails to retry gear shift, gear
P1906 / P1907 stays in previous position and then
Gear Box Shift Locked Ignition is set to “ON”.
/ P1908 / gear shift to any gear becomes
P190A) possible.
P190B (DTC • TCM stops gear shift control.
Gear Box Unintended
P1909 / • Clutch is opened until ignition Ignition is set to “ON”.
Gear Engage
P190B) “OFF”.
P190C (DTC
Gear shift Endless TCM stops gear shift control. Ignition is set to “OFF”.
P190C)
P190D (DTC Clutch speed is lower than specified
Clutch Overspeed TCM controls gear shift to neutral.
P190D) value.
Oil pump temperature is lower than
P190E (DTC • TCM restricts oil pump operation. specified value for more than
Pump Overheating
P190E) • TCM restricts gear shift. specified time, or ignition is set to
“ON”.
P190F (DTC
Accumulator Failed — —
P190F)
Oil pump temperature is lower than
P1980 (DTC
System Misuse TCM restricts gear shift. specified value, or ignition is set to
P1980)
“ON”.
P1981 (DTC CAN Invalid Data of
TCM uses temporary value. Normal condition is recovered.
P1981) Engine Torque
P1982 (DTC
P0604 / P060A • TCM stops creep control.
/ P062F /
EEPROM Error • TCM stops vehicle start control. Normal condition is recovered.
P1702 / P1704
(Application) • TCM stops gear shift control.
/ P1982 /
P1983)
P1983 (DTC
P0604 / P060A • TCM stops engine.
/ P062F /
Monitoring Processor • TCM stops gear shift control. Normal condition is recovered.
P1702 / P1704
Output Failure • TCM disengages clutch.
/ P1982 /
P1983)

• TCM stops engine.
P1984 (DTC TCM Safety Input
• TCM stops gear shift control. Ignition is set to “OFF”.
P1984) Preprocessing Failure
• TCM disengages clutch.
P1985 (DTC
Torque Up Error From
P1707 / — —
ECM
P1985)
P1986 (DTC Vehicle equipment
P1986 / information self-learning
P1987) not completed • TCM stops cranking.
P1987 (DTC • TCM uses temporary value.
Vehicle equipment
P1986 /
information not matched
P1987)
P2712 (DTC Hydraulic Power Unit
TCM restricts gear shift. Ignition is set to “ON”.
P2712) Leakage
P2789 (DTC Clutch “A” Adaptive
— —
P2789) Learning at Limit
U0073 (DTC Control Module • TCM stops gear shift request to
U0073) Communication Bus Off gears other than neutral.
• TCM controls gear shift to neutral
U0100 (DTC when vehicle stopping. Normal condition is recovered.
U0100 / U0121 Lost Communication With
• TCM stops vehicle start control.
/ U0140 / ECM
U0155) • TCM stops creep control.
U0121 (DTC
U0100 / U0121 Lost Communication With
TCM uses temporary value.
/ U0140 / ABS/ESP® Control Module
U0155)
U0140 (DTC
U0100 / U0121 Lost Communication With • TCM uses temporary value. Normal condition is recovered.
/ U0140 / Body Control Module • TCM stops cranking.
U0155)
U0155 (DTC
Lost Communication With
U0100 / U0121
Instrument Panel Cluster TCM uses temporary value.
/ U0140 /
(IPC) Control Module
U0155)
Scan Tool Data

AENNTA0E5404009 (06(01)
TCM
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 CAN communication system. (Troubleshooting for Communication Bus Off): CAN in
Section 10H
– Check TCM power circuit and ground circuit. (TCM Power Supply and Ground Circuit Check)
Normal condition /
Reference value
• Vehicle: Stop
0 rpm
Input Shaft Revolution (Input Shaft • Shift selector: R, D or M range
Revolution (rpm)) The same value as
Vehicle: Running
engine speed reading
• Vehicle: Stop
0 rpm
Output Shaft Revolution (Output Shaft • Shift selector: R, D or M range
Revolution (rpm)) • Vehicle: Running at 10 km/h (6 mile/h)
Approx. 100 rpm
• Shift selector: R range
Clutch Position Sensor (Clutch Ignition: “ON” 800 to 1500
Position Sensor) Engine: Idle speed 100 to 500
Shift selector: R range 600 to 800
Select Position Sensor (Select
Shift selector: N range 600 to 800
Position Sensor)
Shift selector: D or M range 200 to 400
Shift selector: R range 600 to 800
Shift Position Sensor (Shift Position
Shift selector: N range 400 to 600
Sensor)
Shift selector: D or M range 200 to 400
Battery Voltage (Battery Voltage (V)) Engine: Idle speed 13 to 15 V
• Shift selector: N range
4 to 6 MPa
Oil Pressure (Oil Pressure (MPa)) • Brake pedal: Released
(40 to 60 bar)
Clutch Solenoid Control Value (Clutch Ignition: “ON” 0 mA
Solenoid Control Value (mA)) Engine: Idle speed 264 to 794 mA
Ignition: “ON” 0 mA
Select Solenoid Control Value (Select
Gear is in shift operation with vehicle stationary with
Solenoid Control Value (mA)) 0 mA or more
ignition “ON”
Shift Solenoid No.1 (Odd Side) Ignition: “ON” 0 mA
Control Value (Shift Solenoid No.1 Gear is in shift operation with vehicle stationary with
0 mA or more
(Odd Side) Control Value (mA)) ignition “ON”
Shift Solenoid No.2 (Even Side) Ignition: “ON” 0 mA
Control Value (Shift Solenoid No.2 Gear is in shift operation with vehicle stationary with
0 mA or more
(Even Side) Control Value (mA)) ignition “ON”
Gear Shift Count (for Maintenance)
The total number of gear shifts stored in the TCM is displayed
(Gear Shift Count (for Maintenance))
• Engine: Specified idle speed after warming up
Engine Speed (Engine Speed (rpm)) Approx. 750 rpm
• Engine: Stop
0 to 10%
Throttle Position (Throttle Position • Accelerator pedal: Released
(%)) • Engine: Stop
90 to 100%
• Engine: Stop
Accel Effective Position (Accel 0 to 2%
Effective Position (Accelerator
• Engine: Stop
Effective Position (%))) 90 to 100%
ECT (ECT (Engine Coolant Approx. 80 to 100 °C
Engine: Specified idle speed after warming up
Temperature, °C, °F)) (176 to 212 °F)
Normal condition /
Reference value
Outside Air Temp (Outside Air Temp Outside air temperature
Engine: Cold and ignition “ON”
(Outside Air Temperature, °C, °F)) is displayed.
Barometric Pressure (Barometric Barometric pressure is
Engine: Cold and ignition “ON”
Pressure (kPa)) displayed.
The same value as
Vehicle Speed (Vehicle Speed (km/h)) Vehicle: Running
speedometer reading
Closed
• Ignition: “ON” Slipping Before
Clutch Control Status (Clutch Control • Shift selector: Being shifted from N to D Engaging
Status) • Ignition: “ON”
Slipping After Engaging
• Shift selector: After completion of N to D shift
• Engine: Idle speed
Opened
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
3rd
Gear Position (Gear Position)
4th
5th
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
2nd
Manual Gear Position (Manual Gear • Manual mode gear position: 2
Position) • Shift selector: M range
3rd
4th
5th
Estimated Clutch Temperature
Estimated clutch temperature: Same as engine Approx. –40 to 350 °C (–
(Estimated Clutch Temperature (°C,
coolant temperature after vehicle stopping 40 to 662 °F)
°F))
Ignition: “ON” Normal
Clutch High Temperature Control Estimated clutch temperature: Higher than 120 °C
Hot Mode 1
Status (Clutch High Temperature (248 °F)
Control Status) Estimated clutch temperature: Higher than Hot
Hot Mode 2
Mode 1
Automatic Discrimination (ABS/ESP)
— Complete
(Automatic Discrimination (ABS/ESP))
ABS Equipped (ABS Equipped) — YES
ESP / ABS + Hill Hold Equipped (ESP
— NO
/ ABS + Hill Hold Equipped)
Automatic Discrimination (Automatic
— Complete
Discrimination (AEB))
AEB Equipped (AEB Equipped) — NO
Normal condition /
Reference value
Automatic Discrimination (Push Start)
(Automatic Discrimination (Push — Complete
Start))
Push Start System Equipped (Push
— NO
Start System Equipped)
Lever Position Switch: M1 (Lever Shift selector: R or N range ON
Position Switch: M1 (ON/OFF)) Shift selector: D, M, + or – range OFF
Lever Position Switch: M2 (Lever Shift selector: N, D, M, + or – range ON
Position Switch: M2 (ON/OFF)) Shift selector: R range OFF
Lever Position Switch: M3 (Lever Shift selector: M, + or – range ON
Position Switch: M3 (ON/OFF)) Shift selector: R, N or D range OFF
Lever Position Switch: M4 (Lever Shift selector: R, N, D, M or + range ON
Position Switch: M4 (ON/OFF)) Shift selector: – range OFF
Lever Position Switch: M5 (Lever Shift selector: R, N, D, M or – range ON
Position Switch: M5 (ON/OFF)) Shift selector: + range OFF
Lever Position Switch: H1 (Lever Shift selector: R range ON
Position Switch: H1 (ON/OFF)) Other than above condition OFF
Lever Position Switch: H2 (Lever Shift selector: N range ON
Lever Position Switch: H3 (Lever Shift selector: D, M, + or – range ON
Driv Door SW (W/H) (Driv Door SW Driver side front door: Open ON
(W/H) (Driver’s Door Switch Wiring
Driver side front door: Close OFF
Harness) (ON/OFF))
Brake Pedal Switch No.1 (Brake Brake pedal: Fully depressed ON
Pedal Switch No.1 (ON/OFF)) Brake pedal: Released OFF
Brake Pedal Switch No.2 (Brake Brake pedal: Released ON
Pedal Switch No.2 (ON/OFF)) Brake pedal: Fully depressed OFF
Repeating gear shift operation with vehicle
Hydraulic Pump Active (Hydraulic ON
stationary with ignition “ON”
Pump Active (ON/OFF))
Driv Door SW (CAN) (Driv Door SW Driver side front door: Open Open
(CAN) (Driver’s Door Switch (CAN))) Driver side front door: Close Close
Parking Brake SW (Parking Brake SW Parking brake lever: Pulled ON
(Parking Brake Switch) (ON/OFF)) Parking brake lever: Released OFF
A/C Comp Clutch (A/C Comp Clutch A/C compressor magnet clutch: Connected ON
(ON/OFF)) A/C compressor magnet clutch: Released OFF
Fuel Cut Active (Fuel Cut Active (ON/ Fuel cut operating ON
OFF)) Fuel cut not operating OFF
Hill Hold Control Active (Hill Hold
— ON
Control Active (ON/OFF))
Transaxle Warning Light (Lighting) Engine: Running with faulty condition ON
(Transaxle Warning Light (Lighting)
Engine: Running without faulty condition OFF
(ON/OFF))
Transaxle Warning Light (Flashing) Clutch: Overheating ON
(Transaxle Warning Light (Flashing)
Clutch: Normal condition OFF
(ON/OFF))
Engine: Running with faulty condition ON
MIL Request (MIL Request (ON/OFF))
Engine: Running without faulty condition OFF
• Engine: Running
• Shift selector: D or M range ON
• Brake pedal / Parking brake: Released
Creep Control Active (Creep Control
• Engine: Running
Active (ON/OFF))
• Shift selector: D or M range OFF
• Brake pedal / Parking brake: Depressed
Ignition: “ON” OFF
Normal condition /
Reference value
Driv Door SW (Driv Door SW (Driver’s Driver side front door: Open ON
Door Switch) (ON/OFF)) Driver side front door: Close OFF
A/M State (A/M State (Automatic / Shift selector: D, N or R range Automatic
Manual State)) Shift selector: M range Manual
After completion of contact-point learning Complete
Contact Point Learning Complete
Before completion of contact-point learning (after
(Contact Point Learning Complete) Incomplete
reset of learning)
After completion of clutch close learning Complete
Clutch Close Learning Complete
Before completion of clutch close learning (after
(Clutch Close Learning Complete) Incomplete
reset of learning)
Clutch End Stroke Learning Complete After completion of clutch end stroke learning Complete
(Clutch End Stroke Learning Before completion of clutch end stroke learning
Incomplete
Complete) (after reset of learning)
After completion of clutch-stroke learning Complete
Clutch Stroke Check Complete
Before completion of clutch-stroke learning (after
(Clutch Stroke Check Complete) Incomplete
reset of learning)
After completion of grid learning Complete
Grid Learning Complete (Grid
Before completion of grid learning (after reset of
Learning Complete) 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
(Transmission Gear Selector Position)
Shift selector: D range D
Shift selector: M range M
Scan Tool Data Definitions: Select Solenoid Control Value (mA)

Input Shaft Revolution (rpm) This parameter indicates control current value that TCM
This parameter indicates input shaft speed detected by outputs to select solenoid valve.
clutch speed sensor.
Shift Solenoid No.1 (Odd Side) Control Value (mA)
Output Shaft Revolution (rpm) This parameter indicates control current value that TCM
This parameter indicates output shaft speed calculated outputs to shift solenoid valve 1.
by multiplying input shaft speed and reduction gear ratio.
Shift Solenoid No.2 (Even Side) Control Value (mA)
Clutch Position Sensor This parameter indicates control current value that TCM
This parameter indicates the states of clutch position outputs to shift solenoid valve 2.
sensor.
Gear Shift Count (for Maintenance)
Select Position Sensor This parameter indicates the total number of gear shifts
This parameter indicates the states of select position stored in TCM.
sensor.
Engine Speed (rpm)
Shift Position Sensor This parameter indicates engine speed sent from ECM
This parameter indicates the states of shift position through CAN.
sensor.
Throttle Position (%)
Battery Voltage (V) This parameter indicates throttle position sent from ECM
This parameter indicates battery positive voltage through CAN.
inputted to TCM.
Accel Effective Position (Accelerator Effective
Oil Pressure (MPa) Position (%))
This parameter indicates oil pressure detected by This parameter indicates accelerator pedal position sent
pressure sensor. from ECM through CAN.
Clutch Solenoid Control Value (mA) ECT (Engine Coolant Temperature, °C, °F)
This parameter indicates control current value that TCM This parameter indicates engine coolant temperature
outputs to clutch solenoid valve. sent from ECM through CAN.
Outside Air Temp (Outside Air Temperature, °C, °F) Push Start System Equipped
This parameter indicates outside air temperature sent This parameter is indicated all the time without change.
from BCM through CAN.
Lever Position Switch: M1 (ON/OFF)
Barometric Pressure (kPa) This parameter indicates the states of R or N range
This parameter indicates barometric pressure sent from switch in shift selector.
ECM through CAN. ON: Shift selector is in R or N.
OFF: Shift selector is in D, M, + or -.
Vehicle Speed (km/h)
This parameter indicates vehicle speed detected by Lever Position Switch: M2 (ON/OFF)
VSS. This parameter indicates the states of N, D, M, + or –
range switch in shift selector.
Clutch Control Status ON: Shift selector is in N, D, M, + or -.
This parameter indicates the states of clutch control. OFF: Shift selector is in R.
Closed: Shift selector is in N with ignition “ON” and
engine stopped. Lever Position Switch: M3 (ON/OFF)
Slipping Before Engaging: After shift selector is shifted This parameter indicates the states of M, + or – range
from N to D with ignition “ON” (status shown for short switch in shift selector.
duration). ON: Shift selector is in M, + or –.
Opened: Shift selector is in N with engine idling. OFF: Shift selector is in R, N or D.
Gear Position Lever Position Switch: M4 (ON/OFF)

This parameter indicates shift position information in This parameter indicates the states of R, N, D, M or +
drive mode. range switch in shift selector.
ON: Shift selector is in R, N, D, M or +.
Manual Gear Position OFF: Shift selector is in -.
This parameter indicates shift position information in
manual mode. Lever Position Switch: M5 (ON/OFF)
This parameter indicates the states of R, N, D, M or –
Estimated Clutch Temperature (°C, °F) range switch in shift selector.
This parameter indicates estimated clutch temperature ON: Shift selector is in R, N, D, M or -.
calculated by TCM. OFF: Shift selector is in +.
Clutch High Temperature Control Status Lever Position Switch: H1 (ON/OFF)

This parameter indicates the states of clutch high This parameter indicates the states of reverse sensor in
temperature control. shift selector.
Normal: Estimated clutch temperature is less than 120 ON: Shift selector is in R.
°C (248 °F). OFF: Shift selector is in N, D, M, + or -.
Hot Mode 1: Estimated clutch temperature is higher than
120 °C (248 °F). Lever Position Switch: H2 (ON/OFF)
Hot Mode 2: Estimated clutch temperature is higher than This parameter indicates the states of neutral sensor in
hot mode 1. shift selector.
ON: Shift selector is in N.
Automatic Discrimination (ABS/ESP) OFF: Shift selector is in R, D, M, + or -.
This parameter is indicated all the time without change.
Lever Position Switch: H3 (ON/OFF)
ABS Equipped This parameter indicates the states of forward sensor in
This parameter is indicated all the time without change. shift selector.
ON: Shift selector is in D, M, + or -.
ESP / ABS + Hill Hold Equipped OFF: Shift selector is in R or N.
Driv Door SW (W/H) (Driver’s Door Switch Wiring
Automatic Discrimination (AEB) Harness) (ON/OFF)
This parameter is indicated all the time without change. This parameter indicates driver’s door switch wiring
harness.
AEB Equipped ON: Driver's door is open.
This parameter is indicated all the time without change. OFF: Driver's door is closed.
Automatic Discrimination (Push Start)

Brake Pedal Switch No.1 (ON/OFF) OFF: Clutch temperature is normal.

This parameter indicates brake light switch inputted to
TCM. MIL Request (ON/OFF)
ON: Brake light switch is ON. (Brake pedal depressed) This parameter indicates the states of MIL output signal
OFF: Brake light switch is OFF. (Brake pedal released) from TCM through CAN.
ON: TCM requests combination meter to turn on MIL.
Brake Pedal Switch No.2 (ON/OFF) OFF: TCM does not request combination meter to turn
This parameter indicates brake switch inputted to TCM. on MIL.
ON: Brake switch is ON. (Brake pedal released)
OFF: Brake switch is OFF. (Brake pedal depressed) Creep Control Active (ON/OFF)
This parameter indicates the states of creep control.
Hydraulic Pump Active (ON/OFF) ON: Creep control operating
This parameter indicates the states of hydraulic pump. OFF: Creep control not operating
ON: Hydraulic pump operating
OFF: Hydraulic pump not operating Driv Door SW (Driver’s Door Switch) (ON/OFF)
This parameter indicates driver’s door switch inputted to
Driv Door SW (CAN) (Driver’s Door Switch (CAN)) TCM.
This parameter indicates driver’s door switch sent from ON: Driver's door is open.
BCM through CAN. OFF: Driver's door is closed.
Open: Driver's door is open.
Close: Driver's door is closed. A/M State (Automatic / Manual State)
This parameter indicates the gear shifting mode.
Parking Brake SW (Parking Brake Switch) (ON/OFF) Automatic: Automatic gear shifting
This parameter indicates parking brake switch sent from Manual: Manual gear shifting
BCM through CAN.
ON: Parking brake lever is pulled. Contact Point Learning Complete
OFF: Parking brake lever is released. This parameter indicates the states of contact-point
learning.
A/C Comp Clutch (ON/OFF) Complete: Contact-point learning is completed.
This parameter indicates air conditioner request Incomplete: Contact-point learning is not completed.
information received from BCM through CAN.
ON: A/C request signal is ON. Clutch Close Learning Complete
OFF: A/C request signal is OFF. This parameter indicates the states of clutch close
learning.
Fuel Cut Active (ON/OFF) Complete: Clutch close learning is completed.
This parameter indicates the state of fuel cut signal from Incomplete: Clutch close learning is not completed.
ECM through CAN.
ON: Fuel injection is cut (output signal to injector is Clutch End Stroke Learning Complete
stopped). This parameter indicates the states of clutch end stroke
OFF: Fuel injection is not cut. learning.
Complete: Clutch end stroke learning is completed.
Hill Hold Control Active (ON/OFF) Incomplete: Clutch end stroke learning is not completed.
This parameter indicates all the time without change.
Clutch Stroke Check Complete
Transaxle Warning Light (Lighting) (ON/OFF) This parameter indicates the states of clutch stroke
This parameter indicates the states of auto gear shift check.
warning light (lighting) output signal from TCM through Complete: Clutch-stroke learning is completed.
CAN. Incomplete: Clutch-stroke learning is not completed.
ON: Engine is running with faulty condition.
OFF: Engine is running in normal condition. Grid Learning Complete
This parameter indicates the states of grid learning.
Transaxle Warning Light (Flashing) (ON/OFF) Complete: Grid learning is completed.
This parameter indicates the states of auto gear shift Incomplete: Grid learning is not completed.
warning light (flashing) output signal from TCM through
CAN. Transmission Gear Selector Position
ON: Clutch is overheating. This parameter indicates shift position information.
Auto Gear Shift Symptom Diagnosis

AENNTA0E5404010 (06(03)
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
Ignition “START” signal
Clutch position sensor
Select position sensor
Clutch solenoid valve

Select solenoid valve
Clutch speed sensor
Shift position sensor
Back up light signal

Brake light switch
Manual transaxle
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 vehicle run
Poor startability and acceleration in D, M or R range

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
Others Shock
Large starting shock in D, M or R range

Large shock at gear change
Back up light does not come on
Unable to start engine
IDL70A540139-02
MIL Does Not Come ON with Ignition “ON” and Engine Stopped (but Engine Can Be Started)
AENNTA0E5404011 (06(03)
Refer to “MIL Does Not Come ON with Ignition “ON” and Engine Stopped (but Engine Can Be Started)” in Section 1A.
MIL Remains ON after Engine Starts

AENNTA0E5404012 (06(03)
Refer to “MIL Remains ON after Engine Starts” in Section 1A.
Auto Gear Shift Warning Light Does Not Come ON at Ignition “ON” and Engine Stopped
AENNTA0E5404013 (06(03)
Troubleshooting
Step 1 CAN-DTC check


No Go to Step 2.

1) Check combination meter. (Inspection of Combination Meter and Its Circuit) in Section 9C
Is check result OK?
Yes Replace auto gear shift actuator unit. (Auto Gear Shift Actuator Unit Removal and Installation)
No Replace combination meter. (Combination Meter Removal and Installation) in Section 9C
Auto Gear Shift Warning Light Remains ON after Engine Starts

AENNTA0E5404014 (06(03)
Troubleshooting
Step 1 DTC check


No Replace combination meter and recheck DTC. (Combination Meter Removal and Installation) in
Section 9C
If auto gear shift warning light still remains ON, replace TCM and recheck DTC. (TCM Removal
and Installation)
Starting Motor Control Relay Circuit Check

AENNTA0E5404015 (06(01)
Circuit Diagram
[A]
4
1
9 7
C15-19 GRY
[B]
A1
5 6
A2 2
C15-21 GRN
8
RED
YEL
[B]
5 4 3 B1
ILSD0A540005-03
[A]: Ignition switch model 1. TCM 6. Engine switch

[B]: Keyless push start model 2. Starting motor control relay 7. “KEY2” fuse
A1: Starting motor control relay power supply (switch side) circuit 3. Starting motor 8. “ST” fuse
A2: Starting motor control relay signal circuit 4. ECM 9. Ignition switch
B1: Starting motor power supply circuit 5. BCM
Troubleshooting
Step 1 DTC check


No Go to Step 2.
Step 2 Starting motor control relay power supply (switch side) check
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?
Yes Go to Step 3.
Step 3 Starting motor control relay signal circuit (coil side) check
1) Disconnect TCM connector and starting motor connectors.
2) Check for proper terminal connection to TCM and starting motor connectors.
Is check result OK?
Yes Go to Step 4.
Step 4 Starting motor control relay check

1) Check starting motor control relay. (Starting Motor Control Relay and Back Up Light Relay Inspection)
Is check result OK?
Yes Go to Step 5.
No Repair starting motor control relay.
Step 5 Starting motor power supply circuit check

1) Disconnect starting motor cable. (Starting Motor Removal and Installation) in Section 1I
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?
Yes Replace starting motor. (Starting Motor Removal and Installation) in Section 1I
DTC P0070
AENNTA0E5404016 (06(02)
P0070: Ambient Air Temperature Sensor Circuit • CAN communication line
TCM received abnormality of outside air temperature signal from • Outside air temperature sensor and/or its
BCM. circuit
• BCM
• TCM
NOTE
Check that the following conditions are satisfied in this procedure.
• DTC U0073 or U0140 is not detected.
• 11 V < Battery voltage < 15 V

DTC Troubleshooting
Step 1 Was “Auto Gear Shift System Check” performed?
Yes Go to Step 2.
No Go to “Auto Gear Shift System Check”.


No Go to Step 3.

1) Check DTC in BCM. (DTC Check) in Section 10B

No Go to Step 4.
Step 4 DTC check

2) Perform “DTC Confirmation Procedure” and recheck DTC. (DTC Check)
Is DTC P0070 detected?
Yes Replace TCM and recheck DTC. (TCM Removal and Installation)
If DTC P0070 is still detected, replace BCM. (BCM Removal and Installation) in Section 10B
No Intermittent trouble. (Intermittent Connection and Poor Contact Inspection) in Section 00
DTC P0560 / P0562 / P1711

AENNTA0E5404017 (06(02)
P0560: System Voltage • TCM power supply circuit and/or ground
This DTC is detected if any one of the following conditions is met. 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 • TCM
range.
P0562: System Voltage Low
Power supply voltage from battery to TCM is lower than specified
range.
P1711: TCM Power Input Low Voltage
TCM power supply voltage from battery is lower than specified value
for specified time.
Circuit Diagram
1
A1
2
C15-24 GRY
3
C15-26 WHT
4 A2
C15-28 LT GRN 5
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
ILSD0A540006-01
[A]: TCM connector (View: [a]) A3: Ignition power supply circuit 3. “T/M” fuse
A1: Electric motor power supply circuit 1. TCM 4. “IG1 SIG” fuse
A2: TCM power supply circuit 2. “T/M PUMP” fuse 5. To IG11 relay

P0560
NOTE
Check that the following condition is satisfied in this procedure.
• DTC P0562 is not detected.
P0562 / P1711
DTC Troubleshooting
Yes Go to Step 2.
Step 2 TCM power supply and ground circuit check

1) Check TCM power supply and ground circuits. (TCM Power Supply and Ground Circuit Check)
Is check result OK?
Yes Go to Step 3.
No Repair TCM power supply and/or ground circuit.

Is check result OK?
DTC P0572 / P0573

AENNTA0E5404018 (06(02)
P0572: Brake Switch “A” Circuit Low • Brake light switch and/or its circuit
There is no signal from brake light switch and brake switch for more • TCM
than specified time.
P0573: Brake Switch “A” Circuit High
Vehicle is driven more than specified operating range, but brake light
switch cannot be changed (stays ON).
Circuit Diagram
[B]
+BB IG1
4 3
6 5 A1 1 B1
LT GRN BLU C15-1
7 A2
PNK B2
BRN C15-2
2
4
[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
ILSD0A540007-01
[A]: TCM connector (View: [a]) B2: Brake light switch signal circuit 5. “IG1 SIG” fuse
[B]: With cruise control model 1. Brake light switch 6. “B/U” fuse
A1: Brake switch power supply circuit 2. Brake light 7. “STOP” fuse
A2: Brake light switch power supply circuit 3. TCM
B1: Brake switch signal circuit 4. ECM

P0572
NOTE
• 11 V < Ignition voltage < 15 V

2) Depress and release brake pedal.
P0573
! WARNING
accident can occur.
• Perform the road test with 2 persons, a driver and a technician.
NOTE
• Check that the following conditions are satisfied 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 40 km/h (25 mile/h) continuously for more than 45 sec.
3) Stop vehicle continuously for more than 30 sec.
DTC Troubleshooting
Yes Go to Step 2.
Step 2 Brake light switch power supply circuit check

1) With ignition “OFF”, disconnect brake light switch connector.
2) Check for proper terminal connection to brake light switch connector.
4) Check that voltage between each of “A1” and “A2” circuits and ground is battery voltage.
Is check result OK?
Yes Go to Step 3.

1) With ignition “OFF”, disconnect TCM connector.
2) Check for proper terminal connection to TCM connector.
• 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?
Yes Go to Step 4.
Step 4 Brake light switch check

1) Check brake light switch. (Brake Light Switch Inspection) in Section 4A
Is check result OK?
No Replace brake light switch. (Brake Light Switch Removal and Installation) in Section 4A
DTC P0602
AENNTA0E5404019 (06(02)
NOTE
After reprogramming of TCM is executed, if DTC P0602 is indicated, it is possible that the
reprogramming of TCM is not completed correctly.

P0602: Control Module Programming Error • Reprogramming of TCM
TCM internal failure (data programming error) • TCM
(1 D/C detection logic but auto gear shift warning light does not light
up)

DTC Troubleshooting
Yes Go to Step 2.
Step 2 DTC check

Is there any DTC(s) other than P0602 detected?

No Go to Step 3.
Step 3 Reprogramming operation procedure check and equipment preparation
Is there a problem with reprogramming operation procedure, SUZUKI scan tool or DLC?
Yes Go to Step 4.
No Check the operation procedures and inspect SUZUKI scan tool and DLC.
Step 4 TCM reprogramming
Was reprogramming of TCM executed?
Yes Intermittent trouble.

No Replace TCM and recheck DTC. (TCM Removal and Installation)
DTC P0604 / P060A / P062F / P1702 / P1704 / P1982 / P1983

AENNTA0E5404020 (06(02)

P0604: Internal Control Module Random Access Memory (RAM) TCM
Error
TCM internal failure (RAM error).
P060A: Internal Control Module Monitoring Processor
Performance
TCM internal failure (SMP error).
P062F: Internal Control Module EEPROM Error
TCM internal failure (EEPROM error).
P1702: Internal Control Module Memory Check Sum Error
TCM internal failure (check sum error).
P1704: Internal Control Module Memory EEPROM Error
TCM internal failure (EEPROM memory error).
P1982: Internal Control Module EEPROM Error (Application)
TCM internal failure (EEPROM application error).
P1983: Internal Control Module Monitoring Processor Output
Failure
TCM internal failure (monitoring processor output failure).

P0604
1) Open driver side front door.
P060A / P062F / P1704 / P1982 / P1983

P1702
DTC Troubleshooting
Step 1 DTC check

Is DTC P0604, P060A, P062F, P1702, P1704, P1982 or P1983 detected?
No Intermittent trouble.
DTC P0615
AENNTA0E5404021 (06(02)
P0615: Starter Relay Circuit • Starting motor control relay and/or its circuit
Request to starting motor control relay and feedback signal disagree. • TCM
Circuit Diagram
[A]
4
1
9 7
C15-19 PNK
[B]
A1
5 6
A2 2
C15-21 GRN
8
RED
YEL
[B]
5 4 3 B1
IMTA0A540008-01
[A]: Ignition switch model 1. TCM 6. Engine switch

[B]: Keyless push start model 2. Starting motor control relay 7. “KEY2” fuse
A1: Starting motor control relay power supply (coil side) circuit 3. Starting motor 8. “ST” fuse
A2: Starting motor control relay signal circuit 4. ECM 9. Ignition switch
B1: Starting motor power supply circuit 5. BCM
NOTE
1) Start engine, if possible.
DTC Troubleshooting
Yes Go to Step 2.
Step 2 Starting motor control relay power supply (coil side) check
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”.
Is check result OK?
Yes Go to Step 3.
Step 3 Starting motor control relay drive circuit check


• 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?
Yes Go to Step 4.
Step 4 Starting motor control relay check

1) Check starting motor control relay. (Starting Motor Control Relay and Back Up Light Relay Inspection)
Is check result OK?
Yes Replace TCM and recheck DTC. “TCM Removal and Installation”
No Repair starting motor control relay.
DTC P0715 / P0716

AENNTA0E5404022 (06(02)
P0715: Input / Turbine Speed Sensor “A” Circuit • Clutch speed sensor and/or its circuit
There is no clutch speed sensor signal for more than specified time or • Countershaft 2nd gear
clutch speed sensor signal is incorrect.
• TCM
P0716: Input / Turbine Speed Sensor “A” Circuit Range /
Performance
Clutch speed rises rapidly.

P0715
! WARNING
accident can occur.
NOTE
– DTC P1852 is not detected.
1) Start engine and run at idle speed for 1 min.

2) Drive vehicle at more than 20 km/h (12 mile/h) continuously for 1 min.
P0716
! WARNING
accident can occur.

NOTE
– DTC P1852 is not detected.
1) Start engine and drive vehicle at more than 40 km/h (25 mile/h) continuously for 1 min.
DTC Troubleshooting
Yes Go to Step 2.
Step 2 Clutch speed sensor and countershaft 2nd gear check

1) Check clutch speed sensor. (Clutch Speed Sensor Inspection)
Is check result OK?
No Replace defective parts.
• Clutch speed sensor: (Clutch Speed Sensor Removal and Installation)
• Countershaft 2nd gear: (Countershaft Disassembly and Reassembly)
DTC P0720 / P0721

AENNTA0E5404023 (06(02)
P0720: Output Speed Sensor Circuit • VSS and/or its circuit
There is no VSS signal for more than specified time or VSS signal is • Speed sensor ring
incorrect.
• TCM
P0721: Output Speed Sensor Circuit Range / Performance
VSS signal rises rapidly.
Circuit Diagram
A2 2 A1
C15-3 BEG BLU 4
GRY
3
A3
[A] C15
10 9 8 7 6 5 4 3 2 1
[a]
23 22 21 20 19 18 17 16 15 14 13 12 11
28 27 26 25 24
IMTA0A540019-01
[A]: TCM connector (View: [a]) A3: VSS ground circuit 3. ECM
A1: VSS power supply circuit 1. TCM 4. To main relay
A2: VSS signal circuit 2. VSS

P0720
! WARNING
accident can occur.
NOTE
– DTC P1909 or U0073 is not detected.
1) Start engine and drive vehicle at more than 20 km/h (12 mile/h) continuously for 1 min.
P0721
! WARNING
accident can occur.
NOTE
• Check that the following condition is satisfied 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 40 km/h (25 mile/h) continuously for 45 sec.
DTC Troubleshooting
Yes Go to Step 2.
Step 2 VSS power supply circuit check

1) With ignition “OFF”, disconnect VSS connector.
2) Check for proper terminal connection to VSS connector.
4) Check that voltage between “A1” and “A3” is battery voltage.
Is check result OK?
Yes Go to Step 4.
No Go to Step 3.
Step 3 VSS ground circuit check

Is check result OK?
Yes Repair “A3” circuit.

Step 4 VSS signal circuit check

• Resistance between “A2” circuit terminal and other terminal at clutch speed sensor connector: infinity
Is check result OK?
Yes Go to Step 5.
Step 5 VSS and speed sensor ring check

1) Check VSS and speed sensor ring. (VSS Inspection)
• VSS: (VSS Inspection)
• Speed sensor ring: (Speed Sensor Ring Inspection)
Is check result OK?
• VSS: (VSS Removal and Installation)
• Speed sensor ring: (Differential Disassembly and Reassembly)
DTC P0805
AENNTA0E5404024 (06(02)
P0805: Clutch Position Sensor Circuit • Clutch position sensor (auto gear shift
This DTC is detected 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
specified time.
• Clutch position sensor signal is less than specified value for
specified time.
NOTE
DTC Troubleshooting
Yes Go to Step 2.
Step 2 DTC check

Yes Replace clutch position sensor (auto gear shift actuator unit) and recheck DTC. (Auto Gear Shift
Actuator Unit Removal and Installation)
If DTC P0805 is still detected, replace TCM. (TCM Removal and Installation)
DTC P0840 / P0841

AENNTA0E5404025 (06(02)
P0840: Transmission Fluid Pressure Sensor / Switch “A” Circuit • Pressure sensor (auto gear shift actuator
This DTC is detected if any one of the following conditions is met. unit) and/or its circuit
• Pressure sensor signal is more than specified value. • TCM
• Pressure sensor signal is less than specified value.
P0841: Transmission Fluid Pressure Sensor / Switch “A” Circuit
Range / Performance
Pressure sensor signal is changed drastically due to noise.
NOTE
Check that the following conditions are met in this procedure.

DTC Troubleshooting
Yes Go to Step 2.
Step 2 DTC check

Is DTC P0840 or P0841 detected?
Yes Replace pressure sensor (auto gear shift actuator unit) and recheck DTC. (Auto Gear Shift
If DTC P0840 or P0841 is still detected, replace TCM. (TCM Removal and Installation)
DTC P0904 / P0914

AENNTA0E5404026 (06(02)
P0904: Gate Select Position Circuit • Select position sensor (auto gear shift
If any one of the following conditions is met. actuator unit)
• Select position sensor signal is more than specified value for • TCM
specified time.
• Select position sensor signal is less than specified value for
specified time.
P0914: Gear Shift Position Circuit • Shift position sensor (auto gear shift
If any one of the following conditions is met. actuator unit)
• Shift position sensor signal is more than specified value for • TCM
specified time.
• Shift position sensor signal is less than specified value for specified
time.
NOTE
Check that the following conditions are met in this procedure.
DTC Troubleshooting

Yes Go to Step 2.
Step 2 DTC check

Yes Replace sensor (auto gear shift actuator unit) and recheck DTC. (Auto Gear Shift Actuator Unit
If DTC P0904 or P0914 is still detected, replace TCM. (TCM Removal and Installation)
DTC P080A / P185A / P185B

AENNTA0E5404027 (06(02)
P080A: Clutch Position Not Learned • Clutch disc
Clutch-contact-point learning (recognition of clutch engaging point) is • Clutch cover
not completed.
• Clutch release system
P185A: Clutch End Stroke Position Selftune • Flywheel
Clutch-end-stroke-position learning (recognition of clutch stopper • Clutch anchor
position) is not completed. • TCM
P185B: Clutch Stroke Selftune
Clutch-stroke learning (recognition of distance between clutch closed
position and clutch stopper) is not possible.

P080A / P185A
P185B / P080A
NOTE
Check that the following condition is met in this procedure.
• DTC P185A or P2789 is not detected.
DTC Troubleshooting
Yes Go to Step 2.
Step 2 DTC check

Is DTC P080A, P185A or P185B detected?
Yes Go to Step 3.
Step 3 Initialization for clutch system

1) Perform “Clutch Assembly Initialization”. (TCM and Clutch Initialization):
Is DTC P080A, P185A or P185B detected?
Yes Go to Step 4.
No End.
Step 4 Clutch anchor check

1) Check clutch anchor for proper installation and operation, and for obstructions within its operating range
referring to “Installation” under “Auto Gear Shift Actuator Unit Removal and Installation”.
Is check result OK?
Yes Go to Step 5.
Step 5 Clutch and flywheel check

1) Dismount auto gear shift unit. (Auto Gear Shift Unit Dismounting and Remounting)
2) Check the following parts.
• Clutch cover and clutch disc: (Clutch Cover and Clutch Disc Inspection)
• Clutch release system: (Clutch Release System Component Inspection)
• Flywheel: (Flywheel Inspection) in Section 1D
Is check result OK?
Yes Replace TCM recheck DTC. (TCM Removal and Installation)

• Clutch cover and clutch disc: (Clutch Cover and Clutch Disc Removal and Installation)
• Clutch release system: (Clutch Release System Component Removal and Installation)
• Flywheel: (Flywheel Removal and Installation) in Section 1D
DTC P0944
AENNTA0E5404028 (06(02)
P0944: Hydraulic Pressure Unit Loss of Pressure • Electric motor
Pressure sensor signal is less than specified value. • Auto gear shift actuator unit oil leakage
• TCM
NOTE
• DTC P0840 or P0841 is not detected.
DTC Troubleshooting

Yes Go to Step 2.
Step 2 Check Auto gear shift actuator unit oil leakage check
1) Check auto gear shift actuator unit oil level and leakage. (Auto Gear Shift Actuator Oil Level Check)
Is check result OK?
Yes Go to Step 3.
No Replace auto gear shift actuator unit and recheck DTC. (Auto Gear Shift Actuator Unit Removal
and Installation)
Step 3 DTC check

Yes Replace auto gear shift actuator unit and recheck DTC. (Auto Gear Shift Actuator Unit Removal
and Installation)
DTC P0945
AENNTA0E5404029 (06(02)
P0945: Hydraulic Pump Relay Circuit / Open • Electric motor power supply circuit
Power supply voltage from battery to electric motor is lower than • “AMT PUMP” fuse
specified value.
• TCM
Circuit Diagram
1
A1
2
C15-24 GRY
3
C15-26 WHT
4 A2
C15-28 LT GRN 5
[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
ILSD0A540009-01
[A]: TCM connector (View: [a]) 1. TCM 4. “IG1 SIG” fuse

A1: Electric motor power supply circuit 1 2. “T/M PUMP” fuse 5. To IG11 relay
A2: Electric motor power supply circuit 2 3. “T/M” fuse

DTC Troubleshooting
Yes Go to Step 2.
Step 2 “AMT PUMP” fuse check

1) Check “AMT PUMP” fuse for blowout.
Is check result OK?
Yes Go to Step 4.
No Go to Step 3.
Step 3 Electric motor power supply circuit check 1

Is check result OK?
Yes Replace “AMT PUMP” fuse.

Step 4 Electric motor power supply circuit check 2

• Resistance between “A2” circuit terminal and other terminal at TCM connector: infinity
• Voltage of “A2” circuit: approx. 0 V (When ignition is “ON”).
Is check result OK?
DTC P1706
AENNTA0E5404030 (06(02)
P1706: Torque Request Communication Error From TCM TCM
ECM detects abnormality of CAN communication data from TCM.
up)
! WARNING
accident can occur.

NOTE
– DTC U0073 or P1909 is not detected.
1) Start engine and drive vehicle.
DTC Troubleshooting
Yes Go to Step 2.
Step 2 DTC check


DTC P1707 / P1985

AENNTA0E5404031 (06(02)
P1707: Torque Reduction Error From ECM • CAN communication line
TCM detects a condition which is not acceptable for engine torque • ECM
reduction in ECM.
• TCM
up)
P1985: Torque Up Error From ECM
TCM detects a condition which is not acceptable for engine torque up
in ECM.
up)
! WARNING
accident can occur.
NOTE
– DTC U0073 or U0100 is not detected.

DTC Troubleshooting
Yes Go to Step 2.


No Go to Step 3.

1) Check DTC in ECM. (DTC Check) in Section 1A

No Go to Step 4.
Step 4 DTC check

If DTC P1707 or P1985 is still detected, replace ECM. (ECM Removal and Installation) in Section
1C
DTC P1844
AENNTA0E5404032 (06(02)
P1844: Grid Position Not Learned • Engage piston and select piston (auto gear
Grid learning (recognition of proper gear engagement) is not shift actuator unit)
completed. • Gear shift and select shaft assembly
• Auto gear shift unit internal parts
• TCM

DTC Troubleshooting

Yes Go to Step 2.
Step 2 DTC check


No Go to Step 3.
Step 3 TCM learning

1) Perform “Shift Tower Initialization” under “TCM and Clutch Initialization”.
Yes Go to Step 4.
No End.
Step 4 TCM learning

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”.
5) Repeat Step 1) to 4).
Yes Go to Step 5.
No End.
Step 5 Auto gear shift mechanical parts check

2) Check the following parts for proper operation.
• Auto gear shift actuator unit (engage piston and select piston): (Auto Gear Shift Actuator Unit Removal
and Installation)
• Gear shift and select shaft assembly: “Gear Shift and Select Shaft Assembly Removal and
Installation”
• Gear shift shaft components: (Gear Shift Shaft and Fork Inspection)
Is check result OK?
• Engage piston and select piston (auto gear shift actuator unit): (Auto Gear Shift Actuator Unit
• Gear shift and select shaft assembly: “Gear Shift and Select Shaft Assembly Removal and
Installation”
• Gear shift shaft components: (Auto Gear Shift Disassembly and Reassembly)
DTC P184A
AENNTA0E5404033 (06(02)

P184A: Pump Off Failed • Electric motor
Oil pump functions for more than specified time. • Accumulator (auto gear shift actuator unit)
• TCM
NOTE
• DTC P0945 or P185C is not detected.
DTC Troubleshooting
Yes Go to Step 2.
Step 2 Auto gear shift actuator unit oil leakage check

1) Check auto gear shift actuator unit oil level and leakage. “Auto Gear Shift Actuator Oil Level Check”
Is check result OK?
Yes Go to Step 3.
and Installation).
Step 3 DTC check

Is DTC P184A detected?
Yes Replace electric motor and recheck DTC. (Auto Gear Shift Electric Motor Removal and Installation)
If DTC P184A is still detected, replace auto gear shift actuator unit. (Auto Gear Shift Electric Motor
DTC P184B / P184C / P184D

AENNTA0E5404034 (06(02)

P184B: Solenoid Driver “A” Circuit Range/Performance TCM
Malfunction of solenoid driver “A” (driver for clutch solenoid valve and
shift solenoid valve 1) is detected.
P184C: Solenoid Driver “A” Feedback Signal Range/Performance
• 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.
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.

P184B / P184D
NOTE
• DTC P184E is not detected.
P184C
! WARNING
accident can occur.
NOTE
• Check that the following conditions are met in this procedure.
– DTC P184B, P184D, P184E, P1854 or P1888 is not detected.
DTC Troubleshooting
Yes Go to Step 2.
Step 2 DTC check

Is DTC P184B, P184C or P184D detected?
DTC P184E / P184F / P1854 / P1855

AENNTA0E5404035 (06(02)
P184E: TCM Internal Supply Voltage “B” Circuit TCM
Power supply for sub-microcomputer is out of specified range.
P184F: TCM Internal Supply Voltage “C” Circuit
More than specified time has passed after power OFF (latch circuit
OFF), but TCM stays ON.
P1854: TCM Internal Supply Voltage “A” Low
Power supply voltage for solenoid drivers is lower than specified
value.
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.

P184E
NOTE
P184F / P1855
P1855
NOTE
• 10 V < Battery voltage or 10 V < ignition voltage
DTC Troubleshooting
Yes Go to Step 2.
Step 2 DTC check

Is DTC P184E, P184F, P1854 or P1855 detected?
DTC P1850 / P1851 / P1888 / P1889

AENNTA0E5404036 (06(02)
P1850: Gear Shift Odd Actuator Circuit • Shift solenoid valve 1 (auto gear shift
Malfunction of shift solenoid valve 1 is detected. actuator unit)
(1 D/C detection logic) • TCM
P1851: Gear Shift Even Actuator Circuit • Shift solenoid valve 2 (auto gear shift
Malfunction of shift solenoid valve 2 is detected. actuator unit)
P1888: Clutch Actuator Circuit • Clutch solenoid valve (auto gear shift
Malfunction of clutch solenoid valve is detected. actuator unit)
P1889: Gate Select Actuator Circuit • Select solenoid valve (auto gear shift
Malfunction of select solenoid valve is detected. actuator unit)
! WARNING
accident can occur.
NOTE
– DTC P184B, P184C, P184D, P184E or P1854 is not detected.
1) Start engine and drive vehicle at more than 30 km/h (17 mile/h) continuously for more than 30 sec.
DTC Troubleshooting
Yes Go to Step 2.
Step 2 DTC check

Is DTC P1850, P1851, P1888 or P1889 detected?
and Installation)
If DTC P1850, P1851, P1888 or P1889 is still detected, replace TCM. (TCM Removal and
Installation)
DTC P1852 / P1853

AENNTA0E5404037 (06(02)
P1852: Sensor Power Supply “A” TCM
• 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.
P1853: Sensor Power Supply “B”
• 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.
NOTE
DTC Troubleshooting
Yes Go to Step 2.
Step 2 DTC check

DTC P185C
AENNTA0E5404038 (06(02)

P185C: Hydraulic Pump Relay Circuit • Electric motor and/or its circuit
This DTC is detected if any one of the following conditions is met. • TCM
• 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.
NOTE
• DTC P0840, P0841 are P1852 are not detected.
• 10 V < Battery voltage

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
Yes Go to Step 2.
Step 2 DTC check

Is there any DTC(s) other than P185C detected?

No Go to Step 3.
Step 3 Electric motor connector check

1) Disconnect electric motor connector.
2) Check for proper terminal connection to electric motor connector.
3) If connection is OK, connect electric motor connector.
4) Leave 1 sec. with ignition “OFF”.
Is DTC P185C detected?
Yes Replace electric motor and recheck DTC. (Auto Gear Shift Electric Motor Removal and Installation)
If DTC P185C is still detected, replace TCM. (TCM Removal and Installation)
DTC P185E / P185F

AENNTA0E5404039 (06(02)
P185E: TCM Safety Function Failure TCM
TCM internal failure (safety function control error).
P185F: TCM Safety Integrity Function Failure
MMP failure is detected by SMP in TCM.

DTC Troubleshooting
Yes Go to Step 2.
Step 2 DTC check

Is DTC P185E or P185F detected?
Yes Go to Step 3.
Step 3 DTC check

Is there any DTC(s) other than DTC P185E or P185F detected?

DTC P1884
AENNTA0E5404040 (06(02)
P1884: Reverse Lamp Control Circuit • Back up light relay and/or its circuit
Malfunction of back up light relay and its circuit (open, shorted to • TCM
power supply or shorted to ground) is detected.
Circuit Diagram
4 2
3
BRN YEL 5
C15-25 PPL BLK
A1 A2
[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
ILSD0A540011-01
[A]: TCM connector (View: [a]) 1. TCM 4. Back up light

A1: Back up light relay drive circuit 2. Back up light relay 5. To IG11 relay
A2: Back up light relay ground circuit 3. “BACK” fuse
NOTE
• DTC P184D, P184E or P1854 is not detected.

2) Set shift selector to R range.
3) Set shift selector to N range.
DTC Troubleshooting
Yes Go to Step 2.
Step 2 Back up light relay drive circuit check

1) With ignition “OFF”, remove back up light relay.
2) Check for proper terminal connection to back up light relay connector.
4) Check that voltage between “A1” and “A2” is battery voltage.
Is check result OK?
Yes Go to Step 4.
No Go to Step 3.
Step 3 Back up light relay ground circuit check

Is check result OK?

If this DTC is detected again, replace TCM and recheck DTC. (TCM Removal and Installation)
Step 4 Back up light relay check

1) Check back up light relay. (Starting Motor Control Relay and Back Up Light Relay Inspection)
Is check result OK?
No Replace back up light relay.
DTC P1885
AENNTA0E5404041 (06(02)
P1885: Door Switch Circuit • Driver side front door switch and/or its
Driver side front door switch signal is not inputted for specified time. circuit
Circuit Diagram
1
A1
2
C15-23 PNK
[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
IGSD0A541055-02
[A]: TCM connector (View: [a]) 1. TCM 3. BCM

A1: Driver side front door switch signal circuit 2. Driver side front door switch
NOTE

2) Open driver side front door and then close it.
DTC Troubleshooting
Yes Go to Step 2.
Step 2 Door switch signal circuit check

1) With ignition “OFF”, disconnect TCM connector, “L02” connector from BCM and driver side front door
switch connector.
2) Check for proper terminal connection to TCM connector and driver side front door switch connector.
• Resistance between “A1” circuit terminal and other terminal at TCM connector: infinity
Is check result OK?
Yes Go to Step 3.
Step 3 Door switch check

1) Check driver side front door switch. (Door Switch Inspection) in Section 9F
Is check result OK?
No Replace driver side front door switch. (Door Switch Removal and Installation) in Section 9F
DTC P1886
AENNTA0E5404042 (06(02)
P1886: Dual Port RAM Check TCM
TCM internal failure (data integrity error).

DTC Troubleshooting
Yes Go to Step 2.
Step 2 DTC check

DTC P188A / P188B / P188F

AENNTA0E5404043 (06(02)

P188A: Transmission Range Sensor Circuit Fault Type “A” • Shift selector and/or its circuit
None of shift selector position switch signals and hall sensor signals is • TCM
inputted.
P188B: Transmission Range Sensor Circuit Fault Type “B”
None of shift selector position switch signals is inputted.
P188F: Transmission Range Sensor Circuit Fault Type “F”
Failure of shift selector position switch signals and hall sensor signals
except P188A, P188B, P188C, P188D and P188E.
Circuit Diagram
+BB
A1
3 1
2
B1
WHT
GRY C15-11
D1
4 LT BLU C15-22
D2
5 YEL 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
BLK 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
IMTA0A540010-04
[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
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. “T/M2” fuse 11. Hall sensor H3
NOTE

2) Set shift selector to R, N, D, M, + and – range.
DTC Troubleshooting
Yes Go to Step 2.
Step 2 Shift selector ground circuit check

1) With ignition “OFF”, disconnect TCM connector and shift selector connectors.
2) Check for proper terminal connection to TCM connector and shift selector connectors.
• 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?
Yes Go to Step 3.
Step 3 Shift selector check

1) Check shift selector. (Shift Selector Inspection)
Is check result OK?
No Replace shift selector. (Shift Selector Removal and Installation)
DTC P188C
AENNTA0E5404044 (06(02)
P188C: Transmission Range Sensor Circuit Fault Type “C” • Shift selector and/or its circuit
One of M1, M2, H1, H2 or H3 sensor signal is not inputted or • TCM
abnormal.
Circuit Diagram
+BB
A1
3 1
2
B1
WHT
GRY C15-11
D1
4 LT BLU C15-22
D2
5 YEL 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
BLK 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
IMTA0A540010-04
NOTE

DTC Troubleshooting
Yes Go to Step 2.
Step 2 Lever position switch signal and hall sensor signal circuit check
• 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 “E1” 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?
Yes Go to Step 3.

Is check result OK?
DTC P188D / P188E

AENNTA0E5404045 (06(02)
P188D: Transmission Range Sensor Circuit Fault Type “D” • Shift selector and/or its circuit
M3, M4 and M5 shift selector position switch signals are not inputted. • TCM
P188E: Transmission Range Sensor Circuit Fault Type “E”
One of M3, M4, M5 or H2 sensor signal is not inputted or abnormal.
Circuit Diagram
+BB
A1
3 1
2
B1
WHT
GRY C15-11
D1
4 LT BLU C15-22
D2
5 YEL 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
BLK 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
IMTA0A540010-04
NOTE

DTC Troubleshooting
Yes Go to Step 2.
Step 2 Lever position sensor signal circuit check

• 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
• Voltage of “D3”, “D4”, “D5” and “E2” circuits: approx. 0 V (When ignition is “ON”).
Is check result OK?
Yes Go to Step 3.

Is check result OK?
DTC P1902
AENNTA0E5404046 (06(02)
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
• “AMT2” fuse
Circuit Diagram
+BB
A1
3 1
2
B1
WHT
GRY C15-11
D1
4 LT BLU C15-22
D2
5 YEL 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
BLK 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
IMTA0A540010-04
NOTE

DTC Troubleshooting
Yes Go to Step 2.
Step 2 Shift selector power supply circuit check

1) With ignition “OFF”, disconnect shift selector connector.
2) Check for proper terminal connection to shift selector connector.
Is check result OK?
Yes Go to Step 3.
Step 3 Shift selector drive circuit check

• Resistance between “B1” circuit terminal and other terminal at TCM connector: infinity
• Voltage of “B1” circuit: approx. 0 V (When ignition is “ON”).
Is check result OK?
Yes Go to Step 4.

Is check result OK?
DTC P1903 / P1904

AENNTA0E5404047 (06(02)
P1903: Clutch Not Opening Before Gear Shifting • Clutch disc
Clutch is not released before gear shifting. • Clutch cover
P1904: Clutch Closing During Engage
Clutch is engaged during gear shifting. • Flywheel
(1 D/C detection logic) • Clutch anchor
• Valve body (auto gear shift actuator unit)
• Auto gear shift actuator fluid leakage (auto
gear shift actuator unit)
• TCM
! WARNING
accident can occur.

NOTE
• Check that the following condition is met in this procedure.
1) Start engine.
2) Drive vehicle at more than 40 km/h (25 mile/h) continuously for more than 30 sec.
3) Stop vehicle.
DTC Troubleshooting
Yes Go to Step 2.
Step 2 DTC check

Is DTC P0944, P184A or P185C detected?

No Go to Step 3.

1) Check clutch anchor for proper installation and operation, and for obstructions within its operating range.
Is check result OK?
Yes Go to Step 4.

Is check result OK?

DTC P1905
AENNTA0E5404048 (06(02)

P1905: Clutch Control Error • Clutch disc
If any one of the following conditions is met. • Clutch cover
• Clutch is engaged suddenly. • Clutch release system
• Clutch sticks at disengaged state. • Flywheel
• Clutch anchor
• Valve body (auto gear shift actuator unit)
• Auto gear shift actuator fluid leakage (auto
gear shift actuator unit)
• TCM
! WARNING
accident can occur.
NOTE
– 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.
DTC Troubleshooting
Yes Go to Step 2.
Step 2 DTC check

Is DTC P0944, P184A or P185C detected?

No Go to Step 3.

Is check result OK?
Yes Go to Step 4.

Is check result OK?

DTC P1906 / P1907 / P1908 / P190A

AENNTA0E5404049 (06(02)
P1906: Gear Box Disengage Failed • Clutch disc
Gear is not disengaged. • Clutch cover
P1907: Gear Box Shift Failed
Gear is shifted to unintended position. • Flywheel
(1 D/C detection logic) • Auto gear shift actuator unit
P1908: Gear Box Engage Failed • Gear shift and select shaft assembly
Gear cannot be engaged.
P190A: Gear Box Shift Locked • TCM
Gear shift is not completed.
! WARNING
accident can occur.
P1906 / P1908
NOTE
1) Start engine.
2) Drive vehicle in D range and check that shift up functions properly from 1st to 5th.
3) Stop vehicle.
P1907 / P190A
NOTE
– 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.
DTC Troubleshooting
Yes Go to Step 2.
Step 2 DTC check

Is there any DTC(s) other than P1906, P1907, P1908 or P190A?

No Go to Step 3.

Is check result OK?
Yes Go to Step 4.

• Auto gear shift actuator unit (engage piston and select piston): (Auto Gear Shift Actuator Unit Removal
and Installation)
• Gear shift and select shaft assembly: (Gear Shift and Select Shaft Assembly Removal and
Installation)
• Input shaft (gear and synchronizer sleeve & hub assembly): (Input Shaft Disassembly and
Reassembly)
• Countershaft (gear and synchronizer sleeve & hub assembly): (Countershaft Disassembly and
Reassembly)
Is check result OK?
Yes Go to Step 5.
• Auto gear shift actuator unit (engage piston and select piston): (Auto Gear Shift Actuator Unit
Installation)
Reassembly)
Reassembly)
Step 5 Initialization for clutch system

1) Install gear shift and select shaft assembly. (Gear Shift and Select Shaft Assembly Removal and
Installation)
2) Install auto gear shift actuator unit. (Auto Gear Shift Actuator Unit Removal and Installation)
3) Remount auto gear shift unit. (Auto Gear Shift Unit Dismounting and Remounting)
4) Perform “All Learning Value Initialization” and “Shift Tower Initialization” under “TCM and Clutch
Initialization”.
Is DTC P1906, P1907, P1908 or P190A detected?
No End.
DTC P1909 / P190B

AENNTA0E5404050 (06(02)
P1909: Gear Box Unintended Gear Disengage • Gear shift and select shaft assembly
Gear is disengaged without request of disengagement. • Auto gear shift unit internal parts
• TCM
P190B: Gear Box Unintended Gear Engage
Gear is engaged without gear shift request.

P1909
NOTE
• DTC P0914 or P1853 is not detected.
1) Start engine.
2) Select shift selector to D range.
3) Select shift selector to N range.
P190B
NOTE
• DTC P0904, P0914 or P1853 is not detected.

2) Set shift selector to N range.
DTC Troubleshooting
Yes Go to Step 2.
Step 2 DTC check

Is there any DTC(s) other than P1909 or P190B?

No Go to Step 3.

Installation)
Reassembly)
Reassembly)
Is check result OK?
Installation)
Reassembly)
Reassembly)
DTC P190C
AENNTA0E5404051 (06(02)
P190C: Gear shift Endless • Clutch release system
Gear shift is not completed within specified time. • Gear shift and select shaft assembly
• TCM
! WARNING
accident can occur.
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.
DTC Troubleshooting
Yes Go to Step 2.
Step 2 DTC check

Is there any DTC(s) other than P190C?

No Go to Step 3.
Step 3 Clutch release system check

1) Check clutch release system. (Clutch Release System Component Inspection)
Is check result OK?
Yes Go to Step 4.
No Replace defective parts. (Clutch Release System Component Removal and Installation)

Installation)
Is check result OK?
Installation)
DTC P190D
AENNTA0E5404052 (06(02)
P190D: Clutch Overspeed • Auto gear shift actuator unit
Clutch speed exceeds specified value while gear is engaged. • TCM
! WARNING
accident can occur.
NOTE
– DTC P0715, P0716 or P1852 is not detected.
1) Drive vehicle at 40 km/h (25 mile/h) or more.
DTC Troubleshooting
Yes Go to Step 2.
Step 2 DTC check

Is DTC P190D detected?
and Installation)
If DTC P190D is still detected, replace TCM. (TCM Removal and Installation)
DTC P190E
AENNTA0E5404053 (06(02)
P190E: Pump Overheating • Electric motor
Estimated oil pump temperature exceeds specified value. • TCM

2) Set shift selector from N to D range.
3) Set shift selector from D to N range.
4) Repeat Step 2) – 3) continuously for more than 50 times.
DTC Troubleshooting
Yes Go to Step 2.
Step 2 DTC check

Is DTC P190E detected?
Yes Replace electric motor and recheck DTC. (Auto Gear Shift Actuator Unit Removal and Installation)
If DTC P190E is still detected, replace TCM. (TCM Removal and Installation)
DTC P190F
AENNTA0E5404054 (06(02)
P190F: Accumulator Failed • Auto gear shift actuator unit
Accumulated oil volume exceeds specified limit. • TCM
NOTE

4) Repeat Step 2)- 3) more than 50 times.
DTC Troubleshooting
Yes Go to Step 2.
Step 2 DTC check

Is DTC P190F detected?
and Installation)
If DTC P190F is still detected, replace TCM. (TCM Removal and Installation)
DTC P1980
AENNTA0E5404055 (06(02)
P1980: System Misuse Excessive gear shift operation
If any one of the following conditions is met.
• The number of gear shift exceeds specified value during specified
period of time.
• Oil pump temperature exceeds specified value.
up)
NOTE
This DTC was detected by excessive shifting movement and is not trouble.
Therefore, when this DTC is detected, leave vehicle with engine off and cool an oil pump.
1) Start engine.
4) Repeat Step 2) – 3) continuously very fast.
DTC Troubleshooting
Yes Go to Step 2.
Step 2 DTC check

Yes Leave vehicle with engine off and hood opened to cool oil pump.
DTC P1981
AENNTA0E5404056 (06(02)
P1981: CAN Invalid Data of Engine Torque • CAN communication line
Invalid data of engine torque value is inputted. • ECM
• TCM
up)
! WARNING
accident can occur.
NOTE
– DTC U0073 or U0100 is not detected.
DTC Troubleshooting
Yes Go to Step 2.


No Go to Step 3.

1) Check DTC in ECM. (DTC Check) in Section 1A

No Go to Step 4.
Step 4 DTC check

If DTC P1981 is still detected, replace ECM. (ECM Removal and Installation) in Section 1C
DTC P1984
AENNTA0E5404057 (06(02)
P1984: TCM Safety Input Preprocessing Failure • Clutch disc
• TCM internal failure (safety input preprocessing control error). • Clutch release system
• The amount of clutch slip exceeds the specified value. • Flywheel
• TCM

DTC Troubleshooting
Yes Go to Step 2.
Step 2 DTC check

Yes Go to Step 3.
No End.
Step 3 DTC check

Is DTC(s) other than DTC P1984 detected?

No Go to Step 4.

Is check result OK?

DTC P1986 / P1987

AENNTA0E5404058 (06(02)
P1986: Vehicle Equipment Information Self-Learning Not • CAN communication line
Completed • Combination meter
TCM does not complete vehicle equipment information self learning.
• BCM
P1987: Vehicle Equipment Information Not Matched • TCM
Vehicle equipment information does not match to vehicle equipment
information self-learning results stored into TCM.
NOTE

• DTC U0073, U0100, U0140 or U0155 is not detected.
P1986
2) Set ignition “OFF” for 1 min.
3) Repeat Step 1) - 2) 5 times.
P1987
DTC Troubleshooting
Yes Go to Step 2.
No Go to “Auto Gear Shift System Check”


No Go to step 3.
Step 3 Combination meter and BCM check

1) Check that combination meter and BCM with the correct part number are installed.
Is check result OK?
No Replace combination meter and/or BCM and recheck DTC.
• BCM: (BCM Removal and Installation) in Section 10B
DTC P2712
AENNTA0E5404059 (06(02)
P2712: Hydraulic Power Unit Leakage • Accumulator (auto gear shift actuator unit)
Oil pressure in the accumulator is lower than the specified value. • TCM

DTC Troubleshooting
Yes Go to Step 2.
Step 2 DTC check


and Installation)
DTC P2789
AENNTA0E5404060 (06(02)
P2789: Clutch “A” Adaptive Learning at Limit • Clutch disc
• Clutch closed position is more than specified value. • Clutch release system
• Clutch closed position is less than specified value. • Flywheel
• Clutch anchor
• TCM
NOTE
• DTC P0805, P184B, P184C or P1852 is not detected.
DTC Troubleshooting
Yes Go to Step 2.
Step 2 TCM learning

1) Perform “Clutch Assembly Initialization” under “TCM and Clutch Initialization”.
Yes Go to Step 3.
No End.
Step 3 DTC check


No Go to Step 3.

Is check result OK?
Yes Go to Step 4.

Is check result OK?

DTC U0073 DTC U0100 / U0121 / U0140 / U0155

AENNTA0E5404061 (06(02) AENNTA0E5404062 (06(02)
Refer to “CAN DTC (Lost Communication and Refer to “Troubleshooting for Lost Communication”:
Communication Bus Off) Table”: CAN in Section 10H. CAN in Section 10H.
TCM Power Supply and Ground Circuit Check

AENNTA0E5404063 (06(01)
Circuit Diagram
1
A1
2
C15-24 GRY
3
C15-26 WHT
4 A2
C15-28 LT GRN 5
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
ILSD0A540010-01
[A]: TCM connector (View: [a]) A3: Ignition power supply circuit 3. “T/M” fuse
A1: Electric motor power supply circuit 1. TCM 4. “IG1 SIG” fuse
A2: TCM power supply circuit 2. “T/M PUMP” fuse 5. To IG11 relay
Troubleshooting
Step 1 TCM power supply circuit check

Is check result OK?
Yes Go to Step 2.
No Check that “T/M2” fuse has not blown. If check result is OK, repair or replace defective wire
harness.
Step 2 Electric motor power supply circuit check

Is check result OK?
Yes Go to Step 3.
No Check that “T/M PUMP” fuse has not blown. If check result is OK, repair or replace defective wire
harness.

Is check result OK?
Yes Go to Step 4.
No Check that “IG1 SIG” fuse has not blown. If check result is OK, repair or replace defective wire
harness.
Step 4 Auto gear shift actuator unit check

1) Check auto gear shift actuator unit bolts for looseness. (Auto Gear Shift Actuator Unit Removal and
Installation)
Is check result OK?
Yes TCM power supply and ground circuits are in good condition.
No Tighten auto gear shift actuator unit bolt to specified torque. (Gear Shift and Select Shaft Assembly
Components)
Inspection of TCM and Its Circuits

AENNTA0E5404064 (06(01)
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).
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])
Connector “C15”
Terminal Normal
Wire color Circuit Condition
No. voltage
Ignition: “ON”
10 to 14 V
Brake pedal: Released
C15-1 BLU Brake switch signal circuit
Ignition: “ON”
Approx. 0 V
Brake pedal: Fully depressed
Ignition: “ON”
Approx. 0 V
Brake pedal: Released
C15-2 BRN Brake light switch signal circuit
Ignition: “ON”
10 to 14 V
Brake pedal: Fully depressed
C15-3* BEG VSS signal circuit
“VSS signal”
C15-4 BLK Shift selector ground circuit Approx. 0 V Constantly
C15-5 — — — —
C15-6 — — — —
C15-7* RED CAN (high) communication circuit
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
C15-10* WHT CAN (low) communication circuit
C15-11 GRY 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
Terminal Normal
Wire color Circuit Condition
No. voltage
C15-15 — — — —
Ignition: “ON”
10 to 14 V
C15-16 PPL Lever position sensor M4 signal circuit Shift selector: + range
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”
C15-19* PNK Starting motor control relay signal circuit
“Starting motor control relay signal”
Ignition: “ON”
10 to 14 V
C15-20 YEL Lever position sensor M2 signal circuit Shift selector: R range
Approx. 0 V Ignition: “START”
C15-21* GRN Starting motor control relay drive circuit Refer to reference waveform.
“Starting motor control relay signal”
Ignition: “ON”
10 to 14 V Shift selector: D, M, + or –
C15-22 LT BLU Lever position sensor M1 signal circuit
range
10 to 14 V Driver side front door: Close
C15-23 PNK 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
C15-26 WHT TCM power supply circuit 10 to 14 V Constantly
C15-27 — — — —
C15-28 LT GRN Ignition ON signal circuit
Reference Waveform
Oscilloscope display
Shown below is typical waveform display provided using
oscilloscope.
NOTE
• Display includes the following types of
data:
ICP70A110009-01


CAN communication signal
CAN (high) communication signal (1)

+ C15-7
1
– Ground
CAN (low) communication signal (2)

IGJC0A541073-01
+ C15-10
2
– Ground
Starting motor control relay signal
Starting motor control relay drive signal (1)
• Engine: Stop Channel Probe Terminal No.
• Ignition: “ON” + C15-21
1
– Ground
ST signal (2)
+ C15-19
2
– Ground
• Ignition: → “ON” → “START”
I8C50B111041-01
VSS signal
+ C15-3
1
– Ground
Engine: Drive vehicle at 20 km/h (12 mile/h)
IJCA0A540024-01
3. Ignition: “ON”
4. Ignition: “START”
5. Starting motor control relay: “ON”
Repair Instructions
TCM and Clutch Initialization Replacement /
AENNTA0E5406001 (08(03) Initialization
Reinstallation
1) Select learning procedure in the following table. • Manual transaxle or
manual transaxle parts
(separated from engine)
• Auto gear shift actuator All Learning Value
unit or Auto gear shift Initialization
actuator parts
• Dismount manual
transaxle
Replacement / or R, and check parameter of “Gear Position”

Initialization displayed on SUZUKI scan tool also shows the
Reinstallation
Gear shift and select shaft same indication. (Scan Tool Data)
Shift Tower Initialization Shift tower initialization:
assembly
• Clutch a) Connect SUZUKI scan tool to DLC. (Suzuki
• Engine parts (after Clutch Assembly SDT-II Connection and Disconnection) in Section
separation of manual Initialization 0A.
transaxle from engine) b) Set ignition “ON”.
New auto gear shift unit c) Select “Shift Tower Initialization” function under
Clutch-contact-point
and new auto gear shift “Utility” mode on SUZUKI scan tool, and follow
learning Initialization
actuator unit the instructions displayed on SUZUKI scan tool.
2) Apply parking brake and select shift selector to N d) Select “Show AGS Learning Result” function
range. under “Utility” mode on SUZUKI scan tool.
3) Perform selected initialization procedure as follows. e) Check that displayed values for all items on
All learning value initialization: SUZUKI scan tool are within the specified range.
Perform the following procedure if any value is
a) Connect SUZUKI scan tool to DLC. (Suzuki
out of the specified range.
SDT-II Connection and Disconnection) in Section
0A. Scan tool data Specified value
Select stroke Hi-Lo More than 340
b) Set ignition “ON”. Select stroke Hi-Mid More than 145
c) Select “All Learning Value Initialization” function Select stroke Mid-Lo More than 170
under “Utility” mode on SUZUKI scan tool, and Shift stroke 1st-2nd More than 450
follow the instructions displayed on SUZUKI Shift stroke 3rd-4th More than 450
scan tool. Shift stroke 5th-Reverse More than 450
d) Select “Show AGS Learning Result” function Shift alignment 1st-3rd Less than 20
under “Utility” mode on SUZUKI scan tool. Shift alignment 3rd-5th Less than 20
e) Check that displayed values for all items on Shift alignment 1st-5th Less than 20
SUZUKI scan tool are within the specified range. Shift alignment 2nd-4th Less than 20
Perform the following procedure if any value is Shift alignment 4th-Reverse Less than 20
out of the specified range. Shift alignment 2nd-Reverse Less than 20
Scan tool data Specified value
i) Set ignition “OFF”.
Select stroke Hi-Lo More than 340
Select stroke Hi-Mid More than 145 ii) Move vehicle to rotate tires a half of a turn
Select stroke Mid-Lo More than 170 forward or backward with tires in contact with
Shift stroke 1st-2nd More than 450 ground.
Shift stroke 3rd-4th More than 450 iii) Repeat Step c) to f).
Shift stroke 5th-Reverse More than 450 f) Check that clutch release arm moves to
Shift alignment 1st-3rd Less than 20 disengage clutch and condition of “Clutch
Shift alignment 3rd-5th Less than 20 Control Status” displayed on SUZUKI scan tool
Shift alignment 1st-5th Less than 20 changes “Closed” to “Opened” when starting
Shift alignment 2nd-4th Less than 20 engine.
Shift alignment 4th-Reverse Less than 20 g) With engine idling, check that combination meter
Shift alignment 2nd-Reverse Less than 20 (information display) shows N, 1st or R
according to shift selector operation from N to D
i) Set ignition “OFF”.
or R, and check parameter of “Gear Position”
ii) Move vehicle to rotate tires a half of a turn displayed on SUZUKI scan tool also shows the
forward or backward with tires in contact with same indication. (Scan Tool Data)
ground. Clutch assembly initialization:
iii) Repeat Step c) to f). a) Connect SUZUKI scan tool to DLC. (Suzuki
f) Check that clutch release arm moves to SDT-II Connection and Disconnection) in Section
disengage clutch and condition of “Clutch 0A.
Control Status” displayed on SUZUKI scan tool b) Set ignition “ON”.
changes “Closed” to “Opened” when starting
c) Select “Clutch Assembly Initialization” function
engine.
under “Utility” mode on SUZUKI scan tool, and
g) With engine idling, check that combination meter follow the instructions displayed on SUZUKI
(information display) shows N, 1st or R scan tool.
according to shift selector operation from N to D
d) Check that DTC P080A, P185A or P185B is not

detected. (DTC Check) 1
e) Check that clutch release arm moves to
2
disengage clutch and condition of “Clutch
Control Status” displayed on SUZUKI scan tool
changes “Closed” to “Opened” when starting
engine. (Scan Tool Data)
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 3
parameter of “Gear Position” displayed on
SUZUKI scan tool as well. (Scan Tool Data)
Clutch-contact-point Learning Initialization:
a) Start engine and run it for 20 sec.
IGSD0A541007-01
b) Set ignition “OFF” for 5 sec.
c) Set ignition “ON”. Auto Gear Shift Transaxle Oil Level Check
d) Check that DTC P080A or P185B is not AENNTA0E5406003 (08(03)
detected. (DTC Check) 1) Hoist vehicle horizontally.

e) Check that release arm moves according to shift 2) Remove center and left under cover. (Engine Under
selector operation of N to D or D to N, and check Cover and Engine Under Side Cover Removal and
parameter of “Clutch Control Status” displayed Installation) in Section 9H
on SUZUKI scan tool as well. (Scan Tool Data) 3) Check oil leakage.
f) Check that combination meter (information Repair leaky point, if any.
display) shows N, 1st or R according to shift 4) Remove oil level / filler plug (1).
selector operation of N to D or R, and check 5) Check oil contamination and check that oil level
parameter of “Gear Position” displayed on reaches lower end of oil level / filler plug hole (2).
SUZUKI scan tool as well. (Scan Tool Data) If oil is excessively dirty or insufficient, change oil or
add specified oil up to plug hole. (Auto Gear Shift
Auto Gear Shift Actuator Oil Level Check Transaxle Oil Change)
AENNTA0E5406002 (08(03)
1) Connect SUZUKI scan tool to DLC. (Suzuki SDT-II Special tool
Connection and Disconnection) in Section 0A. (A): 09922M36310
2) Set ignition “ON”. 6) Apply sealant to thread of level / filler plug, and then
3) Select “Oil Discharge” function under “Utility” mode tighten it to specified torque.
on SUZUKI scan tool, and follow the instructions “A”: Sealant 99000–31260 (SUZUKI Bond
displayed on SUZUKI scan tool. No.1217G)
4) After completing “Oil Discharge”, set ignition “OFF”
and disconnect SUZUKI scan tool from DLC. (Suzuki Tightening torque
SDT-II Connection and Disconnection) in Section 0A Oil level / filler plug (a): 21 N·m (2.1 kgf-m, 15.5
lbf-ft)
5) Check auto gear shift actuator oil level in reservoir
(1) is between “MAX” mark (2) and “MIN” mark (3) on
reservoir.
If oil level is out of specified range, replace auto gear
shift actuator unit. (Auto Gear Shift Actuator Unit
1, (a), “A”
IFRA0B522002-01
9) Apply sealant to thread of oil level / filler plug, and

then tighten it to specified torque.
2
No.1217G)
Tightening torque
Oil level / filler plug (b): 21 N·m (2.1 kgf-m, 15.5
(A)
lbf-ft)
IJW60P321037-01
7) Check auto gear shift transaxle oil for leakage.

8) Install center and left under cover. (Engine Under
2, (b), “A”
Auto Gear Shift Transaxle Oil Change
AENNTA0E5406004 (08(01)
1) Stop engine and hoist vehicle horizontally.
2) Remove center and left under cover. (Engine Under
Cover and Engine Under Side Cover Removal and 1, (a), “A”
Installation) in Section 9H IFRA0B522003-01
3) Check oil leakage. 10) Check auto gear shift for leakage.
Repair leaky point, if any.
11) Install center and left under cover. (Engine Under
4) Remove oil level / filler plug (2). Cover and Engine Under Side Cover Removal and
5) Remove drain plug (1) and drain oil. Installation) in Section 9H
6) Apply sealant to thread of drain plug, and tighten it to
specified torque. Differential Side Oil Seal Replacement
AENNTA0E5406005 (08(01)
“A”: Sealant 99000–31260 (SUZUKI Bond 1) Drain transaxle oil. (Auto Gear Shift Transaxle Oil
No.1217G) Change)
Tightening torque 2) Remove front drive shaft assembly. (Front Drive
Oil drain plug (a): 21 N·m (2.1 kgf-m, 15.5 lbf-ft) Shaft Assembly Removal and Installation): Front in
Section 3A
7) Add new specified oil until oil level reaches lower
end of oil filler plug hole. 3) Remove oil seal (1) using special tool.
Special tool
NOTE
(A): 09913M50121
It is highly recommended to use “SUZUKI
GEAR OIL 75W”.
Auto gear shift transaxle oil specification

: SUZUKI GEAR OIL 75W 99000–22B27–036
: API GL-4 (For SAE classification, refer to
viscosity chart)
Auto gear shift transaxle oil capacity
(A)
Viscosity chart
1
I9P60A522004-01
75W 4) Install new oil seal (1) to specified position using

C - 30 - 20 - 10 0 10 20 30 40
special tools.
F - 22 -4 14 32 50 68 86 104
[a]
NOTE
IFFA0B521002-01
• When installing oil seal, face its spring
[a]: Temperature
side inward.
• Check that oil seal is installed horizontally
8) Check oil level. (Auto Gear Shift Transaxle Oil Level
to surface of case after installing oil seal.
Check)
Special tool
(A): 09944M66010
(B): 09924M74510 1, “A”
(C): 09925M16010
(D): 09925M15410
Distance from case end face to left oil seal
“a”: 1.0 – 2.0 mm (0.04 – 0.07 in.)
(B) (B)
Distance from case end face to right oil seal (A) (A)
“b”: –0.5 – 0.5 mm (–0.02 – 0.01 in.)
5) Apply grease to oil seal lip. Then, check drive shaft
where oil seal contacts and check its smoothness.
“a” “b”
IFRA0A521007-01
6) Install front drive shaft assembly. (Front Drive Shaft

Section 3A
7) Add transaxle oil. (Auto Gear Shift Transaxle Oil
Change)
Shift Selector Components

AENNTA0E5406006 (12(01)
(a)
IMTA0A540011-01
1. Shift selector knob 3. Shift selector indicator : 13 Nm (1.3 kgf-m, 9.5 lbf-ft)
2. Shift selector boot 4. Shift selector
Shift Selector Removal and Installation Removal

AENNTA0E5406007 (08(01)
Reference: “Shift Selector Inspection” 1) Shift selector to N range.

front covers. (Center Console Box Removal and
3) For keyless push start model, remove rear vent No.2 3
duct. (Rear Ventilation Duct Removal and Installation
(If Equipped)) in Section 7B
4) Disconnect 2 connectors from shift selector.
2 1
5) Remove shift selector nuts (1) and then remove shift
selector (2).
IMTA0A540014-01
3) Disconnect shift selector indicator connector (1).
1 2 1
IMTA0A540015-01
4) Release claws (1) and then remove shift selector

indicator (2) and shift selector boot (3).
IMTA0A540012-01
Installation
3
• Tighten shift selector nuts (1) to specified torque.
2
Tightening torque
Shift selector nut (a): 13 N·m (1.3 kgf-m, 9.5 lbf-ft)
1
IMTA0A540016-01
5) Releasing claws (1) and then remove shift lever boot

1, (a) 1, (a) (2) from shift selector indicator (3).
3
1
IMTA0A540013-01
Shift Selector Disassembly and Reassembly

AENNTA0E5406008 (08(02)
Disassembly
1) Releasing claws (1) by pressing in arrow direction
shown as figure and pull down shift lever boot (2), IMTA0A540017-01
2) Remove shift selector knob (3) by rotating 6) Remove shift selector indicator harness according to
counterclockwise. the following procedure, if necessary.
a) Disconnect lever position sensor connector (1).
IMTA0A540033-01
b) Remove shift selector indicator harness

connector (1) from shift selector.
2
IMTA0A540035-02
c. Install shift selector indicator harness connector

1 (1) to shift selector.
d. Fix shift selector indicator harness (2) to shift
selector.
IMTA0A540034-01
c) Remove shift selector indicator harness from

shift selector.
Reassembly 2
Reverse disassembly procedure noting the following

points.
• Install shift selector indicator harness to shift selector
according to the following procedure, if removed.
a. Connect lever position sensor connector (1). 1
b. Fix shift selector indicator harness (2) to shift
selector.
IMTA0A540036-01
e. Fix shift selector indicator harness (1) to shift

selector as shown in figure.
NOTICE
If [a] part of shift selector indicator harness is
installed while it is stretched, shift selector
indicator harness and connector may be
damaged when shift console is removed.
Install shift selector indicator harness so that
there is as much slack in the [a] part as
possible.
NOTICE
Rotating shift selector knob beyond specified
range may damage the knob.
Do not rotate the knob excessively.
NOTE
2 The tightening torque is a reference value.
Tightening torque
Shift selector knob: 6.0 N·m (0.61 kgf-m, 4.50 lbf-
ft)
1 [a]
IMTA0A540037-02
2. Tape
• Tighten shift selector knob by turning it clockwise 4

times by hand from torque rise point.
Shift Selector Inspection

AENNTA0E5406009 (08(03)
Hall Sensor
1) Remove floor console rear box and floor console front covers. (Center Console Box Removal and Installation) in
Section 9H
2) For keyless push start model, remove rear vent No.2 duct. (Rear Ventilation Duct Removal and Installation (If
Equipped)) in Section 7B
3) Check voltage between terminal “10” of shift selector connector (1) and each terminal of each shift position,
referring to the following table.
If check result is not as specified, replace shift selector. (Shift Selector Removal and Installation)
Terminal No.
Shift position
13 12 9 8 7 1 2 6
R 0V 10 – 14 V 10 – 14 V 0V 0V 0V 10 – 14 V 10 – 14 V
N 0V 0V 10 – 14 V 0V 0V 10 – 14 V 0V 10 – 14 V
D 10 – 14 V 0V 10 – 14 V 0V 0V 10 – 14 V 10 – 14 V 0V
M 10 – 14 V 0V 0V 0V 0V 10 – 14 V 10 – 14 V 0V
+ 10 – 14 V 0V 0V 0V 10 – 14 V 10 – 14 V 10 – 14 V 0V
– 10 – 14 V 0V 0V 10 – 14 V 0V 10 – 14 V 10 – 14 V 0V
[A]
5 4 3 2 1
16 15 14 13 12 11 10 9 8 7 6
[a]
IMTA0A540018-01
[A]: Shift selector connector (View: [a])

2. Service wire
Auto Gear Shift Actuator Unit Removal and • If clutch cylinder gets stuck and clutch
Installation anchor cannot be removed from clutch
AENNTA0E5406010 (08(01) release fork, loosen bolts on mating face
Reference: “Precautions for Electrical System Work” between engine and transmission and
NOTICE make space of clutch release fork to
remove it.
Performing the following prohibited
• If auto gear shift actuator unit is removed
operations will affect the original
from gear shift and select shaft assembly
performance of auto gear shift actuator unit.
keeps gears engaged, move engage lever
• Do not disassemble the auto gear shift on the top of gear shift and select shaft
actuator unit. assembly to N position before installing
• Do not remove the motor. auto gear shift actuator unit to gear shift
• Regarding auto gear shift actuator unit and select shaft assembly.
removal and installation, check specified
torque and do not use impact tool. NOTE
• Use care not to allow dust to enter auto Do not close driver side front door without
gear shift actuator unit. disconnecting negative (–) cable at battery
• Do not place auto gear shift actuator unit after completing “Oil Discharge”.
on its side or upside down.
4) After completing “Oil Discharge”, set ignition “OFF”
• Do not give an impact to hydraulic unit. and disconnect SUZUKI scan tool from DLC. (Suzuki
Removal
5) Place shift selector in N.
Connection and Disconnection) in Section 0A. 6) Remove battery and battery tray. (Battery Removal
7) Remove harness clamp (2) and bolts (1).
3) Select “Oil Discharge” function under “Utility” mode
on SUZUKI scan tool, and follow the instructions
displayed on SUZUKI scan tool.
NOTICE
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.
3 1
1
2
2 3
4
ILSD0A540015-01

1 Installation) in Section 9H
13) Disconnect clutch speed sensor connector (1) and
wiring harness clamps (2).
2
ILSD0A540013-01
8) Remove EVAP canister purge valve. (EVAP System

Components) in Section 1B
9) Disconnect auto gear shift actuator unit connector
turning the lock lever (2) clockwise while releasing
lock claw (1) by pushing it inward. 2
2 1
IGSD0A541010-04
14) Disconnect clutch anchor (1).
IGJC0A541018-02
10) Disconnect connectors from ECM. (ECM Removal

11) Disconnect engine harness (1) from relay fusebox
(2), Detach clamp (3) and remove ground bolt (4).
1
IGSD0A541011-02
15) Remove auto gear shift actuator unit bolt (1), nuts
(2), and remove transmission hook (3), and then
remove actuator bracket bolts (4), auto gear shift
actuator unit (5) and O-ring.
5 4
1
IK1K0A540061-01
3 17) Remove clutch actuator anchor (1) as follows, if
2
ILSD0A540014-01
necessary.
16) Remove actuator harness (1) as follows, if • Push the clutch actuator anchor out of the clutch
necessary: cable (2) in arrow direction as shown in figure.
• Pull the cap (2) and lock lever (3) in arrow • Push the clutch actuator anchor downwards
direction as shown in figure. maintaining the anchor slit position vertically
upward and remove clutch actuator anchor.
• Disconnect transmission control unit connector (4)
18) Remove the clutch actuator anchor guide (3) if
• Disconnect motor connector (5).
necessary.
4 3
5
1 3
ILSD0A540034-02
19) Remove the clutch actuator boot (1) if necessary.

1
IK1K0A540060-01
• Disconnect clutch position sensor connector (1).
1
ILSD0A540035-01
Installation
NOTICE
Auto gear shift actuator unit of supply part is
filled with oil and the breather cap (1) is
sealed using rubber cap (2).
“a”
2
1
1
IGJC0A541022-01
ILSD0A540033-01
Reverse removal procedure noting the following points. “a”
• Install new clutch actuator boot (1) using special tool

(A) as shown in figure by running along the rim of
“A”
base plate (2), if necessary.
Special tool
(A): 09925M57610
IGJC0A541023-01
“a”: Approx. 10°

2
1 • Tighten auto gear shift actuator unit bolt (1), nuts (2)
and actuator bracket bolts (3) 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
(A)
kgf-m, 17.0 lbf-ft)
Actuator bracket bolt (c): 23 N·m (2.3 kgf-m, 17.0
lbf-ft)
1, (a)
ILSD0A540036-01
• Use new O-ring.

3, (c)
• Check that O-ring and gear shift and select shaft
assembly are free from foreign material such as dust
or oil.
• Check that engage piston (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.
2, (b)
IGSD0A541013-02
• Connect connector and fix wire harness with clamp

securely.
• Initialize auto gear shift actuator unit. (TCM and

Clutch Initialization)
(A)
Auto Gear Shift Oil Reservoir Tank Removal and
Installation 1
AENNTA0E5406011 (08(01)
Removal
1) Remove auto gear shift actuator unit and actuator
harness. (Auto Gear Shift Actuator Unit Removal
and Installation)
2) Mount auto gear shift actuator unit (1) on special tool
and clean actuator unit.
Special tool
(A): 09921M05520
IK1K0A540066-01
1
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
(A)
1
[B]
IK1K0A540067-01
IK1K0A540064-01 6) Drain oil from auto gear shift oil reservoir tank (1)
3) Remove the oil reservoir tank breather cap and while holding base plate (2) of actuator unit as
clean it. shown in figure.
4) Clean oil reservoir tank cap (1) surface and remove
it.
2 1
IK1K0A540065-01
5) Remove the oil reservoir tank trap (1) along with O-

ring using special tool and put it on the container, if
necessary.
Special tool IKBA0A540033-02
(A): 09925M57610 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.
c) Remove oil reservoir tank by pulling in upward
direction as shown in figure. 2
2
1
1
IK1K0A540070-01
9) Clean the baseplate area properly and cover the

area with a cover cap (1) or the like.
2
2 1
3 IK1K0A540071-01
Installation
1) Install new O-ring (1) into the oil reservoir tank (2).
IK1K0A540068-01
d) Remove the O-ring (1) from oil reservoir tank

1
sitting area in base plate using a special tool.
Special tool 2
(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
1 actuator unit by moving it vertically towards the
mating surface as shown in figure.
b) Hand tighten upper screws (2).
c) Tighten lower screw (3) to specified torque.
IK1K0A540069-01 Tightening torque
8) Drain the oil from oil reservoir tank and base plate Oil reservoir tank lower screw (a): 10 N·m (
sitting area (1) with syringe (2) or the like. 1.0 kgf-m, 7.5 lbf-ft)
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)
7) Install auto gear shift actuator unit and actuator

harness. “Auto Gear Shift Actuator Unit Removal
2, “3”, (b) and Installation”
1
Auto Gear Shift Electric Motor Removal and

Installation
AENNTA0E5406012 (08(01)
Removal
2, “2”, (b) harness. (Auto Gear Shift Actuator Unit Removal
2, “1”, (b) and Installation)
2) Mount auto gear shift actuator unit (1) on special tool
and clean actuator unit.
Special tool
1 (A): 09921M05520
3, (a) 1
(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
5) If removed, install oil trap and O-ring back into oil
reservoir tank.
6) Install and tighten oil reservoir tank cap (1) and cover
IK1K0A540064-01
it with breather cap.
3) Clean motor surface properly.
NOTE 4) Remove screws (1) and then remove auto gear shift
The tightening torque is a reference value. electric motor (2) and sponge (3).
Tightening torque
Oil reservoir tank cap (a): 2 N·m (0.2 kgf-m, 1.5
lbf-ft)
1, (a)
IK1K0A540074-01
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.
NOTE
Align auto gear shift electric motor shaft
1 (1)with the axis passing through the two
fixing holes by using hands as shown in
figure.
IK1K0A540076-01
6) Remove the oldham joint (1) using a plier.
IK1K0A540077-01
Installation
1) Place new oldham joint (1) on base plate.
Removal
and Installation)
2) Remove auto gear shift oil reservoir tank. (Auto Gear
Shift Oil Reservoir Tank Removal and Installation)
1
3) Remove TCM screws (1) in numerical order (“1” –
“4”) as shown in figure.
1, “4”
1, “1”
1, “2”
1, “3”
IK1K0A540082-01
IK1K0A540080-01
4) Insert special tools to screw holes.
a) Ensure proper seating of auto gear shift electric
NOTE
motor (1).
b) Firstly tighten new auto gear shift electric motor Insertion of special tools to two screw holes
screws (2) by approximately 180° and then as a guide will guarantee right TCM
tighten it to specified torque in numerical order translation during the dismounting.
(“1” – “3”) as shown in figure.
Special tool
Tightening torque (A): 09932M97690
Auto gear shift electric motor screw (a): 6
N·m (0.6 kgf-m, 4.5 lbf-ft)
(A)
(A)
2, “1”, (a)
2, “2”, (a)
IK1K0A540083-01
5) Remove the TCM from the valve body and unscrew

special tools.
2, “3”, (a)
IK1K0A540081-01
Installation
harness. (Auto Gear Shift Actuator Unit Removal 1) Clean the valve body face properly.
and Installation) 2) Insert special tools to screw holes.
TCM Removal and Installation

AENNTA0E5406013 (08(01)
NOTE Removal
Insertion of special tools to two screw holes 1) Remove auto gear shift actuator unit, clutch actuator
as a guide will guarantee right TCM anchor, clutch actuator boot and disconnect clutch
translation during the mounting. position sensor connector. (Auto Gear Shift Actuator
Unit Removal and Installation)
Special tool 2) Drain auto gear shift actuator oil. “Auto Gear Shift Oil
(A): 09932M97690 Reservoir Tank Removal and Installation”
3) Clean auto gear shift actuator unit properly.
NOTICE
Carefully clean both side (circlip side and
(A)
cable side) of the clutch actuator.
(A)
4) Remove clutch actuator circlip (1) with plier or other
similar tool.
IK1K0A540083-01
3) Install the TCM (2) to the valve body and unscrew

special tools.
Special tool
: 09932M97690
4) Tighten new TCM screws (1) to specified torque in
numerical order (“1” – “4”) as shown in figure. 1
Tightening torque
TCM screw (a): 6 N·m (0.6 kgf-m, 4.5 lbf-ft)
1, “4”, (a)
1, “1”, (a)
ILSD0A540022-02
5) Move the clutch actuator piston (1) towards the

direction as shown in figure and remove clutch
2
actuator plug with O-ring (2) using a plier or other
similar tool.
NOTE
Place a container under the clutch piston cap
during removal.
1, “2”, (a)
1, “3”, (a)
IK1K0A540084-01
5) Install auto gear shift oil reservoir tank. (Auto Gear

Shift Oil Reservoir Tank Removal and Installation) 1
and Installation) 2
Clutch Actuator Piston Assembly Removal and ILSD0A540021-04

Installation 6) Remove clutch actuator piston sub-assembly (1) and
AENNTA0E5406014 (08(01)
clutch actuator spring (2).
NOTE
3 2
Take proper care while removing piston so as
not to damage internal surface of cylinder
bore.
1
IMTA0A540023-01
Special tool
(A): 09925M57610
1
ILSD0A540029-01
7) Remove spring guide (1) using special tool.
NOTE
Ensure that special tool tip is smooth and
free from dent.
Special tool
(A): 09925M57610 (A)
1
ILSD0A540018-04
Installation
NOTE
Replace new clutch actuator circlip, clutch
actuator plug with O-ring, clutch piston sub-
assembly, clutch actuator spring, spring
guide and clutch actuator oil seal as a set
only.
1) Install new clutch actuator oil seal (1) using special

tool till clicking sound is heard.
1 Special tool
(A): 09951M17620
(A)
ILSD0A540019-04
8) Remove clutch actuator oil seal (1) using special

tool.
NOTE
Shift the clutch actuator oil seal position
from seated position (2) to loose position (3)
from cable side of cylinder as the clutch
actuator oil seal may be hard to be removed.
(A)
1 ILSD0A540024-05
[A] [B]
2 3
(A)
ILSD0A540023-03
[A] [B]
1
1
(A)
(A)
ILSD0A540032-05
[A]: Correct direction (a): Long distance

[B]: Incorrect direction (b): Short distance
3) Prepare and install the new clutch actuator piston

1 1 sub-assembly (1) and spring (2) with special tool.
ILSD0A540031-08
Special tool
[A]: Correct direction [B]: Incorrect direction
(A): 09951M17610
2) Install new spring guide (1) using special tool till NOTE
clicking sound is heard.
• Prepare and install the new clutch actuator
Special tool piston sub-assembly (1) and spring (2)
(A): 09951M17620 with special tool.
NOTE • The orientation of spring guide (3) and
clutch actuator oil seal (4) should be in
Outer dia of spring guide should not create correct position as shown in figure.
scratches on bore while installation.
• Take proper care while installing piston so
as not to damage internal surface of
cylinder bore. Also, there is a possibility of
contamination with foreign materials being
attached to the magnet part of piston sub-
assembly. So ensure that the surface is
free from foreign materials.
[A] [B]
1
3
3
[A] 5
4
IMTA0A540026-01
[A]: Correct orientation 5. Clutch actuator oil seal seating area 2

[B]: Incorrect orientation
ILSD0A540027-06
5) Press clutch actuator plug (1) and install new clutch

actuator circlip (2) with plier or other similar tool.
NOTE
Rotate the circlip with plier to check proper
fitment to groove.
(A)
2 2
1
ILSD0A540025-04
4) Pull clutch cable (1) as direction shown in figure and

install new clutch actuator plug (2) with new O-ring.
ILSD0A540028-05
6) Remove special tool as shown in figure.

Special tool
(A): 09951M17610
2) Remove gear shift and select shaft assembly bolts

(1), and remove gear shift and select shaft assembly
(2).
1 1
(A)
ILSD0A540030-03
7) Check clutch actuator piston for smooth movement.
NOTE 2
1
In case the clutch actuator piston movement

IGSD0A541014-04
is hard, repeat the entire procedure of clutch
actuator piston assembly.
Installation
8) Fill new auto gear shift actuator oil in reservoir tank. 1) Install gear shift and select shaft assembly to
(Auto Gear Shift Oil Reservoir Tank Removal and transaxle left case as follows.
Installation) a) Clean mating surfaces of gear shift and select
9) Connect clutch position sensor connector and install shaft assembly and left case.
new clutch actuator boot, new clutch actuator anchor b) Apply specified amount of sealant to left case as
and auto gear shift actuator unit. (Auto Gear Shift shown in figure.
No.1217G)
Gear Shift and Select Shaft Assembly
Components Sealant amount for transaxle left case
AENNTA0E5406015 (12(01) “a”: 1.5 mm (0.059 in.)
(a)
“a”
“A”
“A” “a”
IGJC0A541025-01
1. Gear shift and select shaft assembly : Do not reuse.

IGSD0A541015-01
: 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
c) Install gear shift and select shaft assembly to left
case.
Gear Shift and Select Shaft Assembly Removal
2) Tighten new gear shift and select shaft assembly
and Installation
AENNTA0E5406016 (08(01) bolts (1) to specified torque.
Removal
NOTICE
1) Remove auto gear shift actuator unit. (Auto Gear
Shift Actuator Unit Removal and Installation) The gear shift and select shaft assembly
bolts are pre-coated with adhesive. If the
bolts are reused, they may work loose.
Replace gear shift and select shaft assembly 1) Apply oil to new O-ring, and then install it on clutch
bolts with new ones whenever they are speed sensor.
removed. 2) Install clutch speed sensor (1) and tighten clutch
speed sensor bolt (2) to specified torque.
Tightening torque
Gear shift and select shaft assembly bolt (a): 23 Tightening torque
N·m (2.3 kgf-m, 17.0 lbf-ft) Clutch speed sensor bolt (a): 10 N·m (1.0 kgf-m,
7.5 lbf-ft)
1, (a)
1, (a)
IGSD0A541016-02 IGJC0A541029-01
3) Install auto gear shift actuator unit. (Auto Gear Shift 3) Add auto gear shift oil. (Auto Gear Shift Transaxle Oil
Actuator Unit Removal and Installation) Change)
4) Initialize gear shift and select shaft assembly. (TCM 4) Connect clutch speed sensor connector.
and Clutch Initialization) 5) Lower vehicle and connect negative (–) cable at
battery.
Clutch Speed Sensor Removal and Installation
AENNTA0E5406017 (08(01)
Clutch Speed Sensor Inspection
Reference: “Precautions for Electrical System Work” AENNTA0E5406018 (08(03)
Reference: “Clutch Speed Sensor Removal and
Removal Installation”
1) Hoist vehicle and drain auto gear shift oil. (Auto Gear 1) Remove clutch speed sensor. (Clutch Speed Sensor
Shift Transaxle Oil Change) Removal and Installation)
2) Disconnect clutch speed sensor connector (1). 2) Check the following points.
3) Remove clutch speed sensor (2). • Check that O-ring (1) is free from damage.
IDL70A540033-01
• Check that end face of sensor and countershaft

2nd gear teeth are free from any metal particles
2 and damage.
1
IGJC0A541028-01
Installation
Reference: “Clutch Speed Sensor Inspection”
IMTA0A540029-01
Installation
Reference: “VSS Inspection”
IJCA0A540055-01
1) Apply oil to new O-ring, and then install it on VSS.
3) Check clutch speed sensor as follows. 2) Install VSS (1) and then tighten VSS bolt (2) to
If faulty condition is found, replace clutch speed specified 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
1
material (iron) (2) in front of clutch speed sensor.
2, (a)
NOTE
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)
IMTA0A540030-01
3) Connect VSS connector.

1 2 3
“a” 4) Install center and left under cover. (Engine Under
3
VSS Inspection
AENNTA0E5406020 (08(03)
Reference: “VSS Removal and Installation”
2 1
1) Remove VSS. (VSS Removal and Installation)
IDL70A540034-01
• Check that O-ring (1) is free from damage.
VSS Removal and Installation
AENNTA0E5406019 (08(01) • Check that end face of sensor and speed sensor
Reference: “Precautions for Electrical System Work” ring teeth are free from any metal particles and
damage.
Removal
2) Disconnect VSS connector.
3) Remove VSS bolt (1) and then remove VSS (2).
NOTE
Keep approximately 1 mm (0.03 in) gap “a”
between ferromagnetic material (iron) and
1 end face of VSS.
VSS resistance
Resistance alternates between 100 Ω or
smaller (ON) and infinity (OFF)
IDLA0A520019-01
1 2 3
3) Check VSS as follows.
If faulty condition is found, replace VSS. (VSS 3
a) Connect battery (1) and ohmmeter (3) to VSS as
shown in figure.
“a”
b) Check that VSS resistance varies as specified
1
below by passing ferromagnetic material (iron) 2
(2) at VSS side. IDLA0A520020-01
Starting Motor Control Relay and Back Up Light

Relay Inspection
AENNTA0E5406021 (08(03)
Auto Gear Shift Unit Components

AENNTA0E5406022 (12(01)
(a) (a)
(b)
(a)
IGJC0A541032-01
1. Engine : 55 Nm (5.6 kgf-m, 40.5 lbf-ft)

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 Remounting

AENNTA0E5406023 (08(01)

1
Dismounting
Shift Actuator Unit Removal and Installation)
3) Disconnect ground cable (1) and ground cable
clamp (2).
IGSD0A541034-01
1
2
IGSD0A541033-02
3. VSS connector
4) Drain auto gear shift oil. (Auto Gear Shift Transaxle

Oil Change)
5) Remove exhaust pipe. (Exhaust Pipe and Muffler IGJC0A541034-02
Removal and Installation) in Section 1K 9) Support engine assembly using shackle, engine
6) Remove front drive shaft assembly. (Front Drive hook, chain hoist or the like. Refer to Step 34) of
Shaft Assembly Removal and Installation): Front in removal procedure in “Engine Assembly Removal
Section 3A and Installation” in Section 1D.
7) Remove starting motor. (Starting Motor Removal and 10) Remove the following parts. (Engine Mounting
Installation) in Section 1I Components) in Section 1D
8) Disconnect the following electric wires / connectors • Engine left mounting
and each clamp. • Engine rear torque rod
• Engine harness clamps (1) • Engine rear torque rod bracket
• Auto gear shift actuator unit connector (2) 11) Remove bolts and nut fastening engine and auto
• VSS connector (3). gear shift unit, and then detach auto gear shift unit
from engine.
Remounting
Reverse dismounting procedure noting the following
points.
NOTICE
remounting the manual transaxle can cause
damage to parts.
• When installing the auto gear shift unit, 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.

– Auto gear shift unit to engine bolt and nut: (Auto
Gear Shift Unit Components)
– Auto gear shift unit to engine rear mounting bracket
bolts: (Engine Mounting Components) in Section
1D
– Front drive shaft: (Front Drive Shaft Assembly 1, (a)
IGSD0A541035-01
• Set each clamp for wiring securely.
– Starting motor: (Starting Motor Removal and
Installation) in Section 1I • Add auto gear shift oil. (Auto Gear Shift Transaxle Oil
Change)
– Engine left mounting: (Engine Mounting
Components) in Section 1D • Initialize auto gear shift.
– Engine rear torque rod: (Engine Mounting – When removed or new manual transaxle is
Components) in Section 1D installed, refer to “All Learning Value Initialization:”
under “TCM and Clutch Initialization”.
– Engine rear torque rod bracket: (Engine Mounting
Components) in Section 1D – When new manual transaxle and new auto gear
shift actuator unit are installed as a set, refer to
• Tighten ground cable bolt (1) to specified torque. “Clutch-contact-point Learning Initialization:” under
Tightening torque “TCM and Clutch Initialization”.
Ground cable bolt (a): 25 N·m (2.5 kgf-m, 18.5 lbf- • Check function of engine, clutch and transaxle.
ft) • Check that there is no oil leakage at each connection.
Auto Gear Shift Components

AENNTA0E5406024 (12(01)
(a)
(a)
30
35
OIL
28 19
(a)
(a)
(c) 3 1217G
29
16 21 1217G (b)
OIL
19 20 A
2 1217G
23
(c)
34 33
18 25
32
26
32 27
(a)
15
18
(a) 4
17
(c)
13
14
20 A
31
1 (c)
9 6
22 1217G (b) 10
12
24
11 A
7
(a)
8
IMTA0A540039-01
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 gear shift : Apply sealant 99000-31260 to threads.
&select shaft assembly
3. Gear shift and select shaft assembly 23. Transaxle case plug
: For details, refer to “Gear Shift and Select Shaft Assembly Removal and
Installation”
: 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 “Auto Gear Shift Disassembly and Reassembly”.
5. Differential assembly 25. Breather plug
: For details, refer to “Differential Disassembly and Reassembly”.
6. Reverse gear shaft 26. Breather hose
7. Washer 27. Breather union
8. Reverse idler gear 28. Auto gear shift actuator bracket
9. Reverse gear shift lever 29. Clutch speed sensor
10. Reverse gear shift locating ball assembly 30. Transmission hook
11. Input shaft oil seal 31. Countershaft right bearing outer race
12. Countershaft oil channel 32. Outer race
13. Bearing stopper plate 33. Differential side shim
14. Input shaft oil channel 34. VSS
15. Magnet 35. Auto gear shift actuator unit
16. Oil gutter : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
17. Countershaft circlip : 21 Nm (2.0 kgf-m, 15.5 lbf-ft)
19. O-ring : Do not reuse.
20. Oil seal : Apply transaxle oil.
Auto Gear Shift Disassembly and Reassembly

AENNTA0E5406025 (08(02)
Disassembly
1) Dismount auto gear shift unit. (Auto Gear Shift Unit
Dismounting and Remounting)
Shift Actuator Unit Removal and Installation) 1
3) Remove gear shift and select shaft assembly. (Gear
Installation)
4) Remove clutch speed sensor. (Clutch Speed Sensor
5) Remove VSS. (VSS Removal and Installation)
6) Remove reverse gear shaft bolt (1) with gasket.
IGJC0A541037-01
1
8) Remove transaxle left case plug (1) with flat-bladed
screwdriver (2) or the like.
IGSD0A521008-01
7) Remove transaxle case bolts (1).

1
2
IGJC0A541038-01
9) While expanding countershaft circlip (1) to unhook it

from bearing groove, remove transaxle left case (2)
from right case using special tool.
(A)
NOTE IGSD0A521012-01
When removing transaxle left case, circlip 3. Countershaft left bearing

comes out with left case and bearing remains
at countershaft side. 10) Remove reverse gear shift lever bolts (1) and
reverse gear shift lever (2).
Special tool
11) Remove reverse gear shaft (3), washer (4) and
(A): 09912M34510
reverse idler gear (5).
3
1
5
IGSD0A521011-01
2
IGSD0A521013-01
12) Remove magnet from right case.

13) 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).
NOTICE
The reverse gear shift lever bolts are pre-
4 coated with adhesive. If these bolts are
3 5 reused, they may work loose.
Replace the reverse gear shift lever bolts with
new ones whenever they are removed.
1
Tightening torque
Reverse gear shift lever bolt (a): 10 N·m (1.0 kgf-
m, 7.5 lbf-ft)
2
IGSD0A521014-01 (A)
1
14) Remove differential assembly from transaxle right
case.
2, (a)
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
gear shift shaft (4) and low speed gear shift shaft (5)
IGJA0A540069-01
all together, and then install them into transaxle right
case so as not to damage oil seal by input shaft 6) Install reverse idler gear (1), washer (2) and reverse
spline. gear shaft (3).
NOTE NOTE
• Input shaft right bearing on shaft can be Position reverse gear shift lever (4) not to
installed into transaxle right case (6) 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
3 5
5
1
2 3
2
IGSD0A521014-01
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
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.
NOTICE
1 Fitting failure of circlip into bearing groove
2 causes noise or breakage of countershaft
related parts because of wrong positioning of
IGJC0A541042-01
countershaft.
8) Install magnet (1) to right case and input shaft oil Fit circlip into bearing groove.
channel (2) to input shaft.
IGSD0A521017-01
IGSD0A521016-01
12) Tighten transaxle case bolts (1) to specified torque.
9) Clean mating surfaces of both right and left cases, Tightening torque
and apply sealant to transaxle right case (1) as Transaxle case bolt (a): 23 N·m (2.3 kgf-m, 17.0
shown in figure. lbf-ft)
No.1217G)
Sealant amount for transaxle right case
“a”: 1.5 mm (0.059 in.)
1,(a)
“a”
“A” “a”
1 “A”
1,(a)
IFRA0A521021-01
IGSD0A521018-01
13) Tighten new reverse gear shaft bolt (1) with new Transaxle Left Case Disassembly and
gasket to specified torque. Reassembly
AENNTA0E5406026 (08(02)
NOTICE Reference: “Auto Gear Shift Unit Dismounting and
The reverse gear shaft bolt is pre-coated with Remounting”
adhesive. If the bolt is reused, it may work Reference: “Auto Gear Shift Components”
loose.
Replace the reverse gear shaft bolt with new Disassembly
one whenever it is removed. 1) Remove circlip (1) and oil gutter (2), if necessary.
Tightening torque
Reverse gear shaft bolt (a): 23 N·m (2.3 kgf-m, 2
1
17.0 lbf-ft)
1, (a)
ILSB0B522002-01
2) Remove differential side oil seal from transaxle left

case, if necessary. (Differential Side Oil Seal
Replacement)
IDL70A540059-01
14) Install new transaxle case plug (1) using special tool. 3) Remove differential side bearing outer race (1) using
special tools, and then remove shim.
Special tool
(B): 09924M74510 (A): 09942M15511
(B): 09944M96013
(C): 09921M26010
(B)
(A) (C)
(A)
(B)
1
1
IGSB0A522013-01
Reassembly
IGSD0A521020-01 1) Install new circlip and oil gutter (1), if removed.
15) Install VSS. (VSS Removal and Installation)
NOTE
16) Install clutch speed sensor. (Clutch Speed Sensor
When installing oil gutter, fit its claws into
holes of transaxle left case securely.
17) Install gear shift and select shaft assembly. (Gear
Installation)
18) Remount auto gear shift unit. (Auto Gear Shift Unit
Dismounting and Remounting)
“a” 2
IGSD0A541037-01
f) Measure depth “b” from mating surface of

1 transaxle left case (1) to installation position of
ILSB0B522003-01 differential side bearing outer race.
2) Install new differential side oil seal to transaxle left
1
case, if removed (Differential Side Oil Seal
Replacement)
3) Calculate clearance “c” for selection of applicable
differential side shim as follows.
a) Install differential side bearing outer race to
transaxle right case. (Transaxle Right Case
b) Install differential assembly (2) to transaxle right
case (1).
c) Install differential side bearing (3) outer race of “b”
transaxle left case side 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
turn differential assembly 10 times or more. 1
IGSD0A541038-01
1
g) Calculate clearance “c” by the following formula.
3
Clearance “c” = depth “b” - distance “a”
“c”
2 “b” “a”
IGSD0A541036-01
e) Measure distance “a” from mating surface of

transaxle right case (1) to differential side
bearing outer race (2).
IGSD0A541039-01
4) Select shim closest to calculated shim thickness

from the following available sizes.
Available shim thickness

0.491 – 0.530 mm
0.66 mm (0.0260 in.)
(0.01933 – 0.02087 in.)

0.531 – 0.570 mm
0.70 mm (0.0276 in.) (A)
(0.02091 – 0.02244 in.)
0.571 – 0.610 mm
0.74 mm (0.0291 in.)
(0.02248 – 0.02402 in.)
0.611 – 0.650 mm
0.78 mm (0.0307 in.)
(0.02406 – 0.02559 in.)
0.651 – 0.690 mm 1
0.82 mm (0.0323 in.)
(0.02563 – 0.02717 in.)
0.691 – 0.730 mm
0.86 mm (0.0339 in.)
(0.02720 – 0.02874 in.)
0.731 – 0.770 mm
0.90 mm (0.0354 in.)
(0.02878 – 0.03031 in.)
0.771 – 0.810 mm
0.94 mm (0.0370 in.)
(0.03035 – 0.03189 in.)
0.811 – 0.850 mm IGJA0A520028-01
0.98 mm (0.0386 in.)
(0.03193 – 0.03346 in.)
0.851 – 0.890 mm Transaxle Right Case Disassembly and
1.02 mm (0.0402 in.)
(0.03350 – 0.03504 in.) Reassembly
0.891 – 0.930 mm AENNTA0E5406027 (08(02)
1.06 mm (0.0417 in.) Reference: “Auto Gear Shift Unit Dismounting and
(0.03508 – 0.03661 in.)
Remounting”
0.931 – 0.970 mm
1.10 mm (0.0433 in.) Reference: “Auto Gear Shift Components”
(0.03665 – 0.03819 in.)
0.971 – 1.010 mm
1.14 mm (0.0449 in.) Disassembly
(0.03823 – 0.03976 in.)
1.011 – 1.050 mm 1) Remove differential side oil seal from transaxle right
1.18 mm (0.0465 in.) case, if necessary. (Differential Side Oil Seal
(0.03980 – 0.04134 in.)
1.051 – 1.090 mm Replacement)
1.22 mm (0.0480 in.)
(0.04138 – 0.04291 in.) 2) Remove differential side bearing outer race (1) using
1.091 – 1.130 mm special tool, if necessary.
1.26 mm (0.0496 in.)
(0.04295 – 0.04449 in.)
Special tool
1.131 – 1.170 mm
1.30 mm (0.0512 in.) (A): 09925M16510
(0.04453 – 0.04606 in.)
1.171 – 1.210 mm
1.34 mm (0.0528 in.)
(0.04610 – 0.04764 in.)
1.211 – 1.250 mm (A)
1.38 mm (0.0543 in.)
(0.04768 – 0.04921 in)
1.251 – 1.290 mm
1.42 mm (0.0559 in.)
(0.04925 – 0.05079 in.)
5) Install differential side shim(s) (1).

1
IGJA0A520029-01
3) Remove input shaft oil seal (1) using special tool, if

necessary.
Special tool
(A): 09913M50121
IGJA0A520027-01
6) Install countershaft right bearing outer race (1) using

special tool and hammer.
Special tool
(A): 09913M85210
(B): 09913M80113
(A)
(B)
(A)
IDLA0A520045-01
1, “A”
4) Remove bearing stopper plate (1), countershaft right IDLA0A520048-01
bearing outer race (2) and countershaft oil channel
2) Install countershaft oil channel (1) and countershaft
(3), if necessary.
right bearing outer race (2), if removed.
NOTE
3
Install countershaft oil channel aligning its
ridge (3) with ridge (4) of transaxle right case.
1 3
IDLA0A520046-01
5) Remove reverse gear shift locating ball assembly

(1), if necessary.
1 2
IDLA0A520049-01
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.
IGSD0A521022-01
Tightening torque
Reassembly Bearing stopper plate bolt (a): 10 N·m (1.0 kgf-
m, 7.5 lbf-ft)
1) Install new input shaft oil seal (1) facing its spring
side upward up to bottom of transaxle right case
hole, if removed. Use special tool and hammer for
installation and apply grease to oil seal lip.
Special tool
(A): 09926M37610M003
1
2, (a)
(A)
IGSD0A521024-01
4) Install differential side bearing outer race (1) using

special tool, if removed.
Special tool IGSD0A521040-01
(A): 09913M85210 5) Install reverse gear shift locating ball assembly, if

removed.
6) Install new differential side oil seal to transaxle right
case, if removed. (Differential Side Oil Seal
Replacement)
Input Shaft Components

AENNTA0E5406028 (12(01)
8
6
5
OIL
3
7
17
1
OIL
4
OIL
2
15
8
OIL
12
16
11
14
13
9
OIL
3
OIL
3
OIL
10
IMTA0A540040-01
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
: For assembly, refer to “Input Shaft Disassembly
and Reassembly”.
7. High speed synchronizer key 14. 5th gear synchronizer sleeve & hub
: For assembly, refer to “Input Shaft Disassembly
and Reassembly”.
Input Shaft Disassembly and Reassembly

AENNTA0E5406029 (08(02)
Reference: “Auto Gear Shift Unit Dismounting and
Remounting”
Reference: “Auto Gear Shift Disassembly and
Reassembly”
Reference: “Input Shaft Components”
Disassembly
! CAUTION IDL70A540071-01
Using an inappropriate hydraulic press or 3) Remove 5th gear synchronizer hub plate.
bearing puller could cause personal injury. 4) Remove 5th gear synchronizer sleeve & hub
Use the hydraulic press and bearing puller assembly (1), 5th gear synchronizer ring and 5th
which are capable of safely bearing a load of gear (2) from input shaft (3) using bearing puller and
at least 5 tons (11,000 lbs). hydraulic press.
NOTICE 4
Supporting the gear on the concave side of 1
3
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
2
hydraulic press.
IDL70A540072-02
4. Metal stick
5
1
2 5) Remove 5th gear needle bearing from input shaft.
4
6) Remove 5th gear spacer according to the following
procedure.
a) Engage high speed synchronizer sleeve with 4th
gear.
3
b) Push down input shaft (1) a little using bearing
3
IDL70A540070-01 puller (2) and hydraulic press.
5. Metal stick

1 2
IDL70A540076-01
10) Remove 3rd gear needle bearing from input shaft.

IKRC0A520004-01 11) Disassemble synchronizer sleeve & hub assembly.
c) Remove 5th gear spacer (1) using bearing puller
(2) and hydraulic press. Reassembly
necessary.
2) Check clearance “a” between synchronizer ring (2)
1
2 gear (3rd, 4th and 5th)
Standard: 0.40 – 1.10 mm (0.016 – 0.043 in.)
IDL70A540074-01
7) Remove 4th gear, 4th gear synchronizer ring and 4th

gear needle bearing from input shaft.
“a”
1
IDLA0A520052-01
3) To ensure lubrication of input shaft (1), blow air into

oil holes (2) as shown in figure and check that they
are free from any obstruction.
IDL70A540075-02
9) Remove high speed synchronizer sleeve & hub

assembly (1) and 3rd gear (2) from input shaft (4)
using bearing puller (3) and hydraulic press.
6) Install 3rd gear needle bearing and apply transaxle

oil to it, and then install 3rd gear (1) and 3rd gear
2 synchronizer ring (2) to input shaft.
7) Install high speed synchronizer sleeve & hub
1
assembly (3) using special tool and hydraulic press.
NOTE
2 check that synchronizer ring keys (4) are
IDL70A540078-02 aligned with key slots (5) in sleeve & hub
4) Install new right bearing (1) to input shaft (2) using assembly.
special tool and hydraulic press. • Check free rotation of 3rd gear after press-
Special tool fitting sleeve & hub assembly.
(A): 09913M80113
Special tool
(A): 09913M84510
(A)
(A)
1
[b] 3
2
[a]
2
5
IDL70A540079-01 4
IDL70A540081-02
5) Fit high speed synchronizer sleeve (1) to hub (2) and
3 keys (3) as shown in figure. [a]: 3rd gear side [b]: Long flange
NOTE 8) Install new circlip with flat face upper side.

• No specific direction is assigned to high 9) Install 4th gear needle bearing (2) and apply
speed synchronizer sleeve or each key but transaxle oil to it, and then install synchronizer ring
it is assigned as sleeve & hub assembly. (4) and 4th gear (3).
10) Install 5th gear spacer (1) using special tool and
Synchronizer key installation position hydraulic press.
Special tool
(A): 09913M84510
3
(A)
2
2 1
1 3
4
IDL70A540082-01
1
11) Install 5th gear needle bearing and apply transaxle
oil to it, and then install 5th gear and synchronizer
ring.
2 12) Install 5th gear synchronizer hub (1) using special
IDL70A540080-03
tool and hydraulic press.
NOTE 14) Install 5th gear synchronizer hub plate.

• Inside diameter of 5th gear synchronizer 15) Select new circlip (1) that makes thrust clearance “a”
hub is smaller than that of high speed of 5th gear synchronizer hub plate 0.1 mm (0.004 in)
synchronizer hub. or less and install it.
• While press-fitting hub, check that Available circlip thickness
synchronizer ring key protrusions (2) are Clearance “b” Circlip thickness
aligned with key slots (3) in hub. 2.000 – 2.049 mm
2.00 mm (0.0787 in.)
• Check free rotation of 5th gear after (0.0787 – 0.0806 in.)
pressfitting hub. 2.050 – 2.099 mm
2.05 mm (0.0807 in.)
(0.0807 – 0.0826 in.)
Special tool 2.100 – 2.149 mm
2.10 mm (0.0827 in.)
(A): 09913M80113 (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
(A) 2.20 mm (0.0866 in.)
(0.0866 – 0.0885 in.)
1 2.250 – 2.300 mm
2.25 mm (0.0886 in.)
[a] (0.0886 – 0.0905 in.)
3
1
“a” “b”
2
IJCA0A540073-01
[a]: 5th gear side
13) Fit 5th gear synchronizer sleeve (1) to hub (2) and 3
keys (3) as shown in figure.
NOTE
IDL70A540085-01
• No specific direction is assigned to each 16) Press-fit left bearing (1) using special tool and
key. hydraulic press.
• When fitting sleeve to hub, raise the hub
Special tool
and check that the sleeve comes off with
(A): 09944M66060
the self-weight.
Synchronizer key installation position (A)
1
3
IDL70A540086-01
2
IELA0B540025-01
Countershaft Components
AENNTA0E5406030 (12(01)
OIL
7
6
9
4
OIL
8
OIL
2
15
5
3 14 1
1
OIL
13
1
12
OIL
7
10
11
1
IGSD0A521029-01
1. Circlip 7. Needle bearing 13. Countershaft 1st gear

2. Countershaft left bearing 8. Countershaft 2nd gear 14. Countershaft
: For assembly, refer to “Countershaft Disassembly
and Reassembly”
3. Countershaft 5th gear 9. 2nd gear synchronizer ring 15. Countershaft right bearing
: For assembly, refer to “Countershaft Disassembly inner race
and Reassembly”
4. Countershaft 4th gear 10. Low speed synchronizer key : Apply transaxle oil
and Reassembly”
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
and Reassembly”
Countershaft Disassembly and Reassembly NOTICE

AENNTA0E5406031 (08(02)
Reference: “Auto Gear Shift Unit Dismounting and Supporting the gear on the concave side of
Remounting” the bearing puller can cause damage to the
Reference: “Auto Gear Shift Disassembly and gear.
Reassembly” Support the gear on the flat side of the
Reference: “Input Shaft Components” bearing puller.
Disassembly 1) Remove circlip (1) using snap ring pliers (2).
! CAUTION
6) Apply bearing puller (3) to 2nd gear (2) and remove

3rd gear (1) together with 2nd gear using hydraulic
press.
2
1
1
2
IDL70A540088-02
2) Remove left bearing (1) using bearing puller (2) and IDL70A540092-01
hydraulic press. 7) Remove 2nd gear synchronizer ring and 2nd gear
needle bearing.
3
1
1
2
IDL70A540089-01
3. Metal stick IDL70A540093-02
9) Apply bearing puller (3) to 1st gear (2) and remove

3) Remove circlip (1) using snap ring pliers (2). low speed synchronizer sleeve & hub assembly (1),
1st gear synchronizer ring and 1st gear using
hydraulic press.
3
1
2
IDL70A540090-02
4) Apply bearing puller (3) to 4th gear (2) and remove

IDL70A540094-01
5th gear (1) together with 4th gear using hydraulic
press. 10) Remove 1st gear needle bearing.
1 2
IDL70A540091-01 IDL70A540095-02
5) Remove 3rd and 4th gear spacer. 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 amount of grinding to the minimum
amount if necessary.
2 2
3
“a” “a”
1
3
1
1
IDLA0A520052-01
IDL70A540096-01
13) Break the thinnest portion of bearing inner race (2) 3) To ensure lubrication of countershaft (1), blow air
with a chisel (1) and remove bearing inner race. into oil holes (2) as shown in figure and check that
they are free from any obstruction.
1
2
1
2 IDL70A540099-02
IDL70A540097-01
4) Install right bearing inner race (1) using special tool
Reassembly and hydraulic press.
1) Clean all components thoroughly, check them for Special tool
any abnormal condition and replace defective parts (A): 09913M80113
with new ones if necessary.
2) Check clearance “a” between synchronizer ring (2) (A)
Also, check gear teeth for damage. 1

gear (1st and 2nd)
Standard: 0.40 – 1.10 mm (0.016 – 0.043 in.)
IDL70A540098-01

6) Fit low speed synchronizer sleeve (1) to hub (2) and
3 keys (3) as shown in figure.
NOTE
• No specific direction is assigned to low
speed synchronizer hub or each key but it
• When fitting synchronizer hub into sleeve, Special tool

raise the sleeve and check that the hub (A): 09925M18011
comes off with the self-weight.
(A)
[b]
1
[a]
IDL70A540102-01
[a]: 2nd gear side [b]: Long flange
1
12) Install 3rd and 4th gear spacer (1) and then install
4th gear (2) using special tool and hydraulic press.
2
Special tool
IDL70A540100-03
(A): 09925M18011
7) Install 1st gear needle bearing and apply transaxle
oil to it, and then install 1st gear (1) and 1st gear
(A)
synchronizer ring to countershaft.
8) Install low speed sleeve & hub assembly (2) using 2
special tool and hydraulic press.
NOTE 1
[b]
check that synchronizer ring keys (3) are [a]
assembly.
• Check free rotation of 1st gear (1) after
press-fitting sleeve & hub assembly. IDL70A540103-01
Special tool [a]: 3rd and 4th gear spacer side [b]: Long flange
(A): 09940M51710
13) Install 5th gear (1) using special tool and hydraulic
press.
(A) Special tool
(A): 09925M18011
2
[a]
(A)
4
3
1 [b]
[a]
IDL70A540101-02
[a]: 1st gear side

10) Install 2nd gear needle bearing and apply transaxle IDL70A540104-01
oil to it, and then install 2nd gear synchronizer ring [a]: 4th gear side [b]: Long flange
and 2nd gear to countershaft.
11) Install 3rd gear (1) using special tool and hydraulic 14) Select new circlip (1) that makes thrust clearance “a”
press. of 5th gear 0.1 mm (0.004 in) or less and install it.
Available circlip thickness 15) Install left bearing (1) using special tools and
Clearance “b” Circlip thickness hydraulic press.
2.150 – 2.200 mm(0.0846 2.15 mm (0.0846 in.) Special tool
– 0.0866 in.) (A): 09913M80113
2.200 – 2.250 mm(0.0866 2.20 mm (0.0866 in.)
– 0.0886 in.)
2.250 – 2.300 mm(0.0886 2.25 mm (0.0886 in.) (A)
[b]
– 0.0906 in.)
2.300 – 2.350 mm(0.0906 2.30 mm (0.0906 in.) 1
– 0.0925 in.)
2.350 – 2.400 mm(0.0925 2.35 mm (0.0925 in.)
[a]
– 0.0945 in.)
2.400 – 2.450 mm(0.0945 2.40 mm (0.0945 in.)
– 0.0965 in.)
IDL70A540106-01
1
[a]: 5th gear side [b]: Gloves
2
“a” “b”
IDL70A540105-01
2. Countershaft 4. 4th gear

3. 5th gear
Gear Shift Shaft Components

AENNTA0E5406032 (12(01)
(a)
4
IDL70A540157-01
1. Low speed gear shift shaft 3. 5th & 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

AENNTA0E5406033 (08(03)
1) Using feeler gauge, check clearance between fork
(1) and sleeve (2) replace those parts if it exceeds
specified value.
Clearance “a” between fork and sleeve
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.
Differential Components
AENNTA0E5406034 (12(01)
OIL
OIL
4 5
2 3
OIL
12 2
OIL
1 6
3
OIL
11 8
OIL
4
OIL
5
10 (a) 7
9
6
IGSD0A541043-01
1. Differential pinion washer 6. Differential side bearing 11. Differential pinion shaft
2. Differential pinion 7. Speed sensor ring 12. Differential pinion shaft pin
3. Differential side gear 8. Differential case : 100 Nm (10.2 kgf-m, 74.0 lbf-ft)
4. Spring washer 9. Final gear : Apply transaxle oil.
5. Side gear washer 10. Final gear bolt : Do not reuse
Differential Disassembly and Reassembly Reference: “Differential Components”

AENNTA0E5406035 (08(02)
Reference: “Auto Gear Shift Unit Dismounting and
Disassembly
Remounting”
Reference: “Auto Gear Shift Disassembly and 1) Support the final gear with soft jawed vise.
Reassembly”
NOTICE
Keep a thick hosiery cloth or soft PU strips
between the jaws of the bench vice and the (A)
1
teeth of the final gear to protect the final gear
teeth.
2 3
2) Remove final gear bolts (1) and then remove final

gear (2) from differential case (3).
NOTICE
Support the differential case so that it
doesn’t fall down when removing the final IGSD0A541044-01
gear bolts. 5) Remove differential pinion shaft pin (1) using special
tool and hammer, and then disassemble component
parts.
Special tool
2 3 (A): 09922M85811
(A)
1
1
ILSA0P540013-01
3) Remove left side bearing (1) using special tool,

bearing puller (2) and hydraulic press.
IKRC0A520006-01
Special tool
(A): 09913M75821 Reassembly
Judging from abnormality noted before disassembly and
what is found through visual check of component parts
(A) after disassembly, prepare replacing parts and proceed
to reassembly. Check that all parts are clean.
1) Install differential pinions, differential side gears (1),
1
washers and pinion shaft to differential case (2) and
measure thrust play of differential side gear at each
side as follows.
2 If measured value is out of specification, select
suitable side gear washer (3) from the following
available sizes, install it and check again.
IFRA0B522009-01
Special tool
4) Remove right side bearing (1) and speed sensor ring (A): 09900M20607
(2) using special tool, bearing puller (3) and (B): 09900M20701
hydraulic press. Support speed sensor ring on the (C): 09952M06010
flat side of the bearing puller. a) Hold differential assembly with soft jawed vise
Special tool and apply measuring tip or face of dial gauge to
(A): 09913M75821 side gear as shown in figure.
b) Move side gear up and down by hand and read
dial gauge.
Differential side gear thrust play
0.03 – 0.31 mm (0.0012 – 0.0112 in.)
(B): 09944M77030
(A)
[A]
(B)
2 (A)
3
1 (B)
4
(C) 1
1
2
IDL70A540113-01
[B] 4) Install right side bearing (1) using special tool and
(A)
hydraulic press.
Special tool
2
(A): 09913M70123
(A)
(B)
4
1
1
3
2
1
IGSD0A521032-01
[A]: Right side 4. Spring washer

[B]: Left side
Available side gear washer thickness

IDL70A540114-01
0.60 mm (0.0236 in.) 0.85 mm (0.0335 in.)
5) Install left side bearing (1) using special tool and
0.65 mm (0.0256 in.) 0.90 mm (0.0354 in.)
hydraulic press.
0.70 mm (0.0276 in.) 0.95 mm (0.0374 in.)
0.75 mm (0.0295 in.) 1.00 mm (0.0394 in.) Special tool
0.80 mm (0.0315 in.) 1.05 mm (0.0413 in.) (A): 09913M70123
(B): 09941M34513M004
2) Install new differential pinion shaft pin (1) from left
side until depth “a” becomes 7.20 – 7.60 mm (0.283 (A)
– 0.299 in.) as shown using special tool.
Special tool 1
(A): 09922M85811
(A)
“a”
(B)
IDL70A540115-01
6) Support final gear (1) with soft jawed vise and tighten
1 new final gear bolts (2) to specified torque.
NOTICE
Keep thick hosiery cloth or soft PU strips
IDL70A540112-02
between the jaws of the bench vice and the
3) Install speed sensor ring (1) using special tool and
teeth of the final gear to protect the final gear
hydraulic press.
teeth.
Special tool
(A): 09913M75510
Tightening torque
Final gear bolt (a): 100 N·m (10.2 kgf-m, 74.0 lbf- Speed Sensor Ring Inspection
ft) AENNTA0E5406036 (08(03)
Check speed sensor ring for crack and damage.
2, (a) If any defect is found, replace speed sensor ring.
IJCA0A540088-02
IGJC0B520006-01
Clutch Cover and Clutch Disc Components

AENNTA0E5406037 (12(01)
(a)
1 A
2 A
9
5
3
4 A
10 (a)
7
IGJC0A541053-01
1. Clutch release shaft seal 7. Clutch disc

: Apply grease 99000-25480 to seal lip.
2. Clutch release shaft No.2 bushing 8. Release arm
: Apply grease 99000-25480 to bushing inside.
3. Release shaft 9. Pin
: Apply grease 99000-25480 to the end of release shaft arm.
4. Clutch release shaft No.1 bushing 10. Clutch cover bolt
: Apply grease 99000-25480 to bushing inside. : For tightening order, refer to “Clutch Cover and Clutch Disc Removal and
Installation”.
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 NOTE

Installation For centering of clutch disc spline, tighten
AENNTA0E5406038 (08(01)
Reference: “Clutch Cover and Clutch Disc Components” clutch cover bolts while pushing clutch disc
with special tool.
NOTE
Special tool
Do not remove auto gear shift actuator unit
(A): 09924M17811
from auto gear shift when removing or
(B): 09923M36320
installing the clutch related parts.
Tightening torque
Removal Clutch cover bolt* (a): 5.0 Nm → 23 Nm
1) Dismount auto gear shift unit. (Auto Gear Shift Unit (0.51 kgf-m → 2.3 kgf-m, 4.0 lbf-ft → 17.0 lbf-
Dismounting and Remounting) ft)
2) Hold flywheel with special tool and remove clutch Clutch cover bolt (b): 23 N·m (2.3 kgf-m, 17.0
cover bolts (1), clutch cover (2) and clutch disc. lbf-ft)
Special tool 4, “4”, (a)

(A): 09924M17811
3, “2”, (b)
1
1
3, “1”, (b)
(B)
4, “5”, (a)
2
(A)
1
1
I9P60A531018-01
4, “6”, (a)
Installation
3, “3”, (b)
Reference: “Clutch Cover and Clutch Disc Inspection” I9P60A531019-02
NOTE 4) Measure each diaphragm spring height.

If diaphragm spring height uniformity is out of
Before assembling, check the following
specification, remove and reinstall clutch cover.
items.
• Before assembling, check that flywheel Diaphragm spring height uniformity
surface and pressure plate surface have 0.6 mm (0.024 in.) or less
been cleaned and dried thoroughly. 5) Slightly apply grease to spline (1) of input shaft.
• Old grease and dust are removed from
input shaft and clutch disc hub spline. NOTICE
When a large quantity of grease is applied,
1) Hold flywheel with special tool (A). grease may be scattered to clutch disc.
2) Align clutch disc with crankshaft center using special When grease is applied, reduce quantity as
tool (B) and install clutch cover (1). much as possible.
3) Install and tighten clutch cover bolts using the
following procedure: NOTE
a) Tighten 3 bolts (3) by hand. When replacing clutch disc with new one, it
is not necessary to apply grease to input
b) Tighten other 3 bolts (4) evenly and gradually to
shaft.
5.0 Nm (0.51 kgf-m, 4.0 lbf-ft).
c) Fully tighten all bolts evenly and gradually to “A”: Grease 99000–25210 (SUZUKI Super
specified torque in numerical order (“1” – “6”) Grease I)
starting from bolt nearby strut plate rivet (2).
I3RM0A530015-01
1, “A”
ILSA0P540015-01
Clutch Release System Component Removal
6) Join auto gear shift unit with engine. (Auto Gear Shift and Installation
AENNTA0E5406040 (08(01)
Unit Dismounting and Remounting) Reference: “Clutch Cover and Clutch Disc Components”
7) Initialize clutch system. (TCM and Clutch
Initialization) Removal
1) Remove release arm by loosening its bolt.
Clutch Cover and Clutch Disc Inspection 2) Remove release bearing by turning release shaft.
AENNTA0E5406039 (08(03)
Reference: “Clutch Cover and Clutch Disc Removal and 3) Remove clutch release shaft No.2 bushing and
Installation” release shaft seal as follows.
a) Drive out clutch release shaft No.2 bushing and
Clutch Disc release shaft seal (1) together using special tool
At clutch cover side of clutch disc, measure depth “a” of and hammer, and remove release shaft seal.
rivet head depression, i.e. distance between rivet head
and facing surface. Special tool
If depression is found to have reached service limit at (A): 09922M46010
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.)
1
“a”
(A)
IGJC0A531018-01
IDL70A540120-01
Clutch Cover b) Pry out clutch release shaft No.2 bushing (1)
Check clutch cover as follows. using pliers.
1) Check diaphragm spring (1) for abnormal wear or
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.
1) Press-fit a new No.1 bushing (1) using special tool

and hammer, and then apply grease to bushing
inside.
1 “A”: Grease 99000–25480 (ECSTAR Grease A)
Special tool
(A): 09943M88211
(B): 09923M46030
IDL70A540121-02
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 1, “A” (B) (A)
No.1 bushing (2).
IDL70A540124-01
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.
Special tool
(A): 09922M46010
4) Apply grease to release shaft seal (2) lip, and then
2 1 install it with special tool facing its lip downward
(inside) until it is flush with case surface.
IDL70A540122-01 “A”: Grease 99000–25480 (ECSTAR Grease A)
b) Connect special tools to tap (1) and pull out No.1 Special tool
bushing. (B): 09925M98221
Special tool 5) Caulk seal at [A] using caulking tool and hammer.
(B): 09923M46020
(C): 09930M30104
1 (B) (C) (C)
IDL70A540123-01
Installation
Reference: “Clutch Release System Component
Inspection”
8) Set release arm (1) to release shaft (2) aligning

punch mark (4) of release arm with punch mark (3)
of release shaft. Then tighten release arm bolt to
specified torque.
Tightening torque
Release arm bolt (a): 23 N·m (2.3 kgf-m, 17.0 lbf-
ft)
(a)
[A]
I9P60A531021-02
6) Clean the following parts.

• Arm part of release shaft (1).
• Inner circumference of release bearing (2). IGSD0A541045-01
• Release bearing sliding part of transaxle right

case (3). Clutch Release System Component Inspection
AENNTA0E5406041 (08(03)
7) Apply grease to the following parts and then set Reference: “Clutch Release System Component
release bearing. Removal and Installation”
NOTE Clutch Release Bearing

When replacing release bearing with new Check release bearing (1) for smooth rotation. If
one, it is not necessary to apply grease to abnormality is found, replace it.
release bearing.
NOTICE
• Arm part of release shaft. If the release bearing is washed, the grease
• Inner circumference of release bearing. contained within the release bearing may
• Release bearing sliding part of transaxle right wash away, causing the bearing to seize up.
case. Do not wash the release bearing.
1
“A”
3
I7V20A531009-01
Clutch Release Shaft

Check clutch release shaft and its pin for deflection or
2, “A”
damage.
ILSA0P540016-01
If abnormality is found, replace it.
I3RM0A530021-01
Specifications
AENNTA0E5407001 (09(t)
NOTE
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Oil level / filler plug 21 2.1 15.5 (T5D001) / (T5D003)
Oil drain plug 21 2.1 15.5 (T5D002)
Shift selector nut 13 1.3 9.5 (T5D004)
Shift selector knob 6.0 0.61 4.50 (T5D005)
Auto gear shift actuator unit bolt 23 2.3 17.0 (T5D006)
Auto gear shift actuator unit nut 23 2.3 17.0 (T5D007)
Actuator bracket bolt 23 2.3 17.0 (T5D008)
Oil reservoir tank lower screw 10 1.0 7.5 (T5D009)
Oil reservoir tank upper screw 10 1.0 7.5 (T5D010)
Oil reservoir tank cap 2 0.2 1.5 (T5D011)
Auto gear shift electric motor screw 6 0.6 4.5 (T5D012)
TCM screw 6 0.6 4.5 (T5D013)
Gear shift and select shaft assembly bolt 23 2.3 17.0 (T5D014)
Clutch speed sensor bolt 10 1.0 7.5 (T5D015)
VSS bolt 10 1.0 7.5 (T5D016)
Ground cable bolt 25 2.5 18.5 (T5D017)
Reverse gear shift lever bolt 10 1.0 7.5 (T5D018)
Transaxle case bolt 23 2.3 17.0 (T5D019)
Reverse gear shaft bolt 23 2.3 17.0 (T5D020)
Bearing stopper plate bolt 10 1.0 7.5 (T5D021)
Final gear bolt 100 10.2 74.0 (T5D022)
Clutch cover bolt* 5.0 Nm → 23 Nm (0.51 kgf-m → 2.3 kgf- (T5D023)
m, 4.0 lbf-ft → 17.0 lbf-ft)
Clutch cover bolt 23 2.3 17.0 (T5D024)
Release arm bolt 23 2.3 17.0 (T5D025)
Reference:
“Shift Selector Components”
“Gear Shift and Select Shaft Assembly Components”
“Auto Gear Shift Unit Components”
“Auto Gear Shift Components”
“Gear Shift Shaft Components”

AENNTA0E5408001 (11(m)
Grease SUZUKI Super Grease I P/No.: 99000–25210 (M5D010)
ECSTAR Grease A P/No.: 99000–25480 (M5D004) / (M5D005) /
(M5D009) / (M5D011) /
(M5D012) / (M5D013) /
(M5D014)
Oil Auto gear shift actuator oil (550 ML) P/No.: 99000–24121– (M5D006)
135
Sealant SUZUKI Bond No.1217G P/No.: 99000–31260 (M5D001) / (M5D002) /
(M5D003) / (M5D007) /
(M5D008)
NOTE
“Auto Gear Shift Components”
“Input Shaft Components”
“Countershaft Components”
Special Tool
AENNTA0E5408002 (11(s)
09900M20607 09900M20701
Dial gauge Magnetic stand
(L5D048) (L5D049)
09912M34510 09913M50121
Case separator Oil seal remover
(L5D021) (L5D002) / (L5D030)
09913M70123 09913M75510
(L5D054) / (L5D055) (L5D052)
09913M75821 09913M80113
Bearing installer attachment Bearing installer
(L5D045) / (L5D046) (L5D032) / (L5D034) /
(L5D037) / (L5D039) /
(L5D044)
09913M84510 09913M85210
(L5D035) / (L5D036) (L5D028) / (L5D033)
09921M05520 09921M26010
Actuator stand Bearing outer race remover
collar
(L5D008) / (L5D011) (L5D027)
09922M28111 09922M36310
Reverse gear shift lever Oil level gauge
positioner
(L5D022) (L5D001)
09922M46010 09922M85811
Clutch bushing remover Spring pin remover (4.5 mm)
(L5D060) / (L5D065) (L5D047) / (L5D051)
09923M36320 09923M46020
Clutch center guide (15 mm) Joint pipe
(L5D059) (L5D061)
09923M46030 09924M17811
Joint pipe Flywheel holder
(L5D064) (L5D057) / (L5D058)
09924M74510 09924M74590
Bearing and oil seal handle Input shaft oil seal installer
attachment
(L5D004) / (L5D024) (L5D023)
09925M15410 09925M16010
Oil seal installer Drive gear bearing installer
(L5D006) (L5D005)
09925M16510 09925M18011
Oil seal installer Transmission gear, bush
and bearing installer
(L5D029) (L5D041) / (L5D042) /
(L5D043)
09925M57610 09925M98221
Rubber boot installer Bearing installer
(L5D007) / (L5D009) / (L5D066)
(L5D010) / (L5D015) /
(L5D016)
09926M37610M003 09930M30104
Bearing remover attachment Sliding shaft
(L5D031) (L5D062)
09932M97690 09940M51710
Guide Bearing installer
(L5D012) / (L5D013) / (L5D040)
(L5D014)
09941M34513M004 09942M15511
Bearing installer adapter Sliding hammer
(L5D056) (L5D025)
09943M88211 09944M66010
Pinion bearing installer Oil seal installer
(L5D063) (L5D003)
09944M66060 09944M77030
Bearing installer Bearing / cover installer
support
(L5D038) (L5D053)
09944M96013 09951M17610
Bearing outer race remover Guid, Cluch Piston
Assembly
(L5D026) (L5D019) / (L5D020)
09951M17620 09952M06010
Installer, Lip Seal Dial gauge plate No.1
(L5D017) / (L5D018) (L5D050)
Section 6
Steering
CONTENTS
Precautions .................................................6-1 Steering Lower Shaft Removal and

Precautions............................................................. 6-1 Installation .......................................................6B-15
Precautions for Steering ....................................... 6-1 Steering Gear Case Assembly Components ....6B-17
Tie-Rod End Boot On-Vehicle Inspection .........6B-17
Steering General Diagnosis.................... 6A-1 Tie-Rod End Removal and Installation..............6B-18
Precautions...........................................................6A-1 Tie-Rod End Inspection.....................................6B-19
Precautions for Steering General Diagnosis ....... 6A-1 Steering Gear Case Assembly Removal and
Installation .......................................................6B-19
Diagnostic Information and Procedures............6A-1
Steering Rack Boot Inspection..........................6B-20
Steering Symptom Diagnosis.............................. 6A-1
Tie-Rod / Rack Boot Removal and Installation ..6B-20
Steering Wheel and Column................... 6B-1 Pinion Shaft Rotation Torque Inspection...........6B-21
Pinion Shaft Rotation Torque Adjustment .........6B-21
Precautions...........................................................6B-1
Precautions for Steering Wheel and Column ...... 6B-1 Specifications.....................................................6B-22
Tightening Torque Specifications......................6B-22
General Description .............................................6B-1
Steering Wheel and Column Construction .......... 6B-1 Special Tools and Equipment ...........................6B-23
Recommended Service Material .......................6B-23
Diagnostic Information and Procedures............6B-1
Special Tool ......................................................6B-23
Checking Steering Column for Accident
Damage ............................................................ 6B-1 Power Assisted Steering System........... 6C-1 6
Repair Instructions ..............................................6B-1
Precautions...........................................................6C-1
Steering Wheel and Column Components.......... 6B-1
Precautions for Diagnosing Trouble....................6C-1
Steering Wheel Removal and Installation ........... 6B-3
General Description .............................................6C-1
Contact Coil Assembly Removal and
P/S System Description ......................................6C-1
Installation......................................................... 6B-4
Description of EPS System Component
Centering of Contact Coil Assembly ................... 6B-6
Function ............................................................6C-1
Contact Coil Assembly Inspection....................... 6B-7
P/S Control Module Input / Output Diagram........6C-3
Steering Angle Sensor On-Vehicle Inspection .... 6B-7
OBD System Description ....................................6C-4
Steering Angle Sensor Removal and
Installation......................................................... 6B-7
(Non-ESP® Model) ...........................................6C-5
Steering Angle Sensor Inspection....................... 6B-8
Steering Column Removal and Installation ......... 6B-8 Schematic and Routing Diagram ........................6C-5
Steering Shaft Joint On-Vehicle Inspection ...... 6B-11 P/S System Diagram...........................................6C-5
Steering Column Inspection .............................. 6B-11 Component Location ...........................................6C-7
Steering Lower Shaft Inspection ....................... 6B-11 Power Steering Control System Component
Steering Lock Removal and Installation............ 6B-12 Location.............................................................6C-7
Steering Lock Disassembly and Reassembly Diagnostic Information and Procedures ............6C-9
(Ignition Switch Model).................................... 6B-13 P/S System Check ..............................................6C-9
Steering Lock Inspection (Ignition Switch P/S Warning Light Check ..................................6C-12
Model) ............................................................. 6B-14 DTC Check........................................................6C-12
Auto Steering Lock Inspection (Keyless Push DTC Clearance .................................................6C-13
Start Model) .................................................... 6B-14 DTC Table.........................................................6C-13
Ignition Switch Removal and Installation Fail-Safe Table..................................................6C-14
(Ignition Switch Model).................................... 6B-15 Scan Tool Data .................................................6C-16
Ignition Switch Inspection (Ignition Switch Visual Inspection ...............................................6C-19
Model) ............................................................. 6B-15 P/S System Symptom Diagnosis ......................6C-19
P/S Warning Light Does Not Come ON with DTC C116C / C116D ........................................6C-32
Ignition “ON” before Engine Starts ..................6C-20 DTC U0073 .......................................................6C-32
P/S Warning Light Remains ON Steady or DTC U0100 / U0121 / U0126 / U0140 / U0155
Blinks after Engine Starts................................6C-22 / U1082............................................................6C-32
DTC C1111 / C1113 / C1115 / C1116 ..............6C-22 P/S Control Module Power Supply and
DTC C1131 .......................................................6C-24 Ground Circuit Check......................................6C-33
DTC C1141 / C1142 / C1143 / C1145 / C1146 ..6C-25 Inspection of P/S Control Module and Its
DTC C1152 / C1154..........................................6C-27 Circuits ............................................................6C-34
DTC C1153 / C1155..........................................6C-28 Steering Wheel Play Check ..............................6C-36
DTC C1160 .......................................................6C-28 Steering Force Check .......................................6C-36
DTC C1161 / C1162 / C1166 ............................6C-29 Repair Instructions ............................................6C-36
DTC C1163 .......................................................6C-30 Sensor Calibration (Non-ESP® Model).............6C-36
DTC C116A.......................................................6C-31 Torque Sensor and Its Circuit Inspection ..........6C-37
DTC C116B.......................................................6C-31
Precautions: 6-1
Precautions
Steering
Precautions
Precautions for Steering
AENNTA0E6000001 (01(01)
General Precautions


Warning for Air Bag

Warning for Vehicle Equipped with Supplemental Restraint (Air Bag) System
Refer to “Warning for Vehicle Equipped with Supplemental Restraint (Air Bag) System” in Section 00.

Warning for P/S System

Refer to “Warning for P/S System” in Section 00.

6A-1 Steering General Diagnosis:
Steering General Diagnosis

Steering
Precautions
Precautions for Steering General Diagnosis
AENNTA0E6100001 (01(01)
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.

Steering Symptom Diagnosis
AENNTA0E6104001 (06(04)
Hard steering
• Insufficient tire pressure Adjust tire pressure.
• Binding tie-rod end ball joint Replace tie-rod end. (Tie-Rod End Removal and
• Binding suspension arm ball joint Replace suspension arm. (Suspension Arm Removal and
• Binding steering column Replace steering column assembly. (Steering Column
• Improper tooth contact between rack and pinion Check pinion shaft rotation torque or replace steering gear
case assembly.
• Pinion shaft rotation torque: (Pinion Shaft Rotation
Torque Inspection) in Section 6B
• Steering gear case assembly: (Steering Gear Case
• Malfunction of power steering system Check and correct. (P/S System Check) in Section 6C
• Disturbed front wheel alignment Check and adjust front wheel alignment. (Front Wheel
Too much play in steering

• Loose or rattle steering wheel Check steering wheel play. (Steering Wheel Play Check) in
Section 6C
• Worn wheel bearing(s) Replace wheel bearing(s). (Front Wheel Hub Assembly and
Steering Knuckle Removal and Installation): Front in
Section 3A
• Loose steering gear case bolt Tighten steering gear case bolt. (Steering Gear Case
• Worn joint of steering column Replace steering column assembly. (Steering Column
• Worn tie-rod end or tie-rod ball joint Replace tie-rod end or tie-rod.
• Tie-rod end: (Tie-Rod End Removal and Installation) in
Section 6B
• Tie-rod: (Tie-Rod / Rack Boot Removal and Installation)
in Section 6B
• Worn suspension arm joint Replace suspension arm. (Suspension Arm Removal and
Steering General Diagnosis: 6A-2
case assembly.
• Faulty steering gear case assembly Replace steering gear case assembly. (Steering Gear Case
Poor return ability

• Insufficient tire pressure Adjust tire pressure.
• Binding tie-rod end ball joint Replace tie-rod end. (Tie-Rod End Removal and
• Binding suspension arm joint Replace suspension arm. (Suspension Arm Removal and
• Binding steering column Replace steering column. (Steering Column Removal and
case assembly.
Steering noise (Rattle or chuckle)

• Broken or damaged wheel bearing(s) Replace wheel bearing(s). (Front Wheel Hub Assembly and
Section 3A
• Worn tie-rod end or tie-rod ball joint Replace tie-rod end or tie-rod.
Section 6B
• Tie-rod: (Tie-Rod / Rack Boot Removal and Installation)
in Section 6B
• Loose steering gear case bolt Tighten steering gear case bolt. (Steering Gear Case
case assembly.
• Faulty steering column Replace steering column assembly. (Steering Column
Wander or poor steering stability

• Mismatched tire or uneven tire pressure Replace or adjust tire pressure. (Wheel (with Tire) Removal
6A-3 Steering General Diagnosis:
• Loose suspension arm joint and tie-rod end Replace suspension arm or tie-rod end.
• Suspension arm: (Suspension Arm Removal and
Section 6B
• Faulty front strut assembly or mounting Replace front strut assembly or repair mounting. (Front
Strut Assembly Removal and Installation) in Section 2B
• Broken or sagging coil spring Replace coil spring. (Front Strut Assembly Disassembly and
• Loose stabilizer bar Tighten or replace stabilizer bar or bushing. (Front
Suspension Frame, Stabilizer Bar and Bushing Removal
case assembly.
Erratic steering when braking

• Uneven tire pressure Adjust tire pressure.
• Worn wheel bearing(s) Replace wheel bearing(s). (Front Wheel Hub Assembly and
Section 3A
• Brakes not working in unison Check and repair brake system. (Brake System Description)
in Section 4A
• Front brake disc stained with brake fluid Clean and check brake disc and caliper.
• Brake disc: (Front Brake Pad Removal and Installation) in
Section 4B
• Brake caliper: (Front Brake Caliper Removal and
• Warped brake disc Replace brake disc. (Front Brake Disc Removal and
• Badly worn brake pad Replace brake pad. (Front Brake Pad Removal and
• Broken or sagging coil spring Replace coil spring. (Front Strut Assembly Disassembly and
Steering lock does not operate (not locked or released)

• Faulty steering lock (ignition switch model) / auto
steering lock (keyless push start model) Check steering lock / auto steering lock.
• Steering lock: (Steering Lock Inspection (Ignition Switch
Model)) in Section 6B
Steering General Diagnosis: 6A-4
• Auto steering lock: (Auto Steering Lock Inspection

(Keyless Push Start Model)) in Section 6B
6B-1 Steering Wheel and Column:
Steering Wheel and Column

Steering
Precautions
Precautions for Steering Wheel and Column
AENNTA0E6200001 (01(01)
For service precautions, refer to “Precautions for Handling and Storage of Air Bag System Components”
• 4-channel air bag model: (Precautions for Handling and Storage of Air Bag System Components): 4-Channel in
Section 8B
• 8-channel air bag model: (Precautions for Handling and Storage of Air Bag System Components): 8-Channel in
Section 8B
General Description
Steering Wheel and Column Construction
AENNTA0E6201001 (03(01)
• The steering column is of a collapsible tube type. The column contracts in the event of a heavy frontal collision to
absorb impact energy and thus helps reduce injuries to the driver. The steering column also has the following
features:
– The steering column is provided with a telescopic and tilt adjustment mechanism. This mechanism allows step-
less adjustment of the whole steering column in up-and-down and back-and-forth directions.
– The steering column incorporates a steering lock to help prevent theft. On the ignition switch model, the ignition
switch is installed on the steering column together with the steering lock.
When servicing the steering column, it is important that only the specified fasteners 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 air bag (inflator) module of the supplemental restraint (air bag) system installed at
the center. During service operations on the steering wheel, the air bag (inflator) module should be handled
carefully while observing all instructions in “Precautions for Air Bag System Service”: 4-Channel in Section 8B (4-
channel air bag model) or “Precautions for Air Bag System Service”: 8-Channel in Section 8B (8-channel air bag
model) to prevent accidental deployment.
• Two types of steering column are provided: tilt and telescopic steering type and tilt steering type.

Checking Steering Column for Accident Damage
AENNTA0E6204001 (06(01)
Refer to “Steering Column Inspection”.
Repair Instructions
Steering Wheel and Column Components
AENNTA0E6206001 (12(01)
Steering Wheel and Column: 6B-2
[B]
19
3
6 7
[A]
13
12 18
11 (b)
10 (b)
14
9 (c)
[D]
8 (c)
16
15
19
[C]
20
17 (a)
1
IMTA0A620001-02
[A]: Keyless push start model 7. Steering lower shaft 17. Steering shaft nut
[B]: Ignition switch model 8. Steering column nut 18. Steering lock bolt
: For tightening order, refer to “Steering : For tightening and loosening procedures of
Column Removal and Installation”. steering lock bolt, refer to “Steering Lock
[C]: Auto-On headlight model 9. Steering column lower bolt 19. Steering angle sensor
: For tightening order, refer to “Steering : For installation, refer to “Steering Angle
Column Removal and Installation”. Sensor Removal and Installation”.
[D]: Non-auto-on headlight model 10. Steering column joint bolt 20. Lighting and turn signal switch incorporating
: For tightening order, refer to “Steering steering angle sensor
Lower Shaft Removal and Installation”.
1. Driver air bag (inflator) module 11. Steering lower shaft joint bolt : 33 Nm (3.4 kgf-m, 24.5 lbf-ft)
: For tightening order, refer to “Steering
Lower Shaft Removal and Installation”.
2. Steering wheel 12. Ignition switch : 35 Nm (3.6 kgf-m, 26.0 lbf-ft)
3. Steering column upper cover 13. Steering lock : 14 Nm (1.4 kgf-m, 10.5 lbf-ft)
4. Steering column lower cover 14. Ignition switch cylinder : Do not reuse.
5. Contact coil assembly 15. Steering joint cover
: Center contact coil cable
assembly.(Centering of Contact Coil
Assembly)
6. Steering column 16. Auto steering lock
Steering Wheel Removal and Installation 5) Remove steering shaft nut and then make alignment
AENNTA0E6206002 (08(01) marks (1) across steering wheel and shaft for correct
reinstallation.
Reference: “Steering Wheel and Column Components”
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
impaired if the steering column assembly I4RS0A620005-01
receives an excessively large force. 6) Remove steering wheel using special tool.
Be careful not to strongly impact the
Special tool
steering column assembly when removing
(A): 09944M36011
and installing steering wheel.
Removal
1) Park vehicle on a level surface, apply parking brake,
set steering wheel in straight ahead position.
3) Remove driver air bag (inflator) module from (A)
steering wheel.
• 4-channel air bag model: (Driver Air Bag (Inflator)
IGSD0A620002-01
Module Removal and Installation): 4-Channel in
Section 8B Installation
Module Removal and Installation): 8-Channel in NOTICE
Section 8B If the operations in Step 1) – 3) are omitted or
4) Disconnect steering switch connector (if equipped). not performed as instructed, the contact coil
assembly will break when the steering wheel
is turned.
Perform Step 1) – 3) exactly as instructed.
NOTICE
1) Check that vehicle’s front wheels are at straight
The coil in the contact coil assembly will
ahead position.
break if the contact coil is turned too much.
2) If contact coil is turned after removing steering Do not turn the contact coil more than about
wheel, center contact coil assembly. (Centering of two and a half turns in either direction from
Contact Coil Assembly) the neutral position.
3) Install steering wheel to steering shaft with 2 grooves
(1) in contact coil assembly fitted on 2 lugs (2) on Removal
back side of steering wheel, while aligning marks (3) 1) Remove steering wheel from steering column.
on steering wheel and steering shaft each other. (Steering Wheel Removal and Installation)
4) Tighten steering shaft nut (4) to specified torque. 2) Remove standard screw (1), and then detach
Tightening torque steering column lower cover (2).
Steering shaft nut (a): 33 N·m (3.4 kgf-m, 24.5 3) Remove tapping screws (3), and then detach
lbf-ft) steering column upper cover (4).
1 4
3
4, (a)
1
3
2 I9P60A620004-02
4) Disconnect contact coil assembly connector (1) as

follows.
a) Release locking slider (2) by sliding it in arrow
IGSD0A620003-01
direction “1”.
5) Connect steering switch connector (if equipped). b) After unlocking, disconnect contact coil
assembly connector by pulling it in arrow
6) Install driver air bag (inflator) module to steering
direction “2”.
wheel.
Without steering switch
Section 8B 3

Section 8B
7) Enable air bag system. “1”
2
• 4-channel air bag model: (Enabling Air Bag
System): 4-Channel in Section 8B “2” 1

8) Calibrate steering angle sensor, if steering wheel is
replaced.
IFKA0P620009-01
• ESP® model: (Sensor Calibration) in Section 4F
3: Contact coil assembly
• Non-ESP® model: (Sensor Calibration (Non-
ESP® Model)) in Section 6C
Contact Coil Assembly Removal and

Installation
AENNTA0E6206003 (08(01)
Reference: “Steering Wheel and Column Components”
With steering switch without cruise control Reference: “Centering of Contact Coil Assembly”
system 1) Check that vehicle’s front wheels are in straight
ahead position.
2) Install steering angle sensor (if equipped) to contact
coil assembly. (Steering Angle Sensor Removal and
3 Installation) in Section 4F
3) Install contact coil assembly (1) to lighting and turn
signal switch.
“2” NOTE
1
New contact coil assembly is supplied with
“1” contact coil set and held at its center position
2 with a folding type lock pin (2).
IFKA0P620010-01
After installing contact coil assembly to
steering column, fold handle part (3) in arrow
direction.
With cruise control system

1
2
“2” 1
3
“1”
IKRA0A620003-01
4) Connect contact coil assembly connector (1) and

horn connector (2) to contact coil assembly (3)
2 securely. Check that contact coil assembly connector
IHSB0A620001-01
is locked.
5) Connect steering angle sensor connector (4) to
steering angle sensor (5) (non-auto-on headlight
5) Disconnect horn connector (1) and steering angle model).
sensor connector (2) (if equipped). Without steering switch
6) Release claws (3) and remove contact coil assembly
3 5
(4).
1
4 2 4
IGSB0A620004-01
2
1
IFKA0P620011-01
7) Remove steering angle sensor (if equipped) from

contact coil assembly. (Steering Angle Sensor
Installation
Reference: “Contact Coil Assembly Inspection”
With steering switch without cruise control 8) Install steering wheel to steering column. (Steering
system Wheel Removal and Installation)
Centering of Contact Coil Assembly

AENNTA0E6206004 (08(03)
3 Reference: “Contact Coil Assembly Removal and
Installation”
1) Remove steering wheel. (Steering Wheel Removal
and Installation)
2 2) Turn contact coil counterclockwise slowly with a light
force till contact coil will not turn any further.
1
NOTE
Contact coil can turn about 5 turns at
maximum, that is, if it is at the center
IGSB0A620005-01
position, it can turn about two and a half
turns both clockwise and counterclockwise.
With cruise control system
IDL10A620002-01
3) From the position of Step 3), turn contact coil

1 assembly clockwise to place connector at top
IHSB0A620002-01
position within one rotation.
6) Install steering column upper cover (4) with tapping 4) Turn rotation part (2) two turns clockwise to place
screws (3). connector (1) at top position. Check that triangle
7) Install steering column lower cover (2) with standard mark (4) on rotation part is aligned with that on
screw (1). stationary part (3) and flat cable (6) is visible in hole
(5) as shown in figure.
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
3
1
I9P60A620004-02
Steering angle specification

6 Vehicle condition Steering angle
Front wheels in straight ahead
5
0 ± 3°
position
1 Rotate steering wheel once
360 ± 3°
clockwise
-360 ± 3°
counterclockwise
4 I6JB01460032-01
Steering Angle Sensor Removal and Installation

AENNTA0E6206007 (08(01)
3
Auto-On Headlight Model
IDL10A620003-01
Steering angle sensor is incorporated in lighting and turn
signal switch. Refer to (Lighting and Turn Signal Switch
Contact Coil Assembly Inspection Removal and Installation) in Section 9B.
AENNTA0E6206005 (08(03)
Refer to “Contact Coil and Its Circuit Check”.
• 4-channel air bag model: (Contact Coil and Its Circuit Non-Auto-On Headlight Model
Check): 4-Channel in Section 8B NOTE
• 8-channel air bag model: (Contact Coil and Its Circuit
If you rotate the rotor of the steering angle
Check): 8-Channel in Section 8B
sensor with the sensor removed, DTC may be
set even though the steering angle sensor
Steering Angle Sensor On-Vehicle Inspection status is normal.
AENNTA0E6206006 (08(03)
ESP® Model Do not rotate the rotor when removing and
Refer to “Steering Angle Sensor On-Vehicle Inspection” installing the steering angle sensor.
in Section 4F.
Removal
Non-ESP® Model 1) Remove steering wheel. (Steering Wheel Removal
and Installation)
SDT-II Connection and Disconnection” in Section 2) Remove contact coil assembly. (Contact Coil
0A. Assembly Removal and Installation)
2) Calibrate steering angle sensor. (Sensor Calibration 3) Remove steering angle sensor (1) from contact coil
(Non-ESP® Model)) in Section 6C assembly (2) while opening fitting engagement
hooks (3) of contact coil assembly.
scan tool. Refer to Operator’s Manual of SUZUKI
scan tool for further details.
4) Check “Steering Angle Sensor” under “Data List” of
SUZUKI scan tool in the following steering wheel
conditions.
• Front wheels are in straight ahead position.
• Rotate steering wheel once clockwise from
• Rotate steering wheel once counterclockwise
from straight ahead position.
Replace steering angle sensor if check result is not
as specified.
• Check connector terminals for bend, corrosion or rust.

Replace steering angle sensor (1) (non-auto-on
1 headlight model) or lighting and turn signal switch (2)
(auto-on headlight model) if defective.
Non-auto-on headlight model
3
3 1
3 2
IGRA0A620002-01
Installation
• Install steering angle sensor to contact coil after IFRA0P460022-01
performing centering of contact coil assembly.
(Centering of Contact Coil Assembly)
Auto-on headlight model
• Do not rotate rotor of removed steering angle sensor
(1) until steering angle sensor is reinstalled to contact
coil (2).
NOTE
A new steering angle sensor is secured by a
lock pin. After installing new steering angle
sensor to contact coil, remove the lock pin
from the steering angle sensor.
2
• Fit wide groove (3) to wide projection (4) and narrow IKRA0A620004-01
groove (5) to narrow projection (6).
4
Steering Column Removal and Installation
1 AENNTA0E6206009 (08(01)
2 3 Reference: “Steering Wheel and Column Components”
NOTICE
The steering column assembly can be easily
damaged during and after removal.
To avoid damaging the steering column
assembly, take the following precautions
when removing it and when setting it down
after removal:
5
6 • Do not release tilt lever with steering
IGRA0A620003-01 column nuts loosened or steering column
• Calibrate steering angle sensor, if steering angle removed from vehicle. Doing so may
sensor is replaced. increase operating force for tilt motion.
– ESP® model: (Sensor Calibration) in Section 4F • The impact energy absorbing function of
– Non-ESP® model: (Sensor Calibration (Non-ESP® the steering column assembly may be
Model)) in Section 6C impaired if the steering column assembly
receives an excessively large force.
Be careful not to strongly impact the
Steering Angle Sensor Inspection steering column assembly when removing
AENNTA0E6206008 (08(03)
• Check sensor for dents, crack or deformation. and installing it.
• Check sensor connectors (sensor side and harness • Never drop the steering column assembly
side) and sensor connector lock mechanism for on its end. This could collapse the steering
damage. shaft or loosen capsules that maintain the
design length of the column.
• Do not lean the steering column assembly Ignition switch model

against something. This could cause it to
bend or deform.
• Do not loosen the steering column nuts
when the steering lower shaft is still
installed. This could cause damage to the 2
shaft joint bearing.
Removal 4 3
1) Remove contact coil assembly. (Contact Coil

2) For ignition switch model, remove immobilizer 5 5
control module from steering lock. (Immobilizer
Control Module Removal and Installation): Ignition
Switch Model in Section 10C 2
3) Remove the following switches.

• Lighting and turn signal switch: (Lighting and Turn 6
Signal Switch Removal and Installation) in Section
9B
• Wiper and washer switch: (Wiper and Washer IFRA0A620017-01
Switch Removal and Installation) in Section 9D
4) Remove steering column hole cover. (Instrument Keyless push start model
5) Remove steering lower shaft. (Steering Lower Shaft
6) Disconnect P/S control module connectors (1), and
then detach their harness clamps.
2
5 5
6
1
IFRA0A620003-01
7) For keyless push start model, disconnect auto IFRA0A620018-01
steering lock connector (1). 11) Remove steering column.

8) For ignition switch model, disconnect both key
reminder switch connector (3) and ignition switch Installation
connector (4). Reference: “Steering Column Inspection”
9) Detach steering column harness clamps (2). NOTICE
10) Remove steering column nuts (5) and steering
Tightening the fasteners in the wrong order
column lower bolt (6).
may cause damage to the steering shaft joint
of steering column.
Tighten the steering column nuts in the order
given before installing the steering lower
shaft.
1) Check that vehicle’s front wheels are in straight

ahead position.
2) Install steering column. Keyless push start model

3) Tighten steering column lower bolt (1) to specified
torque.
4) Install steering column nuts (2) to specified torque.
Tightening torque
Steering column lower bolt (a): 14 N·m (1.4 kgf- 6
m, 10.5 lbf-ft)
Steering column nut (b): 14 N·m (1.4 kgf-m, 10.5
lbf-ft)
3
5) Check that telescopic and tilt functions operate
smoothly when the lever is released, and the 2, (b) 2, (b)
functions are securely fixed when lever is locked.
6) For keyless push start model, connect auto steering
lock connector (3). 6
7) For ignition switch model, connect both key reminder

switch connector (4) and ignition switch connector 1, (a)
(5).
8) Attach steering column harness clamps (6) in place.
Ignition switch model
IFRA0A620020-01
9) Connect P/S control module connectors (1).
5 4
2, (b) 2, (b)
6 1
IFRA0A620003-01
1, (a) 10) Install steering lower shaft. (Steering Lower Shaft

11) Install the following switches.
IFRA0A620019-01 • Lighting and turn signal switch: (Lighting and Turn
Signal Switch Removal and Installation) in Section
9B
• Wiper and washer switch: (Wiper and Washer
Switch Removal and Installation) in Section 9D
12) For ignition switch model, install immobilizer control
module to steering lock. (Immobilizer Control Module
Removal and Installation): Ignition Switch Model in
Section 10C
13) Install contact coil assembly. (Contact Coil Assembly
14) Install steering column hole cover. (Instrument Panel
15) Enable air bag system.
16) Calibrate steering angle sensor, if steering column is

replaced.
• ESP® model: (Sensor Calibration) in Section 4F
• Non-ESP® model: (Sensor Calibration (Non-
[a]
ESP® Model)) in Section 6C
[b]
Steering Shaft Joint On-Vehicle Inspection
AENNTA0E6206010 (08(03)
Check steering shaft joint for wear, breakage and any
other damage. Replace steering column assembly with
new one if defective. IFRA0A620005-01
• Check that distances “a”, “b” and “c” shown in figure

are as specified.
Power steering column length (tilt type)
“a”: 462.0 ± 1.5 mm (18.19 ± 0.059 in.)
“b”: 244.0 ± 1.5 mm (9.606 ± 0.059 in.)
“c”: 113.4 ± 1.3 mm (4.465 ± 0.051 in.)
Power steering column length (tilt and telescopic
type)
“a”: 480.0 mm (18.90 in.) (fully extended) / 444.0
mm (17.48 in.) (fully retracted)
“b”: 244.0 ± 1.5 mm (9.606 ± 0.059 in.)
“c”: 113.4 ± 1.3 mm (4.465 ± 0.051 in.)
I9P60A620041-01
“a”
Steering Column Inspection

AENNTA0E6206011 (08(03)
Reference: “Steering Column Removal and Installation”
NOTE
Steering column assembly should be
checked if vehicle was involved in an
accident and steering column assembly was
exposed to impact or air bag 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.
“b”
IFRA0A620004-01 “c”
• Check steering column assembly for looseness in

arrow directions [a] and [b] in figure with tilt lever
locked. IFRA0A620006-01
Steering Lower Shaft Inspection

AENNTA0E6206012 (08(03)
Reference: “Steering Column Removal and Installation”
• Adjust distance “a” between yoke centers of steering
lower shaft bearing to 268.4 mm (10.57 in.).
• Then check that steering lower shaft retracts by 25

mm (0.98 in.) and extends by 5 mm (0.20 in.) from [A] [B]
distance “a”.
4
1 1
[a] 3
[b]
1 2
1
IFRA0A620007-01
“a”
IAP70A620006-01 [A]: Ignition switch model [B]: Keyless push start model
[a]: Retracts by 25 mm (0.98 in.) 1. Yoke

[b]: Extends by 5 mm (0.20 in.) Installation
Reference: “Steering Lock Inspection (Ignition Switch
• Check steering lower shaft for smooth rotation. Model)”
Reference: “Auto Steering Lock Inspection (Keyless
Steering Lock Removal and Installation Push Start Model)”
AENNTA0E6206013 (08(01) 1) For ignition switch model: Align oblong hole (2) in
Removal steering shaft (3) with center of hole (1) in steering
column.
! WARNING
Turn ignition key to “LOCK” position and pull it out,
Steering lock is made of magnesium. and then align lug of steering lock with hole in
Drilling, cutting or filing the steering lock steering shaft.
may spark to ignite magnesium powder,
causing a fire or burn.
Do not perform drilling, cutting or filing
magnesium powder on the steering lock.
3
NOTICE
Failure to take the following precautions 1
when removing or installing the steering lock
can cause failure of the steering lock.
2
• 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 IFRA0A620008-01
other foreign materials. 2) For ignition switch model: Install steering lock to
steering shaft with key cylinder (1) toward steering
1) Remove steering column (1). (Steering Column wheel.
Removal and Installation) For keyless push start model: Install auto steering
2) Hold steering column using vise. lock with the column cover mounting screw hole (2)
3) Loosen steering lock bolt(s) (2) using chisel, and toward P/S motor side.
then remove auto steering lock (3) or steering lock
(4) from steering column.
7) For ignition switch model: If ignition switch cylinder

has been replaced, register ignition key transponder
[A]
1 code in BCM after completing installation. (Ignition
Key / Remote Controller Registration) in Section 10B
[a] 8) Check steering column and torque sensor after
installation. If faulty condition is found, replace
steering column.
• Steering column: (Steering Column Inspection)
• Torque sensor: (Torque Sensor and Its Circuit
[B]
Steering Lock Disassembly and Reassembly
(Ignition Switch Model)
AENNTA0E6206014 (08(02)
[b]
Reference: “Steering Lock Removal and Installation”
NOTE
Ignition switch and ignition switch cylinder
can be replaced without removing steering
2
lock.
IFRA0A620009-01
When removing steering lock, refer to
“Steering Lock Removal and Installation”.
[A]: Ignition switch model [a]: Steering wheel side
[B]: Keyless push start model [b]: P/S motor side
Disassembly
3) Tighten new steering lock bolts (1) until head of each 1) Remove ignition switch (1). (Ignition Switch Removal
bolt is broken off. and Installation (Ignition Switch Model))
2) Turn ignition key to “ACC”, and then push lock button
1 (4) on ignition switch cylinder using a rod (2) of about
2 mm (0.08 in) in diameter inserted through hole (3).
3) Pull out ignition switch cylinder (5) from steering lock
(6).
1
IFRA0A620010-01
6
and Installation)
5) For keyless push start model, register auto steering
lock unit as follows.
a) Check that battery voltage is 12 V or more. 2
b) Turn off all electrical loads.

c) Set ignition “ACC” and keep it in that position for 3
5 seconds or more.
NOTICE
If the above steps are not followed, the
registration process will not be completed
properly, making it impossible for the auto 4
steering unit to be unlocked. This may 5
require another replacement of the auto I9P60A620032-02
steering unit.
Be sure to follow the above steps when Reassembly
registering the auto steering unit. Reverse removal procedure noting the following points.
• Turn ignition key to “ACC”, and then insert ignition
6) Set ignition to “ACC” or “ON” and check that steering
switch cylinder into steering lock securely.
shaft rotates smoothly. Then set ignition to “LOCK”
(“OFF”) (and pull out key for ignition switch model)
and check that steering wheel is locked.
• If ignition switch cylinder has been replaced, register Auto Steering Lock Inspection (Keyless Push
ignition key transponder code in BCM after completing Start Model)
installation. (Ignition Key / Remote Controller AENNTA0E6206016 (08(03)
Registration) in Section 10B 1) Remove steering column lower cover and steering
column hole cover.
Steering Lock Inspection (Ignition Switch • Steering column lower cover: (Steering Wheel and
Model) Column Components)
AENNTA0E6206015 (08(03)
• Steering column hole cover: (Instrument Panel
Key Reminder Switch Inspection
1) Disconnect key reminder switch connector (1) from
2) Measure voltage between terminals “1” – “5” and
steering lock (2).
ground respectively under conditions described in
2) Check continuity between terminals of key reminder the table below. If check result is not as specified,
switch connector. check auto steering lock wire harness for open or
If check result is not as specified, replace steering short and if auto steering lock wire harness is in
lock. good condition, replace auto steering lock (1).
(Steering Lock Removal and Installation)
2
Auto steering lock unit terminal voltage
Normal
Terminal Condition
voltage
1
1 10 – 14 V Ignition is in any mode.
• Any door opened or closed
10 – 14 V with ignition “OFF”*
2
• Ignition “OFF” → “ACC”*
2 1 0–1V Other than above condition
• Any door opened or closed
10 – 14 V with ignition “OFF”*
I9P60A620033-05 3
• Ignition “OFF” → “ACC”*
Key reminder switch continuity 0–1V Other than above condition
Refer to • Any door opened or closed
[A] “G146-4” with ignition “OFF”*
1 2 (Auto
[B] • Ignition “OFF” → “ACC”*
steering
[C]
4 lock LIN
[D]
communica
I9P60A620034-02
tion signal)
[A]: Terminal [C]: Key inserted bellow.
[B]: Condition [D]: Key pulled out
0–1V Other than above condition

Steering Lock Inspection 5 0–1V Ignition is in any mode.
1) Insert ignition key (1).
2) Check lock shaft (2) for operation as follows. “G146-4” (Auto steering lock LIN communication
a) Lock shaft moves in arrow direction “1”, when signal)
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.
2
“2” “1”
1
IMTA0A620009-01
1. Auto steering lock LIN communication signal
IAP70A620007-01
NOTE Ignition Switch Inspection (Ignition Switch

*: Voltage can be checked only for a short Model)
AENNTA0E6206018 (08(03)
time while locking or releasing auto steering Reference: “Ignition Switch Removal and Installation
lock. (Ignition Switch Model)”
Check for continuity between terminals at each switch
position. If check result is not as specified, replace
1
ignition switch.
3 2 1
6 5 4
[A]
[a] I9P60A620037-05
654321
Ignition switch continuity
IDL10A620014-01
[A]: Connector “G146” (View: [a]) Terminal

1 2 3 4 5 6
Position
LOCK
Ignition Switch Removal and Installation ACC

(Ignition Switch Model)
AENNTA0E6206017 (08(01) ON
START
Removal
I9P60A620038-01
1) Remove steering column upper cover and lower
cover. (Contact Coil Assembly Removal and
Installation) Steering Lower Shaft Removal and Installation
AENNTA0E6206019 (08(01)
2) Check that ignition key is removed. Reference: “Steering Wheel and Column Components”
3) Disconnect connector (1) from ignition switch (2).
NOTICE
4) Remove screws (4), and then remove ignition switch
from steering lock (3). If the steering wheel is turned with the
steering lower shaft removed, the neutral
3 setting of the contact coil may be disturbed.
2 If it is turned in either direction more than
4 2
about two and a half turns, the contact coil
will break.
3
Never turn the steering wheel with the
steering lower shaft removed.
1
Removal
1) Turn steering wheel so that vehicle’s front wheels
are at straight ahead position.
2) Set ignition “LOCK”. For ignition switch model,
I9P60A620036-06 remove key.
3) Remove steering joint cover. (Steering Wheel and
Installation Column Components)
Reference: “Ignition Switch Inspection (Ignition Switch
Model)” 4) Make matchmarks (1) on the following parts for
Reverse removal procedure. correct reinstallation.
• Steering lower shaft joint (2) and steering column
(3)
• Steering lower shaft joint and pinion shaft (4)
NOTE
Turn steering wheel a little for removal of 3
steering lower shaft joint bolt.
1
2
1
2
IMTA0A620004-01
2 3) Fit joint part of steering lower shaft (1) onto pinion

shaft (2) while aligning matchmarks (3).
1
NOTE
4
Turn steering wheel a little for installation of
IMTA0A620002-02 steering lower shaft joint bolt (pinion shaft
5) Remove steering column joint bolt (1) and steering side).
lower shaft joint bolt (2).
6) Remove steering lower shaft (3).
1
3
3
2 2
IMTA0A620003-01 IMTA0A620005-01
4) Tighten new steering lower shaft joint bolt (1) and

Installation new steering column joint bolt (2) in numerical order
(“1” to “2”) to specified torque.
NOTICE
Tightening torque
The steering lower shaft joint bolts are
Steering lower shaft joint bolt (a): 35 N·m (3.6
precoated with friction stabilizer. If the bolts
kgf-m, 26.0 lbf-ft)
are reused, they may work loose.
Steering column joint bolt (b): 35 N·m (3.6 kgf-
Never reuse the steering lower shaft joint
m, 26.0 lbf-ft)
bolts.
1) Check that vehicle’s front wheels are in straight 2, “2”, (b)
ahead position.
2) Fit joint part of steering lower shaft (1) into steering
column (2) while aligning matchmarks (3).
“b”
1, “1”, (a)
IMTA0A620006-01
5) Install steering joint cover. (Steering Wheel and

Column Components)
Steering Gear Case Assembly Components

AENNTA0E6206020 (12(01)
(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 : 85 Nm (8.7 kgf-m, 63.0 lbf-ft)
Tie-rod lock washer 8. Tie-rod end nut : 80 Nm (8.2 kgf-m, 59.0 lbf-ft)
2. : For removing and installing
procedure of tie-rod lock
washer, refer to “Tie-Rod /
Rack Boot Removal and
Installation”.
Tie-rod 9. Clip : 60 Nm (6.1 kgf-m, 44.5 lbf-ft)
3. : Apply grease 99000-25050
to tie-rod, referring to “Tie-
Rod / Rack Boot Removal and
Installation”.
4. Band 10. Steering gear cover : Do not reuse.
5. Boot 11. Steering rack damper screw lock nut
Tie-Rod End Boot On-Vehicle Inspection

AENNTA0E6206021 (08(03)
Check boot for crack and damage.
Replace tie-rod end, if defective.
(A)
I9P60A630016-01
4) To facilitate adjustment after installation, make mark

(1) of tie-rod end lock nut (2) position on tie-rod end
thread. Then, loosen lock nut and remove tie-rod
end (3) from tie-rod (4).
IFRA0A620012-01
Tie-Rod End Removal and Installation

AENNTA0E6206022 (08(01)
Reference: “Tie-Rod End Boot On-Vehicle Inspection”
Reference: “Steering Gear Case Assembly 2
Components”
Removal
1) Hoist vehicle, and then remove front wheel. (Wheel
2) Remove clip (2) and tie-rod end nut (1) from tie-rod 3
end. 4
1
IDAA0A630014-01
Installation
Reference: “Tie-Rod End Inspection”
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.
IFRA0A620013-01
3) Disconnect tie-rod end (1) from steering knuckle (2)

using special tool. 3
Special tool 1 4
(A): 09913M65210
IDAA0A630014-01
2) Connect tie-rod end to steering knuckle. Tighten tie-

rod end nut (1) to specified torque.
Tightening torque
Tie-rod end nut (a): 45 N·m (4.6 kgf-m, 33.5 lbf-
ft)
3) Install new clip (2).
Before starting the procedure below, set the

front wheels in straight ahead position and
then lock the steering wheel by changing
ignition mode to “OFF” or removing ignition
key at “LOCK” position.
Removal
1) Remove front suspension frame with steering gear
case assembly. (Front Suspension Frame, Stabilizer
Bar and Bushing Removal and Installation) in
Section 2B
2
2) Remove steering gear cover (1) after detaching its
claws (3) from gear case.
1, (a)
3) Remove steering gear case bolts (4), and then
remove steering gear case assembly (2) from front
suspension frame.
IFRA0A620014-01
4) Install front wheel. (Wheel (with Tire) Removal and 1

3 2
6) After checking that front wheel alignment is as
specified, tighten tie-rod end lock nut to specified
torque. 1
Tightening torque 2
Tie-rod end lock nut: 45 N·m (4.6 kgf-m, 33.5 lbf-
ft)
Tie-Rod End Inspection

AENNTA0E6206023 (08(03)
Reference: “Tie-Rod End Removal and Installation”
• Check tie-rod end ball joint for play.
• Check tie-rod ball joint for play. 4 4
IFRA0A620015-01
If result of either inspection is not OK, replace with
new one.
Installation
NOTICE
The steering gear case bolts are pre-coated
with friction stabilizer. If these bolts are
reused, they may work loose.
Never reuse the steering gear case bolts.
I9P60A630019-01 1) Mount steering gear case assembly (1) to front

suspension frame.
Steering Gear Case Assembly Removal and 2) Install new steering gear case bolts (2) to specified
Installation torques.
AENNTA0E6206024 (08(01)
Reference: “Steering Gear Case Assembly Tightening torque
Components” Steering gear case bolt (a): 80 N·m (8.2 kgf-m,
Reference: “Steering Shaft Joint On-Vehicle Inspection” 59.0 lbf-ft)
NOTICE 3) Aligning protrusion on new steering gear cover (4)
Failure to take proper precautions before with notch on steering gear case assembly at
starting the procedure below can result in specified position (3), install steering gear packing to
damage to the contact coil of the air bag steering gear case.
system.
NOTICE Removal
Once steering gear cover use, the packing 1) Remove steering gear case assembly. (Steering
part transforms. If this cover is reused, water Gear Case Assembly Removal and Installation)
may enter into gearbox. 2) Remove tie-rod end. (Tie-Rod End Removal and
Never reuse the steering gear cover. Installation)
3) Remove band (2) and rack boot clip (1).
4) Remove boot (3) from tie-rod.
4
2
1 3
IDAA0A630019-01
5) Unbend bent parts of tie-rod lock washer (1).

6) Hold steering rack end (4) using vise (2) with suitable
2, (a) 2, (a)
IJCA0A620016-01
spacers (3) as shown and remove tie-rod (5) from
steering rack (6).
4) Install front suspension frame with steering gear
case assembly. (Front Suspension Frame, Stabilizer
Bar and Bushing Removal and Installation) in 4 3
Section 2B
“b”
Steering Rack Boot Inspection
AENNTA0E6206025 (08(03) “a”
Check the steering rack boot for the following points.
Repair or replace steering rack boot if defective.
• Check steering rack boot (3) for deformation,
deterioration or crack.
• Check steering rack boot clip (1) and band (2) for
fitting.
5
2 6
1
IDL10A630030-01
“a”: 5 mm (0.20 in.) “b”: 10 mm (0.39 in.) or more
Installation
Reference: “Steering Rack Boot Inspection”
3
1) Install tie-rod (1) and new tie-rod lock washer (3) to
1 rack (2), and then tighten tie-rod to specified torque.
I9P60A630026-02
Tightening torque
Tie-rod (a): 85 N·m (8.7 kgf-m, 63.0 lbf-ft)
Tie-Rod / Rack Boot Removal and Installation
AENNTA0E6206026 (08(01)
Reference: “Steering Gear Case Assembly
Components”
5) Install tie-rod end. (Tie-Rod End Removal and

Installation)
6) Install steering gear case assembly. (Steering Gear
Case Assembly Removal and Installation)
Pinion Shaft Rotation Torque Inspection

AENNTA0E6206027 (08(03)
1) Remove steering gear case assembly. (Steering
1, (a)
Gear Case Assembly Removal and Installation)
2) Remove steering rack boots. (Tie-Rod / Rack Boot
3
2 Removal and Installation)
3) Check pinion shaft rotation torque with rack position
IDL10A630025-01
centered using special tool.
2) Bend lock washer (1) at 2 places as shown in figure. Check that rack as a whole moves smoothly.
If check result is not as specified, adjust pinion shaft
rotation torque.
Special tool
1 (A): 09944M16810
Rotation torque specification
1.01 – 1.71 Nm (0.10 – 0.17 kgf-m, 1.0 – 1.5 lbf-ft)
Rotation torque specification (with steering rack
boots) (Reference)
1.51 – 2.11 Nm (0.15 – 0.22kgf-m, 1.5 lbf-ft)
I9P60A630029-02
3) Apply grease to section “A” of tie-rod indicated in

figure. Position boot properly in grooves of steering
gear case and tie-rod.
(A)
Check that boot is free from twist and dent.
“A”: Grease 99000–25050 (SUZUKI Super
Grease E)
IHSE0A620011-01
Pinion Shaft Rotation Torque Adjustment

“A” AENNTA0E6206028 (08(03)
1) Remove steering gear case assembly. (Steering
IDAA0A630021-01 Gear Case Assembly Removal and Installation)
4) Fasten new band (1) using special tool, and install 2) Remove steering rack boots. (Tie-Rod / Rack Boot
rack boot clip (2). Removal and Installation)
Special tool 3) Set steering rack position in center of steering rack
(A): 09943M55010 stroke.
4) Loosen rack damper screw lock nut (1).
1
5) Loosen rack damper screw (2).
6) Apply sealant “A” to rack damper screw and tighten
rack damper screw as follows.
2
(A) “A”: Sealant 99000–31110 (SUZUKI Bond
No.1215)
a) Tighten rack damper screw to 10 Nm (1.0 kgf-m,
I9P60A630031-01 7.5 lbf-ft).
b) Turn rack damper screw back by 60°. Tightening torque

Rack damper screw lock nut (a): 60 N·m (6.1
Tightening torque
kgf-m, 44.5 lbf-ft)
Rack damper screw* (a): 10 Nm → –60° (1.0 kgf-
m → –60°, 7.5 lbf-ft → –60°)
1
3
2, (a)
2, “A”, (a) 2
IMTA0A620007-01
“A”
7) Check pinion shaft rotation torque and adjust it if

necessary by tightening or loosening rack damper
screw. (Pinion Shaft Rotation Torque Inspection)
8) Apply sealant “A” to mating surfaces of steering gear
case (3) and rack damper screw lock nut (2) and
thread portion of rack damper screw lock nut. IMTA0A620008-02
10) Recheck pinion shaft rotation torque is as specified.

(Pinion Shaft Rotation Torque Inspection)
No.1215)
11) Install steering rack boots. (Tie-Rod / Rack Boot
9) Hold rack damper screw (1) in that position and Removal and Installation)
tighten rack damper screw lock nut to specified 12) Install steering gear case assembly. (Steering Gear
torque. Case Assembly Removal and Installation)
Specifications
AENNTA0E6207001 (09(t)
NOTE
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Steering shaft nut 33 3.4 24.5 (T6B001)
Steering column lower bolt 14 1.4 10.5 (T6B002)
Steering column nut 14 1.4 10.5 (T6B003)
Steering lower shaft joint bolt 35 3.6 26.0 (T6B004)
Steering column joint bolt 35 3.6 26.0 (T6B005)
Tie-rod end nut 45 4.6 33.5 (T6B006)
Tie-rod end lock nut 45 4.6 33.5 (T6B007)
Steering gear case bolt 80 8.2 59.0 (T6B008)
Tie-rod 85 8.7 63.0 (T6B009)
Rack damper screw* 10 Nm → –60° (1.0 kgf-m → –60°, 7.5 lbf-ft (T6B010)
→ –60°)
Rack damper screw lock nut 60 6.1 44.5 (T6B011)
Reference:
“Steering Wheel and Column Components”
“Steering Gear Case Assembly Components”

AENNTA0E6208001 (11(m)
Grease SUZUKI Super Grease E P/No.: 99000–25050 (M6B001)
Sealant SUZUKI Bond No.1215 P/No.: 99000–31110 (M6B002) / (M6B003)
NOTE
“Steering Gear Case Assembly Components”
Special Tool
AENNTA0E6208002 (11(s)
09913M65210 09943M55010
Tie-rod end remover Boot clamp pliers
(L6B002) (L6B003)
09944M16810 09944M36011
Pinion torque checking Steering wheel remover
socket
(L6B004) (L6B001)
Power Assisted Steering System: 6C-1
Power Assisted Steering System

Steering
Precautions
AENNTA0E6300001 (01(01)
! WARNING
accident can occur.
• Perform the road test using 2 persons, a driver and a tester.
NOTE
• 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. (DTC Clearance)
General Description
P/S System Description
AENNTA0E6301001 (03(01)
Power steering system employs an electronic power steering (EPS) system that is of a column assist type.
EPS system consists of P/S control module incorporated in P/S motor, and torque sensor. All of them are included in
steering column assembly.
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”.
Description of EPS System Component Function

AENNTA0E6301002 (03(01)
EPS system components Function
Steering Torque sensor Using two circuits (i.e. main and sub circuits), torque sensor outputs
column voltages proportional to steering input torque and direction to P/S control
assembly module.
P/S control P/S motor P/S motor produces steering assist torques that correspond to electric
module / current from P/S control module.
motor Rotation Rotation angle sensor consists of an exciter coil and a pair of fixed detector
assembly angle sensor coils, and outputs signals proportional to motor rotation angle to P/S
control module.
P/S control • P/S control module controls P/S motor drive current by determining its
module 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.
ESP® control module (with ESP®) ESP® control module transmits “Yaw rate signal” to P/S control module
through CAN communication.
Steering angle sensor (non-auto-on Steering angle sensor transmits “Steering angle signal” to P/S control
headlight model) / lighting and turn module through CAN communication.
signal switch incorporating steering
angle sensor (auto-on headlight
model)
P/S warning light Refer to “OBD System Description” for operation of the P/S warning light.
6C-2 Power Assisted Steering System:
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 box, torsion bar connecting the input and output shafts, torque sensor and P/S motor.
Torque sensor
Torque sensor adopts a non-contact inductance sensing system, and consists of stationary sensor sleeve and sensing
coils on torque sensor shaft (input shaft), worm wheel shaft (output shaft) and amplifier which outputs signal from each
coil to P/S control module. The sensor sleeve is located under the sensing coils and provides slits at different pitch. On
the other hand, the worm wheel shaft (output shaft) provides vertical grooves under the sensor sleeve. The amplifier
consists of dual circuit, main circuit and sub circuit. This dual circuit enables the P/S control module to compute
steering assist torque corresponding to steering wheel handling force based on signal from main circuit while the
control module computes steering assist torque in fail-safe mode based on signal from sub circuit.
Torque sensing principle

1) When handling force is applied to steering wheel (torque sensor shaft) against worm wheel shaft (output shaft)
which is stationary with road friction, torsion occurs in torsion bar.
2) A phase deviation relative to the torsion angle is generated between worm wheel shaft (output shaft) and slit, and
the worm wheel shaft (output shaft) is magnetized accordingly. At this moment, inductance of two sensor coil
fluctuates inversely proportional to displacement between the worm wheel shaft (output shaft) and slit.
3) Variation of the inductance detected in the sensor coil is converted to voltage signal in the amplifier and outputted
to the P/S control module.
4) Main signal voltage and sub signal voltage of torque sensor output are 2.5 V with steering wheel at straight ahead
position (with no handling force applied). In this position, P/S control module judges steering handling torque is
zero. However, when steering wheel is rotated with handling force, P/S control module controls the steering based
on main signal from torque sensor which varies with the handling force. When main signal voltage of torque sensor
output 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.
[A]
V
3
7
5
6
2 1
2.5V 9
8
[B] [C] [D]
8 4
5
IEFA0A630018-01
[A]: Torque sensor output characteristics 2. Sub signal 7. Sensor coil

[B]: Left side steering 3. Torque sensor 8. Torsion bar
[C]: Steering wheel straight ahead position 4. Torque sensor shaft (input shaft) 9. Slit
(steering wheel handling torque 0)
[D]: Right side steering 5. Sensor sleeve
1. Main signal 6. Worm wheel shaft (output shaft)
P/S motor
When the steering wheel is turned to right or left, P/S Handling of steering when P/S system stops
control module feeds an alternating current to transistors The system has a fail-safe function, which works as
in the P/S control module appropriate to the necessary manual steering without power assist when engine is
torque based on the signals from the torque sensor and stopped or power steering system is malfunctioning.
rotation angle sensor. Receiving the alternating current, When steering wheel is rotated by hand under these
the six transistors are switched ON or OFF and feed the conditions, torsion bar (1) is twisted but steering assist is
alternating current to a three-phase stator coil (1) in P/S not available without supply of electricity. Therefore,
motor to create a current circuit. The current circuit steering torque sensor shaft (input shaft) (2) in steering
alternates the three-phase stator coil to plus and minus column bumps against manual stopper (4) in worm
phases, thus the inside rotor (permanent magnet) (2) is wheel shaft (output shaft) (3) and torque sensor shaft
rotated to assist steering. (input shaft) rotates worm wheel shaft (output shaft)
directly.
2
3
1
2
N
“a”
S
1
IFRA0B630012-01
3
3. Inverter 4
IDMAKPF60003-01
Rotation angle sensor “a”: Maximum torsional angle of torsion bar

Rotation angle sensor consists of an energized coil (1) to
generate a magnetic field and a pair of detector coils to P/S Control Module
generate a current for detecting motor rotation angle, P/S control module determines basic assist power based
and the rotor (2) is off-center positioned from the center on steering assist control and improves feeling of the
of the motor shaft (3). And, the rotation angle sensor steering by using steering return control and steering
calculates the motor rotation angle as follows. converging control. Further, the P/S control module
• Magnetic field generated by energized coil is controls motor current to harmonize target current with
modulated corresponding to rotation of rotor with P/S actual current in accordance with computing result of
motor. each control and maximum current limit control.
• Induced electromotive force in each of detector coil 1 And, the P/S control module communicates with ECM,
(4) and detector coil 2 (5) is fluctuated corresponding ESP® control module (with ESP®), steering angle sensor
to change of the magnetic field. (non-auto-on headlight model) / lighting and turn signal
switch incorporating steering angle sensor (auto-on
• Receiving the induced electromotive force from each
headlight model) and combination meter through CAN
detector coil, P/S control module calculates rotation
communication.
angle of the P/S motor.
1 4
2
(+)
(+)
(-)
(-)
5
3
(-) (+)
IFRA0B630013-01
P/S Control Module Input / Output Diagram

AENNTA0E6301003 (03(01)
P/S control module
Steering
Torque sensor assist control
Steering
Motor angular speed return control
(detected value)
Steering
converging control
Electric current of motor Target electric Motor electric
P/S motor
(measured value) current computation current control
Maximum
electric current
ECM CAN limit control
CAN ECM
ESP® control module CAN communication

CAN
(with ESP®) function
CAN Combination meter
Steering angle sensor Fail-safe control

(non-auto-on headlight model)
/ Lighting and turn signal
CAN
switch incorporating steering
angle sensor
IMTA0A630001-02
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
speed of the vehicle. The compensation current based on “steering angle signal”
Steering return control
transmitted from steering angle sensor is applied to assist 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.
• The P/S warning light turns on when the ignition is

OBD System Description “ON” (but the engine at stop) regardless of the
AENNTA0E6301004 (03(01) condition of the P/S control system. This is only to
The P/S control module has an on-board self-diagnostic check if the P/S warning light operates properly.
function which detects a malfunction in this system.
• When the engine is started, on-board diagnosis (self-
Have full understanding of “OBD System Description”
diagnosis) is performed and the P/S warning light
and each item in “Precautions for Diagnosing Trouble”,
turns off if no trouble is found.
before executing diagnosis according to “P/S System
Check”. • When the P/S control module detects a trouble, the P/
The P/S control module performs on-board diagnosis S warning light comes on to warn the driver of the
(self-diagnosis) on the system and operates the P/S trouble. At the same time, a DTC is stored in the
warning light (1) as follows. module.

[A]
1 (Non-ESP® Model)
AENNTA0E6301005 (03(01)
When the following conditions are met, steering angle
sensor calibration should be performed since the original
calibration data are deleted.
Condition requiring
Sensor to be calibrated
calibration
Steering angle sensor (non- • Steering angle sensor
auto-on headlight model) / (non-auto-on headlight
lighting and turn signal model) / lighting and
switch incorporating turn signal switch
[B] steering angle sensor incorporating steering
1
(auto-on headlight model) angle sensor (auto-on
headlight model) is
replaced.
• P/S control module
(steering column
assembly) is replaced.
• Steering wheel is
replaced.
• Adjustment of front
IMTA0A630003-02 wheel alignment.
Perform sensor calibration according to “Sensor
Calibration (Non-ESP® Model)”.

P/S System Diagram
AENNTA0E6302001 (10(01)
1
15
16
17 RED E10-1
6
7
BLK E10-2
E11-8 GRN
18
8
25
20 GRN G10-3 E11-6 YEL
19
5V
2
BRN 21
E11-7 RED
22 4
RED G10-5
23 3 3 9
WHT G10-6
BLK
5 E11-1 WHT
RED WHT
24 E11-5 BLK
12V
10
11
13
12
14
IMTA0A630002-02
1. P/S control module / motor assembly 10. Fail-safe relay 19. “MTR” fuse
2. CPU 11. P/S motor 20. To ignition power supply
3. CAN driver 12. Rotation angle sensor 21. Combination meter
4. 9 V regulator 13. Rotation angle sensor exciter circuit 22. P/S warning light
5. 3 V reference power supply 14. Rotation angle sensor signal receive circuit 23. Meter driver
6. Torque sensor 15. Relay box 24. To other control modules by CAN
7. Torque sensor (main) circuit 16. “P/S” fuse 25. “IG1 SIG2” fuse
8. Torque sensor (sub) circuit 17. To continuous power supply
9. Torque sensor amplifier 18. J/B
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”.
[A] E10 [A] E11

[A] G10
[a]
1 4 3 2 1
2 1 8 7 6 5 4 3 2 1
8 7 6 5
IMTA0A630011-01
[A]: P/S control module connector (View: [a]) 1. P/S control module
Component Location
Power Steering Control System Component Location
AENNTA0E6303001 (04(01)
[A] [B]
5
6 12 13
[A]
2
1
2
1
[B]
10 3
14
IMTA0A630004-03
[A]: Segment display type 5. BCM 11. ECM

[B]: Color dot display type 6. “MTR” fuse 12. Steering angle sensor
1. Combination meter 7. “IG1 SIG2” fuse 13. Lighting and turn signal switch incorporating
steering angle sensor
2. P/S warning light 8. P/S control module / motor assembly 14. ESP® control module (with ESP®)
3. “P/S” fuse 9. Steering column assembly (including P/S
control module / motor assembly and torque
sensor)
4. Relay box 10. Steering gear case assembly

P/S System Check
AENNTA0E6304001 (06(01)
! WARNING
accident can occur.
• Perform the road test using 2 persons, a driver and a tester.
NOTE
Refer to the following items for the details of each step.

1) Perform “Step 1: Customer Complaint Analysis”.
Yes Go to Step 2.
Step 2 DTC check, record and clearance

1) Check for DTC (including pending DTC). (Step 2: DTC Check, Record and Clearance)
Is there any DTC?
Yes Print DTC or write it down and clear it referring to “DTC Clearance”, and then go to Step 3.
No Go to Step 4.

1) Perform “Step 3 and 4: Visual Inspection”.

No Go to Step 5.

1) Perform “Step 3 and 4: Visual Inspection”.

No Go to Step 8.

1) Check trouble symptom. (Step 5: Trouble Symptom Confirmation)
Yes Go to Step 6.
No Go to Step 7.
Step 6 Rechecking and record of DTC

1) Recheck for DTC. (Step 6 and 7: Rechecking and Record of DTC)
Yes Go to Step 9.
No Go to Step 8.
Step 7 Rechecking and record of DTC

1) Recheck for DTC. (Step 6 and 7: Rechecking and Record of DTC)
Yes Go to Step 9.
No Go to Step 10.
Step 8 Steering symptom diagnosis and P/S system symptom diagnosis

1) Check and repair. (Step 8: Steering Symptom Diagnosis and P/S System Symptom Diagnosis)
• Steering symptom diagnosis: (Steering Symptom Diagnosis) in Section 6A
• P/S system symptom diagnosis: (P/S System Symptom Diagnosis)
Yes Go to Step 11.

No Check and repair defective part, and then go to Step 10.

1) Check and repair. (Step 9: Troubleshooting for DTC)
Yes Go to Step 11.

No Check and repair defective part, and then go to Step 11.

1) Check for intermittent problems. (Step 10: Intermittent Problems Check)

No Go to Step 11.


Yes Go to Step 6.
No End.
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.
IAP70A630004-01
Step 2: DTC Check, Record and Clearance Step 5: Trouble Symptom Confirmation
Check DTC (current and pending DTC) referring to “DTC Based on “Step 1: Customer Complaint Analysis” and
Check”. “Step 2: DTC Check, Record and Clearance”, check
If DTC is indicated, print or write down the DTC and then trouble symptoms. Also, check trouble symptoms by
clear the DTC referring to “DTC Clearance”. performing test drive and turning steering wheel fully to
right and left with vehicle stopped.
Step 3 and 4: Visual Inspection
Visually check P/S warning light for proper operation, Step 6 and 7: Rechecking and Record of DTC
connectors for proper condition and each part condition Refer to “DTC Check” for checking procedure.
referring to “Visual Inspection”.
Step 8: Steering Symptom Diagnosis and P/S

System Symptom Diagnosis [A]
1
Perform basic steering system check first. (Steering
Symptom Diagnosis) in Section 6A Near the end of flow,
check the parts of the system suspected as a possible
cause referring to “P/S System Symptom Diagnosis” 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.
Step 9: Troubleshooting for DTC

Perform applicable DTC troubleshooting and repair or [B]
1
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 and related circuit of DTC recorded in Step 2.
Step 11: Final Confirmation Test

Check that the problem symptom has disappeared and
IMTA0A630003-02
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
AENNTA0E6304003 (06(01)
P/S Warning Light Check
AENNTA0E6304002 (06(01) 1) Connect SUZUKI scan tool to DLC. Refer to “Suzuki
1) Set ignition “ON” (without running engine) and check SDT-II Connection and Disconnection” in Section
if the P/S warning light (1) comes on. If the P/S 0A.
warning light does not come on, go to “P/S Warning 2) Check DTC and follow the instructions displayed on
Light Does Not Come ON with Ignition “ON” before SUZUKI scan tool.
Engine Starts” of the diagnostic flows. If necessary, refer to Operator's Manual of SUZUKI
2) Start engine and check if the P/S warning light turns scan tool for further details.
OFF. If P/S warning light remains ON and no DTC is NOTE
stored in P/S control module, go to “P/S Warning
Light Remains ON Steady or Blinks after Engine • A communication error may occur due to
Starts” for troubleshooting. temporary overlap of communication load.
tool and P/S control module is not
possible, perform the following checks:
tool function.
– Check DLC power circuit and ground
circuit.
DLC cable.
“Diagnosis flow: [a]” in
“Troubleshooting” of “Troubleshooting • If communication between SUZUKI scan

for Lost Communication”: CAN in tool and P/S control module is not
Section 10H.) possible, perform the following checks:
– Check CAN communication system. – Check communication condition
(“Control Module Communication Bus between PC and VCI using SUZUKI scan
Off” is detected in any control module.) tool function.
(Troubleshooting for Communication – Check DLC power circuit and ground
Bus Off): CAN in Section 10H circuit.
– Check central gateway control module – Check DLC cable. If necessary, check
power supply circuit and ground circuit. DLC cable by substituting a known-good
(Inspection of Central Gateway Control DLC cable.
– Check P/S control module power circuit gateway control module. (Refer to
and ground circuit. (P/S Control Module “Diagnosis flow: [a]” in
Power Supply and Ground Circuit “Troubleshooting” of “Troubleshooting
Check) for Lost Communication”: CAN in
Section 10H.)
“Suzuki SDT-II Connection and Disconnection” in – Check CAN communication system.
Section 0A. (“Control Module Communication Bus
Off” is detected in any control module.)
DTC Clearance Bus Off): CAN in Section 10H
AENNTA0E6304004 (06(01)
1) Connect SUZUKI scan tool to DLC. Refer to “Suzuki – Check central gateway control module
SDT-II Connection and Disconnection” in Section power supply circuit and ground circuit.
0A. (Inspection of Central Gateway Control
2) Clear DTC and follow the instructions displayed on Module and Its Circuits): CAN (Central
SUZUKI scan tool. Gateway) in Section 10H
If necessary, refer to Operator's Manual of SUZUKI – Check P/S control module power circuit
scan tool for further details. and ground circuit. (P/S Control Module
Power Supply and Ground Circuit
NOTE Check)
Section 0A.
DTC Table
AENNTA0E6304005 (06(01)
NOTE
• If you do not perform the “P/S System Check” before starting the DTC diagnosis, the diagnosis will
show a false result.
Perform “P/S System Check” before starting the diagnosis.
• *1: 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.
• *2: Whether P/S warning light lights up or not depends on DTC detecting condition.
P/S warning
DTC DTC name D/C *1
light
C1111 (DTC C1111 / C1113 /
Torque Sensor (Main) Circuit Malfunction 1 Lights up
C1115 / C1116)
C1113 (DTC C1111 / C1113 /
Torque Sensor (Main and Sub) Signal Difference 1 Lights up
C1115 / C1116)
C1115 (DTC C1111 / C1113 /
Torque Sensor (Sub) Circuit Malfunction 1 Lights up
C1115 / C1116)
C1116 (DTC C1111 / C1113 / Torque Sensor Power Supply (9 V) Circuit
1 Lights up
C1115 / C1116) Malfunction
P/S warning
DTC DTC name D/C *1
light
C1131 (DTC C1131) Rotation Angle Sensor Signal Malfunction 1 Lights up
C1141 (DTC C1141 / C1142 /
P/S Motor Circuit Voltage Malfunction 1 Lights up
C1143 / C1145 / C1146)
C1142 (DTC C1141 / C1142 /
P/S Motor Circuit Current Malfunction 1 1 Lights up
C1143 / C1145 / C1146)
C1143 (DTC C1141 / C1142 /
P/S Motor Circuit Current Too Big 1 Lights up
C1143 / C1145 / C1146)
C1145 (DTC C1141 / C1142 /
P/S Motor Circuit Current Malfunction 2 1 Lights up
C1143 / C1145 / C1146)
C1146 (DTC C1141 / C1142 /
P/S Motor Voltage Malfunction 1 Lights up
C1143 / C1145 / C1146)
C1152 (DTC C1152 / C1154) Fail-Safe Relay Malfunction (Melting Stuck) 1 Lights up
C1153 (DTC C1153 / C1155) Power Supply Voltage Too Low or Too High 1 Lights up
C1154 (DTC C1152 / C1154) Fail-Safe Relay Malfunction (Contact) 1 Lights up
C1155 (DTC C1153 / C1155) P/S Control Module Internal Failure 1 *2
C1160 (DTC C1160) Assist Map Signal Failure 1 Lights up
C1161 (DTC C1161 / C1162 /
CAN Invalid Data from Vehicle Speed 1 Lights up
C1166)
C1162 (DTC C1161 / C1162 /
CAN Invalid Data from Engine Speed 1 Lights up
C1166)
C1163 (DTC C1163) CAN Invalid Data from Steering Angle Sensor 1 Lights up
C1166 (DTC C1161 / C1162 /
Reliability Defect Of Vehicle Speed Data 1 Lights up
C1166)
C116A (DTC C116A) Steering Angle Sensor Calibration Incomplete 1 Lights up
C116B (DTC C116B) Steering Angle Sensor Calibration Defect 1 Lights up
C116C (DTC C116C /
Steering Angle Sensor Circuit Performance 1 Lights up
C116D)
C116D (DTC C116C /
Steering Angle Sensor Specification Unregistered 1 Lights up
C116D)
U0073 (DTC U0073) Control Module Communication Bus Off 1 Off
U0100 (DTC U0100 / U0121 /
U0126 / U0140 / U0155 / Lost Communication With ECM 1 *2
U1082)
U0121 (DTC U0100 / U0121 /
Lost Communication With ABS / ESP® Control
U0126 / U0140 / U0155 / 1 Off
Module
U1082)
U0126 (DTC U0100 / U0121 /
Lost Communication With Steering Angle Sensor
U0126 / U0140 / U0155 / 1 Lights up
Module
U1082)
U0140 (DTC U0100 / U0121 /
U0126 / U0140 / U0155 / Lost Communication With Body Control Module 1 Off
U1082)
U0155 (DTC U0100 / U0121 /
Lost Communication With Instrument Panel
U0126 / U0140 / U0155 / 1 Off
Cluster (IPC) Control Module
U1082)
U1082 (DTC U0100 / U0121 /
Lost Communication With ENG A-STOP Control
U0126 / U0140 / U0155 / 1 Off
Module
U1082)
Fail-Safe Table
AENNTA0E6304006 (06(01)
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 (DTC
C1111 / C1113 /
C1115 / C1116)
C1113 (DTC
C1111 / C1113 /
C1115 / C1116)
C1115 (DTC
C1111 / C1113 /
C1115 / C1116)
C1116 (DTC
C1111 / C1113 /
C1115 / C1116)
C1131 (DTC
C1131)
C1141 (DTC
C1141 / C1142 /
C1143 / C1145 /
C1146)
P/S motor and fail-safe relay turned off. Ignition is set to “OFF”.
C1142 (DTC
C1141 / C1142 /
C1143 / C1145 /
C1146)
C1143 (DTC
C1141 / C1142 /
C1143 / C1145 /
C1146)
C1145 (DTC
C1141 / C1142 /
C1143 / C1145 /
C1146)
C1146 (DTC
C1141 / C1142 /
C1143 / C1145 /
C1146)
C1152 (DTC
C1152 / C1154)
If one of the following conditions is met:
C1153 (DTC P/S motor turned off or assist value is • Voltage at fail-safe relay contact is higher than
C1153 / C1155) decreased to minimum. 10 V or lower than 18.2 V.
• Ignition is set to “OFF”.
C1154 (DTC Recovery from malfunction or setting ignition to
P/S motor turned off.
C1152 / C1154) “OFF”.
C1155 (DTC P/S motor turned off or P/S motor and fail-safe
Ignition is set to “OFF”.
C1153 / C1155) relay turned off.
C1160 (DTC
Default assist map is applied. Setting of correct assist map.
C1160)
C1161 (DTC Receiving invalid data, stops steering return
C1161 / C1162 / control and decreases the assist value to Normal data is received or ignition is set to “OFF”.
C1166) minimum level.
C1162 (DTC
C1161 / C1162 / - Normal data is received or ignition is set to “OFF”.
C1166)
C1163 (DTC Receiving vehicle information, stops steering
Normal data is received or ignition is set to “OFF”.
C1163) return control.
C1166 (DTC Receiving invalid data, stops steering return
C1161 / C1162 / control and decreases the assist value to Normal data is received or ignition is set to “OFF”.
C1166) minimum level.
DTC Fail-safe operation Fail-safe operation cancel condition

C116A (DTC Receiving vehicle information, stops steering Corrected calibration signal of steering angle is
C116A) return control. received or ignition is set to “OFF”.
C116B (DTC Receiving vehicle information, stops steering Corrected calibration signal of steering angle is
C116B) return control. received or ignition is set to “OFF”.
C116C (DTC Receiving vehicle information, stops steering
C116C / C116D) return control.
C116D (DTC Receiving vehicle information, stops steering
C116C / C116D) return control.
U0073(DTC
- Normal data is received or ignition is set to “OFF”.
U0073)
U0100 (DTC
U0100 / U0121 / Assist is stopped or assist value is decreased
Normal data is received or ignition is set to “OFF”.
U0126 / U0140 / to minimum.
U0155 / U1082)
U0121 (DTC
U0100 / U0121 /
- Ignition is set to “OFF”.
U0126 / U0140 /
U0155 / U1082)
U0126 (DTC Receiving vehicle information, stops steering
U0100 / U0121 / return control.
U0126 / U0140 /
U0155 / U1082)
U0140 (DTC
U0100 / U0121 /
U0126 / U0140 /
U0155 / U1082)
U0155 (DTC
U0100 / U0121 /
U0126 / U0140 /
U0155 / U1082)
U1082 (DTC
U0100 / U0121 /
U0126 / U0140 /
U0155 / U1082)
Scan Tool Data

AENNTA0E6304007 (06(01)
P/S Control Module
NOTE
• If communication between SUZUKI scan tool and P/S control module is not possible, perform the
following checks:
– Check P/S control module power circuit and ground circuit. (P/S Control Module Power Supply
• *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 /
Reference value
Battery Voltage(Battery
Approx. 12 to 14 V Engine running at idle speed
Voltage (V))
Sensor Power
Supply(Sensor Power
Supply (Torque Sensor Approx. 8 – 10 V Engine running at idle speed
Power Supply Voltage,
V))
Engine running at idle speed
Approx. ±0 Nm
Sensor (Main) Torque Steering wheel at neutral
(Sensor (Main) Torque Engine running at idle speed
7.2 to 12.6 Nm
(Torque Sensor (Main), Vehicle stationary and steering wheel turned fully to right *1
Nm)) Engine running at idle speed
–7.2 to –12.6 Nm
Vehicle stationary and steering wheel turned fully to left *1
Approx. ±0 Nm
Sensor (Sub) Torque Steering wheel at neutral
(Sensor (Sub) Torque Engine running at idle speed
–7.2 to –12.6 Nm
(Torque Sensor (Sub), Vehicle stationary and steering wheel turned fully to right *1
Nm)) Engine running at idle speed
7.2 to 12.6 Nm
Approx. ±0 Nm
Steering wheel at neutral
Control Torque (Control Engine running at idle speed
Approx. 7 Nm
Torque (Nm)) Vehicle stationary and steering wheel turned fully to right *1
Approx. –7 Nm
0.0 A
Target Motor Current Steering wheel at neutral
(Target Motor Current Engine running at idle speed
(A)) Approx. 50 A Vehicle stationary and steering wheel turned fully to right or left
*1, *2
Measured MOT Current 0.0 A
(Measured MOT Current
(Measured Motor
Approx. 50 A Vehicle stationary and steering wheel turned fully to right or left
Current, A))
*1, *2
Vehicle Speed (Vehicle Drive vehicle at 40 km/h using chassis dynamometer or while
Approx. 40 km/h
Speed (km/h)) checking speedometer
Engine Speed (Engine 0 rpm Set ignition “ON”
Speed (rpm)) Specified idle speed Engine running at idle speed after warming up
IGN Switch Status (IGN ON Set ignition “ON”
Switch Status (Ignition
Switch Status, ON / OFF Other than above condition
OFF))
System Power Status ON Current flowing to P/S control module power supply
(System Power Status
OFF Other than above condition
(ON / OFF))
Torque Sensor Status ON Voltage is outputted from P/S control module to torque sensor
(Torque Sensor Status OFF Other then above condition
(ON / OFF))
Fail Safe FET Status ON Power steering system operates normally
(Fail Safe FET Status
(Fail Safe Field Effect
OFF Performing fail-safe operation
Transistor Status, ON /
OFF))
Normal condition /
Reference value
0 ± 3° Front wheels in straight ahead position
Internal Steering Angle 360° ± 3° Rotate steering wheel once counterclockwise
Sensor (Internal Steering
Angle Sensor (°)) –360° ± 3° Rotate steering wheel once clockwise
Steering Angle Sensor 0 ± 3° Front wheels in straight ahead position

(Steering Angle Sensor 360° ± 3° Rotate steering wheel once counterclockwise
(°)) –360° ± 3° Rotate steering wheel once clockwise
ESP Neutral position is registered with ESP® control module
Neutral Position Except ESP Neutral position is registered with P/S control module
Registration ECU
(Neutral Position
Registration ECU
(Steering Angle Sensor
Neutral Position Undecided Other than above condition
Registration Electronic
Control Unit, Except ESP
/ ESP / Undecided))
Scan Tool Data Definitions The motor circuit condition is diagnosed by comparing
Battery Voltage (V) this parameter with “Target Motor Current” parameter
This parameter indicates battery positive voltage. described previously.
Sensor Power Supply (Torque Sensor Power Supply Vehicle Speed (km/h)
Voltage, V) Vehicle speed signal is fed from ECM.
This parameter indicates the power supply voltage which P/S control module determines the amount of power
the P/S control module supplies to the torque sensor. assist based on this vehicle speed signal and the torque
sensor signal.
Sensor (Main) Torque (Torque Sensor (Main), Nm)
The torque sensor is installed to detect the steering force Engine Speed (rpm)
and the steering direction. Engine speed signal is fed from the ECM so that it can
It consists of two potentiometers and the main torque be used for trouble diagnosis of the electric power
sensor is one of these. steering system.
Sensor (Sub) Torque (Torque Sensor (Sub), Nm) IGN Switch Status (Ignition Switch Status, ON / OFF)
The torque sensor is installed to detect the steering force This parameter indicates the condition of the power
and the steering direction. supply through the ignition switch.
It consists of two potentiometers and the sub-torque ON: Ignition ON
sensor is one of these. OFF: Ignition OFF
Its output characteristics are compared with those of the
main torque sensor. System Power Status (ON / OFF)
This parameter indicates input status of EPS system
Control Torque (Nm) power supply.
This parameter is an internal parameter of the P/S ON: Current flowing to P/S control module power supply
control module. OFF: Other than above condition
It is obtained by computing the torque sensor input
signal. Torque Sensor Status (ON / OFF)
This parameter indicates the output status of the torque
Target Motor Current (A) sensor power supply.
Based on the input signal, the P/S control module ON: Voltage is outputted from P/S control module to
determines the assist amount and controls the current to torque sensor
the motor suitable for that assist amount. OFF: Other than above condition
This parameter indicates that control value.
Fail Safe FET Status (Fail Safe Field Effect Transistor
Measured MOT Current (Measured Motor Current, A) Status, ON / OFF)
This parameter indicates the actually measured value of This parameter indicates the status of the motor drive
the current flowing to the P/S motor. power supply circuit.
ON: EPS system operates normally The numerical value changes in the positive direction
OFF: Performing fail-safe operation when turning steering wheel to counterclockwise.
The numerical value changes on the negative side when
Internal Steering Angle Sensor (°) turning the steering wheel to clockwise.
This parameter indicates the value of the absolute angle
in the steering angle sensor. Neutral Position Registration ECU (Steering Angle
The numerical value changes in the positive direction Sensor Neutral Position Registration Electronic
when turning steering wheel to counterclockwise. Control Unit, Except ESP / ESP / Undecided)
The numerical value changes on the negative side when This parameter indicates the control module which
turning the steering wheel to clockwise. “steering angle sensor neutral position” was registered
with.
Steering Angle Sensor (°) Except ESP: Steering angle sensor neutral position is
This parameter indicates the value of the absolute angle registered with P/S control module
after the steering angle sensor calibration. ESP: Steering angle sensor neutral position is registered
When the calibration of the steering angle sensor is not with ESP® control module
finished, indication is fixed in “0”. Undecided: Other than above condition
Visual Inspection
AENNTA0E6304008 (06(01)
Battery Fluid level, leakage
“Battery Description” in Section 1J
indicator
Connectors of electric wire “Intermittent Connection and Poor Contact Inspection” in Section
Disconnection, friction
harness 00
Fuses Blowout —
P/S warning light Operation “P/S Warning Light Check”
P/S System Symptom Diagnosis

AENNTA0E6304009 (06(04)
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 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” and “Front Wheel Alignment Inspection and Adjustment” in Section
2B before diagnosis.
Steering wheel feels heavy

• Improper installation of steering wheel Install steering wheel correctly. (Steering Wheel Removal
• Poor performance of torque sensor Check torque sensor. (Torque Sensor and Its Circuit
Inspection)
• Poor performance of P/S motor Check P/S motor. (Scan Tool Data)
• Malfunction of steering gear case assembly Replace steering gear case assembly. (Steering Gear Case
• Vehicle speed data provided through CAN
communication Check vehicle speed data. (Scan Tool Data)
Steering wheel feels heavy momentarily when turning it to left or right

Poor recovery from turns

Inspection)
Vehicle pulls to one side during straight driving

Inspection)
• Malfunction of steering neutral position memorized
in P/S control module (built in steering column
assembly) Replace steering column. (Steering Column Removal and
Abnormal noise
• Malfunction of P/S motor (built in steering column
assembly) Replace steering column. (Steering Column Removal and
P/S Warning Light Does Not Come ON with Ignition “ON” before Engine Starts
AENNTA0E6304010 (06(03)
Wiring Diagram
2 3
10
1 GRN G10-3
A1
5
BRN 6
G240-3 4
7
G240-19 RED G10-5

8 9 9
A2 G240-7 WHT G10-6
BLK G240-5
BLK E10-2
[A] [B] [C]

[a]
12 11 10 9 8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
2 1 24 23 22 21 20 19 18 17 16 15 14 13
IMTA0A630005-04
[A]: P/S control module connector “E10” (View: [a]) 1. To ignition power supply 6. Combination meter
[B]: P/S control module connector “G10” (View: [a]) 2. J/B 7. P/S warning light
[C]: Combination meter connector “G240” (View: [a]) 3. P/S control module / motor assembly 8. Meter driver
A1: Combination meter power supply circuit 4. CPU 9. CAN driver
A2: Combination meter ground circuit 5. “MTR” fuse 10. “IG1 SIG2” fuse
Troubleshooting
Step 1 P/S warning light check

Do other warning lights come ON?
Yes Go to Step 2.
No Go to Step 4.
Step 2 DTC check

1) Connect scan tool to DLC with ignition “OFF”.
2) When ignition is “ON”, check DTC.
Is DTC U0073 or U0155 detected?
Yes Refer to “CAN DTC (Lost Communication and Communication Bus Off) Table”: CAN in Section
10H.
No Go to Step 3.

Does P/S warning light stay OFF?
Yes Replace steering column assembly. (Steering Column Removal and Installation) in Section 6B
No End.
Step 4 Fuse check
Is circuit fuse for combination meter in good condition?
Yes Go to Step 5.

1) Check CAN communication circuit between combination meter and P/S control module.
(Troubleshooting for Lost Communication): CAN in Section 10H
Is CAN communication circuit in good condition?
Yes Go to Step 6.
No Repair or replace.
Step 6 Combination meter power supply circuit check

1) Remove combination meter with ignition “OFF”. (Combination Meter Removal and Installation) in Section
9C
2) Check for proper connection to combination meter connector.
3) If check result is OK, set ignition “ON”.
4) Check voltage between “G240-3” terminal and “G240-5” terminal is battery voltage.
Is check result OK?
Yes Replace combination meter and recheck DTC.

No Go to Step 7.
Step 7 Combination meter ground circuit check

2) Check resistance between “G240-5” terminal and ground is 1 Ω or less.
Is check result OK?


P/S Warning Light Remains ON Steady or Blinks after Engine Starts

AENNTA0E6304011 (06(03)
Wiring Diagram
2 3
10
1 GRN G10-3
A1
5
BRN 6
G240-3 4
7
G240-19 RED G10-5

8 9 9
A2 G240-7 WHT G10-6
BLK G240-5
BLK E10-2
[A] [B] [C]

[a]
12 11 10 9 8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
2 1 24 23 22 21 20 19 18 17 16 15 14 13
IMTA0A630005-04
[A]: P/S control module connector “E10” (View: [a]) 1. To ignition power supply 6. Combination meter
[B]: P/S control module connector “G10” (View: [a]) 2. J/B 7. P/S warning light
[C]: Combination meter connector “G240” (View: [a]) 3. P/S control module / motor assembly 8. Meter driver
A1: Combination meter power supply circuit 4. CPU 9. CAN driver
A2: Combination meter ground circuit 5. “MTR” fuse 10. “IG1 SIG2” fuse
Troubleshooting
Step 1 DTC check

1) Start engine and recheck DTC of P/S control module.
Is DTC(s) detected?

No Go to Step 2.
Step 2 P/S control module check

1) Replace steering column assembly. (Steering Column Removal and Installation) in Section 6B
Does P/S warning light stay ON or blink?
Yes Replace combination meter. (Combination Meter Removal and Installation) in Section 9C
No End.
DTC C1111 / C1113 / C1115 / C1116

AENNTA0E6304012 (06(02)

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 (4.5 V) or lower than specified value (0.5 V) for
• P/S control module (steering column assembly)
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
C1115: Torque Sensor (Sub) Circuit Malfunction
Voltage of torque sensor signal (sub) circuit is higher than
specified value (4.5 V) or lower than specified value (0.5 V) for
C1116: Torque Sensor Power Supply (9 V) Circuit
Malfunction
Reference power supply voltage (9 V) for torque sensor circuit
is lower than specified lower limit for more than specified time.
Circuit Diagram
1 [A]
5
5V A1
E11-8 GRN 4 3 2 1
9 8 7 6 5
B1
10 A2
7 RED E10-1 [B]
E11-6 YEL
5V
A3 2 1
11 B2 E11-7 RED
2 3
12
8 GRN G10-3
6 [C]
A4
E11-1 WHT 8 7 6 5 4 3 2 1
4
A5
B3 E11-5 BLK [a]
BLK E10-2
IMTA0A630006-02
[A]: Torque sensor connector “E11” (View [a]) B1. P/S control module power supply circuit 6. Torque sensor amplifier
[B]: P/S control module connector “E10” (View [a]) B2. IG1 power supply circuit 7. To continuous power supply
[C]: P/S control module connector “G10” (View [a]) B3. P/S control module ground circuit 8. To ignition power supply
A1: Torque sensor signal (main) circuit 1. P/S control module / motor assembly 9. Relay box
A2: Torque sensor signal (sub) circuit 2. CPU 10. “P/S” fuse
A3: 9 V power supply for torque sensor circuit 3. 9 V regulator 11. J/B
A4: 3 V reference power supply for torque sensor circuit 4. 3 V reference power supply 12. “IG1 SIG2” fuse
A5: Torque sensor ground circuit 5. Torque sensor

Upon completion of initial check, turn steering wheel in both directions fully with vehicle stopped, and then handle
steering while driving.
DTC Troubleshooting
Step 1 Was “P/S System Check” performed?

Yes Go to Step 2.
No Go to “P/S System Check”.
Step 2 P/S control module power supply and ground circuit check
1) Check P/S control module power supply and ground circuits. (P/S Control Module Power Supply and
Is check result OK?
Yes Go to Step 3.
Step 3 P/S control module check

1) With ignition “OFF”, disconnect “E11” connector.
2) Check for proper connection to “E11” connector.
4) Check voltage between “E11” connector terminals.
• “E11-7” and “E11-5” is approx. 9 V.
• “E11-1” and “E11-5” is approx. 3.3 V.
Is check result OK?
Yes Go to Step 4.
No Replace steering column assembly. (Steering Column Removal and Installation) in Section 6B
Step 4 Torque sensor check

1) Check torque sensor. (Torque Sensor and Its Circuit Inspection)
Is the sensor in good condition?
Yes Substitute a known-good steering column assembly and recheck DTC. (Steering Column Removal
No Replace steering column assembly. (Steering Column Removal and Installation) in Section 6B
DTC C1131
AENNTA0E6304013 (06(02)
C1131: Rotation Angle Sensor Signal Malfunction • Rotation angle sensor (steering column assembly)
Rotation angle sensor output signal error continues for • P/S control module (steering column assembly)
more than specified period.
Circuit Diagram
6
[a]
3
A1
4
1 RED E10-1
[A]
5 7 9
A2
11
2 GRN G10-3 8
2 1
10
[B]
8 7 6 5 4 3 2 1
A3
BLK E10-2
IMTA0A630007-02
[A]: P/S control module connector “E10” (View: [a]) 2. To ignition power supply 8. Rotation angle sensor
[B]: P/S control module connector “G10” (View: [a]) 3. Relay box 9. Rotation angle sensor exciter circuit
A1: P/S control module power supply circuit 4. “P/S” fuse 10. Rotation angle sensor signal receive circuit
A2: IG1 power supply circuit 5. J/B 11. “IG1 SIG2” fuse
A3: P/S control module ground circuit 6. P/S control module / motor assembly
1. To continuous power supply 7. CPU
DTC Troubleshooting
Step 1 Was “EPS System Check” performed?
Yes Go to Step 2.
No Go to “P/S System Check” and recheck DTC.
Is check result OK?
DTC C1141 / C1142 / C1143 / C1145 / C1146

AENNTA0E6304014 (06(02)

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 (steering column
V or more, or motor drive circuit is defective. assembly)
C1142: P/S Motor Circuit Current Malfunction 1
Measured motor drive current is bigger than target value by 10 A or more.
C1143: P/S Motor Circuit Current Too Big
Measured motor drive current is more than 137 A.
C1145: P/S Motor Circuit Current Malfunction 2
Target motor drive current is more than 4 A or measured motor drive
current is less than 2 A.
C1146: P/S Motor Voltage Malfunction
Motor voltage calculated in P/S control module is abnormal.
Circuit Diagram
6
[a]
3
A1 12V
4
1 RED E10-1
9
[A]
5 7
A2 8
10
2 GRN G10-3
2 1
[B]
8 7 6 5 4 3 2 1
A3
BLK E10-2
IMTA0A630008-04
[A]: P/S control module connector “E10” (View: [a]) 1. To continuous power supply 6. P/S control module / motor assembly
[B]: P/S control module connector “G10” (View: [a]) 2. To ignition power supply 7. CPU
A1: P/S control module power supply circuit 3. Relay box 8. P/S motor
A2: IG1 power supply circuit 4. “P/S” fuse 9. Fail-safe relay
A3: P/S control module ground circuit 5. J/B 10. “IG1 SIG2” fuse
DTC Troubleshooting
Yes Go to Step 2.
Is check result OK?
DTC C1152 / C1154

AENNTA0E6304015 (06(02)
C1152: Fail-Safe Relay Malfunction (Melting Stuck) P/S control module (steering column assembly)
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
6
[a]
3
A1 12V
4
1 RED E10-1
9
[A]
5 7
A2 8
10
2 GRN G10-3
2 1
[B]
8 7 6 5 4 3 2 1
A3
BLK E10-2
IMTA0A630008-04
A1: P/S control module power supply circuit 3. Relay box 8. P/S motor
A2: IG1 power supply circuit 4. “P/S” fuse 9. Fail-safe relay
A3: P/S control module ground circuit 5. J/B 10. “IG1 SIG2” fuse

2) Start engine.
DTC Troubleshooting
Yes Go to Step 2.
Is check result OK?
DTC C1153 / C1155

AENNTA0E6304016 (06(02)
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 (steering column
engine speed is more than 600 rpm and fail-safe relay ON is assembly)
commanded, or voltage at fail-safe relay contact is higher than 19.2 V.
C1155: P/S Control Module Internal Failure
P/S control module is internal failure.
Circuit Diagram
[a]
3 A1
4
5 RED E10-1 2
A2 [A]
BLK E10-2
2 1
IMTA0A630009-01
[A]: P/S control module connector “E10” (View [a]) 1. P/S control module / motor assembly 4. “P/S” fuse
A1: P/S control module power supply circuit 2. CPU 5. To continuous power supply
A2: P/S control module ground circuit 3. Relay box

Run engine at idle speed for more than 5 seconds.
DTC Troubleshooting
Yes Go to Step 2.
Is check result OK?
Yes Go to Step 3.
Step 3 P/S control module power supply voltage check

1) Measure battery voltage with engine running at 3000 rpm.
Is voltage between 9 V and 15 V?
No Check charging system. (Generator Test) in Section 1J
DTC C1160
AENNTA0E6304017 (06(02)

C1160: Assist Map Signal Failure P/S control module (steering column assembly)
Assist map data is not set in P/S control module.
Circuit Diagram
6
[a]
3
A1
4
1 RED E10-1
5 [A]
A2
7
8
2 GRN G10-3
2 1
[B]
A3
8 7 6 5 4 3 2 1
BLK E10-2
IMTA0A630010-04
A1: P/S control module power supply circuit 3. Relay box 8. “IG1 SIG2” fuse
A2: IG1 power supply circuit 4. “P/S” fuse
A3: P/S control module ground circuit 5. J/B

DTC Troubleshooting
Yes Go Step 2.
Is check result OK?
DTC C1161 / C1162 / C1166

AENNTA0E6304018 (06(02)

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
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.

C1161 / C1166
Refer to “DTC Confirmation Procedure” for DTC P0500 Vehicle Speed Sensor “A”. (DTC P0500) in Section 1A
C1162
Refer to “DTC Confirmation Procedure” for DTC P0335 Crankshaft Position Sensor “A” Circuit. (DTC P0335 / P0336)
in Section 1A
DTC Troubleshooting
Yes Go to Step 2.
Step 2 DTC check

1) Check ECM for DTC. (DTC Check)
Is DTC(s) detected?
Yes Go to troubleshooting for applicable DTC. (ECM-related faulty) (DTC Table) in Section 1A
No Substitute a known-good steering column assembly and recheck DTC. (Steering Column Removal
DTC C1163
AENNTA0E6304019 (06(02)
C1163: CAN Invalid Data from Steering Angle Sensor • Steering angle sensor
Invalid data of steering angle is received from steering • P/S control module (steering column assembly)
angle sensor.
DTC Troubleshooting
Yes Go to Step 2.
Step 2 DTC check

Is other DTC(s) than C1163 detected?

No Replace steering angle sensor and recheck DTC. If DTC C1163 is still detected, substitute a
known-good steering column assembly and recheck DTC.
• Steering angle sensor: (Steering Angle Sensor Removal and Installation) in Section 6B
• Steering column assembly: (Steering Column Removal and Installation) in Section 6B
DTC C116A
AENNTA0E6304020 (06(02)
C116A: Steering Angle Sensor Calibration Incomplete • Steering angle sensor
Incomplete calibration signal of steering angle is received • P/S control module (steering column assembly)
from steering angle sensor.

1) Set ignition “ON” and “OFF”.
2) Set ignition “ON” again.
DTC Troubleshooting
Yes Go to Step 2.
Step 2 DTC check

Is other DTC(s) than C116A detected?

No Go to Step 3.

1) Perform sensor calibration. (Sensor Calibration (Non-ESP® Model))
Is DTC C116A still detected?
Yes Replace steering angle sensor and recheck DTC. If DTC C116A is still detected, substitute a
No End.
DTC C116B
AENNTA0E6304021 (06(02)
C116B: Steering Angle Sensor Calibration Defect • Steering angle sensor
Steering angle sensor detects calibration defect. • P/S control module (steering column assembly)

1) Set ignition “ON” and “OFF”.
2) Set ignition “ON” again.
DTC Troubleshooting

Yes Go to Step 2.
Step 2 DTC check

Is other DTC(s) than C116B detected?

No Go to Step 3.

1) Perform sensor calibration. (Sensor Calibration (Non-ESP® Model))
Is DTC C116B still detected?
Yes Replace steering angle sensor and recheck DTC. If DTC C116B is still detected, substitute a
No End.
DTC C116C / C116D

AENNTA0E6304022 (06(02)
C116C: Steering Angle Sensor Circuit Performance • Steering angle sensor
CPU in steering angle sensor detects internal defect. • P/S control module (steering column
C116D: P/S Control Module Internal Failure assembly)
Steering angle sensor detects unconfirmed failure.
DTC Troubleshooting
Yes Go to Step 2.
Step 2 DTC check

Is other DTC(s) than C116C or C116D detected?

No Replace steering angle sensor and recheck DTC. If DTC C116C or C116D is still detected,
substitute a known-good steering column assembly and recheck DTC.
DTC U0073 DTC U0100 / U0121 / U0126 / U0140 / U0155 /

AENNTA0E6304023 (06(02)
Refer to “Troubleshooting for Communication Bus Off”:
U1082
AENNTA0E6304024 (06(02)
CAN in Section 10H. Refer to “Troubleshooting for Lost Communication”:
CAN in Section 10H.
P/S Control Module Power Supply and Ground Circuit Check

AENNTA0E6304025 (06(01)
Circuit Diagram
6
[a]
3
A1
4
1 RED E10-1
5 [A]
A2
7
8
2 GRN G10-3
2 1
[B]
A3
8 7 6 5 4 3 2 1
BLK E10-2
IMTA0A630010-04
A1: P/S control module power supply circuit 3. Relay box 8. “IG1 SIG2” fuse
A2: IG1 power supply circuit 4. “P/S” fuse
A3: P/S control module ground circuit 5. J/B
Troubleshooting
Step 1 Circuit fuse check

2) Disconnect “E10” and “G10” connectors.
3) Check for proper connection to “G10-3” and “E10-1” terminals.
4) If connections are OK, check “P/S” fuse and “IG1 SIG2” fuse for blowing.
Is check result OK?
Yes Go to Step 2.
No Replace fuse(s) and check for short to ground in circuits connected to fuse(s).
Step 2 P/S control module power supply circuit check

1) Check voltage between “E10-1” terminal and ground.
Is voltage 10 – 14 V?
Yes Go to Step 3.
No “A1” circuit is open.
Step 3 IG1 power supply circuit check

2) Check voltage between “G10-3” terminal and ground.
Yes Go to Step 4.
No “A2” circuit is open.
Step 4 P/S control module ground circuit check

2) Check for proper connection to “E10-2” terminal.
3) Check resistance between “E10-2” terminal and ground.
Yes End.
No “A3” circuit is open or too high in resistance.
Inspection of P/S Control Module and Its Circuits

AENNTA0E6304026 (06(01)
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.
[C] [B]
8 7 6 5 4 3 2 1 4 3 2 1
8 7 6 5
[A] [a]
1
2 1
IFRA0A630013-01
[A]: P/S control module connector “E10” (View: [a]) [B]: Torque sensor connector “E11” (View: [a]) [C]: P/S control module connector “G10” (View: [a])
Voltage Check
1) Remove steering column hole cover. (Instrument Panel Removal and Installation) in Section 9C
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.
“E10” connector
Terminal Circuit Wire color Normal voltage Condition
Main power supply for P/S control
1 RED Approx. 12 V Ignition in any position / mode
module
2 Ground for P/S control module BLK 0V Ignition in any position / mode
“G10” connector
IG1 power supply for P/S control
3 GRN Approx. 12 V Ignition “ON”
module
Refer to Oscilloscope Display.
5 CAN (HI1) communication circuit RED
Refer to Oscilloscope Display.
6 CAN (LO1) communication circuit WHT
“E11” connector
3 V reference power supply for
1 WHT Approx. 3.3 V Ignition “ON”
torque sensor
5 Ground for torque sensor BLK 0V Ignition in any position / mode
Engine: Idle speed
Approx. 2.5 V
Engine: Idle speed
Approx. 1.1 V Vehicle stationary and steering
6 Torque sensor signal (Sub) YEL
wheel turned fully to right *1
Engine: Idle speed
wheel turned fully to left *1
9 V reference power supply for
7 RED Approx. 9 V Engine: Idle speed
torque sensor
Engine: Idle speed
Approx. 2.5 V
Engine: Idle speed
8 Torque sensor signal (Main) GRN
wheel turned fully to right *1
Engine: Idle speed
wheel turned fully to left *1
Reference Waveform
Shown below is typical waveform display provided by
oscilloscope.
NOTE
data:
I8T401111066-01


CAN communication signal – Steering shaft joint for wear

Channel Probe Terminal No. – Steering pinion or rack gear for wear or breakage
CH1 + G10-5 – Each part for looseness
– Ground
CH2 + G10-6 Steering wheel play “a”
– Ground : 0 – 30 mm (0.00 – 1.18 in.)
• Ignition mode: “ON”
“a”
I8C50A630015-02
Steering Force Check

AENNTA0E6304028 (06(01)
1) Place vehicle on level road and set steering wheel at
IAW101630008-01
[a]: CH1 1. CAN communication signal
2) Check that tire inflation pressure is as specified
[b]: CH2 referring to the “Tire Placard”.
3) Start engine.
4) With engine idling, measure steering force using
Steering Wheel Play Check spring balance (1).
AENNTA0E6304027 (06(01)
• Check steering wheel for looseness or rattle by Steering force
moving it in axial and lateral directions. : 30 N (3.1 kgf, 6.7 lbf) or less
If check result is not OK, repair or replace steering
wheel.
• Check steering wheel for play, holding vehicle in
straight ahead position on the ground with engine
stopped.
If steering wheel play is not as specified, check the
following components and replace any of them if
defective.
– Tie-rod end and tie-rod ball joint for wear 1
I8C50A630016-01
– Suspension arm joint for wear
Repair Instructions
Sensor Calibration (Non-ESP® Model)
AENNTA0E6306001 (08(03)
NOTE
• If any DTC other than C1160, C116A and
C116B is detected, repair the cause of the
detected DTC first.
• P/S control module has reference values
for power steering and steering angle
sensor has its own reference point stored.
Condition requiring
Sensor [A]
calibration [F] [N.m]
Steering angle sensor (non- • Steering angle sensor
auto-on headlight model) / (non-auto-on headlight 7.2 - 12.6
lighting and turn signal model) / lighting and
0
switch incorporating turn signal switch
steering angle sensor incorporating steering
-7.2 - -12.6
(auto-on headlight model) angle sensor (auto-on
headlight model) is [H] [E] [H]
replaced.
[C] [D]
• P/S control module
[B]
(steering column [G] [N.m]
assembly) is replaced.
• Steering wheel is 7.2 - 12.6
replaced.
0
• Adjustment of front
wheel alignment. -7.2 - -12.6
1) Park vehicle on level surface, apply parking brake, [H] [E] [H]
set steering wheel in straight ahead position, stop [C] [D]

engine and release brake pedal. IDL10A630031-01
[A]: Main signal

NOTE
[B]: Sub signal
Keep condition of Step 1) until sensor [C]: Steering force at left turn
calibration is completed, in order to calibrate [D]: Steering force at right turn
sensor correctly. [E]: Steering wheel at straight ahead position
[F]: “Sensor (Main) Torque” in “Data List” displayed on scan tool
2) Connect SUZUKI scan tool to DLC. (Suzuki SDT-II [G]: “Sensor (Sub) Torque” in “Data List” displayed on scan tool
Connection and Disconnection) in Section 0A [H]: Turn steering wheel fully and hold it with force applied.
3) Set ignition “ON” and check that no DTC is detected

4) If check result is not as specified, repair or replace
except C1160, C116A and C116B. If any DTC is
any of the following items.
detected, repair or replace trouble area.
• Torque sensor harness and connector
4) Select menu “Sensor Calibration” under “Utility”
mode of SUZUKI scan tool and calibrate sensor with • Torque sensor (steering column assembly)
ignition “ON”. Refer to Operator’s Manual of SUZUKI • P/S control module (steering column assembly)
5) After completing the calibration, check DTC(s) is not Using Voltmeter
stored P/S control module. 1) Remove steering column hole cover. (Instrument
6) Check that ignition is “OFF” and then disconnect Panel Removal and Installation) in Section 9C
SUZUKI scan tool from DLC. 2) Start engine and measure voltage between terminals
“5” – “8” and “7” – “8” at “E11” connector (1)
Torque Sensor and Its Circuit Inspection connected to P/S control module / motor assembly
AENNTA0E6306002 (08(03) (2).
2) Start engine and select “Sensor (Main) Torque” and
“Sensor (Sub) Torque” in “Data list” mode on
SUZUKI scan tool.
3) Check each of “Sensor (Main) Torque” and “Sensor
(Sub) Torque” changes linearly as specified in the
following graph.

[A]
[a]
1
4 3 2 1
8 7 6 5
IFRA0A630016-01
[A]: P/S control module connector “E11” (View: [a])
3) Check voltage changes linearly in main signal and

sub signal as specified in the following graph.
[A]
[F] [V]
Approx. 3.8 V
Approx. 2.5 V
Approx. 1.2 V
[H] [E] [H]
[C] [D]
[B]
[G] [V]
Approx. 3.8 V
Approx. 2.5 V
Approx. 1.2 V
[H] [E] [H]
[C] [D]
IDL10A630032-01
[A]: Main signal

[B]: Sub signal
[C]: Steering force at left turn
[D]: Steering force at right turn
[E]: Steering wheel at straight ahead position
[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.
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)
Section 7
HVAC
CONTENTS
Precautions .................................................7-1 DTC B1513-71 / B1514-71 / B1531-71 .............7B-37

Precautions............................................................. 7-1 DTC B1546-00 ..................................................7B-40
Precautions for HVAC ........................................... 7-1 DTC B1549-87 / U2005-87 ...............................7B-41
A/C System Caution.............................................. 7-1 DTC B1563-81 ..................................................7B-42
Precautions for Servicing A/C System .................. 7-1 DTC U0073-87 ..................................................7B-42
DTC U0100-87 / U0155-87 ...............................7B-42
HVAC System........................................... 7B-1 Inspection of Auto A/C Panel and Its Circuit .....7B-42
Precautions...........................................................7B-1 Inspection of A/C System Circuits at BCM........7B-44
Precautions for Diagnosing Trouble.................... 7B-1 Inspection of A/C System Circuits at ECM........7B-44
General Description .............................................7B-1 Repair Instructions ............................................7B-44
Auto A/C System Description.............................. 7B-1 Operation Procedure for Refrigerant Charge ....7B-44
HVAC Control Description................................... 7B-1 A/C System Major Components........................7B-49
Sub-Cool A/C System Description ...................... 7B-2 Radiator Cooling Fan Removal and
Compressor Drive Belt Description ..................... 7B-3 Installation .......................................................7B-51
A/C Operation Description .................................. 7B-3 Radiator Cooling Fan Inspection.......................7B-51
OBD System Description .................................... 7B-5 Condenser Assembly On-Vehicle Inspection....7B-51
CAN Communication System Description........... 7B-5 Condenser Assembly Removal and
Installation .......................................................7B-51
Schematic and Routing Diagram........................7B-5
Desiccant Removal and Installation ..................7B-52
Auto A/C Electronic Control Input / Output
HVAC Unit Components ...................................7B-53
Block Diagram................................................... 7B-5
HVAC Unit Removal and Installation ................7B-54
Auto A/C System Circuit Diagram ....................... 7B-7
Auto A/C Panel Removal and Installation .........7B-57
Component Location ...........................................7B-8
Blower Motor Removal and Installation.............7B-58 7
Auto A/C Control System Component
Blower Motor Inspection....................................7B-58
Location ............................................................ 7B-8
Blower Motor Controller Removal and
Diagnostic Information and Procedures..........7B-10 Installation .......................................................7B-59
A/C System Performance Inspection ................ 7B-10 Blower Motor Controller Inspection ...................7B-59
Trouble Diagnosis for Abnormal Pressure ........ 7B-14 Evaporator Inspection .......................................7B-60
A/C System Symptom Diagnosis ...................... 7B-16 Evaporator Temperature Sensor Removal
Abnormal Noise Symptom Diagnosis of A/C and Installation ................................................7B-60
System ............................................................ 7B-18 Evaporator Temperature Sensor Inspection .....7B-60
Air Conditioning System Check......................... 7B-20 Expansion Valve Removal and Installation .......7B-61
Visual Inspection ............................................... 7B-22 Expansion Valve Inspection ..............................7B-61
DTC Check ....................................................... 7B-23 A/C Refrigerant Pressure Sensor and Its
DTC Clearance ................................................. 7B-23 Circuit Inspection.............................................7B-61
DTC Table......................................................... 7B-23 A/C Refrigerant Pressure Sensor Removal
Fail-Safe Table.................................................. 7B-24 and Installation ................................................7B-62
Scan Tool Data ................................................. 7B-25 Temperature Control Actuator Removal and
DTC B1501-11 / B1501-13 ............................... 7B-29 Installation .......................................................7B-62
DTC B1503-11 / B1503-13 ............................... 7B-29 Temperature Control Actuator Inspection .........7B-63
DTC B1508-11 / B1508-13 ............................... 7B-29 Air Flow Control Actuator Removal and
DTC B150A-11.................................................. 7B-30 Installation .......................................................7B-63
DTC B150A-13.................................................. 7B-32 Air Flow Control Actuator Inspection.................7B-64
DTC B150C-11 / B1519-11 / B151B-11 ............ 7B-33 Air Intake Control Actuator Removal and
DTC B150C-13 / B1519-13 / B151B-13 ............ 7B-35 Installation .......................................................7B-64
Air Intake Control Actuator Inspection............... 7B-65 HVAC System Relay Inspection........................7B-69
Actuator Linkage Inspection.............................. 7B-66 Compressor Drive Belt Inspection.....................7B-69
Sunload Sensor Removal and Installation ........ 7B-66 Compressor Drive Belt Removal and
Sunload Sensor Inspection ............................... 7B-66 Installation .......................................................7B-70
Outside Air Temperature Sensor Removal Compressor Assembly Removal and
and Installation ................................................ 7B-67 Installation .......................................................7B-71
Outside Air Temperature Sensor Inspection ..... 7B-67 Compressor Assembly Components.................7B-72
Ventilator Duct Removal and Installation .......... 7B-67 Magnet Clutch Inspection..................................7B-73
Center Ventilation Louver Removal and Magnet Clutch Removal and Installation...........7B-73
Installation ....................................................... 7B-67 Relief Valve Inspection......................................7B-75
Side Ventilation Louver Removal and Relief Valve Removal and Installation...............7B-75
Installation ....................................................... 7B-67 Specifications .....................................................7B-75
Rear Ventilation Louver Removal and Tightening Torque Specifications......................7B-76
Installation (If Equipped) ................................. 7B-68 Special Tools and Equipment ...........................7B-76
Rear Ventilation Duct Removal and Recommended Service Material .......................7B-76
Installation (If Equipped) ................................. 7B-68 Special Tool ......................................................7B-76
HVAC Air Filter Removal and Installation ......... 7B-69
HVAC Air Filter Inspection ................................ 7B-69
Precautions: 7-1
Precautions
HVAC
Precautions
Precautions for HVAC Handling HFC-134a (R-134a) Refrigerant and
AENNTA0E7000001 (01(01) Specified Compressor Oil
General Precautions
Refer to “General Precautions” in Section 00. ! WARNING
Precautions for Electrical Circuit Service • If HFC-134a (R-134a) is exposed to high

Refer to “Precautions for Electrical Circuit Service” in temperatures, it turns into a poisonous
Section 00. gas.
Take the following precautions to prevent
Caution for Fastener health problems caused by HFC-134a (R-
Refer to “Caution for Fastener” in Section 00. 134a) gas.
– Do not handle refrigerant in or near any
Warning for Air Bag area where welding or steam cleaning is
Refer to “Warning for Air Bag” in Section 00. performed.
– Keep refrigerant in a cold and dark
place. Avoid storing it under direct
Observe “Reassembling Note for Wiring Harness” in
sunlight, in a place close to fire or inside
Section 9A whenever installing wiring harness.
a vehicle.
– If HFC-134a (R-134a) is burned, avoid
Precautions for Ignition Mode breathing fumes.
Refer to “Ignition Modes and Ignition Switch Positions” in • Contact of liquid HFC-134a (R-134a)
Section 0A. refrigerant with skin and eyes will cause
frostbite. The refrigerant cools the surface
Caution for Vehicles Equipped with DCM coming in contact with it to a temperature
Refer to “Caution for Vehicles Equipped with DCM” in much lower than the freezing point of
Section 00. water.
Avoid contact with HFC-134a (R-134a)
A/C System Caution refrigerant and wear goggles and gloves
AENNTA0E7000002 (01(01) whenever handling the refrigerant. Should
NOTICE the refrigerant happen to contact your
The A/C system of this vehicle uses HFC- eyes or skin, immediately take action as
134a (R-134a) refrigerant. The compressor oil described below to prevent aggravating
and parts used in the system are also made the condition:
of materials compatible with this refrigerant. – In the event of eye contact, do not touch
If this system is serviced using compressor the eye with your hand. Instead, pour
oils or parts that are not appropriate for HFC- fresh cold water over the eye to raise
134a (R-134a) refrigerant, refrigerant leakage gradually the temperature. After
and damage or other faulty conditions will washing the eye thoroughly with water,
occur in the A/C system. This will also cause receive medical attention as soon as
damage to or faulty operation of the servicing possible.
equipment. – If liquid HFC-134a (R-134a) contacts
Use only HFC-134a (R-134a) refrigerant and your skin, wash the affected area
also use only the specified compressor oil thoroughly with water. Since the skin
and replacement parts. may have been frostbitten, receive
medical attention.
Precautions for Servicing A/C System

AENNTA0E7000003 (01(01) NOTE
• 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
7-2 Precautions:
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 A/
C compressor with specified amount of
compressor oil from suction side referring
to “Replenishing Compressor Oil” in
“Operation Procedure for Refrigerant
Charge” in Section 7B.
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.
• If refrigerant has been completely
discharged out of A/C system, repair it and
replace desiccant together. (Desiccant
• 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.
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.
HVAC System: 7B-1
HVAC System
HVAC
Precautions
AENNTA0E7200001 (01(01)
• Do not disconnect connectors from BCM, battery cable from battery, BCM ground wire harness from body or main
fuse before checking diagnostic information (diagnostic trouble codes) stored in BCM memory.
• Diagnostic trouble codes stored in BCM can be checked on SUZUKI scan tool. Before checking diagnostic trouble
codes, read this manual and Operator's Manual of SUZUKI scan tool to know how to read diagnostic trouble codes.
• Read “Warning for Air Bag” in Section 00 before inspection.
General Description
Auto A/C System Description Using thus obtained target temperature control door
AENNTA0E7201001 (03(01) position, it further calculates the target air flow control
• In the automatic air conditioning system (auto A/C), door position and controls the air flow control actuator so
BCM automatically controls inside air temperature, that the current air flow control door position becomes
blower fan speed, air inlet and outlet, etc. Once users the target position.
set desired inside air temperature with the
temperature control switch and push “AUTO” switch, Air Intake Position Control
BCM starts detecting the inside air temperature, the BCM determines the air intake position based on signals
outside air temperature, sunlight and the engine from the temperature control switch, inside air
coolant temperature by means of the inside air temperature sensor and outside air temperature sensor
temperature sensor, the outside air temperature and controls the air intake control actuator.
sensor, the sunload sensor, and the ECT sensor, Furthermore, when the defroster switch is turned on,
respectively. In this way, BCM keeps in-car BCM fixes the position of the air intake control door to
temperature at the desired level at all times. the FRESH (FRE) position to clear fog from windshield.
• For further information on the auto A/C system, refer
to “Auto A/C Control System Component Location”, A/C Compressor Relay Control
“A/C System Major Components” and “Auto A/C BCM outputs A/C switch ON signal to ECM when the
Electronic Control Input / Output Block Diagram”. vehicle state satisfies the conditions described below.
• A/C switch is ON
HVAC Control Description • Evaporator temperature is higher than specified value
AENNTA0E7201002 (03(01)
Temperature Control • Evaporator temperature sensor malfunction is not
BCM calculates the target temperature control door detected
position based on signals from the temperature control ECM and BCM are using CAN communication system to
switch, inside air temperature sensor, outside air communicate with other control modules. For more
temperature sensor and sunload sensor and controls the detail of CAN communication, refer to Communication
temperature control actuator so that the current position System Description. (Communication System
of the temperature control door matches its target Description): CAN in Section 10H
position. ECM turns ON the A/C compressor relay when the
vehicle state satisfies the conditions described below.
Fan Speed Control • A/C switch ON signal is inputted
BCM calculates the target blower fan speed based on • A/C refrigerant pressure is within specified range
signals from the temperature control switch, inside air
temperature sensor, outside air temperature sensor, • Engine speed is within specified range
ECT sensor and sunload sensor, compares the speed • Engine coolant temperature is lower than specified
thus calculated with the current blower fan speed value
inputted from the blower motor controller to adjust the • Throttle opening is lower than specified value
current blower fan speed to the target level. • Vehicle is not in either starting or quick acceleration
state
Air Flow Outlet Control
• ECT sensor malfunction is not detected
BCM calculates the target temperature control door
position based on signals from the temperature control • A/C refrigerant pressure sensor malfunction is not
switch, inside air temperature sensor, outside air detected
temperature sensor, ECT sensor and sunload sensor.
7B-2 HVAC System:
Radiator Cooling Fan Relay Control

ECM turns ON the radiator cooling fan relay at the same
time when ECM turns ON the A/C compressor relay.
HVAC System Construction
9
12
10
13 13
9
24 23
19
1
20
22
14
15
18 11 11
17
16
21
8
6
4
2
7
5
: [A]
3
: [B]
: [C]
IFRA0A721001-01
[A]: Air flow 7. Liquid pipe 16. Evaporator

[B]: Refrigerant flow 8. Expansion valve 17. Air intake door
[C]: Engine coolant flow 9. Side ventilation air 18. Temperature control door
1. HVAC unit 10. Center ventilation air 19. Air flow control door
2. Compressor 11. Front foot air 20. Heater core
3. Condenser assembly 12. Defroster air 21. HVAC air filter
4. Receiver / dryer 13. Demister air 22. Engine
5. Discharge hose 14. Fresh air 23. Radiator
6. Suction hose 15. Recirculation air 24. Reservoir
Sub-Cool A/C System Description

AENNTA0E7201003 (03(01)
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.
HVAC System: 7B-3
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

AENNTA0E7201004 (03(01)
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.
A/C Operation Description

AENNTA0E7201005 (03(01)
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”: CAN in Section
10H.
7B-4 HVAC System:
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.
Control at ABS model: ECM stops A/C compressor temporarily by turning A/C
shortage of Brake booster compressor relay OFF according to signals from brake booster
brake booster switch, wheel switch and others so as to ensure enough vacuum for braking.
vacuum speed sensor
and brake
switch
ESP® model: ECM stops A/C compressor temporarily by turning A/C
Brake booster compressor relay OFF according to signals from brake booster
pressure pressure sensor and others so as to ensure enough vacuum for
sensor, wheel braking.
speed sensor
and brake
switch
HVAC System: 7B-5
Input sensor
Control item Description
(or signal)
Radiator (condenser) cooling fan A/C refrigerant ECM drives radiator cooling fan in low or high speed mode under
relay control pressure sensor the following conditions by turning radiator cooling fan relays
and wheel No.1, No.2 and No.3 ON/OFF according to signals from A/C
speed sensor 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.

AENNTA0E7201006 (03(01)
BCM detects malfunctions, which may occur in the 1
following areas:
• Inside air temperature sensor
• Sunload sensor
• CAN communication line
• LIN communication line
• Temperature control actuator
• Air flow control actuator
IMTA0A720001-03
• Air intake control actuator
• Auto A/C panel
• BCM AENNTA0E7201007 (03(01)
When BCM detects malfunction, the “AUTO” display (1) BCM communicates with other control modules through
flashes to warn and the diagnostic trouble code (DTC) is CAN communication. For CAN communication, refer to
stored in the memory of the module. When diagnosing Communication System Description. (Communication
trouble, the DTC can be checked with “DTC Check”. System Description): CAN in Section 10H

Auto A/C Electronic Control Input / Output Block Diagram
AENNTA0E7202001 (10(01)
7B-6 HVAC System:
Input sensor (or signal) Electronic control Output actuator (or signal)
Auto A/C panel BCM Auto A/C panel

Temperature control switch LCD
Blower speed switch Air intake indicator
Temperature control
“MODE” (air flow) switch A/C indicator
Air intake switch Defroster indicator
A/C switch Air flow control
Rear defogger indicator
“AUTO” switch
Defroster switch
Air intake control
Rear defogger switch
“OFF” switch
Blower motor control Temperature control actuator
Inside air temperature sensor
Sunload sensor ENG A-STOP control

Air intake control actuator
position sensor
Air flow control actuator Blower motor controller

position sensor
Temperature control actuator position

sensor Air flow control actuator
Blower motor controller
Outside air temperature sensor

LIN communication
Evaporator temperature sensor ECM
Combination meter CAN communication Electric load signal

Auto A/C signal
Illumination signal
IS A/C status Warning function
Combination meter
IS A/C signal
Self-diagnosis
ECM
Compressor signal
Engine speed signal Fail-safe function
Engine coolant temperature signal
Vehicle speed signal
A/C refrigerant pressure signal
ECM
APP sensor
A/C compressor relay control A/C compressor relay
ECT sensor
CKP sensor
Compressor
BCM Radiator cooling fan relay control Radiator cooling fan relay
A/C switch status
Evaporator temperature signal
Electric load signal
Radiator cooling fan motor
Wheel speed sensor
ABS/ESP® control module

Wheel speed signal
Brake booster vacuum signal
(ABSmodel/ESP® model)
Brake booster swich (ABS model)
CAN communication
Brake booster pressure sensor
(ESP® model) LIN communication
IMTA0A720002-06
HVAC System: 7B-7
Auto A/C System Circuit Diagram

AENNTA0E7202002 (10(01)
23
1 12V 5V
24 25
31
52 YEL G227-5
32
2
51 RED G227-2
53 33
12V
26
34
54 PPL G227-4
3 35
27
12V 36
4 31
5 37
BLK 28
YEL 38
53
6 11 39
12
45 40
41
7 42
G227-7 29
BLU 13
G227-8
8 BLK
PNK
WHT LT GRN 43
9 5V 5V
44
BLK E04-11 LT GRN
LT GRN G05-11 29
E04-6 BRN
10
14
5V
GRY 15 12V 46
LT GRN G05-3 G04-15 LT BLU
16 RED G05-19 5V
47
G05-22 LT BLU
17 12V
18 48
G04-16 BLU
19 30 5V G04-32 LT GRN
5V
G05-4 GRN
G05-20 PPL
20
12V
49
12V G05-17 PPL

G05-1 LT BLU
5V
21
G05-21 GRY
12V
50
G05-18 PNK
G05-5 WHT
5V
G05-2 BRN
22 54 RED E04-5 G04-22 YEL
54 22
WHT E04-17
IMTA0A720003-02
7B-8 HVAC System:
1. J/B 20. A/C refrigerant pressure sensor 39. Blower speed switch (UP)
2. Rear defogger relay 21. CKP sensor 40. Blower speed switch (DOWN)
3. Rear defogger 22. CAN driver 41. Defroster switch
4. Relay box 23. Auto A/C panel 42. Rear defogger switch
5. Blower motor relay 24. Power supply switch 43. BCM
6. Main relay 25. Power supply circuit 44. Outside air temperature sensor
7. Radiator cooling fan relay No.1 26. Illumination light 45. Inside air temperature sensor
8. Radiator cooling fan relay No.2 27. Indicator light 46. Evaporator temperature sensor
9. Radiator cooling fan relay No.3 28. LCD back light 47. Sunload sensor
10. A/C compressor relay 29. LIN driver 48. Temperature control actuator
11. Blower motor 30. CPU 49. Air flow control actuator
12. Diode 31. LCD 50. Air intake control actuator
13. Radiator cooling fan motor 32. Temperature control switch (UP) 51. To lighting switch or BCM
14. Compressor 33. Temperature control switch (DOWN) 52. To battery
15. Blower motor controller 34. A/C switch 53. To ignition power supply
16. ECM 35. “MODE” (air flow) switch 54. To other control module and DLC connected by CAN
17. APP sensor (main) 36. “AUTO” switch 55. To combination meter
18. APP sensor (sub) 37. “OFF” switch
19. ECT sensor 38. Air intake switch
Component Location
Auto A/C Control System Component Location
AENNTA0E7203001 (04(01)
HVAC System: 7B-9
31
18
15
1
19
11 6
4 7 8 9 10 13 14 12
24 23 22
IMTA0A720004-04
7B-10 HVAC System:
15
[A]: 33
[B]: 34
20
32
27
26
29
16
25 28
30
17
21
IMTA0A720005-01
[A]: ABS model 11. Blower speed switch 23. Blower motor controller
[B]: ESP® model 12. “MODE” (air flow) switch 24. Blower motor
1. BCM 13. Defroster switch 25. Radiator cooling fan relay No.1
2. Rear defogger relay 14. Rear defogger switch 26. Radiator cooling fan relay No.2
3. Auto A/C panel 15. HVAC unit 27. Radiator cooling fan relay No.3
4. Inside air temperature sensor 16. Compressor 28. Blower motor relay
5. Sunload sensor 17. Radiator cooling fan 29. A/C compressor relay
6. Temperature control switch 18. Temperature control actuator 30. Main relay
7. Air intake switch 19. Air flow control actuator 31. Air intake control actuator
8. A/C switch 20. A/C refrigerant pressure sensor 32. ECM
9. “OFF” switch 21. Outside air temperature sensor 33. Brake booster switch
10. “AUTO” switch 22. Evaporator temperature sensor 34. Brake booster pressure sensor

A/C System Performance Inspection
AENNTA0E7204001 (06(01)
1) Check that vehicle and environmental conditions are as follows.
• Vehicle is put indoors.
• Ambient temperature is within 25 – 35 °C (77 – 95 °F).
• Relative humidity is within 30 – 70%.
HVAC System: 7B-11
• 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 charging valve (4) and low pressure charging hose (5)
to low pressure charging valve (6).
NOTE
For locations of high pressure charging valve and low pressure charging valve, refer to “A/C System
Major Components”.
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 switch to maximum speed position, temperature control switch to
maximum cold position, “MODE” (air flow) switch to face position, air intake switch 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.
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.
7B-12 HVAC System:
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”.
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 measured 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.
Cooling inspection graph (High and low pressure gauge)
2
psi kPa kgf/cm %
319.1 2200 22
304.6 2100 21
290.0 2000 20
275.6 1900 19
261.1 1800 18
246.6 1700 17
70
232.1 1600 16
217.6 1500 15 30
203.1 1400 14
188.5 1300 13 “f”
[e]
[a] 174.0 1200 12
159.5 1100 11
145.0 1000 10 “g”
[d]
130.5 900 9
116.0 800 8
102.0 700 7
87.0 600 6
72.5 500 5 “h”
70
[b] 58.0 400 4
30
43.5 300 3 [e]
29.0 200 2 “i”
14.5 100 1
0
25 30 35 °C 40 °C
77 86 95 °F 104 °F
[c ]
IMTA0A720046-03
[a]: Pressure on high pressure gauge [c]: Ambient temperature [e]: Acceptable range
[b]: Pressure on low pressure gauge [d]: Humidity
HVAC System: 7B-13
An example of normal condition, judged from measurement result and cooling inspection graph (ambient
temperature at 30 °C (86 °F))
1170 – 1290 kPa
Pressure on high pressure gauge (HI) (11.9 – 13.2 kgf/cm2)
(170 – 187 psi)
260 – 330 kPa
Pressure on low pressure gauge (LO) (2.7 – 3.4 kgf/cm2)
(37.7 – 47.9 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 of Check radiator cooling fan.
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.
(Engine Cooling Symptom
Diagnosis) in Section 1F
Pressure is lower than Insufficient refrigerant (insufficient charge or leakage) Check for leakage, repair if
acceptable range (“g” area) necessary and recharge.
Expansion valve malfunction (valve opens too wide) Check expansion valve.
Compressor malfunction (insufficient compression) Check compressor.
Low pressure gauge

Pressure is higher than Expansion valve malfunction (valve opens too wide) Check expansion valve.
acceptable range (“h” area) Compressor malfunction (insufficient compression) Check compressor.
Pressure is lower than Insufficient refrigerant (insufficient charge or leakage) Check for leakage, repair if
acceptable range (“i” area) necessary and recharge.
Expansion valve malfunction (valve opens too narrow) Check expansion valve.
Clogged refrigerant passage (crashed pipe) Repair or replace.
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 30 °C (86 °F) and the one at air outlet of center ventilation louver is 17 °C
(62.6 °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.
7B-14 HVAC System:
Cooling inspection graph (Thermometer at center ventilation louver)

°F °C %
86.1 30
84.2 29
82.4 28
70
80.6 27
78.8 26
77.0 25
75.2 24 [c]
73.4 23
71.6 22
69.8 21
68.0 20 “f”
66.2 19 30
64.4 18 [d]
62.6 17 [e]
[a] 60.8 16
59.0 15
57.2 14
55.4 13
53.6 12 “g”
51.8 11
50.0 10
48.2 9
25 30 35 °C 40 °C
77 86 95 °F 104 °F
[b]
IMTA0A720047-03
[a]: Temperature at outlet of center ventilation louver [c]: Humidity [e]: Crossing point
[b]: Temperature near air inlet of HVAC unit [d]: Acceptable range
Thermometer at center ventilation louver

Crossing point is higher than Insufficient or excessive charge of Check refrigerant pressure.
acceptable range (“f” area) refrigerant
Dirty or bent evaporator fins Clean or repair.
Air leakage from cooling (heater) unit Repair or replace.
or air duct
Malfunctioning, switch over function of Repair or replace.
door in cooling (heater) unit
Compressor malfunction Check compressor.
Crossing point is lower than Insufficient air volume from center Check blower motor and fan.
acceptable range (“g” area) ventilation louver (heater blower
malfunction)
Compressor malfunction Check compressor.
12) After completion of repair, check the system performance again.
Trouble Diagnosis for Abnormal Pressure

AENNTA0E7204002 (06(01)
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”.
2. Use these values in place of the normal pressure in the following table.
HVAC System: 7B-15
Condition
Manifold gauge (kPa (kgf/cm2)
Possible cause Correction
(psi)) Detail
LO HI
260 – 330 (2.7 – 1170 – 1290 Normal condition
3.4) (37.7 – 47.9) (11.9 – 13.2) — —
(170 – 187)
Negative 500 – 600 (5.1 LO gauge reads negative Dust particles accumulate Replace expansion valve.
pressure – 6.1) (72.6 – pressure, while HI gauge or water droplets are Replace condenser
87.0) reads extremely low frozen inside expansion assembly.
pressure. valve, preventing Evacuate A/C system and
Presence of frost around refrigerant from flowing. recharge system with
tubing to and from fresh refrigerant.
condenser assembly and
expansion valve.
Normal Normal During A/C operation, LO Expansion valve is frozen Replace expansion valve.
condition: condition: gauge sometimes due to moisture in system, Replace condenser
260 – 330 (2.7 – 1170 – 1290 indicates negative temporarily shutting off assembly.
3.4) (37.7 – 47.9) (11.9 – 13.2) pressure, and sometimes refrigeration cycle. Evacuate A/C system and
↑↓ (170 – 187) normal pressure. Also HI recharge system with
Abnormal ↑↓ gauge reading fluctuates fresh refrigerant.
condition: Abnormal between abnormal and
Negative condition: normal pressures.
pressure 700 – 1000 (7.2
– 10.2) (102 –
145)
50 – 150 (0.5 – 700 – 1000 Both LO and HI gauges Insufficient refrigerant in Using leak detector, check
1.5) (7.26 – 21.7) (7.2 – 10.2) indicate low readings. system (refrigerant for leakage and repair if
(102 – 145) Output air is slightly cold. leakage). 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 (4.1 – Pressure on LO gauge is Internal leakage in Check compressor and
6.1) (58.1 – 87.0) high. compressor. repair or replace if
Pressure on HI gauge is necessary.
low.
Both pressures become
equal right after A/C is
turned OFF.
7B-16 HVAC System:
Condition
Manifold gauge (kPa (kgf/cm2)
Possible cause Correction
(psi)) Detail
LO HI
400 – 450 (4.1 – 2000 – 2500 High pressure reading on Overcharged A/C system. Adjust refrigerant to
4.6) (58.1 – 65.2) (20.4 – 25.5) both LO and HI gauges. Faulty radiator cooling specified amount.
(290 – 362) operation. Clean condenser.
Faulty radiator cooling fan Check and repair radiator
operation. cooling fan.
High pressure reading on Presence of air in A/C Replace condenser.
both LO and HI gauges. system (improperly Check quantity of
Low pressure tubing is not evacuated). compressor oil and
cold when touched. presence of contaminants
in oil.
Evacuate system and
recharge system with
fresh refrigerant.
450 – 550 (4.6 – High pressure reading on Faulty expansion valve. Replace expansion valve.
5.6) (65.3 – 79.7) both LO and HI gauges. Refrigerant flow is not
Large amount of frost or regulated properly.
dew on low pressure
tubing.
A/C System Symptom Diagnosis

AENNTA0E7204003 (06(04)
Blower motor does not operate

• Blown fuse Check related fuses, and then check for short circuit to
ground.
• Faulty blower motor relay Check blower motor relay. (HVAC System Relay Inspection)
• Faulty blower motor Check blower motor. (Blower Motor Inspection)
• Faulty blower motor controller Check blower motor controller. (Blower Motor Controller
Inspection)
• Faulty auto A/C panel Check auto A/C panel. (Inspection of Auto A/C Panel and
Its Circuit)
• Faulty BCM Check BCM. (Inspection of BCM and Its Circuits) in Section
10B
No cool air comes out (A/C system does not operate)

ground.
• Faulty A/C compressor relay Check A/C compressor relay. (HVAC System Relay
Inspection)
• Faulty auto A/C panel Check auto A/C panel. (Inspection of Auto A/C Panel and
Its Circuit)
®
• Faulty ABS/ESP Check ABS/ESP® control module.
• ABS model: (ABS Check) in Section 4E
• ESP® model: (ESP® System Check) in Section 4F
• Faulty ECM and its circuit Check ECM. (Inspection of A/C System Circuits at ECM)
• Faulty magnet clutch Check magnet clutch. (Magnet Clutch Inspection)
• Loose or broken compressor drive belt Check compressor drive belt. (Compressor Drive Belt
Inspection)
• Faulty compressor Check compressor.
HVAC System: 7B-17
• No refrigerant Check amount of refrigerant and system for leakage.

Recover refrigerant, evacuate and charge A/C system.
(Operation Procedure for Refrigerant Charge)
• Faulty A/C refrigerant pressure sensor Check A/C refrigerant pressure sensor. (A/C Refrigerant
Pressure Sensor and Its Circuit Inspection)
• Faulty evaporator temperature sensor Check evaporator temperature sensor. (Evaporator
Temperature Sensor Inspection)
10B
No cool air comes out (radiator cooling fan motor does not operate)
ground.
• Faulty radiator cooling fan relay Check radiator cooling fan relay. (HVAC System Relay
Inspection)
Assembly On-Vehicle Inspection) in Section 1F
• Faulty ECM Check ECM. (Inspection of A/C System Circuits at ECM)
10B
Cool air does not come out or insufficient cooling (A/C compressor in normal operation)
• Faulty temperature control actuator Check temperature control actuator. (Temperature Control
Actuator Inspection)
• Air leakage from HVAC unit or air duct Repair HVAC unit or air duct.
Inspection)
• Faulty compressor Check compressor.
• Faulty expansion valve Check expansion valve. (Expansion Valve Inspection)
• Faulty heater and ventilation system Check HVAC unit.
• Insufficient or excessive charge of refrigerant Check amount of refrigerant and system for leakage.
• Excessive compressor oil in A/C system Drain excessive compressor oil from A/C system circuit and
compressor.
• Clogged condenser Check condenser. (Condenser Assembly On-Vehicle
Inspection)
• Clogged or frosted evaporator Check evaporator and evaporator temperature sensor.
• Evaporator: (Evaporator Inspection)
• Evaporator temperature sensor: (Evaporator
• Air in A/C system Replace condenser, and then evacuate and charge A/C
system with refrigerant. (Operation Procedure for
Refrigerant Charge)
Cool air does not come out intermittently

• Excessive amount of refrigerant Check the amount of refrigerant.
• Faulty expansion valve Check expansion valve. (Expansion Valve Inspection)
7B-18 HVAC System:

• Excessive moisture in A/C system Replace condenser, and then evacuate and charge A/C
system. (Operation Procedure for Refrigerant Charge)
• Faulty wiring connection Repair wiring if necessary.
Cool air comes out only at high speed

Inspection)
• Faulty A/C compressor Check A/C compressor.
• Clogged condenser Check condenser. (Condenser Assembly On-Vehicle
Inspection)
• Insufficient charge of refrigerant Check the amount of refrigerant and system for leakage.
• Air in A/C system Replace condenser, and then evacuate and charge A/C
system with refrigerant. (Operation Procedure for
Refrigerant Charge)
Cool air does not come out only at high speed

• Excessive amount of refrigerant Check the amount of refrigerant.
• Frosted evaporator Check evaporator and evaporator temperature sensor.
Insufficient cool air flow

• Air leakage from HVAC unit or air duct Repair HVAC unit or air duct.
• Clogged or frosted evaporator Check evaporator and evaporator temperature sensor.
• Faulty wiring or grounding Repair wiring if necessary.
Abnormal Noise Symptom Diagnosis of A/C System

AENNTA0E7204004 (06(04)
Abnormal Noise from Compressor
During compressor operation, a rumbling noise is heard as to engine speed increases

• Inadequate clearance in scroll area Replace compressor. (Compressor Assembly Removal and
Installation)
Loud noise is heard at certain rpm, irrespective of greatness of speed in

• Loose or faulty compressor drive belt Check compressor drive belt. (Compressor Drive Belt
Inspection)
• Loose compressor mounting bolts Retighten mounting bolts. (Compressor Assembly Removal
and Installation)
Loud rattle is heard at low engine rpm

• Loose compressor armature plate bolt Replace compressor if it has operated in rattling condition
for a long time.
HVAC System: 7B-19
Retighten armature plate bolt. (Magnet Clutch Removal and

Installation)
Abnormal Noise from Magnet Clutch
Rumbling noise is heard when compressor is not in operation

• Worn or damaged bearings Replace magnet clutch assembly. (Magnet Clutch Removal
and Installation)
Chattering noise is heard when compressor is in operation

• Faulty magnet clutch clearance (excessive
clearance) Adjust magnet clutch clearance. (Magnet Clutch Removal
and Installation)
• Worn magnet clutch friction surface Replace magnet clutch assembly. (Magnet Clutch Removal
and Installation)
• Compressor oil leakage from shaft seal,
contaminating friction surface Replace compressor body assembly. (Compressor
Abnormal Noise from Tubing
Droning noise is heard from inside of the vehicle, but not particularly noticeable in engine compartment
• Faulty tubing clamps Reposition clamps or increase number of clamps.
• Resonance caused by pulsation from variations in
refrigerant pressure Attach a silencer to tubing, or modify its position and length.
Abnormal Noise from Condenser Assembly
Considerable vibration in condenser assembly

• Resonance from condenser assembly bracket and
body Firmly insert a silencer between condenser assembly
bracket and body.
Abnormal Noise from Crankshaft Pulley
Large rattling noise is heard at idle or sudden acceleration

• Loosen crankshaft pulley bolt Retighten bolt. (Timing Chain Cover Components) in
Section 1D
Abnormal Noise from Tension Pulley
Clattering noise is heard from pulley

• Worn or damaged bearing Replace tension pulley.
Pulley cranks upon contact

• Cracked or loose bracket Replace or retighten bracket.
7B-20 HVAC System:
Abnormal Noise from Evaporator
Whistling sound is heard from evaporator

• Depending on the combination of the interior /
exterior temperatures, engine rpm and refrigerant
pressure, the refrigerant flowing out of the
expansion valve may generate whistling sound. Slightly decreasing amount of refrigerant may stop this
noise.
Check expansion valve and replace it if faulty. (Expansion
Valve Inspection)
Abnormal Noise from Blower Motor
Blower motor emits a chirping sound in proportion to its speed of rotation

• Worn or damaged motor brushes or commutator Replace blower motor. (Blower Motor Removal and
Installation)
Fluttering noise or large droning noise is heard from blower motor

• Leaves or other debris introduced from fresh air
inlet to blower motor Remove debris and check that screen at fresh air inlet is
intact.
Air Conditioning System Check

AENNTA0E7204005 (06(01)

1) Perform “Step 1. Customer Complaint Analysis”.
Yes Go to Step 2.

1) Perform “Step 2. Visual Inspection”.
Yes Repair or replace defective part.

No Go to Step 3.
Step 3 DTC check

1) Perform “Step 3. DTC Check”.
Is there any DTC?
Yes Go to Step 4.
No Go to Step 5.
Step 4 DTC troubleshooting

1) Perform “Step 4. DTC Troubleshooting”.

HVAC System: 7B-21
No Go to Step 5.
Step 5 A/C system performance inspection

1) Perform “Step 5. A/C System Performance Inspection”.

No Go to Step 6.
Step 6 A/C system symptom diagnosis

1) Check and repair A/C system. (Step 6. A/C System Symptom Diagnosis)

No Go to Step 7.
Step 7 Check for intermittent problem

1) Check for intermittent problems. (Step 7. Intermittent Problem Check)

No Go to Step 8.

1) Perform “Step 8. Final Confirmation Test”.
Is there any malfunction code?
Yes Go to Step 4.
No End.
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.
7B-22 HVAC System:
Customer’s Name: Model: VIN:
Date of Issue: Date of Reg: Date of Problem: Mileage:
“AUTO” indicator lamp abnormal: fails to turn on/fails to turn off / blinks
Abnormal noise while compressor is working: from compressor /
from condenser fan motor other
Problem Symptoms Chattering from compressor:
Condenser fan motor does not work:
Compressor does not work:
Other:
Continuous / Intermittent( times a day, a month)/
Frequency of Occurrence
other
Vehicle at stop & compressor is working:
For some time after A/C switch is ON:
Conditions for
When outside air temperature is high:
Occurrence of Problem
When outside air temperature is low:
All the time:
Weather: fair/cloudy/rain/snow/other
Environmental Condition
Temperature: C ( F)
First check: No DTC / DTC ( )
DTC
Second check after test drive: No DTC / DTC ( )
IFRA0A722027-01
Step 2. Visual Inspection Step 6. A/C System Symptom Diagnosis

As a preliminary step, perform visual check of the items Check any part or system suspected to be a possible
that support proper function of the air conditioning cause referring to “A/C System Symptom Diagnosis”.
system referring to “Visual Inspection”.
Step 7. Intermittent Problem Check
Step 3. DTC Check Check parts that are prone to cause intermittent problem
Check DTC referring to “DTC Check”. (e.g. wire harness, connector, etc.), referring to
“Intermittent Connection and Poor Contact Inspection” in
Step 4. DTC Troubleshooting Section 00 and related circuit of trouble code recorded.
Based on the DTC, perform an applicable DTC
diagnostic flow and locate the cause of the trouble, Step 8. Final Confirmation Test
namely in a sensor, wire harness, connector, actuator, Check that trouble symptom has disappeared and A/C
ECM or other part and repair faulty parts. system is free from abnormal conditions. Clear recorded
DTCs, check that the same DTC is not detected and
Step 5. A/C System Performance Inspection check if any other DTC is detected.
Check A/C system suspected to be a possible cause
referring to “A/C System Performance Inspection”.
Visual Inspection
AENNTA0E7204006 (06(01)
• Battery – Fluid level and corrosion of terminals “Battery Description” in Section 1J
• Connectors of electric wire harness – “Intermittent Connection and Poor Contact Inspection” in Section
Disconnection and friction 00
• Fuses – Blowout “Intermittent Connection and Poor Contact Inspection” in Section
00
HVAC System: 7B-23

• Parts – Installation and damage —
DTC Check – Check DLC power circuit and ground

AENNTA0E7204007 (06(01) circuit.
0A.
DLC cable.
2) Light sunload sensor with an incandescent light of
approximately 100 W placed directly above it at
distance of about 100 mm (3.94 in.).
NOTE “Diagnosis flow: [a]” in
“Troubleshooting” of “Troubleshooting
DTC B150A-13 is detected even though there for Lost Communication”: CAN in
is not any malfunction if sunload sensor is Section 10H.)
not lit by an incandescent light. Light the
sunload sensor with a light. – Check CAN communication system.
3) Set ignition “ON”. Off” is detected in any control module.)
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 – Check central gateway control module
details. power supply circuit and ground circuit.
NOTE Module and Its Circuits): CAN (Central
temporary overlap of communication load. – Check BCM power circuit and ground
If communication error occurs, wait about circuit. (BCM Power Supply and Ground
10 seconds and try the operation again. Circuit Check) in Section 10B
• If communication between SUZUKI scan 5) Disconnect SUZUKI scan tool from DLC. Refer to
tool and BCM is not possible, perform the “Suzuki SDT-II Connection and Disconnection” in
following checks: Section 0A.
between PC and VCI using SUZUKI scan DTC Clearance
tool function. AENNTA0E7204008 (06(01)
Refer to “DTC Clearance” in Section 10B.
DTC Table
AENNTA0E7204009 (06(01)
NOTE
Perform “Air Conditioning System Check” before starting DTC troubleshooting.
DTC
DTC name “AUTO” indicator
Display SUZUKI scan tool
B1501-11 (DTC B1501-11 / B1501- Outside Air Temperature Sensor Circuit Short To
Blinking
13) Ground
B1501-13 (DTC B1501-11 / B1501-
Outside Air Temperature Sensor Circuit Open Blinking
13)
B1503-11 (DTC B1503-11 / B1503- A/C Evaporator Temperature Sensor Circuit Short
Blinking
13) To Ground
B1503-13 (DTC B1503-11 / B1503-
A/C Evaporator Temperature Sensor Circuit Open Blinking
13)
B1508-11 (DTC B1508-11 / B1508- Inside Air Temperature Sensor Circuit Short To
Blinking
13) Ground
B1508-13 (DTC B1508-11 / B1508-
Inside Air Temperature Sensor Circuit Open Blinking
13)
B150A-11 (DTC B150A-11) Sunload Sensor Circuit Short To Ground Off
B150A-13 (DTC B150A-13) Sunload Sensor Circuit Open Off
7B-24 HVAC System:
DTC
DTC name “AUTO” indicator
Display SUZUKI scan tool
B150C-11 (DTC B150C-11 / Temperature Control Actuator Position Sensor
Blinking
B1519-11 / B151B-11) Circuit Short To Ground
B150C-13 (DTC B150C-13 / Temperature Control Actuator Position Sensor
Blinking
B1519-13 / B151B-13) Circuit Open
B1513-71 (DTC B1513-71 / B1514-
Temperature Control Actuator Stuck Blinking
71 / B1531-71)
B1514-71 (DTC B1513-71 / B1514-
Air Flow Control Actuator Stuck Blinking
71 / B1531-71)
B1519-11 (DTC B150C-11 / B1519- Air Flow Control Actuator Position Sensor Circuit
Blinking
11 / B151B-11) Short To Ground
B1519-13 (DTC B150C-13 / Air Flow Control Actuator Position Sensor Circuit
Blinking
B1519-13 / B151B-13) Open
B151B-11 (DTC B150C-11 / B1519- Air Intake Control Actuator Position Sensor Circuit
Blinking
11 / B151B-11) Short To Ground
B151B-13 (DTC B150C-13 / Air Intake Control Actuator Position Sensor Circuit
Blinking
B1519-13 / B151B-13) Open
B1531-71 (DTC B1513-71 / B1514-
Air Intake Control Actuator Stuck Blinking
71 / B1531-71)
B1546-00 (DTC B1546-00) A/C Refrigerant Pressure Off
B1549-87 (DTC B1549-87 / U2005-
LIN Invalid Data from BCM to Auto A/C Panel Blinking
87)
B1563-81 (DTC B1563-81) A/C Refrigerant Pressure Sensor and/or Its Circuit Off
U0073-88 (DTC U0073-87) Control Module Communication Bus Off Blinking
U0100-87 (DTC U0100-87 /
Lost Communication With ECM Blinking
U0155-87)
U0155-87 (DTC U0100-87 / Lost Communication With Instrument Panel
Off
U0155-87) Cluster (IPC) Control Module
U2005-87 (DTC B1549-87 / U2005-
LIN Lost Communication with Auto A/C Panel Blinking
87)
Fail-Safe Table
AENNTA0E7204010 (06(01)
DTC Fail-safe operation
B1501-11 (DTC
B1501-11 /
B1501-13)
BCM controls actuators assuming that outside air temperature is 20 °C (68 °F).
B1501-13 (DTC
B1501-11 /
B1501-13)
B1503-11 (DTC
B1503-11 /
B1503-13)
BCM controls actuators assuming that evaporator temperature is 0 °C (32 °F).
B1503-13 (DTC
B1503-11 /
B1503-13)
B1508-11 (DTC
B1508-11 /
B1508-13) /
BCM controls actuators assuming that inside air temperature is 25 °C (77 °F).
B1508-13 (DTC
B1508-11 /
B1508-13)
HVAC System: 7B-25
DTC Fail-safe operation

BCM controls actuators assuming the following points.
• Temperature control selector is at 25 °C (77 °F) position.
B1549-87/ • Mode switch is in “DEF” mode.
U2005-87 (DTC
• Air intake switch is in “FRE” mode.
B1549-87 /
U2005-87) • Blower fan speed is “Auto”.
• A/C system is ON.
• Rear defogger is OFF.
U0100-87 (DTC
BCM controls actuators assuming that water air temperature is 80 °C (77 °F).
U0100-87 /
BCM controls actuators assuming that speed is 255 km/h (158 MPH).
U0155-87)
Scan Tool Data

AENNTA0E7204011 (06(01)
BCM
NOTE
• If communication between SUZUKI scan tool and BCM is not possible, perform the following
checks:
– Check BCM power circuit and ground circuit. (BCM Power Supply and Ground Circuit Check) in
Section 10B
Normal condition /
Scan tool data Condition
Reference value
Temp Cont Switch Ignition: “ON”
Maxcool
(Temp Cont Switch Temperature control switch: “LO” position
(Temperature control Ignition: “ON”
18 °C (64.4 °F) – 32 °C (89.6
switch position, Each reference value is relative to the selected position
°F)
Maxcool, °C / °F, according to temperature control switch.
Maxhot)) Ignition: “ON”
Maxhot
Temperature control switch: “HI” position
Mode Cont Switch Ignition: “ON”
FACE
(Mode Cont Switch (Air “MODE” switch: “FACE” position
flow switch position, Ignition: “ON”
B/L
AUTO, FACE, B/L, “MODE” switch: “FACE” + “FOOT” position
FOOT, DFR/FOOT, Ignition: “ON”
FOOT
DFR)) “MODE” switch: “FOOT” position
Ignition: “ON”
DFR/FOOT
“MODE” switch: “FOOT” + “DEF” position
Ignition: “ON”
DFR
Defroster switch: ON
Ignition: “ON”
AUTO
“AUTO” switch: ON
7B-26 HVAC System:
Normal condition /
Reference value
Fan Cont Switch (Fan Ignition: “ON”
OFF
Cont Switch (Blower Blower speed switch: OFF
speed switch, AUTO, Ignition: “ON”
OFF, 1st – 8th)) Each reference value is relative to the selected position 1st – 8th
according to blower speed switch.
Ignition: “ON”
AUTO
Air Intake Mode (Air Ignition: “ON”
REC
Intake Mode (Air intake Air intake switch: “REC” position
switch position, AUTO, Ignition: “ON”
FRE
FRE, REC)) Air intake switch: “FRE” position
Ignition: “ON”
AUTO
Engine: Idle speed with no load applied after warming up 590 – 690 rpm
Speed (rpm))
Vehicle Speed (Vehicle
Vehicle stops 0 km/h (0 MPH)
Speed (km/h, MPH))
ECT (ECT (Engine
Approx. 80 °C (176 °F) – 100
coolant temperature °C, At specified idle speed after warming up
°C (212 °F)
°F))
Destination (Destination
(N/A, JP, EU, UK, US,
CA, AU, SA, IN, CN, Displays the current destination.
MX, DE km/mile, DE km,
DE mile))
Outside Air Temp
(Outside Air Temp Ignition: “ON” –40 °C – 87.5 °C (–40 °F –
(Outside air Each reference value is relative to outside air temperature. 189.5 °F)
temperature, °C, °F))
Cabin Temperature
Ignition: “ON” –40 °C – 87.5 °C (–40 °F –
(Cabin Temperature (In-
Each reference value is relative to in-car temperature. 189.5 °F)
car temperature, °C, °F))
Sun Load (Sun Load (W/ Ignition: “ON”
0 W/m2 – 1275 W/m2
m2)) Each reference value depends on the situation.
Evaporator Temp
A/C switch: ON
(Evaporator Temp
Temperature control switch: “LO” position 0 °C – 5 °C (32 °F – 41 °F)
(Evaporator
Blower speed switch: 1st position
temperature, °C, °F))
Refrigerant Pressure 1170 – 1290 kPa
(Refrigerant Pressure Ignition: “ON” (For details, refer to pressure
(A/C refrigerant absolute A/C system: ON (compressor is operating) of high pressure gauge under
pressure, kPa)) Ambient temperature: 30 °C (86 °F) “A/C System Performance
Inspection”.)
Target Air Mix Pos Sen Ignition: “ON”
Approx. 3.7 V
(Target Air Mix Pos Sen Temperature control switch: “LO” position
(Target temperature
Ignition: “ON”
control actuator position Approx. 1.0 V
Temperature control switch: “HI” position
sensor, V))
Air Mix Pos Sen(Air Mix Ignition: “ON”
Approx. 3.7 V
Pos Sen (Temperature Temperature control switch: “LO” position
control actuator position Ignition: “ON”
Approx. 1.0 V
sensor, V)) Temperature control switch: “HI” position
Target Mode Pos Sen Ignition: “ON”
Approx. 3.7 V
(Target Mode Pos Sen “MODE” switch: “FACE” position
(Target air flow control
Ignition: “ON”
actuator position sensor, Approx. 1.0 V
V))
HVAC System: 7B-27
Normal condition /
Reference value
Mode Pos Sen (Mode Ignition: “ON”
Approx. 3.7 V
Pos Sensor (Air flow “MODE” switch: “FACE” position
control actuator position Ignition: “ON”
Approx. 1.0 V
sensor, V)) Defroster switch: ON
Target Mode Position Ignition: “ON”
FACE
(Target Mode Position “MODE” switch: “FACE” position
(Target air flow control Ignition: “ON”
B/L
actuator position, FACE, “MODE” switch: “FACE” + “FOOT” position
FACE + FOOT, FOOT, Ignition: “ON”
FOOT
FOOT + DEF, DEF)) “MODE” switch: “FOOT” position
Ignition: “ON”
DFR/FOOT
“MODE” switch: “FOOT” + “DEF” position
Ignition: “ON”
DFR
Target Air Intake Control Ignition: “ON”
Approx. 4.0 V
Actuator Position Air intake switch: “REC” position
Sensor (Target Air
Ignition: “ON”
Intake Control Actuator Approx. 1.6 V
Air intake switch: “FRE” position
Position Sensor (V))
Target Air Intake Pos Ignition: “ON”
REC
(Target Air Intake Pos Air intake switch: “REC” position
(Target air intake H-REC
Ignition: “ON”
actuator position, REC, (A temperature to switch to H-
Air intake mode in “AUTO” and changing temperature
H-REC, FRE)) REC varies depending on
control selector from “LO” to “HI”
vehicle condition.)
Ignition: “ON”
FRE
Air intake switch: “FRE” position
Fan Desired Volt (Fan Ignition: “ON”
Approx. 4.0 V
Desired Volt (Fan Blower speed switch: 1st position
desired voltage, V)) Ignition: “ON”
Approx. 5.4 V
Blower speed switch: 2nd position
Ignition: “ON”
Approx. 6.5 V
Blower speed switch: 3rd position
Ignition: “ON”
Approx. 7.7 V
Blower speed switch: 4th position
Ignition: “ON”
Approx. 8.8 V
Ignition: “ON”
Approx. 9.9 V
Ignition: “ON”
Approx. 11.1 V
Ignition: “ON”
Approx. 12.5 V
ENG A-STOP Level A Idling stop system control level is A. ON
(ENG A-STOP Level A
Other than above position OFF
(ON, OFF))
ENG A-STOP Level B Idling stop system control level is B. ON
(ENG A-STOP Level B
(ON, OFF))
ENG A-STOP Level C Idling stop system control level is C. ON
(ENG A-STOP Level C
(ON, OFF))
A/C Cont Sig (A/C Cont Ignition: “ON”
ON
Sig (A/C control signal, A/C switch: ON
ON, OFF)) Ignition: “ON”
OFF
A/C switch: OFF
7B-28 HVAC System:
Normal condition /
Reference value
Blower Load Sig (Blower Ignition: “ON”
ON
Load Sig (Blower fan Blower speed switch: 4th or higher speed position
load signal, ON, OFF)) Ignition: “ON”
OFF
Blower speed switch: Other than above position
Rear DEF Indicator Ignition: “ON”
ON
(Rear DEF Indicator Rear defogger switch: ON
(Rear DEF indicator, Ignition: “ON”
OFF
ON, OFF)) Rear defogger switch: OFF
A/C Comp Clutch (A/C A/C switch: ON
Comp Clutch Blower speed switch: Other than OFF position with engine ON
(Compressor magnet running
clutch, ON, OFF)) A/C switch: OFF with engine running OFF
Engine Run Request BCM sends the engine start request. ON
(Engine Run Request
(Engine start request Other than above condition OFF
signal, ON, OFF))
Auto Fan Control (Auto Ignition “ON” and AUTO switch turned ON ON
Fan Control (Automatic
blower motor control, Ignition “ON” and AUTO switch turned OFF OFF
ON, OFF))
Auto Mode Control Ignition “ON” and AUTO switch turned ON ON
(Auto Mode Control
(Automatic air flow Ignition “ON” and AUTO switch turned OFF OFF
control, ON, OFF))
Auto F/R Control (Auto Ignition “ON” and AUTO switch turned ON ON
F/R Control (Automatic
air intake control, ON, Ignition “ON” and AUTO switch turned OFF OFF
OFF))
Scan Tool Data Definitions ECT (Engine coolant temperature °C, °F)
Temp Cont Switch (Temperature control switch This parameter indicates the engine coolant temperature
position, Maxcool, °C / °F, Maxhot) calculated by ECM.
This parameter indicates the selected position of
temperature control switch. Destination (N/A, JP, EU, UK, US, CA, AU, SA, IN, CN,
MX, DE km/mile, DE km, DE mile)
Mode Cont Switch (Air flow switch position, AUTO, This parameter indicates the Destination.
FACE, B/L, FOOT, DFR/FOOT, DFR)
This parameter indicates the selected position of Outside Air Temp (Outside air temperature, °C, °F)
“MODE” switch. This parameter indicates the outside air temperature
calculated by BCM.
Fan Cont Switch (Blower speed switch, AUTO, OFF,
1st – 8th) Cabin Temperature (In-car temperature, °C, °F)
This parameter indicates the selected position of blower This parameter indicates the in-car temperature
speed switch. detected by inside air temperature sensor.
Air Intake Mode (Air intake switch position, AUTO, Sun Load (W/m2)
FRE, REC) This parameter indicates the amount of sunlight
This parameter indicates the selected position of air detected by sunload sensor.
intake switch.
Evaporator Temp (Evaporator temperature, °C, °F)
Engine Speed (rpm) This parameter indicates the temperature of evaporator
This parameter indicates engine speed sent from ECM detected by evaporator temperature sensor.
through CAN.
Refrigerant Pressure (A/C refrigerant absolute
Vehicle Speed (km/h, MPH) pressure, kPa)
This parameter indicates the vehicle speed calculated by This parameter indicates the A/C refrigerant absolute
ECM. pressure detected by A/C refrigerant pressure sensor.
HVAC System: 7B-29
Target Air Mix Pos Sen (Target temperature control ENG A-STOP Level B (ON, OFF)
actuator position sensor, V) This parameter indicates the selected status of “Normal”
This parameter indicates the target door position of mode selected by setting mode of combination meter.
temperature control actuator calculated by BCM.
ENG A-STOP Level C (ON, OFF)
Air Mix Pos Sen (Temperature control actuator This parameter indicates the selected status of “Comfort”
position sensor, V) mode selected by setting mode of combination meter.
This parameter indicates the input signal from position
sensor in temperature control actuator. A/C Cont Sig (A/C control signal, ON, OFF)
This parameter indicates the state of A/C indicator.
Target Mode Pos Sen (Target air flow control
actuator position sensor, V) Blower Load Sig (Blower fan load signal, ON, OFF)
This parameter indicates the target door position of air ON: Blower speed switch is in 3rd or higher position.
flow control actuator calculated by the BCM. OFF: Blower speed switch is in OFF position.
Mode Pos Sensor (Air flow control actuator position Rear DEF Indicator (Rear DEF indicator, ON, OFF)
sensor, V) This parameter indicates the state of rear defogger
This parameter indicates the input signal from position indicator light.
sensor in air flow control actuator.
A/C Comp Clutch (Compressor magnet clutch, ON,
Target Mode Position (Target air flow control OFF)
actuator position, FACE, FACE + FOOT, FOOT, FOOT This parameter indicates the state of the compressor
+ DEF, DEF) magnet clutch.
FACE: “MODE” switch is in FACE position.
FACE + FOOT: “MODE” switch is in FACE-FOOT Engine Run Request (Engine start request signal,
position. ON, OFF)
FOOT: “MODE” switch is in FOOT position. This parameter indicates engine start request from BCM
FOOT + DEF: “MODE” switch is in FOOT-DEF position. on vehicle with ENG A-STOP system.
DEF: “MODE” switch is in DEF position. ON: BCM sends the engine start request.
OFF: Other than above condition
Target Air Intake Control Actuator Position Sensor
(V) Auto Fan Control (Automatic blower motor control,
This parameter indicates the target door position of air ON, OFF)
intake control actuator calculated by the BCM. This parameter indicates the state of the blower motor
control.
Target Air Intake Pos (Target air intake actuator
position, REC, H-REC, FRE) Auto Mode Control (Automatic air flow control, ON,
REC: Air intake mode is in REC mode. OFF)
This parameter indicates the state of the air flow control.
Fan Desired Volt (Fan desired voltage, V)
This parameter indicates the desired voltage of blower Auto F/R Control (Automatic air intake control, ON,
motor. OFF)
Auto F/R Control (Automatic air intake control, ON, OFF)
ENG A-STOP Level A (ON, OFF)
This parameter indicates the selected status of
“Economy” mode selected by setting mode of
combination meter.
DTC B1501-11 / B1501-13

AENNTA0E7204012 (06(02)
Refer to “DTC B1501-11 / B1501-13” in Section 10B.
DTC B1503-11 / B1503-13

AENNTA0E7204013 (06(02)
Refer to “DTC B1503-11 / B1503-13” in Section 10B.
DTC B1508-11 / B1508-13

AENNTA0E7204014 (06(02)
7B-30 HVAC System:

B1508-11: Inside Air Temperature Sensor Circuit Short To Ground • Auto A/C panel (incorporating inside
Inside air temperature sensor signal voltage is lower than specified value for air temperature sensor)
specified time continuously. • BCM
B1508-13: Inside Air Temperature Sensor Circuit Open
Inside air temperature sensor signal voltage is higher than specified value
for specified time continuously.

1) Start engine and operate A/C system.
DTC Troubleshooting
NOTE
The following flow shows “DTC B1508-11: Inside Air Temperature Sensor and/or Its Circuit
Malfunction”. Check “DTC B1508-13” in the same manner as “DTC B1508-11”.
Step 1 Was “Air Conditioning System Check” performed?
Yes Go to Step 2.
No Go to “Air Conditioning System Check”.
Step 2 DTC check

3) Set ignition “ON” and check for DTC. (DTC Check)
Is DTC B1508-11 still detected?
Yes Replace auto A/C panel (incorporating inside air temperature sensor). (Auto A/C Panel Removal
and Installation)
DTC B150A-11
AENNTA0E7204015 (06(02)
B150A-11: Sunload Sensor Circuit Short To Ground • Sunload sensor circuit
Sunload sensor signal voltage is lower than specified value for • Sunload sensor
specified time continuously.
• BCM
HVAC System: 7B-31
Circuit Diagram
2
A1
5V
LT BLU G05-22
1
YEL G04-22
A2
[A] G05
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
[a] 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
[A] G04
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
IFRA0A722007-01
[A]: BCM connector (View: [a]) A2: Ground for sensors circuit 2. BCM
A1: Sunload sensor signal circuit 1. Sunload sensor

DTC Troubleshooting
Yes Go to Step 2.
Step 2 Scan tool parameter check

1) Check “Sun Load” using “Data list” mode on SUZUKI scan tool. (Scan Tool Data)
Is sun load value over 1275 W/m2?
Yes Go to Step 3.
Step 3 Sunload sensor signal circuit check

1) Disconnect sunload sensor connector.
Is sun load value over 1275 W/m2?
Yes Go to Step 4.
No Replace sunload sensor. (Sunload Sensor Removal and Installation)

1) Disconnect “G05” connector.
2) Check that resistance between “A1” circuit and ground is infinity.
Is resistance as specified?
Yes Replace BCM and recheck DTC. (BCM Removal and Installation) in Section 10B
No Replace instrument panel harness.
7B-32 HVAC System:
DTC B150A-13
AENNTA0E7204016 (06(02)
B150A-13: Sunload Sensor Circuit Open • Sunload sensor circuit
Sunload sensor signal voltage is higher than specified value for • Sunload sensor
specified time continuously.
• BCM
Circuit Diagram
2
A1
5V
LT BLU G05-22
1
YEL G04-22
A2
[A] G05
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
[a] 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
[A] G04
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
IFRA0A722007-01
[A]: BCM connector (View: [a]) A2: Ground for sensors circuit 2. BCM
A1: Sunload sensor signal circuit 1. Sunload sensor

DTC Troubleshooting
NOTE
• When DTC B1503-13, B150A-13, B150C-13, B1519-13 and/or B151B-13 is indicated together, it is
possible that sensor ground circuit is open.
• DTC B150A-13 is detected even though there is not any malfunction if sunload sensor is not lit by an
incandescent light. Light the sunload sensor with a light.
Yes Go to Step 2.

1) Apply incandescent light or sun shine in a sunny day to sunload sensor vertically.
Is sun load value 0 W/m2?
Yes Go to Step 3.

1) Disconnect sunload sensor connector.
HVAC System: 7B-33
2) Connect the “A1” and “A2” circuit terminals of sunload sensor connector using service wire.
Yes Go to Step 4.
No Replace sunload sensor. (Sunload Sensor Removal and Installation)

1) Connect the “A1” and “A2” circuit terminals of “G04” and “G05” connectors using service wire.
DTC B150C-11 / B1519-11 / B151B-11

AENNTA0E7204017 (06(02)
B150C-11: Temperature Control Actuator Position Sensor • Temperature control actuator circuit
Circuit Short To Ground • Temperature control actuator
Signal voltage of position sensor in temperature control actuator is
• BCM
lower than specified value for specified time continuously.
B1519-11: Air Flow Control Actuator Position Sensor Circuit • Air flow control actuator circuit
Short To Ground • Air flow control actuator
Signal voltage of position sensor in air flow control actuator is lower
• BCM
than specified value for specified time continuously.
B151B-11: Air Intake Control Actuator Position Sensor Circuit • Air intake control actuator circuit
Short To Ground • Air intake control actuator
Signal voltage of position sensor in air intake control actuator is
• BCM
lower than specified value for specified time continuously.
7B-34 HVAC System:
Circuit Diagram
4
12V
A1
BLU G04-16
LT GRN G04-32
A3 A2 5V
1 GRN G05-4 5V
PPL G05-20
A4
YEL G04-22 12V
A5
B1
PPL G05-17
LT BLU G05-1
B3 B2
2 5V
GRY G05-21
B4
12V
B5
C1
PNK G05-18
WHT G05-5
C3 C2
3 5V
BRN G05-2
C4
C5
[A] G05
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
[a] 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
[A] G04
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
IMTA0A720006-03
[A]: BCM connector (View: [a]) B2: Air flow control actuator circuit (“FACE”) C4: Air intake control actuator position sensor
signal circuit
A1: Temperature control actuator circuit B3: Air flow control actuator position sensor C5: Air intake control actuator position sensor
(“COOL”) power supply circuit ground circuit
A2: Temperature control actuator circuit (“HOT”) B4: Air flow control actuator position sensor 1. Temperature control actuator
signal circuit
A3: Temperature control actuator position B5: Air flow control actuator position sensor 2. Air flow control actuator
sensor power supply circuit ground circuit
A4: Temperature control actuator position C1: Air intake control actuator circuit (“FRE”) 3. Air intake control actuator
sensor signal circuit
A5: Temperature control actuator position C2: Air intake control actuator circuit (“REC”) 4. BCM
sensor ground circuit
B1: Air flow control actuator circuit (“DEF”) C3: Air intake control actuator position sensor
power supply circuit

DTC Troubleshooting
NOTE
• The following flow shows “DTC B150C-11: Temperature Control Actuator (Position Sensor) and/or
Its Circuit Malfunction”.
• Check “DTC B1519-11 / B151B-11” in the same manner as “DTC B150C-11” referring to the following
table.
DTC Parameter Circuit

B1519-11 Mode Pos Sensor “B3” and “B4” circuit
HVAC System: 7B-35

B151B-11 R/F Pos Sensor ”C3” and “C4” circuit
Yes Go to Step 2.

1) Check “Air Mix Pos Sen” using “Data list” mode on SUZUKI scan tool. (Scan Tool Data)
Is voltage below 0.1 V?
Yes Go to Step 3.
Step 3 Temperature control actuator position sensor signal circuit check

1) Disconnect temperature control actuator connector.
Is voltage below 0.1 V?
Yes Go to Step 4.
No Replace temperature control actuator. (Temperature Control Actuator Removal and Installation)

2) Measure voltage between “A3” circuit terminal of temperature control actuator connector and ground.
Is voltage 5 V?
Yes Go to Step 6.
No Go to Step 5.

• Resistance of “A3” circuit between temperature control actuator and ground: infinity
Are resistances as specified?

1) Check that resistance between the “A3” and “A4” circuit terminals and ground is infinity.
Is resistance as specified?
DTC B150C-13 / B1519-13 / B151B-13

AENNTA0E7204018 (06(02)
7B-36 HVAC System:

B150C-13: Temperature Control Actuator Position Sensor • Temperature control actuator circuit
Circuit Open • Temperature control actuator
Signal voltage of position sensor in temperature control actuator is
• BCM
higher than specified value for specified time continuously.
B1519-13: Air Flow Control Actuator Position Sensor Circuit • Air flow control actuator circuit
Open • Air flow control actuator
Signal voltage of position sensor in air flow control actuator is
• BCM
B151B-13: Air Intake Control Actuator Position Sensor Circuit • Air intake control actuator circuit
Open • Air intake control actuator
Signal voltage of position sensor in air intake control actuator is
• BCM
Circuit Diagram
4
12V
A1
BLU G04-16
LT GRN G04-32
A3 A2 5V
1 GRN G05-4 5V
PPL G05-20
A4
YEL G04-22 12V
A5
B1
PPL G05-17
LT BLU G05-1
B3 B2
2 5V
GRY G05-21
B4
12V
B5
C1
PNK G05-18
WHT G05-5
C3 C2
3 5V
BRN G05-2
C4
C5
[A] G05
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
[a] 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
[A] G04
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
IMTA0A720006-03
signal circuit
signal circuit
HVAC System: 7B-37

DTC Troubleshooting
NOTE
• When DTC B1503-13, B150A-13, B150C-13, B1519-13 and/or B151B-13 is indicated together, it is
possible that sensor ground circuit is open.
• The following flow shows “DTC B150C-13: Temperature Control Actuator (Position Sensor) and/or
Its Circuit Malfunction”.
• Check “DTC B1519-13 / B151B-13” in the same manner as “DTC B150C-13” referring to the following
table.

B151B-13 R/F Pos Sensor “C4” and “C5” circuit
Yes Go to Step 2.

Is voltage over 4.8 V?
Yes Go to Step 3.

1) Disconnect temperature control actuator connector.
2) Connect the “A4” and “A5” circuit terminals of temperature control actuator connector using service wire.
Yes Go to Step 4.

1) Connect the “A4” and “A5” circuit terminals of “G04” and “G05” connectors using service wire.
DTC B1513-71 / B1514-71 / B1531-71

AENNTA0E7204019 (06(02)
7B-38 HVAC System:

B1513-71: Temperature Control Actuator Stuck • Temperature control actuator circuit
Difference between target opening and actual opening is more than specified • Temperature control actuator
value even though temperature control actuator has operated for specified
• BCM
time.
B1514-71: Air Flow Control Actuator Stuck • Air flow control actuator circuit
Difference between target opening and actual opening is more than specified • Air flow control actuator
value even though air flow control actuator has operated for specified time.
• BCM
B1531-71: Air Intake Control Actuator Stuck • Air intake control actuator circuit
Difference between target opening and actual opening is more than specified • Air intake control actuator
value even though air intake control actuator has operated for specified time.
• BCM
Circuit Diagram
4
12V
A1
BLU G04-16
LT GRN G04-32
A3 A2 5V
1 GRN G05-4 5V
PPL G05-20
A4
YEL G04-22 12V
A5
B1
PPL G05-17
LT BLU G05-1
B3 B2
2 5V
GRY G05-21
B4
12V
B5
C1
PNK G05-18
WHT G05-5
C3 C2
3 5V
BRN G05-2
C4
C5
[A] G05
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
[a] 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
[A] G04
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
IMTA0A720006-03
signal circuit
signal circuit
HVAC System: 7B-39

B1513-71
2) Push temperature control switch to change position from “LO” to “HI”.
B1514-71
2) Push “MODE” (air flow) switch to change position from “FACE” to “DEF”.
B1531-71
2) Push air intake switch to change position from “REC” to “FRE”.
DTC Troubleshooting
NOTE
• When DTC B1513-71, B1514-71 and/or B1531-71 is detected, check that there is any obstruction in
opening range of actuator linkage.
• The following flow shows “DTC B1513-71: Temperature Control Actuator and/or Its Circuit
Malfunction”.
• Check “DTC B1514-71 / B1531-71” in the same manner as “DTC B1513-71” referring to the following
table.

B1531-71 R/F Pos Sensor “C1” and “C2” circuit
Yes Go to Step 2.

Is check result OK?
Yes Intermittent trouble. (Intermittent Connection and Poor Contact Inspection) in Section 00
No Go to Step 3.
Step 3 Temperature control actuator circuit check

1) Disconnect “G05” and temperature control actuator connectors.
• Resistance of “A1” and “A2” circuits between temperature control actuator and ground: infinity
Yes Go to Step 4.
Step 4 Temperature control actuator check

1) Check temperature control actuator. (Temperature Control Actuator Inspection)
7B-40 HVAC System:
Is actuator in good condition?
DTC B1546-00
AENNTA0E7204020 (06(02)
B1546-00: A/C Refrigerant Pressure • A/C refrigerant pressure sensor
A/C refrigerant pressure is less than specified value, though • Outside air temperature sensor
outside air temperature is more than specified value.
• Insufficient of refrigerant
• BCM

DTC Troubleshooting
Yes Go to Step 2.
Step 2 A/C refrigerant pressure check

1) Turn on A/C switch and operate compressor.
2) Check “Refrigerant Pressure” using “Data list” mode on SUZUKI scan tool. (Scan Tool Data)
Is pressure over 0.34 MPa?
Yes Go to Step 3.
No Charge refrigerant and recheck DTC. (Operation Procedure for Refrigerant Charge)

1) Check A/C refrigerant pressure sensor. (A/C Refrigerant Pressure Sensor and Its Circuit Inspection)
Is sensor in good condition?
Yes Go to Step 4.
Installation)
Step 4 Outside air temperature sensor check

1) Check outside air temperature sensor. (Outside Air Temperature Sensor Inspection) in Section 10B
Is sensor in good condition?
Yes Go to Step 5.
No Replace outside air temperature sensor. (Outside Air Temperature Sensor Removal and
Step 5 A/C system check

1) Check A/C system. (A/C System Performance Inspection)
Is system in good condition?

HVAC System: 7B-41
No Perform “Trouble Diagnosis for Abnormal Pressure” and recheck DTC.
DTC B1549-87 / U2005-87

AENNTA0E7204021 (06(02)
B1549-87: LIN Invalid Data from BCM to Auto A/C Panel • LIN communication circuit
Transmitted data from BCM to auto A/C panel via LIN is faulty. • BCM
U2005-87: LIN Lost Communication with Auto A/C Panel
• Auto A/C panel
Received data from auto A/C panel via LIN is faulty.
Circuit Diagram
1 A1 2
12V
3 G227-7 LT GRN G05-11 3
[A] G05 [B] G227
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 4 3 2 1
[a]
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 8 7 6 5
IFRA0A722021-01
[A]: BCM connector (View: [a]) A1: LIN communication signal circuit 2. BCM
[B]: Auto A/C panel connector (View: [a]) 1. Auto A/C panel 3. LIN driver

DTC Troubleshooting
Yes Go to Step 2.
Step 2 DTC check

3) Set ignition “ON” and check for DTC.
Is DTC B1549-87 or U2005-87 still detected?
Yes Go to Step 3.
Step 3 LIN communication signal circuit check

1) Disconnect “G05” and “G227” connectors.
7B-42 HVAC System:
• Resistance between “A1” circuit terminal and other terminal at BCM connector: infinity
Yes Replace BCM and/or auto A/C panel and recheck DTC.
• BCM: (BCM Removal and Installation) in Section 10B
• Auto A/C panel: (Auto A/C Panel Removal and Installation)
DTC B1563-81
AENNTA0E7204022 (06(02)
B1563-81: A/C Refrigerant Pressure Sensor and/or Its Circuit • A/C refrigerant pressure sensor
BCM receives invalid data of A/C refrigerant pressure signal from ECM. • ECM
• BCM
NOTE
• U0073-88, U0100-87 and/or U0155-87 are not detected
DTC Troubleshooting
Yes Go to Step 2.
Step 2 DTC check

1) Check DTC of ECM. (DTC Check) in Section 1A
Yes Go to applicable DTC diagnosis flow. (DTC Table) in Section 1A

No Replace BCM and recheck DTC. (BCM Removal and Installation) in Section 10B
DTC U0073-87 DTC U0100-87 / U0155-87

AENNTA0E7204023 (06(02) AENNTA0E7204024 (06(02)
Refer to “Troubleshooting for Communication Bus Off”: Refer to “Troubleshooting for Lost Communication”:
CAN in Section 10H. CAN in Section 10H.
Inspection of Auto A/C Panel and Its Circuit

AENNTA0E7204025 (06(01)
Auto A/C panel and its circuits can be checked at auto A/C panel wiring connector by measuring voltage.
NOTICE
If you connect a voltmeter or an ohmmeter directly to the auto A/C panel with the auto A/C panel
connector disconnected, you can damage the auto A/C panel.
Never connect a voltmeter or an ohmmeter directly to any terminal on the auto A/C panel with the auto
A/C panel connector disconnected.
HVAC System: 7B-43
Voltage and Signal Check

1) Remove auto A/C panel referring to “Auto A/C Panel Removal and Installation”.
2) Connect “G227” connector.
3) Check voltage and signal 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”.
• Normal voltage of circuits with asterisk (*1) cannot be measured correctly with voltmeter because
they are pulse signals. Check them with oscilloscope.
[A] G227
1
4 3 2 1
[a] 8 7 6 5
I9P60A723018-04
[A]: Auto A/C panel connector (View: [a]) 1. Auto A/C panel
“G227” connector
Terminal Wire color Circuit Normal voltage Condition
Ignition: “ON”
Approx. 0 V
Lighting switch: OFF position
G227-2 RED Illumination switch
Ignition: “ON”
Approx. 12 V
Lighting switch: ON position
Ignition: “ON”
G227-4 PPL Ground for illumination Approx. 0 V
Lighting switch: OFF position
G227-5 YEL Power supply
Approx. 0 V Ignition: “OFF”
G227-7 LT GRN LIN communication signal *1 Refer to “Reference Waveform”.
G227-8 BLK Ground for auto A/C panel Approx. 0 V Ignition: “ON”
Reference Waveform
Shown below is typical waveform display provided by
oscilloscope.
NOTE
data:
IAW101970026-01
[a]: Waveform of channel 1 [c]: VOLT/DIV of each channel

[b]: Ground level of each channel [d]: TIME/DIV

7B-44 HVAC System:
LIN communication signal (1): .

1 + G227-7 Inspection of A/C System Circuits at BCM
– G227-8 AENNTA0E7204026 (06(01)
Refer to “Inspection of BCM and Its Circuits” in Section
10B.
• Ignition: “ON” Inspection of A/C System Circuits at ECM
AENNTA0E7204027 (06(01)
Check the voltage related to A/C system at ECM
terminals. (Inspection of ECM and Its Circuits) in Section
1A
I9P60A723031-01
1. LIN communication signal
Repair Instructions
Operation Procedure for Refrigerant Charge • Check local governmental regulations
AENNTA0E7206001 (08(01) regarding working with refrigerator
NOTE
systems and its tooling.
• For locations of high pressure service
valve and low pressure service valve, refer
to “A/C System Major Components”.
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 NOTE
When discharging refrigerant out of A/C system, always
recover it using refrigerant recovery and recycling • After recovering refrigerant from system,
equipment because discharging refrigerant HFC-134a measure the amount of removed
(R-134a) into atmosphere would cause adverse effect to compressor oil to determine the amount of
environment. compressor oil for replenishment.
• When handling recovery and recycling
equipment, follow the instruction manual
for the equipment.
HVAC System: 7B-45
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))
IELA0A722040-01
Amount of oil in compressor
Replenishing compressor oil 110 – 120 cm3 (110 – 120 ml, 3.72 – 4.06 US.oz, 3.87 –
It is necessary to replenish compressor with specified 4.22 Imp.oz)
amount of compressor oil from compressor suction side
1 2
hole (1) before evacuating system and charging it with
refrigerant.
"C"
"A"
"B"
I7V20A720017-01
1. New compressor 2. Removed compressor
1 When replacing other parts

Replenish compressor with the following amount of oil.
Amount of compressor oil to be replenished
IMTA0A720007-01 Evaporator: 15 cm3 (15 ml, 0.51 US.oz, 0.53 Imp.oz)
Condenser (with receiver/dryer): 20 cm3 (20 ml, 0.68
When charging refrigerant only US.oz, 0.70 Imp.oz)
When charging refrigerant without replacing any Hoses: 5 cm3 (5 ml, 0.17 US.oz, 0.18 Imp.oz) each
component, replenish compressor with compressor oil of Pipes: 5 cm3 (5 ml, 0.17 US.oz, 0.18 Imp.oz) each
the same amount measured when recovering
refrigerant. If lost oil is not measured, add 30 cm3 (30 ml, Evacuation
1.02 US.oz, 1.05 Imp.oz) of oil.
NOTICE
When replacing compressor Attempting to evacuate the A/C system when
refrigerant remains in the system will
NOTICE damage the vacuum pump.
Use of a compressor oil other than the Do not evacuate the A/C system before
specified oil is inappropriate for the completely recovering the refrigerant from
components of the A/C system and may the system.
cause problems with operation of the
system.
Use only the specified compressor oil or
equivalent.
7B-46 HVAC System:
NOTE
3
If A/C system circuit is opened (exposed) to 11
atmosphere, system must be evacuated 9
using a vacuum pump. The A/C system 10 8
should be fitted with manifold gauge set, and
should be evacuated for approximately 15
minutes.
1
1) Connect high pressure charging hose (1) and low 2
pressure charging hose (2) of manifold gauge set (3)
as follows:
High pressure charging hose → High pressure 5
7 6
charging valve (4) on discharge hose
Low pressure charging hose → Low pressure 4
charging valve (5) on suction pipe
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). IELA0A722034-02
When this occurs, open the other side valve (LO)

(10) of the gauge set. Checking A/C system for pressure leakage
After completing the evacuation, close manifold gauge
4) Approximately 10 minutes later, low pressure gauge
high pressure valve and low pressure valve and wait for
(11) should show a vacuum lower than –100 kPa (–
10 minutes. Check that low pressure gauge reading has
1.0 kgf/cm2, –750 mmHg, –14.5 psi), indicating that
not changed.
no leakage exists.
NOTE
NOTE
If gauge reading moves closer to “0”, there is
• If the system does not show a vacuum leakage somewhere. Check the tubing
below –100 kPa (–1.0 kgf/cm2, –750 mmHg, connections and make necessary
–14.5 psi), close both valves, stop vacuum corrections.
pump and watch change in reading of low Then, evacuate system once again and check
pressure gauge. that there is no leakage.
• Increase in gauge reading suggests of
leakage. In this case, repair the system Charge
before continuing its evacuation.
• If the gauge shows a stable reading ! WARNING
(suggesting no leakage), continue
There is a risk of personal injury or health
evacuation.
problems if the A/C system is charged with
5) Carry out evacuation for a total of at least 15 refrigerant incorrectly or if refrigerant
minutes. containers are improperly handled.
Take the following precautions to reduce the
6) Continue evacuation until lower pressure gauge risk of injury or health problems.
indicates a vacuum less than –100 kPa (–1.0 kgf/
cm2, –750 mmHg, –14.5 psi), and then close both • Perform the refrigerant charge operation
valves. with the engine stopped. Charge the high
pressure side first and then the low
7) Stop vacuum pump. Disconnect center charging
pressure side. If you do not, the refrigerant
hose from pump inlet. Now, the system is ready for
may flow backward and cause the hose or
charging refrigerant.
refrigerant container to burst.
• 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.
HVAC System: 7B-47
• Never expose the refrigerant container to a ! WARNING

heat higher than 40 °C (104 °F). Liquid
refrigerant will turn into a toxic gas. If the high pressure valve is not closed
securely, the refrigerant may flow backwards
NOTICE and cause the hose or refrigerant container
to burst, possibly resulting in a personal
Failure to take proper precautions when injury.
charging the A/C system can result in Close the high pressure valve securely.
charging the system with the incorrect
amount of refrigerant and can lead to poor 5) Start engine and keep engine speed at 1500 r/min,
system operation or damage to system and then operate A/C system.
components.
6) Charge A/C system with vapor refrigerant. At this
• Since the A/C system has no sight glass, time, refrigerant container should be held upright.
first recover refrigerant and evacuate the
system, and then fill the system with the 3
specified amount of refrigerant.
• Charge the system only when the
6 5
compressor is not hot to assure that you
have used the correct amount of 4
refrigerant.
• Check the pressure gauges before and
during charging to assure that there is the
correct amount of refrigerant in the
system. 1
2
• 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 IELA0A722041-01
refrigerant service container.
7) When refrigerant container (1) is emptied, use the
When charging the system with the
following procedure to replace it with a new
refrigerant recovered using the refrigerant
refrigerant container.
recycling equipment, follow the procedure
described in the equipment manufacturer’s a) Close low pressure valve.
instruction manual. b) Replace empty container with a refrigerant
container which has been charged with
Perform initial charge through high pressure side with refrigerant. When using refrigerant container tap
the engine stopped. valve (2), use the following procedure for
Next, charge the system with refrigerant as follows from replacement.
low pressure side with engine running. i) Turn handle of tap valve counterclockwise to
1) Check if hoses are routed properly after evacuating retract needle (3), and then remove
system. refrigerant container tap valve by loosening
2) Connect low pressure charging hose (1) and high its plate nut (4).
pressure charging hose (2) of manifold gauge set (3) ii) Install refrigerant container tap valve to new
in position. Then, open refrigerant container valve (4) refrigerant container.
to purge charging line.
3) Open high pressure valve (5) to charge system with
refrigerant.
4) After a while, open low pressure valve (6) and close
high pressure valve.
7B-48 HVAC System:
4
1 2
I2RH01720018-01
c) Purge any air from center charging hose.

When using refrigerant container tap valve, use
the following procedure to purge air.
i) Fully tighten refrigerant container tap valve
(1), and then loosen (open) plate nut (2)
slightly.
ii) Open low pressure valve (3) of manifold
gauge set (4) a little. IELA0A722042-01
iii) As soon as refrigerant comes out with a

“hiss” through a clearance between Removal of manifold gauge set
refrigerant container and tap valve, tighten
plate nut as well as low pressure valve. ! WARNING
iv) Turn handle of tap valve clockwise so that its If the manifold gauge set is removed
needle is screwed into the new container to carelessly, refrigerant under pressure may
make a hole for refrigerant flow. 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 valve of manifold gauge set.
(high pressure 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
I2RH01720019-01 valves. Perform this operation quickly.
8) After the system is charged with specified amount of 5) Put caps on service valves.
refrigerant or when low pressure gauge (1) and high
pressure gauge (2) have indicated the following Checking A/C system for refrigerant leakage
specified values, close low pressure valve (3) on Whenever refrigerant leakage is suspected in the
manifold gauge set (4). system or any service operation has been performed
Specified amount of refrigerant which may result in malfunction of lines and connections,
410 ± 20 g (14.5 ± 0.705 oz) it is important to perform check for leakage.
Common sense should be used during refrigerant
Low pressure side and high pressure side leakage test, since the need and extent of any such test
example will, in general, depend upon the nature of a complaint
Gauges should read as follows when ambient and the type of a service performed on the system.
temperature is 30 °C (86 °F).
Pressure on high 1170 – 1290 kPa (11.9 – 13.2
pressure gauge kgf/cm2) (170 – 187 psi)
Pressure on low 260 – 330 kPa (2.7 – 3.4 kgf/
pressure gauge cm2) (37.7 – 47.9 psi)
HVAC System: 7B-49
Liquid leak detector For connections in such confined areas, as those around
evaporator and condenser, electronic (refrigerant) leak
! WARNING detector (1) is more practical for determining leakage.
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. 1
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 IDAA0A722074-01
leakage.
A/C System Major Components

AENNTA0E7206002 (12(01)
7B-50 HVAC System:
18 17
8 16
12
3
1
2
OIL
9
OIL
10
OIL
9
11
OIL
6 (a)
OIL
9
OIL
9
(a)
15
(a)
7
OIL
20
13 (b)
OIL
19 (c)
14
IMTA0A720008-04
HVAC System: 7B-51
1. HVAC unit 9. O-ring 17. Aspirator hose

: Apply compressor oil.
2. Suction pipe 10. Liquid pipe 18. Aspirator
3. Suction hose 11. High pressure charging valve 19. Filter cap
4. Discharge hose 12. Low pressure charging valve 20. Desiccant
5. Compressor 13. Compressor mounting bolt : 11 Nm (1.1 kgf-m, 8.5 lbf-ft)
: For tightening procedure of compressor
mounting bolt, refer to “Compressor
Assembly Removal and Installation”.
6. A/C refrigerant pressure sensor 14. Condenser bolt : 25 Nm (2.5 kgf-m, 18.5 lbf-ft)
: For tightening procedure of condenser bolt,
refer to “Condenser Assembly Removal and
Installation”.
7. Condenser with receiver / dryer 15. Drain hose : 3.9 Nm (0.40 kgf-m, 3.0 lbf-ft)
8. Expansion valve 16. Cap : Do not reuse.
Radiator Cooling Fan Removal and Installation 4) Remove engine undercover, engine under side
AENNTA0E7206003 (08(01) covers, front bumper lower absorber, front end upper
Refer to “Radiator Cooling Fan Assembly Removal and
cover and front end lower covers. (Engine Under
Installation” in Section 1F.
Radiator Cooling Fan Inspection 5) Remove discharge hose bolt (1) and liquid pipe bolt
AENNTA0E7206004 (08(03)
Refer to “Radiator Cooling Fan Assembly On-Vehicle (2).
Inspection” in Section 1F. 6) Disconnect discharge hose (3) and liquid pipe (4)
from condenser assembly (5).
Condenser Assembly On-Vehicle Inspection
AENNTA0E7206005 (08(03)
• Condenser fins for clogging.
If clogged, wash condenser with water and dry it with
compressed air.
• Condenser fins for leakage and breakage. 1
3
If any defects are found, repair or replace condenser.
• Condenser fittings for leakage.
If any defects are found, repair or replace condenser.
Condenser Assembly Removal and Installation

AENNTA0E7206006 (08(01)
2
NOTICE 4
Condenser and radiator fins can easily be

bent during removal of the condenser 5
assembly.
Remove the condenser assembly carefully
not to damage the condenser and radiator IMTA0A720009-01
fins. If any of them is bent, straighten it using 7) Remove condenser bolts (1) and then remove
a flat-bladed screwdriver or pliers. condenser assembly (2).
Removal
1) Recover refrigerant from A/C system referring to
“Recovery” in “Operation Procedure for Refrigerant
Charge”.
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. (Front Bumper and Radiator
7B-52 HVAC System:
• Evacuate and charge A/C system referring to

2 1 “Evacuation” and “Charge” in “Operation Procedure
for Refrigerant Charge”.
Desiccant Removal and Installation

AENNTA0E7206007 (08(01)
Removal
1) Recover refrigerant from A/C system referring to
“Recovery” in “Operation Procedure for Refrigerant
Charge”.
2) Remove condenser assembly. (Condenser
3) Remove filter cap (1) and O-rings (2), and then
remove desiccant (3) from receiver / dryer (4).
1
IMTA0A720010-01
2
Installation
Reference: “Condenser Assembly On-Vehicle 1
Inspection” 4
Reverse removal procedure noting the following points. IMTA0A720048-01
• Apply compressor oil to new O-rings of discharge

hose and liquid pipe. Installation
: Compressor oil 95590–58D30 (Compressor oil • Do not take new desiccant out from plastic bag until
(ND-OIL8)) just before inserting it into receiver/dryer.
• Replenish compressor with specified amount of • Apply specified compressor oil to O-rings.
compressor oil from compressor suction side referring
: Compressor oil 95590–58D30 (Compressor oil
to “Replenishing Compressor Oil” in “Operation
(ND-OIL8))
Procedure for Refrigerant Charge”.
• Tighten condenser bolts (1) in numerical order (“1” – • Tighten filter cap (1) to specified torque.
“3”). Tightening torque
Filter cap (a): 3.9 N·m (0.40 kgf-m, 3.0 lbf-ft)
1, “1” 1, “2”
1, (a)
IMTA0A720049-01
• Replenish compressor with specified amount of

“Evacuation” and “Charge” in “Operation Procedure
1, “3” 1, “3” for Refrigerant Charge”.
IMTA0A720011-01
HVAC System: 7B-53
HVAC Unit Components

AENNTA0E7206008 (12(01)
16
26 17 28
17 1 22
27 36
11
12
6
13
23
10
2
35
15
18
24
32
29
34 8
3
5
30
25
20 33 9
14
(a)
31
[A]
21
19
IMTA0A720018-01
[A]: Forward 13. Air flow control door assembly (FOOT) 26. Air flow control actuator
1. Right case 14. Air intake control door 27. Temperature control actuator
2. Left case 15. Temperature control shaft 28. Defroster duct packing
7B-54 HVAC System:
3. Blower upper case 16. Air flow control actuator lever plate 29. Air filter
: For installation, refer to “HVAC Air
Filter Removal and Installation”.
4. Blower lower case 17. Air flow control actuator lever 30. Heater pipe packing
5. Air intake case 18. Evaporator 31. Expansion valve packing
6. Fresh air inlet duct 19. Blower motor 32. Evaporator temperature sensor
: For installation, refer to “Evaporator
Temperature Sensor Removal and
Installation”.
7. Evaporator 20. Expansion valve 33. Heater pipe bracket
8. Filter cover 21. Blower motor controller 34. Heater pipe cover
9. Air intake control actuator lever 22. Fresh air inlet duct packing 35. Air duct
10. Temperature control door 23. Foot duct (driver side) 36. Air flow control actuator rod
11. Air flow control door assembly (FACE) 24. Foot duct (passenger side) : 3.5 Nm (0.36 kgf-m, 2.5 lbf-ft)
12. Air flow control door assembly (DEF) 25. Air intake control actuator : Do not reuse.
HVAC Unit Removal and Installation 8) Remove suction hose bolt (1), and then remove
AENNTA0E7206009 (08(01) liquid pipe (2) and suction pipe (3) from expansion
Reference: “HVAC Unit Components”
valve (4).
Reference: “Evaporator Temperature Sensor Inspection”
Removal
2) Recover refrigerant from A/C system using recovery
and recycling equipment referring to “Recovery” in
“Operation Procedure for Refrigerant Charge”.
and Engine Under Side Cover Removal and 3
4
4) Drain engine coolant. (Cooling System Draining) in
Section 1F 1
5) Remove cowl top garnish. (Cowl Top Garnish
2
IMTA0A720013-01
6) Remove air cleaner assembly. (Air Cleaner 9) Remove instrument panel from vehicle body.
Assembly Removal and Installation) in Section 1D (Instrument Panel Removal and Installation) in
7) Disconnect heater hoses (1) from HVAC unit. Section 9C
10) Disconnect drain hose (1) from HVAC unit (2) pulling
it in arrow direction.
IMTA0A720012-01
HVAC System: 7B-55
11) Remove HVAC unit stud cover cap (1) pulling it in

arrow direction.
1
1
IMTA0A720016-01
IMTA0A720014-01
12) Remove HVAC bolt (1) and HVAC nuts (2), and then remove HVAC unit (3) puling it in arrow direction.
NOTE
When removing HVAC unit, be careful not to spill engine coolant and compressor oil on vehicle floor.
7B-56 HVAC System:
2
3
2
IMTA0A720015-01
13) Remove drain hose (1) from vehicle, if necessary.

HVAC System: 7B-57
• Install new expansion valve packing (1) to installation

hole uniformly.
1
IDAA0A722036-01
• Apply compressor oil to new O-rings of suction pipe

and liquid pipe.
(ND-OIL8))
• Be careful not to mistake the connection of heater
IMTA0A720017-01 inlet hose and heater outlet hose and install clamp to
specified position. (Cooling System Components) in
Installation Section 1F
Reference: “Evaporator Inspection” • Replenish compressor with specified amount of
Reference: “Evaporator Temperature Sensor Inspection” compressor oil from compressor suction side referring
Reverse removal procedure noting the following points. to “Replenishing Compressor Oil” in “Operation
• Install drain hose (1) as follows. Procedure for Refrigerant Charge”.
– Align matchmark (4) on drain hose and rib (3) of • Evacuate and charge A/C system referring to
HVAC unit (4). “Evacuation” and “Charge” in “Operation Procedure
– Fit hose grommet (5) to dash panel hole so that for Refrigerant Charge”.
lower lip of the grommet is put outside of the panel. • Refill cooling system with coolant. (Cooling System
Auto A/C Panel Removal and Installation

AENNTA0E7206010 (08(01)
1
Removal
2
1) Remove instrument panel center lower right garnish.
(Instrument Panel Disassembly and Reassembly) in
Section 9C
2) Remove auto A/C panel (1) pulling it in arrow
direction.
3
4
1
IMTA0A720019-01
7B-58 HVAC System:
A B C A
1 A A
A
A
B 1
B
C C
IMTA0A720021-03
3) Disconnect blower motor connector (1).

4) Remove blower motor screws (2), and then remove
blower motor (3) from HVAC unit.
IMTA0A720020-03
3) Disconnect auto A/C panel connector and aspirator

hose.
2
Installation
Reverse removal procedure. 1
Blower Motor Removal and Installation

AENNTA0E7206011 (08(01)
Reference: “Precautions for Electrical System Work” 2
NOTICE
removing or installing blower motor can 2
result in damage.
3
• When removing and installing the blower
motor, hold its flange.
• When placing blower motor on a
IMTA0A720022-01
workbench or other flat surface, check that
its flange faces downward. Installation
• Do not drop or otherwise expose the Reverse removal procedure.
blower motor to large shock. The blower
motor that has received large shock Blower Motor Inspection
should be replaced. AENNTA0E7206012 (08(03)
Reference: “Blower Motor Removal and Installation”
Removal • Check resistance between two blower motor terminals
1) Remove glove box. (Instrument Panel Removal and as shown.
Installation) in Section 9C If there is no continuity, replace blower motor.
2) Remove clips (A), and then remove instrument panel
under assist cover (1) pulling it in arrow direction.
HVAC System: 7B-59
I9P60A721013-01
• Check blower motor for operation and current.

A A
a. Put blower motor (1) in a soft jawed vise.
b. Connect battery to blower motor as shown.
c. Check if blower motor operates smoothly without
noise. 1
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 IMTA0A720021-03
motor. 3) Disconnect connector (1) from blower motor resistor
Blower motor specified current at 12 V (2), and then remove blower motor resistor from
16 A maximum at 20 – 25 °C (68 – 77 °F) HVAC unit by removing screws (3).
1 1
I9P60A721039-01
2 3
Blower Motor Controller Removal and IDAA0A721010-01
Installation
AENNTA0E7206013 (08(01) Installation
Reference: “Precautions for Electrical System Work” Reverse removal procedure.
Removal Blower Motor Controller Inspection

1) Remove glove box. (Instrument Panel Removal and AENNTA0E7206014 (08(03)
Installation) in Section 9C Reference: “Blower Motor Controller Removal and

Installation”
under assist cover (1) pulling it in arrow direction. 1) Check internal circuit of controller for resistance as
follows.
a) Measure resistance between terminals “2” and
“4” of blower motor controller.
Blower motor controller resistance
“2” – “4”: approximately 10 kΩ at 25 °C (77
°F)
If check result is not as specified, replace blower
motor controller.
b) Connect positive (+) terminal of an ohmmeter to
terminal “1” of blower motor controller and
negative (–) terminal to terminal “2” of the
controller. The result should indicate no
continuity.
2) Check controller for operation as follows.
7B-60 HVAC System:
a) Using bulb (3.4 W) (5) and service wire, connect

battery positive (+) terminal to terminal “1” of
blower motor controller as shown in figure.
b) Using service wire, connect battery negative (–)
terminal to terminal “2” of blower motor 1
controller. 2
c) Arrange 3 new 1.5 V batteries (6) in series
(check that total voltage is 4.5 – 5.0 V) and I7RW01721018-01
connect its positive (+) terminal to terminal “4” of
blower motor controller and negative (–) terminal Installation
to terminal “2” of the controller. Reference: “Evaporator Temperature Sensor Inspection”
The bulb should light. If bulb does not light, Reverse removal procedure noting the following point.
replace blower motor controller. • Install evaporator temperature sensor (1) onto
evaporator (2) as shown.
“2” “1”
“4” “3”
6
1
1
3
4 5
4 2
5
IFRA0A721019-02
6
IDAA0A723015-01 3. 50.0 mm (1.96 in.)
4. Holding part fixed to 13th fin from the left
Evaporator Inspection 5. Sensor part fixed to 15th fin from the left
AENNTA0E7206015 (08(03) 6. Pipe fitting
Reference: “HVAC Unit Removal and Installation”
Reference: “HVAC Unit Components”
Check the following items. Evaporator Temperature Sensor Inspection
AENNTA0E7206017 (08(03)
• Evaporator fins for clogging Reference: “Evaporator Temperature Sensor Removal
If clogged, wash evaporator fins with water, and then and Installation”
dry it with compressed air. Check resistance between terminals of evaporator
• Evaporator fins for leakage and breakage temperature sensor (1).
If evaporator fins are leaky or broken, repair or If check result is not as specified, replace evaporator
replace evaporator. temperature sensor.
• Evaporator fittings for leakage Evaporator temperature sensor resistance
If evaporator fittings are leaky, repair or replace 0 °C (32 °F): 6.7 – 6.9 kΩ
evaporator. 25 °C (77 °F): 2.0 – 2.2 kΩ
Evaporator Temperature Sensor Removal and

Installation
AENNTA0E7206016 (08(01)
Removal
1) Remove HVAC unit from vehicle. (HVAC Unit
2) Remove evaporator temperature sensor (1) from
evaporator (2) by disassembling HVAC unit referring
to “HVAC Unit Components”.
HVAC System: 7B-61
• Tighten expansion valve bolts (1) to specified torque.

Tightening torque
Expansion valve bolt (a): 3.5 N·m (0.36 kgf-m, 2.5
lbf-ft)
1 1, (a)
k 10
8
7
[A] 5
IMTA0A720023-01
4
3
“Evacuation” and “Charge” in “Operation Procedure
2 for Refrigerant Charge”.
1
Expansion Valve Inspection

0 5 10 15 20 25 30 (°C) AENNTA0E7206019 (08(03)
32 41 50 59 68 77 86 (°F)
Reference: “Expansion Valve Removal and Installation”
[B]
IDAA0A722041-01 Refer to “A/C System Performance Inspection”.
[A]: Resistance [B]: Temperature
A/C Refrigerant Pressure Sensor and Its Circuit
Expansion Valve Removal and Installation Inspection
AENNTA0E7206018 (08(01) AENNTA0E7206020 (08(03)
Reference: “HVAC Unit Components” Reference: “A/C Refrigerant Pressure Sensor Removal
and Installation”
Removal Reference: “Precautions for Electrical System Work”
1) Recover refrigerant from A/C system using recovery 1) Disconnect A/C refrigerant pressure sensor
and recycling equipment referring to “Recovery” in connector.
“Operation Procedure for Refrigerant Charge”. 2) Set ignition “ON”.
2) Remove air cleaner assembly. (Air Cleaner 3) Check that voltage between “GRY” wire terminal and
Assembly Removal and Installation) in Section 1D “BLU” wire terminal of A/C refrigerant pressure
3) Remove suction pipe bolt (1), and then remove liquid sensor connector is 4.75 V to 5.25 V.
pipe and suction pipe from expansion valve (2). If check result is not as specified, check A/C
refrigerant pressure sensor circuit.
4) Remove expansion valve bolts (3) and remove
expansion valve. 4) Connect A/C refrigerant pressure sensor connector
with ignition “OFF”.
5) Connect manifold gauge set to charging valves.
1
6) Check A/C refrigerant pressure sensor voltage of
3
ECM connector. (Inspection of ECM and Its Circuits)
in Section 1A
If voltage is not as specified, replace A/C refrigerant
pressure sensor.
2
2
IFRA0A721020-01
Installation
Reference: “Expansion Valve Inspection”
• Apply compressor oil to O-rings of expansion valve
and pipes.
(ND-OIL8))
7B-62 HVAC System:
A/C refrigerant pressure sensor voltage • Apply compressor oil to new O-ring of A/C refrigerant
specifications (A/C refrigerant pressure measured pressure sensor.
by manifold gauge)
(ND-OIL8))
(V)
5.0 • Tighten A/C refrigerant pressure sensor (1) to
specified torque.
4.0 Tightening torque
A/C refrigerant pressure sensor (a): 11 N·m (1.1
3.0 kgf-m, 8.5 lbf-ft)
[A]
2.0
1.0
0.5 1.0 1.5 2.0 2.5 3.0 3.5 (MPa)

[B]
IAW101720062-02
1, (a)
[A]: Voltage [B]: Pressure on high pressure gauge
A/C Refrigerant Pressure Sensor Removal and

Installation
AENNTA0E7206021 (08(01)
Removal
IMTA0A720025-01
2) Disconnect A/C refrigerant pressure sensor “Evacuation” and “Charge” in “Operation Procedure
connector (1). for Refrigerant Charge”.
3) While holding liquid pipe (2) using backup wrench,
remove A/C refrigerant pressure sensor (3). Temperature Control Actuator Removal and
Installation
AENNTA0E7206022 (08(01)
Removal
1
2) Disconnect temperature control actuator connector
(1).
3) Remove temperature control actuator (2) from HVAC
unit by removing screws (3).
IMTA0A720024-01
Installation
Reference: “A/C Refrigerant Pressure Sensor and Its
Circuit Inspection”
HVAC System: 7B-63
Temperature control actuator resistance

3
Arm position Resistance (25 °C (77 °F))
MAX COOL [a] Approx. 4.4 kΩ
MAX HOT [b] Approx. 1.2 kΩ
1 3) Using ohmmeter, measure resistance between

terminal “3” and terminal “1”.
If check result is not as specified, replace
temperature control actuator (2).
Temperature control actuator resistance (Total
resistance)
2
6 kΩ
3
IFRA0A722012-01
2
Installation 3
Reference: “Temperature Control Actuator Inspection” 1

• Check that gear (1) on temperature control actuator 5 4 3 2 1
engages in pinion (2).
• Check that protrusion (3) on HVAC unit fits into hole
(4) on temperature control actuator. [b]
2 4 “a”
[a]
IFRA0A722014-01
4
M
5
1
1
IFRA0A722013-01 2
3
Temperature Control Actuator Inspection 5 4 3 2 1
AENNTA0E7206023 (08(03) 1
Reference: “Temperature Control Actuator Removal and
IDAA0A723023-01
Installation”
“a”: 80° 3. Gear
1) Set gear to actuator and check if gear operates
smoothly when battery voltage is applied to terminals
of actuator connector (1).
Temperature control actuator operation Air Flow Control Actuator Removal and
Installation
1 AENNTA0E7206024 (08(01)
5 4 3 2 1 Removal
1) Remove HVAC unit from vehicle. (HVAC Unit
Terminal
Arm operation
2) Remove air flow control actuator screws (1) and
move air flow control actuator (2) in arrow direction
as shown in figure.
IFRA0A722022-01
3) Remove protrusion (3) on link by unhooking claws
2) Using ohmmeter, measure resistance between (4), and then remove air flow control actuator.
terminal “2” and terminal “1” of actuator connector
(1) at each arm position.
7B-64 HVAC System:
2) Using ohmmeter, measure resistance between

1 terminal “2” and terminal “1” of actuator connector
(1) at each actuator link position.
3 Air flow control actuator resistance
4
DEF [a] Approx. 1.2 kΩ
2
DEF/FOOT [b] Approx. 2.0 kΩ
FOOT [c] Approx. 2.8 kΩ
B/L [d] Approx. 3.6 kΩ
FACE [e] Approx. 4.4 kΩ
3) Using ohmmeter, measure resistance between

1
IMTA0A720050-01
terminal “3” and terminal “1” of actuator connector.
If check result is not as specified, replace air flow
Installation control actuator.
Reference: “Air Flow Control Actuator Inspection” Air flow control actuator resistance (Total
Reverse removal procedure noting the following points. resistance)
• Check that protrusion (1) on links fit into hole (2) in 6 kΩ
plate respectively.
2
• Check that protrusions (3) on HVAC unit fits into holes
(4) on air flow control actuator.
4
3 1
5 4 3 2 1
2
3
3
1
“a”
[b]
“b”
[c] [a]
[e] “c”
[d]
IMTA0A720051-01 “d”
IMTA0A720027-01
Air Flow Control Actuator Inspection

AENNTA0E7206025 (08(03)
4
Reference: “Air Flow Control Actuator Removal and
M
Installation” 5
1) Set arm to actuator and check if arm operates 1
smoothly when battery voltage is applied to terminals 2
of actuator connector (1). 3

Air flow control actuator operation 5 4 3 2 1
1
1
IDAA0A723023-01
“a”: 20° “d”: 80°

“b”: 40° 2. Air flow control actuator
5 4 3 2 1 “c”: 60° 3. Arm
Terminal Air Intake Control Actuator Removal and

4 5
Arm operation Installation
FACE DEF AENNTA0E7206026 (08(01)
DEF FACE
IMTA0A720026-02
Removal
1) Remove glove box.
HVAC System: 7B-65

under assist cover (1) pulling it in arrow direction.
4 3
A A 1
IFRA0A722023-01
Air Intake Control Actuator Inspection

AENNTA0E7206027 (08(03)
1
Reference: “Air Flow Control Actuator Removal and
Installation”
1) Set arm to actuator and check if arm operates
IMTA0A720021-03
smoothly when battery voltage is applied to terminals
3) Disconnect air intake control actuator connector (1). of actuator connector (1).
4) Remove air intake control actuator (2) by removing Air intake control actuator operation
screws (3).
1
3 1
5 4 3 2 1
Terminal
Arm operation
IFRA0A722025-01
2 2) Using ohmmeter, measure resistance between

terminal “2” and terminal “3” of actuator connector
(1) at each arm position.
3
IFRA0A722024-01 Air intake control actuator resistance
Installation FRE [a] Approx. 2.0 kΩ
Reference: “Air Flow Control Actuator Inspection” REC [b] Approx. 4.8 kΩ
• Check that protrusion (1) on link fits into groove (2) on 3) Using ohmmeter, measure resistance between
arm. terminal “1” and terminal “3” of actuator connector.
• Check that protrusion (3) on HVAC unit fits into hole Air intake control actuator resistance (Total
(4) on air intake control actuator. resistance)
6 kΩ
7B-66 HVAC System:
[a]
3
“a”
2
[b]
1
5 4 3 2 1
2
1
IFRA0A722026-02
4
M
5
IMTA0A720028-02
2
1
1
Installation
5 4 3 2 1
3 Reference: “Sunload Sensor Inspection”
IDAA0A723031-01
“a”: 71° 3. Arm
• Install sunload sensor (1) to instrument panel, fitting
2. Air intake control actuator tabs (2) of sunload sensor into grooves (3) in
instrument panel as shown in figure.
Actuator Linkage Inspection 2
AENNTA0E7206028 (08(03)
3
• Check that each actuator linkage operates smoothly.
• Check actuator rod for bend. [A]
• Check each actuator linkage for breakage. 1
• Check that there is not any obstruction in operating

range of actuator linkage.
If check result is not OK, repair or replace faulty I9P60A723025-01
part(s). [A]: Vehicle forward
Sunload Sensor Removal and Installation Sunload Sensor Inspection

AENNTA0E7206029 (08(01) AENNTA0E7206030 (08(03)
Reference: “Precautions for Electrical System Work” Reference: “Sunload Sensor Removal and Installation”
1) Light sunload sensor vertically with an incandescent
Removal light or sun shine in a sunny day.
1) Disable air bag system. 2) Measure voltage between terminals “1” and “2” of
• 4-channel air bag model: (Disabling Air Bag sunload sensor as shown in figure.
System): 4-Channel in Section 8B If check result is not as specified, replace sunload
• 8-channel air bag model: (Disabling Air Bag sensor.
System): 8-Channel in Section 8B NOTE
2) Remove instrument panel from vehicle. (Instrument
In case of using incandescent light, prepare
light of approximately 100 W and light
3) Disconnect sunload sensor connector (1). sunload sensor approximately 100 mm (3.94
4) Remove sunload sensor (2) from instrument panel in.) away from the sensor.
by depressing tabs and pushing sensor upward from
underneath. Sunload sensor voltage specification (Low)
Higher than 0.4 V
HVAC System: 7B-67
1
V
“1” 1
“2”
I9P60A723014-04
3) Cover sunload sensor with black cloth and measure 1

voltage between terminals “1” and “2” of sunload
sensor as shown in figure.
If check result is not as specified, replace sunload 1
sensor.
Sunload sensor voltage specification (High) 2
Lower than 0.1 V IMTA0A720029-01
Installation
V
Side Ventilation Louver Removal and
“1”
“2” Installation
AENNTA0E7206035 (08(01)
Driver-Side Side Ventilation Louver
I9P60A723014-04 Removal
1) Remove instrument driver garnish. (Instrument
Outside Air Temperature Sensor Removal and Panel Disassembly and Reassembly) in Section 9C
Installation 2) Release tabs (1), and then remove driver-side side
AENNTA0E7206031 (08(01)
Refer to “Outside Air Temperature Sensor Removal and ventilation louver (2) from instrument panel driver
Installation” in Section 10B. garnish.
Outside Air Temperature Sensor Inspection 1

AENNTA0E7206032 (08(03)
Refer to “Outside Air Temperature Sensor Inspection” in 2
Section 10B.
Ventilator Duct Removal and Installation

AENNTA0E7206033 (08(01)
Refer to “Instrument Panel Disassembly and
Reassembly” in Section 9C.
1
Center Ventilation Louver Removal and

Installation
AENNTA0E7206034 (08(01) IMTA0A720030-01
Removal
1) Remove instrument panel center garnish. Installation
(Smartphone Linkage Display Audio Unit Removal Reverse removal procedure.
and Installation) in Section 9O
Passenger-Side Side Ventilation Louver
2) Release tabs (1), and then remove center ventilation
Removal
louvers (2) from instrument panel center garnish.
1) Remove instrument assist garnish. (Instrument
Panel Disassembly and Reassembly) in Section 9C
2) Release tabs (1), and then remove passenger-side
side ventilation louver (2) from instrument panel
assist garnish.
7B-68 HVAC System:
Rear Ventilation Duct No.2

1 Removal
2
front covers. (Trim / Console Removal and
1
3) Remove clip (A), and then remove floor console box
center bracket (1) referring to “Trim / Console
Removal and Installation” in Section 9H.
IMTA0A720031-01 4) Remove rear ventilation No.2 duct (2).
Installation A
“1”
Rear Ventilation Louver Removal and “2”

Installation (If Equipped)
AENNTA0E7206036 (08(01)
Removal
1) Remove floor console box rear cover. (Trim /
Console Removal and Installation) in Section 9H
2) Release tabs (1), and then remove rear ventilation
louver (2) from floor console box rear cover.
1 2
A
1
2
IMTA0A720033-03
Installation
• Insert protrusions (1) on rear ventilation No.2 duct into
the holes in floor console cover front bracket (2).
IMTA0A720032-01
Installation
Rear Ventilation Duct Removal and Installation

(If Equipped)
AENNTA0E7206037 (08(01)
Rear Ventilation Duct No.1
Refer to “Instrument Panel Disassembly and
Reassembly” in Section 9C.
HVAC System: 7B-69
2
1 2
1 3
IGSB0A721026-01
HVAC Air Filter Inspection

AENNTA0E7206039 (08(03)
Reference: “HVAC Air Filter Removal and Installation”
Check that filter is not excessively dirty, damaged or oily.
Clean filter with compressed air from its air outlet side.
UP
IDL10A721045-01
IMTA0A720034-01 HVAC System Relay Inspection

AENNTA0E7206040 (08(03)
A/C Compressor Relay
HVAC Air Filter Removal and Installation Refer to “Control Relay Inspection” in Section 10B.
AENNTA0E7206038 (08(01)
Removal
Blower Motor Relay
1) Remove glove box. (Instrument Panel Removal and
2) Remove HVAC air filter cover (1) from HVAC unit. Radiator Cooling Fan Relay
3) Remove air filter (2) from HVAC unit. Refer to “Control Relay Inspection” in Section 10B.
Compressor Drive Belt Inspection

AENNTA0E7206041 (08(03)
2 1
1) Check compressor drive belt (1) for wear, cracks,
deformation and contamination. If any defect is
found, replace the belt with new one. (Compressor
Drive Belt Removal and Installation)
2) Start engine and stop it after 2 or 3 seconds to
IGSB0A721025-01 stabilize compressor drive belt tension.
3) Hoist vehicle and remove right side front wheel.
Installation (Wheel (with Tire) Removal and Installation) in
Reference: “HVAC Air Filter Inspection” Section 2D
4) Remove right side engine under side cover. (Engine
• Position air filter (1) and HVAC air filter cover (2) Under Cover and Engine Under Side Cover
directing its arrow mark (3) upward. Removal and Installation) in Section 9H
5) Check compressor drive belt tension by tension
meter following the instructions mentioned in the
tension meter manual. If compressor drive belt
tension is not as specified, replace the belt with new
one.
Compressor drive belt tension
Belt in use: 292 – 567 N (29.8 – 57.8 kgf or 65.6–
127.5 lbf)
7B-70 HVAC System:
New belt: 402 – 780 N (41.0 – 79.5 kgf or 90.4 –

175.4 lbf) 1, (A)
Recommended belt tension meter specification

Gates Corporation “550” or equivalent
Setting value for belt tension meter “550” 1, (A)
MASS 14.0
WIDTH 4.0
SPAN 178
NOTE
• For using general belt tension meter (other
than Gates Corporation “550”) refer to the
following belt specification values.
2 3
– Length: 733 mm IDP70P720018-02
– Weight: 45 g 4) Remove compressor drive belt (1) by turning
– Distance between the contact points of crankshaft pulley (2) clockwise.
belt and pulley: 178 mm
• For the setting of the belt tension meter,
follow the operation manual of belt tension
meter.
2 1
IDP70P720019-03
Installation
1) Fit ribs of compressor drive belt (1) into grooves of
2 3
magnet clutch pulley (2).
IGSA0P722048-01
2) Fit compressor drive belt into groove in special tool
2. Crankshaft pulley 3. Magnet clutch pulley (3) as shown in figure.
Special tool
Compressor Drive Belt Removal and
(A): 09991M07420
Installation
AENNTA0E7206042 (08(01) 3) Fit ribs of special tool and compressor drive belt into
Removal
grooves of crankshaft pulley (4) as shown in figure.
1) Hoist vehicle and remove right side front wheel.
(Wheel (with Tire) Removal and Installation) in
Section 2D
2) Remove right side engine under side cover. (Engine
3) Place special tool (1) between crankshaft pulley (2)
and compressor drive belt (3) as shown in figure.
Special tool
(A): 09991M07410
HVAC System: 7B-71

Belt Removal and Installation)
4) Disconnect magnet clutch lead wire connector (1).
3, (A) 5) Disconnect discharge hose (2) and suction hose (3)
from compressor (4).
1
3, (A) NOTE
Cap open fittings immediately to keep
moisture out of the system.
6) Remove compressor mounting bolts (5), and then

remove compressor.
1
5 2
4 1 2
3, (A) 4
IDP70P720020-02
4) Turn crankshaft pulley (1) clockwise until ribs of

3
compressor drive belt (2) fit into grooves of
crankshaft pulley and magnet clutch pulley (3)
completely.
4
5
IMTA0A720036-03
Installation
Reference: “Magnet Clutch Inspection”
1 2 3 Reverse removal procedure noting the following points.
IDP70P720022-02
• Apply compressor oil to new O-rings of discharge
5) Turn crankshaft clockwise 720° and check that all hose and suction hose.
ribs of the belt fit into grooves of pulleys.
6) Check compressor drive belt tension. (Compressor
(ND-OIL8))
Drive Belt Inspection)
7) Install right side engine under side cover. (Engine • Tighten compressor mounting bolts (1) in numerical
Under Cover and Engine Under Side Cover order (“1” – “3”) to specified torque as shown in figure.
Removal and Installation) in Section 9H • Tighten discharge hose bolt (2) and suction hose bolt
8) Install right side front wheel. (Wheel (with Tire) (3) to specified torque.
Removal and Installation) in Section 2D Tightening torque
Compressor mounting bolt (a): 25 N·m (2.5 kgf-
Compressor Assembly Removal and m, 18.5 lbf-ft)
Installation Discharge hose bolt (b): 11 N·m (1.1 kgf-m, 8.5
AENNTA0E7206043 (08(01)
lbf-ft)
Suction hose bolt (c): 11 N·m (1.1 kgf-m, 8.5 lbf-
ft)
Removal
7B-72 HVAC System:
• Replenish compressor with specified amount of

1, “1”, (a) • Evacuate and charge A/C system referring to
2, (b) “Evacuation” and “Charge” in “Operation Procedure
1, “3”, (a)
3, (c)
1, “2”, (a)
IMTA0A720037-02
• Check compressor drive belt tension. (Compressor

Drive Belt Inspection)
Compressor Assembly Components

AENNTA0E7206044 (12(01)
9 (c) (b)
7
OIL
8
5
4
3 (a)
1
IMTA0A720038-01
1. Magnet clutch assembly 6. Compressor body : 13 Nm (1.3 kgf-m, 9.5 lbf-ft)
2. Clip set 7. Relief valve set : 3.7 Nm (0.38 kgf-m, 3.0 lbf-ft)
O-ring: Apply compressor oil.
3. Armature plate bolt 8. Clutch coil harness bracket : Do not reuse.
4. Spacer shim 9. Clutch coil harness bracket screw
5. Snap ring : 18 Nm (1.8 kgf-m, 13.5 lbf-ft)
HVAC System: 7B-73
Magnet Clutch Inspection 3) Remove armature plate and spacer shim(s).

AENNTA0E7206045 (08(03)
Reference: “Compressor Assembly Removal and 4) Remove snap ring (1), and then remove clutch pulley
Installation” (2).
• Check armature plate for wear and magnet clutch
pulley for oil soak respectively.
• Check magnet clutch pulley bearing for noise, wear
and grease leakage.
1
• Using ohmmeter (1), measure resistance of stator coil
between clutch lead wire (2) and compressor body.
If check result is not as specified, replace magnet 2
clutch assembly.
Magnet clutch coil resistance
4.9 – 5.3 Ω (at 20 °C (68 °F))
1
IFKA0P721047-02
2
5) Remove snap ring (1).
2
1
IMTA0A720039-01
Magnet Clutch Removal and Installation

AENNTA0E7206046 (08(01)
Reference: “Compressor Assembly Removal and
Installation” IFKA0P721048-02
Reference: “A/C System Major Components” 2. Clutch coil
Removal 6) Remove clutch coil harness bracket (2) by removing

1) Remove compressor from vehicle. (Compressor its screw (1), and then remove clutch coil (3).
2) Fix armature plate (1) with special tool and remove 3
armature plate bolt (2).
Special tool
(A): 09917M68222
(A)
1 1
2
IMTA0A720040-01
Installation
• Install clutch coil by fitting protrusion (1) of clutch coil
onto hole (2) in compressor.
IGSA0P722059-01
7B-74 HVAC System:
(A)
1, (a)
2
IFKA0P721055-01
• Tighten clutch coil harness bracket screw (1) to

specified torque.
IMTA0A720042-01
Tightening torque • Check clearance between armature plate (3) and

Clutch coil harness bracket screw (a): 3.7 N·m ( magnet clutch pulley (4) as follows. If clearance is out
0.38 kgf-m, 3.0 lbf-ft) of specified range, adjust it by putting shim(s) on
compressor shaft.
a. Put compressor in a soft jawed vise (1).
b. Set dial gauge (2) on armature plate, and then
adjust its pointer at 0.
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.)
e. Disconnect battery negative (–) terminal from
compressor body assembly. (At this point,
1, (a)
armature plate and magnet clutch pulley are not in
contact.)
f. Read stroke of armature plate from dial gauge by
IMTA0A720041-01 performing Step d) – e) repeatedly. (Stroke of
• Install new snap rings. armature plate indicates clearance between
• Install the same amount of removing spacer shim(s). armature plate and magnet clutch pulley.)
• Tighten new armature plate bolt (1) to specified NOTE
torque.
Clip set in supply parts includes several
Special tool shims in different thickness. Adjust the air
(A): 09917M68222 gap in combination with three pieces at a
maximum.
Tightening torque
Armature plate bolt (a): 18 N·m (1.8 kgf-m, 13.5 Standard clearance between armature plate
lbf-ft) and magnet clutch pulley
“a”: 0.30 – 0.55 mm (0.012 – 0.022 in.)
HVAC System: 7B-75
2
3
“a”
4
1
IFKA0P721045-01
IMTA0A720044-01
Relief Valve Inspection
AENNTA0E7206047 (08(03)
1) Check A/C system referring to “A/C System Installation
Performance Inspection” and “Trouble Diagnosis for Reverse removal procedure noting the following points.
Abnormal Pressure”. • Use new O-ring.
2) Check relief valve for refrigerant leakage using leak • Apply compressor oil to O-ring.
detector (1). : Compressor oil 95590–58D30 (Compressor oil
If there is refrigerant leakage, replace relief valve. (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
1, (a)
IMTA0A720043-01
Relief Valve Removal and Installation

AENNTA0E7206048 (08(01)
Removal
IMTA0A720045-01
and recycling equipment referring to “Recovery” in • Evacuate and charge A/C system referring to
“Operation Procedure for Refrigerant Charge”. “Evacuation” and “Charge” in “Operation Procedure
2) Remove relief valve (1) from compressor.
Specifications
7B-76 HVAC System:

AENNTA0E7207001 (09(t)
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Filter cap 3.9 0.40 3.0 (T7B001)
Expansion valve bolt 3.5 0.36 2.5 (T7B002)
A/C refrigerant pressure sensor 11 1.1 8.5 (T7B003)
Compressor mounting bolt 25 2.5 18.5 (T7B004)
Discharge hose bolt 11 1.1 8.5 (T7B005)
Suction hose bolt 11 1.1 8.5 (T7B006)
Clutch coil harness bracket screw 3.7 0.38 3.0 (T7B007)
Armature plate bolt 18 1.8 13.5 (T7B008)
Relief valve 13 1.3 9.5 (T7B009)
Reference:
“A/C System Major Components”
“HVAC Unit Components”
“Compressor Assembly Components”

AENNTA0E7208001 (11(m)
Compressor oil Compressor oil (ND-OIL8) P/No.: 95590–58D30 (M7B001) / (M7B002) /
(M7B003) / (M7B004) /
(M7B005) / (M7B006) /
(M7B007) / (M7B008)
NOTE
“A/C System Major Components”
“Compressor Assembly Components”
Special Tool
AENNTA0E7208002 (11(s)
09917M68222 09991M07410
Crankshaft pulley holder Drive belt remover
(L7B003) / (L7B004) (L7B001)
09991M07420
Drive belt installer
(L7B002)
Section 8
Restraint
CONTENTS
Precautions .................................................8-1 Component Location ...........................................8B-5

Precautions............................................................. 8-1 Air Bag System Component, Wiring and
Precautions for Restraint ...................................... 8-1 Connector Location ...........................................8B-5
Diagnostic Information and Procedures ............8B-6
Seat Belts ................................................. 8A-1 Air Bag Diagnostic System Check ......................8B-7
Precautions...........................................................8A-1 Visual Inspection .................................................8B-7
Precautions for Service and Diagnosis of Seat “AIR BAG” Warning Light Check.........................8B-8
Belt.................................................................... 8A-1 Self-Diagnosis Function ......................................8B-8
General Description .............................................8A-1 DTC Check..........................................................8B-8
Seat Belt Construction ........................................ 8A-1 DTC Clearance ...................................................8B-8
DTC Table...........................................................8B-9
Diagnostic Information and Procedures............8A-3
Scan Tool Data .................................................8B-10
Repair and Inspection Required after
“AIR BAG” Warning Light Comes ON Steady ...8B-11
Accident ............................................................ 8A-3
“AIR BAG” Warning Light Does Not Come ON ..8B-12
Repair Instructions ..............................................8A-3
DTC B1002-00 ..................................................8B-14
Front Seat Belt Components............................... 8A-3
DTC B1003-04 ..................................................8B-14
Front Seat Belt Assembly Removal and
DTC B1004-17 ..................................................8B-15
Installation......................................................... 8A-4
DTC B1004-18 ..................................................8B-16
Front Seat Belt Assembly Inspection .................. 8A-5
DTC B1032-00 / B1035-00................................8B-17
Front Seat Belt Buckle Inspection ....................... 8A-6
DTC B1060-14 ..................................................8B-17
Passenger Seat Belt Reminder Sensor
DTC B1060-15 ..................................................8B-19
Inspection.......................................................... 8A-7
DTC B1060-1A..................................................8B-20
Rear Seat Belt Components ............................... 8A-8
DTC B1060-1B..................................................8B-22
Rear Side Seat Belt Assembly Removal and
DTC B1062-14 ..................................................8B-24
Installation......................................................... 8A-8
DTC B1062-15 ..................................................8B-26
Rear Center Seat Belt Removal and
DTC B1062-1A..................................................8B-27
Installation......................................................... 8A-8
DTC B1062-1B..................................................8B-30
Rear Seat Belt Assembly Inspection................... 8A-9 8
DTC B1064-14 / B1065-14................................8B-32
Rear Seat Belt Buckle Inspection ....................... 8A-9
DTC B1064-15 / B1065-15................................8B-33
Specifications.......................................................8A-9 DTC B1064-1A / B1065-1A...............................8B-35
Tightening Torque Specifications........................ 8A-9 DTC B1064-1B / B1065-1B...............................8B-37
DTC B1090-01 / B1090-95................................8B-38
Air Bag System ........................................ 8B-1 DTC B1090-87 ..................................................8B-39
4-Channel.................................................................8B-1 DTC U0073-88 ..................................................8B-42
Precautions...........................................................8B-1 SDM Power Supply and Ground Circuit
Precautions for Air Bag System Service ............. 8B-1 Check ..............................................................8B-42
Precautions for Handling and Storage of Air Contact Coil and Its Circuit Check ....................8B-44
Bag System Components ................................. 8B-1 Repair and Inspection Required after
Precautions for Disposal of Air Bag and Seat Accident ..........................................................8B-46
Belt Pretensioner .............................................. 8B-3 Repair Instructions ............................................8B-48
General Description .............................................8B-3 Disabling Air Bag System..................................8B-48
Air Bag System Construction .............................. 8B-3 Enabling Air Bag System ..................................8B-49
Schematic and Routing Diagram........................8B-4 Release of Shorting Bar ....................................8B-49
Air Bag System Input / Output Diagram .............. 8B-4 SDM Removal and Installation..........................8B-50
Air Bag System Circuit Diagram.......................... 8B-4 SDM Inspection.................................................8B-50
Driver Air Bag (Inflator) Module Removal and DTC B1060-15 ..................................................8B-86
Installation ....................................................... 8B-51 DTC B1060-1A..................................................8B-88
Driver Air Bag (Inflator) Module Inspection ....... 8B-52 DTC B1060-1B..................................................8B-90
Passenger Air Bag (Inflator) Module Removal DTC B1062-14 ..................................................8B-92
and Installation ................................................ 8B-52 DTC B1062-15 ..................................................8B-93
Passenger Air Bag (Inflator) Module DTC B1062-1A..................................................8B-95
Inspection........................................................ 8B-53 DTC B1062-1B..................................................8B-97
Seat Belt Pretensioner Components................. 8B-54 DTC B1064-14 / B1065-14................................8B-99
Seat Belt Pretensioner Removal and DTC B1064-15 / B1065-15..............................8B-101
Installation ....................................................... 8B-54 DTC B1064-1A / B1065-1A.............................8B-102
Seat Belt Pretensioner Inspection..................... 8B-54 DTC B1064-1B / B1065-1B.............................8B-104
Forward Impact Sensor Removal and DTC B1068-14 / B1069-14..............................8B-106
Installation ....................................................... 8B-54 DTC B1068-15 / B1069-15..............................8B-108
Forward Impact Sensor Inspection ................... 8B-55 DTC B1068-1A / B1069-1A.............................8B-110
Passenger Air Bag (Inflator) Module Repair DTC B1068-1B / B1069-1B.............................8B-113
Harness Installation ........................................8B-55 DTC B106C-14 / B106D-14 ............................8B-115
Air Bag (Inflator) Module and Seat Belt DTC B106C-15 / B106D-15 ............................8B-117
Pretensioner Disposal ..................................... 8B-56 DTC B106C-1A / B106D-1A............................8B-118
Deployed Air Bag (Inflator) Module and DTC B106C-1B / B106D-1B............................8B-120
Activated Seat Belt Pretensioner Disposal ..... 8B-60 DTC B1090-01 / B1090-95..............................8B-123
Specifications.....................................................8B-61 DTC B1090-87 ................................................8B-123
Tightening Torque Specifications...................... 8B-61 DTC B1093-01 / B1093-95 / B1094-01 /
Special Tools and Equipment ...........................8B-61 B1094-95.......................................................8B-126
Use of Special Tools ......................................... 8B-61 DTC B1093-87 / B1094-87..............................8B-128
Special Tool ...................................................... 8B-62 DTC B1095-01 / B1095-95 / B1096-01 /
8-Channel...............................................................8B-64 B1096-95.......................................................8B-131
DTC B1095-87 / B1096-87..............................8B-132
Precautions.........................................................8B-64
DTC U0073-88 ................................................8B-135
Precautions for Air Bag System Service ...........8B-64
SDM Power Supply and Ground Circuit
Precautions for Handling and Storage of Air
Check ............................................................8B-135
Bag System Components ............................... 8B-64
Contact Coil and Its Circuit Check ..................8B-136
Precautions for Disposal of Air Bag and Seat
Repair and Inspection Required after
Belt Pretensioner ............................................ 8B-66
Accident ........................................................8B-138
General Description ...........................................8B-66
Repair Instructions ..........................................8B-141
Air Bag System Construction ............................ 8B-66
Disabling Air Bag System................................8B-141
Air Bag System Input / Output Table................. 8B-67
Enabling Air Bag System ................................8B-141
Schematic and Routing Diagram......................8B-67
Release of Shorting Bar ..................................8B-141
Air Bag System Input / Output Diagram ............ 8B-68
SDM Removal and Installation ........................8B-142
Air Bag System Circuit Diagram........................ 8B-68
SDM Inspection...............................................8B-142
Component Location .........................................8B-70 Driver Air Bag (Inflator) Module Removal and
Air Bag System Component, Wiring and Installation .....................................................8B-142
Connector Location ......................................... 8B-70 Driver Air Bag (Inflator) Module Inspection .....8B-142
Diagnostic Information and Procedures..........8B-72 Passenger Air Bag (Inflator) Module Removal
Air Bag Diagnostic System Check .................... 8B-72 and Installation ..............................................8B-142
Visual Inspection ............................................... 8B-73 Passenger Air Bag (Inflator) Module
“AIR BAG” Warning Light Check....................... 8B-73 Inspection......................................................8B-142
Self-Diagnosis Function .................................... 8B-73 Seat Belt Pretensioner Components...............8B-142
DTC Check........................................................ 8B-73 Seat Belt Pretensioner Removal and
DTC Clearance ................................................. 8B-74 Installation .....................................................8B-142
DTC Table......................................................... 8B-74 Seat Belt Pretensioner Inspection...................8B-143
Scan Tool Data ................................................. 8B-76 Side-Air Bag (Inflator) Module Components ...8B-143
“AIR BAG” Warning Light Comes ON Steady ... 8B-78 Side-Air Bag (Inflator) Module Removal and
“AIR BAG” Warning Light Does Not Come ON .. 8B-79 Installation .....................................................8B-143
DTC B1002-00 .................................................. 8B-81 Side-Air Bag (Inflator) Module Inspection .......8B-144
DTC B1003-04 .................................................. 8B-81 Curtain Air Bag (Inflator) Module Components 8B-145
DTC B1004-17 .................................................. 8B-82 Curtain Air Bag (Inflator) Module Removal
DTC B1004-18 .................................................. 8B-83 and Installation ..............................................8B-145
DTC B1032-00 / B1033-00 / B1034-00 / Curtain Air Bag (Inflator) Module Inspection ...8B-147
B1035-00 / B1036-00 / B1037-00 ................... 8B-84 Forward Impact Sensor Removal and
DTC B1060-14 .................................................. 8B-85 Installation .....................................................8B-147
Forward Impact Sensor Inspection ................. 8B-147 Air Bag (Inflator) Module and Seat Belt
Side-Impact Pressure Sensor Removal and Pretensioner Disposal ...................................8B-149
Installation..................................................... 8B-147 Deployed Air Bag (Inflator) Module and
Side-Impact Pressure Sensor Inspection........ 8B-148 Activated Seat Belt Pretensioner Disposal....8B-154
Side-Impact G Sensor Removal and Specifications...................................................8B-154
Installation..................................................... 8B-148 Tightening Torque Specifications....................8B-154
Side-Impact G Sensor Inspection ................... 8B-149 Special Tools and Equipment .........................8B-155
Passenger Air Bag (Inflator) Module Repair Use of Special Tools .......................................8B-155
Harness Installation ...................................... 8B-149 Special Tool ....................................................8B-155
8-1 Precautions:
Precautions
Restraint
Precautions
Precautions for Restraint
AENNTA0E8000001 (01(01)
General Precautions


Warning for Air Bag



Seat Belts: 8A-1
Seat Belts
Restraint
Precautions
Precautions for Service and Diagnosis of Seat • Never bend or damage buckle and tongue plate.
Belt • Do not bleach or dye webbing. (Use only mild soap
AENNTA0E8100001 (01(01)
and lukewarm water to clean it.)
! WARNING
• When installing a seat belt anchor bolt, first tighten it
• If a seat belt is combined with any buckle by hand to prevent cross-threading and then tighten to
that is not originally paired with the belt, specified torque.
the latch plate of the belt may not fully • Do not attempt any repair on seat belt assembly. If
engage with the buckle and thus may not any fault is found, replace the seat belt as an
lock reliably when the belt is fastened. assembly.
Always replace the seat belt and buckle as • Keep belts dry and clean at all times.
a set. SUZUKI only supplies the buckle and • Any defective part must be replaced with a new one.
seat belt assembly packaged together as a
set. • Replace seat belt assembly whose webbing is cut or
damaged.
• A seat belt pretensioner that has been
activated can no longer protect the seat • Do not put anything into trim panel opening which seat
belt wearer. belt webbing passes through.
Replace any seat belt whose pretensioner • After an accident, whether the seat belt pretensioner
has been activated with a new seat belt has activated or not, perform checks and repairs
and buckle set. described on;
– “Repair and Inspection Required after Accident”: 4-
Before servicing or replacing seat belt assembly, refer to Channel in Section 8B
the following precautions. – “Repair and Inspection Required after Accident”: 8-
• Check if tongue plate and buckle are normal. Channel in Section 8B
• Keep sharp edges and damaging objects away from
webbing.
General Description
Seat Belt Construction
AENNTA0E8101001 (03(01)
8A-2 Seat Belts:
[A] [B]
10 10
11 11
2
9
4 3
7 4
5 8
IMTA0A810001-02
[A]: Segment display type 4. Rear side seat belt assembly (with ELR) 9. Passenger seat belt reminder sensor
[B]: Color dot display type 5. Buckle for rear side seat belt 10. Combination meter
1. Front seat belt assembly (with ELR) 6. Retractor 11. Front seat belt reminder light
2. Seat belt pretensioner 7. Rear center seat belt
3. Buckle for front seat belt 8. Buckle for rear center seat belt
Seat Belt Assembly with ELR driver and passenger air bag (inflator) module, when an
Seat belt assembly with emergency locking retractor impact at the front of vehicle exceeds the specified
(ELR) is designed so that it locks immediately (to value.
prevent the webbing from being pulled out of the When servicing front seat belt assembly, observe all
retractor any further) when any of the following items is WARNINGs and CAUTIONs and “Precautions for Air
detected as exceeding each set value: Bag System Service”: 4-Channel in Section 8B or
• Speed at which the webbing is pulled out of the “Precautions for Air Bag System Service”: 8-Channel in
retractor Section 8B.
• Acceleration or deceleration of vehicle speed
Seat Belt Reminder
• Inclination If driver or passenger seat belt is unfastened under the
following conditions, seat belt reminder light and warning
Seat Belt Assembly with ELR and Pretensioner buzzer inform that driver or passenger seat belt is
The seat belt assembly with ELR and a pretensioner has unfastened. Seat belt reminder light is located in
a pretensioner mechanism which operates in linkage combination meter. Warning buzzer is located inside
with the air bag in addition to the described ELR. combination meter. These reminder light and warning
The pretensioner is incorporated in retractor and buzzer operate as follows:
controlled by SDM as one of air bag system
components. It will be activated at the same time as the
Seat Belts: 8A-3
• Seat belt reminder light comes on if driver or • While vehicle is running at more than 15 km/h (9 mile/
passenger seat belt is unfastened when ignition is h) and if driver or passenger seat belt is unfastened,
“ON”. warning buzzer operates for approximately 95
• If vehicle runs with seat belt unfastened and the seconds and the corresponding seat belt reminder
speed exceeds 15 km/h (9 mile/h), warning buzzer light flashes synchronously with buzzer. When
operates for approximately 95 seconds and the warning buzzer stops operating, the corresponding
corresponding seat belt reminder light flashes seat belt reminder light stays ON.
synchronously with buzzer. When warning buzzer
stops operating, the corresponding seat belt reminder
light stays ON.

Repair and Inspection Required after Accident
AENNTA0E8104001 (06(01)
After an accident, whether the seat belt pretensioner has activated or not, perform checks and repairs referring to
“Repair and Inspection Required after Accident”: 4-Channel in Section 8B or “Repair and Inspection Required after
Accident”: 8-Channel in Section 8B.
Repair Instructions
Front Seat Belt Components
AENNTA0E8106001 (12(01)
NOTE
The figure shows the driver’s seat belt. The tightening torque for the passenger’s seat belt is the same.
8A-4 Seat Belts:
5 , “2 ” (b)
4 , “3” (a)
2
4 , “1 ” (a)
4 , “4” (a)
(a)
IMTA0A810002-01
1. Center pillar upper trim 4. Front seat belt bolt : 5.5 Nm (0.56 kgf-m, 4.0 lbf-ft)
: Tightening order: “1” – “4”.
2. Seat belt assembly 5. Front seat belt screw
3. 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.
• Do not disassemble or repair seat belt

Front Seat Belt Assembly Removal and components. If any abnormalities are
Installation found, replace the seat belt components
AENNTA0E8106002 (08(01) with a new replacement set.
Reference: “Front Seat Belt Components” • Before servicing the seat belt, read
Reference: “Precautions for Electrical System Work” “Precautions for Service and Diagnosis of
Seat Belt” and follow all the instructions
! WARNING
provided.
servicing seat belt pretensioner may result in
personal injury.
Seat Belts: 8A-5
Removal
NOTE
Refer to “Repair and Inspection Required
after Accident”: 4-Channel in Section 8B or
“Repair and Inspection Required after
Accident”: 8-Channel in Section 8B before
replacing an activated pretensioner.

• 4-channel air bag system: (Disabling Air Bag
System): 4-Channel in Section 8B 1 3
• 8-channel air bag system: (Disabling Air Bag

2) Remove center pillar lower trim. (Trim / Console
3) Disconnect connector (1) from seat belt pretensioner 2
IMTA0A810004-01
a) Release lock button (3) by pulling it in arrow
direction “1”. • Tighten bolts and screw of front seat belt assembly in
numerical order to specified torque. (Front Seat Belt
b) Disconnect connector with lock released by
Components)
pulling it in arrow direction “2”.
• Connect connector (2) to seat belt pretensioner (1) as
follows.
3
a. Connect connector to seat belt pretensioner with
lock button (3) released by pushing it in arrow
“1”
direction “1”.
“2” b. Press lock button to lock connector securely by
pushing it in arrow direction “2”.
1
“2”
2
“1”
IMTA0A810003-01
4) Remove front seat belt bolts and front seat belt

screw of front seat belt assembly. (Front Seat Belt
Components)
5) Remove front seat belt assembly.
Installation
Reference: “Front Seat Belt Assembly Inspection” IMTA0A810005-01
Reverse removal procedure noting the following points. • Enable air bag system.
• Fit claw (2) on seat belt pretensioner (1) into cutout (3) – 4-channel air bag system: (Enabling Air Bag
on body panel. System): 4-Channel in Section 8B
– 8-channel air bag system: (Enabling Air Bag
Front Seat Belt Assembly Inspection

AENNTA0E8106003 (08(03)
8A-6 Seat Belts:
Reference: “Front Seat Belt Assembly Removal and Webbing

Installation” Check that webbing is not damaged.
! WARNING Seat Belt Pretensioner

Failure to take proper precautions when 1) Check the following points.
servicing seat belt components or attempting • Let the seat belt retract fully to check its smooth
to disassemble or repair the seat belt retraction.
pretensioner may cause personal injury. • Retractor should lock webbing when pulled
• Never measure the resistance of a seat belt quickly.
pretensioner with a tester. Electric current • Retractor should lock its webbing when tilted
from the tester may trigger activation of forward and backward, and leftward and
the seat belt pretensioner. rightward.
2) Replace seat belt assembly with new one if any of
the following symptom is found.
• Pretensioner has activated.
• There is a crack in seat belt pretensioner.
• Seat belt pretensioner is damaged or a strong
impact (e.g. dropping) was applied to it.
I9P60A810006-01
• When placing a live seat belt pretensioner

1
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 2
I9P60A810008-01
side of a live seat belt pretensioner. Also
1. Webbing 2. Seat belt pretensioner
avoid placing one live seat belt
pretensioner on top of another.
Front Seat Belt Buckle Inspection
1 AENNTA0E8106004 (08(03)
Belt Latch
• Check that tongue plate (2) is latched securely.
• Check that lock is released by pressing release button
(3) when tongue plate is latched to buckle (1).
IBP80A810010-01
3
NOTICE
If a seat belt pretensioner is dropped, it may
not work normally.
If a seat belt pretensioner is dropped, replace 1
I8T201810005-01
both the seat belt and buckle with a new
replacement set.
Seat Belt Buckle Switch
Seat belts and attaching parts can affect the vital 1) Disconnect seat belt buckle switch connector (4).
components and systems of vehicle. 2) Check continuity between seat belt buckle switch
Therefore, they should be checked carefully and connector terminals “1” and “2”.
replaced with genuine parts only.
Seat Belts: 8A-7
2 1
4
7
1 2
1 2
[A]
4 1
1
4
3
6
5
3
[B] 1 2
4
2 7
3 IMTA0A810006-01
1. Seat belt buckle switch

2. Passenger seat belt reminder sensor
IJHA0A810009-01
3. BCM
[A]: Driver seat 2. Passenger seat belt reminder 6. Passenger seat belt reminder sensor connector
sensor (buckle side)
[B]: Passenger seat 3. BCM 7. Passenger seat belt reminder sensor connector (floor
1. Seat belt buckle switch harness side)
Seat belt buckle switch continuity 2) Check continuity between terminal “1” of passenger
seat belt reminder sensor connector (buckle side) (1)
Terminal and terminal “1” of passenger seat belt reminder
1 2
Seat belt status sensor connector (floor harness side) (2).
Unlatched
Passenger seat belt reminder sensor continuity
Latched Terminal “1” - “1”: Continuity exists
I9P60A810010-01
Passenger Seat Belt Reminder Sensor

Inspection
AENNTA0E8106005 (08(03)
1) Disconnect seat belt buckle switch connector (4) and
floor harness connector (5).
1
2 1
1 2
IMTA0A810007-01
8A-8 Seat Belts:
3) Check continuity 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 AENNTA0E8106007 (08(01)
sensor connector (floor harness side). Reference: “Rear Seat Belt Components”
Passenger seat belt Passenger seat belt

Removal
Terminal
reminder sensor connector reminder sensor connector 1) Remove rear seat assembly. (Front Seat Removal
(buckle side) (floor harness side)
and Installation) in Section 9G
Seat status 1 2 1 2
2) Remove quarter lower trim and upper trim. (Trim /
Occupied
Console Removal and Installation) in Section 9H
3) Remove nuts and bolts and then remove rear side
Not occupied seat belt assembly.
IAP70A810005-01
Installation
Passenger seat belt reminder sensor resistance
Reference: “Rear Seat Belt Assembly Inspection”
Terminal Seat status Resistance Reverse removal procedure noting the following points.
Occupied Less than 100Ω
“2” – “2” • Tighten bolts and nuts of rear side seat belt in
Not occupied More than 1MΩ
numerical order to specified torque. (Rear Seat Belt
Components)
Rear Seat Belt Components
AENNTA0E8106006 (12(01) • Do not step on vehicle bead (2) when installing anchor
NOTE plate (1).
The figure shows right-side rear seat belt and • Fit tab (3) of rear right-side seat belt buckle (4) to hole
rear center seat belt. Left-side rear seat belt (5) of floor paneling.
is the same as the right-side rear seat belt.
[A] [B]
2
6, “2” (a) 3
1 6, “1” (a)
5
4
1
IFRA0A810006-01
[A]: Rear side seat belt assembly and rear left-side seat belt buckle
[B]: Rear right-side seat belt buckle
2
5, “3” (a) 4 (a)

Rear Center Seat Belt Removal and Installation
AENNTA0E8106008 (08(01)
Reference: “Rear Seat Belt Components”
Removal
3
1) Remove rear seat cushion assembly. (Front Seat
Removal and Installation) in Section 9G
2) Remove bolts and then remove rear center seat belt.
(a)
Installation
IMTA0A810008-01
Reference: “Rear Seat Belt Assembly Inspection”
1. Rear side seat belt assembly Reverse removal procedure noting the following points.
2. Rear center seat belt
3. Rear center seat belt buckle
• Tighten bolts of rear center seat belt to specified
4. Rear side seat belt buckle torque. (Rear Seat Belt Components)
5. Rear side seat belt bolt • Do not step on vehicle bead (2) when installing anchor
plate (1).
6. Rear side seat belt nut
: Tightening order: “1” – “3”. • Fit tab (3) of rear center seat belt buckle (4) to hole (5)
: 43 Nm (4.4 kgf-m, 32.0 lbf-ft) of floor paneling.
Seat Belts: 8A-9
Seat belts and attaching parts can affect the vital

[A] [B] components and systems of vehicle.
2 Therefore, they should be checked carefully and
3 replaced with genuine parts only.
Webbing
Check that webbing is not damaged.
5
4 Retractor (Rear Side Seat Belt)
1
IFRA0A810007-01
• Check that retractor locks webbing when pulled
[A]: Rear center seat belt [B]: Rear center seat belt buckle quickly.
assembly
• Check that retractor locks its webbing when tilted
forward and backward, and leftward and rightward.
Rear Seat Belt Assembly Inspection
AENNTA0E8106009 (08(03)
Reference: “Rear Side Seat Belt Assembly Removal and Rear Seat Belt Buckle Inspection
Installation” AENNTA0E8106010 (08(03)
Reference: “Rear Center Seat Belt Removal and Refer to “Front Seat Belt Buckle Inspection”.
Installation”
Specifications
AENNTA0E8107001 (09(t)
Reference:
“Front Seat Belt Components”
“Rear Seat Belt Components”
8B-1 Air Bag System: 4-Channel
Air Bag System

Restraint
4-Channel
Precautions
Precautions for Air Bag System Service
AENNTA0E8210001 (01(01)
! WARNING
• Performing service operations on or

around air bag system components or
wiring without temporarily deactivating the
air bag system may result in accidental
activation of the air bag system. This could
cause injury or the need for extra repairs to
the air bag system.
Temporarily deactivate the air bag system
before performing service operations on or
around air bag system components.
Follow the procedures described in IJHA0A820001-01
“Disabling Air Bag System”: 4-Channel.
• If you disconnect the connector from the When checking each wiring harness, use special tool
air bag (inflator) module with a screwdriver referring to “Use of Special Tools”: 4-Channel.
or the like, static electricity may trigger
Special tool
deployment of the air bag, which could
(A): 09932M76010
result in personal injury.
Never insert a screwdriver or the like
between the air bag (inflator) module and
the connector.
• When storing air bag system components, select a

place where the ambient temperature is below 65 °C
(149 °F).
(A)
• When applying paint around the air bag system
related parts, be careful that the harness or connector
(A)
will not be exposed to the paint mist.

Bag System Components IJHA0A820002-01
AENNTA0E8210002 (01(01)
! WARNING SDM
Measuring the resistance of any air bag ! WARNING
(inflator) module (driver or passenger) or any
seat belt pretensioner (driver or passenger • If the SDM is not rigidly attached to the
pretensioner) with a tester is dangerous, as vehicle, it could accidentally cause the air
the electric current from the tester may bags to deploy when the air bag system is
trigger the air bag or pretensioner. powered, possibly causing personal injury.
Never measure the resistance of an air bag Always check that the SDM is rigidly
(inflator) module or seat belt pretensioner. attached to the vehicle before supplying
power to the air bag system.
• The SDM that has been involved in an
accident severe enough to cause
deployment of air bags is not guaranteed
to provide its original performance.
Air Bag System: 4-Channel 8B-2
Never use an SDM that has been involved Live (Inactivated) Seat Belt Pretensioner
in an air bag deployment accident. Refer to
“Air Bag Diagnostic System Check”: 4- ! WARNING
Channel for the SDM check procedure.
handling and storing a live (non-activated)
• Never disassemble SDM. seat belt pretensioner can result in personal
• When storing SDM, select a place where neither high injury due to accidental activation of the
temperature nor high humidity is anticipated and oil, pretensioner.
water and dust are kept off. • Handle or store a live seat belt
pretensioner in a place with an ambient
temperature below 65 °C (150 °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
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 IMTA0A821001-01
toward the front of the vehicle to ensure proper

operation of the air bag system. Special care is necessary when handling and storing a
live (inactivated) pretensioner. Accidental activation of
Live (Undeployed) Air Bag (Inflator) Module pretensioner will cause high pressure gas to blow off
Special care is necessary when handling and storing live from the exhaust hole and retract the webbing (1) quickly
(undeployed) air bag (inflator) modules. Accidental into the retractor assembly (2). These actions may throw
deployment of air bag (inflator) module could throw itself the pretensioner itself or objects around it in the air.
or objects around it in the air.
2
I9P60A820003-01
IMTA0A821027-01
Deployed Air Bag (Inflator) Module and Activated

Seat Belt Pretensioner 2
Refer to “Deployed Air Bag (Inflator) Module and

Activated Seat Belt Pretensioner Disposal”: 4-Channel.
Air Bag Wire Harness and Connector

Air bag wire harness is included in main harness (1),
instrument panel harness (2) and floor harness (3). Air
bag wire harness can be identified easily as the 1
connector side wire harness is covered with a yellow
protection tube or yellow tape, or the connector itself is 4
yellow-colored or orange-colored. Be careful when 3

handling it.
• If damaged harness, connector or terminal is found on
an air bag wire harness, replace the harness.
IMTA0A821003-02
• When installing the air bag wire harness, be careful so
that it is not caught or does not interfere with other
parts. Precautions for Disposal of Air Bag and Seat
• Check that air bag system grounding point (4) is clean
Belt Pretensioner
AENNTA0E8210003 (01(01)
and ground terminal is securely fastened for optimum When disposal is necessary, deploy / activate the air bag
metal-to-metal contact. Poor grounding can cause and seat belt pretensioner. (Air Bag (Inflator) Module and
intermittent problems that are difficult to diagnose. Seat Belt Pretensioner Disposal): 4-Channel
General Description
Air Bag System Construction
AENNTA0E8211001 (03(01)
A 4-channel air bag system is employed in this model.
The 4-channel air bag system consists of the following
components.
• Driver and passenger air bag (inflator) modules
• Driver and passenger seat belt pretensioners
• Forward impact sensor
• SDM
To supplement protection offered by seat belts, the air
bag system includes the following air bags: front air bag
for driver seat and front air bag for passenger seat.
In addition to these air bags, the system also includes
seat belt pretensioners for driver and passenger.
In the event of a frontal collision with an impact larger
than the preset level, the front air bag (inflator) modules IBP80A820002-02
(stowed in the center of the steering wheel for the driver 1. Driver air bag (inflator) module 3. Seat belt pretensioner
seat and under the top of instrument panel for passenger 2. Passenger air bag (inflator) module
seat) are deployed.
The front seat belt pretensioners are activated whenever The air bag system is designed to activate only in severe
a frontal impact exceeding the preset level is detected to frontal collisions. It is not designed to activate in rear
take up the sag in the seat belts. impacts, side impacts, rollovers, or minor frontal
collisions; it would offer no protection in these types of
accidents.
IDL10A820003-01

Air Bag System Input / Output Diagram
AENNTA0E8212001 (10(01)
INPUT SDM OUTPUT
Driver air bag (inflator) module

Battery voltage DC / DC converter Safing power driver
Front air bag

and Passenger air bag (inflator) module
Back up capacitor seat belt
pretensioner
deployment Driver seat belt pretensioner
X-Y G sensor driver
(Longitudinal /
lateral acceleration) Passenger seat belt pretensioner
Main CPU
Forward impact sensor
BCM
Combination meter
IMTA0A821032-01
Air Bag System Circuit Diagram

AENNTA0E8212002 (10(01)
5
11
YEL/BLK YEL/BLK G11-12
10 G11-21 YEL
GRN GRN G11-13
[E40] G11-22 GRY
[E382] [G334]
[G347] [S172] [S121] 12
BLU G11-11
16
L1
[G211] G11-24 YEL YEL
1 L2
G11-23 PPL PPL
2 L3 [G372] [G373] [G259] 13
BRN
3 7 [G241] L4
8 L04-3 YEL
9 RED G11-15
6 6 L04-4 GRY
WHT G11-14 [L283] 14
BLK
L04-6 YEL
RED G11-10
4
L04-5 PPL
[L285] 15
G11-9 PPL
[L01] 19
: 17 G11-16 BLK
: 18
IMTA0A821004-01
1. Ignition power supply 8. CPU (Combination meter) 15. Passenger seat belt pretensioner
2. J/B 9. “AIR BAG” warning light 16. DLC
3. “MTR” fuse 10. Forward impact sensor 17. Shorting bar
4. “A/B” fuse 11. Contact coil assembly 18. Connection detection pin
5. SDM 12. Driver air bag (inflator) module 19. BCM
6. CAN driver 13. Passenger air bag (inflator) module
7. Combination meter 14. Driver seat belt pretensioner
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
G11-1 — G11-14 CAN (Lo)
G11-2 — G11-15 CAN (Hi)
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 air bag (inflator) module (+)
G11-9 Air bag deployed signal G11-22 Driver air bag (inflator) module (–)
G11-10 Power supply G11-23 Passenger air bag (inflator) module (–)
G11-11 DLC G11-24 Passenger air bag (inflator) module (+)
G11-12 Forward impact sensor (+) G11-25 —
G11-13 Forward impact sensor (–) G11-26 —
Component Location
Air Bag System Component, Wiring and Connector Location
AENNTA0E8213001 (04(01)
“G373” “G372” “G241”

“G259”
3
[b]
“G271” [c]
[B] [a]
4
“E40”
“L285” “E382”
“S121”
“G334”
6
2
“S172”
“G347”
[A]
[C]
[d]
[B]
“L283”
4
[a] [b]
[c] [d]
8
“L04” “G11”
IMTA0A821002-02
[A]: Main harness 2. Driver air bag (inflator) module 6. Contact coil assembly
[B]: Floor harness 3. Passenger air bag (inflator) module 7. Forward impact sensor
[C]: Instrument panel harness 4. Retractor pretensioner 8. SDM
1. “AIR BAG” warning light 5. “A/B” fuse (in junction block)

Air Bag Diagnostic System Check

AENNTA0E8214001 (06(01)
Referring to “Precautions for Air Bag System Service”: 4-Channel, check air bag system according to the following
procedure.
Step 1 DTC check

1) Check DTC. (DTC Check): 4-Channel
2) Clear DTC. (DTC Clearance): 4-Channel
Is there any DTC(s) when rechecking?
Yes Go to applicable DTC diagnosis flow, and go to Step 5.

No Go to Step 2.

1) Perform “Visual Inspection”: 4-Channel.
Yes Repair faulty part or replace it, and go to Step 5.

No Go to Step 3.
Step 3 Impact sign check

1) Check vehicle for evidence of impact.
Are there any signs of impact?
Yes Check faulty connections and replace them according to “Repair and Inspection Required after
Accident”: 4-Channel, and go to Step 5.
No Go to Step 4.

1) Check intermittent problems. (Intermittent Connection and Poor Contact Inspection) in Section 00

No Go to Step 5.

1) Check that problematic symptom has gone and air bag system is free from any abnormal conditions. If
what has been repaired is related to DTC, clear DTC once and check that no DTC is indicated.
Does malfunction recur?
Yes Return to Step 1.

No End.
Visual Inspection
AENNTA0E8214002 (06(01)
Inspection item Reference
Battery Fluid level, leakage “Battery Description” in Section 1J
“Intermittent Connection and Poor Contact Inspection”
Connectors of electric wire harness Disconnection, friction
in Section 00
Fuses Burning
“Air Bag System Component, Wiring and Connector
Air bag system component Installation, damage
Location”: 4-Channel
Other parts that can be checked visually
“AIR BAG” Warning Light Check If necessary, refer to Operator's Manual of SUZUKI
AENNTA0E8214003 (06(01) scan tool for further details.
2) Check that “AIR BAG” warning light (1) is on for 6 NOTE
seconds. If “AIR BAG” warning light is not on, refer to • A communication error may occur due to
““AIR BAG” Warning Light Does Not Come ON”: 4- temporary overlap of communication load.
Channel. If “AIR BAG” warning light is kept ON and If communication error occurs, wait about
no DTC is detected in SDM, refer to ““AIR BAG” 10 seconds and try the operation again.
Warning Light Comes ON Steady”: 4-Channel.
tool and SDM is not possible, perform the
following checks:
tool function.
– Check DLC power circuit and ground
circuit.
1
DLC cable.
IMTA0A821005-02
Self-Diagnosis Function “Diagnosis flow: [a]” in
AENNTA0E8214004 (06(01)
SDM also has self-diagnosis function that memorizes “Troubleshooting” of “Troubleshooting
DTC when an error is detected. After understanding the for Lost Communication”: CAN in
following descriptions, perform troubleshooting referring Section 10H.)
to “Air Bag Diagnostic System Check”: 4-Channel when – Check CAN communication system.
an error is detected. (“Control Module Communication Bus
• SDM always monitors system while ignition is “ON”. If Off” is detected in any control module.)
an error is detected, it notifies driver of error by turning (Troubleshooting for Communication
on “AIR BAG” warning light (1) and detected error is Bus Off): CAN in Section 10H
stored in SDM memory as DTC. – Check central gateway control module
• “AIR BAG” warning light turns on for about 6 seconds power circuit and ground circuit.
when ignition is “ON” to indicate that it operates (Inspection of Central Gateway Control
properly and turns off if no error is found in air bag Module and Its Circuits): CAN (Central
system. Gateway) in Section 10H
– Check SDM power circuit and ground
circuit. (SDM Power Supply and Ground
Circuit Check): 4-Channel

Section 0A.
1
DTC Clearance
AENNTA0E8214006 (06(01)
1) Connect SUZUKI scan tool to DLC Refer to “Suzuki
IMTA0A821005-02 0A.
2) Clear DTC and follow the instructions displayed on
DTC Check SUZUKI scan tool.
AENNTA0E8214005 (06(01)
If necessary, refer to Operator's Manual of SUZUKI
1) Connect SUZUKI scan tool to DLC Refer to “Suzuki scan tool for further details.
0A.
SUZUKI scan tool.
NOTE “Troubleshooting” of “Troubleshooting

• A communication error may occur due to Section 10H.)
If communication error occurs, wait about – Check CAN communication system.
10 seconds and try the operation again. (“Control Module Communication Bus
• If communication between SUZUKI scan (Troubleshooting for Communication
tool and SDM is not possible, perform the Bus Off): CAN in Section 10H
following checks:
– Check central gateway control module
– Check communication condition power circuit and ground circuit.
between PC and VCI using SUZUKI scan (Inspection of Central Gateway Control
tool function. Module and Its Circuits): CAN (Central
– Check DLC power circuit and ground Gateway) in Section 10H
circuit. – Check SDM power circuit and ground
– Check DLC cable. If necessary, check circuit. (SDM Power Supply and Ground
DLC cable by substituting a known-good Circuit Check): 4-Channel
DLC cable. • If DTC B1003-04, B1032-00 or B1035-00 is
– Check CAN communication circuit and stored in SDM, it is not possible to clear
connectors between DLC and central DTC.
“Diagnosis flow: [a]” in 3) Disconnect SUZUKI scan tool from DLC. Refer to
Section 0A.
DTC Table
AENNTA0E8214007 (06(01)
DTC DTC name
B1002-00 (DTC B1002-00): 4-Channel Intermittent Connection of SDM Connector
B1003-04 (DTC B1003-04): 4-Channel SDM Internal Failure
B1004-17 (DTC B1004-17): 4-Channel Power Source Voltage Too High
B1004-18 (DTC B1004-18): 4-Channel Power Source Voltage Too Low
B1032-00 (DTC B1032-00 / B1035-00):
Front Air Bag Deployment Record
4-Channel
B1035-00 (DTC B1032-00 / B1035-00):
Seat Belt Pretensioner Activation Record
4-Channel
B1060-14 (DTC B1060-14): 4-Channel Driver Air Bag (1st Stage) Circuit Shorted to Ground
B1060-15 (DTC B1060-15): 4-Channel Driver Air Bag (1st Stage) Circuit Shorted to Power Supply
B1060-1A (DTC B1060-1A): 4-Channel Driver Air Bag (1st Stage) Circuit Low Resistance
B1060-1B (DTC B1060-1B): 4-Channel Driver Air Bag (1st Stage) Circuit High Resistance
B1062-14 (DTC B1062-14): 4-Channel Passenger Air Bag (1st Stage) Circuit Shorted to Ground
B1062-15 (DTC B1062-15): 4-Channel Passenger Air Bag (1st Stage) Circuit Shorted to Power Supply
B1062-1A (DTC B1062-1A): 4-Channel Passenger Air Bag (1st Stage) Circuit Low Resistance
B1062-1B (DTC B1062-1B): 4-Channel Passenger Air Bag (1st Stage) Circuit High Resistance
B1064-14 (DTC B1064-14 / B1065-14):
Driver Seat Belt Pretensioner Circuit Shorted to Ground
4-Channel
B1064-15 (DTC B1064-15 / B1065-15):
Driver Seat Belt Pretensioner Circuit Shorted to Power Supply
4-Channel
B1064-1A (DTC B1064-1A / B1065-
Driver Seat Belt Pretensioner Circuit Low Resistance
1A): 4-Channel
B1064-1B (DTC B1064-1B / B1065-
Driver Seat Belt Pretensioner Circuit High Resistance
1B): 4-Channel
B1065-14 (DTC B1064-14 / B1065-14):
Passenger Seat Belt Pretensioner Circuit Shorted to Ground
4-Channel
B1065-15 (DTC B1064-15 / B1065-15):
Passenger Seat Belt Pretensioner Circuit Shorted to Power Supply
4-Channel
B1065-1A (DTC B1064-1A / B1065-
Passenger Seat Belt Pretensioner Circuit Low Resistance
1A): 4-Channel
B1065-1B (DTC B1064-1B / B1065-
Passenger Seat Belt Pretensioner Circuit High Resistance
1B): 4-Channel
DTC DTC name

B1090-01 (DTC B1090-01 / B1090-95):
Driver Forward Impact Sensor No Response
4-Channel
B1090-87 (DTC B1090-87): 4-Channel Driver Forward Impact Sensor Communication Data Invalid
B1090-95 (DTC B1090-01 / B1090-95):
Driver Forward Impact Sensor Communication Data Inconsistent
4-Channel
U0073-88 (DTC U0073-88): 4-Channel Control Module Communication Bus Off
Scan Tool Data

AENNTA0E8214008 (06(01)
Air Bag Control Module
NOTE
• If communication between SUZUKI scan tool and SDM is not possible, perform the following
checks:
– Check central gateway control module power circuit and ground circuit. (Inspection of Central
Gateway Control Module and Its Circuits): CAN (Central Gateway) in Section 10H
– Check SDM power circuit and ground circuit. (SDM Power Supply and Ground Circuit Check): 4-
Channel
Scan tool data Normal condition / Reference value

System ID (System ID (4ch)): 4-Channel 4ch
Battery Voltage (Battery Voltage (V)): 4-Channel 10 – 14 V
Backup Voltage (Backup Voltage (V)): 4-Channel 27.0 – 33.0 V
Driver Air Bag Initiator Resistance (Driver Air Bag Initiator
1.0 – 4.5 Ω
Resistance (Ω)): 4-Channel
Passenger Air Bag Initiator Resistance (Passenger Air Bag
1.0 – 3.8 Ω
Initiator Resistance (Ω)): 4-Channel
Driver-Side Seat Belt Pretensioner Initiator Resistance
(Driver-Side Seat Belt Pretensioner Initiator Resistance 1.0 – 3.8 Ω
(Ω)): 4-Channel
Passenger-Side Seat Belt Pretensioner Initiator Resistance
(Passenger-Side Seat Belt Pretensioner Initiator 1.0 – 3.8 Ω
Scan Tool Data Definition Driver Air Bag Initiator Resistance (Ω)
System ID (4ch) This parameter indicates resistance of driver air bag
This parameter indicates number of initiator circuits. initiator circuit.
Battery Voltage (V) Passenger Air Bag Initiator Resistance (Ω)

Power supply voltage is an analog input signal read by This parameter indicates resistance of passenger air bag
SDM. initiator circuit.
Backup Voltage (V) Driver-Side Seat Belt Pretensioner Initiator

This parameter indicates capacity of backup capacitor Resistance (Ω)
installed to maintain ignition current (as much as This parameter indicates resistance of driver seat belt
possible) even when power supply to SDM that ignites pretensioner initiator circuit.
inflator is shut off.
Passenger-Side Seat Belt Pretensioner Initiator

Resistance (Ω)
This parameter indicates resistance of passenger seat
belt pretensioner initiator circuit.
“AIR BAG” Warning Light Comes ON Steady

AENNTA0E8214009 (06(03)
Circuit Diagram
3 6 2
4
1 BRN G241-3
7
BLK G241-5
G241-19 RED G11-15
8 8
G241-7 WHT G11-14
5
RED G11-10
BLK G11-16
[A] [B]
[a] 1 2 3 4 5 6
1 2 3 4 5 6 7 8 9 10 11 12 7 8 9 10 11 L1 L2 12 13 14 15
13 14 15 16 17 18 19 20 21 22 23 24
16 17 18 19 20 21 22 23 24 25 26
IMTA0A821006-02
[A]: “G241” connector (View: [a]) 3. J/B 7. CPU (Combination meter)

[B]: “G11” connector (View: [a]) 4. “MTR” fuse 8. CAN driver
1. Ignition power supply 5. “A/B” fuse
2. SDM 6. Combination meter
Troubleshooting
Step 1 SDM connector check

1) Check for proper connection to SDM connector.
Yes Go to Step 2.
Step 2 DTC check

1) Perform “DTC Check”: 4-Channel.

No Go to Step 3.
Step 3 SDM power supply and ground circuit check

1) Check SDM power supply circuit and ground circuit. (SDM Power Supply and Ground Circuit Check): 4-
Channel
Is check result OK?
Yes Go to Step 4.
No Repair SDM power supply and ground circuits.

1) Check CAN communication circuit between SDM and combination meter.
Is check result OK?
Yes Go to Step 5.
No Repair defective wire harness.

Does “AIR BAG” warning light stay on?
Yes Replace SDM and recheck “AIR BAG” warning light operation. (SDM Removal and Installation): 4-
Channel
No End.
NOTE
Upon completion of inspection and repair work, perform the following items.
• Reconnect all air bag system components and check that all components are properly mounted.
• Repeat “Air Bag Diagnostic System Check”: 4-Channel to check that the trouble has been solved.
“AIR BAG” Warning Light Does Not Come ON

AENNTA0E8214010 (06(03)
Circuit Diagram
3 6 2
4
1 BRN G241-3
7
BLK G241-5
G241-19 RED G11-15
8 8
G241-7 WHT G11-14
5
RED G11-10
BLK G11-16
[A] [B]
[a] 1 2 3 4 5 6
1 2 3 4 5 6 7 8 9 10 11 12 7 8 9 10 11 L1 L2 12 13 14 15
13 14 15 16 17 18 19 20 21 22 23 24
16 17 18 19 20 21 22 23 24 25 26
IMTA0A821006-02

Troubleshooting

Do other indicator lights come ON?
Yes Go to Step 2.
No Go to Step 3.
Step 2 DTC check


No Replace SDM and recheck DTC. (SDM Removal and Installation): 4-Channel
Step 3 Fuse check
Is “MTR” fuse for combination meter in good condition?
Yes Go to Step 4.

Is check result OK?
Yes Go to Step 5.

2) Remove combination meter. (Combination Meter Removal and Installation) in Section 9C
3) Check for proper connection to “G241” connector.
5) Measure voltage between “G241-3” terminal and ground.
Special tool
: 09932M76010
Is it 10 – 14 V?
Yes Go to Step 6.

1) Measure resistance between “G241-5” terminal and ground.
Special tool
: 09932M76010
Is resistance less than 1 Ω?
Yes Replace combination meter and recheck “AIR BAG” warning light operation. (Combination Meter
NOTE
DTC B1002-00
AENNTA0E8214011 (06(02)
B1002-00: Intermittent Connection of SDM Connector • SDM connector
Faulty connection of SDM connector. • SDM
DTC Troubleshooting
Step 1 Was “Air Bag Diagnostic System Check” performed?
Yes Go to Step 2.
No Go to “Air Bag Diagnostic System Check”: 4-Channel.

1) Check proper connection of SDM connector and “Connection detection pin” of SDM connector.
Is check result OK?
Yes Replace SDM and recheck DTC. (SDM Removal and Installation): 4-Channel
No Check intermittent trouble. (Intermittent Connection and Poor Contact Inspection) in Section 00
NOTE
• Clear DTCs, referring to “DTC Clearance”: 4-Channel if any DTC is detected.
DTC B1003-04
AENNTA0E8214012 (06(02)
B1003-04: SDM Internal Failure SDM
Malfunctioning SDM internal circuit, G sensor, memory or CPU.
DTC Troubleshooting
Yes Go to Step 2.
Step 2 DTC check


NOTE
DTC B1004-17
AENNTA0E8214013 (06(02)
B1004-17: Power Source Voltage Too High • Charging system
Power supply voltage is more than specified range. • SDM
Circuit Diagram
5 3
2
1 RED G11-10
BLK G11-16
[A]
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
IJHA0A820008-01
[A]: “G11” connector (View: [a]) 2. “A/B” fuse 4. Instrument panel harness
1. Ignition power supply 3. SDM 5. J/B
DTC Troubleshooting
Yes Go to Step 2.
Step 2 SDM power voltage check

2) Disconnect “G11” connector. (SDM Removal and Installation): 4-Channel
3) Start engine and set engine speed at 3000 rpm or more.
Special tool
: 09932M76010
Is voltage 15 V or less?
Yes Go to Step 3.
No Check charging system and repair wiring. (Generator Test) in Section 1J
Step 3 DTC check

2) Connect “G11” connector. (SDM Removal and Installation): 4-Channel
Is DTC B1004-17 detected?
NOTE
DTC B1004-18
AENNTA0E8214014 (06(02)
B1004-18: Power Source Voltage Too Low • Charging system
Power supply voltage is less than specified range. • SDM
Circuit Diagram
5 3
2
1 RED G11-10
BLK G11-16
[A]
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
IJHA0A820008-01
DTC Troubleshooting
Yes Go to Step 2.
Step 2 SDM power supply circuit and ground circuit check

Channel
Is check result OK?

Yes Go to Step 3.
Step 3 DTC check

NOTE
DTC B1032-00 / B1035-00

AENNTA0E8214015 (06(02)
B1032-00: Front Air Bag Deployment Record If this DTC has been recorded even though air bag or
Deployment of front air bag 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 air bag (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
Yes Replace SDM. (SDM Removal and Installation): 4-Channel

NOTE
DTC B1060-14
AENNTA0E8214016 (06(02)
B1060-14: Driver Air Bag (1st Stage) Circuit Shorted to Ground • Driver air bag (inflator) module circuit
Driver air bag (inflator) module circuit has been shorted to ground. • Contact coil assembly
• SDM
Circuit Diagram
3
[S121] [S172] [G347]
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
IMTA0A821007-05
[A]: “S121” connector (View: [a]) A2: Driver air bag (inflator) module deployment 4. Shorting bar
signal ground circuit
[B]: “G347” connector (View: [a]) 1. Driver air bag (inflator) module 5. Instrument panel harness
[C]: “G11” connector (View: [a]) 2. Contact coil assembly
A1: Driver air bag (inflator) module deployment 3. SDM
signal output circuit
DTC Troubleshooting
Yes Go to Step 2.
Step 2 Driver air bag (inflator) module circuit check

2) Disconnect “G347” connector. (Contact Coil Assembly Removal and Installation) in Section 6B
4) Release shorting bar in SDM connector. (Release of Shorting Bar): 4-Channel
Special tool
: 09932M76010
Is check result OK?
Yes Go to Step 3.
Step 3 Contact coil circuit check

2) Remove driver air bag (inflator) module from steering wheel. (Driver Air Bag (Inflator) Module Removal
and Installation): 4-Channel
Special tool
: 09932M76010
Is check result OK?
No Replace contact coil assembly. (Contact Coil Assembly Removal and Installation) in Section 6B
NOTE
DTC B1060-15
AENNTA0E8214017 (06(02)
B1060-15: Driver Air Bag (1st Stage) Circuit Shorted to Power Supply • Driver air bag (inflator) module circuit
Driver air bag (inflator) module circuit has been shorted to power supply. • Contact coil assembly
• SDM
Circuit Diagram
3
[S121] [S172] [G347]
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
IMTA0A821007-05
DTC Troubleshooting
Yes Go to Step 2.


• Voltage between each of “A1” and “A2” circuits and ground: 0 V
Special tool
: 09932M76010
Is check result OK?
Yes Go to Step 3.

Special tool
: 09932M76010
Is check result OK?
NOTE
DTC B1060-1A
AENNTA0E8214018 (06(02)
B1060-1A: Driver Air Bag (1st Stage) Circuit Low Resistance • Driver air bag (inflator) module circuit
Driver air bag (inflator) module circuit resistance is less than • Contact coil assembly
specified range.
• Driver air bag (inflator) module
• SDM
Circuit Diagram
3
[S121] [S172] [G347]
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
IMTA0A821007-05
DTC Troubleshooting
Yes Go to Step 2.
Step 2 Driver air bag (inflator) module check

3) Connect “BASE OF COLUMN” harness (1) of special tools (A) and (B) to “G347” connector.
Special tool
(A): 09932M75011
(B): 09932M78340
[G347]
1
(B)
(A)
IJHA0A820011-01

Is DTC B1060-1A detected?
Yes Go to Step 3.
No Go to Step 4.

• Resistance between “G11-21” and “G11-22” terminals: infinity
Special tool
: 09932M76010
Is check result OK?

1) Check contact coil circuit. (Contact Coil and Its Circuit Check): 4-Channel
Is check result OK?
Yes Replace driver air bag (inflator) module. (Driver Air Bag (Inflator) Module Removal and
Installation): 4-Channel
NOTE
DTC B1060-1B
AENNTA0E8214019 (06(02)
B1060-1B: Driver Air Bag (1st Stage) Circuit High Resistance • Driver air bag (inflator) module circuit
Driver air bag (inflator) module circuit resistance is more than • Contact coil assembly
specified range.
• SDM
Circuit Diagram
3
[S121] [S172] [G347]
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
IMTA0A821007-05
DTC Troubleshooting
Yes Go to Step 2.

4) Connect “BASE OF COLUMN” harness (1) of special tools (A) and (B) to “G347” connector.
Special tool
(A): 09932M75011
(B): 09932M78340
[G347]
1
(B)
(A)
IJHA0A820011-01

Is DTC B1060-1B detected?
Yes Go to Step 3.
No Go to Step 4.

• Resistance of “A1” and “A2” circuits: 1 Ω or less
Special tool
: 09932M76010
Is check result OK?
Yes Replace SDM with new one. (SDM Removal and Installation): 4-Channel

Is check result OK?
NOTE
DTC B1062-14
AENNTA0E8214020 (06(02)
B1062-14: Passenger Air Bag (1st Stage) Circuit • Passenger air bag (inflator) module circuit
Shorted to Ground • SDM
Passenger air bag (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 1 2 3 4 5 6
:4
7 8 9 10 11 L1 L2 12 13 14 15
:5
16 17 18 19 20 21 22 23 24 25 26
IJHA0A820012-01
[A]: “G259” connector (View: [a]) A2: Passenger air bag (inflator) module 2. SDM
deployment signal ground circuit
[B]: “G372” connector (View: [a]) A3: Passenger air bag (inflator) module 3. Shorting bar
deployment signal output circuit
[C]: “G11” connector (View: [a]) A4: Passenger air bag (inflator) module 4. Instrument panel harness
A1: Passenger air bag (inflator) module 1. Passenger air bag (inflator) module 5. Passenger air bag (inflator) module harness
DTC Troubleshooting
Yes Go to Step 2.
Step 2 Passenger air bag (inflator) module circuit check

2) Disconnect “G259” connector. (Passenger Air Bag (Inflator) Module Removal and Installation): 4-
Channel
Special tool
: 09932M76010
Is check result OK?
No Go to Step 3.

Special tool
: 09932M76010
Is check result OK?
Yes Replace passenger air bag (inflator) module harness.

NOTE
DTC B1062-15
AENNTA0E8214021 (06(02)
B1062-15: Passenger Air Bag (1st Stage) Circuit • Passenger air bag (inflator) module circuit
Shorted to Power Supply • SDM
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 1 2 3 4 5 6
:4
7 8 9 10 11 L1 L2 12 13 14 15
:5
16 17 18 19 20 21 22 23 24 25 26
IJHA0A820012-01
DTC Troubleshooting
Yes Go to Step 2.

Channel

Special tool
: 09932M76010
Is check result OK?
No Go to Step 3.

Special tool
: 09932M76010
Is check result OK?

NOTE
DTC B1062-1A
AENNTA0E8214022 (06(02)
B1062-1A: Passenger Air Bag (1st Stage) Circuit Low • Passenger air bag (inflator) module circuit
Resistance • Passenger air bag (inflator) module
Passenger air bag (inflator) module circuit resistance is
• SDM
less 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 1 2 3 4 5 6
:4
7 8 9 10 11 L1 L2 12 13 14 15
:5
16 17 18 19 20 21 22 23 24 25 26
IJHA0A820012-01
DTC Troubleshooting
Yes Go to Step 2.
Step 2 Passenger air bag (inflator) module check

Channel
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)
IMTA0A821008-02

Yes Go to Step 3.
No Replace passenger air bag (inflator) module. (Passenger Air Bag (Inflator) Module Removal and

Special tool
: 09932M76010
Is check result OK?
No Go to Step 4.

Special tool
: 09932M76010
Is check result OK?

NOTE
DTC B1062-1B
AENNTA0E8214023 (06(02)
B1062-1B: Passenger Air Bag (1st Stage) Circuit High • Passenger air bag (inflator) module circuit
Resistance • Passenger air bag (inflator) module
Passenger air bag (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 1 2 3 4 5 6
:4
7 8 9 10 11 L1 L2 12 13 14 15
:5
16 17 18 19 20 21 22 23 24 25 26
IJHA0A820012-01
DTC Troubleshooting
Yes Go to Step 2.

Channel
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)
IMTA0A821008-02

Yes Go to Step 3.

• Resistance between “G11-24” and “G259-1” terminals: 1 Ω or less
Special tool
: 09932M76010
Is check result OK?
No Go to Step 4.

Special tool
: 09932M76010
Is check result OK?


NOTE
DTC B1064-14 / B1065-14

AENNTA0E8214024 (06(02)
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]) B1: Passenger seat belt pretensioner operation 3. SDM
[B]: “L04” connector (View: [a]) B2: Passenger seat belt pretensioner operation 4. Shorting bar
A1: Driver seat belt pretensioner operation 1. Driver seat belt pretensioner 5. Floor harness
A2: Driver seat belt pretensioner operation 2. Passenger seat belt pretensioner
DTC Troubleshooting
Yes Go to Step 2.
Step 2 Seat belt pretensioner circuit check

2) Disconnect “L283” or “L285” connector. (Seat Belt Pretensioner Removal and Installation): 4-Channel
3) Disconnect “L04” connector. (SDM Removal and Installation): 4-Channel
• 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?
No Replace floor harness.
NOTE
DTC B1064-15 / B1065-15

AENNTA0E8214025 (06(02)
B1064-15: Driver Seat Belt Pretensioner Circuit • Driver / passenger seat belt pretensioner circuit
Driver seat belt pretensioner circuit has been shorted to
power supply.
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
DTC Troubleshooting
Yes Go to Step 2.

• 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
DTC B1064-1A / B1065-1A

AENNTA0E8214026 (06(02)
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
DTC Troubleshooting
Yes Go to Step 2.
Step 2 Seat belt pretensioner check

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)]
(B)
(A)
(C)
IMTA0A821009-02

Is DTC B1064-1A or B1065-1A detected?
Yes Go to Step 3.
No Replace seat belt pretensioner. (Front Seat Belt Assembly Removal and Installation) in Section 8A

• Resistance between “L04-3” and “L04-4” terminals (DTC B1064-1A): infinity
Special tool
: 09932M76010
Is check result OK?
NOTE
DTC B1064-1B / B1065-1B

AENNTA0E8214027 (06(02)
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
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
DTC Troubleshooting
Yes Go to Step 2.

2) Check for proper connection to “L283” or “L285” connector.
4) Connect “STEERING WHEEL” harness (1) of special tool (A), (B) and (C) to “L283” or “L285” connector.
Special tool
(A): 09932M76010
(B): 09932M78310
(C): 09932M75011
[L283 (L285)]
(B)
(A)
(C)
IMTA0A821009-02

Is DTC B1064-1B or B1065-1B detected?
Yes Go to Step 3.
No Replace seat belt pretensioner. (Front Seat Belt Assembly Removal and Installation) in Section 8A

2) Check for proper connection to “L04” connector.
• 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
DTC B1090-01 / B1090-95

AENNTA0E8214028 (06(02)

B1090-01: Driver Forward Impact Sensor No Response • Forward impact sensor
Forward impact sensor has communicated with no response or • Forward impact sensor circuit
inconsistent ID code.
• SDM
B1090-95: Driver Forward Impact Sensor Communication Data
Inconsistent
Forward impact sensor has communicated with inconsistent ID code.
DTC Troubleshooting
Yes Go to Step 2.
Step 2 DTC check

1) Check if DTC B1090-87 is detected. (DTC Check): 4-Channel

No Go to Step 3.
Step 3 Forward impact sensor check

2) Replace forward impact sensor. (Forward Impact Sensor Removal and Installation): 4-Channel
Is DTC detected?
No End.
NOTE
DTC B1090-87
AENNTA0E8214029 (06(02)
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] [E382] [G334] 2

A1 A3
1
A2 A4
GRN GRN G11-13
[A] [B] [D]

:3
:4 [a] 6 5 4 3 2 1 1 2 3 4 5 6
1 2
12 11 10 9 8 7 7 8 9 10 11 L1 L2 12 13 14 15
18 17 16 15 14 13 16 17 18 19 20 21 22 23 24 25 26
[C]
1 2 3 4 5 6
7 8 9 10 11 12
13 1415 16 17 18
IMTA0A821010-02
[A]: “E40” connector (View: [a]) A1: Forward impact sensor signal output circuit 1. Forward impact sensor
[B]: “E382” connector (View: [a]) A2: Forward impact sensor signal ground circuit 2. SDM
[C]: “G334” 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
Yes Go to Step 2.
Step 2 Forward impact sensor circuit check

Special tool
: 09932M76010
Is check result OK?
Yes Go to Step 3.

Special tool
: 09932M76010
Is check result OK?

Yes Go to Step 4.

Special tool
: 09932M76010
Is check result OK?
Yes Go to Step 5.

Special tool
: 09932M76010
Is check result OK?
Yes Go to Step 6.

2) Disconnect “E40” connector. (Forward Impact Sensor Removal and Installation): 4-Channel
Special tool
: 09932M76010
Is check result OK?
Yes Go to Step 7.
No Replace main harness.

• Resistance between “E40-1” and “E40-2” terminals: infinity
Special tool
: 09932M76010
Is check result OK?
Yes Go to Step 8.

Special tool
: 09932M76010
Is check result OK?
Yes Go to Step 9.

Special tool
: 09932M76010
Is check result OK?
Yes Go to Step 10.


Is DTC detected?
No End.
NOTE
DTC U0073-88
AENNTA0E8214030 (06(02)
SDM Power Supply and Ground Circuit Check

AENNTA0E8214031 (06(01)
Circuit Diagram
5 3
2
1 RED G11-10
BLK G11-16
[A]
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
IJHA0A820008-01
Troubleshooting
Step 1 Battery voltage check

1) Check battery voltage.
Is voltage in 10 – 14 V?
Yes Go to Step 2.
No Check charging system and repair it. (Generator Test) in Section 1J
Step 2 SDM connection check

Is it connected securely?
Yes Go to Step 3.
If OK, replace SDM and recheck connection. (SDM Removal and Installation): 4-Channel
Step 3 Fuse check

2) Check “A/B” fuse.
Is “A/B” fuse in good condition?
Yes Go to Step 4.
No Replace instrument panel harness and then replace “A/B” fuse.
Step 4 Power circuit check

Special tool
: 09932M76010
Is voltage in 10 – 14 V?
Yes Go to Step 5.
Step 5 Ground circuit check

Special tool
: 09932M76010
Yes SDM power supply circuit and ground circuit are in good condition.
Contact Coil and Its Circuit Check

AENNTA0E8214032 (06(01)
Circuit Diagram
3
[S121] [S172] [G347]
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
IMTA0A821007-05
Troubleshooting

Special tool
: 09932M76010
Is check result OK?
Yes Go to Step 2.
No Check for defective wire harness. If check result is OK, replace contact coil assembly. (Contact Coil
Step 2 Contact coil circuit (driver air bag (inflator) module circuit) check
1) Remove contact coil assembly. (Contact Coil Assembly Removal and Installation) in Section 6B
• Resistance between “S121-1” and “S172-2” terminals: 1 Ω or less
• Resistance between “S121-2” and “S172-1” terminals: 1 Ω or less
Special tool
(A): 09932M76010
[S172]
2 1
(A)
[S121]
1 2
IJHA0A820021-01
Is check result OK?
Yes Go to Step 3.
Step 3 Contact coil circuit (horn circuit) check

• Resistance between “S61-1” and “S173-1” terminals: infinity
Special tool
(A): 09932M76010
[S61]
6 5 4 3 2 1
(A)
[S173]
6 5 4 3 2 1
IMTA0A821012-01
Is check result OK?
Yes Go to Step 4.

1) Measure resistance between each terminal of contact coil and other terminals.
Is each measured resistance infinite?
Yes Contact coil and its circuit are in good condition.

Repair and Inspection Required after Accident – SDM

AENNTA0E8214033 (06(01)
– Contact coil
! WARNING
– Air bag wire harnesses (in main
Failure to properly check and repair a vehicle harness, instrument panel harness and
that has been involved in an accident can floor harness) and passenger air bag
result in unsafe operating conditions. harness
• For any vehicle that was involved in an • Perform all repairs in a manner which
accident, check all air bag system assures that the vehicle’s original
components including the electrical configuration is restored.
harness and the areas where they are • The SDM that has been involved in an
mounted, even if the air bag system was accident severe enough to cause
not activated. Any components deformed deployment of air bags is not guaranteed
or otherwise damaged must be replaced. to provide its original performance.
• Never use air bag system parts from • Never use an SDM that has been involved
another vehicle model. in an air bag deployment accident.
• Do not repair the following parts.
Replace any of them that are found faulty. Accident with Deployment / Activation – Component
– Driver / passenger air bag (inflator) Replacement
modules Replace the following components when driver and
passenger air bags are deployed.
– Driver / passenger seat belt
pretensioners • Driver and passenger air bag (inflator) modules
– Forward impact sensor • Driver / passenger seat belt pretensioners
• SDM
• Forward impact sensor – Check instrument panel for crack and deformation.
• Instrument panel • Passenger air bag (inflator) module
– Check for dents, crack, damage and installation
Accident with or without Deployment / Activation – condition.
Component Inspections
– Check harness and connector for damage and
Check the following air bag system components after
tightness.
any crash, whether air bag system was activated or not.
If any faulty condition is found in the following checks,
replace faulty component.
• Steering column and steering lower shaft
– Check for length, damage and bend according to
“Steering Column Inspection” in Section 6B.
• Steering column bracket
– Check for damage and bend according to “Steering
Column Inspection” in Section 6B.
• Steering wheel and driver air bag (inflator) module
– Check air bag (inflator) module for damage and
installation condition.
– Check trim cover (pad surface) for crack.
– Check wire harness and connector for damage and
tightness.
IMTA0A821013-01
• 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
plate, etc.).
– Check connector or lead wire of SDM for scorch,
melt or damage.
IMTA0A821014-01
– Check SDM connector and terminals for tightness.
• Contact coil assembly – Check DTC and follow referring corresponding
diagnostic flow if any DTC is found.
– Check wire harness and connectors for damage
and tightness.
– Check contact coil case for damage.
– Check contact coil circuit referring to “Contact Coil
and Its Circuit Check”: 4-Channel.
IGSB0A821043-01
• Air bag wire harnesses and connectors

– Check for damage, deformation and poor
connections.
Refer to “Intermittent Connection and Poor Contact
Inspection” in Section 00.
I9P60A820041-01
– Check wire harnesses for tightness.
• Instrument panel member and reinforcement
– Check for any distortion, bend, crack and other
damage.
• Seat belt pretensioner

2
condition.
tightness.
IMTA0A821003-02
2
1. Main harness 3. Floor harness
I9P60A820003-01
2. Instrument panel harness 4. Grounding point
1. Webbing 2. Retractor assembly

• Seat belts and mounting points
– Check sensor (1) and lamp support right brace (2)
for damage, bend and rust. – Refer to “Front Seat Belt Components” in Section
8A.
– Check connector (3) and lead wire (4) of forward
impact sensor for scorch, melt and damage. • “AIR BAG” warning light
– Perform “Air Bag Diagnostic System Check”: 4-
Channel after vehicle is completely repaired.
IMTA0A821015-01
Repair Instructions
Disabling Air Bag System
AENNTA0E8216001 (08(03)
When servicing air bag system, related parts and working around air bag (inflator) module, disable air bag (inflator)
modules as follows.
Servicing item Disabling procedure

• When disconnecting or connecting air bag system
connectors.
Disconnect negative (–) cable at battery. (Disabling
• When removing or installing air bag system Procedure (Disconnecting Negative (–) Battery Cable)): 4-
components. Channel
• When servicing air bag system, related parts or working
around air bag (inflator) module with ignition “OFF”.
• When servicing air bag system, related parts or workingRemove “A/B” fuse. (Disabling Procedure (Removing “A/
around air bag (inflator) module with ignition “ON”. B” Fuse)): 4-Channel
• When performing electric welding. Disconnect negative (–) cable at battery, and remove all
air bag (inflator) modules, forward impact sensor and
• When there is a possibility that air bag system or SDM. (Disabling Procedure (Disconnecting Negative (–)
related parts would be heated up to 90 °C (194 °F) and Battery Cable and Removing All Air Bag (Inflator)
more by electric welding or paint baking process. Module)): 4-Channel
Disabling Procedure (Disconnecting Negative (–) Disabling Procedure (Disconnecting Negative (–)
Battery Cable) Battery Cable and Removing All Air Bag (Inflator)
1) Set front wheels in straight ahead position. Module)
2) Set ignition “OFF”. 1) Set front wheels in straight ahead position.
3) Disconnect negative (–) cable at battery. 2) Set ignition “OFF”.
4) Wait for at least 90 seconds after performing Step 3). 3) Disconnect negative (–) cable at battery.
4) Wait for at least 90 seconds after performing Step 3).
Disabling Procedure (Removing “A/B” Fuse) 5) Remove all air bag (inflator) modules.
NOTE
Enabling Air Bag System
“AIR BAG” warning light will light if “A/B” AENNTA0E8216002 (08(03)
fuse is disconnected, but this is normal and 1) Check that removed components are installed and/
DTC for air bag system will not be detected. or disconnected connectors are connected properly.
3) Connect negative (–) cable at battery and/or install
2) Remove “A/B” fuse from J/B.
“A/B” fuse to J/B.
3) Wait for at least 90 seconds after performing Step 2).
4) Start working and set ignition “ON”.
5) Check if “AIR BAG” warning light turns on for about 6
seconds and then turns off.
6) Perform “Air Bag Diagnostic System Check”: 4-
Channel if defective.
Release of Shorting Bar

AENNTA0E8216003 (08(03)
Release shorting bar in SDM connector inserting release tool.
NOTE
• To prevent accidental deployment of air bag 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 – Bend, scratch, deformation on mating surface of

AENNTA0E8216004 (08(01) vehicle body where SDM is mounted
– Foreign material or rust on mating surface of
! WARNING vehicle body where SDM is mounted
• Tighten SDM bolts (1) in numerical order (“1” – “2”) to
If the SDM is handled roughly when
specified torque.
performing the service operations described
below, there is a risk of personal injury due to Tightening torque
accidental activation of the air bag system. SDM bolt (a): 8.8 N·m (0.90 kgf-m, 6.5 lbf-ft)
Read “Precautions for Air Bag System
Service”: 4-Channel before starting the
operations described below and follow all of
the instructions provided.
1, “1”, (a)
Removal
1) Disable air bag system. (Disabling Air Bag System):
4-Channel
2) Remove floor console side covers. (Trim / Console
3) Turn over floor carpet.
4) Disconnect SDM connectors (1).
5) Remove SDM bolts (2) and remove SDM (3).
1, “2”, (a)
1, “2”, (a)
3
IMTA0A821017-01
2
• Enable air bag system. (Enabling Air Bag System): 4-
Channel
SDM Inspection
AENNTA0E8216005 (08(03)
Reference: “SDM Removal and Installation”: 4-Channel
NOTICE
The SDM may not function properly if you do
not handle it carefully.
2 1 • Do not connect any type of tester to the
2
SDM.
IMTA0A821016-01
Installation
Reference: “SDM Inspection”: 4-Channel
• Check that none of the following faulty conditions
exists.
NOTE
after Accident”: 4-Channel before replacing
deployed air bag.
Removal
1) Set steering wheel in straight ahead position.
4-Channel
3) Insert a flat-bladed screwdriver (3) into service hole
(2) of steering wheel (1) and push spring pin (4) in
I9W10P821002-01 arrow direction to release lock.
• Never repair or disassemble the SDM.
• Replace the SDM if it has been dropped. 4
If any faulty condition is found in the following checks,

replace the SDM with new one.
• Check air bag module is deployed or pretensioner is
activated.
3
• Check SDM for dents, crack or deformation.
• Check SDM connector for damage, crack or lock
mechanism.
• Check SDM terminal for bend, corrosion or rust. 4
• Check DTC B1003-04, B1032-00 or B1035-00 is
stored in SDM.
Driver Air Bag (Inflator) Module Removal and

Installation
AENNTA0E8216006 (08(01)
3 2
! WARNING 4
2
2
1
performing service on the driver air bag IFKA0P821046-01
(inflator) module can result in personal injury 4) Disconnect horn connector (1).
or non-activation of the air bag in the event of
a collision. 5) Disconnect driver air bag (inflator) module connector
• Never disassemble or repair an air bag
(inflator) module. If any abnormal a) Release lock button (3) by pulling it in arrow
condition is found, replace the module direction “1”.
with a new one. b) Disconnect connector with lock released by
• Carefully read “Precautions for Air Bag pulling it in arrow direction “2”.
System Service”: 4-Channel, “Precautions
for Handling and Storage of Air Bag
System Components”: 4-Channel and
“Precautions for Disposal of Air Bag and “1” “2”
Seat Belt Pretensioner”: 4-Channel and
follow all of the instructions provided.
NOTICE
An air bag (inflator) module that has been
dropped may not operate correctly. 3 2
Never use an air bag (inflator) module that
has been dropped. Replace the module with a
1
new one. IJSE0A820008-01
6) Remove driver air bag (inflator) module from • Connector is damaged.

steering wheel. • Air bag (inflator) module bracket of steering wheel is
deformed or damaged.
Installation
• Unable to install new air bag (inflator) module
Reference: “Driver Air Bag (Inflator) Module Inspection”:
smoothly (Clearance (1) between steering wheel and
4-Channel
air bag (inflator) module is uneven).
• Lock connector for driver air bag (inflator) module
securely.
1
• Insert two upper pins (1) of driver air bag (inflator)
module first, and then bottom pin (2).
IA1J0P821055-01
Passenger Air Bag (Inflator) Module Removal

and Installation
AENNTA0E8216008 (08(01)
2
IJHA0A820027-01
• Enable air bag system. (Enabling Air Bag System): 4- ! WARNING
Channel
Driver Air Bag (Inflator) Module Inspection performing service on the passenger air bag
AENNTA0E8216007 (08(03) (inflator) module can result in personal injury
Reference: “Driver Air Bag (Inflator) Module Removal or non-activation of the air bag in the event of
and Installation”: 4-Channel a collision.
! WARNING • Never disassemble or repair an air bag
(inflator) module. If any abnormal
Failure to take proper precautions when condition is found, replace the module
checking the driver air bag (inflator) module with a new one.
can result in personal injury due to • Carefully read “Precautions for Air Bag
accidental deployment of the air bag. System Service”: 4-Channel, “Precautions
Never measure the resistance of the air bag for Handling and Storage of Air Bag
(inflator) module. System Components”: 4-Channel and
“Precautions for Disposal of Air Bag and
Seat Belt Pretensioner”: 4-Channel and
NOTICE
dropped may not operate correctly.
new one.
I9P60A820053-01 NOTE
Check air bag (inflator) module and if any of the following after Accident”: 4-Channel before replacing a
conditions is found, replace air bag (inflator) module or deployed air bag.
steering wheel with new one.
• Air bag is deployed. Removal
• Air bag (inflator) module is damaged or a strong 1) Disable air bag system. (Disabling Air Bag System):
impact was applied to it. 4-Channel
2) Remove instrument panel from vehicle body. Installation

(Instrument Panel Removal and Installation) in Reference: “Passenger Air Bag (Inflator) Module
Section 9C Inspection”: 4-Channel
3) Disconnect clamp (1) and passenger air bag Reverse removal procedure noting the following points.
(inflator) module connector (2) as shown in figure. • Insert claws (1) on passenger air bag (inflator) module
a) Release lock button (3) by pulling it in arrow (2) into hole in instrument main upper panel securely.
direction “1”. • Lock connector for passenger air bag (inflator) module
b) Disconnect connector with lock released by securely.
pulling it in arrow direction “2”. • Tighten passenger air bag (inflator) module bolts (3)
to specified torque.
Tightening torque
Passenger air bag (inflator) module bolt (a): 23
N·m (2.3 kgf-m, 17.0 lbf-ft)
1
“2”
“1”
2
3, (a) 3, (a)
3
IMTA0A821018-02
4) Remove instrument main upper panel from steering

support member. (Instrument Panel Disassembly
and Reassembly) in Section 9C
1
5) Remove passenger air bag (inflator) module screws
IMTA0A821020-01
(1), and then remove passenger air bag (inflator)
module (2) from instrument main upper panel by • Enable air bag system. (Enabling Air Bag System): 4-
unhooking claws (3). Channel
Passenger Air Bag (Inflator) Module Inspection

3 AENNTA0E8216009 (08(03)
Reference: “Passenger Air Bag (Inflator) Module
Removal and Installation”: 4-Channel
! WARNING
checking the passenger air bag (inflator)
1 1 module can result in personal injury due to
accidental deployment of the air bag.
Never measure the resistance of the air bag
2
(inflator) module.
3
IMTA0A821019-02
Check seat belt assembly (retractor pretensioner) and if

any of the following conditions is found, replace seat belt
assembly (retractor pretensioner) with new one.
• Pretensioner is activated.
NOTE
As retractor pretensioners are controlled
with driver and passenger air bags, you
should judge that pretensioners have been
activated if air bags have deployed.
• Retractor pretensioner is damaged or a strong impact

I9P60A820062-01 was applied to it.
• Connector is damaged.
Check air bag (inflator) module and if any of the following
conditions is found, replace air bag (inflator) module with Forward Impact Sensor Removal and
new one. Installation
AENNTA0E8216013 (08(01)
• Air bag is deployed.
• Air bag (inflator) module is damaged or a strong
impact was applied to it. ! WARNING
• Air bag (inflator) module bracket is bent or deformed. handling the air bag system sensor can
result in personal injury due to non-deployed
Seat Belt Pretensioner Components air bag system in the event of an accident or
AENNTA0E8216010 (12(01)
accidental air bag deployment.
Refer to “Front Seat Belt Components” in Section 8A.
• Never impact or shake the sensor.
Otherwise, proper operation of the sensor
Seat Belt Pretensioner Removal and Installation
AENNTA0E8216011 (08(01) cannot be assured.
Refer to “Front Seat Belt Assembly Removal and • Always tighten the mounting bolt to
Installation” in Section 8A. specified torque when installing the
sensor. Otherwise, proper operation of the
Seat Belt Pretensioner Inspection sensor cannot be assured.
AENNTA0E8216012 (08(03)
Reference: “Seat Belt Pretensioner Removal and
Removal
Installation”: 4-Channel
! WARNING 4-Channel
checking the seat belt pretensioner can
result in personal injury due to accidental 3) Remove driver-side headlight unit. (Headlight Unit
activate of the seat belt pretensioner. Removal and Installation) in Section 9B
Never measure the resistance of the seat belt 4) Disconnect forward impact sensor connector as
pretensioner. follows.
a) While pressing lock button (3) in arrow direction
“1”, pull forward impact sensor connector in
arrow direction “2” to release the lock.
b) While pressing lock button in arrow direction “1”,
disconnect impact sensor connector by pulling it
in arrow direction “2”.
5) Remove forward impact sensor bolt (4), and then
remove forward impact sensor (1) from lamp support
right brace.
IJHA0A810008-01
6) Install front bumper. (Front Bumper and Radiator

7) Enable air bag system. (Enabling Air Bag System):
4-Channel
Forward Impact Sensor Inspection

4 1 AENNTA0E8216014 (08(03)
Reference: “Forward Impact Sensor Removal and
2
Check forward impact sensor and if any of the following
conditions is found, replace it with new one.
“1”
• Driver air bag or passenger air bag is deployed.
“2” • Check sensor is dented, cracked or deformed.
3
• Check sensor connectors (sensor side and harness
side) and sensor connector lock mechanism are
damaged or cracked.
• Check connector terminals are bent, corroded or
rusted.
IMTA0A821021-01
Installation Passenger Air Bag (Inflator) Module Repair

Reference: “Forward Impact Sensor Inspection”: 4- Harness Installation
AENNTA0E8216015 (08(01)
Channel Reference: “Precautions for Electrical System Work”
1) Check that none of the following faulty conditions 1) Disable air bag system. (Disabling Air Bag System):
exists. 4-Channel
• Bend, deformation or rust on front side member 2) Remove glove box. (Instrument Panel Removal and
• Foreign material on sensor Installation) in Section 9C
2) Align mounting pin (1) with mounting hole (2) in lamp 3) Disconnect clamp (1) and passenger air bag
support right brace to install forward impact sensor (inflator) module connector (2) as shown in figure.
(3). a) Release lock button (3) by pulling it in arrow
3) Tighten forward impact sensor bolt (4) to specified direction “1”.
torque. b) Disconnect connector with lock released by
Tightening torque pulling it in arrow direction “2”.
Forward impact sensor bolt (a): 8.8 N·m (0.90
kgf-m, 6.5 lbf-ft)
4, (a)
“2”
2
1 “1”
3
3
IMTA0A821018-02
IMTA0A821022-01
4) Disconnect instrument panel harness (1) from
passenger air bag (inflator) module harness (3) as
4) Connect forward impact sensor connector securely.
follows.
5) Install driver-side headlight unit. (Headlight Unit
a) Release locking slider (2) by sliding it in arrow Deployment / Activation method depends upon final
direction “1”. disposition of vehicle. Review the following instructions
b) Disconnect instrument panel harness connector to determine which method will work best in a given
by pulling it in arrow direction “2”. situation.
Deployment / Activation Outside the Vehicle: When you
intend to return vehicle to service, deploy air bag
(inflator) module(s) and/or activate seat belt
2 pretensioner(s) outside the vehicle.
“1”
“2” Deployment / Activation Inside the Vehicle: When
vehicle will be destroyed or salvaged for component
1 parts, deploy air bag module(s) and/or activate seat belt
pretensioner(s) installed on vehicle.
! WARNING
deploying an air bag (inflator) module and/or
activating a seat belt pretensioner can result
3 in severe personal injury.
Take all of the following precautions when
activating a seat belt pretensioner:
• Strictly follow the procedure described in
IMTA0A821023-01 this section.
5) Remove passenger air bag (inflator) module harness • Read “Precautions for Air Bag System
from instrument panel. Service”: 4-Channel and follow all of the
6) Install passenger air bag (inflator) module repair instructions provided.
harness to instrument panel. • Only one person should perform this work
7) Connect passenger air bag (inflator) module repair to avoid accidental deployment/activation.
harness to instrument panel harness connector • Perform this work in a well-ventilated area
securely. as smoke is produced when the air bag
8) Install glove box. (Instrument Panel Removal and (inflator) module / pretensioner is
Installation) in Section 9C activated.
9) Enable air bag system. (Enabling Air Bag System): • Wear safety glasses throughout the
4-Channel disposal procedure from the very
beginning. The air bag (inflator) module /
10) Check that no DTC is detected in SDM with ignition seat belt pretensioner will immediately be
“ON”. activated when a 12-volt battery is
connected.
Air Bag (Inflator) Module and Seat Belt • Wear suitable ear protection when
Pretensioner Disposal activating an air bag (inflator) module /
AENNTA0E8216016 (08(03)
seat belt pretensioner. Also, advise
! WARNING
persons in nearby areas to wear suitable
If live air bag (inflator) modules or seat belt ear protection.
pretensioners are disposed of without being • Do not activate two or more air bag
deployed/activated beforehand using the (inflator) modules, seat belt pretensioners,
proper procedure, there is a risk of personal or a combination of two at the same time.
injury and health problems from contact with • Never connect the deployment harness to
the harmful substances that may come out if any 12-volt battery before connecting it to
the deployment container seal is broken. the air bag (inflator) module or seat belt
Before disposing of any live air bag (inflator) pretensioner. The deployment harness
modules or seat belt pretensioners, deploy/ must remain shorted and not be connected
activate them using the specified procedure. to a 12-volt battery until preparation for
Never dispose of any live ones through activation of the air bag (inflator) module /
ordinary refuse disposal channels. seat belt pretensioner is completed.
Air bag (inflator) module / seat belt pretensioner can be

deployed / activated inside or outside the vehicle.
• Never disconnect banana plug (1) till

deployment harness (A) is connected to 3
vehicle battery as static may cause

accidental deployment of air bag.
2
• Check that there is no open, short or
damage in deployment harness and
adapter cable of special tool.
Special tool 1
(A): 09932M75032
(A)
1
I8G001821052-01
IMTA0A821025-01
Deployment / Activation 3) Connect deployment harness (A) and adapter cable

Removal (B) to driver air bag (inflator) module.
Remove air bag (inflator) module or seat belt Special tool
pretensioner from vehicle. (A): 09932M75032
• Driver air bag (inflator) module: (Driver Air Bag (B): 09932M76510
(Inflator) Module Removal and Installation): 4-
Channel
• Passenger air bag (inflator) module: (Passenger Air
Bag (Inflator) Module Removal and Installation): 4-
Channel
• Seat belt pretensioner: (Front Seat Belt Assembly
Removal and Installation) in Section 8A
Setting
Driver air bag (inflator) module 1 (B)
1) Clear space (3) on ground about 185 cm (6.1 ft) in
diameter where driver air bag (inflator) module (1) is (A)
set for deployment. Paved and outdoor location IMTA0A821026-01
where there is no activity is preferred. If outdoor 1. Banana plug

location is not available, use space on shop floor
where there is no activity and sufficient ventilation is Passenger air bag (inflator) module
provided. 1) Turn deployment surface upward and tighten to
Check that no loose or flammable object exists deployment fixture (A) to specified torque using
within deployment area. passenger air bag (inflator) module bolt.
2) Place driver air bag (inflator) module with its vinyl
Special tool
trim cover facing up (2) on ground in Step 1).
(A): 09932M75041
Tightening torque
Passenger air bag (inflator) module bolt (a): 23
N·m (2.3 kgf-m, 17.0 lbf-ft)
[a] 3
5
4
1 2
(A) (a)
IMTA0A821028-01 IFRA0A820059-01
[a]: Air bag deployment direction 3) Hold seat belt pretensioner (1) vertically, tie webbing
1. Passenger air bag (inflator) module (2) tightly at 10 cm (3.9 in.) from cutting edge as
shown.
2) Connect deployment harness (A) and adapter cable
(B) to passenger air bag (inflator) module.
2 “a”
Special tool
(A): 09932M75032
(B): 09932M76510
1
(B)
IFRA0A820060-01
“a”: 10 cm (3.9 in.)
1
4) Tie seat belt pretensioner with wire harness (1) to
(A) tire at least 3 times as shown.
Wire harness section
IMTA0A821029-01
1.25 mm2 (0.0019 in.2 or more)
1. Banana plug
Retractor pretensioner
1) Cut webbing (1) at tongue plate stopper (2) of seat
belt pretensioner (3) side as shown.
2) Remove tongue plate (4) and shoulder anchor (5)
from webbing.
1
IFRA0A820061-01
5) Connect deployment harness (A) and adapter cable

(B) to seat belt pretensioner.
Special tool
(A): 09932M75032
(B): 09932M76510
Special tool
(B) (A): 09932M75032
(B): 09932M76510
3) Place 12 V vehicle battery (1) near the shorted end
(A) of deployment harness (A).
4) Check that area around air bag (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.
1
IFRA0A820062-01
6) Connect deployment harness to 12 V vehicle battery.
1. Banana plug ! WARNING
6) Pile 3 tires (2) and wheel-installed tire (1) on top of Failure to take proper precautions when
tire with seat belt pretensioner, and tie them with handling a deployed air bag and/or activated
wire harness (3) as shown. seat belt pretensioner may result in a fire,
personal injury or health problems.
Special tool
(A): 09932M75032 • Wait for at least 30 minutes before
(B): 09932M76510 touching any metal surface of an activated
air bag (inflator) module / seat belt
pretensioner.
1 • Leave air bag (inflator) module / seat belt
pretensioner for 30 minutes or more after
deployment / activation to prevent
3 accident due to remaining heat. After
checking that air bag (inflator) module /
2 seat belt pretensioner has got cold,
dispose of it.
• Do not place an activated air bag (inflator)
module / seat belt pretensioner near any
(B)
flammable objects because it is hot
enough to start a fire.
1 • Do not pour water, oil, etc. over an air bag
(inflator) module / seat belt pretensioner
immediately after its activation.
• Follow all of the procedures described in
(A)
this section.
4
IFRA0A820063-01
NOTE
4. Banana plug • When air bag (inflator) module deploys and
seat belt pretensioner activates, rapid gas
7) Drape blanket over those tires. expansion will create substantial report.
Wear suitable ear protection. Notify all
Deployment people in immediate area that you intend
1) Clear space (4) on ground about 185 cm (6.1 ft) in to deploy air bag (inflator) module or
diameter where air bag (inflator) module or seat belt activate seat belt pretensioner and suitable
pretensioner is set for deployment. Paved and ear protection should be worn.
outdoor location where there is no activity is • When driver air bag (inflator) module
preferred. If outdoor location is not available, use deploys, driver air bag (inflator) module
space on shop floor where there is no activity and may jump about 30 cm (1.0 ft) vertically.
sufficient ventilation is provided. This is normal reaction to force of rapid
Check that no loose or flammable object exists gas expansion inside of drive air bag
within deployment area. (inflator) module.
2) Stretch deployment harness (A) from air bag • After air bag (inflator) module has been
(inflator) module or seat belt pretensioner to its full deployed, surface of air bag (inflator) may
length 10 m (33 ft). contain powdery residue. This powder
consists primarily of cornstarch (used to

lubricate bag (inflator) as it inflates) and 1
by-products of chemical reaction.
2
(A) (B)
“a”
4
2 I8T201821025-01
(B)
9) Wash your hands with mild soap and water.
1
(A)
Deployed Air Bag (Inflator) Module and
Activated Seat Belt Pretensioner Disposal
AENNTA0E8216017 (08(03)
! WARNING
“a”
If live air bag (inflator) modules or seat belt
2 3 pretensioners are disposed of without being
1 deployed / activated beforehand using the
4
proper procedure, there is a risk of personal
injury and health problems from contact with
the harmful substances that may come out if
the deployment container seal is broken.
(B)
Before disposing of any live air bag (inflator)
(A)
modules or seat belt pretensioners, deploy /
activate them using the specified procedure.
Never dispose of any live ones through
ordinary refuse disposal channels.
“a”
2 Deployed air bag (inflator) module and activated seat

belt pretensioner can be disposed of in the same way
1
which is used for disposal of any other parts. For their
disposal, however, the following points should be noted.
IMTA0A821030-01 • Immediately after deployment / activation air bag
“a”. 10 m (33 ft) 4. Clear space 185 cm (6.1 ft) (inflator) module and seat belt pretensioner are hot.
3. Blanket Wait for 30 minutes to cool them off before handling
them.
7) Put on safety glasses (1) and pair of shop gloves (2) • Never apply water and oil etc. to deployed air bag
to protect your eyes and hands from possible (inflator) module and activated seat belt pretensioner
irritation and heat when handling deployed air bag to cool them off. Do not get on deployed air bag
(inflator) module or activated seat belt pretensioner. (inflator) module and activated seat belt pretensioner.
8) Dispose of deployed air bag (inflator) module or
activated seat belt pretensioner through normal
refuse channels after it has cooled for at least 30
minutes and tightly seal air bag (inflator) module or
seat belt pretensioner in strong vinyl bag.
IYSQ01820095-01
• After air bag (inflator) module has been deployed,

surface of air bag may contain a powdery residue. As
with many service procedures, wear gloves and safety
glasses.
• When disposing of deployed air bag (inflator) module
and activated seat belt pretensioner, seal it in a vinyl
bag.
I3JA01820119-01
• When air bag (inflator) module and seat belt

pretensioner have been deployed / activated inside
vehicle, leave them as installed to vehicle and scrap
them.
• Wash your hands with mild soap and water after
handling them.
Specifications
AENNTA0E8217001 (09(t)
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
SDM bolt 8.8 0.90 6.5 (T8B101)
Passenger air bag (inflator) module bolt 23 2.3 17.0 (T8B102) / (T8B104)
Forward impact sensor bolt 8.8 0.90 6.5 (T8B103)
Reference:

Use of Special Tools
AENNTA0E8218001 (11(01)
Be familiar with tools listed under heading “Special Tool”.
Study proper use of measurement tools such as Air Bag
Driver / Passenger Load Tool, Connector Test Adapter
Kit and digital multimeter.
Special tool
(A): 09932M76010
This must be used whenever a diagnostic procedure (A) (A)
requests checking or probing a terminal.
Using appropriate adapter in special tool will check that IGSB0A821059-01
no damage to terminal will occur from multimeter probe, The adapter (1) will also give an idea of whether or not
such as spread or bend. contact tension is sufficient, helping to find an open or
intermittent open due to poor terminal contact. SDM
shorting bar release tool (2) is included in connector test
adapter kit. Inserting it into SDM connector (3) will
release shorting bar.
Do not use “PASSENGER INFLATOR” connector (3).

3 By connecting load tool instead of inflator modules and
pretensioners, service work to decide location of cause
of trouble – whether it is in harness or in component –
can be performed.
Special tool
2, (A)
(B): 09932M75011
1, (A)
IJHA0A820040-01
This tool is used as a diagnostic aid and safety device to

prevent inadvertent air bag (inflator) module deployment.
The load tool has three connectors attached to its case
which are electrically functional and serve as resistive
load substitutions.
Use “BASE OF COLUMN” connector (1) instead of
resistance load of driver air bag (inflator) module and
contact coil.
Use “STEERING WHEEL” connector (2) instead of
resistance load of driver / passenger air bag (inflator) I1JA01820004-01
modules and seat belt pretensioner.
Special Tool
AENNTA0E8218002 (11(s)
09932M75011 09932M75032
Air bag driver / Passenger Air bag deployment harness
load tool
(L8B109) / (L8B112) / (L8B153) / (L8B154) /
(L8B121) / (L8B126) / (L8B157) / (L8B159) /
(L8B133) / (L8B137) / (L8B161) / (L8B163)
(L8B166)
09932M75041 09932M76010
Passenger air bag (inflator) Connector test adapter set
module deployment fixture
(L8B156) This set includes the
following items. 1.
Connector test adapter kit
(09932-75020), 2.
Connector test adapter &
shorting bar release tool
(09932-76020)(L8B101) /
(L8B102) / (L8B103) /
(L8B104) / (L8B105) /
(L8B106) / (L8B107) /
(L8B108) / (L8B111) /
(L8B114) / (L8B115) /
(L8B116) / (L8B117) /
(L8B118) / (L8B119) /
(L8B122) / (L8B123) /
(L8B124) / (L8B127) /
(L8B128) / (L8B129) /
(L8B130) / (L8B131) /
(L8B134) / (L8B135) /
(L8B138) / (L8B139) /
(L8B140) / (L8B141) /
(L8B142) / (L8B143) /
(L8B144) / (L8B145) /
(L8B146) / (L8B147) /
(L8B148) / (L8B149) /
(L8B150) / (L8B151) /
(L8B152) / (L8B165)
09932M76510 09932M78310
Deployment adapter cable Adapter cable
(L8B155) / (L8B158) / (L8B120) / (L8B125) /
(L8B160) / (L8B162) / (L8B132) / (L8B136)
(L8B164)
09932M78340
Deployment adapter cable
(L8B110) / (L8B113)
8-Channel
Precautions
Precautions for Air Bag System Service
AENNTA0E8220001 (01(01)
! WARNING
• Performing service operations on or

around air bag system components or
wiring without temporarily deactivating the
air bag system may result in accidental
activation of the air bag system. This could I8B701821001-02
cause injury or the need for extra repairs to
the air bag system.
Temporarily deactivate the air bag system
before performing service operations on or
around air bag system components.
Follow the procedures described in
“Disabling Air Bag System”: 8-Channel.
• 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 air bag 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.
IJKA0P822001-01
• If you disconnect the connector from the
air bag (inflator) module with a screwdriver
or the like, static electricity may trigger When checking each wiring harness, use special tool (A)
deployment of the air bag, which could referring to “Use of Special Tools”: 8-Channel.
result in personal injury. Never insert a Special tool
screwdriver or the like between the air bag (A): 09932M76010
(inflator) module and the connector.
• When storing air bag system components, select a

place where the ambient temperature is below 65 °C
(149 °F).
• When applying paint around the air bag system
related parts, be careful that the harness or connector
will not be exposed to the paint mist. (A)

Bag System Components (A)
AENNTA0E8220002 (01(01)
! WARNING
I8T201821003-02
Measuring the resistance of any air bag
(inflator) module or any seat belt SDM
pretensioner with a tester is dangerous, as
the electric current from the tester may ! WARNING
trigger the air bag or pretensioner.
Never measure the resistance of an air bag • If the SDM is not rigidly attached to the
(inflator) module or seat belt pretensioner. vehicle, it could accidentally cause the air
bags to deploy when the air bag system is
powered, possibly causing personal injury.
Always check that the SDM is rigidly

attached to the vehicle before supplying [A]
power to the air bag system.
to provide its original performance.
Never use an SDM that has been involved
[B]
in an air bag deployment accident. Refer to
“Air Bag Diagnostic System Check”: 8-
Channel 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.
: [C]
IMTA0A822032-01
[A]: Always carry air bag (inflator) module with trim cover (air bag opening)
away from body.
[B]: Always place air bag (inflator) module on workbench with trim cover
(air bag opening) up, away from loose objects.
[C]: Air bag deployment direction
Live (Inactivated) Seat Belt Pretensioner
! WARNING
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 (150 °F), without
I9W10P821061-01
high humidity and away from electric noise
• If SDM has been dropped, replace it with new one. sources.
• If SDM installation part of floor is damaged, repair it • Never carry a live seat belt pretensioner by
completely before reinstallation. holding the belt webbing.
• All SDM and mounting bracket fasteners must be • When placing a live seat belt pretensioner
carefully torqued and the arrow on SDM must point on a workbench or other flat surface,
toward the front of the vehicle to ensure proper check that the pretensioner’s exhaust hole
operation of the air bag system. side faces (1) upward.
• Do not put anything on the exhaust hole
Live (Undeployed) Air Bag (Inflator) Module
Special care is necessary when handling and storing live
(undeployed) air bag (inflator) modules. Accidental
deployment of air bag (inflator) module could throw itself
or objects around it in the air.
as the connector side wire harness is covered with a

yellow protection tube or tape. Be careful when handling
1
it.
• If damaged harness, connector or terminal is found on
an air bag wire harness, replace the harness.
• When installing the air bag wire harness, be careful so
that it is not caught or does not interfere with other
parts.
• Check that air bag system grounding point (5) 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.
IMTA0A821001-01
2 6
Special care is necessary when handling and storing a 4
live (inactivated) pretensioner. Accidental activation of
pretensioner will cause high pressure gas to blow off
from the exhaust hole and retract the webbing (1) quickly
into the retractor assembly (2). These actions may throw
the pretensioner itself or objects around it in the air.
7 5
4
1
3
2
IDK80P822003-01
IMTA0A822003-02
Deployed Air Bag (Inflator) Module and Activated 6. Passenger air bag harness 7. Side-air bag harness
Seat Belt Pretensioner
Refer to “Deployed Air Bag (Inflator) Module and
Precautions for Disposal of Air Bag and Seat
Activated Seat Belt Pretensioner Disposal”: 8-Channel.
Belt Pretensioner
AENNTA0E8220003 (01(01)
Air Bag Wire Harness and Connector When disposal is necessary, deploy / activate the air bag
Air bag wire harness is included in main harness (1), and seat belt pretensioner. (Air Bag (Inflator) Module and
instrument panel harness (2), floor harness (3) and door Seat Belt Pretensioner Disposal): 8-Channel
harness (4). Air bag wire harness can be identified easily
General Description
Air Bag System Construction To supplement protection offered by seat belts, the air
AENNTA0E8221001 (03(01) bag system includes the following air bags: front air bags
An 8-channel airbag system is employed in this model.
for driver and passenger seats, side-air bags for driver
The 8-channel airbag system consists of the following
and passenger seats, and driver and passenger curtain
components.
air bags.
• Driver and passenger air bag (inflator) modules In addition to these air bags, the system also includes
• Driver and passenger side-air bag (inflator) modules seat belt pretensioners for driver and passenger.
• Driver and passenger front seat belt pretensioners In the event of a frontal collision with an impact larger
than the preset level, the front air bag (inflator) modules
• Driver and passenger curtain air bag (inflator)
(stowed in the center of the steering wheel for the driver
modules
seat and under the top of instrument panel for passenger
• Forward impact sensor seat) are deployed. In the event of a sideward impact
• Driver and passenger front side-impact G sensors exceeding the preset level, the driver and passenger
• Driver and passenger side-impact pressure sensors side-air bag inflator modules as well as the curtain air
bag inflator module (stowed in each side of roof) on the
• SDM
impact side are deployed.
The front seat belt pretensioners are activated whenever The air bag system is designed to activate only in severe
a frontal or sideward impact exceeding the preset level is frontal and sideward collisions. It is not designed to
detected to take up the sag in the seat belts. activate in rear impacts, rollovers, or minor frontal and
sideward collisions; it would offer no protection in these
2 types of accidents.
1
IEFA0A820004-01
5 3
IL2R0A820001-01
1. Driver air bag (inflator) 4. Side-air bag (inflator) module

module
2. Passenger air bag (inflator) 5. Curtain air bag (inflator)
module module
3. Front seat belt pretensioner
Air Bag System Input / Output Table

AENNTA0E8221002 (03(01)
OUTPUT
(deployment Passenger Passenger Passenger
Driver Driver
& activation Driver air air bag Driver front Passenger
front side-air bag side-air curtain air curtain air
device) bag (inflator) (inflator)
seat belt
seat belt (inflator) bag (inflator) bag (inflator) bag (inflator)
module pretensioner pretensioner
module module module module module
INPUT
(sensor signal)
X-Y G sensor
(longitudinal / lateral
acceleration) in SDM
Forward impact
sensor
Driver side-impact
pressure sensor
Passenger
side-impact
pressure sensor
Driver side-impact
G sensor
Passenger
side-impact G sensor
IMTA0A822034-01

Air Bag System Input / Output Diagram

AENNTA0E8222001 (10(01)
INPUT SDM OUTPUT
Driver air bag (inflator) module

Battery voltage DC / DC converter Safing power driver Front air
bag and
front Passenger air bag (inflator) module
seat belt
Back up capacitor preten-
sioner
deploy- Driver seat belt pretensioner
X-Y G sensor ment
(Longitudinal / driver
Passenger seat belt pretensioner
lateral acceleration)
Forward impact sensor Side

air bag Driver side-air bag (inflator) module
deploy-
Driver side-impact ment
Passenger side-air bag (inflator) module
pressure sensor driver
Passenger side-impact
Main CPU Curtain
pressure sensor Driver curtain air bag (inflator) module
air bag
deploy-
Driver side-impact ment
Passenger curtain air bag (inflator) module
G sensor driver
Passenger side-impact BCM

G sensor
DCM*
Combination meter
*: If equpped
IMTA0A822004-03
Air Bag System Circuit Diagram

AENNTA0E8222002 (10(01)
3 8
2 RED G11-1 G11-19 YEL
4
G11-20 GRY
[A]: [G347] [S172] [S121] 9
5 BLU G11-8 [B]: [G376] [S175]
G11-22 YEL YEL
6 RED G11-9
G11-21 PPL PPL
[G372] [G373] [G259] 10
6 WHT G11-10
L04-10 YEL BLU
L04-11 GRY BLK or GRN

[L288] 11
17
GRN GRN G11-14
[E40] [E382] [G334]
L04-13 YEL BLU
YEL/BLK L04-14
18 L04-12 PPL BLK or GRN
[L289] 12
GRN L04-15
[L43]
L04-4 YEL
YEL/BLK L04-16
L04-3 GRY
19 [L290] 13
LT BLU L04-17
[L44]
L04-1 YEL
L04-2 PPL
G11-15 [L291] 14
YEL/BLK YEL/BLK
20
GRN GRN G11-16
[J13] [J213] [G361]
L04-18 YEL
YEL/BLK YEL/BLK G11-17 L04-19 GRY

21 [L283] 15
LT BLU LT BLU G11-18
[J14] [J212] [G339]
L04-21 YEL
G11-#1 L04-20 PPL

[L285] 16
G11-#2
G11-7 PPL PPL

L04-#3
[G341] [L374]
[L01] 24
L04-#4 7
PPL 25
: 22
: 23 G11-6 BLK
IMTA0A822005-01
[A]: 2P connector with 2 pins 8. Contact coil assembly 17. Forward impact sensor
[B]: 4P connector with 2 pins 9. Driver air bag (inflator) module 18. Driver side-impact G sensor
1. SDM 10. Passenger air bag (inflator) module 19. Passenger side-impact G sensor
2. Ignition power supply 11. Driver side-air bag (inflator) module 20. Driver side-impact pressure sensor
3. J/B 12. Passenger side-air bag (inflator) module 21. Passenger side-impact pressure sensor
4. “A/B” fuse 13. Driver curtain air bag (inflator) module 22. Shorting bar
5. To DLC 14. Passenger curtain air bag (inflator) module 23. Connection detection pin
6. To combination meter 15. Driver seat belt pretensioner 24. BCM
7. IC (Integrated Circuit) 16. Passenger seat belt pretensioner 25. To DCM (if equipped)
Terminal arrangement of SDM connector
[A] [B]
1 2 3 4 5 6 1 2 3 4 5
[a] 7 8 #1 #2 9 10 6 7 #3 #4 8 9
11 12 13 14 15 16 17 18 19 20 21 22 10 11 12 13 14 15 16 17 18 19 20 21
IGW00P822003-01
[A]: SDM connector “G11” (View: [a]) [B]: SDM connector “L04” (View: [a])
“G11” connector
G11-1 Power supply G11-12 —
G11-2 — G11-13 Forward impact sensor (+)
G11-3 — G11-14 Forward impact sensor (–)
G11-4 — G11-15 Driver side-impact pressure sensor (+)
G11-5 — G11-16 Driver side-impact pressure sensor (–)
G11-6 Ground G11-17 Passenger side-impact pressure sensor (+)
G11-7 Air bag deployed signal G11-18 Passenger side-impact pressure sensor (–)
G11-8 DLC G11-19 Driver air bag (inflator) module (+)
G11-9 CAN (Hi) G11-20 Driver air bag (inflator) module (–)
G11-10 CAN (Lo) G11-21 Passenger air bag (inflator) module (–)
G11-11 — G11-22 Passenger air bag (inflator) module (+)
“L04” connector
L04-1 Passenger curtain air bag (inflator) module (+) L04-12 Passenger side-air bag (inflator) module (–)
L04-2 Passenger curtain air bag (inflator) module (–) L04-13 Passenger side-air bag (inflator) module (+)
L04-3 Driver curtain air bag (inflator) module (–) L04-14 Driver side-impact G sensor (+)
L04-4 Driver curtain air bag (inflator) module (+) L04-15 Driver side-impact G sensor (–)
L04-5 — L04-16 Passenger side-impact G sensor (+)
L04-6 — L04-17 Passenger side-impact G sensor (–)
L04-7 — L04-18 Driver seat belt pretensioner (+)
L04-8 — L04-19 Driver seat belt pretensioner (–)
L04-9 — L04-20 Passenger seat belt pretensioner (–)
L04-10 Driver side-air bag (inflator) module (+) L04-21 Passenger seat belt pretensioner (+)
L04-11 Driver side-air bag (inflator) module (–)
Component Location
Air Bag System Component, Wiring and Connector Location
AENNTA0E8223001 (04(01)
[a] [b] [c]
12 13
11
[d] [e] [f]

14
“L04” “G11”
15
“G373” “G372” “G241”

“G259”
4
[d]
“G271” [e]
10
“J14”
“L291” [a]
[b] [G]
6 “E40”
“L285”
“G334”
8 “J212” “E382”
“G339” 2
[c] 3 “S121”
“L290” 9
[C]
“L44” [A]: “S172”
[B]: “S175” [f]
[A]: “G347” [b]
[B]: “G376”
[D]
“L288” [F]
“L289”
[H]
7 “G361”
[c] “L43”
“J213”
“J13”
[H]
[E]
“L283”
5
IMTA0A822002-02
[A]: 2P connector with 2 pins 1. “AIR BAG” warning light 9. Driver curtain air bag (inflator) module
[B]: 4P connector with 2 pins 2. Contact coil assembly 10. Passenger curtain air bag (inflator) module
[C]: Main harness 3. Driver air bag (inflator) module 11. Forward impact sensor
[D]: Instrument panel harness 4. Passenger air bag (inflator) module 12. Side-impact pressure sensor
[E]: Floor harness 5. Driver seat belt pretensioner 13. Side-impact G sensor
[F]: Front door wire (Driver-side) 6. Passenger seat belt pretensioner 14. SDM
[G]: Front door wire (Passenger-side) 7. Driver side-air bag (inflator) module 15. “A/B” fuse
[H]: Side air bag harness 8. Passenger side-air bag (inflator)
module

Air Bag Diagnostic System Check
AENNTA0E8224001 (06(01)
Referring to “Precautions for Air Bag System Service”: 8-Channel, check air bag system according to the following
procedure.
Step 1 DTC check

NOTE
If communication between SUZUKI scan tool and vehicle cannot be established, perform “DLC and Its
Communication Check (No Communication to SDM)”.
Is there any DTC(s) when rechecking?
Yes Go to applicable DTC diagnosis flow, and go to Step 5.

No Go to Step 2.

1) Perform “Visual Inspection”: 8-Channel.

No Go to Step 3.
Step 3 Impact sign check

1) Check vehicle for evidence of impact.
Are there any signs of impact?
Yes Check faulty connections and replace them according to “Repair and Inspection Required after
Accident”: 8-Channel, and go to Step 5.
No Go to Step 4.

1) Check intermittent problems referring to “Intermittent Connection and Poor Contact Inspection” in
Section 00.

No Go to Step 5.

1) Check that problematic symptom has gone and air bag system is free from any abnormal conditions. If
what has been repaired is related to DTC, clear DTC once and check that no DTC is indicated.
Yes Return to Step 1.

No End.
Visual Inspection
AENNTA0E8224002 (06(01)
Inspection item Reference
• Battery – Fluid level, leakage “Battery Description” in Section 1J
• Connectors of electric wire harness – “Intermittent Connection and Poor Contact Inspection” in
Disconnection, friction Section 00
“Air Bag System Component, Wiring and Connector Location”:
• Fuses – Burning
8-Channel
• Air bag system component – Installation, damage —
“AIR BAG” Warning Light Check

AENNTA0E8224003 (06(01)
2) Check that “AIR BAG” warning light (1) is on for 6
seconds. If “AIR BAG” warning light is not on, refer to
““AIR BAG” Warning Light Does Not Come ON”: 8-
Channel. If “AIR BAG” warning light is kept ON and
no DTC is detected in SDM, refer to ““AIR BAG”
Warning Light Comes ON Steady”: 8-Channel.
1
IMTA0A822006-02
DTC Check
AENNTA0E8224005 (06(01)
1) Connect SUZUKI scan tool to DLC Refer to “Suzuki
0A.
1
SUZUKI scan tool.
IMTA0A822006-02 If necessary, refer to Operator's Manual of SUZUKI
Self-Diagnosis Function
AENNTA0E8224004 (06(01) NOTE
SDM also has self-diagnosis function that memorizes
DTC when an error is detected. After understanding the • A communication error may occur due to
following descriptions, perform troubleshooting referring temporary overlap of communication load.
to “Air Bag Diagnostic System Check”: 8-Channel when If communication error occurs, wait about
an error is detected. 10 seconds and try the operation again.
• SDM always monitors system while ignition is “ON”. If • If communication between SUZUKI scan
an error is detected, it notifies driver of error by turning tool and SDM is not possible, perform the
on “AIR BAG” warning light (1) and detected error is following checks:
stored in SDM memory as DTC. – Check communication condition
• “AIR BAG” warning light turns on for about 6 seconds between PC and VCI using SUZUKI scan
with ignition “ON” to indicate that it operates properly tool function.
and turns off if no error is found in air bag system. – Check DLC power circuit and ground
circuit.
– Check DLC cable. If necessary, check • If communication between SUZUKI scan

DLC cable by substituting a known-good tool and SDM is not possible, perform the
DLC cable. following checks:
– Check CAN communication circuit and – Check communication condition
connectors between DLC and central between PC and VCI using SUZUKI scan
gateway control module. (Refer to tool function.
“Diagnosis flow: [a]” in – Check DLC power circuit and ground
“Troubleshooting” of “Troubleshooting circuit.
Section 10H.)
– Check CAN communication system. DLC cable.
“Diagnosis flow: [a]” in
– Check central gateway control module “Troubleshooting” of “Troubleshooting
power supply circuit and ground circuit. for Lost Communication”: CAN in
(Inspection of Central Gateway Control Section 10H.)
– Check SDM power circuit and ground Off” is detected in any control module.)
circuit. (SDM Power Supply and Ground (Troubleshooting for Communication
Circuit Check): 8-Channel Bus Off): CAN in Section 10H
3) Disconnect SUZUKI scan tool from DLC. Refer to – Check central gateway control module
“Suzuki SDT-II Connection and Disconnection” in power supply circuit and ground circuit.
Section 0A. (Inspection of Central Gateway Control
DTC Clearance
AENNTA0E8224006 (06(01) – Check SDM power circuit and ground
1) Connect SUZUKI scan tool to DLC Refer to “Suzuki circuit. (SDM Power Supply and Ground
SDT-II Connection and Disconnection” in Section Circuit Check): 8-Channel
0A. • If DTC B1032-00, B1033-00, B1034-00,
2) Clear DTC and follow the instructions displayed on B1035-00, B1036-00 or B1037-00 or is
SUZUKI scan tool. stored in SDM, it is not possible to clear
If necessary, refer to Operator's Manual of SUZUKI DTC.
NOTE “Suzuki SDT-II Connection and Disconnection” in
Section 0A.
DTC Table
AENNTA0E8224007 (06(01)
DTC DTC name
B1002-00 (DTC B1002-00): 8-Channel Intermittent Connection of SDM Connector
B1003-04 (DTC B1003-04): 8-Channel SDM Internal Failure
B1004-17 (DTC B1004-17): 8-Channel Power Source Voltage Too High
B1004-18 (DTC B1004-18): 8-Channel Power Source Voltage Too Low
B1032-00 (DTC B1032-00 / B1033-00 /
B1034-00 / B1035-00 / B1036-00 / Front Air Bag Deployment Record
B1037-00): 8-Channel
B1033-00 (DTC B1032-00 / B1033-00 /
B1034-00 / B1035-00 / B1036-00 / Side Air Bag Deployment Record (Driver Side)
DTC DTC name

B1034-00 (DTC B1032-00 / B1033-00 /
B1034-00 / B1035-00 / B1036-00 / Side Air Bag Deployment Record (Passenger Side)
B1035-00 (DTC B1032-00 / B1033-00 /
B1034-00 / B1035-00 / B1036-00 / Seat Belt Pretensioner Activation Record
B1036-00 (DTC B1032-00 / B1033-00 /
B1034-00 / B1035-00 / B1036-00 / Curtain Air Bag Deployment Record (Driver Side)
B1037-00 (DTC B1032-00 / B1033-00 /
B1034-00 / B1035-00 / B1036-00 / Curtain Air Bag Deployment Record (Passenger Side)
B1060-14 (DTC B1060-14): 8-Channel Driver Air Bag (1st stage) Circuit Shorted to Ground
B1060-15 (DTC B1060-15): 8-Channel Driver Air Bag (1st stage) Circuit Shorted to Power Supply
B1060-1A (DTC B1060-1A): 8-Channel Driver Air Bag (1st stage) Circuit Low Resistance
B1060-1B (DTC B1060-1B): 8-Channel Driver Air Bag (1st stage) Circuit High Resistance
B1062-14 (DTC B1062-14): 8-Channel Passenger Air Bag (1st stage) Circuit Shorted to Ground
B1062-15 (DTC B1062-15): 8-Channel Passenger Air Bag (1st stage) Circuit Shorted to Power Supply
B1062-1A (DTC B1062-1A): 8-Channel Passenger Air Bag (1st stage) Circuit Low Resistance
B1062-1B (DTC B1062-1B): 8-Channel Passenger Air Bag (1st stage) Circuit High Resistance
B1064-14 (DTC B1064-14 / B1065-14):
Driver Seat Belt Pretensioner Circuit Shorted to Ground
8-Channel
B1064-15 (DTC B1064-15 / B1065-15):
Driver Seat Belt Pretensioner Circuit Shorted to Power Supply
8-Channel
B1064-1A (DTC B1064-1A / B1065-1A):
Driver Seat Belt Pretensioner Circuit Low Resistance
8-Channel
B1064-1B (DTC B1064-1B / B1065-1B):
Driver Seat Belt Pretensioner Circuit High Resistance
8-Channel
B1065-14 (DTC B1064-14 / B1065-14):
Passenger Seat Belt Pretensioner Circuit Shorted to Ground
8-Channel
B1065-15 (DTC B1064-15 / B1065-15):
Passenger Seat Belt Pretensioner Circuit Shorted to Power Supply
8-Channel
B1065-1A (DTC B1064-1A / B1065-1A):
Passenger Seat Belt Pretensioner Circuit Low Resistance
8-Channel
B1065-1B (DTC B1064-1B / B1065-1B):
Passenger Seat Belt Pretensioner Circuit High Resistance
8-Channel
B1068-14 (DTC B1068-14 / B1069-14):
Side Air Bag Circuit Shorted to Ground (Driver Side)
8-Channel
B1068-15 (DTC B1068-15 / B1069-15):
Side Air Bag Circuit Shorted to Power Supply (Driver Side)
8-Channel
B1068-1A (DTC B1068-1A / B1069-1A):
Side Air Bag Circuit Low Resistance (Driver Side)
8-Channel
B1068-1B (DTC B1068-1B / B1069-1B):
Side Air Bag Circuit High Resistance (Driver Side)
8-Channel
B1069-14 (DTC B1068-14 / B1069-14):
Side Air Bag Circuit Shorted to Ground (Passenger Side)
8-Channel
B1069-15 (DTC B1068-15 / B1069-15):
Side Air Bag Circuit Shorted to Power Supply (Passenger Side)
8-Channel
B1069-1A (DTC B1068-1A / B1069-1A):
Side Air Bag Circuit Low Resistance (Passenger Side)
8-Channel
B1069-1B (DTC B1068-1B / B1069-1B):
Side Air Bag Circuit High Resistance (Passenger Side)
8-Channel
B106C-14 (DTC B106C-14 / B106D-
Curtain Air Bag Circuit Shorted to Ground (Driver Side)
14): 8-Channel
B106C-15 (DTC B106C-15 / B106D-
Curtain Air Bag Circuit Shorted to Power Supply (Driver Side)
15): 8-Channel
B106C-1A (DTC B106C-1A / B106D-
Curtain Air Bag Circuit Low Resistance (Driver Side)
1A): 8-Channel
DTC DTC name

B106C-1B (DTC B106C-1B / B106D-
Curtain Air Bag Circuit High Resistance (Driver Side)
1B): 8-Channel
B106D-14 (DTC B106C-14 / B106D-
Curtain Air Bag Circuit Shorted to Ground (Passenger Side)
14): 8-Channel
B106D-15 (DTC B106C-15 / B106D-
Curtain Air Bag Circuit Shorted to Power Supply (Passenger Side)
15): 8-Channel
B106D-1A (DTC B106C-1A / B106D-
Curtain Air Bag Circuit Low Resistance (Passenger Side)
1A): 8-Channel
B106D-1B (DTC B106C-1B / B106D-
Curtain Air Bag Circuit High Resistance (Passenger Side)
1B): 8-Channel
B1090-01 (DTC B1090-01 / B1090-95):
Driver Forward Impact Sensor No Response
8-Channel
B1090-87 (DTC B1090-87): 8-Channel Driver Forward Impact Sensor Communication Data Invalid
B1090-95 (DTC B1090-01 / B1090-95):
Driver Forward Impact Sensor Communication Data Inconsistent
8-Channel
B1093-01 (DTC B1093-01 / B1093-95 /
Side Impact Sensor No Response (Driver Side)
B1094-01 / B1094-95): 8-Channel
B1093-87 (DTC B1093-87 / B1094-87):
Side Impact Sensor Communication Data Invalid (Driver Side)
8-Channel
B1093-95 (DTC B1093-01 / B1093-95 /
Side Impact Sensor Communication Data Inconsistent (Driver Side)
B1094-01 / B1094-95): 8-Channel
B1094-01 (DTC B1093-01 / B1093-95 /
Side Impact Sensor No Response (Passenger Side)
B1094-01 / B1094-95): 8-Channel
B1094-87 (DTC B1093-87 / B1094-87):
Side Impact Sensor Communication Data Invalid (Passenger Side)
8-Channel
B1094-95 (DTC B1093-01 / B1093-95 /
Side Impact Sensor Communication Data Inconsistent (Passenger Side)
B1094-01 / B1094-95): 8-Channel
B1095-01 (DTC B1095-01 / B1095-95 /
Side Rear Impact Sensor No Response (Driver Side)
B1096-01 / B1096-95): 8-Channel
B1095-87 (DTC B1095-87 / B1096-87):
Side Rear Impact Sensor Communication Data Invalid (Driver Side)
8-Channel
B1095-95 (DTC B1095-01 / B1095-95 /
Side Rear Impact Sensor Communication Data Inconsistent (Driver Side)
B1096-01 / B1096-95): 8-Channel
B1096-01 (DTC B1095-01 / B1095-95 /
Side Rear Impact Sensor No Response (Passenger Side)
B1096-01 / B1096-95): 8-Channel
B1096-87 (DTC B1095-87 / B1096-87):
Side Rear Impact Sensor Communication Data Invalid (Passenger Side)
8-Channel
B1096-95 (DTC B1095-01 / B1095-95 / Side Rear Impact Sensor Communication Data Inconsistent (Passenger
B1096-01 / B1096-95): 8-Channel Side)
U0073-88 (DTC U0073-88): 8-Channel Control Module Communication Bus Off
Scan Tool Data

AENNTA0E8224008 (06(01)
SDM
NOTE
• If communication between SUZUKI scan tool and SDM is not possible, perform the following
checks:
– Check SDM power circuit and ground circuit. (SDM Power Supply and Ground Circuit Check): 8-
Channel
Data list of SDM

Scan tool data Normal condition / Reference value
System ID (System ID): 8-Channel 8ch
Battery Voltage (Battery Voltage (V)): 8-Channel 10 – 14 V
Backup Voltage (Backup Voltage (V)): 8-Channel 27.0 – 33.0 V
Driver Air Bag Initiator Resistance (Driver Air Bag Initiator 1.0 – 4.5 Ω
Passenger Air Bag Initiator Resistance (Passenger Air 1.0 – 3.8 Ω
Bag Initiator Resistance (Ω)): 8-Channel
Driver-Side Seat Belt Pretensioner Initiator Resistance 1.0 – 3.8 Ω
(Driver-Side Seat Belt Pretensioner Initiator Resistance
(Ω)): 8-Channel
Passenger-Side Seat Belt Pretensioner Initiator 1.0 – 3.8 Ω
Resistance (Passenger-Side Seat Belt Pretensioner
Driver-Side Side-Air Bag Initiator Resistance (Driver-Side 1.0 – 3.8 Ω
Side-Air Bag Initiator Resistance (Ω)): 8-Channel
Passenger-Side Side-Air Bag Initiator Resistance 1.0 – 3.8 Ω
(Passenger-Side Side-Air Bag Initiator Resistance (Ω)): 8-
Channel
Driver-Side Curtain Air Bag Initiator Resistance (Driver- 1.0 – 3.8 Ω
Side Curtain Air Bag Initiator Resistance (Ω)): 8-Channel
Passenger-Side Curtain Air Bag Initiator Resistance 1.0 – 3.8 Ω
(Passenger-Side Curtain Air Bag Initiator Resistance (Ω)):
8-Channel
Left-Side Rear Seat Belt Pretensioner Initiator Resistance 1.0 – 3.8 Ω
(Left-Side Rear Seat Belt Pretensioner Initiator
Right-Side Rear Seat Belt Pretensioner Initiator 1.0 – 3.8 Ω
Resistance (Right-Side Rear Seat Belt Pretensioner
Scan Tool Data Definitions Passenger Air Bag Initiator Resistance (Ω)
System ID This parameter indicates resistance of passenger air bag
This parameter indicates number of initiator circuits. initiator circuit.
Battery Voltage (V) Driver-Side Seat Belt Pretensioner Initiator

Power supply voltage is an analog input signal read by Resistance (Ω)
SDM. This parameter indicates resistance of driver-side front
seat belt pretensioner initiator circuit.
Backup Voltage (V)
This parameter indicates capacity of backup capacitor Passenger-Side Seat Belt Pretensioner Initiator
installed to maintain ignition current (as much as Resistance (Ω)
possible) even when power supply to SDM that ignites This parameter indicates resistance of passenger-side
inflator is shut off. front seat belt pretensioner initiator circuit.
Driver Air Bag Initiator Resistance (Ω) Driver-Side Side-Air Bag Initiator Resistance (Ω)
This parameter indicates resistance of driver air bag This parameter indicates resistance of driver-side side-
initiator circuit. air bag initiator circuit.
Passenger-Side Side-Air Bag Initiator Resistance (Ω) Left-Side Rear Seat Belt Pretensioner Initiator
This parameter indicates resistance of passenger-side Resistance (Ω)
side-air bag initiator circuit. This parameter indicates resistance of left-side rear seat
belt pretensioner initiator circuit.
Driver-Side Curtain Air Bag Initiator Resistance (Ω)
This parameter indicates resistance of driver-side curtain Right-Side Rear Seat Belt Pretensioner Initiator
air bag initiator circuit. Resistance (Ω)
This parameter indicates resistance of right-side rear
Passenger-Side Curtain Air Bag Initiator Resistance seat belt pretensioner initiator circuit.
(Ω)
This parameter indicates resistance of passenger-side
curtain air bag initiator circuit.
“AIR BAG” Warning Light Comes ON Steady

AENNTA0E8224009 (06(03)
Circuit Diagram
3 6 2
4
1 BRN G241-3
7
BLK G241-5
G241-22 RED G11-9
8 8
G241-10 WHT G11-10
5
RED G11-1
BLK G11-6
[A] [B]
[a] 1 2 3 4 5 6
1 2 3 4 5 6 7 8 9 10 11 12 7 8 #1 #2 9 10
13 14 15 16 17 18 19 20 21 22 23 24
11 12 13 14 15 16 17 18 19 20 21 22
IMTA0A822007-02

Troubleshooting

Yes Go to Step 2.
Step 2 DTC check


No Go to Step 3.
Step 3 SDM power supply and ground circuit check

Channel
Is check result OK?
Yes Go to Step 4.
No Repair SDM power supply and ground circuits.

Is check result OK?
Yes Go to Step 5.

Does “AIR BAG” warning light stay on?
Yes Replace SDM and recheck “AIR BAG” warning light operation. (SDM Removal and Installation): 8-
Channel
No End.
NOTE
“AIR BAG” Warning Light Does Not Come ON

AENNTA0E8224010 (06(03)
Circuit Diagram
3 6 2
4
1 BRN G241-3
7
BLK G241-5
G241-22 RED G11-9
8 8
G241-10 WHT G11-10
5
RED G11-1
BLK G11-6
[A] [B]
[a] 1 2 3 4 5 6
1 2 3 4 5 6 7 8 9 10 11 12 7 8 #1 #2 9 10
13 14 15 16 17 18 19 20 21 22 23 24
11 12 13 14 15 16 17 18 19 20 21 22
IMTA0A822007-02

Troubleshooting

Do other indicator lights come ON?
Yes Go to Step 2.
No Go to Step 3.
Step 2 DTC check

4) Check for DTC. (DTC Check): 8-Channel

No Go to Step 3.
Step 3 Fuse check
Is “MTR” fuse for combination meter in good condition?
Yes Go to Step 4.

Is check result OK?
Yes Go to Step 5.

2) Remove combination meter. (Combination Meter Removal and Installation) in Section 9C
Special tool
: 09932M76010
Is it 10 – 14 V?
Yes Go to Step 6.

Special tool
: 09932M76010
Is resistance less than 1 Ω?
Yes Replace combination meter and recheck “AIR BAG” warning light operation. (Combination Meter
NOTE
DTC B1002-00
AENNTA0E8224011 (06(02)
B1002-00: Intermittent Connection of SDM Connector • SDM connector
Faulty connection of SDM connector. • SDM
DTC Troubleshooting
Yes Go to Step 2.

1) Check proper connection of SDM connector and “Connection detection pin” of SDM connector.
Is check result OK?
Yes Replace SDM with new one. (SDM Removal and Installation): 8-Channel
NOTE
DTC B1003-04
AENNTA0E8224012 (06(02)
B1003-04: SDM Internal Failure SDM
Malfunctioning SDM internal circuit, G sensor, memory or CPU.
DTC Troubleshooting

Yes Go to Step 2.
Step 2 DTC check

NOTE
DTC B1004-17
AENNTA0E8224013 (06(02)
B1004-17: Power Source Voltage Too High • Charging system
Power supply voltage is more than specified range. • SDM and/or its circuit
Circuit Diagram
4 3
A1
2
1 RED G11-1
BLK G11-6
A2
[A]
[a] 1 2 3 4 5 6
7 8 #1 #2 9 10
11 12 13 14 15 16 17 18 19 20 21 22
IHD10P820021-03
[A]: “G11” connector (View: [a]) 1. Ignition power supply 4. J/B

A1: SDM power supply circuit 2. “A/B” fuse
A2: SDM ground circuit 3. SDM
DTC Troubleshooting
Yes Go to Step 2.
Step 2 SDM power voltage check


3) Start engine and set engine speed at 3,000 rpm or more.
Special tool
: 09932M76010
Is voltage 15 V or less?
Yes Go to Step 3.
No Check charging system and repair wiring. (Generator Test) in Section 1J
Step 3 DTC check

NOTE
DTC B1004-18
AENNTA0E8224014 (06(02)
B1004-18: Power Source Voltage Too Low • Charging system
Power supply voltage is less than specified range. • SDM
Circuit Diagram
4 3
A1
2
1 RED G11-1
BLK G11-6
A2
[A]
[a] 1 2 3 4 5 6
7 8 #1 #2 9 10
11 12 13 14 15 16 17 18 19 20 21 22
IHD10P820021-03

DTC Troubleshooting
Yes Go to Step 2.
Step 2 SDM power supply circuit and ground circuit check

Channel
Is check result OK?
Yes Go to Step 3.
Step 3 DTC check

NOTE
DTC B1032-00 / B1033-00 / B1034-00 / B1035-00 / B1036-00 / B1037-00

AENNTA0E8224015 (06(02)
B1032-00: Front Air Bag Deployment Record If this DTC has been recorded even though air
Deployment of front air bag has been recorded in SDM. bag or pretensioner has not been deployed
B1033-00: Side Air Bag Deployment Record (Driver Side) • SDM
Deployment of driver side-air bag (inflator) module has been
• Driver and/or passenger air bag (inflator)
recorded in SDM.
module
B1034-00: Side Air Bag Deployment Record (Passenger Side)
Deployment of passenger side-air bag (inflator) module has been • Driver side-air bag (inflator) module
recorded in SDM. • Passenger side-air bag (inflator) module
B1035-00: Seat Belt Pretensioner Activation Record • Driver and/or passenger front seat belt
Activation of front seat belt pretensioner has been recorded in SDM. pretensioner
B1036-00: Curtain Air Bag Deployment Record (Driver Side)
• Driver curtain air bag (inflator) module
Deployment of driver curtain air bag (inflator) module has been
recorded in SDM. • Passenger curtain air bag (inflator) module
B1037-00: Curtain Air Bag Deployment Record (Passenger • Left-side and/or right-side rear seat belt
Side) pretensioner
Deployment of passenger curtain air bag (inflator) module has been • Those initiator circuits
recorded in SDM.
NOTE
If DTC B1032-00, B1033-00, B1034-00, B1035-00, B1036-00 or B1037-00 is stored in SDM, it is not
possible to clear DTC.
DTC Troubleshooting
Yes Replace SDM. (SDM Removal and Installation): 8-Channel

NOTE
DTC B1060-14
AENNTA0E8224016 (06(02)
B1060-14: Driver Air Bag (1st stage) Circuit Shorted to Ground • Driver air bag (inflator) module circuit
Driver air bag (inflator) module circuit has been shorted to ground. • Contact coil assembly
• SDM
Circuit Diagram
3
[A]:[S172] [A]:[G347]
[S121] [B]:[S175] [B]:[G376]
1 2 A1
YEL G11-19
GRY G11-20
A2
:4
[F]
[C] [D]
1 2 3 4 5 6
[a]
1 2 1 2 7 8 #1 #2 9 10
11 12 13 14 15 16 17 18 19 20 21 22
[E]
1 2 3 4
IMTA0A822008-05
[A]: 2P connector with 2 pins [E]: “G376” connector (View: [a]) 1. Driver air bag (inflator) module
[B]: 4P connector with 2 pins [F]: “G11” connector (View: [a]) 2. Contact coil assembly
[C]: “S121” connector (View: [a]) A1: Driver air bag (inflator) module deployment signal output circuit 3. SDM
[D]: “G347” connector (View: [a]) A2: Driver air bag (inflator) module deployment signal ground circuit 4. Shorting bar
DTC Troubleshooting
Yes Go to Step 2.

2) Disconnect “G347” or “G376” connector. (Contact Coil Assembly Removal and Installation) in Section 6B
Special tool
: 09932M76010
Is check result OK?
Yes Go to Step 3.

1) Connect “G347” or “G376” connector.
• Resistance between each of “A1” and “A2” circuit and ground: infinity
Special tool
: 09932M76010
Is check result OK?
NOTE
DTC B1060-15
AENNTA0E8224017 (06(02)
B1060-15: Driver Air Bag (1st stage) Circuit Shorted to Power Supply • Driver air bag (inflator) module circuit
Driver air bag (inflator) module circuit has been shorted to power supply. • Contact coil assembly
• SDM
Circuit Diagram
3
[A]:[S172] [A]:[G347]
[S121] [B]:[S175] [B]:[G376]
1 2 A1
YEL G11-19
GRY G11-20
A2
:4
[F]
[C] [D]
1 2 3 4 5 6
[a]
1 2 1 2 7 8 #1 #2 9 10
11 12 13 14 15 16 17 18 19 20 21 22
[E]
1 2 3 4
IMTA0A822008-05
DTC Troubleshooting
Yes Go to Step 2.

Special tool
: 09932M76010
Is check result OK?
Yes Go to Step 3.

2) Connect “G347” or “G376” connector.

Special tool
: 09932M76010
Is check result OK?
NOTE
DTC B1060-1A
AENNTA0E8224018 (06(02)
B1060-1A: Driver Air Bag (1st stage) Circuit Low • Driver air bag (inflator) module circuit
Resistance • Contact coil assembly
Driver air bag (inflator) module circuit resistance is less
• SDM
Circuit Diagram
3
[A]:[S172] [A]:[G347]
[S121] [B]:[S175] [B]:[G376]
1 2 A1
YEL G11-19
GRY G11-20
A2
:4
[F]
[C] [D]
1 2 3 4 5 6
[a]
1 2 1 2 7 8 #1 #2 9 10
11 12 13 14 15 16 17 18 19 20 21 22
[E]
1 2 3 4
IMTA0A822008-05
DTC Troubleshooting

Yes Go to Step 2.

3) Connect special tools as follows.
• 2P connector with 2 pins:
– Connect “BASE OF COLUMN” harness (1) of special tools (A) and (B) to “G347” connector.
– Connect “BASE OF COLUMN” harness of special tools (A) and (C) to “G376” connector.
Special tool
(A): 09932M75011
(B): 09932M78340
(C): 09932M77320
[G347], [G376]
(B), (C) 1
(A)
IMTA0A822009-02

Yes Go to Step 3.
No Go to Step 4.

Special tool
: 09932M76010
Is check result OK?

Is check result OK?

NOTE
DTC B1060-1B
AENNTA0E8224019 (06(02)
B1060-1B: Driver Air Bag (1st stage) Circuit High Resistance • Driver air bag (inflator) module circuit
Driver air bag (inflator) module circuit resistance is more than • Contact coil assembly
specified range.
• SDM
Circuit Diagram
3
[A]:[S172] [A]:[G347]
[S121] [B]:[S175] [B]:[G376]
1 2 A1
YEL G11-19
GRY G11-20
A2
:4
[F]
[C] [D]
1 2 3 4 5 6
[a]
1 2 1 2 7 8 #1 #2 9 10
11 12 13 14 15 16 17 18 19 20 21 22
[E]
1 2 3 4
IMTA0A822008-05
DTC Troubleshooting
Yes Go to Step 2.

2) Check for proper connection to “G347” or “G376” connector.
4) Connect special tools as follows.
– Connect “BASE OF COLUMN” harness (1) of special tools (A) and (B) to “G347” connector.
– Connect “BASE OF COLUMN” harness of special tools (A) and (C) to “G376” connector.
Special tool
(A): 09932M75011
(B): 09932M78340
(C): 09932M77320
[G347], [G376]
(B), (C) 1
(A)
IMTA0A822009-02

Yes Go to Step 3.
No Go to Step 4.

• Resistance between “G11-19” and “G347-2” or “G376-1” terminals: 1 Ω or less
• Resistance between “G11-20” and “G347-1” or “G376-2” terminals: 1 Ω or less
Special tool
: 09932M76010
Is check result OK?

Is check result OK?
NOTE
DTC B1062-14
AENNTA0E8224020 (06(02)
B1062-14: Passenger Air Bag (1st stage) Circuit • Passenger air bag (inflator) module circuit
Shorted to Ground • SDM
shorted to ground.
Circuit Diagram
[G259] [G373] [G372]

1 A1 A3
YEL YEL G11-22
PPL PPL G11-21
A2 A4
:3
:4
:5
[C]
[A] [B]
1 2 3 4 5 6
[a] 1 2
7 8 #1 #2 9 10
1 2
11 12 13 14 15 16 17 18 19 20 21 22
IHD10P820023-02
DTC Troubleshooting
Yes Go to Step 2.

Channel

Special tool
: 09932M76010
Is check result OK?
No Go to Step 3.
Step 3 Instrument panel harness circuit check

Special tool
: 09932M76010
Is check result OK?

NOTE
DTC B1062-15
AENNTA0E8224021 (06(02)
B1062-15: Passenger Air Bag (1st stage) Circuit • Passenger air bag (inflator) module circuit
Circuit Diagram
[G259] [G373] [G372]

1 A1 A3
YEL YEL G11-22
PPL PPL G11-21
A2 A4
:3
:4
:5
[C]
[A] [B]
1 2 3 4 5 6
[a] 1 2
7 8 #1 #2 9 10
1 2
11 12 13 14 15 16 17 18 19 20 21 22
IHD10P820023-02
DTC Troubleshooting
Yes Go to Step 2.

Channel
Special tool
: 09932M76010
Is check result OK?
No Go to Step 3.


Special tool
: 09932M76010
Is check result OK?

NOTE
DTC B1062-1A
AENNTA0E8224022 (06(02)
B1062-1A: Passenger Air Bag (1st stage) Circuit Low Resistance • Passenger air bag (inflator) module circuit
Passenger air bag (inflator) module circuit resistance is less than • Passenger air bag (inflator) module
specified range.
• SDM
Circuit Diagram
[G259] [G373] [G372]

1 A1 A3
YEL YEL G11-22
PPL PPL G11-21
A2 A4
:3
:4
:5
[C]
[A] [B]
1 2 3 4 5 6
[a] 1 2
7 8 #1 #2 9 10
1 2
11 12 13 14 15 16 17 18 19 20 21 22
IHD10P820023-02
DTC Troubleshooting
Yes Go to Step 2.

Channel
3) Connect “STEERING WHEEL” harness (1) of special tool (C), (A) and (B) to “G259” connector.
Special tool
(A): 09932M76010
(B): 09932M78310
(C): 09932M75011
(B)
(A) [G259]
(C)
IMTA0A821008-02

Yes Go to Step 3.

Special tool
: 09932M76010
Is check result OK?
No Go to Step 4.

• Resistance between “G11-21” and “G11-22” terminal: infinity
Special tool
: 09932M76010
Is check result OK?

NOTE
DTC B1062-1B
AENNTA0E8224023 (06(02)
B1062-1B: Passenger Air Bag (1st stage) Circuit High Resistance • Passenger air bag (inflator) module circuit
Passenger air bag (inflator) module circuit resistance is more than • Passenger air bag (inflator) module
specified range.
• SDM
Circuit Diagram
[G259] [G373] [G372]

1 A1 A3
YEL YEL G11-22
PPL PPL G11-21
A2 A4
:3
:4
:5
[C]
[A] [B]
1 2 3 4 5 6
[a] 1 2
7 8 #1 #2 9 10
1 2
11 12 13 14 15 16 17 18 19 20 21 22
IHD10P820023-02
DTC Troubleshooting
Yes Go to Step 2.

Channel
4) Connect “STEERING WHEEL” harness (1) of special tool (C), (A) and (B) to “G259” connector.
Special tool
(A): 09932M76010
(B): 09932M78310
(C): 09932M75011
(B)
(A) [G259]
(C)
IMTA0A821008-02

Yes Go to Step 3.

Special tool
: 09932M76010
Is check result OK?
No Go to Step 4.

Special tool
: 09932M76010
Is check result OK?

NOTE
DTC B1064-14 / B1065-14

AENNTA0E8224024 (06(02)
B1064-14: Driver Seat Belt Pretensioner Circuit Shorted to Ground • Driver and/or 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 L04-18
A2
GRY L04-19
[L285]
2 A3
YEL L04-21
A4
PPL L04-20
:4
[A] [B]
[a]
1 2
1 2 3 4 5
6 7 #3 #4 8 9
10 11 12 13 14 15 16 17 18 19 20 21
IHD10P820012-04
[A]: “L283” and “L285” connector (View: [a]) A3: Passenger seat belt pretensioner operation 3. SDM
[B]: “L04” connector (View: [a]) A4: Passenger seat belt pretensioner operation 4. Shorting bar
A1: Driver seat belt pretensioner operation 1. Driver seat belt pretensioner
DTC Troubleshooting
Yes Go to Step 2.

2) Check for proper connection and disconnect connector as follows.
• “L283” or “L285” connector: (Seat Belt Pretensioner Removal and Installation): 8-Channel
• “L04” connector: (SDM Removal and Installation): 8-Channel
Special tool
: 09932M76010
Is check result OK?
NOTE
DTC B1064-15 / B1065-15

AENNTA0E8224025 (06(02)
B1064-15: Driver Seat Belt Pretensioner Circuit • Driver and/or passenger seat belt pretensioner circuit
Driver seat belt pretensioner circuit has been shorted to
power supply.
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 L04-18
A2
GRY L04-19
[L285]
2 A3
YEL L04-21
A4
PPL L04-20
:4
[A] [B]
[a]
1 2
1 2 3 4 5
6 7 #3 #4 8 9
10 11 12 13 14 15 16 17 18 19 20 21
IHD10P820012-04
DTC Troubleshooting
Yes Go to Step 2.

2) Check for proper connection and disconnect connector as follows.
• “L283” or “L285” connector: (Seat Belt Pretensioner Removal and Installation): 8-Channel
• “L04” connector: (SDM Removal and Installation): 8-Channel
Special tool
: 09932M76010
Is check result OK?
NOTE
DTC B1064-1A / B1065-1A

AENNTA0E8224026 (06(02)
B1064-1A: Driver Seat Belt Pretensioner Circuit Low Resistance • Driver and/or passenger seat belt
Driver seat belt pretensioner circuit resistance is less than specified range. pretensioner circuit
B1065-1A: Passenger Seat Belt Pretensioner Circuit Low Resistance • Driver and/or passenger seat belt
Passenger seat belt pretensioner circuit resistance is less than specified pretensioner
range.
• SDM
Circuit Diagram
[L283]
3
1 A1
YEL L04-18
A2
GRY L04-19
[L285]
2 A3
YEL L04-21
A4
PPL L04-20
:4
[A] [B]
[a]
1 2
1 2 3 4 5
6 7 #3 #4 8 9
10 11 12 13 14 15 16 17 18 19 20 21
IHD10P820012-04
DTC Troubleshooting
Yes Go to Step 2.

3) Connect “STEERING WHEEL” harness (1) of special tool (C), (A) and (B) to “L283” or “L285” connector.
Special tool
(A): 09932M76010
(B): 09932M78310
(C): 09932M75011
[L283 (L285)]
(B)
(A)
(C)
IMTA0A821009-02

Is DTC B1064-1A or DTC B1065-1A detected?
Yes Go to Step 3.
No Replace front seat belt pretensioner. (Front Seat Belt Assembly Removal and Installation) in
Section 8A

Special tool
: 09932M76010
Is check result OK?
NOTE
DTC B1064-1B / B1065-1B

AENNTA0E8224027 (06(02)

B1064-1B: Driver Seat Belt Pretensioner Circuit High Resistance • Driver and/or passenger seat belt
Driver seat belt pretensioner circuit resistance is more than specified pretensioner circuit
range. • Driver and/or passenger seat belt
B1065-1B: Passenger Seat Belt Pretensioner Circuit High Resistance pretensioner
Passenger seat belt pretensioner circuit resistance is more than specified
• SDM
range.
Circuit Diagram
[L283]
3
1 A1
YEL L04-18
A2
GRY L04-19
[L285]
2 A3
YEL L04-21
A4
PPL L04-20
:4
[A] [B]
[a]
1 2
1 2 3 4 5
6 7 #3 #4 8 9
10 11 12 13 14 15 16 17 18 19 20 21
IHD10P820012-04
DTC Troubleshooting
Yes Go to Step 2.

Special tool
(A): 09932M76010
(B): 09932M78310
(C): 09932M75011
[L283 (L285)]
(B)
(A)
(C)
IMTA0A821009-02

Is DTC B1064-1B or DTC B1065-1B detected?
Yes Go to Step 3.
No Replace front seat belt pretensioner. (Front Seat Belt Assembly Removal and Installation) in
Section 8A

Special tool
: 09932M76010
Is check result OK?
NOTE
DTC B1068-14 / B1069-14

AENNTA0E8224028 (06(02)

B1068-14: Side Air Bag Circuit Shorted to Ground (Driver Side) • Driver and/or passenger side-air bag
Driver side-air bag (inflator) module circuit has been shorted to ground. (inflator) module circuit
B1069-14: Side Air Bag Circuit Shorted to Ground (Passenger Side) • SDM
Passenger side-air bag (inflator) module circuit has been shorted to ground.
Circuit Diagram
7 [L288]
3
1 A1
BLU YEL L04-10

A2
BLK or GRN GRY L04-11
8 [L289]
2 A3
BLU YEL L04-13

A4
BLK or GRN PPL L04-12
:4
:5
:6
[A] [B] [C]
1 2 1 2
1 2 3 4 5
[a]
6 7 #3 #4 8 9
10 11 12 13 14 15 16 17 18 19 20 21
IK2R0P820009-04
[A]: Driver or passenger side-air bag (inflator) module connector (View: [a]) 2. Passenger side-air bag (inflator) module
[B]: “L288” or “L289” connector (View: [a]) 3. SDM
[C]: “L04” connector (View: [a]) 4. Shorting bar
A1: Driver side-air bag (inflator) module deployment signal output circuit 5. Floor harness
A2: Driver side-air bag (inflator) module deployment signal ground circuit 6. Seat harness
A3: Passenger side-air bag (inflator) module deployment signal output circuit 7. Driver side-air bag (inflator) module connector
A4: Passenger side-air bag (inflator) module deployment signal ground circuit 8. Passenger side-air bag (inflator) module connector
1. Driver side-air bag (inflator) module
DTC Troubleshooting
Yes Go to Step 2.
Step 2 Side-air bag (inflator) module circuit check

2) Disconnect driver or passenger side-air bag (inflator) module connector. (Side-Air Bag (Inflator) Module
Removal and Installation): 8-Channel
Special tool
: 09932M76010
Is check result OK?
No Go to Step 3.
Step 3 Floor harness circuit check

1) Disconnect “L288” or “L289” connector.
Special tool
: 09932M76010
Is check result OK?
Yes Replace seat harness.

NOTE
DTC B1068-15 / B1069-15

AENNTA0E8224029 (06(02)
B1068-15: Side Air Bag Circuit Shorted to Power Supply (Driver Side) • Driver and/or passenger side-
Driver side-air bag (inflator) module circuit has been shorted to power supply. air bag (inflator) module circuit
B1069-15: Side Air Bag Circuit Shorted to Power Supply (Passenger Side) • SDM
Passenger side-air bag (inflator) module circuit has been shorted to power supply.
Circuit Diagram
7 [L288]
3
1 A1
BLU YEL L04-10

A2
8 [L289]
2 A3
BLU YEL L04-13

A4
:4
:5
:6
[A] [B] [C]
1 2 1 2
1 2 3 4 5
[a]
6 7 #3 #4 8 9
10 11 12 13 14 15 16 17 18 19 20 21
IK2R0P820009-04
DTC Troubleshooting
Yes Go to Step 2.

Special tool
: 09932M76010
Is check result OK?

No Go to Step 3.

Special tool
: 09932M76010
Is check result OK?

NOTE
DTC B1068-1A / B1069-1A

AENNTA0E8224030 (06(02)
B1068-1A: Side Air Bag Circuit Low Resistance (Driver Side) • Driver and/or passenger side-air bag
Driver side-air bag (inflator) module circuit resistance is less than (inflator) module circuit
specified range. • Driver and/or passenger side-air bag
B1069-1A: Side Air Bag Circuit Low Resistance (Passenger Side) (inflator) module
Passenger side-air bag (inflator) module circuit resistance is less than
• SDM
specified range.
Circuit Diagram
7 [L288]
3
1 A1
BLU YEL L04-10

A2
8 [L289]
2 A3
BLU YEL L04-13

A4
:4
:5
:6
[A] [B] [C]
1 2 1 2
1 2 3 4 5
[a]
6 7 #3 #4 8 9
10 11 12 13 14 15 16 17 18 19 20 21
IK2R0P820009-04
DTC Troubleshooting
Yes Go to Step 2.
Step 2 Side-air bag (inflator) module check

3) Connect “STEERING WHEEL” harness (1) of special tool (C), (A) and (B) to driver or passenger side-air
bag (inflator) module connector (2).
Special tool
(A): 09932M76010
(B): 09932M78310
(C): 09932M75011
(A)
(B)
(C)
IHW00Q822011-01

Is DTC B1068-1A or DTC B1069-1A detected?
Yes Go to Step 3.
No Replace side-air bag (inflator) module. (Side-Air Bag (Inflator) Module Removal and Installation): 8-
Channel

Special tool
: 09932M76010
Is check result OK?
No Go to Step 4.

Special tool
: 09932M76010
Is check result OK?

NOTE
DTC B1068-1B / B1069-1B

AENNTA0E8224031 (06(02)
B1068-1B: Side Air Bag Circuit High Resistance (Driver Side) • Driver and/or passenger side-air bag
Driver side-air bag (inflator) module circuit resistance is more than (inflator) module circuit
specified range. • Driver and/or passenger side-air bag
B1069-1B: Side Air Bag Circuit High Resistance (Passenger Side) (inflator) module
Passenger side-air bag (inflator) module circuit resistance is more than
• SDM
specified range.
Circuit Diagram
7 [L288]
3
1 A1
BLU YEL L04-10

A2
8 [L289]
2 A3
BLU YEL L04-13

A4
:4
:5
:6
[A] [B] [C]
1 2 1 2
1 2 3 4 5
[a]
6 7 #3 #4 8 9
10 11 12 13 14 15 16 17 18 19 20 21
IK2R0P820009-04
DTC Troubleshooting
Yes Go to Step 2.
Step 2 Side-air bag (inflator) module check

2) Check for proper connection to driver or passenger side-air bag (inflator) module connector.
4) Connect “STEERING WHEEL” harness (1) of special tool (C), (A) and (B) to driver or passenger side-air
bag (inflator) module connector.
Special tool
(A): 09932M76010
(B): 09932M78310
(C): 09932M75011
(A)
(B)
(C)
IHW00Q822011-01

Is DTC B1068-1B or DTC B1069-1B detected?
Yes Go to Step 3.
No Replace side-air bag (inflator) module. (Side-Air Bag (Inflator) Module Removal and Installation): 8-
Channel

• Resistance between “L04-10” and driver side-air bag (inflator) module connector “1” terminals (DTC
B1068-1B): 1 Ω or less
• Resistance between “L04-11” and driver side-air bag (inflator) module connector “2” terminals (DTC
B1068-1B): 1 Ω or less
• Resistance between “L04-13” and passenger side-air bag (inflator) module connector “1” terminals
(DTC B1069-1B): 1 Ω or less
• Resistance between “L04-12” and passenger side-air bag (inflator) module connector “2” terminals
(DTC B1069-1B): 1 Ω or less
Special tool
: 09932M76010
Is check result OK?
No Go to Step 4.

Special tool
: 09932M76010
Is check result OK?

NOTE
DTC B106C-14 / B106D-14

AENNTA0E8224032 (06(02)
B106C-14: Curtain Air Bag Circuit Shorted to Ground • Driver and/or passenger curtain air bag (inflator)
(Driver Side) module circuit
Driver curtain air bag (inflator) module circuit has been • SDM
shorted to ground.
B106D-14: Curtain Air Bag Circuit Shorted to Ground
(Passenger Side)
Passenger curtain air bag (inflator) module circuit has
been shorted to ground.
Circuit Diagram
[L290]
3
1 A1
YEL L04-4
A2
GRY L04-3
[L291]
2 A3
YEL L04-1
A4
PPL L04-2
:4
:5
[A] [B]
1 2
1 2 3 4 5
[a]
6 7 #3 #4 8 9
10 11 12 13 14 15 16 17 18 19 20 21
IK2R0P820010-06
[A]: “L290” and “L291” connector (View: [a]) A3: Passenger curtain air bag (inflator) module 3. SDM
[B]: “L04” connector (View: [a]) A4: Passenger curtain air bag (inflator) module 4. Shorting bar
A1: Driver curtain air bag (inflator) module 1. Driver curtain air bag (inflator) module 5. Floor harness
A2: Driver curtain air bag (inflator) module 2. Passenger curtain air bag (inflator) module
DTC Troubleshooting
Yes Go to Step 2.

2) Disconnect “L290” or “L291” connector. (Curtain Air Bag (Inflator) Module Removal and Installation): 8-
Channel
• Resistance between each of “L04-4” and “L04-3” terminals and ground (DTC B106C-14): infinity
• Resistance between each of “L04-1” and “L04-2” terminals and ground (DTC B106D-14): infinity
Special tool
: 09932M76010
Is check result OK?
NOTE
DTC B106C-15 / B106D-15

AENNTA0E8224033 (06(02)
B106C-15: Curtain Air Bag Circuit Shorted to Power • Driver and/or passenger curtain air bag (inflator)
Supply (Driver Side) module circuit
Driver curtain air bag (inflator) module circuit has been • SDM
B106D-15: Curtain Air Bag Circuit Shorted to Power
Supply (Passenger Side)
Passenger curtain air bag (inflator) module circuit has
been shorted to power supply.
Circuit Diagram
[L290]
3
1 A1
YEL L04-4
A2
GRY L04-3
[L291]
2 A3
YEL L04-1
A4
PPL L04-2
:4
:5
[A] [B]
1 2
1 2 3 4 5
[a]
6 7 #3 #4 8 9
10 11 12 13 14 15 16 17 18 19 20 21
IK2R0P820010-06
DTC Troubleshooting
Yes Go to Step 2.

Channel
• Voltage between each of “A1” and “A2” circuits and ground (DTC B106C-15): 0 V
• Voltage between each of “A3” and “A4” circuits and ground (DTC B106D-15): 0 V
Special tool
: 09932M76010
Is check result OK?
NOTE
DTC B106C-1A / B106D-1A

AENNTA0E8224034 (06(02)
B106C-1A: Curtain Air Bag Circuit Low Resistance (Driver Side) • Driver and/or passenger curtain air bag
Driver curtain air bag (inflator) module circuit resistance is less than (inflator) module circuit
specified range. • Driver and/or passenger curtain air bag
B106D-1A: Curtain Air Bag Circuit Low Resistance (Passenger Side) (inflator) module
Passenger curtain air bag (inflator) module circuit resistance is less than
• SDM
specified range.
Circuit Diagram
[L290]
3
1 A1
YEL L04-4
A2
GRY L04-3
[L291]
2 A3
YEL L04-1
A4
PPL L04-2
:4
:5
[A] [B]
1 2
1 2 3 4 5
[a]
6 7 #3 #4 8 9
10 11 12 13 14 15 16 17 18 19 20 21
IK2R0P820010-06
DTC Troubleshooting
Yes Go to Step 2.
Step 2 Curtain air bag (inflator) module Check

Channel
Special tool
(A): 09932M76010
(B): 09932M78310
(C): 09932M75011
[L290], [L291]
(A)
(B)
(C)
IMTA0A822010-02

Is DTC B106C-1A or DTC B106D-1A detected?
Yes Go to Step 3.
No Replace curtain air bag (inflator) module. (Curtain Air Bag (Inflator) Module Removal and

• Resistance between “L04-4” and “L04-3” terminals (DTC B106C-1A): infinity
• Resistance between “L04-1” and “L04-2” terminals (DTC B106D-1A): infinity
Special tool
: 09932M76010
Is check result OK?
NOTE
DTC B106C-1B / B106D-1B

AENNTA0E8224035 (06(02)

B106C-1B: Curtain Air Bag Circuit High Resistance • Driver and/or passenger curtain air bag (inflator)
(Driver Side) module circuit
Driver curtain air bag (inflator) module circuit resistance is • Driver and/or passenger curtain air bag (inflator)
more than specified range. module
B106D-1B: Curtain Air Bag Circuit High Resistance
• SDM
(Passenger Side)
Passenger curtain air bag (inflator) module circuit
resistance is more than specified range.
Circuit Diagram
[L290]
3
1 A1
YEL L04-4
A2
GRY L04-3
[L291]
2 A3
YEL L04-1
A4
PPL L04-2
:4
:5
[A] [B]
1 2
1 2 3 4 5
[a]
6 7 #3 #4 8 9
10 11 12 13 14 15 16 17 18 19 20 21
IK2R0P820010-06
DTC Troubleshooting
Yes Go to Step 2.
Step 2 Curtain air bag (inflator) module Check

Channel
Special tool
(A): 09932M76010
(B): 09932M78310
(C): 09932M75011
[L290], [L291]
(A)
(B)
(C)
IMTA0A822010-02

Is DTC B106C-1B or DTC B106D-1B detected?
Yes Go to Step 3.
No Replace curtain air bag (inflator) module. (Curtain Air Bag (Inflator) Module Removal and

• Resistance of “A1” and “A2” circuits (DTC B106C-1B): 1 Ω or less
• Resistance of “A3” and “A4” circuits (DTC B106D-1B): 1 Ω or less
Special tool
: 09932M76010
Is check result OK?
NOTE
DTC B1090-01 / B1090-95

AENNTA0E8224036 (06(02)
B1090-01: Driver Forward Impact sensor No Response • Forward impact sensor
Forward impact sensor has communicated with no • Forward impact sensor circuit
response or inconsistent ID code.
• SDM
B1090-95: Driver Forward Impact Sensor
Communication Data Inconsistent
Forward impact sensor has communicated with
DTC Troubleshooting
Yes Go to Step 2.
Step 2 DTC check

Yes Go to applicable DTC diagnosis flow.

No Go to Step 3.

Is DTC detected?
No End.
NOTE
DTC B1090-87
AENNTA0E8224037 (06(02)
B1090-87: Driver Forward Impact Sensor Communication Data Invalid • Forward impact sensor
Forward impact sensor has communicated with invalid data. • Forward impact sensor circuit
• SDM
Circuit Diagram
[E40] [E384] [G336] 2

A1 A3
1
A2 A4
GRN GRN G11-14
:3
:4
:5
[B] [C] [D]
[A]
1 2 3 4 5 6
6 5 4 3 2 1 1 2 3 4 5 6
[a] 7 8 #1 #2 9 10
1 2 12 11 10 9 8 7 7 8 9 10 11 12
18 17 16 15 14 13 13 1415 16 17 18 11 12 13 14 15 16 17 18 19 20 21 22
IMTA0A822011-01
[A]: “E40” connector (View: [a]) A2: Forward impact sensor signal ground circuit 3. Shorting bar
[B]: “E384” connector (View: [a]) A3: Forward impact sensor signal output circuit 4. Instrument panel harness
[C]: “G336” connector (View: [a]) A4: Forward impact sensor signal ground circuit 5. Main harness
[D]: “G11” connector (View: [a]) 1. Forward impact sensor
A1: Forward impact sensor signal output circuit 2. SDM
DTC Troubleshooting
Yes Go to Step 2.

Special tool
: 09932M76010
Is check result OK?
Yes Go to Step 3.

Special tool
: 09932M76010
Is check result OK?
Yes Go to Step 4.

Special tool
: 09932M76010
Is check result OK?
Yes Go to Step 5.

Special tool
: 09932M76010
Is check result OK?
Yes Go to Step 6.

2) Disconnect “E40” connector. (Forward Impact Sensor Removal and Installation): 8-Channel
Special tool
: 09932M76010
Is check result OK?
Yes Go to Step 7.

• Resistance between “E40-1” and “E40-2” terminals: infinity
Special tool
: 09932M76010
Is check result OK?
Yes Go to Step 8.

Special tool
: 09932M76010
Is check result OK?
Yes Go to Step 9.

Special tool
: 09932M76010
Is check result OK?
Yes Go to Step 10.


Is DTC detected?
No End.
NOTE
DTC B1093-01 / B1093-95 / B1094-01 / B1094-95

AENNTA0E8224038 (06(02)

DTC detection condition Trouble area
B1093-01: Side Impact Sensor No Response (Driver Side) • Driver and/or passenger front
Driver front side-impact pressure sensor has communicated with no response. side-impact pressure sensor
B1093-95: Side Impact Sensor Communication Data Inconsistent (Driver circuit
Side) • Driver and/or passenger front
Driver front side-impact pressure sensor has communicated with inconsistent ID side-impact pressure sensor
code.
• SDM
B1094-01: Side Impact Sensor No Response (Passenger Side)
Passenger front side-impact pressure sensor has communicated with no
response.
B1094-95: Side Impact Sensor Communication Data Inconsistent
(Passenger Side)
Passenger front side-impact pressure sensor has communicated with
Circuit Diagram
[J13] [J213] [G361]

3
1 A1 A5

A2 A6
GRN GRN G11-16
[J14] [J212] [G339]
2 A3 A7

A4 A8
:4
:5
[B] [C] [D]

[A]
1 2 3 4 5 6 1 2 3 4 5 6
[a] 6 5 4 3 2 1
1 2 7 8 9 10 11 12 12 11 10 9 8 7 7 8 #1 #2 9 10
13 1415 16 17 18 18 17 16 15 14 13 11 12 13 14 15 16 17 18 19 20 21 22
IMTA0A822012-03
[A]: “J13” and “J14” connector (View: [a]) A3: Passenger front side-impact pressure 1. Driver front side-impact pressure sensor
sensor signal output circuit
[B]: “J213” and “J212” connector (View: [a]) A4: Passenger front side-impact pressure 2. Passenger front side-impact pressure
sensor signal ground circuit sensor
[C]: “G361” and “G339” connector (View: [a]) A5: Driver front side-impact pressure sensor 3. SDM
[D]: “G11” connector (View: [a]) A6: Driver front side-impact pressure sensor 4. Instrument panel harness
A1: Driver front side-impact pressure sensor A7: Passenger front side-impact pressure 5. Front door wire
signal output circuit sensor signal output circuit
A2: Driver front side-impact pressure sensor A8: Passenger front side-impact pressure
signal ground circuit sensor signal ground circuit
DTC Troubleshooting
Yes Go to Step 2.
Step 2 DTC check

1) Check if any of the following DTCs is detected. (DTC Check): 8-Channel
• B1093-87 (DTC B1093-01 or DTC B1093-95)
• B1094-87 (DTC B1094-01 or DTC B1094-95)
Is relevant DTC detected?
Yes Go to applicable DTC diagnosis flow.

No Go to Step 3.
Step 3 Front side-impact pressure sensor check

2) Replace side-impact pressure sensor. (Side-Impact Pressure Sensor Removal and Installation): 8-
Channel
Is DTC detected?
No End.
NOTE
DTC B1093-87 / B1094-87

AENNTA0E8224039 (06(02)
B1093-87: Side Impact Sensor Communication Data • Driver and/or passenger front side-impact pressure
Invalid (Driver Side) sensor circuit
Driver front side-impact pressure sensor has communicated • Driver and/or passenger front side-impact pressure
with invalid data. sensor
B1094-87: Side Impact Sensor Communication Data
• SDM
Invalid (Passenger Side)
Passenger front side-impact pressure sensor has
communicated with invalid data.
Circuit Diagram
[J13] [J213] [G361]

3
1 A1 A5

A2 A6
GRN GRN G11-16
[J14] [J212] [G339]
2 A3 A7

A4 A8
:4
:5
[B] [C] [D]

[A]
1 2 3 4 5 6 1 2 3 4 5 6
[a] 6 5 4 3 2 1
1 2 7 8 9 10 11 12 12 11 10 9 8 7 7 8 #1 #2 9 10
13 1415 16 17 18 18 17 16 15 14 13 11 12 13 14 15 16 17 18 19 20 21 22
IMTA0A822012-03
[A]: “J13” and “J14” connector (View: [a]) A3: Passenger front side-impact pressure 1. Driver front side-impact pressure sensor
sensor signal output circuit
[B]: “J213” and “J212” connector (View: [a]) A4: Passenger front side-impact pressure 2. Passenger front side-impact pressure
sensor signal ground circuit sensor
[C]: “G361” and “G339” connector (View: [a]) A5: Driver front side-impact pressure sensor 3. SDM
[D]: “G11” connector (View: [a]) A6: Driver front side-impact pressure sensor 4. Instrument panel harness
A1: Driver front side-impact pressure sensor A7: Passenger front side-impact pressure 5. Front door wire
signal output circuit sensor signal output circuit
A2: Driver front side-impact pressure sensor A8: Passenger front side-impact pressure
signal ground circuit sensor signal ground circuit
DTC Troubleshooting
Yes Go to Step 2.

3) Disconnect “G361” or “G339” connector.
• Resistance between “G11-15” and “G361-9” terminals (DTC B1093-87): 1 Ω or less
Special tool
: 09932M76010
Is check result OK?

Yes Go to Step 3.

• Resistance between “G11-15” and “G11-16” terminals (DTC B1093-87): infinity
• Resistance between “G11-17” and “G11-18” terminals (DTC B1094-87): infinity
Special tool
: 09932M76010
Is check result OK?
Yes Go to Step 4.

Special tool
: 09932M76010
Is check result OK?
Yes Go to Step 5.

Special tool
: 09932M76010
Is check result OK?
Yes Go to Step 6.
Step 6 Front door wire circuit check

2) Disconnect “J13” or “J14” connector. (Side-Impact Pressure Sensor Removal and Installation): 8-
Channel
• Resistance between “J13-2” and “J213-9” terminals (DTC B1093-87): 1 Ω or less
Special tool
: 09932M76010
Is check result OK?

Yes Go to Step 7.
No Replace defective wire.

• Resistance between “J13-1” and “J13-2” terminals (DTC B1093-87): infinity
• Resistance between “J14-1” and “J14-2” terminals (DTC B1094-87): infinity
Special tool
: 09932M76010
Is check result OK?
Yes Go to Step 8.

• Resistance between each of “A3” and “A4” circuits and ground (DTCB1094-87): infinity
Special tool
: 09932M76010
Is check result OK?
Yes Go to Step 9.

Special tool
: 09932M76010
Is check result OK?
Yes Go to Step 10.

Step 10 Front side-impact pressure sensor check

2) Replace front side-impact pressure sensor. (Side-Impact Pressure Sensor Removal and Installation): 8-
Channel
Is DTC detected?
No End.
DTC B1095-01 / B1095-95 / B1096-01 / B1096-95

AENNTA0E8224040 (06(02)

B1095-01: Side Rear Impact Sensor No Response (Driver Side) • Driver and/or passenger rear
Driver rear side-impact G sensor has communicated with no response. side-impact G sensor circuit
B1095-95: Side Rear Impact Sensor Communication Data Inconsistent (Driver • Driver and/or passenger rear
Side) side-impact G sensor
Driver rear side-impact G sensor has communicated with inconsistent ID code.
• SDM
B1096-01: Side Rear Impact Sensor No Response (Passenger Side)
Passenger rear side-impact G sensor has communicated with no response.
B1096-95: Side Rear Impact Sensor Communication Data Inconsistent
(Passenger Side)
Passenger rear side-impact G sensor has communicated with inconsistent ID code.
DTC Troubleshooting
Yes Go to Step 2.
Step 2 DTC check

1) Check if any of the following DTCs is detected. (DTC Check): 8-Channel
• B1095-87 (DTC B1095-01 or DTC B1095-95)
• B1096-87 (DTC B1096-01 or DTC B1096-95)
Is relevant DTC detected?

No Go to Step 3.
Step 3 Rear side-impact G sensor check

2) Replace rear side-impact G sensor. (Side-Impact G Sensor Removal and Installation): 8-Channel
Is DTC detected?
No End.
NOTE
DTC B1095-87 / B1096-87

AENNTA0E8224041 (06(02)

B1095-87: Side Rear Impact Sensor Communication Data Invalid (Driver Side) • Driver and/or passenger rear
Driver rear side-impact G sensor has communicated with invalid data. side-impact G sensor circuit
B1096-87: Side Rear Impact Sensor Communication Data Invalid (Passenger • Driver and/or passenger rear
Side) side-impact G sensor
Passenger rear side-impact G sensor has communicated with invalid data.
• SDM
Circuit Diagram
3
1 A1
L43-2 YEL/BLK L04-14

A2
L43-1 GRN L04-15
2 A3
L44-2 YEL/BLK L04-16

A4
L44-1 LT BLU L04-17
[B]
[A]
1 2 3 4 5
[a] 1 2
6 7 #3 #4 8 9
10 11 12 13 14 15 16 17 18 19 20 21
IMTA0A822013-02
[A]: “L43” and “L44” connector (View: [a]) A2: Driver rear side-impact G sensor signal 1. Driver rear side-impact G sensor
ground circuit
[B]: “L04” connector (View: [a]) A3: Passenger rear side-impact G sensor signal 2. Passenger rear side-impact G sensor
output circuit
A1: Driver rear side-impact G sensor signal A4: Passenger rear side-impact G sensor signal 3. SDM
output circuit ground circuit
DTC Troubleshooting
Yes Go to Step 2.
Step 2 Floor harness open check

3) Disconnect “L43” or “L44” connector. (Side-Impact G Sensor Removal and Installation): 8-Channel
• Resistance between “L04-14” and “L43-2” terminals (DTC B1095-87): 1 Ω or less
Special tool
: 09932M76010
Is check result OK?
Yes Go to Step 3.

• Resistance between “L04-14” and “L04-15” terminals (DTC B1095-87): infinity
• Resistance between “L04-16” and “L04-17” terminals (DTC B1096-87): infinity
Special tool
: 09932M76010
Is check result OK?
Yes Go to Step 4.

Special tool
: 09932M76010
Is check result OK?
Yes Go to Step 5.

Special tool
: 09932M76010
Is check result OK?
Yes Go to Step 6.
Step 6 Rear side-impact G sensor check

2) Replace rear side-impact G sensor. (Side-Impact G Sensor Removal and Installation): 8-Channel
Is DTC detected?
No End.
NOTE
DTC U0073-88
AENNTA0E8224042 (06(02)
SDM Power Supply and Ground Circuit Check

AENNTA0E8224043 (06(01)
Circuit Diagram
4 3
A1
2
1 RED G11-1
BLK G11-6
A2
[A]
[a] 1 2 3 4 5 6
7 8 #1 #2 9 10
11 12 13 14 15 16 17 18 19 20 21 22
IHD10P820021-03

Troubleshooting
Step 1 Battery voltage check

1) Check battery voltage.
Yes Go to Step 2.
No Check charging system and repair it. (Generator Test) in Section 1J
Step 2 SDM connection check

Is it connected securely?
Yes Go to Step 3.
If OK, substitute a known-good SDM and recheck connection. (SDM Removal and Installation): 8-
Channel
Step 3 Fuse check

2) Check “A/B” fuse.
Is “A/B” fuse in good condition?

Yes Go to Step 4.
No Replace instrument panel harness and then replace “A/B” fuse.
Step 4 SDM power supply circuit check

Special tool
: 09932M76010
Yes Go to Step 5.
Step 5 Ground circuit check

Special tool
: 09932M76010
Yes SDM power supply circuit and ground circuit are in good condition.
Contact Coil and Its Circuit Check

AENNTA0E8224044 (06(01)
Circuit Diagram
3
[A]:[S172] [A]:[G347]
[S121] [B]:[S175] [B]:[G376]
1 2 A1
YEL G11-19
GRY G11-20
A2
:4
[F]
[C] [D]
1 2 3 4 5 6
[a]
1 2 1 2 7 8 #1 #2 9 10
11 12 13 14 15 16 17 18 19 20 21 22
[E]
1 2 3 4
IMTA0A822008-05
Troubleshooting

Special tool
: 09932M76010
Is check result OK?
Yes Go to Step 2.
No Check for defective wire harness. If check result is OK, replace contact coil assembly. (Contact Coil
Step 2 Contact coil circuit (driver air bag (inflator) module circuit) check
1) Remove contact coil assembly. (Contact Coil Assembly Removal and Installation) in Section 6B
– Measure resistance between “S121-1” and “S172-2” terminals: 1 Ω or less
Special tool
: 09932M76010
(A)
[S121]
[S172] [S175]
1 2
1 2 1 2 3 4
IMTA0A822014-01
Is check result OK?
Yes Go to Step 3.
Step 3 Contact coil circuit (horn circuit) check

• Without cruise control system:
• With cruise control system:
Special tool
(A): 09932M76010
[S61]
1 2 3 4 5 6
[S62]
7 8 9 10 11 12
1 2 3 4 5 6
(A)
[S173]
[S171]
7 8 9 10 11 12
1 2 3 4 5 6 1 2 3 4 5 6
IMTA0A822015-01
Is check result OK?
Yes Go to Step 4.

1) Measure resistance between each terminal of contact coil and other terminals.
Is each measured resistance infinite?
Yes Contact coil and its circuit are in good condition.

Repair and Inspection Required after Accident harness and the areas where they are
AENNTA0E8224045 (06(01) mounted, even if the air bag system was
! WARNING not activated. Any components deformed
or otherwise damaged must be replaced.
Failure to properly check and repair a vehicle
that has been involved in an accident can • Never use air bag system parts from
result in unsafe operating conditions. another vehicle model.
• For any vehicle that was involved in an • Do not repair the following parts.
accident, check all air bag system Replace any of them that are found faulty.
components including the electrical
– Driver / passenger air bag (inflator) – Check for length, damage and bend according to
modules “Steering Column Inspection” in Section 6B.
– Driver / passenger side-air bag (inflator) • Steering column bracket
modules – Check for damage and bend according to “Steering
– Driver / passenger curtain air bag Column Inspection” in Section 6B.
(inflator) modules • Steering wheel and driver air bag (inflator) module
– Driver / passenger seat belt – Check air bag (inflator) module for damage and
pretensioners installation condition.
– Forward impact sensor – Check trim cover (pad surface) for crack.
– Driver / passenger front side-impact – Check wire harness and connector for damage and
pressure sensors tightness.
– Driver / passenger rear side-impact G
sensors
– SDM
– Contact coil
– Air bag wire harnesses (in main
harness, instrument panel harness and
floor harness) and seat harness
• Perform all repairs in a manner which
assures that the vehicle’s original
configuration is restored.
IMTA0A821014-01
to provide its original performance. • Contact coil assembly
Never use an SDM that has been involved – Check wire harness and connectors for damage
in an air bag deployment accident. and tightness.
– Check contact coil case for damage.
Accident with Deployment / Activation – Component – Check contact coil circuit referring to “Contact Coil
Replacement and Its Circuit Check”: 8-Channel.
Replace the following components when driver and
passenger air bags are deployed.
• Driver and passenger air bag (inflator) modules
• Driver / passenger seat belt pretensioners
• SDM
• Instrument panel
Replace the following components when side-air bag
and curtain air bag are deployed.
• Side-air bag (inflator) module
• Driver / passenger seat belt pretensioners
I9P60A820041-01
• Curtain air bag (inflator) module
• Instrument panel member and reinforcement
• Driver / passenger front side-impact pressure sensor
– Check for distortion, bend, crack and other
• Driver / passenger rear side-impact G sensor damage.
• SDM – Check instrument panel for crack and deformation.
• Passenger air bag (inflator) module
Accident with or without Deployment / Activation –
Component Inspections – Check for dents, crack, damage and installation
Check the following air bag system components after condition.
any crash, whether air bag system was activated or not. – Check harness and connector for damage and
If any faulty condition is found in the following checks, tightness.
replace faulty component.
• Steering column and steering lower shaft
2 6
4
7 5
4
3
IMTA0A822003-02
1. Main harness 5. Grounding point

IMTA0A821013-01 2. Instrument panel harness 6. Passenger air bag (inflator)
module harness
• SDM 3. Floor harness 7. Side-air bag (inflator) module
– Check for external damage such as deformation, harness
4. Front door wire
scratch, crack and peeled paint.
– Check SDM for deformation which prevents its
proper installation (gap between SDM and SDM
plate, etc.). – Check sensor (1) and lamp support right brace (2)
for damage, bend and rust.
– Check connector or lead wire of SDM for scorch,
melt or damage. – Check connector (3) and lead wire (4) of forward
impact sensor for scorch, melt and damage.
– Check SDM connector and terminals for tightness.
– Check DTC and follow the corresponding
diagnostic flow if any DTC is found.
IGSB0A822097-01
3
• Air bag wire harnesses and connectors
– Check for damage, deformation and poor 4
connections.
Refer to “Intermittent Connection and Poor Contact
Inspection” in Section 00. IMTA0A821015-01
– Check wire harnesses for tightness. • Front side-impact pressure sensors

– Check sensor (1) and front door panel (2) for dents,
crack, deformation and rust.
– Check sensor connectors (sensor side and harness
side) (3) or sensor lead wire (4) for damage, crack,
scorch and melt.
• Seat belt pretensioner

1
condition.
tightness.
IDK80P821005-01
• Seat belts and mounting points

2
– Refer to “Front Seat Belt Components” in Section
8A.
2
4 • “AIR BAG” warning light
– Perform “Air Bag Diagnostic System Check”: 8-
IMTA0A822016-01
Channel after vehicle is completely repaired.
• Rear side-impact G sensors • Side-air bag (inflator) modules
– Check sensor (1) and rear quarter panel (2) for – Check for dents, crack, damage or installation
dents, crack, deformation and rust. condition.
– Check sensor connectors (sensor side and harness – Check seatback trim for crack or deformation.
side) (3) or sensor lead wire (4) for damage, crack, – Check wire harness and connector for damage or
scorch and melt. tightness.
• Curtain air bag (inflator) modules
– Check for dents, crack, damage or installation
condition.
1 – Check wire harness and connector for damage or
tightness.
– Check roof lining for crack or deformation.
2
IMTA0A822017-01
Repair Instructions
Disabling Air Bag System
AENNTA0E8226001 (08(03)
Refer to “Disabling Air Bag System”: 4-Channel.
Enabling Air Bag System Refer to “Enabling Air Bag System”: 4-Channel.
AENNTA0E8226002 (08(03)
Release of Shorting Bar

AENNTA0E8226003 (08(03)
Release shorting bar in SDM connector inserting release tool.
NOTE
• To prevent accidental deployment of air bag 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): 09932M75110
[G11]
(A) [L04] (A)

IHD10P820030-01
SDM Removal and Installation • Check DTC B1032-00, B1033-00, B1034-00, B1035-
AENNTA0E8226004 (08(01) 00, B1036-00 or B1037-00 is stored in SDM.
Reference: “SDM Inspection”: 8-Channel
Refer to “SDM Removal and Installation”: 4-Channel.
Driver Air Bag (Inflator) Module Removal and
Installation
SDM Inspection AENNTA0E8226006 (08(01)
AENNTA0E8226005 (08(03)
Reference: “Driver Air Bag (Inflator) Module Inspection”:
Reference: “SDM Removal and Installation”: 8-Channel
8-Channel
NOTICE Refer to “Driver Air Bag (Inflator) Module Removal and
Installation”: 4-Channel.
The SDM may not function properly if you do
not handle it carefully.
Driver Air Bag (Inflator) Module Inspection
• Do not connect any type of tester to the AENNTA0E8226007 (08(03)
SDM. Reference: “Driver Air Bag (Inflator) Module Removal
and Installation”: 8-Channel
Refer to “Driver Air Bag (Inflator) Module Inspection”: 4-
Channel.
Passenger Air Bag (Inflator) Module Removal

and Installation
AENNTA0E8226008 (08(01)
Inspection”: 8-Channel
Refer to “Passenger Air Bag (Inflator) Module Removal
and Installation”: 4-Channel.
I9W10P821002-01
Passenger Air Bag (Inflator) Module Inspection
• Never repair or disassemble the SDM. AENNTA0E8226009 (08(03)
• Replace the SDM if it has been dropped.
Removal and Installation”: 8-Channel
If any faulty condition is found in the following checks, Refer to “Passenger Air Bag (Inflator) Module
replace the SDM with new one. Inspection”: 4-Channel.
• Check air bag module is deployed or pretensioner is
activated. Seat Belt Pretensioner Components
AENNTA0E8226010 (12(01)
• Check SDM for dents, crack or deformation. Refer to “Front Seat Belt Components” in Section 8A.
• Check SDM connector for damage, crack or lock
mechanism. Seat Belt Pretensioner Removal and Installation
AENNTA0E8226011 (08(01)
• Check SDM terminal for bend, corrosion or rust.
Reference: “Seat Belt Pretensioner Inspection”: 8- “Precautions for Disposal of Air Bag and
Channel Seat Belt Pretensioner”: 8-Channel and
Refer to (Front Seat Belt Assembly Removal and follow all of the instructions provided.
Installation) in Section 8A.
NOTICE
Seat Belt Pretensioner Inspection An air bag (inflator) module that has been
AENNTA0E8226012 (08(03)
Reference: “Seat Belt Pretensioner Removal and dropped may not operate correctly.
Installation”: 8-Channel Never use an air bag (inflator) module that
Refer to “Seat Belt Pretensioner Inspection”: 4-Channel. has been dropped. Replace the module with a
new one.
Side-Air Bag (Inflator) Module Components
AENNTA0E8226013 (12(01) NOTE
after Accident”: 8-Channel before replacing a
deployed air bag.
1
Removal
(a) 1) Disable air bag system. (Disabling Air Bag System):
8-Channel
2) Release hook (1) at the bottom and open slide
fasteners (3) to pull up front seatback trim (2).
2 3
IMTA0A822018-01
1. Front seat
2. Side-air bag (inflator) module
: 5.5 Nm (0.56 kgf-m, 4.0 lbf-ft) 1 1
Side-Air Bag (Inflator) Module Removal and ILKC0P820040-01
Installation 3) Remove side-air bag (inflator) module bracket nut

AENNTA0E8226014 (08(01) (1), and then remove side-air bag (inflator) module
outer bracket (2) and inner bracket (3).
Reference: “Side-Air Bag (Inflator) Module
Components”: 8-Channel
! WARNING
performing service on the side-air bag 3
(inflator) module can result in personal injury
1
a collision.
• Never disassemble or repair an air bag 2
condition is found, replace the module
with a new one.
• Carefully read “Precautions for Air Bag IHD10Q820012-01
System Service”: 8-Channel, “Precautions 4) Remove side-air bag (inflator) module nuts (1) and
for Handling and Storage of Air Bag remove side-air bag (inflator) module (2).
System Components”: 8-Channel and
1 1, (a)
2
IGW00P822069-01 IGW00P822071-01
5) Disconnect side-air bag (inflator) module connector • Tighten side-air bag (inflator) module bracket nut (1)
(1) as shown in figure. to specified torque.
a) Release lock button (2) by pulling it in arrow Tightening torque
direction “1”. Side-air bag (inflator) module bracket nut (a): 5.5
b) Disconnect side-air bag (inflator) module N·m (0.56 kgf-m, 4.0 lbf-ft)
connector with lock released by pulling it in arrow
direction “2”.
1
1, (a)
2 “1” “2”
IGW00P822070-01
• Enable air bag system. (Enabling Air Bag System): 8-

Channel
IHD10Q820008-01
Side-Air Bag (Inflator) Module Inspection
Installation AENNTA0E8226015 (08(03)
Reference: “Side-Air Bag (Inflator) Module Removal and
Reference: “Side-Air Bag (Inflator) Module Inspection”:
8-Channel
Reverse removal procedure noting the following points. ! WARNING
• Lock connector for side-air bag (inflator) module
securely. Failure to take proper precautions when
checking the side-air bag (inflator) module
• Tighten side-air bag (inflator) module nuts (1) to
can result in personal injury due to
specified torque.
accidental deployment of the air bag.
Tightening torque Never measure the resistance of the air bag
Side-air bag (inflator) module nut (a): 5.5 N·m ( (inflator) module.
0.56 kgf-m, 4.0 lbf-ft)
IFJA0P822037-01
• Air bag (inflator) module is damaged or a strong

Check air bag (inflator) module and if any of the following impact was applied to it.
conditions is found, replace air bag (inflator) module with • Connector is damaged.
new one. • Air bag (inflator) module bracket is bent or deformed.
• Air bag is deployed.
Curtain Air Bag (Inflator) Module Components

AENNTA0E8226016 (12(01)
1
(a)
(a)
IMTA0A822019-01
1. Curtain air bag (inflator) module : 11 Nm (1.1 kgf-m, 8.5 lbf-ft)
2. Roof side rail rear pad
Curtain Air Bag (Inflator) Module Removal and • Carefully read “Precautions for Air Bag
Installation System Service”: 8-Channel, “Precautions
AENNTA0E8226017 (08(01) for Handling and Storage of Air Bag
Reference: “Precautions for Electrical System Work” System Components”: 8-Channel and
Reference: “Curtain Air Bag (Inflator) Module “Precautions for Disposal of Air Bag and
Components”: 8-Channel Seat Belt Pretensioner”: 8-Channel and
! WARNING
• Do not install curtain air bag (inflator)
Failure to take proper precautions when module while twisted or bent. Otherwise,
performing service on the curtain air bag curtain air bag (inflator) module may not
(inflator) module can result in personal injury deploy and injury may result.
a collision. NOTICE
• Never disassemble or repair an air bag
dropped may not operate correctly.
condition is found, replace the module
with a new one.
new one.
NOTE 5) Remove curtain air bag (inflator) module bolts (1)

Refer to “Repair and Inspection Required and remove curtain air bag (inflator) module (2).
after Accident”: 8-Channel before replacing a
deployed air bag.
Removal
8-Channel
2) Remove roof lining. (Roof Lining Removal and 2
1
3) Disconnect curtain air bag (inflator) module
connector (1) as shown in figure.
a) Release lock button (2) by pulling it in arrow
direction “1”.
b) Disconnect curtain air bag (inflator) module IMTA0A822022-01
connector with lock released by pulling it in arrow 6) Remove roof side rail rear pad (1) if necessary.
direction “2”.
A
“1”
“2” A
A
1
“1”
1
IMTA0A822020-01
4) Remove tether clip (2) from front pillar while holding

claws (1) pressed in arrow directions.
IMTA0A822023-02
Installation
Reference: “Curtain Air Bag (Inflator) Module
Inspection”: 8-Channel
• Install curtain air bag (inflator) module as follows.
a. Install curtain air bag (inflator) module without
1
twisting line (1).
1
2 IMTA0A822024-01
b. Install curtain air bag (inflator) module without

twisting mounting strap (1).
c. For positioning curtain air bag (inflator) module,
insert metal hooks (2) into body slits (3).
IMTA0A822021-01
3 2 3
1
2
IMTA0A822025-01
I9P60A820071-01
d. Install curtain air bag (inflator) module bolts (1)
and tighten them to specified torque.
Check air bag (inflator) module and if any of the following
NOTE conditions is found, replace air bag (inflator) module with
Check that each bracket of clamping part to new one.
body panel is securely fixed after tightening • Air bag is deployed.
curtain air bag (inflator) module bolts. • Air bag (inflator) module is damaged or a strong
impact was applied to it.
Tightening torque
Curtain air bag (inflator) module bolt (a): 11
N·m (1.1 kgf-m, 8.5 lbf-ft) • Air bag (inflator) module bracket is bent or deformed.
Forward Impact Sensor Removal and

Installation
AENNTA0E8226019 (08(01)
Reference: “Forward Impact Sensor Inspection”: 8-
Channel
Refer to “Forward Impact Sensor Removal and
Installation”: 4-Channel.
1, (a) 1, (a) Forward Impact Sensor Inspection

AENNTA0E8226020 (08(03)
Reference: “Forward Impact Sensor Removal and
Refer to “Forward Impact Sensor Inspection”: 4-
IMTA0A822026-01 Channel.
e. Lock connector for curtain air bag (inflator)
module securely. Side-Impact Pressure Sensor Removal and
• Enable air bag system. (Enabling Air Bag System): 8- Installation
AENNTA0E8226021 (08(01)
Channel Reference: “Precautions for Electrical System Work”
Curtain Air Bag (Inflator) Module Inspection ! WARNING

AENNTA0E8226018 (08(03)
Reference: “Curtain Air Bag (Inflator) Module Removal Failure to take proper precautions when
and Installation”: 8-Channel handling the air bag system sensors can
result in personal injury due to non-deployed
! WARNING air bag system in the event of an accident or
Failure to take proper precautions when accidental air bag deployment.
checking the curtain air bag (inflator) module • Never impact or shake the sensors.
can result in personal injury due to Otherwise, proper operation of the sensors
accidental deployment of the air bag. cannot be assured.
Never measure the resistance of the air bag • Always tighten the mounting bolts to
(inflator) module. specified torque when installing the
sensors. Otherwise, proper operation of
the sensors cannot be assured.
Removal
8-Channel
2) Remove front door trim and door sealing cover.
(Front Door Glass Removal and Installation) in 1, (a)
Section 9E
3) Disconnect side-impact pressure sensor connector
(2) as follows.
a) Release locking slider (1) by sliding it in arrow
direction “1”.
b) Disconnect side-impact pressure sensor
connector by pulling it in arrow direction “2”.
4) Remove side-impact pressure sensor nut (3) and
remove side-impact pressure sensor (4) from front
door panel.
IMTA0A822028-01
3) Connect side-impact pressure sensor connector

securely.
4) Install door sealing cover and front door trim. (Front
4
3 Door Glass Removal and Installation) in Section 9E
8-Channel
Side-Impact Pressure Sensor Inspection

AENNTA0E8226022 (08(03)
2 Reference: “Side-Impact Pressure Sensor Removal and
“1” Check side-impact pressure sensor and if any of the
“2”
following conditions is found, replace it with new one.
1
• Side-air bag/curtain air bag is deployed.
• Sensor has dents, crack or deformation.
• Sensor connectors (sensor side and harness side)
IMTA0A822027-01
and sensor connector lock mechanism are damaged
Installation or cracked.
Reference: “Side-Impact Pressure Sensor Inspection”: • Connector terminals are bent, corroded or rusted.
8-Channel
1) Check that none of the following faulty conditions Side-Impact G Sensor Removal and Installation
AENNTA0E8226023 (08(01)
exists.
• Bend, deformation or rust on front door panel
• Foreign material on sensor ! WARNING
2) Tighten side-impact pressure sensor nut (1) to Failure to take proper precautions when
specified torque. handling the air bag system sensors can
Tightening torque result in personal injury due to non-deployed
Side-impact pressure sensor nut (a): 11 N·m (1.1 air bag system in the event of an accident or
kgf-m, 8.5 lbf-ft) accidental air bag deployment.
• Never impact or shake the sensors.
Otherwise, proper operation of the sensors
cannot be assured.
• Always tighten the mounting bolts to
specified torque when installing the
sensors. Otherwise, proper operation of
the sensors cannot be assured.
Removal
8-Channel
2) Remove quarter lower trim. (Trim / Console Removal
3) Disconnect side-impact G sensor connector (1) as
1, (a)
follows.
a) While pressing lock button (2) in arrow direction
“1”, pull side-impact G sensor connector in arrow
direction “2” to release the lock.
b) While pressing lock button in arrow direction “1”,
disconnect side-impact G sensor connector by
pulling it in arrow direction “2”.
4) Remove side-impact G sensor bolt (3) and remove
side-impact G sensor (4) from quarter inner rear
panel.
IMTA0A822030-01
3) Connect side-impact G sensor connector securely.

4) Install quarter lower trim. (Trim / Console Removal
4
3
8-Channel
Side-Impact G Sensor Inspection

AENNTA0E8226024 (08(03)
Reference: “Side-Impact G Sensor Removal and
“1” Installation”: 8-Channel
1 Check side-impact G sensor and if any of the following
2 conditions is found, replace it with new one.
“2” • Side-air bag/curtain air bag being deployed.
• Check sensor has dents, crack or deformation.
• Check sensor connectors (sensor side and harness
IMTA0A822029-01
side) and sensor connector lock mechanism for
damage or crack.
Installation • Check connector terminals for bend, corrosion or rust.
Reference: “Side-Impact G Sensor Inspection”: 8-
Channel Passenger Air Bag (Inflator) Module Repair
1) Check that none of the following faulty conditions Harness Installation
exists. AENNTA0E8226025 (08(01)
Refer to “Passenger Air Bag (Inflator) Module Repair
• Bend, deformation or rust on quarter inner panel Harness Installation”: 4-Channel.
• Foreign material on sensor
2) Tighten side-impact G sensor bolt (1) to specified Air Bag (Inflator) Module and Seat Belt
torque. Pretensioner Disposal
AENNTA0E8226026 (08(03)
Tightening torque
! WARNING
Side-impact G sensor bolt (a): 8.8 N·m (0.90 kgf-
m, 6.5 lbf-ft) If live air bag (inflator) modules or seat belt
pretensioners are disposed of without being
deployed / activated beforehand using the
Before disposing of any live air bag (inflator) pretensioner. The deployment harness
modules or seat belt pretensioners, deploy/ must remain shorted and not be connected
activate them using the specified procedure. to a 12-volt battery until preparation for
Never dispose of any live ones through activation of the air bag (inflator) module /
ordinary refuse disposal channels. seat belt pretensioner is completed.
• Never disconnect banana plug (1) till
Air bag (inflator) module / seat belt pretensioner can be deployment harness (A) is connected to
deployed / activated inside or outside the vehicle. vehicle battery as static may cause
Deployment / Activation method depends upon final accidental deployment of air bag.
disposition of vehicle. Review the following instructions • Check that there is no open, short or
to determine which method will work best in a given damage in deployment harness and
situation. adapter cable of special tool.
Deployment / Activation Outside the Vehicle: When you
intend to return vehicle to service, deploy air bag Special tool
(inflator) module(s) and/or activate seat belt (A): 09932M75032
pretensioner(s) outside the vehicle.
Deployment / Activation Inside the Vehicle: When
vehicle will be destroyed or salvaged for component
parts, deploy air bag module(s) and/or activate seat belt (A)
pretensioner(s) installed on vehicle.
1
I8G001821052-01
! WARNING
Failure to take proper precautions when Deployment / Activation
deploying an air bag (inflator) module and/or Removal
activating a seat belt pretensioner can result Remove air bag (inflator) module or seat belt
in severe personal injury. pretensioner from vehicle.
Take all of the following precautions when
• Driver air bag (inflator) module: (Driver Air Bag
activating a seat belt pretensioner:
Channel
• Strictly follow the procedure described in
• Passenger air bag (inflator) module: (Passenger Air
this section.
Bag (Inflator) Module Removal and Installation): 8-
• Read “Precautions for Air Bag System Channel
Service”: 8-Channel and follow all of the
• Front seat belt pretensioner: (Front Seat Belt
instructions provided.
Components) in Section 8A
• Only one person should perform this work
• Side-air bag (inflator) module: (Side-Air Bag (Inflator)
to avoid accidental deployment /
Module Removal and Installation): 8-Channel
activation.
• Curtain air bag (inflator) module: (Curtain Air Bag
• Perform this work in a well-ventilated area
as smoke is produced when the air bag
Channel
(inflator) module / pretensioner is
activated.
Setting
• Wear safety glasses throughout the Driver air bag (inflator) module
disposal procedure from the very Refer to “Driver air bag (inflator) module” in “Deployment
beginning. The air bag (inflator) module / / Activation Outside the Vehicle” under “Air Bag (Inflator)
seat belt pretensioner will immediately be Module and Seat Belt Pretensioner Disposal”: 4-
activated when a 12-volt battery is Channel.
connected. .
• Wear suitable ear protection when

activating an air bag (inflator) module / Passenger air bag (inflator) module
seat belt pretensioner. Also, advise Refer to “Passenger air bag (inflator) module” in
persons in nearby areas to wear suitable “Deployment / Activation Outside the Vehicle” under “Air
ear protection. Bag (Inflator) Module and Seat Belt Pretensioner
• Do not activate two or more air bag Disposal”: 4-Channel.
(inflator) modules, seat belt pretensioners, .
or a combination of two at the same time.

• Never connect the deployment harness to
any 12-volt battery before connecting it to
the air bag (inflator) module or seat belt
Seat belt pretensioner Curtain air bag (inflator) module

Refer to “Seat belt pretensioner” in “Deployment / 1) Cut air bag (1) around curtain air bag (inflator)
Activation Outside the Vehicle” under “Air Bag (Inflator) module (2) as shown in figure.
Module and Seat Belt Pretensioner Disposal”: 4-
Channel. 1
.
Side-air bag (inflator) module

1) Turn up deployment direction and tighten to
deployment fixture (A) to specified torque using side-
air bag (inflator) module nuts (1).
Special tool
(A): 09932M75041
Tightening torque
Side-air bag (inflator) module nut (a): 5.5 N·m (
2
0.56 kgf-m, 4.0 lbf-ft)
[a]
2
1, (a)
I9P60A820090-01
2) Tie curtain air bag (inflator) module (3) with wire

harness (2) to tire (1) at least 3 times as shown.
Wire harness section
1.25 mm2 (0.0019 in.2 or more)
(A) 2 3
I9W10P821057-02
[a]: Air bag deployment direction 3. Mounting attachment

1
2. Side-air bag (inflator) module
2) Connect deployment harness (B) and adapter cable

(C) to side-air bag (Inflator) module.
Special tool IDAA0A820161-01
(B): 09932M75032 3) Connect adapter cable (B) to deployment harness
(C): 09932M76510 (A) connector and lock connectors with lock lever.
4) Connect adapter cable (B) to curtain air bag (inflator)
module.
Special tool
(A): 09932M75032
(B): 09932M76510
1 (C) (B)
(B)
IMTA0A822033-01 (A)
1. Banana plug
1
IDAA0A820162-01
1. Banana plug
5) Put tire (2) to which air bag (inflator) module is

secured on tire (1) without wheel and place 2 tires
(3) with wheel on them and place tire (4) with wheel
on top. 4
6) Secure tires with wire harness (5).

Special tool 5
3
(A): 09932M75032
(B): 09932M76510
6 (A)
(B)
IDAA0A820163-01
6. Banana plug
Deployment
1) Clear space (4) on ground about 185 cm (6 ft) in diameter where air bag (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 air bag (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 air bag (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.
! WARNING
Failure to take proper precautions when handling a deployed air bag and/or activated seat belt
pretensioner may result in a fire, personal injury or health problems.
• Wait for at least 30 minutes before touching any metal surface of an activated air bag (inflator)
module / seat belt pretensioner.
• Leave air bag (inflator) module / seat belt pretensioner for 30 minutes or more after deployment /
activation to prevent accident due to remaining heat. After checking that air bag (inflator) module /
seat belt pretensioner has got cold, dispose of it.
• Do not place an activated air bag (inflator) module / seat belt pretensioner near any flammable
objects because it is hot enough to start a fire.
• Do not pour water, oil, etc. over an air bag (inflator) module / seat belt pretensioner immediately after
its activation.
• Follow all of the procedures described in this section.
NOTE
• When air bag (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 air bag
(inflator) module or activate seat belt pretensioner and suitable ear protection should be worn.
• When driver air bag (inflator) module deploys, driver air bag (inflator) module may jump about 30 cm
(1 ft) vertically. This is normal reaction to force of rapid gas expansion inside of drive air bag
(inflator) module.
• After air bag (inflator) module has been deployed, surface of air bag (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.
4 3
(A) (B)
“a” (B)
2 4 (A)
1
(B)
“a”
2
(A)
1
“a”
4
2
1
4
(A)
(B)
(A) (B)
“a”
2
“a”
1
2
1
IGSB0A822119-01
“a”: 10 m (33 ft) 3. Blanket 4. Clear space 185 cm (6 ft)
7) Put on safety glasses (1) and pair of shop gloves (2)

to protect your eyes and hands from possible
irritation and heat when handling deployed air bag
(inflator) module or activated seat belt pretensioner.
8) Dispose of deployed air bag (inflator) module or
activated seat belt pretensioner through normal
refuse channels after it has cooled for at least 30
minutes and tightly seal air bag (inflator) module or
seat belt pretensioner in strong vinyl bag.
• Never apply water and oil, etc. to deployed air bag

1 (inflator) module and activated seat belt pretensioner
to cool them off. Do not get on deployed air bag
2 (inflator) module and activated seat belt pretensioner.
I8T201821025-01
9) Wash your hands with mild soap and water. IYSQ01820095-01
• After air bag (inflator) module has been deployed,

Deployed Air Bag (Inflator) Module and surface of air bag may contain a powdery residue. As
Activated Seat Belt Pretensioner Disposal with many service procedures, wear gloves and safety
AENNTA0E8226027 (08(03)
glasses.
! WARNING
• When disposing of deployed air bag (inflator) module
If live air bag (inflator) modules or seat belt and activated seat belt pretensioner, seal it in a vinyl
pretensioners are disposed of without being bag.
deployed/activated beforehand using the
Before disposing of any live air bag (inflator)
modules or seat belt pretensioners, deploy/
activate them using the specified procedure.
Never dispose of any live ones through
ordinary refuse disposal channels.
Deployed air bag (inflator) module and activated seat I3JA01820119-01
belt pretensioner can be disposed of in the same way • When air bag (inflator) module and seat belt
which is used for disposal of any other parts. For their pretensioner have been deployed / activated inside
disposal, however, the following points should be noted. vehicle, leave them as installed to vehicle and scrap
• Immediately after deployment / activation air bag them.
(inflator) module and seat belt pretensioner are hot. • Wash your hands with mild soap and water after
Wait for 30 minutes to cool them off before handling handling them.
them.
Specifications
AENNTA0E8227001 (09(t)
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Side-air bag (inflator) module nut 5.5 0.56 4.0 (T8B205) / (T8B210)
Side-air bag (inflator) module bracket nut 5.5 0.56 4.0 (T8B206)
Curtain air bag (inflator) module bolt 11 1.1 8.5 (T8B207)
Side-impact pressure sensor nut 11 1.1 8.5 (T8B208)
Side-impact G sensor bolt 8.8 0.90 6.5 (T8B209)
Reference:
“Side-Air Bag (Inflator) Module Components”: 8-Channel
“Curtain Air Bag (Inflator) Module Components”: 8-Channel


Use of Special Tools This tool is used as a diagnostic aid and safety device to
AENNTA0E8228001 (11(01) prevent inadvertent air bag (inflator) module deployment.
Be familiar with tools listed under heading “Special Tool”.
The load tool has three connectors attached to its case
Study proper use of measurement tools such as Air Bag
which are electrically functional and serve as resistive
Driver / Passenger Load Tool, Connector Test Adapter
load substitutions.
Kit and digital multimeter.
Use “BASE OF COLUMN” connector (1) instead of
Special tool resistance load of driver air bag (inflator) module and
(A): 09932M76010 contact coil.
Use “STEERING WHEEL” connector (2) instead of
This must be used whenever a diagnostic procedure
resistance load of driver / passenger air bag (inflator)
requests checking or probing a terminal.
modules, seat belt pretensioner, side-air bag (inflator)
Using appropriate adapter in special tool (A) will check
module and curtain air bag (inflator) module.
that no damage to terminal will occur from multimeter
Do not use “PASSENGER INFLATOR” connector (3).
probe, such as spread or bend.
By connecting load tool instead of inflator modules and
pretensioners, service work to decide location of cause
of trouble – whether it is in harness or in component –
can be performed.
Special tool
(C): 09932M75011
(A) (A)
IFKA0P821060-01
The adapter (1) will also give an idea of whether or not

contact tension is sufficient, helping to find an open or
intermittent open due to poor terminal contact. Inserting
SDM shorting bar release tool (2) into SDM connector
(3) will release shorting bar.
IDAA0A820174-01
2
1
3
IFKA0P821061-01
Special Tool
AENNTA0E8228002 (11(s)
09932M75011 09932M75032
Air bag driver / Passenger Air bag deployment harness
load tool
(L8B275) / (L8B279) / (L8B2157) / (L8B2159) /
(L8B289) / (L8B294) / (L8B2161) / (L8B2163) /
(L8B2101) / (L8B2105) / (L8B2165)
(L8B2113) / (L8B2118) /
(L8B2125) / (L8B2129) /
(L8B2168)
09932M75041 09932M75110
Passenger air bag (inflator) Shorting bar release tool
module deployment fixture
(L8B2158) (L8B2156)
09932M76010 09932M76510
Connector test adapter set Deployment adapter cable
This set includes the (L8B2160) / (L8B2162) /
following items. 1. (L8B2164) / (L8B2166)
Connector test adapter kit
(09932-75020), 2.
Connector test adapter &
shorting bar release tool
(09932-76020)(L8B267) /
(L8B268) / (L8B269) /
(L8B270) / (L8B271) /
(L8B272) / (L8B273) /
(L8B274) / (L8B278) /
(L8B282) / (L8B283) /
(L8B284) / (L8B285) /
(L8B286) / (L8B287) /
(L8B290) / (L8B291) /
(L8B292) / (L8B295) /
(L8B296) / (L8B297) /
(L8B298) / (L8B299) /
(L8B2102) / (L8B2103) /
(L8B2106) / (L8B2107) /
(L8B2108) / (L8B2109) /
(L8B2110) / (L8B2111) /
(L8B2114) / (L8B2115) /
(L8B2116) / (L8B2119) /
(L8B2120) / (L8B2121) /
(L8B2122) / (L8B2123) /
(L8B2126) / (L8B2127) /
(L8B2130) / (L8B2131) /
(L8B2132) / (L8B2133) /
(L8B2134) / (L8B2135) /
(L8B2136) / (L8B2137) /
(L8B2138) / (L8B2139) /
(L8B2140) / (L8B2141) /
(L8B2142) / (L8B2143) /
(L8B2144) / (L8B2145) /
(L8B2146) / (L8B2147) /
(L8B2148) / (L8B2149) /
(L8B2150) / (L8B2151) /
(L8B2152) / (L8B2153) /
(L8B2154) / (L8B2155) /
(L8B2167)
09932M77320 09932M78310
Diagnosis adapter cable 4P Adapter cable
(L8B277) / (L8B281) (L8B288) / (L8B293) /
(L8B2100) / (L8B2104) /
(L8B2112) / (L8B2117) /
(L8B2124) / (L8B2128)
09932M78340
Deployment adapter cable
(L8B276) / (L8B280)
Section 9
Body, Cab and Accessories

CONTENTS
Precautions .................................................9-1 A-5 Engine and A/C Control System Circuit

Precautions............................................................. 9-1 Diagram (K12N) ..............................................9A-55
Precautions for Body, Cab and Accessories......... 9-1 A-6 Auto Gear Shift Control System Circuit
Diagram...........................................................9A-62
Wiring Systems........................................ 9A-1 A-8 Body Control System Circuit Diagram ........9A-64
Precautions...........................................................9A-1 A-9 CAN Circuit Diagram ..................................9A-73
Cautions for Body Electrical System Servicing .... 9A-1 A-9 Central Gateway System Circuit Diagram ..9A-75
A-11 ENG A-STOP System Circuit Diagram.....9A-75
B-1 Windshield Wiper and Washer Circuit
Abbreviations ...................................................... 9A-1
Diagram...........................................................9A-78
Wire / Connector Color Symbols......................... 9A-1
B-2 Rear Wiper and Washer Circuit Diagram
Symbols and Marks ............................................ 9A-1
(If Equipped)....................................................9A-79
How to Read Connector Layout Diagram ........... 9A-2
B-3 Rear Defogger Circuit Diagram ..................9A-79
How to Read Connector Codes and Terminal
B-4 Power Window Circuit Diagram..................9A-80
Nos.................................................................... 9A-3
B-5 Power Door Lock Circuit Diagram ..............9A-83
How to Read Ground Point ................................. 9A-6
B-6 Power Mirror Circuit Diagram (Without
How to Read Power Supply Diagram.................. 9A-7
Remote Retractable Mirror).............................9A-85
How to Read System Circuit Diagram................. 9A-7
B-6 Power Mirror Circuit Diagram (With
Glossary .............................................................. 9A-9
Remote Retractable Mirror).............................9A-87
Connector Layout Diagram ...............................9A-12
B-7 Horn Circuit Diagram ..................................9A-89
Connector Layout Diagram ............................... 9A-12
B-9 Parking Sensor System Circuit Diagram ....9A-89
Engine Compartment ........................................ 9A-12
C-1 Combination Meter Circuit Diagram ...........9A-92
Instrument Panel ............................................... 9A-18
C-2 Head-up Display Circuit Diagram (If
Door, Roof......................................................... 9A-21
Equipped)........................................................9A-94
Floor .................................................................. 9A-25
D-1 Headlight System Circuit Diagram
Rear .................................................................. 9A-27
(Halogen Headlight Model) .............................9A-94
Ground Point ......................................................9A-28 D-1 Headlight System Circuit Diagram (Auto-
Ground Point ..................................................... 9A-29 On LED Headlight Model) ...............................9A-95
Power Supply Diagram ......................................9A-30 D-2 Clearance, Tail and License Plate Light
Power Supply Diagram ..................................... 9A-30 System Circuit Diagram (Non-Auto-On
Fuses and the Protected Parts ......................... 9A-35 Headlight Model) .............................................9A-98
J/B Connector Layout ....................................... 9A-39 D-2 Clearance, Tail and License Plate Light 9
J/B Inner Circuit (Detail) .................................... 9A-41 System Circuit Diagram (Auto-On Headlight
System Circuit Diagram.....................................9A-49 Model) ...........................................................9A-100
System Circuit Diagram .................................... 9A-49 D-3 Front Fog Light System Circuit Diagram
A-1 Cranking System Circuit Diagram (M/T (If Equipped)..................................................9A-100
Model) ............................................................. 9A-49 D-4 Illumination Light System Circuit Diagram 9A-101
A-1 Cranking System Circuit Diagram (AGS D-5 Interior Light System Circuit Diagram.......9A-102
Model) ............................................................. 9A-50 D-6 Turn Signal and Hazard Warning Light
A-1 Main Switch Circuit Diagram (Ignition System Circuit Diagram ................................9A-105
Switch Model) ................................................. 9A-51 D-7 Brake Light System Circuit Diagram ........9A-107
A-1 Main Switch Circuit Diagram (Keyless D-8 Back Up Light System Circuit Diagram ....9A-108
Push Start Model) ........................................... 9A-52 D-9 Headlight Manual Leveling System
A-2 Charging System Circuit Diagram .............. 9A-53 Circuit Diagram (Non-Auto-On Headlight
A-4 Cooling System Circuit Diagram................. 9A-54 Model) ...........................................................9A-109
D-9 Headlight Manual Leveling System DTC B1A81 / B1A82 .........................................9B-13

Circuit Diagram (Auto-On Headlight Model).. 9A-110 DTC B1AA0 / B1AA2 / B1AA3 / B1AA4 ............9B-14
E-2 Auto A/C System Circuit Diagram ............ 9A-110 DTC B1AB0.......................................................9B-15
F-1 Air Bag System Circuit Diagram (4- DTC B1AB1.......................................................9B-15
Channel) ....................................................... 9A-114 DTC U0073 .......................................................9B-16
F-1 Air Bag System Circuit Diagram (8- DTC U0121 / U0140 / U0155 ............................9B-16
Channel) ....................................................... 9A-114 Inspection of Lighting and Turn Signal Switch
F-2 ABS Circuit Diagram................................. 9A-118 and Its Circuits (Auto-On Headlight Model).....9B-16
F-3 ESP® Circuit Diagram .............................. 9A-120 Repair Instructions ............................................9B-17
F-4 Power Steering System Circuit Diagram .. 9A-122 Headlight Unit Removal and Installation ...........9B-17
G-1 Audio System Circuit Diagram ................. 9A-122 Headlight Aiming and Light Intensity Check......9B-19
G-2 Navigation System Circuit Diagram .........9A-126 Front Fog Light Removal and Installation (If
G-3 Accessory Socket System Circuit Equipped)........................................................9B-20
Diagram ........................................................ 9A-132 Front Fog Light Aiming Adjustment (If
G-4 Telematics Data Communication System Equipped)........................................................9B-21
Circuit Diagram (If Equipped)........................ 9A-132 Door Mirror Turn Signal Light Removal and
List of Connector .............................................9A-133 Installation (If Equipped) .................................9B-21
List of Connectors ........................................... 9A-134 License Plate Light Removal and Installation ...9B-21
A Connector .................................................... 9A-134 Rear Combination Light Removal and
C Connector .................................................... 9A-134 Installation .......................................................9B-22
E Connector .................................................... 9A-135 High Mount Stop Light Removal and
G Connector.................................................... 9A-137 Installation .......................................................9B-23
J Connector..................................................... 9A-139 Spot Light Removal and Installation..................9B-23
K Connector .................................................... 9A-140 Dome Light Removal and Installation ...............9B-24
L Connector..................................................... 9A-141 Luggage Compartment Light Removal and
M Connector.................................................... 9A-142 Installation (If Equipped) .................................9B-24
O Connector.................................................... 9A-142 Vanity Light Removal and Installation (If
S Connector .................................................... 9A-142 Equipped)........................................................9B-25
Reassembling Note for Wiring Harness.........9A-142 Glove Box Light Removal and Installation (If
Reassembling Note for Wiring Harness .......... 9A-142 Equipped)........................................................9B-25
Around Engine ................................................ 9A-143 Foot Light Removal and Installation (If
Around Battery ................................................ 9A-144 Equipped)........................................................9B-25
Around Strut .................................................... 9A-147 Door Courtesy Light Removal and Installation
Around Instrument Panel ................................ 9A-148 (If Equipped)....................................................9B-26
Around Main Floor........................................... 9A-150 Headlight Leveling Actuator Inspection .............9B-26
Around Rear End Door.................................... 9A-153 Lighting and Turn Signal Switch Removal and
Specifications...................................................9A-154 Installation .......................................................9B-27
Tightening Torque Specifications.................... 9A-154 Lighting and Turn Signal Switch Inspection ......9B-27
Hazard Warning Switch Removal and
Lighting Systems .................................... 9B-1 Installation .......................................................9B-28
General Description .............................................9B-1 Hazard Warning Switch Inspection ...................9B-28
Lighting System Description................................ 9B-1 Auto-On Headlight Sensor Removal and
Auto-On Headlight System Description (Auto- Installation (If Equipped) .................................9B-29
On Headlight Model) ......................................... 9B-1 Auto-On Headlight Sensor Inspection (If
LED Headlight Description (Auto-On Equipped)........................................................9B-29
Headlight Model) ............................................... 9B-1 Glove Box Light Switch Removal and
DRL System Description (If Equipped) ............... 9B-3 Installation (If Equipped) .................................9B-29
Guide Me Light System Description (Auto-On Glove Box Light Switch Inspection (If
Headlight Model) ............................................... 9B-4 Equipped)........................................................9B-30
Component Location ...........................................9B-5 Lighting System Relay Inspection .....................9B-30
Lighting System Component Location ................ 9B-5 Specifications .....................................................9B-30
Diagnostic Information and Procedures............9B-7 Electric Bulb Capacity .......................................9B-30
Lighting System Self-Diagnosis Function............ 9B-7 Tightening Torque Specifications......................9B-30
DTC Check.......................................................... 9B-8
Instrumentation / Driver Info. / Horn ...... 9C-1
DTC Clearance ................................................... 9B-8
DTC Table........................................................... 9B-9 Precautions...........................................................9C-1
Scan Tool Data ................................................... 9B-9 Precautions for Head-Up Display (If
Lighting System Symptom Diagnosis................ 9B-10 Equipped)..........................................................9C-1
DTC B1A80 ....................................................... 9B-12 General Description .............................................9C-1
Combination Meter Description...........................9C-1 Combination Meter Removal and Installation ...9C-49

Parking Sensor System Description..................9C-12 Instrument Panel Removal and Installation.......9C-50
Parking Sensor Description ..............................9C-13 Instrument Panel Disassembly and
Head-Up Display Description (If Equipped) ......9C-13 Reassembly ....................................................9C-55
Head-Up Display Function Description (If Horn Removal and Installation ..........................9C-61
Equipped)........................................................9C-13 Horn On-Vehicle Inspection ..............................9C-62
Head-Up Display Control Description (If Head-Up Display Removal and Installation (If
Equipped)........................................................9C-14 Equipped)........................................................9C-62
Head-Up Display Basic Operation (If Head-Up Display Switch Removal and
Equipped)........................................................9C-15 Installation (If Equipped) .................................9C-63
Schematic and Routing Diagram......................9C-18 Head-Up Display Switch Inspection (If
Parking Sensor Input / Output Block Diagram ..9C-18 Equipped)........................................................9C-64
Parking Sensor System Circuit Diagram...........9C-18 Parking Sensor System Control Module
Combination Meter Circuit Diagram ..................9C-19 Removal and Installation.................................9C-64
Head-Up Display Circuit Diagram (If Parking Sensor Removal and Installation .........9C-65
Equipped)........................................................9C-21 Parking Sensor Inspection ................................9C-65
Component Location .........................................9C-21 Parking Sensor Buzzer Removal and
Parking Sensor System Component Location ..9C-21 Installation .......................................................9C-66
Head-Up Display Component Location (If Parking Sensor Buzzer Inspection ....................9C-66
Equipped)........................................................9C-22 Specifications.....................................................9C-66
Diagnostic Information and Procedures..........9C-23 Tightening Torque Specifications......................9C-66
Combination Meter Diagnosis Function
Description ......................................................9C-23 Wipers / Washers..................................... 9D-1
Parking Sensor System Self-Diagnosis Component Location ...........................................9D-1
Function ..........................................................9C-23 Washer Tank and Washer Hose Component
Head-Up Display Diagnosis Function Location.............................................................9D-1
Description (If Equipped) ................................9C-24 Diagnostic Information and Procedures ............9D-1
DTC Check .......................................................9C-24 Wiper and Washer Symptom Diagnosis .............9D-1
DTC Clearance .................................................9C-25 Repair Instructions ..............................................9D-2
DTC Table.........................................................9C-26 Washer Tank and Washer Pump Removal
Scan Tool Data .................................................9C-27 and Installation ..................................................9D-2
Scan Tool Active Test .......................................9C-30 Washer Pump Inspection ....................................9D-3
Scan Tool Utility Table ......................................9C-30 Windshield Wiper Motor Removal and
Combination Meter Diagnosis ...........................9C-30 Installation .........................................................9D-3
DTC B1101-04 ..................................................9C-30 Windshield Wiper Motor Operation Inspection ....9D-5
DTC B1102-98 ..................................................9C-31 Rear Wiper Removal and Installation..................9D-6
DTC B1103-16 / B1103-17 ...............................9C-31 Rear Wiper Motor Inspection ..............................9D-7
DTC B1120-29 ..................................................9C-33 Wiper and Washer Switch Removal and
DTC B1801-16 / B1801-17 ...............................9C-33 Installation .........................................................9D-8
DTC B1810-11 / B1810-13 ...............................9C-34 Wiper and Washer Switch Inspection .................9D-8
DTC B1820-04 ..................................................9C-36 Specifications.....................................................9D-10
DTC B1850-81 ..................................................9C-36 Tightening Torque Specifications......................9D-10
DTC B1852-81 ..................................................9C-37
DTC B1855-87 ..................................................9C-39 Glass / Windows / Mirrors....................... 9E-1
DTC B1864-81 / B1865-81 / B1866-81 / Precautions...........................................................9E-1
B1867-81 ........................................................9C-40 Precautions for Working on Glass.......................9E-1
DTC U0073-88 ..................................................9C-41 Precautions for Working on Power Window........9E-1
DTC U0100-87 / U0101-87 / U0121-87 / General Description .............................................9E-1
U0131-87 / U0140-87 / U0151-87 / U0155- Power Window System Description ....................9E-1
87 ....................................................................9C-41 Anti-Pinching Function Description .....................9E-3
DTC U0401-81 ..................................................9C-41 Rear Defogger System Description.....................9E-3
DTC U0422-81 ..................................................9C-42 Inside Rear View Mirror Description....................9E-3
Inspection of Combination Meter and Its
Component Location ...........................................9E-4
Circuit..............................................................9C-42
Power Window Component Location ..................9E-4
Inspection of Parking Sensor System Control
Power Door Mirror Component Location.............9E-4
Module and Its Circuit .....................................9C-45
Rear Defogger Component Location ..................9E-5
Inspection of Head-Up Display and Its Circuit
Diagnostic Information and Procedures ............9E-6
(If Equipped) ...................................................9C-47
Power Window System Symptom Diagnosis ......9E-6
Repair Instructions ............................................9C-49
9-iv Table of Contents
Power Door Mirror Control System Symptom Power Door Lock Operation Description............. 9F-2
Diagnosis .......................................................... 9E-6 Schematic and Routing Diagram ........................ 9F-2
Rear Defogger System Symptom Diagnosis....... 9E-7 Power Door Lock System Circuit Diagram .......... 9F-2
Inspection of Power Window Anti-Pinching Component Location ........................................... 9F-3
Function (Driver side)........................................ 9E-7 Power Door Lock System Component
Inspection of Power Window Main Switch and Location............................................................. 9F-3
Its Circuit ........................................................... 9E-7 Diagnostic Information and Procedures ............ 9F-3
Repair Instructions .............................................. 9E-9 Door Lock Inspection .......................................... 9F-3
Windshield Components ..................................... 9E-9 Power Door Lock System Symptom
Windshield Removal and Installation ................ 9E-10 Diagnosis .......................................................... 9F-3
Rear Quarter Window Glass Components........ 9E-16 Repair Instructions .............................................. 9F-4
Rear Quarter Window Glass Removal and Front Door Lock Assembly Components ............ 9F-4
Installation ....................................................... 9E-17 Front Door Latch Assembly Removal and
Rear End Door Window Glass Components..... 9E-18 Installation ......................................................... 9F-4
Rear End Door Window Glass Removal and Front Door Outside Handle Removal and
Installation ....................................................... 9E-19 Installation ......................................................... 9F-5
Front Door Glass Components ......................... 9E-22 Front Door Latch Striker On-Vehicle
Door Trim Removal and Installation.................. 9E-23 Inspection.......................................................... 9F-6
Front Door Glass Removal and Installation ...... 9E-25 Front Door Latch Striker Removal and
Front Window Regulator Assembly Removal Installation ......................................................... 9F-6
and Installation ................................................ 9E-27 Rear Door Lock Assembly Components ............. 9F-7
Front Window Regulator Assembly Inspection .. 9E-27 Rear Door latch Assembly Removal and
Power Window System Initialization / Reset Installation ......................................................... 9F-7
(Driver Side Only) ........................................... 9E-28 Rear Door Outside Handle Removal and
Rear Door Glass Components .......................... 9E-28 Installation ......................................................... 9F-9
Rear Door Glass Removal and Installation ....... 9E-29 Rear Door Latch Striker On-Vehicle
Rear Window Regulator Assembly Removal Inspection.......................................................... 9F-9
and Installation ................................................ 9E-31 Rear Door Latch Striker Removal and
Rear Window Regulator Assembly Inspection .. 9E-31 Installation ......................................................... 9F-9
Rear Defogger Switch Inspection...................... 9E-32 Rear End Door Lock Assembly Components.... 9F-10
Rear Defogger Inspection ................................. 9E-32 Rear End Door Latch Assembly Removal and
Rear Defogger Relay Inspection ....................... 9E-32 Installation ....................................................... 9F-11
Power Window Main Switch Inspection ............ 9E-32 Rear End Door Opener / Request Switch
Power Window Sub Switch Inspection.............. 9E-32 Removal and Installation................................. 9F-11
Door Mirror Removal and Installation................ 9E-33 Rear End Door Latch Striker On-Vehicle
Door Mirror Disassembly and Disassembly ...... 9E-33 Inspection........................................................ 9F-12
Power Door Mirror Switch Inspection................ 9E-33 Rear End Door Latch Striker Removal and
Door Mirror Motor Inspection ............................ 9E-34 Installation ....................................................... 9F-12
Inner Rear View Mirror (With Auto Dimming) Door Lock Switch and Door Lock Actuator
On-Vehicle Inspection ..................................... 9E-34 Inspection........................................................ 9F-12
Inner Rear View Mirror Removal and Door Switch Removal and Installation .............. 9F-14
Installation ....................................................... 9E-35 Door Switch Inspection ..................................... 9F-15
Inner Rear View Mirror (With Auto Dimming) Power Door Lock Switch Inspection.................. 9F-15
Inspection........................................................ 9E-36 Rear End Door Opener / Request Switch
Rear Defogger Relay Inspection ....................... 9E-36 Inspection........................................................ 9F-16
Auto Mirror Relay Circuit Inspection (If Remote Controller Registration (Keyless
Equipped)........................................................ 9E-36 Push Start Model) ........................................... 9F-16
Automatic Retractable Mirror Mode Selection Remote Controller Battery Replacement
Procedure (If Equipped) .................................. 9E-36 (Keyless Push Start Model)............................. 9F-16
Specifications..................................................... 9E-36 Ignition Key Registration (Ignition Switch
Tightening Torque Specifications...................... 9E-36 Model) ............................................................. 9F-16
Special Tools and Equipment ........................... 9E-36 Replacement of Transmitter Battery (Ignition
Recommended Service Material ....................... 9E-36 Switch Model).................................................. 9F-16
Specifications ..................................................... 9F-16
Security and Locks ..................................9F-1 Tightening Torque Specifications...................... 9F-16
General Description ............................................. 9F-1 Special Tools and Equipment ........................... 9F-17
Power Door Lock System Description................. 9F-1 Recommended Service Material ....................... 9F-17
Emergency Lever of Rear End Door
Description ........................................................ 9F-2 Seats ......................................................... 9G-1
Table of Contents 9-v
Repair Instructions ..............................................9G-1 Specifications.....................................................9H-40

Front Seat Components ......................................9G-1 Plastic Part Specifications.................................9H-40
Front Seat Removal and Installation ...................9G-8 Tightening Torque Specifications......................9H-44
Front Back and Front Cushion Disassembly
and Reassembly .............................................9G-10 Hood / Fenders / Doors ............................9J-1
Rear Seat Components ....................................9G-16 Precautions........................................................... 9J-1
Rear Seat Removal and Installation .................9G-20 Precautions for Disposal of Rear End Door
Rear Back and Rear Seat Cushion Balancer ............................................................ 9J-1
Disassembly and Reassembly ........................9G-21 Diagnostic Information and Procedures ............ 9J-1
Specifications.....................................................9G-24 Hood and Door Opening and Closing
Tightening Torque Specifications......................9G-24 Inspection.......................................................... 9J-1
Repair Instructions .............................................. 9J-1
Exterior Trim / Interior Trim .................... 9H-1 Hood Removal and Installation ........................... 9J-1
Repair Instructions ..............................................9H-1 Hood Inspection and Adjustment ........................ 9J-2
Front Bumper and Radiator Grille Hood Latch and Hood Lock Release Cable
Components......................................................9H-1 Components...................................................... 9J-2
Front Bumper and Radiator Grille Removal Hood Latch and Hood Lock Release Cable
and Installation..................................................9H-3 Removal and Installation................................... 9J-3
Front Bumper and Radiator Grille Front Fender Components .................................. 9J-4
Disassembly and Reassembly ..........................9H-5 Front Fender Removal and Installation ............... 9J-5
Rear Bumper Components .................................9H-8 Front Door Assembly Components ..................... 9J-7
Rear Bumper Removal and Installation ..............9H-9 Front Door Assembly Removal and
Rear Bumper Disassembly and Reassembly....9H-10 Installation ......................................................... 9J-8
Front End Upper Cover, Front Bumper Lower Rear Door Assembly Components...................... 9J-9
Absorber, Front End Lower Cover, Front Rear Door Assembly Removal and
Bumper Member and Front Lower Installation ....................................................... 9J-10
Crossmember Components ............................9H-11 Fuel Filler Door Removal and Installation ......... 9J-10
Front End Upper Cover, Front Bumper Lower Fuel Filler Door Opener Cable Components..... 9J-11
Absorber, Front End Lower Cover, Front Fuel Filler Door Opener Cable Removal and
Bumper Member and Front Lower Installation ....................................................... 9J-11
Crossmember Removal and Installation .........9H-12 Rear End Door Assembly Components ............ 9J-13
Cowl Top Garnish Components ........................9H-13 Rear End Door Assembly Removal and
Cowl Top Garnish Removal and Installation .....9H-14 Installation ....................................................... 9J-14
Hood Silencer Removal and Installation ...........9H-16 Front door, Rear Door and Rear End Door
Dash Panel Outer Silencer Removal and Inspection and Adjustment.............................. 9J-15
Installation.......................................................9H-17 Specifications..................................................... 9J-16
Splash Guard Components...............................9H-18 Tightening Torque Specifications...................... 9J-16
Splash Guard Removal and Installation............9H-18 Special Tools and Equipment ........................... 9J-16
Roof Molding Components ...............................9H-19 Recommended Service Material ....................... 9J-16
Roof Molding Removal and Installation.............9H-20
Rear End Door Spoiler Components.................9H-22 Body Structure......................................... 9K-1
Rear End Door Spoiler Removal and
Precautions...........................................................9K-1
Installation.......................................................9H-23
Precautions for Body Structure ...........................9K-1
Rear End Door Garnish Components ...............9H-23
General Description .............................................9K-2
Rear End Door Garnish Removal and
Body Repair Description .....................................9K-2
Installation.......................................................9H-24
Sheet Metal Description ......................................9K-4
Engine Under Cover and Engine Under Side
Body Structure Description ...............................9K-15
Cover Removal and Installation ......................9H-25
Checking and Straightening Benches
Trim Components .............................................9H-25
Instruction........................................................9K-17
Trim / Console Removal and Installation ..........9H-26
Center Console Box Components ....................9H-29 Component Location .........................................9K-17
Center Console Box Removal and Installation ..9H-31 Silencer Sheet Installation Area ........................9K-17
Floor Carpet Removal and Installation..............9H-33 Diagnostic Information and Procedures ..........9K-18
Main Floor Pad and Front Floor Silencer Inspection for Body Damage.............................9K-18
Sheet Removal and Installation ......................9H-34 Transmission Routes of Impact.........................9K-19
Roof Lining Components ..................................9H-35 Panel Clearance................................................9K-20
Roof Lining Removal and Installation ...............9H-36 Front Body Dimensions.....................................9K-22
Roof Side Rail Absorber Removal and Rear Body Dimensions .....................................9K-24
Installation (If Equipped) .................................9H-39 Side Body Dimensions ......................................9K-25
Accessory Socket Removal and Installation .....9H-40 Underbody Dimensions.....................................9K-31
9-vi Table of Contents
Engine Compartment Dimensions with Schematic and Routing Diagram ....................... 9O-3
Mechanical Parts ............................................ 9K-33 Smartphone Linkage Display Audio System
Front Underbody Dimensions with Circuit Diagram ................................................ 9O-3
Mechanical Parts ............................................ 9K-34 Telematics System Circuit Diagram ................... 9O-4
Front Suspension Frame Dimensions............... 9K-35 360 View Camera Control Module System
Repair Instructions ............................................9K-37 Circuit Diagram ................................................ 9O-5
Hood Lock Member and Headlight Support Component Location .......................................... 9O-6
Removal and Installation................................. 9K-37 Audio System Component Location................... 9O-6
Front Fender Bracket Removal and Telematics System Component Location........... 9O-8
Installation ....................................................... 9K-39 360 View Camera Component Location ............ 9O-9
Front Side Member Removal and Installation ... 9K-43 Diagnostic Information and Procedures ......... 9O-10
Cowl Side Member Removal and Installation ... 9K-48 360 View Camera System Check .................... 9O-11
Front Fender Apron (Front Side) Removal Visual Inspection .............................................. 9O-14
and Installation ................................................ 9K-50 Audio System Symptom Diagnosis .................. 9O-14
Front Fender Apron Removal and Installation .. 9K-57 Telematics System Symptom Diagnosis.......... 9O-15
Front Pillar Outer Removal and Installation ...... 9K-60 360 View Camera Symptom Diagnosis............ 9O-15
Dash Side Removal and Installation ................. 9K-64 Self-Diagnosis Function ................................... 9O-17
Front Pillar Inner Removal and Installation ....... 9K-69 DTC Check....................................................... 9O-17
Center Pillar Outer Removal and Installation .... 9K-76 DTC Clearance ................................................ 9O-17
Center Pillar Inner Removal and Installation..... 9K-78 DTC Table........................................................ 9O-18
Side Sill Outer Removal and Installation...........9K-85 Scan Tool Data ................................................ 9O-22
Side Sill Strength Removal and Installation ...... 9K-88 Scan Tool Active Test Table ............................ 9O-26
Rear Fender Removal and Installation.............. 9K-91 Scan Tool Utility Table ..................................... 9O-27
Rear Wheel House Outer Removal and DTC B1240-11 / B1240-12 / B1240-13 /
Installation ....................................................... 9K-96 B1241-11 / B1241-12 / B1241-13 / B1242-
Rear End Panel Removal and Installation ........ 9K-98 11 / B1242-12 / B1242-13 .............................. 9O-27
Rear Floor (Partial) Removal and Installation . 9K-102 DTC B1240-87 / B124E-00 .............................. 9O-28
Rear Floor Side Member and Rear Wheel DTC B1241-29 / B1251-87............................... 9O-29
House Inner Removal and Installation .......... 9K-107 DTC B1244-23 / B1244-24 / B1245-29 ............ 9O-31
Rear End Pillar Removal and Installation........ 9K-112 DTC B1246-00 /B1246-9A ............................... 9O-32
Roof Removal and Installation ........................ 9K-118 DTC B1246-13 ................................................. 9O-33
Foamed Material Filling Area Repair............... 9K-122 DTC B1246-1C / B1246-49 .............................. 9O-34
Specifications...................................................9K-124 DTC B1249-04 ................................................. 9O-34
Tightening Torque Specifications.................... 9K-125 DTC B124F-00 ................................................. 9O-35
Special Tools and Equipment .........................9K-125 DTC B1250-00 ................................................. 9O-36
Recommended Service Material ..................... 9K-125 DTC B1252-00 ................................................. 9O-36
DTC B1253-16 / B1253-17............................... 9O-37
Paint / Coatings ........................................9L-1 DTC B1261-00 ................................................. 9O-38
General Description ............................................. 9L-1 DTC B1D00-04................................................. 9O-38
Anti-Corrosion Treatment.................................... 9L-1 DTC B1D00-04................................................. 9O-39
Repair Instructions .............................................. 9L-1 DTC B1D01-00 / B1D02-00 / B1D03-00 /
Sealant Application Areas ................................... 9L-1 B1D04-00 ....................................................... 9O-39
Undercoating Application Areas........................ 9L-12 DTC B1D06-1C ................................................ 9O-42
Anti-Corrosion Compound Application Area ..... 9L-14 DTC B1D07-1C ................................................ 9O-45
DTC B1D08-54................................................. 9O-47
Audio Visual / Navigation ....................... 9O-1 DTC B1D09-54................................................. 9O-47
Precautions.......................................................... 9O-1 DTC B1D0B-76 ................................................ 9O-48
Precautions for Rearview Camera (If DTC B1D0E-81 ................................................ 9O-48
Equipped)......................................................... 9O-1 DTC B1D0F-81 ................................................ 9O-49
Precautions for Telematics System (If DTC B1D14-81 / B1D16-81 ............................. 9O-50
Equipped)......................................................... 9O-1 DTC U0073-88 ................................................. 9O-50
Precautions for Data Communication module DTC U0100-87 / U0101-87 / U0121-87 /
replacement (if Equipped) ................................ 9O-1 U0126-87 / U0140-87 / U0151-87.................. 9O-50
Precautions for 360 View Camera ..................... 9O-1 DTC U0401-81 ................................................. 9O-51
DTC U0402-81 ................................................. 9O-51
General Description ............................................ 9O-2
DTC U0415-81 ................................................. 9O-52
Telematics System Description.......................... 9O-2
Data Communication Module Power Supply
Smartphone Linkage Display Audio
and Ground Circuit Check (If Equipped) ........ 9O-53
Description ....................................................... 9O-3
Inspection of Smartphone Linkage Display
360 View Camera Description............................ 9O-3
Audio unit and Its Circuits .............................. 9O-54
Table of Contents 9-vii
Inspection of Telematics System and Its USB Charging Socket Removal and
Circuit (If Equipped) ........................................9O-59 Installation ...................................................... 9O-74
Inspection of 360 view camera control module Data Communication Module Removal and
and Its Circuit ..................................................9O-60 Installation (If Equipped) ................................ 9O-74
Repair Instructions ............................................9O-63 Procedure after Replacing Data
Diagnosis Mode Transition Method...................9O-63 Communication Module ................................. 9O-76
360 View Camera Image Visual Inspection ......9O-63 Data Communication Module Built-in Battery
360 View Camera Calibration ...........................9O-64 Replacement (If Equipped) ............................ 9O-76
Vehicle Icon Color Setting.................................9O-66 TEL / GNSS Antenna Removal and
Smartphone Linkage Display Audio Unit Installation (If Equipped) ................................ 9O-76
Removal and Installation.................................9O-66 Front Camera Removal and Installation........... 9O-77
Steering Switch Removal and Installation.........9O-67 Side Camera Removal and Installation............ 9O-77
Steering Switch (Audio Control Switch and Rear Camera Removal and Installation ........... 9O-77
Hands-Free Switch) Inspection .......................9O-68 360 View Camera Control Module Removal
Front Speaker Removal and Installation ...........9O-69 and Installation ............................................... 9O-77
Rear Speaker Removal and Installation............9O-69 Operation for 360 View Camera Control
Tweeter Removal and Installation.....................9O-69 Module Replacement ..................................... 9O-78
Radio Antenna Removal and Installation ..........9O-69 360 View Camera Digital Cable Inspection...... 9O-78
Radio Antenna Inspection .................................9O-71 Camera Switch Removal and Installation ........ 9O-79
Radio Antenna Feeder Cable Inspection ..........9O-71 Camera Switch Inspection ............................... 9O-79
Radio Antenna Amplifier Power Supply Circuit Specifications.................................................... 9O-79
Inspection........................................................9O-71 Tightening Torque Specifications..................... 9O-79
GPS Antenna Removal and Installation............9O-73 Special Tools and Equipment .......................... 9O-80
Microphone Removal and Installation ...............9O-73 Special Tool ..................................................... 9O-80
USB Socket Removal and Installation ..............9O-73
9-1 Precautions:
Precautions
Precautions
Precautions for Body, Cab and Accessories
AENNTA0E9000001 (01(01)
General Precautions


Warning for Air Bag


Precautions for Working on Glass

Refer to “Precautions for Working on Glass” in Section 9E.
Precautions for Working on Power Window

Refer to “Precautions for Working on Power Window” in Section 9E.
Precautions for 360 View Camera

Refer to “Precautions for 360 View Camera” in Section 9O.

• Observe the following points, or memorized diagnosis code may be deleted.
– Do not disconnect the system connector.
– Do not disconnect negative (–) cable at battery.
– Do not disconnect the system grounding.
– Do not disconnect the system fuse.
– Do not set ignition “OFF” during troubleshooting.
• Before using scan tool, read its Operator’s Manual to know how to use it.
• Clear all DTCs after completing troubleshooting.

Wiring Systems: 9A-1
Wiring Systems
Precautions
Cautions for Body Electrical System Servicing
AENNTA0E9100001 (01(01)
When servicing the electric systems, observe the cautions described in “Precautions for Electrical Circuit Service” in
Section 00 to protect electrical parts and to prevent a fire.
General Description
Abbreviations
AENNTA0E9101001 (01(02)
Refer to “Abbreviations” in Section 0A for the general abbreviations.
Wire / Connector Color Symbols

AENNTA0E9101002 (01(02)
Refer to “Wire Color / Connector Color Symbols” in Section 0A.
Symbols and Marks

AENNTA0E9101003 (01(02)
Battery Ring-terminal ground Ground Normal fuse Slow blow fuse
I2RH01910910-01 IYSQ01910915-01 IYSQ01910916-01

IYSQ01910917-01 IYSQ01910918-01
Circuit breaker Coil, Solenoid Heater Bulb Bulb
IYSQ01910922-01 IYSQ01910923-01
IYSQ01910919-01 IYSQ01910920-01 IYSQ01910921-01
Cigar lighter Motor Pump Horn Speaker
H
IYSQ01910924-01
I5JB0B910995-02
IYSQ01910925-01 IYSQ01910926-01 I2RH01910911-02
Buzzer Chime Capacitor Thermistor Reed switch
IYSQ01910929-01 IYSQ01910930-01
IYSQ01910931-01
IYSQ01910932-01 IYSQ01910933-01
Resistance Variable resistance Variable resistance Transistor NPN Transistor PNP
IYSQ01910934-01 IYSQ01910935-01 IYSQ01910936-01 IYSQ01910937-01 IYSQ01910938-01
Photo transistor Diode Zener diode Light emitting diode Photo diode
IYSQ01910939-01
IYSQ01910940-01 IYSQ01910941-01 IYSQ01910942-01 IYSQ01910943-01
Piezoelectric element Connected harnesses Crossing harnesses Ring terminal Connector

9A-2 Wiring Systems:
IYSQ01910944-01
IYSQ01910945-01 IYSQ01910946-01 IYSQ01910948-01
IYSQ01910947-01
Normally-open relay Normally-closed relay Normally-open switch Normally-closed switch
IYSQ01910949-01 IYSQ01910950-01 IYSQ01910951-01 IYSQ01910952-01
Ignition switch Keyless entry Immobilizer system Combination meter Lighting switch
I3JA01910902-01 I5RH01910901-01 I2RH01910915-01

I2RH01910912-01 I2RH01910916-01
Headlight leveling Hazard warning light Front fog light Rear fog light Spark plug
I3JA01910904-01 I3JA01910905-01 I3JA01910906-01 I3JA01910907-01

I2RH01910921-01
Radiator cooling fan Fuel pump Fuel injector XX control module Windshield wiper
XX
Cont M
I3JA01910908-01 I3JA01910909-01
I2RH01910925-02
I2RH01910922-01 I2RH01910924-01
Windshield washer Rear wiper Rear washer Rear defogger Power window
I3JA01910910-01 I3JA01910911-01 I3JA01910912-01 I2RH01910930-01 I3JA01910913-01

Power door lock Power mirror A/B Pretensioner Passenger side
I3JA01910914-01 I3JA01910915-01 I3JA01910916-01 I3JA01910917-01 I3JA01910918-01

Driver side Seat heater A/C Power steering Side-air bag (R)
I3JA01910919-01 I2RH01910938-01 I3JA01910920-01 I3JA01910921-01 I4JA01910901-01

Side-air bag (L) Side curtain air bag (R) Side curtain air bag (L) Glow plug
I4JA01910902-01 I5RS0A910958-01 I5RS0A910959-01

I4JA01910903-01
How to Read Connector Layout Diagram

AENNTA0E9101004 (01(02)
[A-1]: Harness Symbol and Corresponding Harness Name
A: Battery cable
B: A/C harness
C: Engine harness
D: Injector harness, Oil pressure switch wire
E: Main harness, Power steering wire
F: Console wire
G: Instrument panel harness, Instrument panel antenna wire

J: Side door wire (including P/W related wires)
K: Interior light harness, Roof wire, Roof radio antenna wire, Rear speaker wire
L: Floor harness, Floor antenna wire, Coupling harness, Accessory socket wire, G sensor wire
M: Rear bumper wire
O: Rear end area harness/wires (except Rear bumper wire)
Q: Curtain air bag wire, Side-air bag harness, Pretensioner wire
R: Fuel pump wire
S: Contact coil
[A-2]: Connector Number
[B]: Ground Point No.
11 [B]
L33 L25 L24 L26 (TO O01) L36

L20 L28 R02 Connector code
L09
L10 L 36
L11
L12
[A-1] [A-2]
L14
{ L15
R01
L42
R04
L01 (TO G01)

L02 (TO E04) L05
[B] R05 L13
L03 (TO E05)
L19 L32 L16 L07 (TO K02)
12
I2RH01910901-02
How to Read Connector Codes and Terminal Nos.

AENNTA0E9101005 (01(02)
1) Connector code/Terminal No./Terminal layout
• The connector shape and terminal layout shown in this manual are those viewed from “Z” in the illustration.
Refer to “List of Connectors”.
View Z
"CONNECTOR LIST"
Male terminal A40 Connector code

4 3 2 1
8 7 6 5
(View Z) A40
5
D18
Female terminal D18
1 2 3 4
5 6 7 8
(View Z) Connector code
Terminal No.
IDAA0A910A46-02
NOTE
Molded terminal numbers that are different from the above can be found on some connectors in rare
cases.
These molded numbers are not applied in this manual.
2) Connector type
I2RH01910903-01
3) Terminals in one connector (Broken line) (B15) / Terminals in different connectors (B14, B16)
B15
B14 B16
B15 5 7 B14 5 B16 7
I2RH01910904-02
4) Joint connector (J/C)

• The joint connector (J/C) connects several different wires with the same wire color at one place instead of
connecting them by welding or caulking one by one. It is not an ordinary connector but a part of the continuous
wire in the harness.
Example
J/C
WHT/BLK
WHT/BLK
WHT/BLK
WHT/BLK
WHT/BLK
A A A A A
J/C
A
WHT/BLK
RED/YEL
WHT/BLK
A A A A B B C C
B A A A A B B C C
RED/YEL
RED/YEL
BLK
BLK
C
C BLK
BLK
IGSB0A910945-02
5) Weld splice (W/S)

• Several different wires with the same wire color are joined by welding at a W/S.
Example W/S Connector layout diagram
ORN W/S
ORN
ORN
ORN
ORN
ORN
Weld W/S
W/S W/S W/S
ORN
IGSB0A910946-01
6) Junction block (J/B)
Example
J/B inner circuit
Connector No. / Terminal No.
J/B BCM E39 E40 E41 G32 G33 G34 K01 L04 L05 L06
J/B
IG1 IG1
2
BLK/WHT
IMMOBI IG
6
23
IG Coil 15A IG Coil, etc
5
BCM ;IG1
11
25
MTR 10A MTR Power, etc
6
30
A/B 15A A/B CONT
1
K-LINE
8
K-LINE
3
A/B SIGNAL
9
A/B SIGNAL
2
ORN
A/B SIG
4
J/B A/B SIG

13
MTA
11
29
IG Sig 10A EPS AT
12
9
J/B
GRN
IGSB0A910947-01
7) Connector location, shape and terminal No.

Refer to “Connector Layout Diagram”.

Refer to “System Circuit Diagram”.
Refer to “List of Connectors”.
Referring to connector code in System Circuit Diagram [A], location of the connector, connector shape and
terminal layout can be found respectively.
• When checking connector location
Referring to connector code in Connector Layout Diagram [B], location of the connector can be found.
• When checking connector shape and terminal layout
Referring to connector code and the terminal No. in List of Connector [C], the connector shape and terminal
layout in the connector can be found.
System Circuit Diagram Connector code and terminal No. are shown in each “System Circuit Diagram”. Using
the connector code and terminal No., location of the connector, connector shape and
terminal layout concerned can be found in the applicable “Connector Layout Diagram”
and “List of Connector”.
Connector Layout Diagram Checking objective connector code in the applicable “System Circuit Diagram”,
location of the connector can be found in the applicable “Connector Layout Diagram”.
List of Connector Checking objective connector code and terminal No. in the applicable “System Circuit
Diagram”, the connector shape and terminal layout can be found in the applicable “List
of Connector”.
[B]
C52
C08
C30
17
(G02)
18 C07 C09 C11
C27 C58 C44 C31
(G01) C13
C35
C54 C57
C01
C51 C25 C64
C03
C63 C21
(E40)
C14 18
C50
C47 C49
C56
18
C55
C24
[A]
C26
C48 C53 C05 C20
C04
C29 C19
C
C42
C42
C42
C42
[C]
C01 C02 C03 C07 C08 C09
1 2 1 2 1 2 1 2 3 1 2 3 1 2 3
C13 C14 C15 C16 C19 C21
1 2 3
C42
1 2 3 4
1 2 1 2 1 1 2 3
4 5 6 5 6 7 8
A/T
C22 C23 C24 C25 C26 C27
1 2 1 2 3 1 2 3 1 2 1 2 3
1
C28 C32 C34 C35 C36 C37
1 2 3 4
1 2 3 1 2 1 2 3 4 5
1 1 2
5 6 7 8 6 7 8 9
A/T M/T A/T

C38 C39 C41
C42 C43 C44
1 2 3 1 2 3 1 2 3 1
1 1
4 5 6
M/T
C45 C51 C52 C53 C54 C55
1 2 1 2 1 2 1 2
1 3 1 2 3
3 3 3
4 4 4 4 4 5 6
A/T
C56 C58 C59 C61 C63
201 202 203 204 205 206 207 208 209
1
1 1 210 211 212 213 214 215 216 217
1
2 218 219 220 221 222 223 224 225 226
227 228 229 230 231 232 233 234
C64 C68
1 2 3 4 5 6 7 8 9 201 202 203 204 205 206 207

10 11 12 13 14 15 16 17 208 209 210 211 212 213 214 215 216 217 218 219
18 19 20 21 22 23 24 25 26
220 221 222 223 224 225 226 227 228
27 28 29 30 31 32 33 34
IFRA0A910901-02
How to Read Ground Point

AENNTA0E9101006 (01(02)
Refer to “Ground Point”.
"SYSTEM CIRCUIT DIAGRAM" "GROUND POINT"
Individual
fuse box
20
circuit
15A
10
YEL/BLU
10 11 12
E40
16 20 5 6 7
YEL/BLU
BLU/WHT
BLU/RED
BLU
BLU/BLK
Windshield washer motor
E20 2 1 3 E20 4
BLK
E09 2
Windshield wiper motor

M
M
Off
1
BLK
BLK
On
Circuit
BLK
breaker Left side shown

1 10 9
10
Device body grounding does not give the ground point number.
CROSS-REFERENCE
IGSB0A910948-02
How to Read Power Supply Diagram

AENNTA0E9101007 (01(02)
Refer to “Power Supply Diagram”.
"POWER SUPPLY DIAGRAM"

- +
BLK Fuse number
Battery
Supplementary fuse box

Main fuse box
1 2 3 4 5 6 7 8 29 9
80A 15A 15A 15A 25A 50A 30A 60A 30A 60A
32
E44 3 2 1 B01 1 E45 1 E40 2 1 15A
BLK
BLK
WHT
BRN
PNK
BLU
WHT/BLU
WHT/YEL
BLU/RED
YEL/BLK
RED
WHT
WHT
2 3 4
BLU
BLK
Individual circuit
11 12 13 14 15 16 17 18 19 20 21
fuse box
15A 15A 15A 20A 20A 15A 15A 15A 15A 15A 15A
BLK
BLK
WHT/GRN
WHT/BLK
BLK/WHT
YEL/GRN
BLU/RED
PNK/BLK
YEL/BLU
YEL/BLK
LT GRN
WHT
GRN
RED
YEL
1 2
"SYSTEM CIRCUIT DIAGRAM" 11 12 13 14 15 16 17 18 19 20 21 29 32
13 17
15A 15A Connection to the system
RY indicated
WHT/GRN
Fuse
RED/YEL
YEL
IGSB0A910949-02
How to Read System Circuit Diagram

AENNTA0E9101008 (01(02)
The circuit diagram is designed so the current flows from the top of the diagram (power source) to the bottom of the
diagram (ground) as if giving an image of water flow.
[A]: Fuse No.
[B]: Circuit jumping page / direction
NOTE
This means “Jump to the page directed with the arrow(s) by their number”.
(For example: “Two arrows directing left” means “Jump to two pages before”.)
You will find the same symbol with the arrows directing opposite in the referenced page. The circuit
continues between the symbols.
[C]: Circuit jumping point / direction
NOTE
The circuit continues to the same symbol with opposite direction within the page.
You will find the other symbol in arrow direction.
[D]: Terminals-in-one-connector Mark

[E]: Wire color
[F]: Shield wire
[G]: Ground point
[H]: “From” or “To” (With ID letter (s))
[I]: Specification variation
The white arrow between A and B means “or”.
[J]: “From” (With ID letter (s))
[K]: Twisted wires (Both CAN lines and non-CAN lines)
[L] “To” (With ID letter (s))
[M]: Connector code
[N]: Terminal No.
[O]: Symbol mark
[P]: “SEE” mark
[Q]: Base color “LVN” (Lavender) represents aluminum electric wire
[R]: Weld splice
<1>: 4-Doors
<2>: 2-Doors [I] [J] [K] [L] [M] [N] [O] [P]
3 1 6
Fuse
Fuse
15A 15A 20A
[A]
ECM
E33
A-3
BLK/RED
GB
[B]
ORN
Combination meter
Combination meter
BLU
GRN/BLK
E08 2 1
Main relay
C71 5 <1> TCM
E03 6 <2> C40 1
G20
G20
C-1
C-1
4
E01 1 2
Solenoid
GB GR
4 3
3
GRN/RED
GRN/RED
[C]
WHT
GRN
GRN/BLK
RED
YEL
2
[D] GRN
GRN
BLU
GRN/RED
(CAN)
GRN
2 E34 2
E34 1
E33 1 E34 7 8 10 5 1 O06 O06
GRN
GRN
ECM
[E]
2 5 6 4 4 6
GRN/BLK
BLK
GRN
WHT
ORN
YEL
C26 2
BLK
RED
LVN
<1>
<2>
2 E48 1 2
Sensor
Switch
[F]
OFF ON
Y
E52 1 E52 1
1
[G]
M
Motor
Motor
M
C-1
Fuel pump and gauge
L50
BLK
[H]
BLK
2 BRN/RED 2
<2>
C31 5
E19
RED
<1>
Other system circuit W/S

BRN/RED
BRN/RED
BLK
<2>
<2>
Combination meter
G20 3 Y Y
YEL/RED
8 5 [Q] [R] 5 6 1
GRN/RED
Fuel pump and gauge

YEL
L50 1 3
GR GR
P
2 4
IJSE0A910924-01
Glossary
print=OFF, AENNTA0E9101009 (01(02)
English
A/C & Rear defogger switch
A/C amplifier
A/C mode actuator
A/C Pressure sensor
English
A/T fluid
A/T mode switch
A/T shift illumination
A/T shift lock solenoid
ABS control actuator
Acceleration pedal sensor
Actuator (state)
Additional heater
Additional heater control module
Additional heater relay
Air flow control actuator
Ambient temperature sensor
Antenna amplifier
Audio/Antenna amplifier
Auto-dimming rearview mirror
Back-up light switch wire
Blower motor (control module)
Blower speed selector
Boost pressure (sensor)
Boost pressure control solenoid valve
Cancel switch
Canister purge valve
Circuit breaker
Clutch pedal position switch
CO adjusting resistor
Coil antenna
Combination switch
Condenser (fan)
Console light
Contact coil
Continuously variable transmission
Coupling air temperature sensor
Coupling solenoid
Courtesy light
Cruise actuator
Current sensor
Diesel engine control circuit
Differential temperature (/pressure) sensor
Double relay
Dual cut switch
Dual pressure switch
EGR stepper motor
ESP® control module
ESP® OFF switch
EVAP canister (purge/vent) valve
EVAP leak check module
Evaporator temperature sensor
Exhaust gas temperature sensor
Forward clutch cylinder revolution sensor
Forward sensor
Front (Rear) height sensor
Front clearance light
Front intermittent timer relay
Fuel filter water sensor
Fuel flow actuator
Fuel heating relay
Fuel level gauge
English
Fuel pressure (sensor/regulator)
Fuel pressure regulator valve
Fuel temperature sensor
Gas generator
Glow control module
Hazard warning light
Headlight leveling actuator
Headlight leveling motor
Heated oxygen sensor
Heater blower motor
Heater resistor
High mounted stop light
HVAC control (unit/module)
ID control module
Ignition timing resister
Ignitor
Illumination control module
Individual fuse box
Inlet throttle valve
Input sensor
Inside air temperature sensor
Intake control valve
Interior (dome) light
J/B (Junction Block) side connector
Keyless start control module
Knock sensor
License plate light
Lighting control module
Limit switch
Linear solenoid
Lock up solenoid
Luggage compartment (light)
Master switch
Meter illumination control
Mode actuator
Mode control switch
Mode select switch
Noise (filter/suppressor)
O/D cut switch
Occupant classification module
Oil control valve
Oil level switch
Oil pressure switch
Oil temperature sensor
Output diagnosis coupler
Output shaft speed sensor
Parking brake switch
Parking sensor system
Passenger A/B-OFF light
Position light
Power integration
Pressure regulator
Pressure switch
Pump pressure switch
Rail pressure
Rear intermittent timer relay
Receiver
Reference (zener) diode
English
Refrigerant pressure sensor
Request switch
Roof audio antenna amplifier
Rotation angle sensor
Security
Shift illumination
Shift lock relay
Shift lock solenoid
Side air-bag inflator
Slide switch
Sliding roof
Solenoid valve
Starting motor
Steering angle (switch/sensor)
Stepper motor
Sub fan relay
Sub switch
Sunload sensor
Tail light
Thermo-plug
Throttle motor relay
Throttle position sensor
Tilt switch
Torque sensor
Transaxle range switch sensor
Transmission control module
Triple pressure switch
Trunk room light (switch)
Trunk room lock solenoid
Trunk room request switch
Turn signal light
Tweeter (R) (L)
Universal exhaust gas oxygen sensor
Up (Down) stream turbine temperature
Vanity light
Variable resistance
Vehicle speed sensor
Warning control module
Water-in-fuel (sensor)
Weld splice
With
Without
Woofer
Yaw sensor
Connector Layout Diagram

Connector Layout Diagram
AENNTA0E910A001 (04(01)
Refer to “Engine Compartment”.
Refer to “Instrument Panel”.
Refer to “Door, Roof”.
Refer to “Floor”.
Refer to “Rear”.
Engine Compartment
AENNTA0E910A002 (04(01)
A: Battery Cable / C: Engine Harness (K12N M/T Model)
W/S C94 C96 C47 W/S C36 C168

C
C192 C93 C95 W/S C32 C48 C01
C92
C91
C162
C132 C343
(E371)
A72
C101 A
C194 C282
C283
C37
C31 2
C165
C56
1
C133
C27 3 C195 C97 C98 C42 C39

C141 C102 C196 C103 C104 C122 C29 C123
IMTA0A910929-01
A: Battery cable
No. Color Connective position Remarks
A72 — Battery (–)
C: Engine harness
C01 BLK ECM
C27 GRY Engine oil temperature sensor
C29 BLK Exhaust CMP sensor
C31 BLK CKP sensor
C32 BLK Intake CMP sensor
C36 GRY MAP sensor
C37 GRY Knock sensor
C39 BLK ECT sensor
C42 GRY HO2S-1
C47 BLK MAF and IAT sensor
C48 BLK Electric throttle body
C56 BLK HO2S-2
C91 BLK Fuel injector No.1-1
C92 GRY Fuel injector No.1-2

C101 BLK Ignition coil No.1
C122 GRY EGR stepper motor
C123 BLU EVAP canister purge valve
C132 BLK Intake OCV
C133 BLU Exhaust OCV
C141 BLK A/C compressor
C162 BLK Engine oil pressure switch
C165 BLK Back up light switch
C168 BLK Neutral position switch
C192 — Generator (+B)
C194 D GRY Generator
C195 BLK Starting motor
C196 — Starting motor (+B)
C282 — Main fuse box
C343 N Main harness (To E371)
C: Engine Harness (K12N AGS Model)
W/S C94 C96 C47 W/S C36 C15

C
C192 C93 C95 W/S C33 C32 C48 C01
C92
C91
C162
C132 C343
(E371)
C191
C101 1
C194 C282
C283
C37
C31 2
C56
C133
C344
(E372)
C27 3 C195 C97 C98 C42 C39

C141 C102 C196 C103 C104 C122 C29 C123
IMTA0A910930-01
C: Engine harness
C01 BLK ECM
C15 BLK TCM (AGS)
C27 GRY Engine oil temperature sensor
C29 BLK Exhaust CMP sensor
C31 BLK CKP sensor
C32 BLK Intake CMP sensor
C33 GRY VSS (Vehicle speed sensor)
C36 GRY MAP sensor
C37 GRY Knock sensor
C39 BLK ECT sensor
C42 GRY HO2S-1
C47 BLK MAF and IAT sensor
C48 BLK Electric throttle body
C56 BLK HO2S-2
C122 GRY EGR stepper motor
C123 BLU EVAP canister purge valve
C132 BLK Intake OCV
C133 BLU Exhaust OCV
C141 BLK A/C compressor
C162 BLK Engine oil pressure switch
C191 — Battery (–)
C192 — Generator (+B)
C194 D GRY Generator
C195 BLK Starting motor
C196 — Starting motor (+B)
C343 N Main harness (To E371)
C344 BLK Main harness (To E372)
E: Main Harness
Sub relay box
38
39 E247 E232 E248
40
41
Relay box (K12N)
7 8 9 10 11
12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28 29 30
31 32 33 34
- E223 E461 E227 E235 E224 E229
A : Harogen headlight model

B : LED headlight model E221 - E234 E263 E222 E225 E237
E E371
E64 E312 E01 (C343)
E185 W/S E311 E58 E09
E165 E166
E307
E183
E364
6
W/S
E36
W/S
9
E35
A E68
A E69
B E68 B E69
E153 E154
or or
E178 E179
E155 E156
8 5
E161
E162
E159 E160
W/S
E163
E63
E62
E40
E309
E34
E303
E302
E545
E210 E281
E65 E282
E37 E372
(C344) { E596
E595
E164
Front camera cable

IMTA0A910931-02
E: Main harness
E01 BLK ECM

E09 BLK ABS/ESP® control module
E34 BLK Wheel speed sensor (Front-right)
E35 BLK Wheel speed sensor (Front-left)
E36 BLK A/C refrigerant pressure sensor
E37 BLK Outside air temperature sensor
E40 YEL Driver-side forward impact sensor
Electric load current sensor & battery temperature
E58 GRY
sensor
E62 N Windshield washer motor
E63 BLK Rear washer motor
E64 GRY Windshield wiper motor
E65 GRY Radiator cooling fan motor
E68 BLK Headlight leveling actuator (R)
E69 BLK Headlight leveling actuator (L)
E153 N Headlight HI (R) Halogen headlight model
E154 N Headlight HI (L) Halogen headlight model
E155 BRN Headlight LO (R) Halogen headlight model
E156 BRN Headlight LO (L) Halogen headlight model
E159 GRY Front turn signal light (R)
E160 GRY Front turn signal light (L)
E161 BLK Front position light (R) Halogen headlight model
E162 BLK Front position light (L) Halogen headlight model
E163 BLK Front fog light (R) If equipped
E164 BLK Front fog light (L) If equipped
E165 N Side turn signal light (R) If equipped
E166 N Side turn signal light (L) If equipped
E178 GRY Headlight unit (R) LED headlight model
E179 GRY Headlight unit (L) LED headlight model
E183 GRY Brake fluid level switch
E185 GRY Brake booster switch ABS model
E210 BLK Hood switch With keyless entry system
E221 BLK Main relay
E222 BLK Radiator cooling fan relay No.1
E225 BLK Starting motor control relay
E227 BLK Fuel pump relay
E229 BLK A/C compressor relay
E232 BLK Headlight HI relay
E234 BLK Front fog light relay If equipped
E235 BLK Horn relay
E237 BLK Blower motor relay
E247 BLK Headlight LO relay (R) LED headlight model
E248 BLK Headlight LO relay (L) LED headlight model
E263 BLK Back up relay AGS model
E281 BLK Horn LO
E282 BLK Horn LO
E302 BLK Horn HI
E303 BLK Horn HI
E304 GRY Security horn (Siren) With keyless entry system
E307 GRY Outside warning buzzer Keyless push start model
E311 BLK Main fuse box
E312 GRY Main fuse box
E364 BLK Brake booster pressure sensor ESP® model
E371 N Engine harness (To C343)
E372 BLK Engine harness (To C344) AGS model
E461 BLK “ST2” relay
E595 BLK Front view camera cable (To E596) If equipped
E: Front view camera cable

E545 — Front view camera If equipped
E596 BLK Main harness (To E595) If equipped
Instrument Panel
AENNTA0E910A003 (04(01)
E: Main Harness
E05
E04
E323
E324
FWD
E346 E347 E308 E348 E192 E190
E05
E04
11
7
E387
(L371)
E323
E324
E213
E381
(G333)
E382
(G334)
E181 E191
E10 (M/T model)

E10 (AGS model)
IMTA0A910932-02
E: Main harness
E04 GRY BCM
E05 GRY BCM With keyless entry system
E10 N P/S control module (P/S motor)
E181 N Brake light switch
E190 N CPP switch No.1 M/T model
E191 BLK APP sensor
E192 GRY CPP switch No.2 M/T model
E213 GRY DC/DC converter
E308 BLK Diode Halogen headlight model
E323 N J/B

E324 N J/B
E346 N J/C
E347 N J/C
E348 BLK J/C
Without keyless entry
E381 GRY Instrument panel harness (To G333)
system
E382 N Instrument panel harness (To G334)
E387 N Floor harness (To L371)
G: Instrument Panel Harness, Instrument Panel Audio Antenna Wire, USB Cable, Passenger Air Bag Harness /
S: Contact Coil
G06
G04
G271
G05
S
FWD
G : Instrument panel antenna wire
G236
G221
G62 G128 { G373

G372
G267
G248 G306 S121 G308
G241
G309 G354
G36 G259 G231 G294 G63 G240 S61 G59 (K154)
W/S G153 G232 W/S 14 G35 G38
G340
(K156)
G446
W/S
G G170
G427
G152
G116
G333 G117
(E381) G293
G334 G56
(E382)
G386
G339
(J249)
(J212)
G362 G338
(J214) (J211)
G361
G341
(J213)
(L374)
G50 G147 G146 G17
13
G141 G145
G342
12 G112 G255 G61 G65

{ S171
G346 G144 G211
(L375)
G311 G130 G32

G60
G227 G310 G307 G64
G251 G11 G216 {
S172
G347
G129 G140
G : Camera control cable
G : USB cable
IMTA0A910933-02
G: Instrument panel harness

G04 GRY BCM

G05 BLU BCM With keyless entry system
G06 GRY BCM With keyless entry system
G10 N P/S control module
G11 YEL SDM
G17 N Immobilizer control module Ignition switch model
G32 N Evaporator temperature sensor
G33 N Steering angle sensor
G35 N Sunload sensor Auto A/C model
G36 BLK Auto-on headlight sensor Auto-on headlight model
G38 N Shock sensor With keyless entry system
G56 GRY 360 view camera control module If equipped
G59 N Head-up display control module
G60 BLK Central gateway control module
G61 BLK Blower motor
G62 N Air intake control actuator
G63 GRN Air flow control actuator Auto A/C model
G64 GRN Temperature control actuator Auto A/C model
G65 BLK Blower motor control module Auto A/C model
G112 BRN Glove box light switch
G116 N ENG A-STOP OFF switch
G128 N Glove box light
G129 N Foot light (R) If equipped
G130 N Foot light (L) If equipped
G140 N Engine push start switch Keyless push start model
G141 BLK Combination switch (Wiper)
G144 N or BLK Combination switch (Light)
G145 N Main switch (key) Ignition switch model
G146 N Auto steering lock unit Keyless push start model
G147 N Ignition switch Ignition switch model
G152 BLK Headlight leveling switch
G153 N Hazard switch
G170 GRY ESP® OFF switch ESP® model
G211 BLK DLC
G227 BLK Auto A/C panel Auto A/C model
G231 GRY Audio unit (Microphone) If equipped
G232 GRN Audio unit (Rearview camera) If equipped
G240 N Combination meter
G241 N Combination meter
GRY Display audio unit 12pin connector type
G243
N Audio unit 5pin connector type
GRY Display audio unit 24pin connector type
G248
BLU Audio unit 20pin connector type
G251 BLK Accessory socket
G255 BLK Diode
G271 GRY J/B
G294 N Data communication control module If equipped
G306 BLK J/C
G307 N J/C
G308 BLK J/C
G309 BLK J/C
G310 N J/C
G311 N J/C
Without keyless entry
G333 GRY Main harness (To E381)
system
G334 N Main harness (To E382)
G338 BLK Front door wire (To J211)
G339 BLK Front door wire (To J212)
G340 N Roof wire (To K156)
G341 N Floor harness (To L374)

G342 N Floor harness (To L375)
G346 BLK or N Contact coil (To S171)
G347 YEL Contact coil (To S172)
G361 GRY Front door wire (To J213)
G362 GRY Front door wire (To J214)
G372 YEL Passenger air bag harness (To G373)
G386 N Front door wire (To J249)
G427 BLK View select switch If equipped
G446 N Head-up display switch
G: Instrument panel audio antenna wire

G267 — Audio unit (Radio antenna)
G354 — Roof audio antenna wire (To K154)
G: USB cable
G216 — USB connector If equipped
G221 — Audio unit If equipped
G: Camera control cable

G236 — Audio unit If equipped
G293 — 360 view camera control module If equipped
G: Passenger air bag harness

G259 BLK Front-passenger air bag (inflator) module
G373 YEL Instrument panel harness (To G372)
S: Contact coil
Steering switch (Horn switch, audio control, cruise
S61 —
control)
S121 — Driver air bag (inflator) module
S171 — Instrument panel harness (To G346)
S172 — Instrument panel harness (To G347)
Door, Roof
AENNTA0E910A004 (04(01)
J: Front and Rear Door Wire, Door Courtesy Light Wire
Rear door wire (R)

J148
J35 J28
J83
{ J238
J240
J25 J82
J217 J145 J154
(L381) J86
J31
J85
J153
J
W/S
J81
J27
J147
J87
J13
{ J237
J239
J249
(G386) J36
J211
(G338)
J213 J84
(G361)
J26
J146
J218
(L382)
J32
J21 J14
J141 J80
Rear door wire (L)
J22
Courtesy lamp wire
J212 J214 J142
J79 (G339) (G362)
Courtesy lamp wire
Front door wire (Passenger side)

IMTA0A910934-01
J: Front door wire (Drive side)

J13 YEL Driver-side front side-impact pressure sensor
J21 BLK Front power window motor (Driver side)
J27 N Power mirror assembly (Driver side)
J31 N Front door lock switch & motor (Driver side)
J81 BLK Power window & door lock main switch
J85 N Door request switch (Driver side) Keyless push start model
J87 N Power mirror switch
J141 N Front speaker (R)
J147 BLK Tweeter (R) If equipped
J153 N Driver outside antenna Keyless push start model
J211 BLK Instrument panel harness (To G338)
J213 GRY Instrument panel harness (To G361)

J237 N Door courtesy light wire (To J239) If equipped
J249 N Instrument panel harness (To G386) If equipped
J: Door courtesy light wire (Driver side)

J79 GRY Door courtesy light (Driver side) If equipped
J239 N Front door wire (Driver side) (To J237) If equipped
J: Front door wire (Passenger side)

J14 YEL Passenger-side front side-impact pressure sensor
J22 BLK Front power window motor (Passenger side)
J28 N Power mirror assembly (Passenger side)
J32 N Front door lock switch & motor (Passenger side)
J82 N Power window sub switch
J86 N Door request switch (Passenger side) Keyless push start model
J142 N Front speaker (L)
J148 BLK Tweeter (L) If equipped
J154 N Front-passenger outside antenna Keyless push start model
J212 BLK Instrument panel harness (To G339)
J214 GRY Instrument panel harness (To G362)
J238 N Door courtesy light wire (To J240) If equipped
J: Door courtesy light wire (Passenger side)

J80 GRY Door courtesy light (Passenger side) If equipped
J240 N Front door wire (Passenger side) (To J238) If equipped
J: Rear door wire (R)

J25 BLK Rear power window motor (R)
J35 N Rear door lock motor (R)
J83 N Rear power window sub switch (R)
J145 N Rear speaker (R)
J217 N Floor harness (To L381)
J: Rear door wire (L)

J26 BLK Rear power window motor (L)
J36 N Rear door lock motor (L)
J84 N Rear power window sub switch (L)
J146 N Rear speaker (L)
J218 N Floor harness (To L382)
K: Roof Wire, Roof Audio Antenna Wire
Roof audio antenna wire

K121
K51
K130 K
K52
K127
K54
K154
(G354)
K55
K156
(G340)
K131
K131
FWD
IMTA0A910935-02
K: Roof wire
K51 N Dome light
K52 N Spot light If equipped
K54 N Vanity light (R) If equipped
K55 N Vanity light (L) If equipped
K127 BLK Auto-dimming rearview mirror If equipped
K130 N Microphone If equipped
K131 N J/B
K156 N Instrument panel harness (To G340)
K: Roof audio antenna wire

K121 — Roof audio antenna amplifier
K154 — Instrument panel antenna wire (To G354)
Floor
AENNTA0E910A005 (04(01)
L: Floor Harness / Q: Side-Air Bag Harness
L314
L01
FWD FWD
L371
(E387) L314 L01
L290 L374
W/S (G341)
{ L385
Q134 15
L176
Q105 L105
L162 L106
L291 L04
L382 L285
(J218) L175
L164
L390
(O231)
L13
L44
16
L262
L375
L134 (G342)
L132
L392 L
(M151)
L161
L283
L381
{ L384
Q133
(J217)
Q104
L167
L293 L296
L294 or
L32
L503
L61 L163
L31
L133
L43
IMTA0A910936-02
L: Floor harness
L01 GRN BCM

L04 YEL SDM
L13 N Parking sensor system control module With parking sensor system
L31 N Wheel speed sensor (Rear-right)
L32 N Wheel speed sensor (Rear-left)
L43 YEL Driver-side rear side-impact sensor
L44 YEL Passenger-side rear side-impact sensor
L61 BLK Fuel pump and gauge
L105 N Shift selector No.1 (AGS) AGS model
L106 N Shift selector No.2 (AGS) AGS model
L132 GRY Luggage compartment light If equipped
L133 N Rear combination light (R)
L134 N Rear combination light (L)
L161 N Front door switch (Driver side)
L162 N Front door switch (Passenger side)
L163 N Rear door switch (R)
L164 N Rear door switch (L)
L167 BLK Parking brake switch
L175 N Seat belt switch (Driver side)
L176 N Seat belt switch (Passenger side)
L262 GRY Parking sensor rear buzzer With parking sensor system
L283 BLK Driver seat belt pretensioner
L285 BLK Front-passenger seat belt pretensioner
L290 YEL Driver-side curtain air bag (inflator) module If equipped
L291 YEL Passenger-side curtain air bag (inflator) module If equipped
L292 BLK Rear outside antenna Keyless push start model
L293 N Rear inside antenna Keyless push start model
L294 BLK Mid inside antenna Keyless push start model
L296 BLK Rear accessory socket If equipped
L314 GRY J/B
L371 N Main harness (To E387)
L373 N Accessory socket wire (To L388)
L374 N Instrument panel harness (To G341)
L375 N Instrument panel harness (To G342)
L376 YEL Instrument panel harness (To G343)
L381 N Rear door wire (R) (To J217)
L382 N Rear door wire (L) (To J218)
L384 YEL Side air bag harness (Driver side) (To Q133) If equipped
L385 YEL Side air bag harness (Passenger side) (To Q134) If equipped
L390 N Rear end door harness (To O231)
L392 BLK Rear bumper wire (To M151) With parking sensor system
L503 BLK USB charging socket If equipped
Q: Side-air bag harness

Q104 — Driver-side side-air bag (inflator) module
Q105 — Passenger-side side-air bag (inflator) module
Q133 — Floor harness (To L384)
Q134 — Floor harness (To L385)
Rear
AENNTA0E910A006 (04(01)
M: Rear Bumper Wire / O: Rear End Door Harness
O92
O231
(L390)
O21
O121
O181
O188
O124
M151
(L392)
M116
M117
M54
M120 O182
M M53 17
M118
M119
IMTA0A910937-02
M: Rear bumper wire

M53 BLK License plate light (R)
M54 BLK License plate light (L)
M116 BLK Parking sensor (Rear-right) With parking sensor system
M117 BLK Parking sensor (Rear-center-right) With parking sensor system
M118 BLK Parking sensor (Rear-center-left) With parking sensor system
M119 BLK Parking sensor (Rear-left) With parking sensor system
M120 BLK Rear outside antenna Keyless push start model
M151 N Floor harness (To L392) With parking sensor system
O: Rear end door harness

O21 N Rear wiper motor If equipped
O92 N High mounted stop light
O121 N Rear end door lock switch & motor
O124 N Rear end door request switch Keyless push start model
O181 BLK Rear defogger (+) If equipped
O182 BLK Rear defogger (–) If equipped
O188 N Rearview camera If equipped
O231 N Floor harness (To L390)
Ground Point
Ground Point
AENNTA0E910C001 (04(01)
Reference: “How to Read System Circuit Diagram”
Refer to “Connector Layout Diagram”.
Right side shown 7 (R)
11 (L)
FWD
13 (R)
17
12 (L)
FWD
15
16
14
9 FWD
FWD 8
FWD 5
1
M/T model
1
AGS model
IMTA0A910938-02
Power Supply Diagram

Power Supply Diagram
AENNTA0E910D001 (10(01)
BLK
2
BLK/GRY
1
1
A72
C282
Battery
A-1 WHT
Relay box Starting motor
5A
33
LT GRN
33
5
E312
50A
BLU
A-1 YEL YEL
1
Starting motor
E225
30A
PNK YEL RED
5
4
1
41
15A
120A
C283
BLU
3
1
41
1
Starting motor control relay

PNK
BLK
40
15A
40A
E311
100A
LT GRN BLU WHT
40
1
A-2
E232
C192
GRN
9
3
1
Generator
39
25A
40A
3
80A
GRN YEL
F-4 RED
5
P/S motor
4
2
E10
Headlight HI relay Sub relay box
10
40A
RED
10
4
E312
100A
RED
2
16
25A
WHT Main fuse box

16
17
15A
GRY
17
18
15A
WHT
18
19
30A
Wiring Systems:
GRN
4
3
1
IMTA0A910902-02
9A-31
1 RED
12 11 27 20 21 25 26 28 29 30
Relay box
30A 40A 50A 30A 30A 20A 10A 15A 15A 10A
WHT
WHT
WHT
GRN
GRY
RED
BLU
WHT
GRY
BLU
20 22 25 26 28 29 30
AGS model
5 6
BLU
E323 22 E324 2
11
57 63 61 60 53 50 64 51 62 65 52 66
10A 5A 5A 5A 10A 15A 15A 10A 20A 5A 5A 10A
J/B
G271 17 6
LT BLU
GRY
7 8 BCM
IMTA0A910903-01
<1>
7 8 <1>: Ignition switch model

<2>: Keyless push start model
LT BLU
GRY
Ignition switch
4 3
G147
OFF
ACC
2
PNK
ON
ST G334 11
E382
PNK
5 6
A-1
5 6 1
GRY
BLU
LT GRN
BLU
YEL
G271 21 23 16 E324 3 1
<2>
BCM
7 20 22
Accessory IG11 IG23 IG22 IG21

relay relay relay relay relay
73 74 45 56 44 43 54 69 67 68 55 42 76 78 77 75
15A 5A 5A 5A 15A 10A 5A 10A 10A 10A 15A 30A 5A 25A 15A 10A
Rear
wiper
relay
11
Rear
defogger
79 46 47 48 49 relay E323 5 28 G271 1
/ mirror
10A 20A 10A 10A 20A heater
relay
WHT
BLU
BLK
W/S
71 72
9 10
LOCK 20A 10A
BLK
BLK
/UNLOCK
relay
J/B
BCM
12 14
IMTA0A910904-02
9 10 4
GRN
WHT
BLU
E213 1 8 5
DC/DC converter
4 6 7 9 10
GRN
RED
PPL
YEL
BLK
Pp G
A-5
ECM
E01
70 58 59
5A 5A 15A
J/B
G271 32 18 19 31
LT GRN
LT BLU
GRN
BLU
Lb L G Lg
70 58 58 59
5
IMTA0A910905-01
Fuses and the Protected Parts

AENNTA0E910D002 (10(01)
The chart below describes what parts each fuse protects.
Fuses in Main Fuse Box
NOTE
Refer to “Around Battery” for the installation of the intermediate terminal.
1 3
5
IFRA0A910922-01
No. Fuse Protected circuit

All electric circuit
120 A
Generator
100 A Individual circuit fuse box No.1 (In relay box)
80 A P/S control module (P/S motor)
100 A Individual circuit fuse box No.1 (In relay box)
50 A Individual circuit fuse box No.2 (In J/B)
Individual Circuit Fuse Box No. 1 (In Relay Box)
7 8 9 10 11
12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28 29 30
31 32 33 34
1 8 2 9 3 10 4 11 5 12 6 13 7 14
ILSD0A910987-01
1. BLANK 6. Radiator cooling fan relay No.3 11. Back-up light relay
2. Radiator cooling fan relay No.2 7. A/C compressor relay 12. Radiator cooling fan relay No.1
3. “ST2” relay 8. Main relay 13. Starting motor control relay
4. Fuel pump relay 9. BLANK 14. Blower motor relay
5. Horn relay 10. Front fog light relay
No. Fuse Description on the cover Protected circuit

Starting motor control relay (In relay box)
30 A ST
“ST2” relay (In relay box)
40 A BLW Blower motor relay
40 A BTRY Individual circuit fuse box No.3 (In sub relay box)
40 A ABS MOT ABS/ESP® control module
40 A IGN Individual circuit fuse box No.2 (In J/B)
30 A B/U Individual circuit fuse box No.2 (In J/B)
BLANK BLANK BLANK
BLANK BLANK BLANK
BLANK BLANK BLANK
25 A ABS SOL ABS/ESP® control module
15 A H/L L Headlight LO relay (R)
15 A H/L R Headlight LO relay (L)
30A DCDC DC/DC converter
Radiator cooling fan relay No.1 (In relay box)
30 A RDTR
Radiator cooling fan relay No.2 (In relay box)
30A T/M PUMP TCM (AGS)
BLANK BLANK BLANK
7.5 A CNG VLV BLANK
20 A F/P BLANK
20 A FR FOG Front fog light relay
10 A T/M2 Shift selector No.1 (AGS model)
50 A IGN2 Individual circuit fuse box No.2 (In J/B)
15 A T/M TCM (AGS)
15 A FI Main relay (In relay box)
10 A CPRSR A/C compressor relay (In relay box)
BLANK BLANK BLANK
5A CNG IG1 BLANK
ECM
5A ST SIG
BCM
7.5 A CNG BLANK
Individual Circuit Fuse Box No. 2 (In J/B)
42
43 44 45 46 47 48 49 50 51 52 53
1
54 55 56 57 58 59 60 61 62 63 64 65 66
67 68 69 70 71 72 73 74 75 76 77 78 79
IFRA0A910925-01
1. Rear defogger relay (In J/B)

Power window & door lock main switch
Power window sub switch
30 A P/W
Rear power window sub switch (R)
Rear power window sub switch (L)
10 A MTR Combination meter
Ignition coil No.1
Ignition coil No.2
Ignition coil No.3
15 A IG
Ignition coil No.4
ECM
Immobilizer control module
5A IG1 SIG2 P/S control module
20 A SHIFT BLANK
10 A CHG USB charging socket
10 A STL2 Auto steering lock unit
Front unlock relay (In J/B)
20 A D/L Lock / rear unlock relay (In J/B)
Rear end door unlock relay (In J/B)
15 A STL BCM
10 A HAZ BCM
5A A-STOP BLANK
10 A RR FOG BLANK
5A ABS
15 A S/H BLANK
5A IG1 SIG3 BLANK

DLC
BCM
Shock Sensor
Engine push start switch
Auto mirror relay No.1
Combination switch (Light)
Dome light
10 A DOME2 Spot light
Vanity light (R)
Vanity light (L)
Luggage compartment light
Glove box light
Foot light (R)
Foot light (L)
Door courtesy light (Driver side)
Door courtesy light (Passenger side)
Combination meter
5A DOME
Head-up display control module
Audio unit
15 A RADIO
360 view camera control module
5A CONT
Data communication control module
5A KEY2 Ignition switch
20 A P/W T Power window & door lock main switch
5A KEY Ignition switch
15 A HORN Horn relay (In relay box)
5A TAIL L BCM
BCM
10 A TAIL
10 A A/B SDM
Brake light switch
BCM
TCM (AGS)
Shift selector No.2 (AGS model)
10 A IG1 SIG Central gateway control module
DC/DC converter
Combination switch
BCM
Parking sensor system control module
10 A BACK
Back up light switch
Auto A/C panel
5A ACC3 Audio unit
20 A RR DEF Rear defogger (+)
10 A MRR HTR BLANK
Accessory socket
15 A ACC2
Rear accessory socket
BCM
DC/DC converter
5A ACC Power mirror switch
USB charging socket
Rear wiper motor
10 A WIP
Rear wiper relay (In J/B)
Rear defogger relay (In J/B)
5A IG2 SIG Auto-dimming rearview mirror
Blower motor relay

BCM
15 A WASH Windshield washer motor
Rear washer motor
25 A FR WIP
Combination switch (Wiper)
10 A STOP Brake light switch
Individual Circuit Fuse Box No. 3 (In Sub Relay Box)
38
39
40
41
1 2 3 4 5
IFRA0A910928-01
1. BLANK 3. Headlight HI relay 5. Headlight LO relay (L)

2. Headlight LO relay (R) 4. BLANK

BLANK BLANK BLANK
25 A H/L HI Headlight HI relay (In relay box)
Headlight HI (R)
15 A H/L HI R
Headlight unit (R)
Headlight HI (L)
15 A H/L HI L
Headlight unit (L)
J/B Connector Layout

AENNTA0E910D003 (10(01)
Fuse Side
[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 25 26 27 28 29 30
1 P/W
RR DEF DOME IG1 SIG2
TAIL RR FOG
FR WIP TAIL L A-STOP
MRR HTR RADIO SHIFT
STL2
CHG
MTR
HAZ
STL
D/L
IG
4
ACC3 DOME2
BACK IG1 SIG3
WASH HORN
CONT
P/W T
KEY2
KEY
ABS
S/H
3
2 1
IG2 SIG
IG1SIG
STOP
ACC2
ACC
WIP
A/B
2
3
IMTA0A910907-01
[A]: BCM (J/B side) 2. Fuse

1. BCM 3. Rear defogger relay (In J/B)
: Do not remove BCM except when replacement of BCM or J/B is necessary.
Side View
L314 E323 K131
1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4
7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 5 6 7 8
23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37
35 20 1 5
34 19 2 6
33 18 3 7
32
31 16 4 8
30 15
14
29 13 7 23
28 8 24
27 11 9 25
26 10 10 26
25 9 11 27
24 8 1 12 28
2 13 29
23 7 3 14
4 15 30
52 30 5 16 31
51 29 6 17 32
50 28 18 33
49 27 19 34
48 26 20 35
47 25 21 36
46 24 22 37
45 23 8
44 22 7
43 21 6
42 20 5 1
41 19 4
40 18 3
39 17 2 2
38 16 1
37 15 3
36 14
35 13
34 12
33 11
32 10 1
31 9
2
(Not used)
G271
E324 E325 / L315
1 2 3 4 5 6 7 8 1 2
1 3 2
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52
IMTA0A910908-02
J/B Inner Circuit (Detail)

AENNTA0E910D004 (10(01)
Abbreviations
Abbreviation Full spelling Abbreviation Full spelling
AS Assistant (Front passenger) LP Light
CTR Center O/H Overhead
DR Driver R/B Relay box
F-L Front Left R-L Rear Left
Abbreviation Full spelling Abbreviation Full spelling

F-R Front Right R-R Rear Right
FR Front RR Rear
INP Instrument panel S/H Seat heater
LEV (Headlight) leveling
Terminal number of each connector

E325
Schematic diagram of J/B BCM E323 E324 /L315 G271 K131 L314
43
MTR 10A
42
44 32
IG 15A
33
56 5
IG1 SIG3 5A
39
45 2
IG1 SIG2 5A
2
8
68 26
IG1 SIG 10A
27
28
43
IG11 relay 28
67 35
A/B 10A
26
69 5
BACK 10A
10
44
29
54 4
ABS 5A
4
20
23
1 2
(Continued)
E323
BCM (J/B side) E324 E325 / L315
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 25 26 27 28 29 30 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 1 3 2 1 2
23 24 25 26 27 28 29 30 31 32 33 34 35 36 37
G271 L314
K131
1 2 3 4 5 6 7 8 1 2 3 4 5 6
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 1 2 3 4 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 5 6 7 8 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37
IMTA0A910909-01

E325
1 2 7
21
46
24
74 5
ACC 5A
3
73 14
ACC2 15A
47
Accessory 25
relay
1
4
22
16
1
Rear 24
wiper 7
relay
6 16
75
WIP 10A
27
77 25
WASH 15A
21
IG21 relay 78 20
FR WIP 25A
11
14
21
76 8
IG2 SIG 5A
3
22
8
42
P/W 30A
34
49
35
IG22 relay 34
55
S/H 15A
9
10
20
IG23 relay 18
72 15
MRR HTR 10A
37
Rear defogger relay / 71 38
3 mirror heater relay RR DEF 20A
11
(Continued)
E323
BCM (J/B side) E324 E325 / L315
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 25 26 27 28 29 30 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 1 3 2 1 2
23 24 25 26 27 28 29 30 31 32 33 34 35 36 37
G271 L314
K131
1 2 3 4 5 6 7 8 1 2 3 4 5 6
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 1 2 3 4 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 5 6 7 8 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37
IMTA0A910910-01

E325
2
28
53 24
RR FOG 10A
19
60 34
CONT 5A
10
50
STL 15A
4
64
HORN 15A
26
51
HAZ 10A
27
47
CHG 10A
11
63
KEY 5A
17
62
P/W T 20A
9
48
STL2 10A
13
61
KEY 2 5A
6
65
TAIL L 5A
29
52
A-STOP 5A
6
66
TAIL 10A
30
79 48
STOP 10A
36
46
SHIFT 20A
12
(Continued)
E323
BCM (J/B side) E324 E325 / L315
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 25 26 27 28 29 30 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 1 3 2 1 2
23 24 25 26 27 28 29 30 31 32 33 34 35 36 37
G271 L314
K131
1 2 3 4 5 6 7 8 1 2 3 4 5 6
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 1 2 3 4 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 5 6 7 8 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37
IMTA0A910911-01

E325
4 6
49
D/L 20A
10
50
11
28
Front unlock relay
18
29
51
Lock / rear 8
unlock relay
14
19
Rear end door

unlock relay
26
3
(Continued)
E323
BCM (J/B side) E324 E325 / L315
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 25 26 27 28 29 30 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 1 3 2 1 2
23 24 25 26 27 28 29 30 31 32 33 34 35 36 37
G271 L314
K131
1 2 3 4 5 6 7 8 1 2 3 4 5 6
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 1 2 3 4 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 5 6 7 8 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37
IMTA0A910912-01

E325
37
59 2
RADIO 15A
31
58 18
DOME 5A
19
35
70
ACC3 5A
32
22
57 6
DOME2 10A
7
33
40
6
32
25
30
15
27
52
(Continued)
E323
BCM (J/B side) E324 E325 / L315
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 25 26 27 28 29 30 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 1 3 2 1 2
23 24 25 26 27 28 29 30 31 32 33 34 35 36 37
G271 L314
K131
1 2 3 4 5 6 7 8 1 2 3 4 5 6
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 1 2 3 4 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 5 6 7 8 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37
IMTA0A910913-01

E325
23
25
24
29
30
20
23
45
33
13
14
15
16
31
36
41
16
30
31
13
15
(Continued)
E323
BCM (J/B side) E324 E325 / L315
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 25 26 27 28 29 30 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 1 3 2 1 2
23 24 25 26 27 28 29 30 31 32 33 34 35 36 37
G271 L314
K131
1 2 3 4 5 6 7 8 1 2 3 4 5 6
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 1 2 3 4 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 5 6 7 8 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37
IMTA0A910914-01
System Circuit Diagram

System Circuit Diagram
AENNTA0E910E001 (10(01)
Reference: “How to Read System Circuit Diagram”
Reference: “How to Read Connector Codes and Terminal Nos.”
Refer to “A-1 Cranking System Circuit Diagram (M/T Model)”.
Refer to “A-1 Cranking System Circuit Diagram (AGS Model)”.
Refer to “A-1 Main Switch Circuit Diagram (Ignition Switch Model)”.
Refer to “A-1 Main Switch Circuit Diagram (Keyless Push Start Model)”.
Refer to “A-2 Charging System Circuit Diagram”.
Refer to “A-4 Cooling System Circuit Diagram”.
Refer to “A-5 Engine and A/C Control System Circuit Diagram (K12N)”.
Refer to “A-6 Auto Gear Shift Control System Circuit Diagram”.
Refer to “A-8 Body Control System Circuit Diagram”.
Refer to “A-9 CAN Circuit Diagram”.
Refer to “A-9 Central Gateway System Circuit Diagram”.
Refer to “A-11 ENG A-STOP System Circuit Diagram”.
Refer to “B-1 Windshield Wiper and Washer Circuit Diagram”.
Refer to “B-2 Rear Wiper and Washer Circuit Diagram (If Equipped)”.
Refer to “B-3 Rear Defogger Circuit Diagram”.
Refer to “B-4 Power Window Circuit Diagram”.
Refer to “B-5 Power Door Lock Circuit Diagram”.
Refer to “B-6 Power Mirror Circuit Diagram (Without Remote Retractable Mirror)”.
Refer to “B-6 Power Mirror Circuit Diagram (With Remote Retractable Mirror)”.
Refer to “B-7 Horn Circuit Diagram”.
Refer to “B-9 Parking Sensor System Circuit Diagram”.
Refer to “C-1 Combination Meter Circuit Diagram”.
Refer to “C-2 Head-up Display Circuit Diagram (If Equipped)”.
Refer to “D-1 Headlight System Circuit Diagram (Halogen Headlight Model)”.
Refer to “D-1 Headlight System Circuit Diagram (Auto-On LED Headlight Model)”.
Refer to “D-2 Clearance, Tail and License Plate Light System Circuit Diagram (Non-Auto-On Headlight Model)”.
Refer to “D-2 Clearance, Tail and License Plate Light System Circuit Diagram (Auto-On Headlight Model)”.
Refer to “D-3 Front Fog Light System Circuit Diagram (If Equipped)”.
Refer to “D-4 Illumination Light System Circuit Diagram”.
Refer to “D-5 Interior Light System Circuit Diagram”.
Refer to “D-6 Turn Signal and Hazard Warning Light System Circuit Diagram”.
Refer to “D-7 Brake Light System Circuit Diagram”.
Refer to “D-8 Back Up Light System Circuit Diagram”.
Refer to “D-9 Headlight Manual Leveling System Circuit Diagram (Non-Auto-On Headlight Model)”.
Refer to “D-9 Headlight Manual Leveling System Circuit Diagram (Auto-On Headlight Model)”.
Refer to “E-2 Auto A/C System Circuit Diagram”.
Refer to “F-1 Air Bag System Circuit Diagram (4-Channel)”.
Refer to “F-1 Air Bag System Circuit Diagram (8-Channel)”.
Refer to “F-2 ABS Circuit Diagram”.
Refer to “F-3 ESP® Circuit Diagram”.
Refer to “F-4 Power Steering System Circuit Diagram”.
Refer to “G-1 Audio System Circuit Diagram”.
Refer to “G-2 Navigation System Circuit Diagram”.
Refer to “G-3 Accessory Socket System Circuit Diagram”.
Refer to “G-4 Telematics Data Communication System Circuit Diagram (If Equipped)”.
A-1 Cranking System Circuit Diagram (M/T Model)

AENNTA0E910E002 (10(01)
A72
BLK/YEL
1
1
Battery
BLK/GRY
2
C196
C282
WHT
M
<2>: Ignition switch model
1
1
Main fuse box
C343
E371
C195
YEL YEL
1
E01
LT GRN LT GRN YEL YEL A-11
Y
"ST2" relay
E461
43
5A
Starting motor
ECM
No.33
ST SIG
E05
E225
LT GRN YEL RED
A-1 Cranking System Circuit Diagram (AGS Model)

<1>
5
4
Relay box
15
ST
30A
BCM
No.7
E01
E348
GRN GRN PNK Relay box
3
1
A
A
17
ECM Starting motor control relay
E348
E04
E05
A-5 PPL PPL GRN
Pp
CPP (Clutch pedal position) switch No.2
<1> <1>
E
E
E192 A
15
J/C BCM
E348
E04
PNK
<1>
C
C
E348
E190
12
BLK BLK BLK GRN
6
BCM
1
2
B
B
A
J/C CPP (Clutch pedal position) J/C

E01
E382
G334
G147
switch No.1 PNK PNK PNK

<2> <2> <2>
2
C
C
11
31
ECM J/C Ignition switch
IMTA0A910939-03
AENNTA0E910E003 (10(01)
<1>: Ignition switch model No.7
Relay box
<2>: Keyless push start model 30A
Ignition switch
ST
BCM
G147 2
E04 12
PNK
<1>
G334
PNK
<2>
E382 11
PNK
<1>
RED
E348 C C
J/C
"ST2" relay
C C C

E461
A-11
PNK
PNK
Y
Battery
Main fuse box
E225 4 1
PNK
<1>
E371 8
YEL
C343
PNK
TCM (AGS)
C15 19 E01 31
C191 1 C282 1
5 3
ECM
YEL
21
YEL
No.33
Relay box
GRN
5A
ST SIG
C343
11
GRN
E371
YEL
LT GRN
BLK/GRY
BLK/YEL
WHT
GRN
E371 4
C343
LT GRN
LT GRN
<2>
E348 A A
E01 43 E05 15
J/C
ECM
BCM
YEL
C196 1 C195 1
Starting motor
1 2
IMTA0A910940-02
A-1 Main Switch Circuit Diagram (Ignition Switch Model)

AENNTA0E910E004 (10(01)
No.11 No.27 No.63 No.61 No.44
Relay box
40A 50A 5A 5A 15A
IGN IGN2 KEY KEY2 IG
J/B
J/B
G271 17 6 G271 5
LT BLU
GRY
G147 4 3
WHT
OFF
ACC
Ignition switch
GRY
BLU ON
ST
5 6 1 2
PNK
LT GRN
G334
BLU
YEL
E382 11
PNK
E324 3 1 G271 21 23 16
E348 C
J/C
C
ACC IG11 IG21 IG22 IG23
Relay Relay Relay Relay Relay
PNK
P
No.74 No.68 No.69

5A 10A 10A
A-1
E225
ACC IG1 BACK
J/B
SIG
G271 1
BCM
G04 28 31
YEL
G145 2
GRY
BLK
Main switch (key)
G17 4 3
control module
Immobilizer
1
BLK
1
BLK
G309 C C
J/C
C
BLK
BLK
BLK
12 14
IMTA0A910941-02
A-1 Main Switch Circuit Diagram (Keyless Push Start Model)

AENNTA0E910E005 (10(01)
No.11 No.27
Relay box
No.57
40A 50A
10A
IGN IGN2
DOME2
J/B
G271 40
GRY
BLU
E324 3 1
ACC IG11 IG21 IG22 IG23

Relay
WHT
Relay Relay Relay Relay
G308 D
J/C
D BCM
J/B
G05 31 G06 2 G04 31 28 G05 29 E04 12 G271 1
PNK
WHT
GRY
RED
PNK
BLU
YEL
BLK
E348 C
G140 8 2 7 6 4 3 J/C
C
Push Push
PNK
switch1 switch2
PUSH
IMMOBI P
A-1
E225
5 1
BLK
BLK
G309 C C
J/C
C
BLK
BLK
BLK
12 14
IMTA0A910942-01
A-2 Charging System Circuit Diagram

AENNTA0E910E006 (10(01)
Main fuse box

No.1
120A
C283 1
BLK
ECM
C01 1
BLU
C192 1 C194 1
Strtor coil
IC regulator
Rotor coil
Generator
IMTA0A910943-01
A-4 Cooling System Circuit Diagram

AENNTA0E910E007 (10(01)
No.20
Relay box
30A
Main relay
RDTR
E221
A-5
L
GRY
BLU
Radiator cooling fan relay No.1

GRY
BLU
BLU
BLK
GRY
BLU
E222 1 4 E223 1 4 E224 3 4
3 5 3 5 1 5
LT GRN
GRN
GRN
PNK
LT GRN
BLU
E01 2 27
ECM
E65 2 4 3
M Radiator cooling fan motor
1
BLK
BLK
BLK
6 5
IMTA0A910944-01
A-5 Engine and A/C Control System Circuit Diagram (K12N)

AENNTA0E910E008 (10(f)
C141
C343
E371
E229
GRY GRY GRY GRN
1
5
4
19
10A
No.30
A/C compressor CPRSR
E01
GRY BLU
3
1
BLK BLK
3
41
2
A/C compressor relay
C101
C01
YEL
3
44
C343
E371
E323
WHT WHT WHT
1
10
33
IG
Spark plug
15A
Ignition coil No.1

No.44
BLK WHT WHT
2
1
32
C102
GRN
3
J/B
33
WHT
E221
1
PNK RED
Spark plug
3
1
49
Ignition coil No.2
BLK
ECM
2
BLU RED
C103
5
4
PNK
FI
3
15A
34
Main relay
No.29
Relay box
WHT
Spark plug
Ignition coil No.3
BLK
2
C104
BEG
3
35
E227
BLU
5
4
WHT
Spark plug
Ignition coil No.4 RED BLU
3
1
24
5
1
Fuel pump relay
IMTA0A910945-02
5
1
E01
E371
C343
BLU BLU BLU
L61
L371
E387
9
BLK PNK PNK
56
16
4
3
20
BLU
55
Fuel pump and gauge
BLU BLU
18
C42
C01
PPL
C01
C122
3
GRN BLU
49
3
2
48
BLU
4
GRY
45
RED
1
6
YEL BLU
4
5
46
GRN
2
7
ECM
WHT
6
47
HO2S-1
LT GRN EGR stepper motor
55
C123
GRY BLU
C56
2
1
RED
41
1
52
EVAP canister
purge valve
BLU
C132
2
GRN BLU
2
1
42
Intake OCV
BRN
3
19
C133
WHT BLU
2
1
43
YEL Exhaust OCV
4
8
Wiring Systems:
HO2S-2
BEG
6
56
14
IMTA0A910946-02
9A-57
6
14
C29
BLK BLK BLU
3
1
3
C01
YEL
40
Exhaust CMP sensor
C31
BLK BLU
1
3
PNK
39
CKP sensor
C32
BLK BLU
1
3
E191
E01
BRN PPL
ECM
6
2
20
30
Intake CMP sensor
BLU
C91
MAIN
PNK BLU
19
1
2
31
Fuel injector No.1-1
PNK
4
16
C92
BRN BLU
1
2
36
BLK Fuel injector No.1-2
3
6
C93
WHT BLU
1
2
WHT
11
SUB
2
5

C94
1 YEL GRY BLU

3
1
2
23
APP (Acceleration pedal position) sensor Fuel injector No.2-2

17
IMTA0A910947-02
17
C39
C01
C01
C95
GRY BLU RED BLU
1
2
1
2
20
10
ECT sensor
C96
BEG BLU
C36
1
2
32
GRY BRN
1
2
27
C97
GRN BLU
1
2
12
LT BLU LT BLU
3
14
C98
MAP sensor LT GRN BLU
24
GRY
C47
C48
LT BLU
BRN BRN
4
5
54
LT GRN
LT GRN LT GRN
2
9
M
ECM
6
51
Throttle actuator
YEL
RED
3
1
22
2
13
MAF and IAT sensor-1

BEG
MAIN
GRN
29
1
26
TP sensor
C27
WHT BLU BLU WHT
3
2
1
16
21
SUB
Engine oil temperature sensor

WHT BLK
4
5
15
Electric throttle body
E185
E01
PNK BLK
1
Wiring Systems:
17
12
Brake booster switch
IMTA0A910948-02
9A-59
E192
E01
E348
E348
E01
E323
E181
BLK BLK BLK PPL PPL
6
BLU BLU LT GRN LT GRN
2
1
B
B
E
E
4
5
42
44
27
10A
J/C CPP (Clutch pedal position) J/C Brake light switch
No.68
switch No.2
IG1 SIG
E58
LT BLU
J/B
2
4
E323
LT BLU YEL D-7
Y
Brake light switch
E181
18
29
24
BLU
3
J/B
48
PNK
1
47
YEL YEL
4
22
E382
G334
G346
S171
S61
Electric load current sensor & YEL YEL

6
13
battery temperature sensor
SET-
C01
RES+
CRUISE
CANCEL
WHT
LT GRN LT GRN
ECM
25
5
8
5
12
Contact coil
C37
Steering switch(Cruise control switch)
BLU
2
1
37
Knock sensor
BLK
53
BLK BLK
3
50
C168
C343
E371
E01
YEL YEL
2
1
6
7
Neutral position switch
PNK PNK
12
40
IMTA0A910949-02
C01
E01
A-6 RED
R
RED A-8
R
AGS Control System Circuit Diagram Body Control System Circuit Diagram
3
28
(CAN)
(CAN)
A-6 WHT WHT A-8
W
W
AGS Control System Circuit Diagram Body Control System Circuit Diagram
2
29
E01
E-2 RED LT GRN LT GRN
R
E36
43
33
5A
No.33
ST SIG
E-2 BLU
L
9
E36 Relay box
E-2 GRY GRN A-1
G
A/C refrigerant pressure sensor G
Cranking System Circuit Diagram
E36
14
17
ECM
A-4 LT GRN PNK A-1
Lg
P
Cooling System Circuit Diagram Cranking System Circuit Diagram
2
31
A-4 GRN BRN A-11
G
Br
Cooling System Circuit Diagram ENG A-STOP System Circuit Diagram
27
36
C01
A-2 BLU GRY A-11
L
Gr
Charging System Circuit Diagram ENG A-STOP System Circuit Diagram
1
11
PPL A-11
Pp
ENG A-STOP System Circuit Diagram

37
GRN A-11
G
ENG A-STOP System Circuit Diagram

34
Wiring Systems:
IMTA0A910950-02
9A-61
A-6 Auto Gear Shift Control System Circuit Diagram

No.26 No.21 No.28
Relay box
10A 30A 15A
T/M2 T/M T/M
PUMP
E348
E348
A-1
A-1
J/C
J/C
Gr P
WHT
WHT
WHT
GRN
ECM
PNK
E372 7 E371 7
E387
1
C344 C343 C01 3 2
L371
E371 11 8
C343
WHT
WHT
WHT
WHT
GRN
RED
PNK
(CAN)
C15 24 26 21 19 7 10
TCM (AGS)
11 9 13 17 4 14 16 18 20 22
LT BLU
WHT
GRN
GRY
RED
BRN
BLU
PPL
YEL
BLK
C344
E372 9 4 13 12 2 5 6 10 11 3
LT BLU
WHT
GRN
GRY
RED
BRN
BLU
PPL
YEL
BLK
E387
L371 15 7 3 4 17 13 2 5 14 6
BLK BLK
LT BLU
Shift selector No.1 (AGS)

WHT
GRN
GRY
RED
BRN
BLU
PPL
YEL
BLK
L105 14 3 2 1 6 10 11 7 8 9 12 13
HALL IC
IMTA0A910951-02
L106
L314
LT GRN
5
28
10A
No.68
ILL
IG1 SIG
G342
L375
C-1 PPL PPL PPL RED D-4
C15
Pp
Combination meter J/B
C343
E371
E323
3
2
1
G240 L314 LT GRN LT GRN LT GRN
<1>
28
20
27
E181 J/B
BLU BLU BLU LT GRN

<1> <1>
1
4
5
15
A-5 BLU
L
ECM
E01 <1>
E371
C343
C15
C343
E371
E323
E323
D-8 PPL PPL BRN BRN YEL PNK
Pp
Back up relay
2
3
2
1
E263
16
25
30
24
36
10A
J/B
TCM (AGS)
No.79
STOP
Brake light switch

J/B
L01
PNK
12
BCM
Clutch position
L161
L371
E387
E372
C344
sensor
PNK PNK PNK PNK
1
8
16
23
Front door switch (Driver side)
Speed Sensor
C33
BEG
1
3
P
C343
E371
<1>: Cruise control model
BLK BLK BLU BLU BLU BLU A-5 PUMP MOTOR

L
3
Main relay
2
3
9
E221
VSS (Vehicle speed sensor)

Wiring Systems:
IMTA0A910952-02
9A-63
A-8 Body Control System Circuit Diagram

No.57 No.44
10A 15A
DOME2 IG
J/B
G271 40 5
WHT
G308 D
WHT
<2>
Immobilizer control module

J/C

D
WHT
Combination meter
<1>
G140 8 G17 3
G240 13 2 7 3 4 6 1 5 4 1
GRY
GRY
RED
PNK
BLU
YEL
BLK
BLK
<1>
<1>
<1>
<1>
<1>
<1>
<1>
<2>
LT GRN
BLK
<2>
G04 20 G05 31 G06 2 G05 29 G04 28 31
BCM
L01 16 32 G05 27 G04 1

G309 C C
J/C
BLK
BLK
BLK
BLK
C
BLK
BLK
BLK
BLK

15 12 14
IMTA0A910953-02
E183
E04
E04
BLK BLK GRY LT GRN
6
2
1
11
20
Brake fluid level switch
L167
L01
E37
LT GRN LT GRN BRN
1
6
1
2
20
Parking brake switch
G342
L375
G-1 LT GRN LT GRN
Lg
Audio(Navigation)unit
7
G243
G-2 LT GRN
Lg
Navigation unit
G243
C343
E371
E04
C162
BLU BLU
5
8
1
Engine oil pressure switch
L175
L01
BLK BLK GRY
15
2
1
9
Seat belt switch (Driver side)
BCM
L176
BLK GRN
2
1
25
Seat belt switch (Passenger side)
E304
E04
BLK BLK BLU
6
H
1
2
19
E381
G333
BRN BRN
9
2
13
Security horn (Siren)
G309
G38
G308
G271
BLK BLK BLK WHT WHT
14
1
4
A
A
D
D
40
10A
BLK J/C J/C
13
No.57
Shock sensor
DOME2
J/B
Wiring Systems:
IMTA0A910954-02
9A-65
E05
E05
D-1 LT GRN PNK D-1
Lg
Headlight Headlight
9
13
D-1 BLU
G05
L
Headlight PNK D-1
1
Headlight
26
PPL D-1
E05
Pp
A-1 GRN Headlight
G
12
Cranking
5
E04
E05
A-1 PNK
P
RED D-2
R
Cranking Position, Tail and License Plate Light
12
12
A-1 PPL GRN D-2
Pp
G
Cranking Position, Tail and License Plate Light
15
11
RED D-2
R
Position, Tail and License Plate Light
BCM
6
G05
D-2 GRN
G
14
GRY D-2
Gr
3 Position, Tail and License Plate Light
L01
D-2 RED
R
13
G04
YEL A-1
Y
<2> Main Switch

28
D-2 RED
R
29
E04
GRY A-11
Gr
ENG A-STOP
24
G04
A-11 Br BRN LT BLU A-11

Lb
ENG A-STOP ENG A-STOP

7
19
IMTA0A910955-02
G04
G04
D-6 LT BLU WHT D-6
Lb
Turn Signal and Hazard Warning Light Turn Signal and Hazard Warning Light
27
G04
E04
D-6 LT GRN
Lg
Turn Signal and Hazard Warning Light GRN GRN D-6
G
Turn Signal and Hazard Warning Light
11
22
L01
D-6 GRN GRN
G
Turn Signal and Hazard Warning Light BLU BLU D-6
14
10
D-6 BLU BLU
L
30
BCM
E04
G04
A-9 RED RED A-9
R
R
CAN CAN
5
29
(CAN)
(CAN)
A-9 WHT WHT A-9

W
W
CAN CAN
17
13
Wiring Systems:
IMTA0A910956-02
9A-67
G05
LT GRN E-2
Lg
Auto A/C
11
G04
G243
G04
PPL PPL LT BLU E-2
Lb
Auto A/C
3
15
30
G05
LT BLU E-2
Lb
Auto A/C
22
G248
PPL
18
G05
PNK E-2
P
Auto A/C
18
WHT E-2
W
Auto A/C
5
BRN E-2
Br
Auto A/C
BCM
PPL E-2
Pp
Auto A/C
17
G05
E-2 GRN GRN
G
Auto A/C
4
LT BLU E-2
Lb
Auto A/C
1
E-2 RED
R
Auto A/C
19
GRY E-2
Gr
Auto A/C
21
E-2 LT GRN
Lg
Auto A/C
G04
LT GRN E-2
Lg
Auto A/C
32
BLU E-2
L
G04
Auto A/C
E-2 YEL YEL
16
Auto A/C Y
22
G05
PPL E-2
Pp
Auto A/C
20
IMTA0A910957-02
M151
L392
L01
E05
D-2 RED RED RED LT GRN LT GRN
R
1
11
15
5A
No.33
ST SIG
G338
J211
G04
BLU BLU B-5 Relay box
L
Power Door Lock
25
16
O231
L390
L01
B-5 LT GRN LT GRN GRY GRY B-5
Gr
Lg
Power Door Lock Power Door Lock
3
27
10
17
BRN BRN B-5
Br Power Door Lock
G06
J211
G338
18
B-5 LT BLU LT BLU
Lb
Power Door Lock
5
9
GRN GRN B-5
G
Power Door Lock
26
19
J212
G339
B-5 BLU BLU
L
Power Door Lock
5
10
BCM
E05
LT GRN D-3
Lg
4 Front Fog Light System Circuit Diagram (If Equipped)
G341
L374
L01
F-1 PPL PPL
Pp
Airbag
12
G141
G05
YEL YEL
4
13

G141
RED
3

G04
G308
RED RED
Wiring Systems:
14
J/C
IMTA0A910958-02
9A-69
PNK B-4
P
J81
L01
L161
L01
ON
PNK PNK BLU D-5
L
Interior Light
1
12
OFF
G130
G04
L162
ON
RED GRN GRN
1
17
28
OFF
Front door switch (Passenger side) Foot light (L)
G129
GRN
L163
L01
ON
1
BLU
1
5
OFF
Foot light (R)
Rear door switch (R)
L164
ON
WHT
G05
G339
J212
J238
G240
BCM
GRY GRY GRY D-5
Gr
1
Interior Light
21
1
OFF
15
15
Rear door switch (L)

G05
G338
J211
J237
G239
O121
O231
L390
L01
D-5
ON
BRN BRN BRN
Br
BLK GRN GRN Interior Light
17
1
32
15
2
4
10
OFF
Rear end door switch
IMTA0A910959-02
G146
G271
BLK BLK BLU
12
5
1
13
10A
BLK
14
STL2
No.48
G06
GRN J/B
7
3
< Keyless push start model>
G339
J212
J86
J212
G339
BLK BLK BLK PNK PNK
2
1
4
4
BRN
16
1
2
Door request switch (Passenger side)
G361
J213
J85
J211
G338
BLK BLK BLK PPL PPL LT GRN
13
2
1
4
8
3
4
12
Door request switch (Driver side) Auto steering lock unit
BLK BLK G338

J211
J153
GRN GRN
18
7
2
11
O124
O231
L390
L01
BLK BLK YEL YEL
17
3
1
5
26
BCM
Rear end door opener & request switch RED RED
L390
O231
5
6
1
BLK BLK
16
10
Driver outside antenna
E307
E05
G339
J212
J154
BLK BLK YEL BRN BRN
6
2
1
7
2
14
12
Outside warning buzzer

LT GRN LT GRN
6
6
1
Front-passenger
outside antenna
E09
L01
L392
M151
M120
PPL WHT WHT

7
7
2
28
23

BLU BLU
Wiring Systems:
7
2
1
Rear outside antenna

(Rear end antenna)
IMTA0A910960-02
9A-71
< Keyless push start model>
Rear inside antenna

Mid inside antenna
L294 2 1 L293 2 4
LT GRN
GRN
RED
BLK
L01 22 6 24 8
BCM
IMTA0A910961-02
A-9 CAN Circuit Diagram

BCM
E04 5 17 G04 29 13

P/S control module
WHT
WHT
RED
RED
360 view camera
control module
(CAN) (CAN)
G56 12 13 G10 5 6 G144 4 5

WHT
WHT
WHT
RED
RED
RED
<1>
<1>
<2>
<2>
(CAN) (CAN) (CAN)
G306 A A A A
J/C
A A A
E346 A G306 B B B B
J/C
J/C
A A B B B
E347 A
J/C
WHT
WHT
WHT
RED
RED
RED
<5>
<5>
(CAN) (CAN) (CAN)

A A
WHT
WHT
RED
RED
(CAN) (CAN) 15 <4> 14 <4>

E09 3 15 E01 28 29 G33 3 2 G11 9 <3> 10 <3> G240 19 7
Combination meter
ECM
SDM
Head-up display control module

C01 3 2 20 8
WHT
WHT
RED
RED
<6>
<6>
(CAN) (CAN)
C15 7 10 G59 10 9
TCM (AGS)
<1>: If equipped
<2>: Auto-on headlight model
<3>: With Air-bag (8-Channel)
<4>: With Air-bag (4-Channel)
<5>: Non-auto-on headlight model
<6>: AGS model
IMTA0A910962-03
<1>: If equipped
<7>: Display audio model
<8>: NATSA
Navigation unit
G243 6 <7> 12 <7>

5 <8> 4 <8>
WHT
BLK
(CAN)
G241 9 1
Combination meter
G240 22 10 G241 11 3 G294 5 21

WHT
WHT
WHT
GRN
RED
BLK
<1>
<1>
(CAN) (CAN) (CAN)
G60 20 21 19 18 14 15
8 7
WHT
BLU
(CAN)
G211 11 3
DLC
IMTA0A910963-02
G60
G308
G271
GRN GRN
A
A
24
43
10A
BLK J/C
14
No.68
IG1SIG
<1>: If equipped
G307
BLU BLU
A
A
BLK
10
10
13
5A
J/C
No.60
CONT
J/B
G211
G309
BLK BLK BLK RED A-9,C-1
R
Combination meter
A
A
G240
11
13
20
(CAN)
BLK BLK WHT A-9,C-1
W Combination meter
A
G240
12
21
J/C
A-11 ENG A-STOP System Circuit Diagram

A-9 Central Gateway System Circuit Diagram
BLU BLK A-9,C-1

B
Combination meter
8
G241
11
19
(CAN)
(CAN)
WHT WHT A-9,C-1
W
Combination meter
3
7
G241
18
GRN A-9,G-4
G345
L378
Gr
F-1 Data communication control module

BLU BLU <1>
L
SDM G294
14
2
4
L04
(CAN)
WHT A-9,G-4
W

<1> G294
15

G308
G271
WHT WHT
1
D
D
40
10A
DLC J/C
No.57
DOME2
Wiring Systems:
J/B
IMTA0A910964-02
AENNTA0E910E012 (10(01)
9A-75
No.74 No.68 No.19 No.7
Relay box
Relay box
5A 10A 30A 30A
ACC IG SIG DCDC ST
J/B

E323 5 28
RED
WHT
GRN
BLU
E461 1 5
E225
A-1
"ST2" relay
E213 1 8 5 Y
3 4
YEL
DC/DC
YEL
DC/DC converter
YEL
YEL
4 6 7 9 10
E371 4 No.33
Relay box
C343 5A
ST SIG
GRN
GRY
BRN
PPL
YEL
RED
YEL
E01 37 34 36 11
Y
A-1
Starting motor
C195
ECM
BLK
E323 35 37
No.74 No.59 No.58

5A 15A 5A
ACC3 RADIO DOME
J/B
IMTA0A910965-02
ILL
G116
C-1 PPL PPL RED RED D-4
Pp
Combination meter J/B
1
6
G240 G271
G309
G04
BLK BLK BLK BRN
14
2
5
A
A
19
BLK J/C
13
ENG A-STOP OFF switch
E210
E04
LT BLU
CLOSE
2
7
BLK BLK GRY
5
1
3
OPEN
24
BCM
Hood latch switch
Wiring Systems:
IMTA0A910966-02
9A-77
B-1 Windshield Wiper and Washer Circuit Diagram

AENNTA0E910E014 (10(01)
No.78 No.77 No.78

25A 15A 25A
FR WIP WASH FR WIP
J/B
Windshield washer motor
G271 14 E323 20 11
YEL
E62 1
GRY
GRY
2
BLU
E381 6
G333
BLU
G141 4 7
Washer OFF

switch ON
Wiper
switch
MIST
OFF
INT
LO
HI
INT Unit
2 3 5 6
WHT
GRN
RED
G333
E381 2 3 4
WHT
GRN
RED
E64 3 5 1 2
BLK
LO
Limit switch
HI
M
4
BLK
BLK
BLK
BLK
BLK
6 5 12 14
IMTA0A910967-02
B-2 Rear Wiper and Washer Circuit Diagram (If Equipped)

AENNTA0E910E015 (10(01)
No.75 No.77
10A 15A
WIP WASH
J/B
L314 27 E323 21
Rear washer motor

PPL
E63 1
GRN
E382 14
G334
GRN

G141 8
RWSH RWIP EW
WASH
OFF
ON
ON+WASH
9 6
GRY
G341 17
L374
GRY
PNK
L390 11 17
O231
GRY
PNK
O21 2 4
BLK
Rear wiper motor
Limit
switch
M
3
BLK
BLK
BLK
BLK
O231
10
BLK
L390
BLK
12 14
16 17
IMTA0A910968-01
B-3 Rear Defogger Circuit Diagram

AENNTA0E910E016 (10(01)
Main fuse box

No.5
50A
E312 1
BLU
E324 2
No.76
5A
IG2 SIG
Rear defogger
Relay
No.71
20A
BCM RR DEF
J/B
G05 11 L314 11
G271
E-2
J/B
PNK
Br
LT GRN
L390 1
YEL
O231
BLK
YEL
G227 7 5
Rear defogger
O181 1
Auto A/C panel
DRIVER
IND
IC
O182 1
8
BLK
BLK
BLK
BLK
14 13 17
IMTA0A910969-01
B-4 Power Window Circuit Diagram

No.42 No.62
30A 20A
P/W P/W T
J/B
G271 49 9
WHT
GRY
G338 1 11
J211
WHT
GRY
J81 20 7

AUTO AUTO
LOCK
Window lock
switch
ILL
UP DOWN
Driver switch
CPU
UP DOWN UP DOWN UP DOWN
Passenger Rear Rear

switch switch switch
(R) (L)
9 4 17 3 12 11 13 10 5 6 18 19 14 15
1
PNK
2
3
J213
BLK
BLK
8 4
G361
5
PNK
BCM
6
L01
A-8
G341 2
P L374
PNK
PNK
PNK
P
BLK
BLK
BLK
A-8
L161
Front power window motor (Driver side)

GRN
BRN
RED
BLU
YEL
J213
G361 12 18
J21 6 5 2 1 3 4
BLK
BLK
M
Hall IC A Hall IC B
UP
13
IMTA0A910970-02
6
5
4
3
2
1
J82
J214
G362
G271
GRY GRY
8
1
UP
34
30A
P/W
J22
No.42
RED
G361
J213
1
7
LT GRN LT GRN LT GRN
4
7
13
UP
YEL YEL YEL
6
7
GRN
13
2
5
Front power window
DOWN
motor (Passenger side)
Power window sub switch
J83
J217
L381
L314
GRY GRY
8
6
UP
35
J25
RED
L375
G342
G361
J213
1
7
WHT WHT WHT WHT
4
2
1
2
UP
BLU BLU BLU BLU
6
3
1
GRN
11
2
5
Rear power window
DOWN
motor (R)
Rear power window sub switch (R)
J84
J218
L382
GRY GRY
8
6
UP
34
J26
RED
L374
G341
G361
J213
1
7
WHT GRY GRY GRY
4
2
1
3
J/B
UP
BLU PNK PNK PNK
6
3
4
GRN
11
2
5
Rear power window
DOWN
motor (L)
Rear power window sub switch (L)
IMTA0A910971-03
B-5 Power Door Lock Circuit Diagram

No.49
20A
D/L
FRONT UNLOCK
RELAY
BCM
L01 27 G04 26 10 G06 9 G04 25 9 G271 50 51

LT GRN
LT BLU
WHT
GRN
GRY
BRN
PNK
BLU
<1>
L390 3 G338 19 17 5 16 18 2 12
O231 J211
Front door lock switch & motor (Driver side)

Rear end door opener & request switch
LT BLU
WHT
BRN
PNK
BLU
<1>
LT GRN
GRN
GRY
J31 6 4 3 1 2
O124 2 J81 1 2
M
LOCK UNLOCK
LOCK
LOCK UNLOCK
5
4
BLK
13
BLK
BLK
BLK
BLK
J213
G361 12 18
BLK
BLK
17 13
IMTA0A910972-03
LOCK/REAR UNLOCK BACK DOOR

RELAY UNLOCK
RELAY
BCM
J/B
26 G06 10 G271 28 29 L314 18 8 19
LT GRN
GRN
LT GRN
GRN
BLU
BLU
<1>
Rear end door lock motor & rear end door switch
Front door lock switch & motor (Passenger side)
G339 5 2 12 L390 2
J212 O231
LT GRN
LT GRN
GRN
GRN
LT GRN
GRN
BLU
<1>
BLU
L382 5 4 L381 5 4
J218 J217
2 <2> 1 <2>
BLK
J32 2 5 <1> 4 <1> O121 1

Rear door lock switch & motor (R)
Rear door lock switch & motor (L)
LT GRN
LT GRN
GRN
GRN
M
M
LOCK
J36 2 1 J35 2 1 2
3
BLK
<1>
M M
LOCK LOCK
BLK
<1>
BLK
J212
G339 16
BLK
<1>
BLK
BLK

<2>: With keyless entry system
12 14 17
IMTA0A910973-02
B-6 Power Mirror Circuit Diagram (Without Remote Retractable Mirror)

No.74
5A
ACC
J/B
LT GRN
G271 46
G361 15
J213
LT GRN
J87 3
Retract Angle adjustment

switch switch
Power mirror switch

RTR SET UP DOWN L R
R/L select
L R
switch
8 7 9 10 4 12 5 13
1
2
WHT
3
YEL
WHT
4
PNK
YEL
BLK
PNK
BRN
PPL
J213
G361 17 16 11 10 9
WHT
BRN
PNK
YEL
PPL
BLK
BLK
G362 8 14 11 10 9
J214
Power mirror assembly (L)
J213
WHT
BRN
PNK
YEL
PPL
G361 12 18
J28 11 4 8 9 10
RTR
M1 M2
BLK
BLK
UP DOWN L R
M
SET
13
IMTA0A910974-02
5
LT BLU
WHT
GRY
PNK
YEL
Power mirror assembly (R)
J27 11 4 8 9 10
RTR
UP M1 DOWN L M2 R
M
SET
IMTA0A910975-02
B-6 Power Mirror Circuit Diagram (With Remote Retractable Mirror)

No.57
10A
DOME2
Auto mirror Auto mirror

relay No.1 relay No.2
BCM
G271 30 52
<1>: If equipped
PNK
YEL
4
PNK
YEL
<1>
<1>
5
WHT
Y P
BRN
PPL
G-2
G56
G-2
G56
J213
G361 11 10 9
WHT
BRN
PNK
YEL
PPL
G362 8 14 11 10 9
J214
Power mirror assembly (L)
WHT
BRN
PNK
YEL
PPL
J28 11 4 8 9 10
RTR
UP M1 DOWN L M2 R
M
SET
IMTA0A910976-02
No.74
5A
ACC
J/B
LT GRN
25 27 46
PNK
YEL
G361 17 16 15
J213
LT GRN
PNK
YEL
J87 8 7 3
RTR SET
Angle adjustment
switch
Power mirror switch

UP DOWN L R
Retract R/L select

switch L R
switch
9 10 4 12 5 13
WHT
3
YEL
4
PNK
5
BLK
G338 10 20
J211
BLK
BLK
Power mirror assembly (R)
LT BLU
WHT
GRY
J213
PNK
YEL
G361 12 18
J27 11 4 8 9 10
RTR
BLK
BLK
UP M1 DOWN L M2 R
M
SET
13
IMTA0A910977-02
B-7 Horn Circuit Diagram

AENNTA0E910E021 (10(01)
<1>: Except cruise control model

<2>: Cruise control model
No.64
15A
HORN
J/B
E323 26
WHT
WHT
E235 5 1
Horn relay
GRY 4 3
BLU
E381 15
GRY
GRY
G333
E282 1 E303 1 BLU
H H
Horn LO
Horn HI
E281 1 E302 1
G346
4 <2>
S171
BLK
BLK
Contact coil
1 <1>
4 <2>
BLK
S61 1 <1>
Horn switch
5
IMTA0A910978-02
B-9 Parking Sensor System Circuit Diagram

BLK
16
L262
L13
L314
BLK BLK BLU YEL
15
2
1
9
23
29
10A
No.69
BACK
Parking sensor rear buzzer
BLK J/B
1
M116
M151
L392
L375
G342
YEL YEL YEL BRN
3
6
7
8
4
PPL PPL PNK
2
8
4
5
17
G240
LT GRN LT GRN LT GRN YEL YEL
1
5
5
6
6
10
Parking sensor (rear-left)
Combination meter
M117
YEL
3
RED RED RED RED D-8
R
J/B
2
9
16 L314
13
LT GRN
1
Parking sensor (rear-center-left)
M118
YEL
3
BEG BEG
2
4
15
LT GRN
1
Parking sensor (rear-center-right)
2
1
IMTA0A910979-02
L13 14
BRN
L392 3
M151
2
LT GRN
YEL
BRN
Parking sensor (rear-right)
M119 3 2 1
IMTA0A910980-02
G240
G271
BLK BLK GRN
14
2
18
19
5A
BLK
13
No.58
BLK BRN
DOME
5
3
42
10A
MTR
No.43
L61
L374
G341
G342
L375
YEL YEL LT GRN J/B
2
1
14
15
17
13
Fuel pump and gauge
PPL PPL PPL A-6
Pp
3
GRY GRY L106
16
15
14
G309
PPL PPL C-2

Pp
Head-up display switch

C-1 Combination Meter Circuit Diagram
B
B
G446
A-8 LT GRN
Lg
BCM
G04
13
PPL E-2 PPL G-2
Pp
Pp
Auto A/C panel Audio(Navigation)unit

B
G227 G248
A-9 RED
R
CAN
19
PPL Pp G-2 PPL G-1
Pp
View select switch Audio(Navigation)unit
(CAN)
B
G427 G248
A-9 WHT
Combination meter
W
J/C
CAN
7
PPL F-3
Pp
ESP® OFF SW
G170
C-2 RED
R
Head-up Display
20
PPL G-2
Pp
Headlight leveling switch

G152
(CAN)
C-2 WHT

2022 K12N Baleno 99500M55T00-74E-V1

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00

Precautions............................................................... 00-i Transmission / Transaxle .......................................... 5-i

Suspension................................................................. 2-i Body, Cab and Accessories ...................................... 9-i 5

Precautions ...............................................00-1 Precautions for Vehicle Equipped with ESP®

• When removing parts that are to be reused, keep

• Do not reuse oil seals, gaskets, packing, O-rings, lock

• Check that all parts used for reassembly are

• Use special tools when instructed.

• When installing vehicle parts, check that they do not

• Before disconnecting or connecting connectors, do

voltmeter type is specified, use a voltmeter with high

• Be careful not to touch the electrical terminals of parts

• When it is impossible to insert a tester probe from the

• Never connect any tester (voltmeter, ohmmeter or

In this case, the circuit cannot be identified by wire

[a]: Identical wire colors. 1

• Some wire harnesses in the same circuit may have

Precautions for Electrical System Work

• A twist (1) in the twist pair wire harnesses except

– Perform electric throttle control system ! WARNING

• Tighten wheel fasteners to specified ESP® Control Module

• 4-channel air bag model: (Air Bag System

NOTICE • Never expose the air bag system

• Switch "Communication Function Pause [ON]" NOTE

Open Circuit Check

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

If no continuity is indicated, it means that the circuit

• Damaged connector body, terminals exposed to

• Improperly formed or damaged terminals.

4) Disconnect the connector included in circuit

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

• Poor connection of terminal and wire.

• Broken wire inside the insulation. If one or two strands

OCM: Occupant Classification Module TCC: Torque Converter Clutch

Symbol Definition Symbol Definition

Wire Color / Connector Color Symbols

Fastener Strength Identification I5RH01010001-01

Standard Tightening Torque

Tightening torque chart

Thread diameter (Nominal diameter) (mm)

Vehicle Lifting Points

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

When Using Frame Contact Hoist

When Using Floor Jack Front

Vehicle Identification Number

Engine Identification Number

SUZUKI Scan Tool (Suzuki SDT-II) General Description

Suzuki SDT-II Function

Software function Contents

[A]: G211 connector (View: [a])

Terminal No. Symbol Function

1. Battery label 4. Steering shaft joint cover label

Diagnostic Information and Procedures

• Check CAN communication system.

is detected in any ECU.) (Troubleshooting

Special Tools and Equipment

Maintenance and Lubrication

Spark Plug Replacement

Fuel Evaporative Emission Control System