Suzuki Diesel

Important
WARNING/CAUTION/NOTE
Please read this manual and follow its instructions carefully. To emphasize special information, the words
WARNING, CAUTION and NOTE have special meanings. Pay special attention to the messages highlighted by
these signal words.
WARNING:
Indicates a potential hazard that could result in death or injury.
CAUTION:
Indicates a potential hazard that could result in vehicle damage.
NOTE:
Indicates special information to make maintenance easier or instructions clearer.
WARNING:
This service manual is intended for authorized Suzuki dealers and qualified service mechanics only.
Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to
properly perform the services described in this manual.
Improper repair may result in injury to the mechanic and may render the vehicle unsafe for the driver
and passengers.
WARNING:
For vehicles equipped with a Supplemental Restraint (Air Bag) System:
Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Refer to Air Bag System Components and Wiring Location View under
General Description in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and Ser-
vice Precautions under On-Vehicle Service in air bag system section before performing service
on or around the air bag system components or wiring. Failure to follow WARNINGS could result in
unintentional activation of the system or could render the system inoperative. Either of these two
conditions may result in severe injury.
If the air bag system and another vehicle system both need repair, Suzuki recommends that the air
bag system be repaired first, to help avoid unintended air bag system activation.
Do not modify the steering wheel, instrument panel or any other air bag system component (on or
around air bag system components or wiring). Modifications can adversely affect air bag system
performance and lead to injury.
If the vehicle will be exposed to temperatures over 93C (200F) (for example, during a paint baking
process), remove the air bag system components (air bag (inflator) modules, forward sensor(s),
SDM and/or seat belt pretensioners) beforehand to avoid component damage or unintended activa-
tion.
The circle with a slash in this manual means Dont do this or Dont let this happen.
Foreword
This SUPPLEMENTARY SERVICE MANUAL is a supplement to GRAND VITARA (SQ416/SQ420/SQ625) SER-
VICE MANUAL. It has been prepared exclusively for the following applicable model.
Applicable model: SQ420VD/SQ420WD (GRAND VITARA RHW Diesel engine model) on and after the fol-
lowing vehicle identification numbers (VINs).
JSAFTD83V00100001 ~ JSAFTD83V00200001 ~
JSAFTB83V00100001 ~ JSAFTB83V00200001 ~
This supplementary service manual describes only different service information of the above applicable model
as compared with GRAND VITARA SERVICE MANUAL. Therefore, whenever servicing the above applicable
model, consult his supplement first. And for any section, item or description not found in this supplement, refer to
the related service manual below.
When replacing parts or servicing by disassembling, it is recommended to use SUZUKI genuine parts, tools and
service materials (lubricant, sealants, etc.) as specified in each description.
All information, illustrations and specifications contained in this literature are based on the latest product infor-
mation available at the time of publication approval. And used as the main subject of description is the vehicle of
standard specifications among others.
Therefore, note that illustrations may differ from the vehicle being actually serviced.
The right is reserved to make changes at any time without notice.
RELATED MANUAL:
Manual Name Manual No.

GRAND VITARA (SQ416/SQ420/SQ625) Service Manual 99500-65D20-01E
GRAND VITARA/GRAND VITARA XL-7 (SQ416/SQ420/SQ625/
JA627/JA420WD) Unit Repair Manual (for Manual Transmission, 99501-65D50-01E
Automatic Transmission, Transfer and Differential)
GRAND VITARA/GRAND VITARA XL-7 Wiring Diagram Manual 99512-68D40-015
COPYRIGHT SUZUKI MOTOR CORPORATION 2004

Table of Contents
GENERAL INFORMATION TRANSMISSION, CLUTCH AND 0A 7A2
General Information 0A DIFFERENTIAL 0B 7B1
Maintenance and Lubrication 0B Manual Transmission (Type 3) 7A2 7C1
HEATING AND AIR CONDITIONING Automatic Transmission (4 A/T) 7B1 1A 7D
Heater and Ventilation 1A Clutch 7C1 1B 7E
Air Conditioning (Optional) 1B Transfer 7D 7F
STEERING, SUSPENSION, WHEELS Differential (Front) 7E 3
AND TIRES Differential (Rear) 7F 3A 8
Steering, Suspension, Wheels and Tires 3 ELECTRICAL SYSTEM 3B1 8A
Front End Alignment 3A Electrical System 8 3C 8B
Power Steering (P/S) System 3B1 Wiring Diagram 8A 3C1 8C
Steering Wheel and Column 3C Lightening System 8B 3D 8D
Air Bag Steering Wheel and Column 3C1 Instrumentation / Driver Information 8C 3E 8G
Front Suspension 3D Windows, Mirrors, Security and Lock 8D 3F 8H
Rear Suspension 3E Immobilizer control system 8G
Wheels and Tires 3F Body Electrical Control Module 8H 4A2 9
DRIVE SHAFT AND PROPELLER SHAFT BODY SERVICE 4B
Front Drive Shaft / Shaft Bearing, Body Service 9 10
4A2
Oil Seal RESTRAINT SYSTEM 5 10A
Propeller Shaft 4B Restraint System 10 5A 10B
BRAKE SYSTEM Seat Belt 10A 5B
Brakes 5 Air Bag System 10B 5C
Brake Pipe/Hose/Master Cylinder 5A 5E1
Front Brake 5B
Parking and Rear Brake 5C 6-1
Antilock Brake System (SUMITOMO) 5E1 6A3
ENGINE 6B
Engine General Information and 6C
6-1
Diagnosis (RHW Engine) 6E3
Engine Mechanical (RHW Engine) 6A3 6G
Engine Cooling 6B 6H
Engine Fuel 6C 6K
Engine and Emission Control System
6E3
(RHW Engine)
Cranking System (2.0 kW Reduction
6G
Type)
Charging System 6H
Exhaust System 6K
NOTE:
For the screen toned Sections in the above table, refer to the same section of the Related Manuals
mentioned in FOREWORD of this manual.
GENERAL INFORMATION 0A-1
SECTION 0A
0A
GENERAL INFORMATION
NOTE:
For the items with asterisk (*) in the CONTENTS below, refer to the same section of the Service Man-
ual mentioned in FOREWORD of this manual.
CONTENTS
How to Use This Manual....................................... * Vehicle Identification Number ....................... 0A-5
Precautions......................................................0A-2 Engine Identification Number........................ 0A-5
General Precautions .....................................0A-2 Transmission Identification Number.............. 0A-5
Precautions for Catalytic Converter..................... * Warning, Caution and Information
Precautions for Electrical Circuit Service ............ * Labels...............................................................0A-6
Electrical Circuit Inspection Procedure................ * Vehicle Lifting Points ........................................... *
Open circuit check........................................... * Abbreviations May Be Used in This
Short circuit check (wire harness to Manual.................................................................... *
ground) ............................................................ * Metric Information...........................................0A-7
Intermittent and Poor Connection ....................... *
Metric Fasteners ........................................... 0A-7
Precaution for Installing Mobile
Fastener Strength Identification .......................... *
Communication Equipment ................................. *
Standard Tightening Torque................................ *
Identification Information ...............................0A-5
0A-2 GENERAL INFORMATION
Precautions
General Precautions
The WARNING and CAUTION below describe some general precautions that you should observe when servic-
ing a vehicle. These general precautions apply to many of the service procedures described in this manual, and
they will not necessarily be repeated with each procedure to which they apply.
WARNING:
Whenever raising a vehicle for service, be sure to follow the instructions under Vehicle Lifting
Points on Section 0A.
When it is necessary to do service work with the engine running, make sure that the parking brake
is set fully and the transmission is in Neutral (for manual transmission vehicles) or Park (for auto-
matic transmission vehicles). Keep hands, hair, clothing, tools, etc. away from the fan and belts
when the engine is running.
When it is necessary to run the engine indoors, make sure that the exhaust gas is forced outdoors.
Do not perform service work in areas where combustible materials can come in contact with a hot
exhaust system. When working with toxic or flammable materials (such as gasoline and refriger-
ant), make sure that the area you work in is well-ventilated.
To avoid getting burned, keep away from hot metal parts such as the radiator, exhaust manifold,
tailpipe, muffler, etc.
New and used engine oil can be hazardous. Children and pets may be harmed by swallowing new or
used oil. Keep new and used oil and used engine oil filters away from children and pets.
Continuous contact with used engine oil has been found to cause [skin] cancer in laboratory ani-
mals.
Brief contact with used oil may irritate skin. To minimize your exposure to used engine oil, wear a
long-sleeve shirt and moisture-proof gloves (such as dishwashing gloves) when changing engine
oil.
If engine oil contacts your skin, wash thoroughly with soap and water. Launder any clothing or rags
if wet with oil, recycle or properly dispose of used oil and filters.
Make sure the bonnet is fully closed and latched before driving. If it is not, it can fly up unexpectedly
during driving, obstructing your view and resulting in an accident.
Before starting any service work, cover fenders, seats

and any other parts that are likely to get scratched or
stained during servicing. Also, be aware that what you
wear (e.g, buttons) may cause damage to the vehicles
finish.
When performing service to electrical parts that does

not require use of battery power, disconnect the nega-
tive cable of the battery.
When removing the battery, be sure to disconnect the

negative cable first and then the positive cable. When
reconnecting the battery, connect the positive cable first
and then the negative cable, and replace the terminal
cover.
When removing parts that are to be reused, be sure to

keep them arranged in an orderly manner so that they
may be reinstalled in the proper order and position.
Whenever you use oil seals, gaskets, packing, O-rings,

locking washers, split pins, self-locking nuts, and cer-
tain other parts as specified, be sure to use new ones.
Also, before installing new gaskets, packing, etc., be
sure to remove any residual material from the mating
surfaces.
Make sure that all parts used in reassembly are perfectly

clean.
When use of a certain type of lubricant, bond or sealant
is specified, be sure to use the specified type.
A: Sealant 99000-31150
Be sure to use special tools when instructed.

Special tool
(A): 09917-98221
(B): 09916-58210
When disconnecting vacuum hoses, attach a tag

describing the correct installation positions so that the
hoses can be reinstalled correctly.
After servicing fuel, oil, coolant, vacuum, exhaust or

brake systems, check all lines related to the system for
leaks.
For vehicles equipped with fuel injection systems, never

disconnect the fuel line between the fuel pump and
injector within 30 sec. after engine stop, or fuel can be
sprayed out under pressure.
Be sure to use engine hooks (1) for hanging engine.

Never use engine hook (2) for this purpose. This prohib-
ited service may damage fuel line.
2 1
Identification Information
Vehicle Identification Number
The number is punched on the chassis inside the tire housing on
the right front side and it is also on the left side of instrument
panel depending on the vehicle specification.
Engine Identification Number

The number is punched on the cylinder block.
Transmission Identification Number

The number is located on the transmission case.
[A]: M/T
[B]: A/T
Warning, Caution and Information Labels

The figure below shows main labels among others that are attached to vehicle component parts.
When servicing and handling parts, refer to WARNING/CAUTION instructions printed on labels.
If any WARNING/CAUTION label is found stained or damaged, clean or replace it as necessary.
NOTE:
Air bag CAUTION/WARNING labels are attached on the vehicle equipped with air bag system only.
1. Degassing tank cap (radiator cap) label 6. Transfer label 11. Air bag warning label on driver air bag (inflator) module
2. Radiator cooling fan label 7. Air bag label on passenger air bag (inflator) 12. Air bag warning label on combination switch and con-
module tact coil assembly
3. Air bag label 8. Air bag label on wire harness 13. Air bag warning label on steering column
4. Smoke level label 9. Air bag label on SDM
5. Air bag label on sun visor 10. Seat belt pretensioner label on retractor
Metric Information
Metric Fasteners
Most of the fasteners used for this vehicle are metric fasteners.
When replacing any fasteners, it is most important that replace-
ment fasteners be the correct diameter, thread pitch and strength.
CAUTION:
Note that both ISO and JIS type bolts and nuts are used
for the engine assembly and related parts. Even when the
diameter (1) of the thread is the same, its pitch (2) may
vary between these two types. Installing a mismatched
bolt or nut will cause damage to the thread. As the first
step, make sure to tighten it by hand temporarily and if it
feels tight, check the thread pitch for correct matching.
MAINTENANCE AND LUBRICATION 0B-1
SECTION 0B
0B
MAINTENANCE AND LUBRICATION

WARNING:
Technical service work must be started at least 90 seconds after the ignition switch is turned to the
LOCK position and the negative cable is disconnected from the battery. Otherwise, the system
may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).
NOTE:
CONTENTS
Maintenance Schedule ...................................0B-2 Clutch .............................................................. *

Maintenance Schedule Under Normal Brake discs and pads...................................... *
Driving Conditions .........................................0B-2 Brake drums and shoes .................................. *
Maintenance Recommended Under Brake hoses and pipes.................................... *
Severe Driving Conditions.............................0B-3 Brake fluid ....................................................... *
Maintenance Service.......................................0B-5 Parking brake lever and cable......................... *
Tires/wheel discs............................................. *
Engine ...........................................................0B-5
Suspension system ......................................... *
Accessary drive belt ..................................0B-5
Propeller shafts and drive shafts..................... *
Camshaft timing belt..................................0B-6
Manual transmission oil........................... 0B-11
Engine oil and oil filter ...............................0B-6
Automatic transmission fluid ................... 0B-11
Engine coolant...........................................0B-8
Transfer and differential oil.............................. *
Exhaust system .........................................0B-9
Steering system .............................................. *
Heater (Glow) plugs ..................................0B-9
Power steering (P/S) system
Fuel System ................................................0B-10
(if equipped) ............................................ 0B-12
Air cleaner filter .......................................0B-10
All hinges, latches and locks ........................... *
Fuel lines and connections......................0B-10
Air coditioning filter (if equipped)..................... *
Fuel filter..................................................0B-10
Final lnspection ................................................... *
Fuel tank..................................................0B-11
Chassis and Body .......................................0B-11 Recommended Fluids and Lubricants........0B-13
0B-2 MAINTENANCE AND LUBRICATION
Maintenance Schedule
Maintenance Schedule Under Normal Driving Conditions
NOTE:
This interval should be judged by odometer reading or months, whichever comes first.
This table includes services as scheduled up to 90,000 km (54,000 miles) mileage. Beyond 90,000
km (54,000 miles), carry out the same services at the same intervals respectively.
Km (x 1,000) 15 30 45 60 75 90
Interval Miles (x 1,000) 9 18 27 36 45 54
Months 12 24 36 48 60 72
ENGINE
Accessary drive belt I R
Camshaft timing belt Replace every 150,000 km (90,000 miles).
Engine oil and oil filter Replace every 20,000 km (12,000 miles) or
16 months.
Engine coolant R R
Exhaust system I I I
Heater (Glow) plugs Inspect every 120,000 km (72,000 miles) or
96 months.
FUEL SYSTEM
Air cleaner filter I I R I I R
Fuel lines I I I
Fuel filter Replace every 60,000 km (36,000 miles).
Drain water every 20,000 km (12,000 miles).
Fuel tank I I
CHASSIS AND BODY
Clutch (pedal and fluid level) I I I
Brake discs and pads (thickness, wear, damage) I I I I I I
Brake drums and shoes (wear, damage) I I I
Brake hoses and pipes (leakage, damage, clamp) I I I
Brake fluid R R R
Brake lever and cable (damage, stroke, operation) Inspect at first 15,000 km (9,000 miles) only
Tires (wear, damage, rotation) I I I I I I
Wheel discs (damage) I I I I I I
Suspension system (tightness, damage, rattle, breakage) I I I
Propeller shafts and drive shafts I I
Manual transmission oil (leakage, level) (I: 1st 15,000 km only) I R R
Automatic transmission Fluid level I I I
Fluid change Replace every 165,000 km (99,000 miles)
Fluid hose I
Transfer oil (leakage, level) I I I
Differential oil (leakage, level) (R: 1st 15,000 km only) R or I I I
Steering system (tightness, damage, breakage, rattle) I I I
Power steering (if equipped) I I I I I I
All latches, hinges and locks I I I
Air conditioning filter (if equipped) I R I R
NOTE:
R : Replace or change
I : Inspect and correct, replace or lubricate if necessary
Some maintenance items are required to be serviced at times other than the regular maintenance
times shown at the top of above table. These items can be serviced at an earlier service opportunity
according to customers maintenance convenience. Their next maintenance service should be done
within the specified period.
Maintenance Recommended Under Severe Driving Conditions

If the vehicle is usually used under the conditions corresponding to any severe condition code given below, it is
recommended that applicable maintenance operation be performed at the particular interval as given in the
chart below.
Severe condition code
A : Repeated short trips
B : Driving on rough and/or muddy roads
C : Driving on dusty roads
D : Driving in extremely cold weather and/or salted roads
E : Repeated short trips in extremely cold weather
F : Leaded fuel use
G : Town use/Towing a trailer/Sustained high speed driving/Hot climates, above 30 C (86 F)/Low quality lubri-
cants or fuel
H : Trailer towing (if admitted)
Severe Maintenance
Maintenance Maintenance Interval
Condition Code Operation
Every 15,000 km
I
(9,000 miles) or 12 months
BCD Accessary drive belt (V-rib belt)
Every 45,000 km
R
Every 120,000 km
ACDEG Camshaft timing belt R
(72,000 miles)
Every 10,000 km
ACDEG Engine oil and oil filter R
Every 15,000 km
B Exhaust pipe mountings I
Every 2,500 km
I
(1,500 miles)
C Air cleaner filter *1
Every 30,000 km
R
Every 15,000 km
BCDH Wheel bearing I
Every 15,000 km
B Suspension bolts and nuts T
Every 15,000 km
BDEH Propeller shafts and drive shafts I
Severe Maintenance
Maintenance Maintenance Interval
Condition Code Operation
First time only:
15,000 km (9,000 miles) or 12
months
Manual transmission,
BEH R Second time and after:
transfer and differential oil
Every 30,000 km (18,000 miles) or
24 months reckoning from 0 km (0
miles) or 0 months
Every 30,000 km
BEH Automatic transmission fluid R
Every 15,000 km
I
Air conditioning filter *2 (9,000 miles) or 12 months
CD
(if equipped) Every 45,000 km
R
NOTE:
I : Inspect and correct, replace or lubricate if necessary
R : Replace or change
T : Tighten to the specified torque
*1 : Inspect or replace more frequently if necessary.
*2 : Clean or replace more frequently if the air from the air conditioning decreases.
Maintenance Service
Engine
Accessary drive belt
WARNING:
All inspection and replacement are to be performed with
ENGINE NOT RUNNING.
GENERATOR DRIVE BELT INSPECTION

1) Disconnect negative cable at battery.
2) Inspect belt for cracks, cuts, deformation, wear and cleanli-
ness using mirror under enough lighting.
If any defect exists, replace.
3) Check that belt wear check mark (1) (tension indicator) is
within range a using mirror (4) under enough lighting.
If wear check mark (1) is aligned with maximum wear mark
(2) or out of range a passing mark (2), replace accessary
drive belt with a new one.
4) Connect negative cable to battery.
3. Zero wear mark
GENERATOR DRIVE BELT REPLACEMENT

Replace belt with a new one referring to Generator Belt in Sec-
tion 6H.
AIR CONDITIONING COMPRESSOR DRIVE BELT INSPEC-

TION
Check compressor drive belt (1) for wear, cracks and tension
referring to Compressor Drive Belt in Section 1B.
Repair or replace if any faulty condition is found.
2. Compressor
3. Crankshaft pulley
AIR CONDITIONING COMPRESSOR DRIVE BELT

REPLACEMENT
Replace belt with a new one referring to Compressor Drive Belt
in Section 1B.
Camshaft timing belt

REPLACEMENT
Replace belt with new one. Refer to Timing Belt in Section 6A3
for replacement procedure.
CAUTION:
Do not bend or twist timing belt.
Do not allow timing belt to come into contact with oil,
water, etc.
Engine oil and oil filter

CHANGE
It is recommended to use the following engine oil or higher quality

level oils.
5W-30 : API CF (except CF-2) or ACEA B3-98
15W-40 : API SG/CF (except CF-2) or ACEA B2-96
Select the appropriate oil viscosity according to the left chart.
Before draining engine oil, check engine for oil leakage. If any evi-
dence of leakage is found, make sure to correct defective part
before performing the following work.
1) Remove engine under-cover and drain engine oil by remov-
ing drain plug (1).
2) After draining oil, wipe drain plug clean. Reinstall drain plug,
and tighten it securely as specified below.
Tightening torque
Engine oil drain plug (a): 34 Nm (3.4 kg-m, 25.0 lb-ft)
3) Loosen oil filter (1) by using oil filter wrench (Special tool).
Special tool
(A): 09915-46510
4) Apply engine oil to new oil filter O-ring.

5) Screw new filter on oil filter stand by hand.
6) Tighten filter (1) to specified torque.

Special tool
(A): 09915-46510
Tightening torque
(a): 14 Nm (1.4 kg-m, 10.5 lb-ft)
7) Replenish oil until oil level is brought to FULL level mark (2)
on dipstick. (about 4.75 liters or 10.0/8.4 US/Imp pt.).
NOTE:
Note that amount of oil required when actually changing
oil may somewhat differ from this data depending on var-
ious conditions (temperature, viscosity, etc.)
8) Start engine and run it for three minutes. Stop it and wait
another 5 minutes before checking oil level. Add oil, as nec-
essary, to bring oil level to FULL level mark (2) on dipstick.
9) Check oil filter and drain plug for oil leakage.
1. LOW level mark
Engine coolant
CHANGE
WARNING:
To help avoid danger of being burned, do not remove
degassing tank cap while engine and radiator are still
hot. Scalding fluid and steam can be blown out under
pressure if cap is taken off too soon.
CAUTION:
When changing engine coolant, use mixture of 50% water
and 50% ethylene-glycol base coolant (Anti-freeze/Anti-
corrosion coolant) for the purpose of corrosion protec-
tion and lubrication.
1) Remove degassing tank cap when engine is cool.

2) Remove engine under cover. Loosen radiator drain plug (1)
to drain coolant.
3) Tighten drain plug securely.
4) Fill cooling system with specified coolant through degassing

tank filler inlet, up to FULL level mark (2) on degassing tank
(1).
5) Loosen bleed screw on thermostat cap to bleed air and
tighten it after confirmation of overflow.
6) Run engine with replenishing coolant, until radiator upper
hose is hot.
7) Add coolant as necessary until coolant reaches FULL level
mark on degassing tank.
Reinstall degassing tank cap (3).
Refer to Coolant in Section 6B of this manual for Coolant
Capacity.
Exhaust system
INSPECTION
WARNING:
To avoid danger of being burned, do not touch exhaust
system when it is still hot.
Any service on exhaust system should be performed
when it is cool.
Check exhaust system as follows:

Check rubber mountings for damage and deterioration.
Check exhaust system for leakage, loose connections,
dents, and damages.
If bolts or nuts are loose, tighten them to specification.
Refer to Exhaust System Components in Section 6K for
torque specification of bolts and nuts.
Check nearby body areas for damaged, missing or misposi-
tioned parts, open seams, holes, loose connections or other
defects which could permit exhaust fumes to seep into vehi-
cle.
Make sure that exhaust system components have enough
clearance from underbody to avoid overheating and possible
damage to floor carpet.
Any defects should be fixed at once.
Heater (Glow) plugs

INSPECTION
Check heater (Glow) plug (1) for external damage such as defor-
mation, scratch, crack, etc.
If damage is found, replace.
Fuel System
Air cleaner filter
INSPECTION
1) Unclamp air cleaner case clamps.

2) Take filter out of air cleaner case.
3) Check filter for dirt. Replace excessively dirty filter.
4) Clean filter with compressed air from air outlet side of filter
(i.e., the side facing up when installed).
5) Install filter and clamp case securely.
REPLACEMENT
Replace air cleaner filter with new one according to above steps
1), 2) and 5).
Fuel lines and connections

INSPECTION
1) Visually inspect fuel lines and connections for evidence of
fuel leakage, hose cracking and damage. Make sure all
clamps are secure.
Repair leaky joints, if any.
Replace hoses that are suspected of being cracked.
Fuel filter
REPLACEMENT
1
WARNING:
This work must be performed in a well ventilated area
and away from any open flames (such as gas hot water
heaters).
Replace fuel filter element in fuel filter assembly (1) with new one
referring to Fuel Filter in Section 6C.
WATER DRAINING OF FUEL FILTER

Bleed fuel filter of water referring to Water Draining of Fuel Filter
in Section 6C.
Fuel tank
INSPECTION
Check fuel tank for damage, cracks, fuel leakage, corrosion and
tank bolts looseness.
If a problem is found, repair or replace.
Chassis and Body

Manual transmission oil
INSPECTION
1) Inspect transmission case for evidence of oil leakage.
Repair leaky point if any.
2) Make sure that vehicle is placed level for oil level check.
3) Remove level plug (2) of transmission.
4) Check oil level.
Oil level can be checked roughly by means of level plug hole.
That is, if oil flows out of level plug hole or if oil level is found
up to hole when level plug is removed, oil is properly filled.
If oil is found insufficient, pour specified amount of specified
oil.
5) Tighten level plug to specified torque.
Refer to Transmission Gear Oil in Section 7A2 for installa-
1 2 tion and tightening torque.
1. Drain plug
CHANGE
Change transmission oil with new specified oil referring to Trans-
mission Gear Oil in Section 7A2.
Automatic transmission fluid

INSPECTION
1) Inspect transmission case for evidence of fluid leakage.
Repair leaky point, if any.
2) Make sure that vehicle is placed level for fluid level check.
3) Check fluid level.
For fluid level checking procedure, refer to Fluid level in
Section 7B2 and be sure to perform it under specified condi-
tions. If fluid level is low, replenish specified fluid.
1. Level gauge 4. FULL COLD mark
2. FULL HOT mark 5. LOW COLD mark
3. LOW HOT mark
CHANGE
1) Inspect transmission case for evidence of fluid leakage.

Repair leaky point, if any.
2) Make sure that vehicle is placed level for fluid level check.
3) Change fluid. For its procedure, refer to Fluid Change in
Section 7B2.
1. Drain plug
FLUID COOLER HOSE INSPECTION
Check automatic transmission fluid cooler hose for fluid leakage,

cracks, damage and deterioration.
Replace hose and/or clamp if any faulty condition is found.
Power steering (P/S) system (if equipped)

INSPECTION
1) Visually check power steering system for fluid leakage and

hose for damage and deterioration.
Repair or replace defective parts, if any.
[A]: Figure shows left-hand steering vehicle
2) With engine stopped, check fluid level indicated on fluid tank,

which should be between UPPER and LOWER marks. If
it is lower than LOWER, fill fluid up to UPPER mark.
NOTE:
Be sure to use the specified fluid.
Fluid level should be checked when fluid is cool.
3) Visually check pump drive belt for cracks and wear.

4) Check belt for tension, referring to Accessary Drive Belt in
this Section.
If necessary, have belt or replaced.
Recommended Fluids and Lubricants

Engine oil Refer to Engine Oil and Oil Filter in this Section.
Ethylene-glycol base coolant
Engine coolant
(Antifreeze/Anticorrosion coolant)
Brake fluid DOT 3
Manual transmission oil Refer to Transmission Gear Oil in Section 7A2.
Transfer oil Refer to Transfer Gear Oil in Section 7D.
Differential oil (front & rear) Refer to Gear Oil Change in Section 7E or Changing Oil in Section 7F.
Automatic transmission fluid Refer to Fluid Change in Section 7B1.
Power steering fluid Refer to Required Service Material in Section 3B1.
Door hinges Engine oil or water resistance chassis grease
Hood latch assembly
Key lock cylinder Spray lubricant
HEATER AND VENTILATION 1A-1
SECTION 1A
HEATER AND VENTILATION 1A
WARNING:
For vehicles equipped with a Supplement Restraint (Air Bag) System
unintentional activation of the system or could render the system inoperative. Either or these two
NOTE:
ual mentioned in Foreword of this manual.
CONTENTS
General Description ........................................1A-2 Blower Motor Controller ...................................... *
Major Components ........................................1A-3 HVAC Control Module......................................... *
Wiring Circuit .................................................1A-4 Air Flow Control Actuator .................................... *
Body Ventilation .................................................. * Temperature Control Actuator ............................ *
General Diagnosis...........................................1A-4 Air Intake Actuator .............................................. *
Actuator Linkage Assembly ................................ *
Diagnosis Table ............................................1A-4
Supplementary Heater .................................. 1A-9
HVAC Diagnosis..............................................1A-5 Supplementary heater No.1 ...................... 1A-9
On-Board Diagnostic System ........................1A-5 Supplementary heater No.2 ...................... 1A-9
On-Vehicle Service..........................................1A-6 Supplementary Heater Relay...................... 1A-10
Blower Unit ....................................................1A-6 Heater Unit.................................................. 1A-11
Blower Motor .................................................1A-7 Center Ventilation Louver ................................... *
Blower Motor Relay ............................................. * Rear Duct............................................................ *
1A-2 HEATER AND VENTILATION
General Description
For this system, the supplementary heater operated by electricity is located in the heater unit near the conven-
tional type heater core and adds more heat to the air. The supplementary heater automatically turns ON under
the following conditions.
Temperature selector of HVAC control module = MAX HOT position
Blower speed selector = ON position
Engine coolant temperature = Less than 75 C (167 F)
Battery voltage = More than 9 V
Air flow selector of HVAC control module = FOOT, DEF/FOOT, or DEF position
Engine = Running
3 3
4 4
1
2 2
11 10 8
6 6
1. Fresh air 3. Defroster air 5. Ventilation air 7. Blower unit 9. Heater unit 11. Supplementary heater
2. Recirculation air 4. Demister air 6. Foot air 8. Blower motor 10. Heater core
Major Components
NOTE:
The major components shown below are for vehicle with left steering wheel. For vehicle with right
steering wheel, position of each component is symmetrical except airflow control actuator (8) and
temperature control actuator (9).
13
4
12
10
11
1. Heater unit 4. Defroster duct 7. Rear duct 10. Air intake actuator 13. Supplementary heater No.2
2. Blower unit 5. Ventilation louver 8. Air flow control actuator 11. Blower motor controller
3. Ventilator duct 6. HVAC control module 9. Temperature control actuator 12. Supplementary heater No.1
Wiring Circuit
Refer to A/C System Wiring Circuit Diagram in Section 1B.
General Diagnosis
Diagnosis Table
Condition Possible Cause Correction
Blower motor wont Wiring or grounding faulty Repair as necessary.
work even when Fuse blown Replace fuse.
blower speed selector Blower motor faulty Check blower motor referring to
is ON Blower Motor in this section.
Blower motor relay faulty Check relay referring to Blower
Motor Relay in this section.
Blower motor controller faulty Check blower motor controller
referring to Blower Motor Control-
ler in this section.
Blower speed selector faulty Check HVAC control module refer-
ring to Inspection of HVAC Control
Module and Its Circuits in Section
1B.
Insufficient heat Leakage from heater hoses or clogged up of Replace hoses.
heater hoses
Leakage from heater core or clogged up of Replace heater core referring to
heater core Heater Unit in this section.
Air leakage from heater unit or air duct Repair as necessary.
Air damper broken Repair damper.
Heater and ventilation system faulty Check air intake door and tempera-
ture control door operation.
Supplementary heater faulty Check supplementary heater refer-
ring to Supplementary Heater in
this section.
Temperature control actuator faulty Check temperature control actuator
referring to Temperature Control
Actuator in this section.
HVAC control module faulty Check HVAC control module refer-
ring to HVAC Control Module and
Its Circuits in Section 1B.
Air temperature is not Leakage from heater hoses or clogged up of Replace hoses.
changed even when heater hoses
temperature selector Leakage from heater core or clogged up of Replace heater core referring to
is changed heater core Heater Unit in this section.
Air damper broken Repair damper.
Temperature control actuator faulty Check temperature control actuator
referring to Temperature Control
Actuator in this section.
Temperature selector faulty Check HVAC control module refer-
1B.

Air outlet port is not Air damper broken Repair damper.
changed when air flow Air flow control actuator faulty Check air flow control actuator
selector is changed referring to Air Flow Control Actua-
tor in this section.
Air flow selector faulty Check HVAC control module refer-
1B.
HVAC Diagnosis
On-Board Diagnostic System
HVAC control module detects malfunction(s), which may occur in
the following area. Once it detects any malfunction, it stores diag-
nostic information in its memory.
ECT sensor
Temperature control actuator
Air flow control actuator
Temperature selector of HVAC control module
Blower speed selector of HVAC control module
Air flow selector of HVAC control module
DTC can be checked by using SUZUKI scan tool (2) connected to
DLC (1). For more details, refer to HVAC Diagnosis in Section
1B.
NOTE:
For vehicles without air conditioning system, when
checking for any DTC by using SUZUKI scan tool, DTC
1
No.1503 (A/C Evaporator Temperature Sensor and its
Circuit Malfunction) is displayed on SUZUKI scan tool.
2 Disregard the DTC because the sensor is not equipped
for vehicles without air conditioning system.
For vehicles with air conditioning system, on-board
diagnosis by using SUZUKI scan tool or A/C switch of
HVAC control module is available. However, only
SUZUKI scan tool can be used for on-board diagnosis
because A/C switch is not on HVAC control module for
vehicles without air conditioning system.
On-Vehicle Service
Blower Unit
5
12
3 10
11
9
1. Air intake case 4. Air filter cover 7. Air intake door 10. Blower fan
2. Upper scroll 5. Air filter 8. Air intake actuator 11. Air hose
3. Lower scroll 6. Blower motor controller 9. Blower motor 12. Levers and rods
REMOVAL
1) Disconnect negative () cable at battery.
2) Disable air bag system (if equipped) referring to Disabling
Air Bag System in Section 10B.
3) Open glove box, and then remove screw and damper located
on the right side of the glove box.
4) Remove glove box.
5) Remove passenger lower member (1).
6) Remove A/C controller with bracket from blower unit.

7) Disconnect blower motor lead wire (1), blower motor relay
3
lead wire (2) and blower motor controller lead wire (3) at cou-
plers.
1
2
8) Disconnect air intake actuator coupler.

1
9) Remove fastening nuts (1) and screws (2), and then remove
3 blower unit (3).
2
INSTALLATION
Reverse removal procedure for installation noting the following:
Enable air bag system (if equipped) referring to Enabling Air
Bag System in Section 10B.
Blower Motor
REMOVAL
3) Remove A/C controller with bracket from blower unit.
1
4) Disconnect blower motor lead wire (2) at coupler.
5) Remove blower motor (3) from blower unit (1).
INSPECTION
Check for continuity between terminal to terminal as shown

in the figure. If check result is good, proceed to the next
check. If not, replace.
Connect battery to the blower motor as shown, and then

check if the blower motor operates smoothly.
1 Blower motor specification: 18 24 A at 12 V
1. Airflow
INSTALLATION
Reverse the removal procedure for installation noting the follow-
ing:
Supplementary Heater
Supplementary heater No.1
REMOVAL
Air Bag System in Section 10A.
3) Disconnect supplementary heater No.1 lead wire (1) at cou-
3 pler.
4) Remove bracket (2) and supplementary heater No.1 (3).
2
1
INSPECTION
Check if there is continuity between supplementary heater

terminals. If there is no continuity, replace supplementary
heater.
Check supplementary heater for crack or any other damage.
Replace if needed.
INSTALLATION
Reverse the removal procedure.
NOTE:
Be careful not to pinch harness in other parts.
Supplementary heater No.2

REMOVAL
Air Bag System in Section 10A.
4) Remove temperature control actuator referring to Tempera-
ture Control Actuator in this section.
5) Disconnect supplementary heater No.2 lead wire (1) at cou-

2 pler.
6) Remove supplementary heater No.2 (2).
INSPECTION
Inspect supplementary heater No.2 referring to INSPECTION
under Supplementary Heater No.1 in this section.
INSTALLATION
Reverse the removal procedure.
NOTE:
Be careful not to pinch harness in other parts.
Supplementary Heater Relay

INSPECTION
2) Remove supplementary heater relay (No.1 and No.2) from
circuit fuse box located under the instrument panel on the
1 drivers seat side.
1. Supplementary heater relay No.1
2 2. Supplementary heater relay No.2
3) Check if there is no continuity between terminal c and d.

If there is continuity, replace relay.
4) Check if there is continuity between terminals c and d
when a 12 V battery is connected to terminals a and b.
If there is no continuity, replace relay.
Heater Unit
4
12
7
2
13
3 9
5
10
9
11
1. Heater core 6. Temperature control link assembly 11. Supplementary heater No.1
2. Temperature control door 7. Temperature control actuator 12. Supplementary heater No.2
3. Air flow control door 8. Heater lower case 13. Heater core bracket
4. Air flow control link assembly 9. Heater upper case
5. Air flow control actuator 10. Foot air duct
REMOVAL
WARNING:
Failure to follow the following procedure and WARNING
may cause air bag deployment, personal injury, damage
to parts, or air bag being unable to deploy.
Never rest a steering column assembly on steering
wheel with air bag (inflator) module face down and col-
umn vertical.
When handling the air bag (inflator) modules (driver
and passenger), be careful not to drop it or apply an
impact to it. If an excessive impact was applied (e.g.,
dropped from a height of 91.4 cm (3 feet) or more,
never attempt disassembly or repair but replace it with
a new one.
When grease, cleaning agent. Oil, water, etc. has got
onto air bag (inflator) modules (driver and passenger),
wipe off immediately with a dry cloth.

3) Drain engine coolant and disconnect heater hoses (1) from
heater unit.
4) Remove instrument panel referring to Instrument Panel in
1
Section 9.
5) Remove blower unit referring to Blower Unit in this section.
6) Disconnect rear duct (4) from heater unit.

7) Disconnect air flow control actuator lead wire (1) at coupler
and temperature control actuator lead wire (2) at coupler.
8) Disconnect supplementary heater No.1 (5), No.2 (6) lead
wire at coupler.
1
5
9) Remove SDM (3) (If equipped).
2
3 6
4
10) Remove heater unit (1).

11) Remove temperature control actuator from heater unit and
supplementary heater No.2.
12) Remove heater core pipe clamp and heater core bracket (1).
13) Pull out heater core (1) from heater unit (2).
1
INSTALLATION
Install heater unit by reversing removal procedure, noting the fol-
lowing items.
When installing each part, be careful not to pinch any cable
or wiring harness.
When installing steering column assembly, refer to Steering
Column Installation in Section 3C or 3C1.
Fill engine coolant to radiator.
AIR CONDITIONING (OPTIONAL) 1B-1
SECTION 1B
6F1
6F2
AIR CONDITIONING (OPTIONAL) 6G
6H
1B
WARNING:
For vehicles equipped with a Supplemental Restraint (Air Bag) System: 7A
Service on and around the air bag system components or wiring must be performed only by an 7A1
authorized SUZUKI dealer. Refer to Air Bag System Components and Wiring Location View under 7B1
General Description in air bag system section in order to confirm whether you are performing ser- 7C1
7D
7E
7F
8A
8A
8D
CAUTION: 8E
The air conditioning system of this vehicle uses refrigerant HFC-134a (R-134a).
None of refrigerant, compressor oil and component parts is interchangeable between two types of 9
A/C: one using refrigerant CFC-12 (R-12) and the other using refrigerant HFC-134a (R-134a).
Be sure to check which refrigerant is used before any service work including inspection and mainte- 10
nance. For identification between these two types, refer to the same section of Service Manual men- 10A
tioned in FOREWORD of this manual. 10B
When replenishing or changing refrigerant and compressor oil and when replacing parts, make sure
that the material or the part to be used is appropriate to the A/C installed in the vehicle being serviced.
Use of incorrect one will result in leakage of refrigerant, damage in parts or other faulty condition.
NOTE:
For the items with asterisk (*) in the CONTENTS below, refer to the same section of the Service
Manual mentioned in FOREWORD of this manual.
For the basic service method of the air conditioning system that is not described in this section,
refer to Air Conditioning Basic Manual (99520-02130).
CONTENTS
General Description ............................................. * Abnormal noise from crankshaft pulley .......... *
Major Components and Location ..................1B-3 Abnormal noise from tension pulley ............... *
Wiring Circuit .................................................1B-4 Abnormal noise from evaporator.................... *
Refrigerant Flow of Air Condition System ........... * Abnormal noise from blower motor ................ *
Identification of Refrigerant System .................... * Quickly Checking of Refrigerant Charge............. *
General Diagnosis.......................................... 1B-6 Charge of refrigerant ...................................... *
Checking refrigerant charge........................... *
General Diagnosis Table...............................1B-6
Compression System Diagnosis ......................... *
Diagnosis of Abnormal Noise .............................. *
Performance Diagnosis....................................... *
Abnormal noise from compressor .................. *
Performance diagnosis table.......................... *
Abnormal noise from magnetic clutch ............ *
Detail diagnosis table (Ambient
Abnormal noise from tubing ........................... *
temperature within 30 35 C
Abnormal noise from condenser .................... *
(85 95 F)) ................................................... *
1B-2 AIR CONDITIONING (OPTIONAL)
Inspection of HVAC Control Module and Its DTC B1513 (No.13) : Temperature Control
Circuits ........................................................ 1B-11 Actuator and Its Circuit Malfunction .....................*
HVAC control module voltage table ....... 1B-12 DTC B1514 (No.14) : Air Flow Control Actuator
Reference waveform No.1 ..................... 1B-15 and Its Circuit Malfunction ...................................*
Reference waveform No.2 ..................... 1B-16 DTC B1520 (No.20) : Temperature Selector
Reference graph No.1............................ 1B-17 and Its Circuit Malfunction ...................................*
Inspection of A/C Controller and Its DTC B1521 (No.21) : Blower Speed Selector
Circuits ........................................................ 1B-18 and Its Circuit Malfunction ...................................*
A/C controller voltage value table .......... 1B-19 DTC B1522 (No.22) : Air Flow Selector and
HVAC Diagnoisis.................................................. * Its Circuit Malfunction ..........................................*
On-Board Diagnostic System.............................. * Refrigerant Recovery, Evacuating and
Precautions in Diagnosing Trouble ..................... * Charging................................................................ *
Air Conditioning System Diagnostic Flow Operation Procedure for Charging A/C with
Table ................................................................... * Refrigerant ...........................................................*
Customer complaint analysis ......................... * Recovery..............................................................*
Customer questionnaire (example) ................ * Evacuating ...........................................................*
Visual inspection ............................................ * Evacuating procedure......................................*
Problem symptom confirmation...................... * Checking system for pressure leaks................*
DTC check ..................................................... * Charging ..............................................................*
Troubleshooting for DTC................................ * Removing Manifold Gauge Set............................*
Check for intermittent problem....................... * Leak-Testing Refrigerant System ........................*
Air conditioning system symptom Liquid Leak Detectors ..........................................*
diagnosis........................................................ * On-Vehicle Service ...................................... 1B-24
Final confirmation test .................................... * Precaution............................................................*
Visual Inspection................................................. * Piping.............................................................. *
DTC Check ......................................................... * Handling refrigerant HFC-134a (R-134a)........ *
Using SUZUKI scan tool ................................ * Refrigerant recovery ....................................... *
Not using SUZUKI scan tool .......................... * Refrigerant charge .......................................... *
DTC Clearance ................................................... * Replenishing compressor oil........................... *
Using SUZUKI scan tool ................................ * Air Filter Element .................................................*
Not using SUZUKI scan tool .......................... * Refrigerant Pipes and Hoses...............................*
DTC Table........................................................... * A/C Refrigerant (Dual) Pressure Switch ..............*
Example ......................................................... * A/C Condenser Assembly....................................*
Fail-Safe Table.................................................... * Condenser Cooling Fan Assembly ......................*
Scan Tool Data ........................................... 1B-20 Condenser Dryer (Receiver/Dryer) ......................*
Scan tool data definitions....................... 1B-21 Heater and Cooling Unit ............................. 1B-24
A/C Indicator Lamp Check .................................. * A/C Evaporator ....................................................*
A/C Indication Lamp Does Not Come ON ........ * Expansion Valve ..................................................*
DTC B1501 (No.01) : Outside Air Temperature A/C Evaporator Thermistor (A/C Evaporator
Sensor and Its Circuit Malfunction ...................... * Temperature Sensor)...........................................*
DTC B1502 (No.02) : Inside Air Temperature Outside Air Temperature Sensor (for Vehicle
Sensor and Its Circuit Malfunction ...................... * with Automatic Air Conditioning System).............*
DTC B1503 (No.03) : A/C Evaporator Sunload Sensor (for Vehicle with Automatic
Temperature Sensor and Its Circuit Air Conditioning System) .....................................*
Malfunction.......................................................... * HVAC Control Module .........................................*
DTC B1504 (No.04) : Sunload Sensor and A/C Controller ............................................. 1B-27
Its Circuit Malfunction.......................................... * A/C Signal Relay......................................... 1B-27
DTC B1510 (No.10) : Engine Coolant A/C Compressor Relay and A/C
Temperature (ECT) Sensor and Its Circuit Condenser Cooling Fan Relays.................. 1B-28
Malfunction.......................................................... * Compressor Assembly................................ 1B-28
DTC B1511 (No.11) : Temperature Control Compressor Drive Belt................................ 1B-31
Actuator (Position Sensor) and Its Circuit
Required Service Materials......................... 1B-31
Malfunction.......................................................... *
DTC B1512 (No.12) : Air Flow Control Actuator Tightening Torque Specification ..........................*
(Position Sensor) and Its Circuit Malfunction ...... * Special Tool ................................................ 1B-32
Major Components and Location
1. A/C evaporator 6. Suction hose 11. Foot air 16. Blower unit 21. High pressure charge valve
2. Compressor 7. Condenser outlet pipe 12. Defrost air 17. Blower fan motor 22. Suction pipe
3. Condenser assembly 8. Liquid pipe 13. Demister air 18. Heater core 23. Sight glass
4. Receiver/dryer 9. Expansion valve 14. Fresh air 19. Dual pressure switch 24. Supplementary heater
5. Discharge hose 10. Ventilation air 15. Recirculation air 20. Low pressure charge valve
Wiring Circuit
13 c 36
37
1 14
BLK/BLU BLK/WHT BLK/WHT G52-22 G52-17 ORN
15 G52-18 GRN
WHT/YEL WHT G52-7
a G52-19 GRN/WHT
RED/GRN
16
WHT/GRN YEL/BLK YEL/GRN BLU/BLK G52-4
17
19 YEL/GRN
RED
18 38
G52-11
BLK/RED
YEL BLK/WHT c
22
20 G52-1 GRY GRY/RED
55 YEL/GRN LT GRN G52-2 GRY/BLU GRY/BLK

39
BLU/WHT RED/GRN RED/WHT
2 23
RED/BLK G52-30 G52-27 WHT/RED WHT/YEL
3 4 5 6
12 PPL/WHT G52-29 BLK/RED
21
11 10 9 8 7
24 38 G52-16 GRY/RED
WHT/YEL
YEL/BLK G52-10
BLK G52-15 GRY/BLK
BLU/WHT WHT/GRN 40
G52-12 RED/WHT
26 25
BLU G52-28 WHT/YEL
d e f g BLK/RED
YEL/WHT G52-24 BLK/RED
27
41
G52-9 WHT/BLK
G52-26
42
BLU/BLK c G52-25 PNK
28 BLK/YEL G52-23 G52-3 PPL/RED

h BLK/WHT
43
BLU/GRN G52-20
LT GRN/BLK
30 29
YEL/GRN
46 48
E227-20 RED RED/GRN
BLU/BLK WHT/GRN E228-2
YEL/WHT YEL/GRN
E227-18
47 49
BLU/BLK E227-3
RED RED/WHT
YEL/BLU E227-4 57
31
YEL/BLK E227-29
32 b
PNK
YEL/GRN 50
YEL/RED 33 RED/BLK
34
WHT/RED
c BLK/WHT E39-16 E39-4
b PNK E39-1 E39-8 GRY/WHT E227-21 53
51
E39-13
35 RED/BLU
E39-15
E39-10 GRN/BLK GRY/WHT G52-21
E38-1
E38-2 52
44
a RED/YEL G52-6 54
RED/GRN
RED/GRN
G54-22 e d g f h
RED/BLU G54-11 PPL/YEL G52-5

56 G54-8 G55-2 RED G52-13
YEL/RED G53-6
45
GRY/YEL G53-13
1. Ignition switch 16. TAIL fuse 31. Radiator fan motor No.2 46. Supplementary heater relay No.1
2. Main fuse box 17. HTR fuse 32. A/C signal relay 47. Supplementary heater relay No.2
3. Main fuse 18. FRONT BLOW fuse 33. ECM 48. Supplementary heater No.1
4. IG fuse 19. Rear window defogger relay 34. A/C controller 49. Supplementary heater No.2
5. HTR fuse 20. Blower motor 35. A/C refrigerant (dual) pressure switch 50. Compressor relay
6. RR DEF fuse 21. Blower motor controller 36. HVAC control module 51. Condenser fan motor relay
7. PTC 1 fuse 22. Rear window defogger 37. Air intake actuator 52. Condenser fan motor high relay
8. PTC 2 fuse 23. Blower motor relay 38. Connector 53. A/C compressor
9. RDTR fuse 24. Double relay 39. Temperature control actuator 54. Condenser fan
10. A/C fuse 25. Speedometer 40. Air flow control actuator 55. Battery
11. PTC 1 fuse 26. Oil pressure switch 41. A/C evaporator temperature sensor 56. Outside air temperature sensor
(for vehicle with automatic A/C system)
12. PTC 2 fuse 27. Radiator fan relay No.3 (LOW) 42. Sunload sensor 57. Inside air temperature sensor
(for vehicle with automatic A/C system) (for vehicle with automatic A/C system)
13. Fuse box 28. Radiator fan motor No.1 43. Data link connector
14. METER fuse 29. Radiator fan relay No.2 (HIGH) 44. Headlight relay No.2
15. RADIO DOME fuse 30. Radiator fan relay No.1 (HIGH) 45. BCM
General Diagnosis
General Diagnosis Table
Cool air does not No refrigerant Perform recovery, evacuation and
come out (A/C system charge referring to Recovery,
does not operate) Evacuating and Charging in this
section.
Fuse blown Check related fuses, and check
short circuit to ground.
Wiring or grounding faulty Check wiring and grounding, and
repair as necessary.
A/C evaporator thermistor (A/C evaporator tem- Check A/C evaporator thermistor (A/
perature sensor) faulty C evaporator temperature sensor)
referring to A/C Evaporator Ther-
mistor (A/C Evaporator Tempera-
ture Sensor) in this section.
A/C refrigerant (dual) pressure switch faulty Check A/C refrigerant (dual) pres-
sure switch referring to A/C Refrig-
erant (Dual) Pressure Switch in
this section.
ECT sensor faulty Check ECT sensor referring to
Engine Coolant Temperature
(ECT) Sensor in Section 6E1 or
6E2.
A/C controller faulty Check A/C controller referring to
A/C Controller in this section.
Module and Its Circuits in this sec-
tion.
Cool air does not Fuse blown Check related fuses, and check
come out (A/C com- short circuit to ground.
pressor does not Drive belt loose or broken Replace compressor drive belt.
operate (does not Magnet clutch faulty Check magnet clutch referring to
rotate)) Magnet Clutch in this section.
Compressor relay faulty Check compressor relay referring
to A/C Compressor Relay and A/C
Condenser Cooling Fan Relays in
this section.
A/C compressor faulty Check compressor referring to
Compressor Assembly in this
section.
tion.

come out (A/C con- short circuit to ground.
denser cooling fan Wiring or grounding faulty Check wiring and grounding, and
motor no operation) repair as necessary.
Condenser cooling fan motor relay faulty Check compressor relay referring
to A/C Compressor Relay and A/C
Condenser Cooling Fan Relays in
this section.
Condenser cooling fan motor faulty Check condenser cooling fan motor
referring to Condenser Cooling
Fan Assembly in this section.
come out (Blower short circuit to ground.
motor does not oper- Wiring or grounding faulty Check wiring and grounding, and
ate) repair as necessary.
Blower motor relay faulty Check blower motor relay referring
to Blower Motor Relay in Section
1A.
Blower motor faulty Check blower motor referring to
Blower Motor in Section 1A.
Blower motor controller faulty Check blower motor controller
referring to Blower Motor Control-
ler in Section 1A.
tion.

Cool air does not Insufficient or excessive charge of refrigerant Check the amount of refrigerant.
come out or insuffi- Refrigerant leak in system Check A/C system for leaks.
cient cooling (A/C sys- Air in A/C system Replace desiccant, and perform
tem normal operation) evacuation and charge.
Air leaking from cooling unit or air duct Repair as necessary.
Drive belt slipping Check or replace compressor drive
belt.
Magnetic clutch faulty Check magnetic clutch referring to
Magnetic Clutch in this section.
section.
Excessive compressor oil existing in A/C sys- Pull out compressor oil in A/C sys-
tem tem circuit, and check compressor
referring to Compressor Assem-
bly in this section.
Outside air temperature sensor faulty (for vehi- Check outside air temperature sen-
cle with automatic air conditioning system) sor referring to Outside Air Tem-
perature Sensor Inspection in
Section 8H.
Sunload sensor faulty (for vehicle with auto- Check sunload sensor referring
matic air conditioning system) Sunload Sensor in this section.
A/C refrigerant (dual) pressure switch faulty Check A/C refrigerant (dual) pres-
sure switch referring to A/C Refrig-
erant (Dual) Pressure Switch in
this section.
Condenser cooling fan motor faulty Check condenser cooling fan motor
referring to Condenser Cooling
Fan Assembly in this section.

Cool air does not Condenser clogged Check condenser referring to A/C
come out or insuffi- Condenser Assembly in this sec-
cient cooling (A/C sys- tion.
tem normal operation) A/C evaporator clogged or frosted Check A/C evaporator and A/C
evaporator thermistor (A/C evapo-
rator temperature sensor) referring
to A/C Evaporator and A/C Evap-
orator Thermistor (A/C Evaporator
Temperature Sensor) in this sec-
tion.
A/C evaporator thermistor (A/C evaporator tem- Check A/C evaporator thermistor
perature sensor) faulty (A/C evaporator temperature sen-
sor) referring to A/C Evaporator
Thermistor (A/C Evaporator Tem-
perature Sensor) in this section.
Expansion valve faulty Check expansion valve referring to
Expansion Valve in this section.
Aspirator hose faulty (for vehicle with automatic Check aspirator hose for clogging
air conditioning system) up or dislocation.
Heater and ventilation system faulty Check air intake door and tempera-
ture control door operation.
tion.
Cool air does not Wiring connection faulty Repair as necessary.
come out only inter- Excessive moisture in A/C system Replace desiccant, and perform
mittently evacuation and charge.
Excessive charge of refrigerant Check the amount of refrigerant.
Magnetic clutch faulty Check magnetic clutch referring to
Magnet Clutch in this section.
Expansion valve faulty Check expansion valve referring to
Expansion Valve in this section.
Cool air comes out Air in A/C system Replace desiccant, and perform
only at high speeds evacuation and charge.
Insufficient charge of refrigerant Check the amount of refrigerant.
Drive belt slipping Check or replace compressor drive
belt.
section.
Condenser clogged Check condenser referring to A/C
Condenser Assembly in this sec-
tion.

Cool air does not Excessive charge of refrigerant Check the amount of refrigerant.
come out only at high A/C evaporator frosted Check A/C evaporator thermistor
speeds (A/C evaporator temperature sen-
sor) referring to A/C Evaporator
Thermistor (A/C Evaporator Tem-
perature Sensor) in this section.
Insufficient velocity of Air leaking from cooling unit or air duct Repair as necessary.
cooled air Wiring or grounding faulty Check wiring and grounding, and
repair as necessary.
A/C evaporator clogged or frosted Check A/C evaporator and A/C
evaporator thermistor (A/C evapo-
rator temperature sensor) referring
to A/C Evaporator and A/C Evap-
orator Thermistor (A/C Evaporator
Temperature Sensor) in this sec-
tion.
Inspection of HVAC Control Module and Its

Circuits
CAUTION:
HVAC controller module (1) cannot be checked by itself.
It is strictly prohibited to connect voltmeter to HVAC con-
troller module with couplers disconnected from it.
HVAC Control module and its circuits can be checked at HVAC

control module wiring couplers by measuring voltage.
1
VOLTAGE CHECK
1) Remove HVAC control module from vehicle referring to

HVAC Control Module in this section.
2) Connect HVAC control module and body control module
couplers to HVAC control module and body control module.
3) Check each terminal voltage by referring to the HVAC con-
trol module voltage table.
Terminal arrangement of HVAC control module connector G52 viewed from harness side
14 13 12 11 10 9 8 7 6 5 4 3 2 1
30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15
HVAC control module voltage table
Termi- Wire Measure-

Circuit Normal Value Condition
nal Color ment Ground
Ignition switch ON, Temperature
about 10.0 V selector max HOT to max COOL posi-
Temperature
Ground to tion
G52-1 GRY control actuator
body Ignition switch ON, Temperature
(COOL)
less than 1.5 V selector max COOL to max HOT posi-
tion
about 10.0 V selector max COOL to max HOT posi-
Temperature
GRY/ Ground to tion
G52-2 control actuator
BLU body Ignition switch ON, Temperature
(HOT)
less than 1.5 V selector max HOT to max COOL posi-
tion
Serial communi-
cation line of
G52-3 PPL/RED
data link con-
nector
Ignition switch ON, Rear defogger
less than 1.0 V
Rear defogger Ground to switch ON
G52-4 BLU/BLK
relay output body Ignition switch ON, Rear defogger
10 14 V
switch OFF
Ignition switch ON, Illumination switch
10 14 V ON, Illumination controller to the light-
Illumination Ground to
G52-5 PPL/YEL est position
switch body
0.0 V
OFF
10 14 V
Illumination con- Ground to ON
G52-6 RED/YEL
troller switch body Ignition switch ON, Illumination switch
0.0 V
OFF
Ground to
G52-7 WHT Power supply 10 14 V
body
G52-8
A/C evaporator
WHT/ Ground to See reference
G52-9 temperature Ignition switch ON
BLK body graph No.1.
sensor
Ground to 10 14 V Engine running
G52-10 YEL/BLK Engine on signal
body less than 1.0 V Ignition switch ON
Ground to
G52-11 BLK Ground about 5.0 V Ignition switch ON
body
Output of 5 V
power source for about 5.0 V Ignition switch ON
RED/ air flow control Ground to
G52-12
WHT actuator and body
temperature less than 0.5 V Ignition switch OFF
control actuator

Outside air tem-
perature sensor
Ground to See reference
G52-13 RED (for automatic air Ignition switch ON
body waveform No.1.
conditioning
system)
G52-14
Ignition switch ON, Air flow selector
about 10.0 V
Air flow control Ground to DEF to VENT position
G52-15 GRY/BLK
actuator (VENT) body Ignition switch ON, Air flow selector
less than 1.5 V
VENT to DEF position
Ignition switch ON, Air flow selector
about 10.0 V
GRY/ Air flow control Ground to VENT to DEF position
G52-16
RED actuator (DEF) body Ignition switch ON, Air flow selector
less than 1.5 V
DEF to VENT position
Ignition switch ON, Air Intake switch to
less than 1.0 V
Air intake actua- Ground to FRE (fresh air)
G52-17 ORN
tor (FRE) body Ignition switch ON, Air Intake switch to
10 14 V
REC (recirculation air)
Ignition switch ON, Air Intake switch to
less than 1.0 V
Air intake actua- Ground to REC (recirculation air)
G52-18 GRN
tor (REC) body Ignition switch ON, Air Intake switch to
10 14 V
FRE (fresh air)
Ignition switch ON, Air intake switch to
FRE (fresh air), Engine coolant tem-
less than 1.0 V perature between 60 C (140 F) and
80 C (176 F), Air flow selector at any
GRN/ Air intake actua- Ground to position except VENT position
G52-19
WHT tor (MIX) body Ignition switch ON, Air intake switch to
REC (recirculation air), Engine coolant
10 14 V temperature between 60 C (140 F)
and 80 C (176 F), Air flow selector at
DEF position
Engine running, Blower speed selec-
tor at ON position, Temperature selec-
tor at MAX HOT position, Air flow
less than 1.0 V selector at FOOT, DEF/FOOT, or DEF
LT GRN/ Supplementary Ground to
G52-20 position, Engine coolant temperature
BLK heater relay body
less than 75 C (167 F), Battery volt-
age more than 9 V
Ignition switch ON, Blower speed
10 14 V
selector at OFF position
GRY/ A/C request sig- Ground to less than 1.0 V Ignition switch ON, A/C switch ON
G52-21
WHT nal (if equipped) body 10 14 V Ignition switch ON, A/C switch OFF
BLK/ Ignition switch Ground to 10 14 V Ignition switch ON
G52-22
WHT signal body less than 0.5 V Ignition switch OFF
Ground to
G52-23 BLK/YEL Ground less than 0.5 V
body

Ground to
G52-24 BLK/RED Sensor ground less than 0.5 V
body
Ignition switch ON, Sunload sensor
lighted over vertically with incandes-
Sunload sensor
about 2.5 V cent lamp of 100 watt (distance
(for automatic air Ground to
G52-25 PNK between sunload sensor and incan-
conditioning body
descent lamp 100 mm (3.94 in.))
system)
Ignition switch ON, Sunload sensor
about 4.5 V
covered
YEL/ Ground to See reference
G52-26 ECT signal Ignition switch ON
WHT body waveform No.2.
Temperature about 0.5 V
WHT/ Ground to selector at max COOL position
G52-27 control actuator
RED body Ignition switch ON, Temperature
position sensor about 4.5 V
selector at max HOT position
Ignition switch ON, Air flow selector at
about 4.5 V
VENT position
about 3.7 V
VENT/FOOT position
Air flow control
WHT/ Ground to Ignition switch ON, Air flow selector at
G52-28 actuator posi- about 2.0 V
YEL body FOOT position
tion sensor
about 1.4 V
DEF/FOOT position
less than 0.5 V
DEF position
less than 1.0 V
selector OFF
PPL/ Blower motor Ground to
G52-29 about 2.5 V selector at 1st position (not including
WHT controller body
OFF and AUTO position)
about 10.0 V
selector at 8th position
10 14 V
selector at OFF position
Blower motor Ignition switch ON, Blower speed
Ground to
G52-30 RED/BLK control voltage about 7.5 V selector at 1st position (not including
body
feedback OFF and AUTO position)
less than 0.2 V
selector at 8th position
Reference waveform No.1
NOTE:
The shape of waveform varies with outside air temperature.
Measurement terminal G52-13 to G52-23
Oscilloscope setting CH1: 1 V / DIV
TIME: 40 ms / DIV
Measurement condition Ignition switch turned ON
[A]: Waveform at 20 C (68 F) [B]: Waveform at 0 C (32 F) [C]: Waveform at 30 C (86 F)

Reference waveform No.2
NOTE:
The shape of waveform varies with engine coolant temperature.
Measurement terminal G52-13 to G52-26
Oscilloscope setting CH1: 2 V / DIV
TIME: 2.00 ms / DIV
Measurement condition Ignition switch turned ON
[A]: Waveform at 0 C (32 F) [B]: Waveform at 40 C (104 F) [C]: Waveform at 80 C (176 F)

Reference graph No.1
(V)
0
-30 -20 -10 0 10 20 30 40 50 ( C)
50 70 90 110 ( F)
-10 10 32
Inspection of A/C Controller and Its Circuits
CAUTION:
A/C controller cannot be checked by itself. It is strictly
prohibited to connect voltmeter or ohmmeter to A/C con-
troller with couplers disconnected from it.
A/C controller (1) and its circuits can be checked at A/C controller
wiring couplers by measuring voltage.
VOLTAGE CHECK
1) Remove A/C controller (1) from blower unit referring to A/C

Controller in this section.
2) Connect A/C controller couplers to A/C controller (1).
3) Check each terminal voltage referring to A/C controller volt-
age value table in this section.
[A]: Fig. A
[B]: Fig. B
1. A/C controller
2. AC1-15
Terminal arrangement of A/C controller

A/C controller voltage value table
Termi- Wire Measurement Normal

Circuit Condition
nal color ground value
Fulfill all of the following conditions.
Blower speed selector ON
Fulfill either one of the following conditions.
A/C switch ON
Air flow selector at DEF or DEF/FOOT
Compressor position
0.3 0.3 V
magnet Ground to Engine running
AC1-1 PNK
clutch relay engine (Fig. B) A/C evaporator thermistor (A/C evaporator
drive temperature sensor) temperature input
more than approx. 4 C (39.2 F)
A/C refrigerant (dual) pressure switch ON
Signal input from ECM ON
Except the above conditions with engine run-
12 15 V
ning
Fulfill all of the following conditions.
Blower speed selector ON
Fulfill either one of the following conditions.
A/C switch ON
Air flow selector at DEF or DEF/FOOT
A/C ON sig-
46V position
YEL/ nal output to Ground to
AC1-4 Engine running
RED A/C controller engine (Fig. B)
A/C evaporator thermistor (A/C evaporator
through relay
temperature sensor) temperature input
more than approx. 4 C (39.2 F)
A/C refrigerant (dual) pressure switch ON
Except the above conditions with engine run-
12 15 V
ning
GRY/ A/C ON per- Ground to 10 14 V A/C ON permitted
AC1-8
WHT mission engine (Fig. B) 0.3 0.3 V A/C ON forbidden
A/C refriger- A/C refrigerant (dual) pressure switch is ON
0.3 0.3 V
GRN/ ant (dual) Ground to with engine running
AC1-10
BLU pressure engine (Fig. B) A/C refrigerant (dual) pressure switch is OFF
12 15 V
switch input with engine running
Controller Ground to
AC1-13 BLK 0.3 0.3 V Engine running
main ground body (Fig. A)
Controller
BLK/ Ground to
AC1-16 main power 10 14 V Ignition switch is ON position
WHT engine (Fig. B)
supply
Scan Tool Data

As the data values given below are standard values estimated on the basis of values obtained from the normally
operating vehicles by using a scan tool, use them as reference values. Even when the vehicles are in good con-
dition, there may be cases where the checked values do not fall within each specifies data range. Therefore,
judgement as abnormal should not be made by checking with these data alone.
Normal Condition / Ref-

Scan Tool Data Condition
erence Value
Max Cool, 20 C (68 F),
<For vehicle with automatic A/C system>
20.5 C (68.9 F) ... 29.5
Each reference value is relative to the position of tem-
C (85.1 F), 30 C (86
perature selector of HVAC control module.
TEMP CONT SWITCH F), Max Hot
<For vehicle with manual A/C system>
Max Cool, P1, P2 ... P20,
Each reference value is relative to the position of tem-
P21, Max Hot
perature selector of HVAC control module.
CABIN TEMPERATURE 29 C 47.5 C
Reference value is relative to in-car temperature.
(NOTE 1) (20.2 F 117 F)
OUTSIDE AIR TEMP 29 C 47.5 C
Reference value is relative to outside air temperature.
(NOTE 1) (20.2 F 117.5 F)
Reference value is relative to temperature of evapora- 29 C 47.5 C
EVAPORATOR TEMP
tor. (20.2 F 117.5 F)
80 C 100 C
COOLANT TEMP At specified idle speed after warming up engine
(176 F 212 F)
SUNLOAD (NOTE 1) Reference value depends on the amount of sunlight. 0 W/m2 1963.5 W/m2
AUTO, VENT, BI-LEVEL,
Each reference value is relative to the position of air-
FOOT, DEF-FOOT, DEF
flow selector of HVAC control module.
MODE CONT SWITCH
VENT, BI-LEVEL, FOOT,
Each reference value is relative to the position of air-
DEF-FOOT, DEF
flow selector of HVAC control module.
Each reference value is relative to the position of AUTO, 1st, 2nd ... 7th, 8th
blower speed selector of HVAC control module.
FAN CONT SWITCH
Each reference value is relative to the position of 1st, 2nd ... 7th, 8th
blower speed selector of HVAC control module.
Reference value is relative to the position of blower
FAN DESIRE VOLT 0 15.5 V
speed selector of HVAC control module.
Reference value is relative to the position of tempera- 0.5 V (Max Cool)
AIR MIX POS SENSOR
ture selector of HVAC control module. 4.5 V (Max Hot)
Reference value is relative to the position of airflow 0.5 V (DEF)
MODE POS SENSOR
selector of HVAC control module. 4.5 V (VENT)
A/C system is ON. ON
A/C CONT SIG
A/C system is OFF. OFF
Position of blower speed selector is at 1st or 2nd posi-
ON
tion.
BLOWER FAN LOAD
Position of blower speed selector is at more than 3rd
OFF
position.
Normal Condition / Ref-

Scan Tool Data Condition
erence Value
Fresh air (FRE) mode is activated. FRE
Recirculation air (REC) mode is activated. REC
Engine coolant temperature is less than 60 C.
AIR INTAKE MODE
Air outlet is other than FACE position.
MIX
When air intake mode is changed to recirculation air
(REC) mode.
A/C indicator lamp is lighted. ON
A/C INDICATOR LAMP
A/C indicator lamp is not lighted. OFF
Fresh air (FRE) indicator lamp is lighted. ON
FRE INDICATOR LAMP
Fresh air (FRE) indicator lamp is not lighted. OFF
Recirculation air (REC) indicator lamp is lighted. ON
REC INDICATOR LAMP
Recirculation air (REC) indicator lamp is not lighted. OFF
Rear defogger indicator lamp is lighted. ON
REAR DEF INDICATOR
Rear defogger indicator lamp is not lighted. OFF
Lighting switch is at parking position. ON
ILLUMINATION
Lighting switch is at OFF position. OFF
Engine is running.
Position of temperature selector is at max hot.
Position of blower speed selector is at ON.
Engine coolant temperature is less than 60 C. ON
SUPPLEMENT HEATER
Position of air flow selector is at FOOT, DEF/FOOT,
or DEF.
Battery voltage is more than 9 V.
Other than the above condition OFF
STEERING WHEEL For vehicle equipped with left steering wheel Left
(NOTE 1) For vehicle equipped with right steering wheel Right
For vehicle which uses gasoline fuel Gasoline
FUEL TYPE (NOTE 2)
For vehicle which uses diesel fuel Diesel
NOTE1:
This data is for vehicle with automatic air conditioning system.
NOTE2:
This data is for vehicle with manual air conditioning system.
Scan tool data definitions

TEMP CONT SWITCH
Position of temperature control selector of HVAC control module
CABIN TEMPERATURE (for vehicle with automatic air conditioning system)

In-car temperature detected by inside air temperature sensor installed in HVAC control module
OUTSIDE AIR TEMPERATURE (for vehicle with automatic air conditioning system)
Outside air temperature detected by outside air temperature sensor installed on 4WD air pump assembly
bracket
EVAPORATOR TEMP
Temperature of air passed through evaporator
COOLANT TEMP
Engine coolant temperature detected by engine coolant temperature sensor
SUNLOAD (for vehicle with automatic air conditioning system)

Amount of sunlight detected by sunload sensor installed on the driver side on the dashboard
MODE CONT SWITCH

Position of airflow selector of HVAC control module
FAN CONT SWITCH

Position of blower speed selector of HVAC control module
FAN DESIRE VOLT

Voltage for blower motor
AIR MIX POS SENSOR

Input signal from position sensor in temperature control actuator
MODE POS SENSOR

Input signal form position sensor in air flow control actuator
A/C CONT SIG (ON or OFF)

State of A/C indicator lamp
BLOWER FAN LOAD (ON or OFF)

ON: Position of blower speed selector is at 1st or 2nd position.
OFF: Position of blower speed selector is at more than 3rd position.
AIR INTAKE MODE (FRE, REC or MIX)

State of air intake switch
A/C INDICATOR LAMP (ON or OFF)

State of A/C indicator lamp
FRE INDICATOR LAMP (ON or OFF)

State of fresh air (FRE) indicator lamp
REC INDICATOR LAMP (ON or OFF)

State of recirculation air (REC) indicator lamp
REAR DEF INDICATOR (ON or OFF)

State of rear defogger indicator lamp
ILLUMINATION (ON or OFF)

State of lighting switch
STEERING WHEEL (RIGHT or LEFT) (for vehicle with automatic air conditioning system)
Position of steering wheel
FUEL TYPE (GASOLINE or DIESEL) (for vehicle with manual air conditioning system)
Type of fuel which should be used
SUPPLEMENT HEATER (ON or OFF)

State of supplementary heater in heater and cooling unit
On-Vehicle Service
Heater and Cooling Unit
CAUTION:
Be careful not to damage A/C evaporator fins. If A/C evaporator fin is bent, straighten the bend by
using flat head screwdriver or pair of pliers.
19
18
1
3
5
2
14
10 15
6 21
16
9
4
17
11
5
7
13
11
20 12
1. A/C evaporator 7. Air flow control actuator 13. Foot air duct 19. Packing
2. Heater core 8. Temperature control link assembly 14. Air joint duct 20. Supplementary heater No.1
3. Expansion valve 9. Temperature control actuator 15. Aspirator (for vehicle with automatic A/C 21. Supplementary heater No.2
system)
4. Temperature control door 10. A/C evaporator undercover 16. Aspirator hose (for vehicle with automatic
A/C system)
5. Air flow control door 11. Heater and cooling case 17. Heater core bracket
6. Air flow control link assembly 12. A/C evaporator undercase 18. Pipe assembly
REMOVAL
WARNING:
Failure to follow the following procedure and WARNING
may cause unexpected deployment, personal injury,
damage to parts, or undeployment.
Never rest a steering column assembly on steering
wheel with air bag (inflator) module face down and col-
umn vertical.
When handling the air bag (inflator) modules (driver
and passenger), be careful not to drop it or apply an
impact to it. If an excessive impact was applied (e.g.,
dropped from a height of 91.4 cm (3 feet) or more),
never attempt disassembly or repair but replace it with
a new one.
When grease, cleaning agent, oil, water, and so forth
have got onto air bag (inflator) modules (driver and
passenger), wipe off immediately with a dry cloth.

2) Disable air bag system referring to Disabling Air Bag Sys-
tem in Section 10B.
3) Recover refrigerant by using recovery and recycling equip-
ment.
4) Drain engine coolant, and then disconnect heater hoses
from heater unit.
5) Disconnect suction pipe (1) and condenser outlet pipe (2)

after removing attaching bolt (3).
1 CAUTION:
As soon as suction pipe and condenser outlet pipe are
disconnected, cap opened fittings to prevent ingression
of moisture or dust.
3
2
6) Remove instrument panel referring to Instrument Panel in

Section 9.
7) Remove blower unit referring to Blower Unit in Section 1A.
8) Disconnect rear duct from heater unit.
9) Disconnect A/C evaporator thermistor wire coupler.
10) Disconnect air flow control actuator lead wire at coupler (1)
and temperature control actuator lead wire at coupler (2).
11) Disconnect supplementary heater No.1 (4) and No.2 (5) lead
wires at couplers.
1 12) Remove SDM (3).
4
2
3 5
13) Remove heater and cooling unit from dash panel.
INSTALLATION
1) Install heater and cooling unit by reversing removal proce-
dure noting the following items.
When installing each part, be careful not to catch any wiring
harness.
When installing steering column assembly, refer to Steering
Column in Section 3C.
2) Fill engine coolant to radiator.
3) Enable air bag system referring to Enabling Air Bag System
in Section 10B.
4) Evacuate and charge system referring to Evacuating and
Charging in this section.
A/C Controller
REMOVAL
tem in Section 10B.
3) Remove A/C controller (1) from blower unit by removing
brackets and bolts.
INSTALLATION
Reverse removal procedure for installation noting the following.
Enable air bag system referring to Enabling Air Bag System
in Section 10B.
A/C Signal Relay

INSPECTION
tem in Section 10B.
3) Remove A/C signal relay (1) under the instrumental panel on
the drivers seat side.
1 2. Circuit fuse box
4) Check for continuity between terminal c and d. If there is

continuity, replace relay with new one.
5) Check for continuity between terminals c and d when 12
V battery is connected to terminals a and b. If there is no
A/C Compressor Relay and A/C Condenser

Cooling Fan Relays
INSPECTION

2) Remove condenser cooling fan motor relay (2), condenser
cooling fan motor high relay (3), and/or compressor relay (1)
from vehicle.
3) Check for continuity between terminal c and d. If there is
4) Connect battery positive (+) terminal to terminal b of relay
and battery negative () terminal to terminal a of relay.
Then, check for continuity between terminal c and d. If
there is no continuity, replace relay with new one.
Compressor Assembly
CAUTION:
None of refrigerant, compressor oil and component parts is interchangeable between two types of
A/C system: one using CFC-12 (R-12) refrigerant and the other using HFC-134a (R-134a) refrigerant.
For distinguishing between two types of refrigerant, refer to Identification of Refrigerating System
in this section.
When replenishing or changing refrigerant and compressor oil and when replacing parts with new
ones, make sure if the material or the part to be used is appropriate to the A/C system on the vehi-
cle.
Use of inappropriate refrigerant and compressor oil will result in leakage of refrigerant, damage in
parts or other malfunction.
PRECAUTION
When servicing the compressor, keep any dirt, particle, or foreign material away from the compressor to pre-
vent those ingression. Clean tools and clean work area are important for proper service.
The outside of the compressor should be cleaned before any on-vehicle service or before removal of the
compressor. The parts must be kept clean at all times and any parts to be reassembled should be cleaned
with trichloroethane, naphtha, kerosene or the equivalent solvent, and then dried with air. Use only lint free
cloths to wipe parts.
The operations described here are based on bench overhaul with compressor removed from the vehicle,
except as noted. They have been prepared in order of accessibility of the components.
When compressor is removed from the vehicle for service, the oil in the compressor should be discarded,
and then new refrigerant oil should be added to the compressor.
Minor repair may be done on the vehicle without discharging the refrigerant from the A/C system. For major
repair, the discharge of the refrigerant is required.
INSPECTION
1) Install manifold gauge set (1) as shown in the figure.

2) Close Hi (4) and Lo (5) hand valves.
3) Run engine at fast idle.
4) Check compressor assembly for the following items and
repair compressor assembly if any abnormality is found.
High pressure gauge reading is not low and low pressure
gauge reading is not higher than normal.
Metallic noise
Leakage from shaft seal
2. High pressure side (Delivery side pipe)
3. Lower pressure side (Suction side pipe)
REMOVAL
1) Run engine at idle with the A/C system ON for 10 minutes.
3) Remove air cleaner outlet hose (1).
4) Recover refrigerant from the A/C system using recovery and
recycling equipment.
NOTE:
1
The amount of compressor oil removed must be mea-
sured and the same amount must be poured before
installing the compressor on the vehicle.
5) Disconnect thermal protector lead wire.
6) Disconnect suction hose (1) and discharge hoses (2) from

compressor (3).
NOTE:
Cap open fittings immediately to keep moisture out of
system.
7) Remove compressor drive belt (4) referring to Compressor
Drive Belt in this section.
8) Remove compressor (3) from engine mounting (5).
9) If compressor (3) is replaced, drain oil from compressor (3)
and measure its amount.
INSTALLATION
1) Pour new compressor oil. The amount must be the same
with the amount measured in REMOVAL.
NOTE:
New compressor is filled up with the following amount of
oil.
Amount of oil in compressor: 120 cm3 (120 cc)
2) Install compressor (1) to engine bracket (2).
3) Connect suction hose (3) and discharge hose (4) to com-
pressor (1).
4) Install compressor drive belt (5) referring to Compressor
Drive Belt in this section.
5) Connect thermal protector lead wire.
6) Install air cleaner outlet hose.
7) Perform evacuation and charging referring to Refrigerant
Recovery, Evacuation and Charging in this section.
Compressor Drive Belt

INSPECTION
Check compressor drive belt (1) for wear and cracks. If any
abnormality is found, replace it with new one.
Check for tension of compressor drive belt (1) by measuring
how much it deflects when pushed at intermediate point
between compressor pulley (2) and crank shaft additional
pulley (3) with about 100 Nm (10 kg-m, 7.0 lb-ft) force after
crankshaft additional pulley 1 rotating. If belt tension is out of
specification, adjust belt tension referring to procedure
described below.
Compressor drive belt deflection
(a): 9 mm (0.35 in.)
ADJUSTMENT
1) Remove engine undercover.
2) Loosen tension pulley nut (4).
3) Adjust belt tension by tightening or loosening tension pulley
adjusting bolt (5).
4) Tighten tension pulley nut (4).
5) Turn the crankshaft additional pulley (3) at 360, then
recheck belt for tension.
6) Install engine undercover.
REPLACEMENT
2) Loosen tension pulley nut (4).
3) Loosen belt tension by loosening tension pulley adjusting
bolt (5).
4) Remove compressor drive belt (1).
5) Install new compressor drive belt.
6) Adjust belt tension referring to procedure described above.
Required Service Materials

Recommended SUZUKI product
Material Use
(Part Number)
Compressor oil COMPRESSOR OIL RS20 (150 cc) O-ring
99000-99088-00D0 Each component
Special Tool
Tech-2 kit (SUZUKI scan

tool) See NOTE below.
NOTE:
This kit includes the following items.
1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5. Cigarette cable,
6. DLC loopback adapter, 7. Battery power cable, 8. RS232 cable, 9. RS232 adapter,
10. RS232 loopback connector, 11. Storage case, 12. Power supply
POWER STEERING (P/S) SYSTEM 3B1-1
SECTION 3B1
POWER STEERING (P/S) SYSTEM

WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System:
3B1
NOTE:
Some parts in the Power Steering Gear Box cannot be disassembled or adjusted. For detailed infor-
mation, refer to the description of Power Steering Gear Box Assembly.
All steering gear fasteners are important attaching parts in that they could affect the performance of
vital parts and systems, and/or could result in major repair expense. They must be replaced with
one of the same part number or with an equivalent part if replacement becomes necessary. Do not
use a replacement part of lesser quality or substitute design. Torque values must be used as speci-
fied during reassembly to assure proper retention of these parts.
Although the figures in this section show only the left-hand steering vehicle, the same work proce-
dure and data apply to the right-hand steering vehicle.
CONTENTS
General Description ......................................3B1-3 Fluid .................................................................... *
Power Steering System....................................... * Fluid leakage check ........................................ *
Steering Gear Box............................................... * Hydraulic Pressure in P/S Circuit................ 3B1-4
Power Steering (P/S) Pump ........................3B1-3 Hydraulic pressure check........................ 3B1-4
Diagnosis .......................................................3B1-4 Boot..................................................................... *
Steering rack boot check................................. *
General Diagnosis Table..................................... *
Tie-rod end boot check ................................... *
Steering Wheel.................................................... *
Air Bleeding Procedure ....................................... *
Steering wheel play check............................... *
Steering force check........................................ * On-Vehicle Service .......................................3B1-6
Power Steering Fluid ...................................3B1-4 Tie-Rod End........................................................ *
Power steering fluid level check ..............3B1-4 Power Steering Gear Box Assembly........... 3B1-6
Power Steering Pump Drive Belt.................3B1-4 Rack Boot and Tie-Rod (Other than
Belt inspection ................................................. * Canvas Top LH Model) ....................................... *
Belt tension check ........................................... * Rack Boot and Tie-Rod (Canvas Top
Belt tension adjustment ................................... * LH Model) ........................................................... *
Idle Up System .................................................... * Power Steering Pump ................................. 3B1-8
Idle up system check....................................... * Tightening Torque Specifications .............3B1-15
3B1-2 POWER STEERING (P/S) SYSTEM
Required Service Material..........................3B1-15 Special Tool ................................................ 3B1-16

General Description
Power Steering (P/S) Pump
The power steering pump is a vane type and is driven by the V-ribbed belt from the crankshaft.
13
14
12
2
11
8
2 9
10 7
1 2 6
3
4
15
2
1. Suction connector 4. Spring 7. Cam ring 10. Snap ring 13. Oil seal
2. O-ring 5. Plug 8. Vane 11. Side plate 14. Pump body
3. Flow control valve (Relief valve) 6. Pump cover 9. Rotor 12. Pulley (pump shaft) 15. Flow control valve assembly
Model Vane type

Hydraulic pressure Relieved pressure 7850 kPa (78.5 kg/cm2, 1116 psi)
control Control device Flow control valve
Relief valve
Capacity 0.75 0.8 L
(1.59/1.32 1.69/1.41 US pt/Imp. pt)
Specified fluid DEXRONII A/T fluid or the equivalent
FLOW CONTROl VALVE

As the discharge rate of the P/S pump increases in proportion to the pump revolution speed, a flow control valve
is installed to control it so that the optimum amount of fluid for steering operation is supplied according to the
engine speed (driving condition).
Diagnosis
Power Steering Fluid
Power steering fluid level check
With engine stopped, check fluid level indicated on P/S fluid res-
ervoir. The fluid level should be between UPPER and LOWER
lines. If it is lower than LOWER line, fill fluid up to UPPER line.
NOTE:
Be sure to use the specified power steering fluid.
Fluid level should be checked when fluid is cool.
Power Steering Pump Drive Belt

Refer to Generator belt under Generator in Section 6H for belt
inspection, belt tension check, and belt tension adjustment.
Hydraulic Pressure in P/S Circuit

Hydraulic pressure check
1) After cleaning joint of high pressure hose and P/S pump
thoroughly, disconnect hose from pump and install special
tool (oil pressure gauge, attachment and hose). Then,
tighten each flare nut to specified torque.
CAUTION:
Be careful not to cause damage to A/C condenser fins
during service operation, if equipped.
Special tool
(A) : 09915-77411 (Oil pressure gauge)
(B) : 09915-77420
2) Check each connection for fluid leakage and bleed air refer-
ring to Air Bleeding Procedure in this section.
1. P/S fluid reservoir 4. Union bolt
2. Attachment 5. High pressure side
3. Gasket 6. Low pressure side
3) With engine idling, turn steering wheel and warm up engine

till fluid temperature in P/S fluid reservoir rises to 50 60 C
(122 140 F).
4) Check line pressure by measuring hydraulic pressure with

engine idling and hands off steering wheel.
Line pressure
Lower than 1000 kPa (10 kg/cm2, 142 psi)
When line pressure is higher than specified values, check control
valve and piping for clogging.
1. P/S fluid reservoir 4. P/S gear box
2. Gauge valve (open) 5. High pressure side
3. P/S pump 6. Low pressure side
5) Checking relief pressure
CAUTION:
Be sure not to close gauge valve for longer than 10 sec-
onds.
a) Increase engine speed to about 1500 r/min (rpm). Close
gauge valve gradually while watching pressure increase
indicated by gauge and take reading of relief pressure
(maximum hydraulic pressure).
Relief pressure
7650 8350 kPa
(76.5 83.5 kg/cm2, 1088 1188 psi)
When it is higher than specified values, possible cause is
malfunction of relief valve.
When it is lower than specified values, possible cause is
either failure of P/S pump or settling of relief valve spring.
1. P/S fluid reservoir 4. P/S pump
2. Gauge valve (shut) 5. P/S gear box
3. Oil pressure gauge
b) Next, open gauge valve fully and increase engine speed to

about 1500 r/min (rpm). Then, turn steering wheel to the
left or right fully and take reading of relief pressure.
CAUTION:
Be sure not to hold steering wheel at fully turned position
for longer than 10 seconds.
Relief pressure
7650 8350 kPa
(76.5 83.5 kg/cm2, 1088 1188 psi)
When it is higher than specified values, possible cause is
malfunction of relief valve.
When it is lower than specified values, possible cause is fail-
ure in steering gear box. Replace gear box.
1. P/S fluid reservoir 4. P/S pump
2. Gauge valve (open) 5. P/S gear box
3. Oil pressure gauge
On-Vehicle Service
Power Steering Gear Box Assembly
CAUTION:
Never disassemble P/S gear box. Disassembly will affect
original performance.
REMOVAL
NOTE:
As fluid flows out of disconnected joints, put a receptacle
under joints or a plug to pipe.
1) Take out fluid in P/S fluid reservoir with syringe or the equiv-
alent.
2) Disconnect high pressure pipe (1) from steering gear box by
removing union bolt (2).
3) Disconnect low pressure hose (3) from steering gear box.
4) Remove steering lower shaft bolt (4).
5) Hoist vehicle and remove both right and left wheels.

7) Disconnect both right and left tie rod ends from knuckle
referring to Steps 2) to 3) of Tie-Rod End Removal in this
section.
8) Remove steering gear box mounting bolts (1), and then

remove steering gear box from vehicle.
INSTALLATION
Reverse removal procedure for installation of steering gear box
noting the following points.
CAUTION:
Be sure to confirm that steering wheel and front tires
(wheels) are in straight position when inserting steering
lower joint into steering pinion shaft.
After confirming that front tire is in straight position, install
steering gear box to body temporarily. Next, with tie-rod end
installed to knuckle, set rack in position close to neutral.
Then obtain the neutral state by aligning match marks (1) on
pinion shaft and steering gear case (2) and insert steering
lower joint into pinion shaft (3).
If a plug was put to disconnected pipe when removing steer-

ing gear box, remove that plug before reconnecting pipe.
Use specified torque as given below.

Tightening torque
Steering lower shaft bolt
(a) : 25 Nm (2.5 kg-m, 18.0 lb-ft)
Gear box high pressure pipe union bolt
(b) : 35 Nm (3.5 kg-m, 25.5 lb-ft)
Gear box clinder pipe flare nut
(c) : 25 Nm (2.5 kg-m, 18.0 lb-ft)
Gear box mounting bolt
(d) : 55 Nm (5.5 kg-m, 40.0 lb-ft)
After installation, be sure to fill specified power steering fluid
and bleed air.
Check toe setting and adjust as required referring to the Sec-
tion 3A FRONT END ALIGNMENT.
Power Steering Pump
[A] 3
4
9
1
11 Nm (1.1 kg-m)
7 5 60 Nm (6.0 kg-m)
26 Nm (2.6 kg-m)
11 Nm (1.1 kg-m)
2
8
11 Nm (1.1 kg-m)
11 Nm (1.1 kg-m)
[B]
3
4
9
1
11 Nm (1.1 kg-m)
5 60 Nm (6.0 kg-m)
7
26 Nm (2.6 kg-m)
11 Nm (1.1 kg-m)
2
8
11 Nm (1.1 kg-m)
11 Nm (1.1 kg-m)
[A] : LH steering vehicle 2. Power steering pump bracket 5. Pump union bolt 8. Power steering gear box
[B] : RH steering vehicle 3. Power steering fluid reservoir 6. Low pressure hose and pipe 9. Suction hose
1. Power steering pump assembly 4. High pressure hose and pipe 7. Power steering fluid reservoir bracket Tightening torque
REMOVAL
3
NOTE:
Be sure to clean each joint of suction and discharge
sides thoroughly before removal.
1) Remove P/S fluid from P/S fluid reservoir (3).
2) Disconnect suction hose (1) and low pressure return hose
(2) from P/S fluid reservoir (3).
3) Remove suction hose (4) from pump.
1 2 4
4) Remove union bolt. Then, disconnect high pressure pipe

from pump.
NOTE:
As fluid flows out of disconnected joints, put a receptacle
under joints or a plug to pipe.
5) Remove P/S drive belt referring to Generator belt under

Generator in Section 6H.
2 6) Remove P/S pump mounting bolts (1).

7) Remove P/S pump (2).
NOTE:
Plug each port of removed P/S pump to prevent interfu-
1 sion of dust or any other foreign particle.
DISASSEMBLY
1) Clean its exterior thoroughly.
2) With aluminum plates placed on vise first, fix pump body with
vise.
3) Remove suction connector bolt, suction connector (1) and O-
ring (2) from pump body (14).
4) Remove plug (5), flow control spring (4) and relief valve (flow
13
control valve) (3) from pump body.
14
5) Remove cover bolts, pump cover (6) and O-ring from pump
12 body.
2 11
8 6) Remove snap ring (10) from pump shaft.
9
2 10
7 2
7) Remove vanes (8) from rotor.
1 6
3 8) Remove cam ring (7), rotor (9), side plate (11) and O-rings
15 4 from pump body.
2 9) Pull out P/S pulley (12) from pump body.
5
10) Remove oil seal (13) from pump body.
15. Flow control valve Assembly
INSPECTION
Pump Body, Cover, Side Plate and Shaft
Check sliding surfaces of each part for wear and damage.

If any abnormality is found, replace pump assembly.
Cam Ring
Check vane sliding surface of cam ring for wear and damage.
If any abnormality is found, replace pump assembly.
Rotor and Vane
Check sliding surfaces of rotor and vane for wear and dam-
age.
Check clearance between rotor and vane by using thickness

gauge (1).
Clearance between rotor and vane
Standard : 0.015 mm (0.0006 in.)
Limit : 0.027 mm (0.0011 in.)
Replace pump assembly if any abnormality is found.
Relief Valve (Flow Control Valve) and its Spring
Check fluid passage of relief valve and orifice of connector

for obstruction (clogged).
Check sliding surface of relief valve for wear and damage.
Check free length of relief valve spring (1).

Relief valve spring free length
Standard : 22.0 mm (0.866 in.)
Limit : 19.0 mm (0.748 in.)
Replace pump assembly if any abnormality is found.
ASSEMBLY
Reverse disassembly procedure for assembly, noting the follow-

ing.
1) Apply grease to oil seal lip and apply power steering fluid to
sliding surface of the shaft then insert pulleys shaft (2) from
oil seal side of the pump body.
A : Grease 99000-25010
1. Oil seal
2) Apply power steering fluid to O-rings (1) and fit them to pump
body.
3) Install side plate (1) to pump body.
NOTE:
Carefully align the dowel pins on the side plate (1) at bolt
hole (2) as shown in figure.
4) Apply power steering fluid to sliding surface of rotor (1).

5) Install rotor to shaft, directing dot marked side of rotor facing
up.
6) Install new snap ring (2) to shaft, then make sure to fit snap
into shaft groove securely.
NOTE:
Never reuse the removed snap ring.
3. Dot
7) Apply power steering fluid to sliding surface of cam ring (1).

8) Install cam ring to pump body. The tapered end of cam ring
should face the side plate (2).
9) Apply power steering fluid to each vane (2).

10) Install vanes (10 pieces) to rotor (1).
11) Apply power steering fluid to O-ring (1).

12) Install O-ring to pump body.
13) Apply power steering fluid to sliding surface of pump cover

and rotor.
14) Match the dowel pins (1) to the holes of the cover plate (2) as
shown and install pump cover to pump body.
15) Gradually tighten new pump cover bolts to specified torque.
NOTE:
After installing pump cover (1), make sure if shaft can be
turned by hand.
Tightening torque
Oil pump cover bolts
(a) : 28 Nm (2.8 kg-m, 20.0 lb-ft)
16) Apply power steering fluid to relief valve (flow control valve).
17) Install relief valve (flow control valve) to pump body.
18) Install flow control spring.
19) Apply power steering fluid to O-rings of plug.
20) Install O-rings to plug.
21) Tighten plug to specified torque.
Tightening torque
Plug
(a) : 60 Nm (6.0 kg-m, 43.5 lb-ft)
22) Apply power steering fluid to O-ring of suction connector (1).

23) Install O-ring (2) to suction connector.
24) Install suction connector (1) to pump body as shown in fig-

ure.
Tighten new suction connector bolts to specified torque.
Tightening torque
Suction connector bolt
(a) : 12 Nm (1.2 kg-m, 9.0 lb-ft)
INSTALLATION
Reverse removal procedure noting the following instructions.
For tightening torques, refer to structural diagram on previ-
ous page.
Adjust power steering pump drive belt by referring to Belt
Tension Adjustment under Power Steering Pump Drive
Belt in this section.
Fill specified power steering fluid after installation and bleed
air without failure. (Refer to Air Bleeding Procedure in this
section.)
Tightening Torque Specifications

Tightening torque
Fastening part
Nm kg-m lb-ft
Gear box mounting bolts 55 5.5 40.0
Gear box cylinder pipe flare nuts 25 2.5 18.5
Gear box high pressure pipe union bolt 35 3.5 25.5
Pump union bolt 60 6.0 43.5
Oil pump mount bolts 26 2.6 19.0
Pipe clamp bolt/Reservoir bracket bolt 11 1.1 8.0
Steering shaft joint bolt 25 2.5 18.0
Pump cover bolts 28 2.8 20.0
Plug 60 6.0 43.5
Suction connector bolt 12 1.2 9.0
Required Service Material

Material Use
(Part Number)
Lithium grease SUPER GREASE (A) Oil seal lip of P/S pump pulley shaft
(99000-25010)
Power steering fluid DEXRON II A/T fluid or the equiva- To fill P/S fluid reservoir
lent Parts lubrication when installing
Special Tool
09915-77420 09915-77411 09943-55010

Oil pressure gauge attach- Oil pressure gauge Boot clamp plier
ment and hose set
REAR SUSPENSION 3E-1
SECTION 3E
REAR SUSPENSION
NOTE:
For the descriptions (items) not found in this section, refer to the same section of the Service Man-
ual mentioned in the FOREWORD of this manual.
All suspension fasteners are an important attaching part in that it could affect the performance of
vital parts and systems, and/or could result in major repair expense. They must be replaced with
one of the same part number or with an equivalent part if replacement becomes necessary. Do not
3E
use a replacement part of lesser quality or substitute design. Torque values must be used as speci-
fied during reassembly to assure proper retention of this part.
Never attempt to heat, quench or straighten any suspension part. Replace it with a new part, or
damage to the part may result.
CONTENTS
General Description .............................................. * On-vehicle Service.......................................... 3E-2
Diagnosis ............................................................... * Shock Absorber .................................................. *
Diagnosis Table .................................................. * Coil Spring .......................................................... *
Shock Absorber Check ....................................... * Lower Rod........................................................... *
Lower Rod, Upper Rod, Lateral Rod Upper Rod........................................................... *
Check .................................................................. * Lateral Rod ......................................................... *
Axle Housing and Coil Spring Check .................. * Rear Axle Shaft and Wheel Bearing ............. 3E-2
Rear suspension fasteners.............................. * Rear Axle Shaft Inner Oil Seal ............................ *
Bearing Retainer and Axle Shaft Inner Oil Rear Axle Housing ........................................ 3E-2
Seal Check.......................................................... * Tightening Torque Specification ................... 3E-3
Wheel Disc, Nut & Bearing Check....................... * Required Service Material .............................. 3E-3
3E-2 REAR SUSPENSION
On-vehicle Service
Rear Axle Shaft and Wheel Bearing
REMOVAL
For the details, refer to the same item of the same section in the
service manual mentioned in the FOREWORD of this manual not-
ing following points.
Rear axle shaft length L
Left side : 702 mm (27.6 in.)
Right side : 771 mm (30.4 in.)
Rear Axle Housing

INSTALLATION
For the details, refer to the same item of the same section in the
Service Manual mentioned in the FOREWORD of this manual
noting following points.
Clean mating surfaces of axle housing (1) and differential

carrier and apply sealant A to housing side.
A: Sealant 99000-31110
Install differential carrier assembly to axle housing and

tighten carrier bolts to specified torque.
Tightening torque
Differential carrier bolt (a): 55 Nm (5.5 kg-m, 40.0 lb-ft)
REAR SUSPENSION 3E-3
Apply thread lock cement to thread of propeller shaft flange

bolt if reused. Install propeller shaft to joint flange aligning
match marks and torque flange bolts or nuts to specification.
A: Cement 99000-32110
Tightening torque
Propeller shaft bolt or nut (a): 55 Nm (5.5 kg-m, 40.0 lb-ft)
Tightening Torque Specification

Tightening torque
Fastening part
Nm kg-m lb-ft
Shock absorber nut 29 2.9 21.0
Shock absorber lower nut 100 10.0 72.5
Lower rod front bolt 100 10.0 72.5
Lower rod rear bolt 90 9.0 65.0
Upper rod front bolt 95 9.5 69.0
Upper rod rear bolt 90 9.0 65.0
Lateral rod mounting bolt left side 100 10.0 72.5
Lateral rod mounting nut right side 95 9.5 69.0
Differential carrier bolt 55 5.5 40.0
Propeller shaft bolt or nut 55 5.5 40.0
Brake pipe flare nut 16 1.6 11.5
Bearing retainer nut 23 2.3 17.0
Differentiation gear oil filler & drain plug (filler plug) 50 5.0 36.5
Differentiation gear oil filler & drain plug (drain plug) 27 2.7 16.0
Wheel nut 100 10.0 72.5
Wheel speed sensor bolt 21 2.1 15.5

Material Use
(Part Number)
Lithium grease SUZUKI SUPER GREASE A Oil seal lip
(99000-25010)
Brake fluid DOT 3 Brake reservoir tank
Sealant SUZUKI BOND NO.1215 Joint seam of axle and brake back plate
(99000-31110) Joint seam of bearing retainer and brake
back plate
Joint seam of differential carrier and axle
housing
Drain plug
Mating surface of oil seal and axle housing
Gear oil For gear oil information, refer to Differential gear (Rear axle housing)
Section 7F
Thread lock cement THREAD LOCK CEMENT SUPER Rear propeller shaft flange bolts
1322 (99000-32110)
3E-4 REAR SUSPENSION
BRAKES 5-1
SECTION 5
BRAKES
WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System :
NOTE: 5
For the descriptions (items) not found in this section, refer to the same section of the Service Man-
ual mentioned in the FOREWORD of this manual.
When inspecting and servicing vehicle equipped with ABS, be sure to refer to section 5E1 first.
All brake fasteners are important attaching parts in that they could affect the performance of vital
parts and systems, and/or could result in major repair expense. They must be replaced with one of
same part number or with an equivalent part if replacement becomes necessary. Do not use a
replacement part of lesser quality or substitute design. Torque values must be used as specified
during reassembly to assure proper retention of all parts. There is to be no welding as it may result
in extensive damage and weakening of the metal.
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
BRAKE PIPE/HOSE/MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-1
FRONT BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-1
PARKING AND REAR BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-1
CONTENTS
General Description .............................................. * Brake Hose And Pipe Check .............................. *
Diagnosis ............................................................... * Master Cylinder Check........................................ *
Road Testing Brakes........................................... * Brake Disc Check ............................................... *
Brake Fluid Leaks ............................................... * Brake Pad Check ................................................ *
Substandard Or Contaminated Brake Fluid ........ * Brake Shoe Check .............................................. *
Parking Brake Check and Adjustment ................ *
Diagnosis Table..................................................... *
Flushing Brake Hydraulic System ....................... *
Check and Adjustment ..................................... 5-2 Fluid Pressure Test (if equipped with LSPV) .. 5-2
Bleeding Brakes .................................................. * Booster Operation Check.................................... *
Brake Pedal Free Height Check.......................... * Tightening Torque Specification ..................... 5-4
Brake Light Switch Adjustment ........................... *
Required Service Material ................................ 5-4
Excessive Pedal Travel Check............................ *
Brake Pedal Play Check ..................................... * Special Tool....................................................... 5-5
Brake Fluid Level Check ..................................... *
5-2 BRAKES
Check and Adjustment

Fluid Pressure Test (if equipped with LSPV)
Test procedure for LSPV assembly is as follows.
Before testing, confirm the following.
Fuel tank is filled with fuel fully.
Vehicle is equipped with spare tire, tools, jack and jack han-
dle.
1) Stop vehicle on level floor and place approximately about
240 kg (529 lbs) weight (2) on rear housing so that rear axle
weight 900 kg (1984 lb).
Rear axle weight
L : 900 kg (1984 lb)
2) Install special tool to front and rear brake.
NOTE:
Special tool should be connected to breather of front
(drivers side brake) and rear brakes.
Special tool
Front brake
(A) : 09956-02310
(B) : 09952-46510 (Attachment for vehicle with SUMITOMO
ELECTRIC brake caliper)
(C) : 55473-82030 (Air bleeder plug (1) supplied as a spare
part)
Rear brake
(A) : 09956-02310
(B) : 09952-36310 (Attachment for thread diameter 7 mm of
bleeder plug) or 09952-46510 (Attachment for thread diam-
eter 8 mm of bleeder plug)
(C) : 55473-82030 (Air bleeder plug supplied as a spare
part)
NOTE:
Special tool (B) is used instead of thread diameter 10
mm attachment (3) of special tool (A).
So remove the attachment from (A) and install (B) as
shown in figure.
For vehicle with TOKICO brake caliper, use the attach-
ment included in special tool (A).
For identification of brake caliper type, refer to Disc
Brake Caliper Assembly in Section 5B.
BRAKES 5-3
3) Depress brake pedal gradually till fluid pressure of front

brake becomes as specified below and check corresponding
pressure of rear brake then. It should be within specification
given below.
Rear brake pressure with applied by 8,000 kPa (80 kg/cm2,
1,138 psi) on front brake.
Front brake Rear brake
5,400 6,600 kPa
3 Door
model 54 66 kg/cm2
8,000 kPa
768 938 psi
80 kg/cm2
4,500 7,300 kPa
1,138 psi
5 Door 45 73 kg/cm2
640 1,038 psi
4) As done above, apply 100 kg/cm2 pressure to front brake
and check that rear brake pressure then is within specifica-
tion as given below.
6,000 7,300 kPa
3 Door
model 60 73 kg/cm2
10,000 kPa
853 1,038 psi
100 kg/cm2
5,000 8,000 kPa
1,422 psi
5 Door 50 80 kg/cm2
711 1,138 psi
5) If rear brake pressure is not within specification, adjust it by

changing stay (3) position as follows.
If rear brake pressure is higher than specification, move stay
(3) to direction a and if it is lower, to direction b.
Repeat steps 3) to 5) until rear brake pressure is within spec-
ification.
After adjustment, be sure to torque bolt to specification.
Tightening torque
LSPV stay bolt (a) : 23 Nm (2.3 kg-m, 17.0 lb-ft)
5-4 BRAKES
6) Disconnect brake pipe (2) (connecting between master cylin-

der secondary side and 4-way joint) from master cylinder (1).
Tighten plug (special tool) to master cylinder.
Depress brake pedal. If rear brake pressure is 95 100 kg/
cm2 when front brake pressure is 100 kg/cm2, it means that
front failsafe system functions properly.
10,000 kPa 9,500 10,000 kPa
100 kg/cm2 95 100 kg/cm2
1,422 psi 1,350 1,422 psi
Special tool
(A) : 09956-02210
7) Upon completion of fluid pressure test, bleed brake system

and perform brake test.

Tightening torque
Fastening part
Nm kg-m lb-ft
Brake pipe 2 way (or 4 way) joint bolt 11 1.1 8.0
Brake pipe flare nut 16 1.6 11.5
M8 8.0 0.8 6.0
Front caliper
M10 8.5 0.85 6.5
Brake bleeder plug
Wheel cylinder 7.5 0.75 5.5
LSPV 7.5 0.75 5.5
LSPV mounting bolt 23 2.3 17.0
LSPV stay bolt 23 2.3 17.0
LSPV spring nut 23 2.3 17.0
Wheel nut 100 10.0 72.5
Brake light switch lock nut 7.5 0.75 5.5

Material Use
(Part Number)
Brake fluid Indicated on reservoir cap or described To fill master cylinder reservoir.
in owners manual of vehicle To clean and apply to inner parts of master
cylinder, brake caliper and wheel cylinder
when they are disassembled.
BRAKES 5-5
Special Tool
09950-78220 09900-20205 09956-02310 09956-02210

Flare nut wrench (10 mm) Micrometer (0 25 mm) Fluid pressure gauge Brake circuit plug
09952-36310 09952-46510
Pressure gauge attachment Pressure gauge attachment
(M7) (M8)
5-6 BRAKES
ENGINE GENERAL INFORMATION AND DIAGNOSIS (RHW ENGINE) 6-1-1
SECTION 6-1
ENGINE GENERAL INFORMATION AND

DIAGNOSIS
(RHW ENGINE)
WARNING:
vice on or near the air bag system components or wiring. Please observe all WARNINGS and Pre-
cautions under On-Vehicle Service in air bag system section before performing service on or
around the air bag system components or wiring. Failure to follow WARNINGS could result in unin-
tentional activation of the system or could render the system inoperative. Either of these two condi-
tions may result in severe injury.
NOTE:
Service information for two types of emission control system, Other Than EOBD Spec, and EOBD
Spec, is provided in this section. To distinguish between Other Than EOBD Spec and EOBD 6-1
Spec, refer to Identification of Emission Control System in this section.
CONTENTS
OTHER THAN EOBD SPEC ........................... 6-1-5 Fail-Safe Table........................................... 6-1-18

General Information ....................................... 6-1-5 Diagnostic Trouble Code (DTC)
Identification of Emission Control Table .......................................................... 6-1-19
System ......................................................... 6-1-5 Visual Inspection........................................ 6-1-23
Statement of Cleanliness and Care ............. 6-1-5 Engine Basic Check................................... 6-1-24
General Information on Engine Service ....... 6-1-6 Engine Diagnosis Table ............................. 6-1-25
Precaution on fuel system service............ 6-1-7 Inspection of ECM and Its Circuits............. 6-1-31
Fuel pressure relief procedure ................. 6-1-8 Voltage check......................................... 6-1-31
Fuel leakage check procedure ................. 6-1-8 Resistance check ................................... 6-1-33
Table A-1 Malfunction Indicator Lamp
Engine Diagnosis ........................................... 6-1-9
Circuit Check MIL Does Not Come ON
General Description ..................................... 6-1-9 or Dims at Ignition Switch ON
On-Board Diagnostic System ....................... 6-1-9 (But Engine at Stop)................................... 6-1-34
Precaution in Diagnosing Trouble .............. 6-1-12 Table A-2 Malfunction Indicator Lamp
Engine Diagnostic Flow Table.................... 6-1-13 Circuit Check MIL Remains ON after
Diagnostic step details ........................... 6-1-14 Engine Starts ............................................. 6-1-35
Malfunction Indicator Lamp (MIL) Table A-3 ECM Power and Ground Circuit
Check ......................................................... 6-1-17 Check MIL Doesnt Light at Ignition
Diagnostic Trouble Code (DTC) Check...... 6-1-17 Switch ON and Engine Doesnt Start
Diagnostic Trouble Code (DTC) Though It Is Cranked Up............................ 6-1-36
Clearance ................................................... 6-1-17
6-1-2 ENGINE GENERAL INFORMATION AND DIAGNOSIS (RHW ENGINE)
DTC P0100 (DTC P0100) Mass Air Flow DCT P1107 Swirl Control Solenoid Valve
Circuit Malfunction ..................................... 6-1-37 Circuit Malfunction ......................................6-1-70
DTC P0101 (P0100) MAF Sensor Circuit DTC P1108 Radiator Fan High Speed
Range/Performance Problem .................... 6-1-40 Circuit Malfunction ......................................6-1-72
DTC P0110 Intake Air Temp. (IAT) Circuit DTC P1109 Radiator Fan Low Speed
Malfunction................................................. 6-1-41 Circuit Malfunction ......................................6-1-74
DTC P0115 (DTC P0115) Engine Coolant DTC P1110 A/C Signal Circuit
Temp. Sensor Circuit Malfunction.............. 6-1-43 Malfunction .................................................6-1-75
DTC P0121 (DTC P0120) Throttle Position DTC P1135 3rd Piston Deactivator
Circuit Range/Performance Problem ......... 6-1-45 (Injection Pump Solenoid Valve) Circuit
DTC P0604 (P0120) Throttle Position Malfunction .................................................6-1-76
Sensor Monitoring System Malfunction ..... 6-1-45 DTC P1138 (P0230) Fuel Pressure
DTC P0180 Fuel Temperature Sensor Regulator Circuit Malfunction......................6-1-78
Circuit Malfunction ..................................... 6-1-47 DTC P1402 (P0510) Throttle Solenoid
DTC P0190 (P0190) Fuel Rail Pressure Valve Circuit Malfunction ............................6-1-80
Sensor Circuit Malfunction ......................... 6-1-49 DTC P1511 Ignition Switch Circuit
DTC P0191 (P0230) Fuel Rail Pressure Malfunction .................................................6-1-82
Sensor/Pressure Regulator Consistency DTC P1519 Radiator Fan Circuit
Function ..................................................... 6-1-51 Malfunction .................................................6-1-83
DTC P1112 (P0230) Fuel Pressure DTC P1606 MIL Circuit Malfunction ...........6-1-84
Monitoring Circuit Malfunction.................... 6-1-51 DTC P1608 ECT Warning Lamp Circuit
DTC P0201 (P0200) Injector Circuit Malfunction .................................................6-1-86
Malfunction Cylinder 1 ............................... 6-1-53 DTC P1614 (P0560) Sensor Supply
DTC P0202 (P0200) Injector Circuit Function ......................................................6-1-88
Malfunction Cylinder 2 ............................... 6-1-53 DTC P0221 (P0220) Throttle Position
DTC P0203 (P0200) Injector Circuit Range/Performance Problem 2 ..................6-1-91
Malfunction Cylinder 3 ............................... 6-1-53 DTC P0335 (P0335) Crankshaft Position
DTC P0204 (P0200) Injector Circuit Sensor Circuit Malfunction..........................6-1-93
Malfunction Cylinder 4 ............................... 6-1-53 DTC P0340 (P0335/P0340) Camshaft
DTC P0215 Double Relay Circuit Position Sensor Circuit Malfunction ............6-1-95
Malfunction................................................. 6-1-55 DTC P0500 (P0500) Vehicle Speed
DTC P0230 Fuel Pump Supply Circuit Sensor Circuit Malfunction..........................6-1-98
Malfunction................................................. 6-1-57 DTC P0235 (P0235) Intake Air Pressure
DTC P0243 (P0243) Turbo Pressure Sensor Circuit Malfunction........................6-1-100
Solenoid Valve Circuit Range/ DTC P0560 (P0560) Power Supply
Performance Problem................................ 6-1-59 Circuit Malfunction ....................................6-1-102
DTC P0245 (P0243)/P0246 (P0243) DTC P1613 ECM Not Registered .............6-1-103
Turbo Pressure Solenoid Valve Circuit DTC P1517 Immobilizer System
Range/Performance Problem .................... 6-1-61 Malfunction ...............................................6-1-104
DTC P0380 (P0380)/P1404 (P0380) TABLE B-1 Fuel Pump Circuit
Pre/Post Heat Relay Circuit Inspection .................................................6-1-106
Malfunction................................................. 6-1-62 TABLE B-2 Fuel Pressure
DTC P0381 Glow Indicator Lamp Circuit Inspection .................................................6-1-107
Malfunction................................................. 6-1-64 EOBD SPEC ................................................6-1-108
DTC P0401 (P0903) EGR Solenoid Valve General Information ...................................6-1-108
Flow Insufficient Detected.......................... 6-1-66
Identification of Emission Control
DTC P0402 (P0903) EGR Solenoid Valve
System......................................................6-1-108
Flow Excessive Detected........................... 6-1-66
Statement of Cleanliness and Care ..........6-1-108
DTC P0403 (P0403) EGR Solenoid Valve
General Information on Engine
Circuit Malfunction ..................................... 6-1-67
Service......................................................6-1-109
DTC P0561 (P0560) Stabilization of
Precaution on fuel system service ........6-1-110
Sensor Supply............................................ 6-1-69
Fuel pressure relief procedure..............6-1-111
DTC P0603/P0606/P1171 ECM
Fuel leakage check procedure..............6-1-111
Function ..................................................... 6-1-69
DTC P1169 (P0170) Condenser Voltage Engine Diagnosis .......................................6-1-112
Function 1 .................................................. 6-1-69 General Description ..................................6-1-112
DTC P1170 (P0170) Condenser Voltage On-Board Diagnostic System ...................6-1-112
Function 2 .................................................. 6-1-69 Precaution in Diagnosing Trouble.............6-1-115
DTC P1101 (P0105) Barometric Pressure Engine Diagnostic Flow Table ..................6-1-116
Sensor Circuit Malfunction ......................... 6-1-69 Diagnostic step details..........................6-1-117
ENGINE GENERAL INFORMATION AND DIAGNOSIS (RHW ENGINE) 6-1-3
Malfunction Indicator Lamp (MIL) DTC P0203 (P0203/P0267/P0268/P1374)

Check ....................................................... 6-1-120 Injector Circuit Cylinder 3
Diagnostic Trouble Code (DTC) (Malfunction/Low/High/ Short).................. 6-1-162
Check ....................................................... 6-1-120 DTC P0204 (P0204/P0267/P0268/P1374)
Diagnostic Trouble Code (DTC) Injector Circuit Cylinder 4 (Malfunction/
Clearance................................................. 6-1-120 Low/High/ Short) ...................................... 6-1-164
Fail-Safe Table......................................... 6-1-121 DTC P1169 Condenser 1 Voltage Too
Diagnostic Trouble Code (DTC) Low/High .................................................. 6-1-166
Table ........................................................ 6-1-124 DTC P1170 Condenser 2 Voltage Too
Visual Inspection ...................................... 6-1-129 Low/High .................................................. 6-1-166
Engine Basic Check ................................. 6-1-130 DTC P0215 Engine Shutoff Solenoid....... 6-1-169
Engine Diagnosis Table ........................... 6-1-131 DTC P0230 Fuel Pump Primary
Inspection of ECM and Its Circuits ........... 6-1-137 Circuit....................................................... 6-1-171
Voltage check....................................... 6-1-137 DTC P0243 (P0243/P0246) Turbo
Resistance check ................................. 6-1-139 Charger Waste Gate Solenoid
Table A-1 Malfunction Indicator Lamp (Malfunction/High).................................... 6-1-173
Circuit Check MIL Does Not Come ON DTC P0245 (P0245) Turbo Charger
or Dims at Ignition Switch ON Waste Gate Solenoid Low ....................... 6-1-173
(But Engine at Stop)................................. 6-1-140 DTC P0234 (P0243) Turbo Charger
Table A-2 Malfunction Indicator Lamp Over Boost Condition............................... 6-1-175
Circuit Check MIL Remains ON after DTC P0299 (P0299) Turbo Charger
Engine Starts............................................ 6-1-141 Under Boost ............................................. 6-1-175
Table A-3 ECM Power and Ground DTC P0380 (P1351/P1352/P1349/
Circuit Check MIL Doesnt Light at P1350) Glow Plug Circuit (Excess
Ignition Switch ON and Engine Doesnt Voltage/Relay Jammed/Short/Open) ....... 6-1-176
Start Though It Is Cranked Up. ................ 6-1-142 DTC P1404 TL4226 Circuit
DTC P0100 (P0102/P0103/P3007/ Malfunction............................................... 6-1-176
P3008) Mass Air Flow Circuit DTC P0381 Glow Plug Indicator
(Low Input/High Input/Plausibility at Circuit....................................................... 6-1-178
Low Flow/Plausibility at High Flow) .......... 6-1-143 DTC P0401 (P0401) Exhaust Gas
DTC P0110 (P0112/P0113) Intake Air Recirculation Flow Insufficient
Temperature Sensor Circuit Detected................................................... 6-1-180
(Low/High) ................................................ 6-1-146 DTC P0400 (P0400/P0402/P2143/
DTC P0115 (P0115/P0117/P0118) P2145) Exhaust Gas Recirculation Flow
Engine Coolant Temperature Circuit (Malfunction/Excessive Detected/Exhaust
(Malfunction/Low/High) ............................ 6-1-148 Gas Recirculation Vent Control Circuit
DTC P0220 (P0222/P0223/P0224) Open/High)............................................... 6-1-181
Pedal Position Sensor No.1 Circuit DTC P2144 (P2144) Exhaust Gas
(Low/High/Intermittent) ............................. 6-1-150 Recirculation Vent Control Circuit
DTC P2299 Accelerator Pedal Position Low .......................................................... 6-1-181
Incompatible............................................. 6-1-150 DTC P0105 (P0107/P0108) Barometric
DTC P0180 (P0182/P0183) Fuel Pressure Sensor Circuit (Low Input/High
Temperature Sensor Circuit Input)........................................................ 6-1-183
(Low/High) ................................................ 6-1-152 DTC P0561 (P0642/P0643) Sensor
DTC P0190 (P0192/P0193/P0194) Fuel Reference Voltage Circuit (Low/High)...... 6-1-183
Rail Pressure Sensor Circuit DTC P0603 (P0603) Internal Control
(Low/High/Intermittent) ............................. 6-1-154 Module Keep Alive Memory (KAM)
DTC P0089 (P0089/P0087, P1113/ Error ......................................................... 6-1-183
P0088, P1116/P0094) Fuel Pressure DTC P0604 (P0604) Internal Control
Regulator Performance (Malfunction/ Module Random Access Memory (RAM)
Fuel Rail Pressure Too Low/Too High/ Error ......................................................... 6-1-183
Fuel System Leak Detected Small DTC P1107 (P2009/P2010) Intake
Leak) ........................................................ 6-1-156 Manifold Runner Control Circuit
DTC P0201 (P0201/P0261/P0262/P1372) (Low/High)................................................ 6-1-184
Injector Circuit Cylinder 1 DTC P0480 Fan 1 Control Circuit ............ 6-1-186
(Malfunction/Low/High/ Short).................. 6-1-158 DTC P0481 Fan 2 Control Circuit ............ 6-1-188
DTC P0202 (P0202/P0264/P0265/P1373) DTC P3004 (P3005/P3006) 3rd Piston
Injector Circuit Cylinder 2 (Malfunction/ Deactivator Circuit (Short/Open).............. 6-1-189
Low/High/ Short) ...................................... 6-1-160
6-1-4 ENGINE GENERAL INFORMATION AND DIAGNOSIS (RHW ENGINE)
DTC P0090 (P0090/P0091/P0092) Fuel DTC P0335 (P0335) Crankshaft

Pressure Regulator Control Circuit Position Sensor Circuit .............................6-1-206
(Malfunction/Low/High) ............................ 6-1-191 DTC P0340 (P0341/P0343/P0344/P0016)
DTC P0606 (P0606) ECM Processor ...... 6-1-191 Camshaft Position Sensor Circuit
DTC P1171 ECU Function (Performance/High/Intermittent/
(ECU Internal Fault) ................................. 6-1-191 Crankshaft Position Camshaft Position
DTC P0120 (P0487/P2142) Exhaust Gas Correlation) ...............................................6-1-208
Recirculation Throttle Position Control DTC P0500 (P0500/P0501) Vehicle
Circuit (Malfunction/High)......................... 6-1-193 Speed Sensor (Malfunction/
DTC P2141 (P2141) Exhaust Gas Performance) ............................................6-1-211
Recirculation Throttle Position Control DTC P0235 (P0069/P0235, P1281/
Circuit Low ............................................... 6-1-193 P0237/P0238) Turbo Charger Boost
DTC P1511 Ignition Switch Circuit Sensor Circuit (Manifold Absolute
Malfunction............................................... 6-1-195 Pressure Barometric Pressure
DTC P0485 Fan Power/Ground Correlation/Malfunction/Low/High)............6-1-213
Circuit....................................................... 6-1-196 DTC P0560 (P0562/P0563) System
DTC P0650 (P0650/P1642) Malfunction Voltage (Low/High) ...................................6-1-215
Indicator Lamp (MIL) Control Circuit DTC P1613 ECM Not Registered .............6-1-216
Malfunction (Malfunction/Open) ............... 6-1-197 DTC P1517 Immobilizer System
DTC P0608 (P0658/P0659) Actuator Malfunction ...............................................6-1-217
Supply Voltage Circuit 1 (Low/High) ........ 6-1-199 TABLE B-1 Fuel Pump Circuit
DTC P0609 (P2670/P2671) Actuator Inspection .................................................6-1-219
Supply Voltage Circuit 2 (Low/High) ........ 6-1-201 TABLE B-2 Fuel Pressure Inspection .......6-1-220
DTC P0225 (P0224/P0227/P0228/ Special Tool ................................................6-1-221
P2137) Pedal Position Sensor No.2
Circuit (Intermittent/Low/High/Voltage
Correlation) .............................................. 6-1-204
ENGINE GENERAL INFORMATION AND DIAGNOSIS (RHW ENGINE) (OTHER THAN EOBD SPEC) 6-1-5
OTHER THAN EOBD SPEC

General Information
Identification of Emission Control System
1 For other than EOBD spec, the metal plate type power supply line
(1) for glow plugs is used.
Identify it by the type of glow plug power supply line.
As for the EOBD spec, the wire harness type is used as power
supply line to glow plugs.
Statement of Cleanliness and Care

An automobile engine is a combination of many machined,
honed, polished and lapped surfaces with tolerances that are
measured in the thousands of an millimeter (ten thousands of
inch). Accordingly, when any internal engine parts are serviced,
care and cleanliness are important. Throughout this section, it
should be understood that proper cleaning and protection of
machined surfaces and friction areas is part of the repair proce-
1
dure. This is considered standard shop practice even if not specif-
2
3 ically stated.
4 A liberal coating of engine oil should be applied to friction
areas during assembly to protect and lubricate the surface
on initial operation.
Whenever valve train components, pistons, piston rings, con-
necting rods, rod bearings and crankshaft journal bearings
are removed for service, they should be retained in order. At
the time of installation, they should be installed in the same
locations and with the same mating surfaces as when
removed.
Battery cables should be disconnected before any major
work is performed on the engine. Failure to disconnect
cables may result in damage to wire harness or other electri-
cal parts.
Throughout this manual, the four cylinders of the engine are
identified by numbers: No.1 (1), No.2 (2), No.3 (3) and No.4
(4) as counted from flywheel side to crankshaft pulley side.
6-1-6 ENGINE GENERAL INFORMATION AND DIAGNOSIS (RHW ENGINE) (OTHER THAN EOBD SPEC)
General Information on Engine Service

The following information on engine service should be noted
carefully, as it is important in preventing damage, and in contribut-
ing to reliable engine performance.
When raising or supporting engine for any reason, do not
use a jack under oil pan. Due to small clearance between oil
pan and oil pump strainer, jacking against oil pan may cause
it to be bent against strainer resulting in damaged oil pick-up
unit.
It should be kept in mind, while working on engine, that 12-
volt electrical system is capable of violent and damaging
short circuits. When performing any work where electrical
terminals could possibly be grounded, ground cable of the
battery should be disconnected at battery.
Any time the air cleaner, air cleaner outlet hose, turbo-
charger, intercooler, intercooler outlet hose, throttle valve
assembly or intake manifold is removed, the intake opening
should be covered. This will protect against accidental
entrance of foreign material which could follow intake pas-
sage into cylinder and cause extensive damage when
engine is started.
Precaution on fuel system service

Work must be done with no smoking, in a well-ventilated
area and away from any open flames.
A small amount of fuel may be released after fuel line is dis-
connected.
In order to reduce the chance of personal injury, cover fitting
to be disconnected with a shop cloth. Put that cloth in an
approved container when disconnection is completed.
Never run engine with double relay disconnected when
engine and exhaust system are hot.
Fuel or fuel vapor hose connection varies with each type of
pipe. When reconnecting fuel or fuel vapor hose, be sure to
connect and clamp each hose correctly referring to the fig-
ure.
After connecting, make sure that it has no twist or kink.
[A]: With short pipe, fit hose as far as it reaches pipe joint as shown.
[B]: With following type pipe, fit hose as far as its peripheral projection as shown.
[C]: With bent pipe, fit hose as its bent part as shown or till pipe is about 20 to 30 mm
(0.79 1.18 in.) into the hose.
[D]: With straight pipe, fit hose till pipe is, about 20 to 30 mm (0.79 1.18 in.) into the hose.
1. Hose
2. Pipe
3. Clamp
4. Clamp securely at a position 3 to 7 mm (0.12 0.27 in.) from hose end.
5. 20 to 30 mm (0.79 1.18 in.)
When installing fuel filter union bolt or plug bolt, always use
new gasket and tighten it to specified torque.
When installing injector, fuel feed pipe or fuel pressure regu-
lator, lubricate its O-ring with spindle oil or fuel.
When connecting fuel pipe flare nut, first tighten flare nut by
hand and then tighten it to specified torque, using back-up
wrench.
Fuel pressure relief procedure

Refer to Precautions under Fuel Delivery System in Section
6E3.
Fuel leakage check procedure

After performing any service on fuel system, check to make sure
that there are no fuel leakages as follows.
1) Turn ON ignition switch for 5 seconds (to operate fuel pump)
and then turn it OFF. Repeat this (ON and OFF) 3 or 4 times
ON and apply fuel pressure to fuel line (till fuel pressure is felt by
C
AC
hand placed on fuel return hose).

2) In this state, check to see that there are no fuel leakages
from any part of low pressure fuel system between fuel
pump and injection pump.
3) Check that there are no fuel leakages from any part of high
pressure fuel system between injection pump and fuel injec-
tor by performing the procedure below.
a) Start engine and warm up to normal operating temperature.
b) Check fuel leakage after turning off ignition switch.
c) Again, start engine and accelerate the vehicle up to 3500
rpm with L range (AT) or 1st gear (MT). Then stop vehicle.
d) Check fuel leakage after turning off ignition switch.
Engine Diagnosis
General Description
This vehicle is equipped with an engine and emission control system which are under control of ECM. The
engine and emission control system in this vehicle are controlled by ECM. ECM has an On-Board Diagnostic
system which detects a malfunction in this system and abnormality of those parts that influence the engine
exhaust emission. When diagnosing engine troubles, be sure to have full understanding of the outline of On-
Board Diagnostic System and each item in Precaution in Diagnosing Trouble and execute diagnosis accord-
ing to Engine Diagnostic Flow Table in this section.
There is a close relationship between the engine mechanical, engine cooling 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 malfunction indicator lamp (MIL) doesnt turn ON, it should be diagnosed according to this flow table.

ECM in this vehicle has the following functions.
When the ignition switch is turned ON with the engine at a
stop, MIL (1) turns ON to check the malfunction indicator
lamp (MIL) and its circuit.
When ECM detects a malfunction which gives an adverse
effect to vehicle emission while the engine is running, it
makes the malfunction indicator lamp in the meter cluster of
the instrument panel turn ON and stores the malfunction
1
area in its memory.
As a condition for detecting a malfunction in some areas in
the system being monitored by ECM and turning ON the
malfunction indicator lamp due to that malfunction, 2 driving
cycles detection logic is adopted to prevent erroneous detec-
tion.
When a malfunction is detected, engine and driving condi-
tions then are stored in ECM memory as freeze frame data.
(For the details, refer to description on Freeze frame data.)
2
It is possible to communicate by using not only SUZUKI scan
tool (2) but also generic scan tool. (Diagnostic information
can be accessed by using a scan tool.)
Warm-up Cycle
A warm-up cycle means sufficient vehicle operation such that
the coolant temperature has risen by at least 22C (40F) from
engine starting and reaches a minimum temperature of 70C
(160F).
Driving Cycle
A driving cycle consists of two parts, engine startup and engine
shutoff.
2 Driving Cycle Detection Logic
The malfunction detected in the first driving cycle is stored in
ECM memory (in the form of pending DTC) but the malfunction
indicator lamp does not light at this time. It lights up at the second
detection of same malfunction also in the next driving cycle.
Select Vehicle
Pending Diagnostic Trouble Code (DTC)
Select a Mode
Data List
NOTE:
Data List (GST mode) Pending diagnostic trouble code can be read using
Data List (Select)
Data Graph generic scan tool or GST (Generic Scan Tool) mode of
Trouble Codes SUZUKI scan tool.
Trouble Codes (GST mode)
Snap Shot Pending DTC means a DTC detected and stored temporarily at 1
Misc Test
driving cycle of the DTC which is detected in the 2 driving cycle
SUZUKI -> Other than North America -> SUV ->
GRAND VITARA 2.0 TD -> Engine -> detection logic.
SQ420WD (RHW engine) ->
Freeze Frame Data
NOTE:
Freeze frame data can be read using generic scan tool or
GST (Generic Scan Tool) mode of SUZUKI scan tool.
ECM stores the engine and driving conditions (in the form of data
as shown in the figure) at the moment of the detection of a mal-
function in its memory. This data is called Freeze frame data.
Therefore, it is possible to know engine and driving conditions
(e.g., whether the engine was warm or not, where the vehicle was
running or stopped) when a malfunction was detected by check-
ing the freeze frame data.
Priority of Freeze Frame Data:
As ECM can store freeze frame data for one malfunction only, the
freeze frame data shown as 1 below has a priority for storage. (If
malfunction as described in the upper square 1 below is
detected while the freeze frame data in the lower square 2 has
been stored, the freeze frame data 2 will be updated by the
freeze frame data 1.)
PRIORITY FREEZE FRAME DATA

1 Freeze frame data at initial detection of diagnostic
trouble codes below.
P0100, P0120, P0170, P0190, P0200, P0220,
P0230, P0235, P0243, P0560, P0903
2 Freeze frame data when a diagnostic trouble
code other than those in 1 above is detected.
Freeze Frame Data Clearance:

The freeze frame data is cleared at the same time as clearance of
diagnostic trouble code (DTC).
Data Link Connector (DLC)
DLC (1) in compliance with SAE J1962 in its installation position,

the shape of connector and pin assignment.
K (4) and L (3) lines of ISO 9141 is used for SUZUKI scan tool or
generic scan tool to communication with ECM, ABS control mod-
ule, BCM, HVAC control module and TCM.
SUZUKI serial data line (7) is used for SUZUKI scan tool to com-
municate with immobilizer control module.
2. B+
5. ECM ground
6. Body ground
1
Precaution in Diagnosing Trouble

Dont disconnect couplers from ECM, battery cable from battery, ECM ground wire harness from engine or
main fuse before confirming diagnostic information (DTC, freeze frame data, etc.) stored in ECM memory.
Diagnostic information stored in ECM memory can be cleared as well as checked by using SUZUKI scan
tool or generic scan tool. Before using scan tool, read its Operators (Instruction) Manual carefully to have
good understanding as to what functions are available and how to use it.
Priorities for diagnosing troubles
If troubleshooting priorities for multiple diagnostic code are given in the applicable diagnostic flow, these
should be followed.
If no instructions are given, troubleshoot diagnostic trouble codes according to the following priorities.
1. Fuel pressure (P1112 for Suzuki mode of SUZUKI scan tool/P0230 for generic scan tool)
2. Diagnostic trouble codes other than listed below
DTC indicated by generic scan tool or GST mode of DTC indicated by Suzuki mode of SUZUKI scan tool
SUZUKI scan tool
P0100, P0120, P0170, P0190, P0200, P0220, P0100, P0101, P0121, P0604, P1169, P1170, P0190,
P0230, P0235, P0243, P0560, P0903 P0201, P0202, P0203, P0204, P0221, P1112, P1138,
P0235, P0243, P0245, P0246, P0560, P0561, P0401,
P0402
3. Diagnostic trouble codes described in above list

Be sure to read Precautions for Electrical Circuit Service in Section 0A before inspection and observe what
is written there.
ECM replacement or substitution
When substituting a known-good ECM, check for the following conditions. Neglecting this check may cause
damage to known-good ECM.
Resistance value of all relays, actuators is as specified respectively.
MAF sensor is in good condition and none of power circuit of its sensor is shorted to ground.
ECU code registration
If ECM is replaced, register ECU code into ECM by performing procedure described in Procedure after
ECM Replacement of Section 8G. Otherwise, ECM dose not function as Immobilizer Control System.
Injector code registration
If ECM or injector is replaced, register injector code into ECM by performing procedure described in ECM
Registration of Section 6E3.
Otherwise, it has an adverse effect on engine.
The following harness connector number of this section is corresponding to the following harness connector
number of WIRING DIAGRAM MANUAL.
Connector number of this section Connector number of WIRING DIAGRAM MANUAL
E227 C51-1
E228 C51-2
E229 C51-3
G55 G54
G09 G87
Engine Diagnostic Flow Table

Numbers of each step correspond to the numbers of the items after this table.
Refer to Diagnostic Step Details following this table for the details of each step.
Step Action Yes No

1 Customer Complaint Analysis Go to Step 2. Perform customer
1) Perform customer complaint analysis. complaint analysis.
Was customer complaint analysis performed?
2 Diagnostic Trouble Code (DTC) and Freeze 1) Print DTC and freeze Go to Step 5.
Frame Data Check, Record and Clearance frame data or write
1) Check for DTC referring to Diagnostic Step then down and clear
Details. by referring to DTC
Is there any DTC(s)? Clearance in this sec-
tion.
2) Go to Step 3.
3 ECM Registration Data Check Go to Step 4. Register ECM according
1) Check injector class and transmission type to the registration proce-
of ECM registration data referring to ECM dure, referring to ECM
Registration in this section. Registration in Section
Are registered data in good condition? 6E3.
4 Visual Inspection 1) Repair or replace mal- Go to Step 6.
1) Perform Visual inspection referring to the function part.
Visual Inspection in this section. 2) Go to Step 12.
Is there any faulty condition?
5 Visual Inspection Go to Step 9.
1) Perform visual inspection referring to the
Visual Inspection in this section.
6 Trouble Symptom Confirmation Go to Step 7. Go to Step 8.
1) Confirm trouble symptom referring to the
Trouble Symptom Confirmation in this sec-
tion.
Is trouble symptom identified?
7 Rechecking and Record of DTC/Freeze Frame Go to Step 10. Go to Step 9.
Data
1) Recheck for DTC and freeze frame data
referring to DTC Check in this section.
Is there any DTC(s)?
8 Rechecking and Record of DTC/Freeze Frame Go to Step 11.
Data
Is there any malfunction DTC(s)?
Step Action Yes No

9 Engine Basic Inspection and Engine Diagnosis Go to Step 12. 1) Check and repair mal-
Table function part(s).
1) Check and repair according to Engine 2) Go to Step 12.
Basic Check and Engine Diagnosis Table
in this section.
Are check and repair complete?
10 Troubleshooting for DTC
1) Check and repair according to applicable
DTC diag. flow table in this section.
11 Check for Intermittent Problems 1) Repair or replace mal- Go to Step 12.
1) Check for intermittent problems referring to function part(s).
the Diagnostic Step Details. 2) Go to Step 12.
12 Final Confirmation Test Go to Step 7. End.
1) Clear DTC if any.
2) Perform final confirmation test referring to
the Diagnostic Step Details.
Is there any problem symptom, DTC or
abnormal condition?
Diagnostic step details

1. CUSTOMER COMPLAINT ANALYSIS
Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this
purpose, use of such an inspection form will facilitate collecting information to the point required for proper anal-
ysis and diagnosis.
2. DIAGNOSTIC TROUBLE CODE (DTC)/FREEZE FRAME DATA CHECK, RECORD AND CLEARANCE
First, check DTC (including pending DTC), referring to DTC check in this section. If DTC is indicated, print it
and freeze frame data or write them down and then clear them by referring to DTC clearance in this section.
DTC indicates malfunction that occurred in the system but does not indicate whether it exists now or it occurred
in the past and the normal condition has been restored now. To check which case applies, check the symptom in
question according to Step 6 and recheck DTC according to Step 7 and 8.
Attempt to diagnose a trouble based on DTC in this step only or failure to clear the DTC (including pending DTC)
in this step will lead to incorrect diagnosis, trouble diagnosis of a normal circuit or difficulty in troubleshooting.
NOTE:
If DTC P1112 (for Suzuki mode of SUZUKI scan tool) or P0230 (for generic scan tool or GST mode of
SUZUKI scan tool) is indicated in this step, proceed to Diag. flow table for DTC P1112/P0230 first.
3. ECM REGISTRATION DATA CHECK

Refer to ECM Registration Data Check in Section 6E3 for checking procedure.
4 and 5. VISUAL INSPECTION
As a preliminary step, be sure to perform visual check of the items that support proper function of the engine
referring to Visual Inspection in this section.
6. TROUBLE SYMPTOM CONFIRMATION
Based on information obtained in Step 1 Customer complaint analysis and Step 2 DTC/freeze frame data check,
confirm trouble symptoms. Also, reconfirm DTC according to DTC Confirmation Procedure described in each
DTC flow.
7 and 8. DTC/FREEZE FRAME DATA RECHECK, RECORD AND CLEARANCE
Refer to DTC CHECK in this section for checking procedure.
9. ENGINE BASIC CHECK AND ENGINE DIAGNOSIS TABLE
Perform basic engine check according to the Engine Basic Check in this section first. When the end of the flow
table has been reached, check the parts of the system suspected as a possible cause referring to Engine Diag-
nosis Table in this section and based on symptoms appearing on the vehicle (symptoms obtained through
steps of customer complaint analysis, trouble symptom confirmation and/or basic engine check) and repair or
replace faulty parts, if any.
10. TROUBLESHOOTING FOR DTC (See each DTC Diag. Flow Table)
Based on the DTC indicated in Step 7 or 8 and referring to the applicable DTC diag. flow table in this section,
locate the cause of the trouble, namely in a sensor, switch, wire harness, connector, actuator, ECM or other part
and repair or replace faulty parts.
11. CHECK FOR INTERMITTENT PROBLEM
Check parts where an intermittent trouble is easy to occur (e.g., wire harness, connector, etc.), referring to
Intermittent and Poor Connection in Section 0A and related circuit of DTC recorded in Step 2.
12. FINAL CONFIRMATION TEST
Confirm that the problem symptom has gone and the engine is free from any abnormal conditions. If what has
been repaired is related to the DTC, clear the DTC once and perform DTC confirmation procedure and confirm
that no DTC is indicated.
Customer Problem Inspection Form (Example)
NOTE:
The above form is standard sample. It should be modified according to conditions characteristic of
each market.
Malfunction Indicator Lamp (MIL) Check

1) Turn ON ignition switch (but the engine at stop) and check
that MIL lights.
If MIL does not light up or dims, go to Diagnostic Flow Table
A-1 for troubleshooting.
2) Start engine and check that MIL turns OFF.
If MIL remains ON, and no DTC is stored in ECM, go to
Diagnostic Flow Table A-2 for troubleshooting.
Diagnostic Trouble Code (DTC) Check

1) Prepare generic scan tool or SUZUKI scan tool.
2) Connect it to data link connector (DLC) (1) located on under-
side of instrument panel at drivers seat side.
1 Special tool
(A): SUZUKI scan tool
(A)
3) Turn ignition switch ON and confirm that MIL lights.
4) Read DTC, pending DTC and freeze frame data according to
instructions displayed on scan tool and print them or write
them down. Refer to scan tool operators manual for further
details.
If communication between scan tool and ECM is not possi-
ble, check if scan tool is communicable by connecting it to
ECM in another car. If communication is possible in this
case, scan tool is in good condition. Then check data link
connector and serial data line (circuit) in the car with which
communication was not possible.
5) After completing the check, turn ignition switch off and dis-
connect scan tool from data link connector.
Diagnostic Trouble Code (DTC) Clearance

1) Connect generic scan tool or SUZUKI scan tool to data link
connector in the same manner as when making this connec-
tion for DTC check.
2) Turn ignition switch OFF and then ON (but engine at stop).
3) Erase DTC and pending DTC according to instructions dis-
played on scan tool. Refer to scan tool operators manual for
further details.
NOTE:
When DTC clear command is executed using Suzuki
mode of SUZUKI scan tool with engine run, DTC can not
be cleared from ECM memory.
4) After completing the clearance, turn ignition switch OFF and
disconnect scan tool from data link connector.
Fail-Safe Table
When any of the following DTCs is detected, ECM enters fail-safe mode as long as malfunction continues to
exist but that mode is canceled when ECM detects normal condition after that.
DTC NO. TROUBLE AREA FAIL SAFE OPERATION
P0190 Fuel pressure sensor Each control is performed based on 150 MPa (1500 bar) fuel pres-
(P0190) sure and engine speed is restricted to lower than 2200 rpm.
P0560 Battery voltage Each control is performed based on 7 volts.
(P0560)
P0121 Throttle position sensor Each control is performed based on 5% throttle valve opening and
(P0120) engine speed is restricted to lower than 2200 rpm.
P0221
(P0220)
P0115 Engine coolant tempera- Each control is performed based on 111C with engine run (10C
(P0115) ture sensor with engine stopped).
P0180 Fuel temperature sensor Each control is performed based on 90C.
P0110 Intake air temperature Each control is performed based on 50C.
sensor (in mass air flow)
P0235 Intake air pressure sensor Each control is performed based on the value measured by baro-
(P0235) metric pressure sensor (in ECM). If barometric pressure sensor fails,
900 mbar is used as intake air pressure and engine speed is
restricted to lower than 2200 rpm.
P1101 Barometric pressure sen- Each control is performed based on the value measured by intake
(P0105) sor (in ECM) air pressure sensor. If intake air pressure sensor is failed, 900 mbar
is used as barometric pressure.
P0100 Mass air flow sensor Each control uses the value calculated by barometric pressure and
(P0100) engine speed and engine speed is restricted to lower than 2200 rpm.
P0101 Mass air flow sensor Each control is performed based on 1000 mg/stroke and engine
(P0100) speed is restricted to lower than 2200 rpm.
P0500 Vehicle speed sensor Each control is performed based on 20 km/h.
(P0500)
P0191 Fuel pressure sensor/ Engine speed is restricted to lower than 2200 rpm.
(P0230) pressure regulator
P0401 EGR valve/solenoid Engine speed is restricted to lower than 2200 rpm.
(P0903)
P0561 Sensor supply voltage Engine speed is restricted to lower than 2200 rpm.
(P0560)
P0246 Turbo pressure solenoid Engine speed is restricted to lower than 2200 rpm.
(P0246) valve
P1138 Fuel pressure regulator Engine speed is restricted to lower than 2200 rpm.
(P0230)
P0201 Fuel injector No.1 Engine speed is restricted to lower than 2200 rpm.
(P0200)
(P0200)
(P0200)
(P0200)
NOTE:
For ( ) marked No. in DTC column, it is indicated when generic scan tool is used.
Diagnostic Trouble Code (DTC) Table

DTC NO. DTC NO.
DTC
(Generic (SUZUKI DETECTING CONDITION
DETECTING ITEM DRIVING MIL
scan scan (DTC will set when detecting:)
CYCLE
tool) tool)
Mass air flow sensor circuit 1 driving 1 driving
P0100 Sensor output low or high voltage
malfunction cycle cycle
P0100 Air flow is lower or higher than
Mass air flow sensor circuit 1 driving 1 driving
P0101 specification under specified
range/performance problem cycle cycle
engine RPM
Intake air temperature sen- Intake air temperature sensor cir- 2 driving
P0110
sor circuit malfunction cuit low or high input cycles
Engine coolant temperature Engine coolant temperature sen- 2 driving
P0115 P0115
sensor circuit malfunction sor circuit low or high input cycles
Throttle position sensor mon- Poor performance of throttle posi- 1 driving 1 driving
P0604
itoring system malfunction tion sensor cycle cycle
P0120
Throttle position sensor cir-
P0121
cuit range/performance Throttle position sensor circuit low
1 driving 1 driving
Throttle position sensor cir- or high input, or poor performance
cycle cycle
P0220 P0221 cuit range/performance prob- of throttle position sensor
lem 2
Fuel temperature sensor cir- Fuel temperature circuit low or 2 driving
P0180
cuit malfunction high input cycles
Fuel rail pressure sensor cir- Fuel rail pressureure sensor cir- 1 driving 1 driving
P0190 P0190
cuit malfunction cuit low or high input cycle cycle
Fuel rail pressure sensor
pressure regulator consis- Poor performance of fuel rail pres- 1 driving 1 driving
P0191
tency function (Fuel pump sureure sensor cycle cycle
primary circuit malfunction)
Fuel rail pressure monitoring
circuit malfunction (Fuel Fuel pressure in common rail is 1 driving 1 driving
P1112
P0230 pump primary circuit mal- lower or higher than specification cycle cycle
function)
Monitor signal of fuel pressure
regulator is different from com-
Fuel press regulator circuit 1 driving 1 driving
P1138 mand signal (circuit open or
malfunction cycle cycle
short), or poor performance of
regulator
Monitor signal of fuel injection #1
Injector circuit malfunction is different from command signal 1 driving 1 driving
P0201
cylinder-1 (circuit open or short), or poor cycle cycle
performance of fuel Injector #1
P0200 P0202
P0203
DTC NO. DTC NO.

DTC
CYCLE
tool) tool)
P0200 P0204
Double relay circuit malfunc- 2 driving
P0215 Poor performance of double relay
tion cycles
Fuel pump supply circuit low or
Fuel pump supply circuit mal- 1 driving
P0230 high input, or poor performance of
function cycle
fuel pump
Intake air pressureure sensor cir-
Intake pressure sensor circuit low or high input, or poor per- 1 driving 1 driving
P0235 P0235
cuit malfunction formance of intake air cycle cycle
pressureure sensor
Monitor signal of turbo pres-
sureure regulator solenoid valve is 1 driving
P0243
different from command signal cycle
Turbo pressure solenoid
(circuit open or short)
P0243 valve circuit range/perfor-
Intake air pressureure is higher 1 driving
P0245 mance problem
than specification cycle
Intake air pressureure is lower 1 driving 1 driving
P0246
than specification cycle cycle
Monitor signal of crankshaft posi-
Crankshaft position sensor 1 driving
P0335 P0335 tion sensor is lower or higher than
circuit malfunction cycle
specification
Camshaft position sensor cir-
cuit malfunction (crankshaft Supply voltage low or high input,
P0335/ 1 driving
P0340 position sensor circuit mal- or poor performance of camshaft
P0340 cycle
function/camshaft position or crankshaft position sensor
sensor circuit malfunction
Both pre/post heating relay and
Pre/post heat relay circuit 2 driving
P0380 diagnostic signals are high or low
malfunction cycles
level
P0380
TL4226 circuit function (pre/ Monitor signal of pre/post heating
2 driving
P1404 post heating relay command relay is different from command
cycles
malfunction) signal
Monitor signal of glow indicator
Glow indicator lamp circuit 2 driving
P0381 lamp circuit is different from com-
malfunction cycles
mand signal (circuit open or short)
Monitor signal of EGR solenoid
EGR solenoid valve circuit 1 driving
P0403 P0403 valve is different from command
malfunction cycle
signal (circuit open or short)
EGR solenoid valve flow 1 driving 1 driving
P0401 Insufficient EGR flow
insufficient detected cycle cycle
P0903
EGR solenoid valve flow 1 driving
P0402 Excessive EGR flow
excessive detected cycle
DTC NO. DTC NO.

DTC
CYCLE
tool) tool)
Vehicle speed is lower or higher
2 driving
P0500 P0500 VSS circuit malfunction than specification under certain
cycles
condition
Power supply circuit malfunc- 2 driving
P0560 Power supply low or high input
tion cycles
1 driving 1 driving
P0560 P0561 Stabilization of sensor supply Poor performance of ECM
cycle cycle
Sensor power supply low or high 1 driving
P1614 Sensor supply function
voltage cycle
ECU function (EEPROM 1 driving
P0603 Poor performance of ECM
error) cycle
1 driving
P0606 ECU function (internal fault) Poor performance of ECM
cycle
1 driving 1 driving
P1613 ECU not registered Poor performance of ECM
cycle cycle
Barometric press sensor cir- 2 driving
P0105 P1101 Poor performance of ECM
cuit malfunction cycles
Monitor signal of swirl control
Swirl control solenoid valve solenoid valve circuit is different 2 driving 2 driving
P1107
circuit malfunction from command signal (circuit cycles cycles
open or short)
Monitor signal of radiator relay
Radiator fan high speed cir- 2 driving
P1108 (high) circuit is different from com-
Radiator fan low speed cir- 2 driving
P1109 (low) circuit is different from com-
Monitor signal of A/C cut signal
A/C cut signal circuit mal- 2 driving
P1110 circuit is different from command
function cycles
signal (circuit open or short)
Condenser voltage function 1 1 driving 1 driving
(Fuel trim malfunction) cycle cycle
P0170
Condenser voltage function 2 1 driving 1 driving
(Fuel trim malfunction) cycle cycle
ECU function (ECU internal 2 driving
fault) cycles
Monitor signal of EGR throttle
solenoid valve is different from
Throttle solenoid valve cir- 1 driving
P0510 P1402 command signal (circuit open or
cuit malfunction cycle
short), or poor performance of
valve
Ignition switch circuit mal- Ignition signal is not memorized in 2 driving
P1511
function ECM cycles
DTC NO. DTC NO.

DTC
CYCLE
tool) tool)
No signal or incorrect code input-
ted from immobilizer control mod-
Immobilizer system malfunc-
P1517 ule to ECM
tion
Temporary fault of intermal mem-

ory (status memory) in ECM
Radiator fan relay signal is not
Radiator fan circuit malfunc- 1 driving
P1519 corresponding to radiator fan state
tion cycle
signal
Monitor signal of injection pump
3rd piston deactivator (injec-
solenoid valve is different from 2 driving
P1135 tion pump solenoid valve) cir-
command signal (circuit open or cycles
cuit malfunction
short)

Monitor signal of MIL circuit is dif-
2 driving
P1606 MIL circuit malfunction ferent from command signal (cir-
cycles
cuit open or short)
Monitor signal of engine coolant
Engine coolant temperature
temperature warning lamp circuit 2 driving
P1608 warning lamp circuit malfunc-
is different from command signal cycles
tion
(circuit open or short)
NOTE:
In case that ECM detects a fault (DTC) in column with mark, engine is hard to start unless DTC
is cleared from ECM memory.
DTC DRIVING CYCLE column indicates the number of driving cycle before DTC is stored in ECM
memory.
In case that ECM detects a fault (DTC) in column with mark, it means temporary fault of internal
memory (status memory) for communication to immobilizer control module detected. However, it is
no adverse affect for communication. Therefore, it dose not affect engine and emission control sys-
tem.
Visual Inspection
Visually check the following parts and systems.
INSPECTION ITEM REFERRING SECTION
Engine oil - - - - - level, leakage Section 0B
Engine coolant - - - - - level, leakage Section 0B
Fuel - - - - - level, leakage Section 0B
A/T fluid - - - - - level, leakage Section 0B
Air cleaner element - - - - - dirt, clogging Section 0B
Battery - - - - - fluid level, corrosion of terminal
Drive belt - - - - - tension, damage Section 0B
Accelerator cable - - - - - play (after warm up engine), installation Section 6E3
Vacuum hoses of air intake system - - - - - disconnection, looseness,
deterioration, bend
Connectors of electric wire harness - - - disconnection, friction
Fuses - - - - - burning Section 8A
Parts - - - - - installation, bolt - - - - - looseness
Parts - - - - - deformation
Other parts that can be checked visually
Also add the following items at engine start, if possible.
Malfunction indicator lamp operation Section 6-1
Charge warning lamp operation Section 6H
Engine oil pressure warning lamp operation Section 8C
Engine coolant temperature warning lamp operation Section 8C
Engine coolant temperature meter operation Section 8C
Fuel level meter operation Section 8C
Abnormal air being inhaled from air intake system
Exhaust system - - - - - leakage of exhaust gas, noise
Engine Basic Check

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 table carefully.
Step Action Yes No

1 Was Engine Diag. Flow Table performed? Go to Step 2. Go to Engine Diag. Flow
Table in this section.
2 Check battery voltage. Go to Step 3. Charge or replace battery.
Is it 11 V or more?
3 Is engine cranked? Go to Step 4. Go to Diagnosis in
Section 6G.
4 Does engine start? Go to Step 5. Go to Step 6.
5 Check engine idle speed referring to Idle Go to Step 11 in Engine Go to Improper Engine
speed Inspection in Section 6E3. Diag. Flow Table in this Idling or Engine Fails to
Is check result as specified? section. Idle under Engine Diag-
nosis Table in this sec-
tion.
6 Do you have SUZUKI scan tool? Go to Step 7. Go to Diagnosis in Sec-
tion 8G. If OK, go to Step
8.
7 Check immobilizer system malfunction as fol- Go to Diagnosis in Sec- Go to Step 8.
lows. tion 8G.
1) Execute Data List mode of Suzuki mode
using ECM application of SUZUKI scan tool.
Dose Suzuki scan tool indicate communication
error message?
8 Check fuel supply as follows: Go to Step 10. Go to Step 9.
1) Check to make sure that enough fuel is
filled in fuel tank.
2) Turn ON ignition switch for 5 seconds and
then OFF. Repeat this a few times.
Is fuel return pressure (returning sounds) felt
from fuel return hose when ignition switch is
turned ON?
9 Check fuel pump for operating. Go to Low Pressure Fuel Go to Diag. Flow Table B-
1) Was fuel pump operating sound heard from Supply Inspection in Sec- 1 in this section.
fuel pump for about 5 seconds after ignition tion 6E3.
switch ON and stop?
10 Check fuel injector referring to Fuel Injector in Go to Engine Diagnosis Go to DTC P0201/0202/
Section 6E3. Table in this section. 0203/0204 Flow Table in
Is it in good condition? this section.
Engine Diagnosis Table

Perform troubleshooting referring to the following table when ECM has detected no DTC and no abnormality has
been found in visual inspection and engine basic inspection previously.

Hard starting Lack of fuel in fuel tank Refill.
(Engine cranks OK) Dirty or clogged fuel filter Replace.
Water mixed in fuel filter Repair.
Dirty or clogged fuel hose or pipe Clean.
Fuel injection pipe cracks Replace.
Fuel leakage from fuel injection pipe joints Correct.
Clogged fuel injector Replace.
Faulty fuel pump Inspect and replace.
Faulty ECM Replace.
Faulty fuel pressure sensor Inspect and replace.
Faulty CKP sensor (Engine speed sensor) Inspect and replace.
Faulty CMP sensor Inspect, adjust and replace.
Air mixed in fuel injection pump Refill fuel in fuel tank.
Fuel injection pump internal damage Replace.
Faulty fuel pressure regulator Inspect and replace.
Faulty fuel injector Inspect and replace.
Faulty ECT sensor Inspect and replace.
Faulty glow plug Inspect and replace.
Faulty pre post heating relay Inspect and replace.
Compression leak from valve seat Remove cylinder head and lap
valves.
Sticky valve stem Correct or replace valve.
Weak or damaged valve springs Replace valve springs.
Compression leak at cylinder head gasket Repair or replace.
Sticking or damaged piston ring Replace piston rings.
Worn piston, ring or cylinder Replace ring and piston. Rebore or
replace cylinder.
Immobilizer control system out of order. Refer to Section 8G.
Broken valve timing belt Replace timing belt and repair
valve train.
Faulty EGR throttle valve Inspect and replace.

Improper engine idling Clogged air cleaner element Clean or replace.
or engine fails to idle EGR throttle valve Inspect and replace.
Shortage of fuel in fuel tank Refill.
Dirty or clogged fuel filter Replace.
Fuel leakage from fuel injection pipe joints Repair.
Engine overheating Refer to Overheating section.
Faulty ECM Replace.
Faulty mass air flow sensor Inspect and replace.
Faulty injection pump solenoid valve (3rd piston Inspect and replace.
deactivator)
Faulty TP sensor (accelerator stroke sensor) Inspect and replace.
Faulty VSS Inspect and replace.
Faulty CKP sensor Inspect and replace.
Faulty EGR solenoid valve Inspect and repair or replace EGR
system.
Faulty EGR valve Inspect and repair or replace EGR
system.
Faulty swirl control solenoid valve Inspect and repair or replace swirl
system.
Faulty swirl control valve Inspect and repair or replace swirl
system.
Low compression Previously outlined.
Faulty A/T shift switch Inspect and replace.
Faulty A/C signal Inspect and replace.
Mal-adjusted accelerator cable Adjust.

Abnormal knocking Fuel injection pipe cracks Replace.
Faulty ECM Replace.
Faulty fuel injection pump Inspect and replace.
Faulty pre/post heating relay Inspect and replace.
Faulty fuel temperature sensor Inspect and replace.
Faulty EGR valve Inspect and replace.
Engine hesitates when Clogged air cleaner element Clean or replace.
accelerating Faulty turbocharger. Replace.
Dirty or clogged fuel hose or pipe Clean or replace.
Clogged fuel injector Inspect and replace.
Faulty ECM Inspect and replace.
Fuel injection pump internal damage Inspect and replace.
deactivator)
Faulty MAF sensor Inspect and replace.
Faulty TP sensor (Accelerator stroke sensor) Inspect and replace.
Faulty intake air pressure sensor Inspect and replace.
Faulty IAT sensor Inspect and replace.
system.
system.
system.
system.
Mal-adjusted accelerator cable Replace.

Overheating Insufficient coolant Replenish.
Loose water pump belt Adjust.
Inoperative thermostat Replace.
Poor water pump performance Replace.
Clogged or leaky radiator Flush, repair or replace.
Improper engine oil grade Replace with proper grade oil.
Clogged oil filter or oil strainer Replace or clean (oil strainer).
Not enough oil Replenish.
Poor oil pump performance Repair or replace.
Oil leakage Repair.
Dragging brakes Repair or replace.
Slipping clutch Repair or replace.
Blown cylinder head gasket Replace.
Excessive engine oil Loose oil drain plug Tighten.
consumption Loose oil pan bolts Tighten.
Deteriorated or broken oil pan sealant Replace sealant.
Leaky crankshaft oil seal Replace.
Leaky cylinder head cover gasket Replace.
Improper tightening of oil filter Tighten.
Loose oil pressure switch Tighten.
Leaky crankshaft pulley oil seal Replace.
Leaky camshaft oil seal Replace.
Loose turbocharger oil hose bolts Tighten.
Sticky piston ring Remove carbon and replace rings.
Worn piston and cylinder Replace or rebore cylinder, and
replace piston.
Worn piston ring groove and ring Replace piston and ring.
Improper location of piston ring gap Reposition ring gap.
Worn or damaged valve stem seal Replace.
Worn valve stem Replace.
Lower oil pressure Improper oil viscosity Use oil of proper viscosity.
Malfunctioning oil pressure switch Replace.
Clogged oil strainer Clean.
Functional deterioration of oil pump Replace.
Worn oil pump relief valve Replace.
Excessive clearance in various sliding parts Replace worn parts.

Engine noise Improper valve lash Adjust.
(See NOTE:) Worn valve stem and guide Replace.
Weak or broken valve spring Replace.
Warped or bent valve Replace.
Worn piston, ring and cylinder bore Rebore or replace cylinder.
Replace piston and ring.
Worn crankpin bearing Replace.
Worn crankpin Repair by grinding or replace
crankshaft.
Loose connecting rod nuts Tighten nuts to specification.
Low oil pressure Previously outlined.
Worn crankshaft journal bearing Replace.
Worn crankshaft journal Repair by grinding or replace
crankshaft.
Loose lower crankcase (bearing cap) bolts Tighten bolts to specification.
Excessive crankshaft thrust play Replace thrust bearing.
Engine and emission control system out of Refer to Section 6E3.
order
White or blue smoke Clogged air cleaner element Clean or replace.
EGR throttle valve Inspect and replace.
Faulty ECM registration data Inspect and registered.
Improper oil level Adjust.
Black smoke Faulty turbocharger Inspect and replace.
Clogged air cleaner element Clean or replace.
Faulty TP sensor Inspect and replace.
system.
system.
system.

Black smoke Faulty swirl control valve Inspect and repair or replace swirl
system.
NOTE:
Before checking the mechanical noise, make sure that:
Injection timing is properly adjusted.
Specified fuel is used.
Inspection of ECM and Its Circuits

ECM and its circuits can be checked at ECM wiring couplers by
measuring voltage and resistance.
CAUTION:
ECM cannot be checked by itself. It is strictly prohibited
to connect voltmeter or ohmmeter to ECM with couplers
disconnected from it.
Voltage check
CAUTION:
When measuring the terminal voltages of ECM, try not to
damage the waterproof gel applied on the connector ter-
minal of ECM by inserting a pin, whose diameter is less
than 0.3 mm, along with the wiring of the ECM terminal.
For further details, refer to the figure shown below.
Otherwise, ECM and terminals are damaged by entering
water into the connector and trouble may occur.
1) Remove ECM form ECM bracket referring to Engine Control

Module (ECM) in Section 6E3.
2) Remove harness clamps (1) from ECM harness connector
assemblies (2).
3) Remove connector covers (3) from ECM harness connector
assemblies loosing connector cover locks (4).
4) Connect ECM harness connectors to ECM using connector

lock lever (1).
5) Measure voltage at each terminal with ignition switch turned
ON according to Diag. Flow Table.
NOTE:
As each terminal voltage is affected by the battery volt-
age, confirm that it is 11 V or more when ignition switch
1 is ON.
2. Pin
2
6) After measuring, disconnect ECM harness connectors (1)

from ECM loosing connector lock lever (2).
7) Install connector covers (1) to ECM harness connectors

securely.
8) Tighten harness clamps (2) with ECM harness and ECM
harness connector securely.
9) Connect ECM connector assemblies to ECM using connec-
tor lock lever securely.
NOTE:
When clamp replacement is necessary, be sure to use a
clamp with width and thickness as specified below or
less. If a larger clamp is used, lock lever will be caught by
clamp and it will be impossible to install ECM connector
to ECM.
Width b: 2.3 mm
Thickness a: 1.2 mm
10) Install ECM to bracket referring to Engine Control Module
(ECM) in Section 6E3.
TERMINAL ARRANGEMENT OF ECM CONNECTOR VIEWED FROM HARNESS SIDE

Resistance check
1) Disconnect couplers from ECM with ignition switch OFF.
CAUTION:
Do not touch terminals of ECM itself or connect voltmeter
or ohmmeter (2).
2) Check resistance between each pair of terminals of discon-

nected couplers (1) as listed in the following table.
2
1
CAUTION:
Be sure to connect ohmmeter probe from terminal side
of coupler.
3 When measuring the circuit resistance, use a pin
(diameter is less than 0.3 mm) (3) for touching to the
connector terminal and be careful not to damage to the
terminal of the ECM connectors.
The directly connecting of ohmmeter probe to termi-
nals cause poor connection.
Be sure to turn OFF ignition switch for this check.
Resistance in table represents that when parts temper-
ature is 20C (68F).
STANDARD
TERMINAL CIRCUIT CONDITION
RESISTANCE
E229-2 to E229-9 Fuel injector No.1 Max. 1.0
E228-4 to E228-3 CKP sensor 315 405 At 20C (68F)
Refer to Fuel Temperature Sensor
E228-21 to E228-20 Fuel temperature sensor
Assembly in Section 6E3.
E228-1 to E228-14 Fuel pressure regulator 23 At 20C (68F)
Refer to Engine Coolant Temperature
E228-8 to E228-9 ECT sensor
Sensor (ECT Sensor) in Section 6E3.
E228-37 to Body ground Ground Below 1.5
Table A-1 Malfunction Indicator Lamp Circuit Check MIL Does Not Come
ON or Dims at Ignition Switch ON (But Engine at Stop)
Wiring Diagram
1. ECM 3. Main fuse 5. To radiator fan relay No.3

2. To ignition switch 4. Double relay
Circuit Description
When the ignition switch is turned ON, ECM causes the double relay to turn ON (close the contact point). Then,
ECM being supplied with the main power, turns ON the malfunction indicator lamp (MIL). When the engine
starts to run and no malfunction is detected in the system, MIL goes OFF but if a malfunction was or is detected,
MIL remains ON even when the engine is running.
Inspection
Step Action Yes No

1 MIL Power Supply Check: Go to Step 2. IG COIL fuse blown,
1) Turn ignition switch ON. main fuse blown, Ignition
Do other indicator/warning lights in combination switch malfunction, BLK/
meter comes ON? WHT circuit open and
poor coupler connection
at combination meter.
2 ECM Power and Ground Circuit Check: Go to Step 3. Go to Table A-3 ECM
Does engine start? Power and Ground Cir-
cuit Check in this section.
If engine is not cranked,
go to Diagnosis in Sec-
tion 6G.
3 MIL Circuit Check: Substitute a known-good Faulty combination meter
1) Turn ignition switch OFF. ECM and recheck. or PPL/YEL wire circuit
2) Remove ECM connector cover referring to open.
Voltage Check in this section.
3) Check for proper connection to ECM at ter-
minal E227-30.
4) If OK, then using service wire, ground termi-
nal E227-30 in connector disconnected.
Does MIL turn on at ignition switch ON?
Table A-2 Malfunction Indicator Lamp Circuit Check MIL Remains ON after
Engine Starts
Wiring Diagram/Circuit Description
Refer to Table A-1 Malfunction Indicator Lamp Circuit Check MIL Does Not Come ON or Dims at Ignition
Switch ON (But Engine at Stop) in this section.
Inspection
Step Action Yes No

1 DTC Check. Go to Step 2 of Engine Go to Step 2.
1) With ignition switch OFF, install scan tool. Diag. Flow Table in this
2) Start engine and check DTC. section.
Is there any DTC(s).
2 MIL Circuit Check: PPL/YEL wire shorted to Substitute a known-good
1) Turn ignition switch to OFF position. ground circuit. ECM and recheck.
2) Disconnect ECM connector referring to
Does MIL turn ON at ignition switch ON?
Table A-3 ECM Power and Ground Circuit Check MIL Doesnt Light at Igni-
tion Switch ON and Engine Doesnt Start Though It Is Cranked Up.
Wiring Diagram
Circuit Description
When the ignition switch is turned ON, the double relay turns ON (the contact point closes) and the main power
is supplied to ECM.
Inspection
Step Action Yes No

1 Double Relay Operating Sound Check: Go to Step 5. Go to Step 2.
Is operating sound of double relay heard at igni-
tion switch ON?
2 Fuse Check: Go to Step 3. Check for short in circuits
Is main FI fuse in good condition? connected to this fuse.
3 Double Relay Check: Go to Step 4. Replace double relay.
1) Turn OFF ignition switch and remove double
relay.
2) Check for proper connection to double relay
at terminal 3 and 10.
3) If OK, check double relay referring to Dou-
ble Relay in Section 6E3.
Is check result satisfactory?
4 ECM Power Circuit Check: Go to Step 5. BLK/WHT, YEL/GRN
1) Turn ignition switch to OFF position. or WHT/YEL circuit
2) Remove ECM connector covers referring to open.
3) Install double relay.
minals E227-11, E228-24, E228-1 and
E228-2.
5) If OK, then measure voltage between termi-
nal E227-11 and ground, E228-24 and
ground with ignition switch ON.
Is each voltage 10 14 V?
5 ECM Power Circuit Check: Check ground circuits Go to Step 6.
1) Using service wire, ground terminal E228- BLK for open.
24 and measure voltage between terminal If OK, then substitute a
E228-1 and ground, E228-2 and ground at known-good ECM and
ignition switch ON. recheck.
Is it 10 14 V?
6 Is operating sound of double relay heard in Step Go to Step 7. WHT/YEL or BLU/BLK
1? wire open.
7 Double Relay Check: WHT/YEL or BLU/BLK Replace double relay.
1) Check double relay according to procedure wire open.
in Step 3.
Is double relay in good condition?
DTC P0100 (DTC P0100) Mass Air Flow Circuit Malfunction
NOTE:
In case that DTC P0100 is detected by using the generic scan tool, perform DTC P0100 (P0100)
Mass Air Flow Circuit Malfunction and DTC P0101 (P0100) MAF Sensor Circuit Range/Performance
Problem in this section before ECM replacement because DTC indication of generic scan tool is dif-
ferent from the one of SUZUKI scan tool.
Wiring Diagram
E227 E228 E229
8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9 24 23 22 21 20 19 18 17 16 15 14 13 16 15 14 13 12 11 10 9
24 23 22 21 20 19 18 17 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 32 31 30 29 28 27 26 25
1. Mass air flow sensor 3. Ignition switch 5. Main fuse

2. ECM 4. IG COIL fuse (20 A)
DTC Detecting Condition and Trouble Area
DTC DETECTING CONDITION TROUBLE AREA

Voltage is below 0.1 V on E228-29 wire terminal of ECM. Mass air flow sensor circuit
Mass air flow sensor malfunction
ECM malfunction
DTC Confirmation Procedure
NOTE:
Check to make sure that the following conditions are satisfied when using this DTC Confirmation Pro-
cedure.
Intake air temp.: 8C, 18F or higher
Engine coolant temp.: 8 110C (18 230F)
Altitude (barometric pressure): 2400 m, 8000 ft or less (560 mmHg, 75 kPa or more)
1) Connect scan tool to DLC with ignition switch OFF.

2) Turn ON ignition switch and clear DTC, pending DTC and freeze frame data by using scan tool and run
engine at idle speed.
3) Check DTC and pending DTC by using scan tool.
Troubleshooting
Step Action Yes No

2 MAF sensor power supply Check: Go to Step 3. Faulty BLK/WHT, BLK
1) With ignition switch OFF, disconnect MAF wire.
sensor coupler.
2) With ignition switch ON, check voltage
between BLK/WHT wire terminal of MAF
sensor coupler and BLK wire terminal of
MAF sensor coupler.
Is voltage 10 14 V?
3 Wiring Harness Check: Poor E228-29 terminal PPL/WHT wire circuit
1) Turn ignition switch to OFF position. and PPL/WHT wire ter- open.
2) Remove ECM connector cover referring to minal connection.
Voltage Check in this section. If OK, go to Step 4.
3) Measure resistance between E228-29 ter-
minal of disconnected ECM connector and
PPL/WHT wire terminal of MAF sensor
connector.
Is resistance 1 or less?
4 Wiring Harness Check: Go to Step 5. PPL/WHT wire circuit
1) Check continuity between E228-29 termi- shorted to ground.
nal of disconnected ECM connector and
body ground.
Is it infinite?
5 Wiring Harness Check: Go to Step 6. PPL/WHT wire shorted
1) With ignition switch ON, check voltage to power circuit.
between E228-29 terminal of disconnected
ECM connector and PPL/WHT wire termi-
nal of MAF sensor connector.
Is voltage 0 V?
6 Wiring Harness Check: Poor E228-30 terminal BRN/BLU wire circuit
1) Turn ignition switch to OFF position. and BRN/BLU wire ter- open.
2) Measure resistance between E228-30 terminal connection.
minal of disconnected ECM connector and If OK, go to Step 7.
BRN/BLU wire terminal of MAF sensor
connector.
7 Wiring Harness Check: Go to Step 8. BRN/BLU wire circuit
body ground.
Is it infinite?
8 Wiring Harness Check: Go to Step 9. BRN/BLU wire shorted
ECM connector and BRN/BLU wire termi-
Is voltage 0 V?
Step Action Yes No

9 MAF Sensor Output Voltage Check: Faulty BLK wire connec- Substitute a known-good
1) With ignition switch OFF, connect MAF sen- tion. MAF sensor and recheck.
sor coupler and ECM connector. If OK, substitute a known-
2) Start engine and check voltage between good ECM and recheck.
E228-29 and E228-30 terminals of ECM
connector at idle speed.
Is voltage about 2 3 V?
DTC P0101 (P0100) MAF Sensor Circuit Range/Performance Problem
NOTE:
Mass Air Flow Circuit Malfunction and DTC P0101 (P0100) MAF Sensor Circuit Range/Performance
Problem in this section before ECM replacement because DTC indication of generic scan tool is dif-
ferent from the one of SUZUKI scan tool.
Wiring Diagram
Refer to DTC P0100 (DTC P0100) Mass Air Flow Circuit Malfunction in this section.

Engine speed is greater than 3000 rpm and air flow sensor Clogged or leaky air intake system
output voltage is lower than specified value for more than 4.5 Mass air flow sensor circuit
seconds or engine speed between 700 and 900 rpm and air (Intermittent or high resistance)
flow greater than 800 mg/stroke. Mass air flow sensor malfunction
ECM malfunction
NOTE:
cedure.


engine at idle speed for 10 sec. or more.
3) Then run engine over 3000 rpm for 10 sec. or more.
4) Check DTC and pending DTC.
Troubleshooting
Step Action Yes No

2 1) Turn ignition switch to OFF position. Intermittent trouble or Clogged or leaky air
2) Remove ECM connector cover referring to faulty ECM. intake system.
Voltage Check in this section. Check for intermittent If all are OK, substitute a
3) Connect ECM connectors from ECM. referring to Intermittent known-good MAF sensor
4) Start engine and check voltage between and Poor Connection in and recheck.
E228-29 and E228-30 terminals. Section 0A.
Engine speed at 3000 rpm: about 3 4 V
Engine speed at idling: about 2 3 V
Is each value satisfied?
DTC P0110 Intake Air Temp. (IAT) Circuit Malfunction

Wiring Diagram
E227 E228 E229
8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9 24 23 22 21 20 19 18 17 16 15 14 13 16 15 14 13 12 11 10 9
24 23 22 21 20 19 18 17 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 32 31 30 29 28 27 26 25
1. Mass air flow sensor

2. ECM

Voltage is below 0.1 V or E228-28 wire terminal of ECM or IAT sensor circuit
voltage is greater than 4.8 V on E228-28 wire terminal of IAT sensor malfunction
ECM. ECM malfunction

2) Turn ON ignition switch and clear DTC, pending DTC and freeze frame data by using scan tool.
3) Turn OFF ignition switch, then ON.
Troubleshooting
Step Action Yes No

2 Check IAT Sensor and Its Circuit. Go to Step 3. Intermittent trouble.
1) Connect scan tool with ignition switch OFF. Check for intermittent
2) Turn ignition switch ON. referring to Intermittent
3) Check intake air temp. displayed on scan and Poor Connection in
tool. Section 0A.
Is 40C (40F) or 131C (268F) indicated?
3 Check Wire Harness. Go to Step 4. PPL/RED wire open or
1) Disconnect MAF sensor (built-in IAT sensor) shorted to power, or poor
connector with ignition switch OFF. E228-28 connection.
2) Check for proper connection to MAF sensor If wire and connection are
(built-in IAT sensor) at PPL/RED and OK, substitute a known-
BRN/BLU wire terminals. good ECM and recheck.
3) If OK, then with ignition switch ON, is volt-
age applied to PPL/RED wire terminal of
harness side about 5 V?
4 Does scan tool indicate 40 C (40 F) at Step Go to Step 6. Go to Step 5.
2?
5 Check Wire Harness. Replace MAF sensor PPL/RED wire shorted
1) Disconnect MAF sensor (built-in IAT sensor) (built-in IAT sensor). to ground.
connector. If wire is OK, substitute a
2) Check intake air temp. displayed on scan known-good ECM and
tool. recheck.
Is 40 C (40 F) indicated?
6 Check Wire Harness. Replace MAF sensor (built- BRN/BLU wire open or
1) Using service wire, connect MAF sensor in IAT sensor). poor E228-30 connection.
(built-in IAT sensor) connector terminals. If wire and connection are
(between PPL/RED wire terminal and OK, substitute a known-
BRN/BLU wire terminal of harness side) good ECM and recheck.
2) Turn ignition switch ON and check intake air
temp. displayed on scan tool.
DTC P0115 (DTC P0115) Engine Coolant Temp. Sensor Circuit Malfunction
Wiring Diagram
1. Engine coolant temperature (ECT) sensor

2. ECM

Voltage is below 0.1 V on E228-8 wire terminal of ECM. Engine coolant temperature sensor circuit
Engine coolant temperature sensor malfunc-
tion
ECM malfunction

Troubleshooting
Step Action Yes No

2 Check Wire Harness. Go to Step 3. PPL/BLK wire open or
1) Remove intercooler referring to Intercooler shorted to power/ground.
in Section 6A3. BRN/WHT wire open.
2) Disconnect ECT sensor connector with igni- Poor E228-8 or E228-9
tion switch OFF. connection.
3) Check for proper connection to ECT sensor
at PPL/BLK and BRN/WHT wire termi-
nals.
4) If OK, check voltage between PPL/BLK
and BRN/WHT wire terminals of harness
side with ignition switch ON.
Is voltage about 5 V?
3 Check ECT Sensor and Its Circuit Substitute a known-good Faulty ECT sensor.
1) Connect ECT sensor to its connector. ECM and recheck.
2) Connect scan tool to DLC with ignition
switch OFF and run engine.
Does coolant temp. on scan tool vary?
DTC P0121 (DTC P0120) Throttle Position Circuit Range/Performance Problem

DTC P0604 (P0120) Throttle Position Sensor Monitoring System Malfunction
Wiring Diagram
1. Throttle position sensor 3. Brake lamp switch

2. ECM 4. STOP fuse (20 A)

Voltage is below 0.1 V on E227-15 wire terminal of ECM Throttle position sensor circuit
or voltage is greater than 4.7 V on E227-15 wire terminal Throttle position sensor malfunction
of ECM. Brake (stop) lamp switch
or ECM malfunction
Voltage is greater than 5.2 V on E227-23 wire terminal of
ECM or voltage is less than 4.8 V on E227-23 wire termi-
nal of ECM.
or
Simultaneous operation of the accelerator and the brake.

Troubleshooting
Step Action Yes No

2 Check Sensor Power Supply Circuit Go to DTC P1614 Go to Step 3.
Is DTC below also indicated? (P0560) Sensor Supply
<Using Suzuki mode of SUZUKI scan tool> Function in this section.
P1614
<Using Generic Scan tool or GST mode of
SUZUKI scan tool>
P0560
3 Check Wire Harness. Go to Step 4. LT GRN wire open,
1) Disconnect connector from TP sensor with BRN wire open, poor
ignition switch OFF. E227-23 connection, or
2) Check for proper connection to TP sensor at poor E227-16 connection.
each terminals. If wire and connection are
3) If OK, then with ignition switch ON, check OK, substitute a known-
voltage between LT GRN wire and BRN good ECM and recheck.
wire terminals at connector of TP sensor.
4 Check TP Sensor output voltage. Substitute a known-good GRN/BLU wire open,
1) Turn ignition switch to OFF position. ECM and recheck. GRN/BLU wire shorted
2) Remove ECM connector cover referring to to ground circuit/power
Voltage Check in this section. circuit.
3) Connect ECM connectors from ECM. Poor TP sensor connec-
4) With ignition switch ON, check voltage tor.
between E227-15 and ground, when accel- If wire and connection are
erator pedal is at idle position to fully OK, substitute a known-
depressed position. good TP sensor.
Is voltage 0.5 3.35 V?
DTC P0180 Fuel Temperature Sensor Circuit Malfunction

Wiring Diagram
1. Fuel temperature sensor

2. ECM

Voltage is below 0.1 V on E228-20 wire terminal of ECM or Fuel temperature sensor circuit
voltage is greater than 4.8 V on E228-20 wire terminal of Fuel temperature sensor malfunction
ECM. ECM malfunction

Troubleshooting
Step Action Yes No

2 1) Remove intercooler referring to Inter- Go to Step 3. BLU/ORN wire open or
cooler in Section 6A3. shorted to power/ground.
2) Disconnect fuel temp. sensor connector BRN wire open.
with ignition switch OFF. Poor E228-20 or E228-21
3) Check for proper connection to fuel temp. connection.
sensor at BLU/ORN and BRN wire ter- If wire and connection are
minals. OK, substitute a known-
4) If OK, check voltage between BLU/ORN good ECM and recheck.
and BRN wire terminals with ignition
switch ON.
3 1) Check fuel temp. sensor for resistance Substitute a known-good Replace fuel temp. sen-
referring to Fuel Temperature Sensor in fuel temp. sensor and sor.
Section 6E3. recheck.
Is resistance as specified?
DTC P0190 (P0190) Fuel Rail Pressure Sensor Circuit Malfunction

Wiring Diagram
1. Fuel pressure sensor

2. ECM

Voltage is less than 0.3 V on E228-6 wire terminal of Fuel rail pressure sensor circuit
ECM or voltage is greater than 4.7 V on E228-6 wire ter- Fuel rail pressure sensor malfunction
minal of ECM. ECM malfunction
or
ECM or voltage is less than 4.8 V on E228-5 wire termi-
nal of ECM.

Troubleshooting
Step Action Yes No

1) Connect scan tool to DLC with ignition (P0560) Sensor Supply
switch OFF and then turn ignition switch Function in this section.
ON.
2) Dose scan tool indicate DTC as shown
below?
<Using Suzuki mode of SUZUKI scan tool>
P1614
SUZUKI scan tool>
P0560
3 Check Wire Harness Go to Step 4. LT GRN/BLK wire open,
1) Remove intercooler and intercooler outlet LT GRN/BLK wire
hose. shorted to ground circuit/
2) Disconnect connector from fuel pressure power circuit, GRY wire
sensor with ignition switch OFF. open, poor E228-5 con-
3) Check for proper connection to fuel pres- nection, or poor E228-7
sure sensor at each terminals. connection.
4) If OK, then with ignition switch ON, check If wire and connection are
voltage between LT GRN/BLK wire and OK, substitute a known-
GRY wire terminals at connector of fuel good ECM and recheck.
pressure sensor.
4 Check Fuel Pressure Sensor Output Voltage Substitute a known-good ORN/WHT wire open,
1) Turn ignition switch to OFF position. ECM and recheck. ORN/WHT wire shorted
3) Connect ECm connectors from ECM. If wire and connection are
4) Connect fuel pressure sensor connector. OK, substitute a known-
5) Install intercooler and intercooler outlet good fuel pressure sensor
hose. and recheck.
6) Start engine and check voltage between
E228-6 and E227-32 terminal at idle speed.
Is voltage about 1.3 V?
DTC P0191 (P0230) Fuel Rail Pressure Sensor/Pressure Regulator Consis-

tency Function
DTC P1112 (P0230) Fuel Pressure Monitoring Circuit Malfunction
NOTE:
In case that DTC P0230 is detected by using the generic scan tool, perform DTC P0191 (P0230) Fuel
Rail Pressure Sensor/Pressure Regulator Consistency Function, DTC P1112 (P0230) Fuel Rail Pres-
sure Monitoring Circuit Malfunction and DTC P1138 (P0230) Fuel Pressure regulator Circuit Mal-
function in this section before ECM replacement because DTC indication of generic scan tool is
different from the one of SUZUKI scan tool.
Wiring Diagram
E227 E228 E229
8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9 24 23 22 21 20 19 18 17 16 15 14 13 16 15 14 13 12 11 10 9
24 23 22 21 20 19 18 17 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 32 31 30 29 28 27 26 25
1. Double relay 3. Fuel pressure sensor 5. Double relay fuse (30 A)

2. Fuel pressure regulator 4. ECM

P0191: Double relay and its circuit
The current measured on the fuel pressure regulator does Fuel pressure sensor and its circuit
not correspond to the pressure given by the fuel rail pressure Fuel line clogged or bended
sensor on basis. Injection pump malfunction
P1112: ECM malfunction
Fuel rail pressure is higher than 1450 bars.
or
Reference pressure + 250 bars lower than the fuel rail
pressure measured and fuel pressure regulator below 10%
for more than 0.5 seconds.
or
Reference pressure + 250 bars greater than the fuel rail
pressure measured and fuel pressure regulator above 85%
for more than 0.5 seconds.

3) Then run engine at 1000 rpm or more for 10 sec.
Troubleshooting
Step Action Yes No

2 Check Fuel Shortage Go to Step 3. Supply fuel into fuel tank.
1) Is there enough fuel in fuel tank?
3 Check Wire Harness Go to Step 4. Faulty WHT/GRN wire,
1) Turn ignition switch OFF position. YEL wire or LT GRN/
2) Remove ECM connector covers referring to WHT wire.
Voltage Check in this section. If wire is OK, substitute a
3) Check for proper connection to ECM at known-good double relay
E228-2 and E228-14 terminals. or injection pump and
4) If OK, check resistance between E228-2 recheck.
and E228-14 terminals.
Is resistance 2 3 ?
4 Check Fuel Pressure Sensor Output Voltage Go to Step 5. ORN/WHT wire open,
1) Connect ECM connectors to ECM. ORN/WHT wire shorted
2) Start engine and check voltage between to ground circuit/power
E228-6 and E227-32 terminal at idle speed. circuit.
Is voltage about 1.3 V? Poor fuel pressure sensor
connector terminal con-
nection.
If wire and connection are
OK, substitute a known-
good fuel pressure sensor
and recheck.
5 Check Fuel Leakage Fuel line clogged or Repair or replace.
1) Perform step 1), 2) and 3) of DTC Confir- bended.
mation Procedure. Faulty fuel pressure
2) Check fuel leakage on Fuel System. regulator.
Is it in good condition? If OK, substitute a known-
good ECM and recheck.
DTC P0201 (P0200) Injector Circuit Malfunction Cylinder 1

Wiring Diagram
1. Fuel injector No.1 3. Fuel injector No.3 5. ECM

2. Fuel injector No.2 4. Fuel injector No.4

P0201: Fuel injector circuit
Excess current between E229-2 and E229-9 wire termi- Fuel injector malfunction
nals of ECM. ECM malfunction
P0202:
Excess current between E229-25 and E229-17 wire termi-
nals of ECM.
P0203:
nals of ECM.
P0204:
nals of ECM.

Troubleshooting
Step Action Yes No

2 Check Fuel Injector Circuit For Short Go to Step 3. Short circuit between
1) Turn ignition switch to OFF position. PNK wire and RED
2) Remove ECM connector cover referring to wire, PNK/BLK wire and
Voltage Check in this section. RED/BLK wire, PNK/
3) Check for proper connection to ECM at GRN wire and RED/
E229-2, E229-9, E229-25, E229-17, E229- GRN wire, or PNK/BLU
26, E229-18, E229-1 and E229-10 termi- wire and RED/BLU wire.
nals.
4) If OK, remove intercooler and then discon-
nect connector at all fuel injectors.
5) Check for proper connection of all fuel injec-
tor connector.
6) If OK, measure resistance between the fol-
lowing terminals of fuel injector connectors.
PNK and RED:
Fuel injector No.1
PNK/BLK and RED/BLK:
Fuel injector No.2
PNK/GRN and RED/GRN:
Fuel injector No.3
PNK/BLU and RED/BLU:
Fuel injector No.4
Is resistance between terminals of all fuel injec-
tors infinity ()?
3 Check Fuel Injector Circuit For Open Substitute a known-good Open PNK wire, RED
1) Connect connector to all fuel injectors. ECM and recheck. wire, PNK/BLK wire,
2) Measure for resistance between the follow- RED/BLK wire, PNK/
ing terminals of ECM connector. GRN wire, RED/GRN
E229-2 and E229-9: 0.56 (maximum) wire, PNK/BLU wire or
E229-25 and E229-17: 0.56 (maximum) RED/BLU wire.
E229-26 and E229-18: 0.56 (maximum) If wire is OK, substitute a
E229-1 and E229-10: 0.56 (maximum) known-good fuel injector
Is check result as specified? and recheck.
DTC P0215 Double Relay Circuit Malfunction

Wiring Diagram
1. Double relay 3. Ignition switch 5. Main fuse 7. Double relay fuse (30 A)
2. ECM 4. IG COIL fuse (20 A) 6. To radiator fan relay No.3

Cutting off the ECM supply (for double relay) with no ECM Double relay circuit
command and cutting off the ECM supply (for double relay) Double relay malfunction
for more than 2 seconds. ECM malfunction

3) Turn ON ignition switch after OFF for 5 sec.
Troubleshooting
Step Action Yes No

2 Check Double Relay Function Substitute a known-good Go to Step 3.
1) Turn ignition switch ON for 5 sec. and then ECM and recheck.
OFF.
Is click of double relay heard from double relay
at 2 sec. after ignition switch OFF?
3 1) Remove ECM connector covers referring to Poor E228-1/2 and/or Go to Step 4.
Voltage Check in this section. E227-11 connection.
2) Connect ECM connectors from ECM. If connection is OK,
3) Check voltage between E228-1/2 and substitute a known-good
ground, between E227-11 and ground. ECM and recheck.
Ignition switch ON: 10 14 V
Ignition switch OFF: about 0 V
Is check result as specified?
4 Check Double Relay Go to Step 5. Faulty double relay.
1) Check double relay referring to Double
Relay in Section 6E3.
Is it in good condition?
5 1) Check voltage between E228-24 and Poor E228-24 connec- YEL/GRN wire open or
ground. tion. short.
Ignition switch ON: about 0 V BLU/BLK wire open/
Ignition switch OFF: 10 14 V short.
Is check result as specified? WHT/GRN wire open/
short.
DTC P0230 Fuel Pump Supply Circuit Malfunction

Wiring Diagram
1. Double relay 3. Fuel pump 5. Double relay fuse (30 A)

2. ECM 4. FUEL PUMP fuse (15 A) 6. To radiator fan relay No.3

When ECM detects open or shorted to ground in E228- Fuel pump circuit
48 wire circuit. Fuel pump malfunction
or ECM malfunction
When ECM detects shorted to power in E228-48 wire cir-
cuit.

Troubleshooting
Step Action Yes No

2 Is operating sound heard from fuel pump? Substitute a known-good Go to Step 3.
ECM and recheck.
4 Check Fuel Pump Output Circuit Poor E228-48 connec- GRN/ORN wire open/
1) Turn ignition switch to OFF position. tion short.
2) Remove ECM connector cover referring to BLK, PNK/BLK or
Voltage Check in this section. BRN/RED wire open/
3) Connect ECM connectors from ECM. short
4) Check voltage between E228-48 and Fuse broken
ground. Faulty fuel pump
Within 5 sec. after ignition switch ON: If all are OK, substitute a
about 0 V known-good ECM and
Over 5 sec. after Ignition switch OFF: recheck.
10 14 V
DTC P0243 (P0243) Turbo Pressure Solenoid Valve Circuit Range/Performance

Problem
NOTE:
In case that DTC P0243 is checked by using the generic scan tool, perform DTC P0243 (P0243)
Turbo Pressure Solenoid Valve Circuit Range/Performance Problem and DTC P0245 (P0243)/P0246
(P0243) Turbo Pressure Solenoid Valve Circuit Range/Performance Problem in this section before
ECM replacement because DTC indication of generic scan tool is different from the one of SUZUKI
scan tool.
Wiring Diagram
1. Double relay 3. Boost (turbo) pressure regulator solenoid valve 5. ENG fuse (15 A)
2. ECM 4. Fuel pump 6. FUEL PUMP fuse (15 A)

When ECM detects open or shorted to ground in E229- Boost pressure regulator solenoid valve cir-
31 wire circuit. cuit
or Boost pressure regulator solenoid valve mal-
When ECM detects shorted to power in E229-31 wire cir- function
cuit. ECM malfunction

Troubleshooting
Step Action Yes No

2 Is operating sound heard from fuel pump? Go to Step 3. Proceed to DTC P0230
Fuel Pump Supply Circuit
Malfunction in this sec-
tion.
3 Check Wire Harness Go to Step 4. BLU/WHT wire open,
1) Disconnect boost pressure regulator sole- shorted to power/ground
noid valve connector with ignition switch or fuse broken.
OFF.
between BLU/WHT wire terminal of sole-
noid valve connector disconnected and
ground.
Within 5 sec. after ignition switch ON:
about 12 V
Over 5 sec. after ignition switch ON:
0V
4 Check Boost Pressure Regulator Solenoid GRN/BLK wire open or Faulty solenoid valve.
Valve shorted to power/ground.
1) Check solenoid valve referring to Boost Poor E229-31 connection.
Pressure Regulator Solenoid Valve in Sec- If wire and connection are
tion 6E3. OK, substitute a known-
Is check result as specified? good ECM and recheck.
DTC P0245 (P0243)/P0246 (P0243) Turbo Pressure Solenoid Valve Circuit

Range/Performance Problem
NOTE:
Turbo Pressure Solenoid Valve Circuit Range/Performance Problem and DTC P0245 (P0243)/P0246
(P0243) Turbo Pressure Solenoid Valve Circuit Range/Performance Problem in this section before
ECM replacement because DTC indication of generic scan tool is different from the one of SUZUKI
scan tool.
Wiring Diagram
Refer to DTC P0243 (P0243) Turbo Pressure Solenoid Valve Circuit Range/Performance Problem in this sec-
tion.

P0245: Vacuum circuit for leak, clogged and bended
Reference pressure minus the pressure measured is greater Boost pressure regulator solenoid valve mal-
than 200 mbars for more than 10 seconds with engine run- function
ning at more than 2500 rpm. ECM malfunction
P0246:
Reference pressure minus the pressure measured is greater
than 300 mbars for more than 10 seconds with engine run-
ning at more than 2500 rpm.

3) Run engine over 2500 rpm for 10 sec.
Troubleshooting
Step Action Yes No

2 Check Vacuum Circuit Go to Step 3. Repair or replace.
Check vacuum circuit for leak and clogging.
3 Check boost pressure regulator solenoid valve Substitute a known-good Replace boost pressure
for resistance referring to Boost Pressure Reg- ECM and recheck. regulator solenoid valve.
ulator Solenoid Valve in Section 6E3.
DTC P0380 (P0380)/P1404 (P0380) Pre/Post Heat Relay Circuit Malfunction

Wiring Diagram
E227 E228 E229
8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9 24 23 22 21 20 19 18 17 16 15 14 13 16 15 14 13 12 11 10 9
24 23 22 21 20 19 18 17 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 32 31 30 29 28 27 26 25
1. Pre/post heating relay (control unit) 3. Glow plugs 5. From ignition switch
2. ECM 4. Main fuse

12 V at E229-3 and E229-7 of ECM in operation of pre/ Fuse broken
post heating relay or 0 V at E229-3 and E229-7 of ECM in Pre/post heating relay circuit
operation of pre/post heating relay. Pre/post heating relay malfunction
Glow plug malfunction
ECM malfunction

3) Turn ignition switch ON for 30 sec. after OFF. Then run engine at idle speed for 30 sec.
Troubleshooting
Step Action Yes No

2 Check Wire Harness Go to Step 3. Main fuse broken.
1) Turn ignition switch to OFF position. WHT wire circuit open or
2) Check voltage between pre/post heating shorted to ground.
relay at WHT wire terminal and body
3 Check Wire Harness Poor glow plug BLK wire BLK wire (between pre/
1) Turn ignition switch to OFF position. terminals connection. post heating relay and
2) Check voltage between glow plug each wire If wire are OK, replace glow plug) open, shorted
terminals with ignition switch ON. glow plug. to power/ground.
Is voltage about 12 V for limited time? If OK, go to Step 4.
4 Check Wire Harness Go to Step 5. BLK wire circuit
1) Turn ignition switch to OFF position. (between pre/post heating
2) Disconnect pre/post heating relay connec- relay and ground) open.
tor.
3) Check for proper connection of pro/post
heating relay connector at all terminals.
4) If OK, measure resistance between pre/post
heating relay connector at BLK wire termi-
nal and body ground.
5 Check Wire Harness Go to Step 6. BLK/WHT wire circuit
1) Check voltage between pre/post heating open.
relay connector at BLK/WHT wire terminal
and body ground with ignition switch ON.
6 Check Wire Harness Go to Step 7. LT BLU or BLK/WHT
1) Turn ignition switch to OFF position. wire open or shorted to
2) Connect pre/post heating relay connector. ground.
3) Remove ECM connector cover referring to
4) Check voltage between E229-7/E229-11
and ground with ignition switch ON.
Are they about 12 V?
7 Check Wire Harness Poor E229-3 or E229-7 GRN/BLU wire open or
1) Check voltage between E229-3 and ground connection. shorted to ground.
with ignition switch ON. If connections are in good If OK, substitute a known-
Is it about 0 V? condition, substitute a good pre/post heating
known-good ECM and relay and recheck.
recheck.
DTC P0381 Glow Indicator Lamp Circuit Malfunction

Wiring Diagram
1. Glow indicator lamp (in combination meter)

2. ECM

When ECM detects open or shorted to ground in E227- Glow indicator lamp circuit
14 wire circuit. Glow indicator lamp (combination meter)
or malfunction
When ECM detects shorted to power in E227-14 wire cir- ECM malfunction
cuit.

3) Turn ignition switch ON for 30 sec. after OFF.
Troubleshooting
Step Action Yes No

2 Check Wire Harness Substitute a known-good RED/BLK wire open
<Not Using SUZUKI Scan Tool> ECM and recheck. or short.
1) Turn ignition switch to OFF position. Poor E227-14 connec-
2) Remove ECM connector cover referring to tion.
Voltage Check in this section. Replace combination
3) Supply battery power (12 V) to E227-14 meter.
wire terminal of disconnected ECM connec-
tor by using service wire.
Does glow indicator lamp turn ON?
<Using SUZUKI Scan Tool>
1) Connect SUZUKI scan tool to DLC.
2) Execute Glow Indicator Lamp in Misc Test.
Does glow indicator lamp flash?
Reference:
As soon as ignition is switched on, ECM turns on glow indicator lamp for a period which depends on engine
coolant temp. as shown below.
Engine coolant temp. (C) Time turning on glow indicator lamp (sec.)
30 20
10 5
0 0.5
18 0
DTC P0401 (P0903) EGR Solenoid Valve Flow Insufficient Detected

DTC P0402 (P0903) EGR Solenoid Valve Flow Excessive Detected

Engine speed between 700 and 2700 rpm, injected flow less EGR vacuum circuit
than 42 mm3/stroke, EGR solenoid valve reference value sta- EGR valve malfunction
ble and air flow inconsistent. EGR solenoid valve malfunction
ECM malfunction

3) Run engine between 700 and 2700 rpm for 10 or more.
Troubleshooting
Step Action Yes No

2 Check EGR vacuum circuit and intake air circuit Go to Step 3. Repair or replace.
for leak.
3 Check EGR valve referring to EGR Valve and Go to Step 4. Faulty EGR valve.
EGR Cooler in Section 6E3.
4 Check EGR solenoid valve for resistance refer- Substitute a known-good Replace EGR solenoid
ring to EGR Solenoid Valve in Section 6E3. ECM and recheck. valve.
DTC P0403 (P0403) EGR Solenoid Valve Circuit Malfunction

Wiring Diagram
E227 E228 E229
8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9 24 23 22 21 20 19 18 17 16 15 14 13 16 15 14 13 12 11 10 9
24 23 22 21 20 19 18 17 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 32 31 30 29 28 27 26 25
1. Double relay 3. EGR solenoid valve 5. ENG fuse (15 A)


When ECM detects open or shorted to ground in E228- Fuse broken
36 wire circuit. EGR solenoid valve circuit
or EGR solenoid valve malfunction
cuit.

Troubleshooting
Step Action Yes No

tion.
1) Disconnect EGR solenoid valve connector shorted to power/ground
with ignition switch turned OFF. or fuse broken.
noid valve connector and ground.
10 14 V
about 0 V
4 Check EGR Solenoid Valve LT GRN/RED wire Faulty EGR solenoid
1) Check solenoid valve referring to EGR open or shorted to valve.
Solenoid Valve in Section 6E3. power/ground.
Is it in good condition? Poor E228-36 connec-
tion.
DTC P0561 (P0560) Stabilization of Sensor Supply

DTC P0603/P0606/P1171 ECM Function
DTC P1169 (P0170) Condenser Voltage Function 1
DTC P1170 (P0170) Condenser Voltage Function 2
DTC P1101 (P0105) Barometric Pressure Sensor Circuit Malfunction
NOTE:
Power Supply Circuit Malfunction, DTC P0561 (P0560) Stabilization of Sensor Supply and DTC
P1614 (P0560) Sensor Supply Function in this section before ECM replacement because DTC indica-
tion of generic scan tool is different from the one of SUZUKI scan tool.
Wiring Diagram
1. Double relay 3. Ignition switch 5. Main fuse

2. ECM 4. IG COIL fuse 6. To radiator fan relay No.3
DTC Detecting Condition

This DTC will be set when an internal fault is detected in the ECM.

3) Run engine at idle speed for 10 sec.
Troubleshooting
Step Action Yes No

1 Was Engine Diag. Flow Table performed? Substitute a known-good Go to Engine Diag. Flow
ECM and recheck. Table in this section.
DCT P1107 Swirl Control Solenoid Valve Circuit Malfunction

Wiring Diagram
E227 E228 E229
8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9 24 23 22 21 20 19 18 17 16 15 14 13 16 15 14 13 12 11 10 9
24 23 22 21 20 19 18 17 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 32 31 30 29 28 27 26 25
1. Double relay 3. Swirl control solenoid valve 5. ENG fuse (15 A)


47 wire circuit. Swirl control solenoid valve circuit
or Swirl control solenoid valve malfunction
cuit.

Troubleshooting
Step Action Yes No

tion.
1) Disconnect swirl control solenoid valve con- shorted to power/ground
nector with ignition switch OFF. or fuse broken.
between BLU/WHT wire terminal of swirl
control solenoid valve connector and
ground.
10 14 V
about 0 V
4 Check Swirl Control Solenoid Valve RED/BLK wire open Faulty swirl control sole-
1) Check swirl control solenoid valve referring or shorted to power/ noid valve.
to Swirl Control Solenoid Valve in Section ground.
6E3. Poor E228-47 connec-
Is it in good condition? tion. If wire and con-
nection are OK,
substitute a known-
good ECM and
recheck.
DTC P1108 Radiator Fan High Speed Circuit Malfunction

Wiring Diagram
WHT/GRN 8
BLU
6 9 4
E228-2 WHT/GRN BLU/WHT

7
E227-18 YEL/WHT 7 BLU/BLK
BLK/WHT 1
E227-3 BLU/BLK
3
BLK/WHT
E227-4 YEL/BLU
BLU/GRN
2
BLK
BLU/BLK
BLU/BLK
BLK
E227 E228 E229
8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9 24 23 22 21 20 19 18 17 16 15 14 13 16 15 14 13 12 11 10 9
24 23 22 21 20 19 18 17 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 32 31 30 29 28 27 26 25
1. Radiator fan motor 1 4. Radiator fan relay 3 (Low) 7. From IG COIL fuse (20 A)
2. Radiator fan relay 1 (High/Low) 5. Radiator fan motor 2 8. From main fuse
3. Radiator fan relay 2 (High) 6. ECM 9. Double relay

18 wire circuit. Radiator fan high speed circuit
or Radiator fan relay 1 (high/low) or radiator fan
When ECM detects shorted to power in E227-18 wire cir- relay 2 (high) malfunction
cuit.

3) Start engine and warm up completely.
Troubleshooting
Step Action Yes No

2 Check Wire Harness Poor E227-18 connection. Go to Step 3.
1) Turn ignition switch to OFF position.
3) Check voltage between E227-18 wire termi-
Is it about 12 V?
3 Check Radiator Fan Relay YEL/WHT wire open Faulty radiator fan relay 1
1) Check radiator fan relay 1 and 2 referring to or short to ground. or 2.
Radiator Fan Relay 1 (High/Low) and BLK/WHT wire open
Radiator Fan Relay 2 (High) in Section or short to ground.
6E3. Fuse broken.
Are they in good condition?
DTC P1109 Radiator Fan Low Speed Circuit Malfunction

Wiring Diagram
Refer to DTC P1108 Radiator Fan High Speed Circuit Malfunction in this section.

When ECM detects open or shorted to ground in E227-4 Fuse broken
wire circuit. Radiator fan low speed circuit
or Radiator fan relay 3 (low) malfunction
cuit.

Troubleshooting
Step Action Yes No

Is it about 12 V?
3 Check Radiator Fan Relay YEL/BLU wire open or Faulty radiator fan relay 3.
1) Check radiator fan relay 3 referring to Radi- short to ground.
ator Fan Relay 3 (Low) in Section 6E3. WHT/GRN wire open
Is it in good condition? or short to ground.
Fuse broken.
DTC P1110 A/C Signal Circuit Malfunction

Wiring Diagram
1. A/C control module [A]: Request signal

2. ECM [B]: Control signal

When ECM detects open or shorted to ground in E227- A/C compressor cut out circuit
21 wire circuit. A/C control module malfunction
or ECM malfunction
cuit.
3) Start engine and turn on A/C switch and heater blower fan switch.
Troubleshooting
Step Action Yes No

2 Check Wire Harness Poor E227-21 connection. YEL/BLK wire open or
1) Turn ignition switch to OFF position. If OK, substitute a known- short.
2) Remove ECM connector cover referring to good ECM and recheck. Poor A/C control mod-
Voltage Check in this section. ule connector connec-
3) Check ECM connectors from ECM. tion.
4) Check voltage between E227-21 and If all are in good condition,
ground at engine idling. substitute a known-good
Are they as follows? A/C control module and
A/C switch and heater blower switch OFF: recheck.
0V
A/C switch and heater blower switch ON:
about 12 V
DTC P1135 3rd Piston Deactivator (Injection Pump Solenoid Valve) Circuit
Malfunction
Wiring Diagram
E227 E228 E229
8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9 24 23 22 21 20 19 18 17 16 15 14 13 16 15 14 13 12 11 10 9
24 23 22 21 20 19 18 17 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 32 31 30 29 28 27 26 25
1. Double relay 3. Injection pump solenoid valve (3rd piston deactivator) 5. ENG fuse (15 A)

34 wire circuit. 3rd piston deactivator circuit
or Injection pump (solenoid valve) malfunction
cuit.

3) Run engine at idle speed.
Troubleshooting
Step Action Yes No

tion.
1) Disconnect injection pump solenoid valve short to power/ground or
connector with ignition switch turned OFF. fuse broken.
10 14 V
about 0 V
4 Check Injector Pump Solenoid Valve RED/GRN wire open Faulty injection pump
Check resistance between BLU/WHT wire ter- or shorted to power/ solenoid valve.
minal and RED/GRN wire terminal of valve. ground.
Is it between 25 30 ? Poor E228-34 connec-
tion.
DTC P1138 (P0230) Fuel Pressure Regulator Circuit Malfunction
NOTE:
In case that DTC P0230 is checked by using the generic scan tool, perform DTC P0191 (P0230) Fuel
Rail Pressure Sensor/Pressure Regulator Consistency Function, DTC P1112 (P0230) Fuel Rail Pres-
sure Monitoring Circuit Malfunction and DTC P1138 (P0230) Fuse Pressure regulator Circuit Mal-
function in this section before ECM replacement because DTC indication of generic scan tool is
different from the one of SUZUKI scan tool.
Wiring Diagram
E227 E228 E229
8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9 24 23 22 21 20 19 18 17 16 15 14 13 16 15 14 13 12 11 10 9
24 23 22 21 20 19 18 17 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 32 31 30 29 28 27 26 25
1. Double relay 2. ECM 3. Fuel pressure regulator

When ECM detects open or shorted to ground in E228- Fuse pressure regulator circuit
14 wire circuit. Fuse pressure regulator malfunction
or ECM malfunction
cuit.

3) Run engine at idle speed for 10 sec. and stop it. Then, turn ignition switch ON.
Troubleshooting
Step Action Yes No

2 Check Wire Harness Go to Step 3. YEL wire open or shot to
1) Disconnect connector at fuel pressure regu- ground.
lator.
2) Check voltage between YEL terminal of
regulator connector and ground with ignition
switch ON.
3 Check Fuel Pressure Regulator LT GRN/WHT wire Faulty fuel pressure regu-
Check resistance between YEL wire terminal open or shorted to lator.
and LT GRN/WHT wire terminal of valve. power/ground.
Is it between 2 and 3 ? Poor E228-14 connec-
tion.
DTC P1402 (P0510) Throttle Solenoid Valve Circuit Malfunction

Wiring Diagram
E227 E228 E229
8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9 24 23 22 21 20 19 18 17 16 15 14 13 16 15 14 13 12 11 10 9
24 23 22 21 20 19 18 17 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 32 31 30 29 28 27 26 25
1. Double relay 3. EGR throttle solenoid valve 5. ENG fuse (15 A)


32 wire circuit. EGR throttle solenoid valve circuit
or EGR throttle solenoid valve malfunction
cuit.

3) Turn off ignition switch and then on.
Troubleshooting
Step Action Yes No

tion.
1) Disconnect EGR throttle solenoid valve con- shorted to power/ground
nector with ignition switch turned OFF. or fuse broken.
10 14 V
about 0 V
4 Check EGR Throttle Solenoid Valve PPL/BLK wire open or Faulty EGR throttle sole-
1) Check solenoid valve referring to EGR shorted to power/ noid valve.
Throttle Solenoid Valve in Section 6E3. ground.
tion.
DTC P1511 Ignition Switch Circuit Malfunction

Wiring Diagram
1. Ignition switch 3. IG COIL fuse (20 A)

2. ECM 4. Main fuse

11 wire circuit. Ignition switch circuit
or ECM malfunction
cuit.

Troubleshooting
Step Action Yes No

2 Check Ignition Signal Poor E227-11 connection. BLK/WHT wire open,
1) Turn ignition switch to OFF position. If it is in good condition, shorted to power/ground
2) Remove ECM connector cover referring to substitute a known-good or fuse broken.
Voltage Check in this section. ECM and recheck.
ground.
Ignition switch OFF: 0 V
Is it within specified value?
DTC P1519 Radiator Fan Circuit Malfunction

Wiring Diagram
Refer to DTC P1108 Radiator Fun High Speed Circuit Malfunction in this section.
Troubleshooting
Proceed to DTC P1108 Radiator Fun High Speed Circuit Malfunction and P1109 Radiator Fan Low Speed
Circuit Malfunction in this section for TROUBLESHOOTING.
DTC P1606 MIL Circuit Malfunction

Wiring Diagram
E227 E228 E229
8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9 24 23 22 21 20 19 18 17 16 15 14 13 16 15 14 13 12 11 10 9
24 23 22 21 20 19 18 17 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 32 31 30 29 28 27 26 25
1. Malfunction indicator lamp (MIL) 4. METER fuse (10 A)

2. ECM 5. Combination meter
3. Ignition switch

30 wire circuit. MIL circuit
or Combination meter malfunction
cuit.

Troubleshooting
Step Action Yes No

1 Was Engine Diag. Flow Table performed? Go to Step 2. Go to Engine Diag.
Flow Table in this section.
2 MIL Circuit Check Go to Step 3. Go to Step 4.
1) Turn ignition switch to ON position.
Do other warning lamps come ON?
3 MIL Circuit Check Poor E227-30 connection. PPL/YEL wire open,
1) Turn ignition switch to OFF position. If it is in good condition, shorted to power/ground.
2) Remove ECM connector cover referring to substitute a known-good If it is in good condition,
Voltage Check in this section. ECM and recheck. replace combination
3) Check voltage between PPL/YEL wire ter- meter.
ground.
4 1) Turn ignition switch to OFF position. Open circuit in BLK/ Replace fuse and check
Is METER fuse in good condition? WHT wire to combination for short.
meter or poor connection.
DTC P1608 ECT Warning Lamp Circuit Malfunction

Wiring Diagram
E227 E228 E229
8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9 24 23 22 21 20 19 18 17 16 15 14 13 16 15 14 13 12 11 10 9
24 23 22 21 20 19 18 17 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 32 31 30 29 28 27 26 25
1. Engine coolant temperature warning lamp 4. METER fuse (10 A)

3. Ignition switch

When ECM detects open or short to ground in E227-12 Fuse broken
wire circuit. Engine coolant temperature warning lamp
or circuit
When ECM detects shorted to power in E227-12 wire cir- Combination meter malfunction

Troubleshooting
Step Action Yes No

2 Engine Coolant Warning Lamp Circuit Check Go to Step 3. Go to Step 4.
3 Engine Coolant Warning Lamp Circuit Check Poor E227-12 connection. RED/BLK wire open,
3) Check voltage between RED/BLK wire ter- meter.
ground.
DTC P1614 (P0560) Sensor Supply Function

Wiring Diagram
1. Throttle position sensor 4. Camshaft position sensor

2. Fuel rail pressure sensor 5. ECM
3. Intake air pressure sensor

Voltage is less than 4.8 V on E227-23, E228-23, E228- Sensor power supply circuit
5 and E228-17 of ECM or voltage is greater than 5.2 V Throttle position sensor malfunction
on E227-23, E228-23, E228-5 and E228-17 of ECM. Fuel rail pressure sensor malfunction
Intake air pressure sensor malfunction
Camshaft position (CMP) sensor malfunction
ECM malfunction

Troubleshooting
Step Action Yes No

2 Check TP Sensor Circuit Go to Step 3. LT GRN wire shorted to
1) Disconnect connector from TP sensor with other circuits.
ignition switch turned OFF. If wire are OK, substitute
2) Turn ON ignition switch. a known-good ECM and
3) Check voltage between LT GRN wire ter- recheck.
minal in TP sensor connector and vehicle
body ground.
Is voltage about 5.1 V to 4.88 V?
3 Check TP Sensor Circuit Go to Step 4. Faulty TP sensor.
1) Connect connector to TP sensor with igni-
tion switch turned OFF.
2) Remove ECM connector covers referring to
3) Connect ECM connectors from ECM.
4) Turn ON ignition switch.
5) Check voltage between E227-23 terminal in
ECM connector and vehicle body ground.
4 Check Fuel Rail Pressure Sensor Circuit Go to Step 5. LT GRN/BLK wire
1) Disconnect connector from fuel rail pres- shorted to other circuits.
sure sensor with ignition switch turned OFF. If wire are OK, substitute
3) Check voltage between LT GRN/BLK wire recheck.
terminal in fuel rail pressure sensor connec-
tor and vehicle body ground.
5 Check Fuel Rail Pressure Sensor Circuit Go to Step 6. Faulty fuel rail pressure
1) Connect connector to fuel rail pressure sen- sensor.
sor with ignition switch turned OFF.
ECM harness connector and vehicle body
ground.
6 Check Intake Air Pressure Sensor Circuit Go to Step 7. LT GRN wire shorted to
1) Disconnect connector from intake air pres- other circuits.
minal in intake air pressure sensor connec-
Step Action Yes No

7 Check Intake Air Pressure Sensor Circuit Go to Step 8. Faulty intake air pressure
1) Connect connector to intake air pressure sensor.
sensor with ignition switch turned OFF.
8 Check CMP Sensor Circuit Go to Step 9. BRN/YEL wire shorted
1) Disconnect connector from CMP sensor to other circuits.
with ignition switch turned OFF. If wire are OK, substitute
3) Check voltage between BRN/YEL wire ter- recheck.
minal in CMP sensor connector and vehicle
body ground.
9 Check CMP Sensor Circuit Faulty ECM, substitute a Faulty CMP sensor.
1) Connect connector to CMP sensor with igni- known-good ECM and
tion switch turned OFF. recheck.
DTC P0221 (P0220) Throttle Position Range/Performance Problem 2

Wiring Diagram
Refer to DTC P0121 (P0120) Throttle Position Range/Performance Problem.

Voltage is below 0.1 V on E227-19 wire terminal of ECM Throttle position sensor circuit
or voltage is greater than 4.7 V on E227-19 wire terminal Throttle position sensor malfunction
of ECM. ECM malfunction
or
Voltage on E227-15 wire terminal of ECM approximately
double the voltage on E227-19 wire terminal of ECM.
or
ECM or voltage is below 0.1 V on E227-23 wire terminal
of ECM.
or
ECM.

3) Run engine at idle speed for 10 sec. or more.
Troubleshooting
Step Action Yes No

ON.
below?
<Using Suzuki mode of SUZUKI Scan tool>
P1614
SUZUKI Scan tool>
P0560
3 Check Wire Harness Go to Step 4. LT GRN wire open,
each terminal. If wire and connection are
4 Check TP Sensor Output Voltage Substitute a known-good GRY/BLU wire open,
1) Turn ignition switch to OFF position. ECM and recheck. GRY/BLU, wire shorted
2) Remove ECM connector cover referring to to ground/power or poor
Voltage Check in this section. TP sensor connector.
3) Connect ECM connector from ECM. If wire and connection are
4) With ignition switch ON, check voltage OK, substitute a known-
between E227-19 and ground, when accel- good TP sensor and
erator pedal is at idle position to fully recheck.
depressed position.
DTC P0335 (P0335) Crankshaft Position Sensor Circuit Malfunction
NOTE:
Crankshaft Position Sensor Circuit Malfunction and DTC P0340 (P0335/P0340) Camshaft Position
Sensor Circuit Malfunction in this section before ECM replacement because DTC indication of
generic scan tool is different from the one of SUZUKI scan tool.
Wiring Diagram
1. Crankshaft position sensor (Engine speed sensor)

2. ECM

When ECM (E228-4 wire terminal) judged engine speed Crankshaft position sensor circuit
5400 rpm by the signal of crankshaft position sensor. Crankshaft position sensor rotor malfunction
Crankshaft position sensor malfunction
ECM malfunction

engine at idle speed for 10 sec.
Troubleshooting
Step Action Yes No

2 CKP Sensor and Its Circuit Resistance Check: Go to Step 4. Go to Step 3.
3) Check for proper connection to ECM at
E228-3 and E228-4 terminals.
4) If OK, check resistance of the followings.
Resistance between E228-3 and E228-4
terminals:
315 405 at 20C, 68F
Resistance between each terminal and
ground:
1M or more
3 CKP Sensor Resistance Check: Faulty ORN/BLK wire or Faulty CKP sensor.
1) With ignition switch OFF, disconnect CKP BLU wire.
sensor coupler and remove CKP sensor.
2) Check resistance between terminals of CKP
sensor. (See Fig.)
Were measured resistance values as specified
in Step 2?
4 CKP Sensor Visual Inspection: Intermittent trouble or Replace or reinstall.
1) Check visually CKP sensor and sensing faulty ECM.
rotor for the followings. (See Fig.) Recheck for intermittent
Damage referring to Intermittent
No foreign material attached and Poor Connection in
Correct installation Section 0A.
[A]: Fig. for Step 3

[B]: Fig. for Step 4
DTC P0340 (P0335/P0340) Camshaft Position Sensor Circuit Malfunction
NOTE:
In case that DTC P0340 is detected by using the generic scan tool, perform DTC P0340 (P0335/
P0340) Camshaft Position Sensor Circuit Malfunction and DTC P0335 (P0335) Crankshaft Position
Sensor Circuit Malfunction in this section before ECM replacement because DTC indication of
generic scan tool is different from the one of SUZUKI scan tool.
Wiring Diagram
1. Camshaft position sensor

2. ECM

No camshaft position sensor signal on E228-18 wire ter- Camshaft position sensor circuit
minal of ECM. Camshaft position sensor maladjusted
or Camshaft position sensor malfunction
Voltage is less than 4.8 V on E228-17 wire terminal of Camshaft hub malfunction
ECM or voltage is greater than 5.1 V on E228-17 wire ter- ECM malfunction
minal of ECM.
or
When ECM (E228-4 wire terminal) judged engine speed
5400 rpm by the signal of crankshaft position sensor.

3) Crank engine for 3 seconds or more and keep it at idle for 1 min. if engine start.
Troubleshooting
Step Action Yes No

ON.
below?
P1614
SUZUKI Scan tool>
P0560
3 Is engine cranked? Go to Step 4. Go to Diagnosis in Sec-
tion 6G.
4 Is engine started? Go to Step 5. Check CKP sensor
(Engine speed sensor)
and its circuit according to
DTC P0335 (P0335)
Crankshaft Position Sen-
sor Circuit Malfunction in
this section.
5 Check CMP Sensor and connector for proper Go to Step 6. Correct.
installation.
Is CMP sensor installed properly and connector
connected securely?
6 Check Wire Harness and Connection. Go to Step 7. ORN/BLU or GRY/
1) Disconnect connector from CMP sensor. RED wire open, short or
2) Check for proper connection to CMP sensor poor connection.
at each terminal.
3) If OK, turn ignition switch ON and check for
voltage between ORN/BLU and GRY/
RED terminals of sensor connector discon-
nected.
Is voltage 10 14 V?
7 Check for voltage between BRN/YEL and Go to Step 8. BRN/YEL wire open,
GRY/RED terminals of sensor connector dis- short or poor connection.
connected. If wire and connection are
Is voltage about 5 V? OK, substitute a known-
8 Check Camshaft Hub Check CMP sensor air Clean surfaces of cam-
1) Remove upper timing belt cover. gap referring to Camshaft shaft hub or replace cam-
2) Check camshaft hub for the following. Position Sensor (CMP shaft hub.
Damage Sensor) in Section 6E3.
No foreign material attached If check result is OK, sub-
Is it in good condition? stitute a known-good
CMP sensor and recheck.
[A]: Fig. for Step 6 and 7

DTC P0500 (P0500) Vehicle Speed Sensor Circuit Malfunction

Wiring Diagram
1. Vehicle speed sensor 4. IG COIL fuse (20 A) 7. BCM

2. ECM 5. Main fuse
3. Ignition switch 6. Combination meter

When ECM (E228-15 wire terminal) judged vehicle Vehicle speed sensor circuit
speed 240 km/h (149 mile/h) by the signal of vehicle speed Vehicle speed sensor drive and/or driven
sensor. gears malfunction
or Vehicle speed sensor malfunction
Engine speed is greater than 2500 rpm and air flow greater Combination meter malfunction
than 40 mm3/stroke, when ECM (E228-15 wire terminal) BCM malfunction
judged vehicle speed below 15 km/h (9 mile/h). ECM malfunction
WARNING:
When performing a road test, select a place where there is no traffic or possibility of a traffic acci-
dent and be very careful during testing to avoid occurrence of an accident.
Road test should be carried out with 2 persons, a driver and a tester, on a level road.

2) Turn ON ignition switch and clear DTC, pending DTC and freeze frame data by using scan tool and warm up
engine completely.
3) Increase vehicle speed to 100 110 km/h (60 70 mph).
4) Release accelerator pedal and with engine brake applied, keep vehicle coasting and then stop vehicle.
Troubleshooting
Step Action Yes No

2 Does speedometer indicate vehicle speed? Faulty BLU/YEL wire or Go to Step 3.
poor E228-15 connection.
OK, intermittent trouble or
faulty ECM.
Check for intermittent
referring to Intermittent
and Poor Connection in
Section 0A.
3 VSS Power Supply Voltage Check: Go to Step 4. BLK/WHT or BLK wire
1) With ignition switch OFF, remove VSS cou- open/short.
pler.
2) With ignition switch ON leaving engine OFF,
check voltage between BLK/WHT wire ter-
minal and BLK wire terminal of VSS cou-
pler.
Is voltage 10 14 V?
4 VSS Signal Harness Check: Go to Step 5. Go to Step 6.
check voltage between BLU/YEL wire ter-
pler.
Is voltage 4 V or more?
5 VSS Visual Inspection: Poor VSS connection or Replace VSS.
1) Remove VSS referring to Speed Sensor in VSS malfunction.
Section 7D. If connection is OK, sub-
2) Check VSS drive and driven gears for dam- stitute a known-good VSS
age and excessive wear. and recheck.
6 Speedometer Circuit Check: Substitute a known-good Go to Step 7.
1) With ignition switch OFF, disconnect G11 combination meter and
recheck.
coupler from combination meter.
pler.
7 BCM Circuit Check Substitute a known-good BLU/YEL wire open/
1) With ignition switch OFF, disconnect G55 BCM and recheck. short or faulty ECM.
coupler from BCM. If wire and connection are
2) With ignition switch ON leaving engine OFF, OK, substitute a known-
check voltage between BLU/YEL wire ter- good ECM and recheck.
pler.
DTC P0235 (P0235) Intake Air Pressure Sensor Circuit Malfunction

Wiring Diagram
1. Intake air pressure sensor

2. ECM

Voltage is greater than 5.2 V on E228-23 wire terminal of Intake air pressure sensor circuit
ECM or voltage is less than 4.8 V on E228-23 wire termi- Intake air pressure sensor malfunction
nal of ECM. ECM malfunction
or
Voltage is greater than 5 V on E228-45 wire terminal of
ECM or voltage is less than 1 V on E228-45 wire terminal
of ECM.
or
When ECM (E228-45 wire terminal) judged intake air
pressure greater than 200 mbars by the signal of crank-
shaft position sensor with engine speed less than 850 rpm.
WARNING:
NOTE:
cedure.

3) Run engine at idle speed for 10 sec or more.
Troubleshooting
Step Action Yes No

ON.
below?
P1614
SUZUKI Scan tool>
P0560
3 Intake Air Pressure Sensor Signal Check: Intermittent trouble or Go to Step 4.
1) Turn ignition switch to OFF position. faulty ECM.
2) Remove ECM connector cover referring to Check for intermittent
Voltage Check in this section. referring to Intermittent
3) Connect ECM connectors from ECM. and Poor Connection in
4) Check voltage E228-45 and ground with Section 0A.
ignition switch ON.
Is it between 1 and 5 V?
4 Intake Air Pressure Sensor Check: LT GRN, BRN/RED or Replace intake air pres-
1) Disconnect connector from intake air pres- GRN/ORN circuit open/ sure sensor.
sure sensor. short.
2) Check for proper connection to intake air If wire and connections
pressure sensor at each terminal. are OK, substitute a
3) If OK, check intake air pressure sensor for known-good ECM and
performance referring to Intake Air Pres- recheck.
sure Sensor (Manifold Absolute Pressure
Sensor) in Section 6E3.
DTC P0560 (P0560) Power Supply Circuit Malfunction
NOTE:
Power Supply Circuit Malfunction, DTC P0561 (P0560) Stabilization of Sensor Supply and DTC
P1614 (P0560) Sensor Supply Function in this section before ECM replacement because DTC indica-
tion of generic scan tool is different from the one of SUZUKI scan tool.
Wiring Diagram
1. Double relay 3. Fuel pump 5. Main fuse


Voltage is below 7 V on E227-11, E228-1 and E228-2 Power supply circuit
wire terminals of ECM or voltage is greater than 17.5 V on ECM malfunction
E227-11, E228-1 and E228-2 wire terminals of ECM.

2) Turn ON ignition switch and clear DTC/pending DTC and freeze frame data by using scan tool and run
engine at idle speed for 1 min.
Troubleshooting
Step Action Yes No

2 1) Turn ignition switch to OFF position. Intermittent trouble. BLK/WHT, BLU/BLK or
2) Remove ECM connector cover referring to Check for intermittent WHT/GRN circuit open
Voltage Check in this section. referring to Intermittent or short.
3) Connect ECM connectors to ECM. and Poor Connection in
4) While engine running, check voltage Section 0A.
between following terminals. If wire and connections
E227-11 and ground are OK, substitute a
E228-1 and ground known-good ECM and
E228-2 and ground recheck.
Is each voltage between 7 and 17.5 V?
DTC P1613 ECM Not Registered

This DTC will be set when not registered of fuel injector class and transmission type are detected in ECM.
Troubleshooting
Step Action Yes No

1 1) Register ECM according to the registration Substitute a known-good End.
procedure, referring to ECM Registration ECM and recheck.
in Section 6E3.
2) Check DTC after performing ECM registra-
tion.
Is DTC P1613 still indicated?
DTC P1517 Immobilizer System Malfunction

Wiring Diagram
1
2
E227-10 PNK G09-1
G09-6
E227 E228 E229
8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9 24 23 22 21 20 19 18 17 16 15 14 13 16 15 14 13 12 11 10 9
24 23 22 21 20 19 18 17 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 32 31 30 29 28 27 26 25
1. ECM 2. Immobilizer control module
Detecting Condition and Trouble Area

This DTC will be set when temporary fault of internal mem- PNK wire circuit
ory (status memory) for communication to immobilizer con- Immobilizer control system malfunction
trol module detected in the ECM. ECM malfunction
No signal or incorrect code inputted from immobilizer con-
trol module to ECM.

2) Turn ON ignition switch and clear DTC by using scan tool.
3) Start engine.
4) Check DTC by using scan tool.
Troubleshooting
Step Action Yes No

2 Does engine start? Temporary fault of internal Go to Step 3.
memory (status memory)
for communication to
immobilizer control mod-
ule. However, it is no
adverse affect for commu-
nication. Therefore, it
does not affect engine
and emission control sys-
tem.
3 Check Wire Harness and Connection Go to Step 4. PNK wire is open circuit.
E227-10 terminal.
4) Disconnect immobilizer control module con-
nector.
5) Check for proper connection to immobilizer
control module at G09-1 and G09-6 termi-
nals.
6) If each terminal connection is OK, measure
resistance between G09-1 terminal of
immobilizer control module and E227-10
terminal of ECM connector, between G09-6
terminal of immobilizer control module and
E227-10 terminal of ECM connector.
Is each resistance 1 or less?
4 Check Wire Harness Go to Step 5. PNK wire is shorted to
1) Measure resistance between E227-10 ter- ground.
minal of ECM connector and vehicle body
ground.
Is resistance infinity?
1) Turn ignition switch to ON position. power circuit.
2) Measure voltage between E227-10 terminal
of ECM connector and vehicle body ground.
Is voltage 0 V?
6 Check Immobilizer Control System Substitute a known-good Faulty immobilizer control
1) Check immobilizer control system referring ECM and recheck. system.
to Immobilizer Control System Diagnostic
Flow Table in Section 8G.
TABLE B-1 Fuel Pump Circuit Inspection

Wiring Diagram

2. ECM 4. Fuel Pump fuse (15 A) 6. To radiator fan relay No.3
Inspection
Step Action Yes No

1 Fuel Pump Operation Check: Fuel pump circuit is in Go to Step 2.
1) Turn ON ignition switch. good condition.
Is fuel pump operation sound heard for 5 sec.
after ignition switch ON?
2 Fuel Pump Circuit Check: Go to Step 3. BLK, PNK/BLK or
1) With ignition switch OFF, remove double BRN/RED circuit open
relay from connector. or fuel pump malfunction.
2) Check for proper connection to relay at each
terminal.
3) If OK, using service wire, connect terminals
8 and 5 of relay connector. (See CAUTION.)
Is fuel pump heard to operate at ignition switch
ON?
3 Double Relay Check: GRN/ORN circuit open. Replace double relay.
CAUTION:
Check to make sure that connection is made between correct terminals. Wrong connection can cause
damage to ECM, wire harness etc.
TABLE B-2 Fuel Pressure Inspection

System Diagram
(A): Gauge 1. Fuel tank 4. Fuel temperature sensor

(B): Hose 2. Fuel pump 5. Fuel heater
(C): Attachment 3. Fuel filter
Inspection
NOTE:
Before using the following flow table, check to make sure that battery voltage is higher than 11 V. If
battery voltage is low, pressure becomes lower than specification even if fuel pump and line are in
good condition.
Step Action Yes No

1 1) Install fuel pressure gauge and check fuel Normal fuel pressure. Go to Step 2.
pressure, referring to Low Pressure Fuel
Supply System in Section 6E3.
Is fuel pressure within specified value?
2 Was fuel pressure higher than spec. in Step 1? Clogged fuel heater, fuel Go to Step 3.
filter, fuel temperature or
fuel hose/pipe.
3 Was no fuel pressure applied in Step 1? Shortage of fuel Fuel leakage from fuel
Fuel pump and its cir- line.
cuit defective.
(Refer to Table B-1
Fuel Pump Circuit
Inspection in this sec-
tion.)
6-1-108 ENGINE GENERAL INFORMATION AND DIAGNOSIS (RHW ENGINE) (EOBD SPEC)
EOBD SPEC
General Information
1
For EOBD spec, the wire harness type power supply line (1) for
glow plugs is used.
As for the other than EOBD spec, the metal plate type is used as
power supply line to glow plugs.
Statement of Cleanliness and Care

An automobile engine is a combination of many machined,
honed, polished and lapped surfaces with tolerances that are
measured in the thousands of an millimeter (ten thousands of
inch). Accordingly, when any internal engine parts are serviced,
care and cleanliness are important. Throughout this section, it
should be understood that proper cleaning and protection of
machined surfaces and friction areas is part of the repair proce-
1
dure. This is considered standard shop practice even if not specif-
2
3 ically stated.
4 A liberal coating of engine oil should be applied to friction
areas during assembly to protect and lubricate the surface
on initial operation.
Whenever valve train components, pistons, piston rings, con-
necting rods, rod bearings and crankshaft journal bearings
are removed for service, they should be retained in order. At
the time of installation, they should be installed in the same
locations and with the same mating surfaces as when
removed.
Battery cables should be disconnected before any major
work is performed on the engine. Failure to disconnect
cables may result in damage to wire harness or other electri-
cal parts.
Throughout this manual, the four cylinders of the engine are
identified by numbers: No.1 (1), No.2 (2), No.3 (3) and No.4
(4) as counted from flywheel side to crankshaft pulley side.
ENGINE GENERAL INFORMATION AND DIAGNOSIS (RHW ENGINE) (EOBD SPEC) 6-1-109
General Information on Engine Service

The following information on engine service should be noted
carefully, as it is important in preventing damage, and in contribut-
ing to reliable engine performance.
When raising or supporting engine for any reason, do not
use a jack under oil pan. Due to small clearance between oil
pan and oil pump strainer, jacking against oil pan may cause
it to be bent against strainer resulting in damaged oil pick-up
unit.
It should be kept in mind, while working on engine, that 12-
volt electrical system is capable of violent and damaging
short circuits. When performing any work where electrical
terminals could possibly be grounded, ground cable of the
battery should be disconnected at battery.
Any time the air cleaner, air cleaner outlet hose, turbo-
charger, intercooler, intercooler outlet hose, throttle valve
assembly or intake manifold is removed, the intake opening
should be covered. This will protect against accidental
entrance of foreign material which could follow intake pas-
sage into cylinder and cause extensive damage when
engine is started.
Precaution on fuel system service

Work must be done with no smoking, in a well-ventilated
area and away from any open flames.
A small amount of fuel may be released after fuel line is dis-
connected.
In order to reduce the chance of personal injury, cover fitting
to be disconnected with a shop cloth. Put that cloth in an
approved container when disconnection is completed.
Never run engine with double relay disconnected when
engine and exhaust system are hot.
Fuel or fuel vapor hose connection varies with each type of
pipe. When reconnecting fuel or fuel vapor hose, be sure to
connect and clamp each hose correctly referring to the fig-
ure.
After connecting, make sure that it has no twist or kink.
[A]: With short pipe, fit hose as far as it reaches pipe joint as shown.
[B]: With following type pipe, fit hose as far as its peripheral projection as shown.
[C]: With bent pipe, fit hose as its bent part as shown or till pipe is about 20 to 30 mm
(0.79 1.18 in.) into the hose.
[D]: With straight pipe, fit hose till pipe is, about 20 to 30 mm (0.79 1.18 in.) into the hose.
1. Hose
2. Pipe
3. Clamp
4. Clamp securely at a position 3 to 7 mm (0.12 0.27 in.) from hose end.
5. 20 to 30 mm (0.79 1.18 in.)
When installing fuel filter union bolt or plug bolt, always use
new gasket and tighten it to specified torque.
When installing injector, fuel feed pipe or fuel pressure regu-
lator, lubricate its O-ring with spindle oil or fuel.
When connecting fuel pipe flare nut, first tighten flare nut by
hand and then tighten it to specified torque, using back-up
wrench.
Fuel pressure relief procedure

Refer to Precautions under Fuel Delivery System in Section
6E3.
Fuel leakage check procedure

After performing any service on fuel system, check to make sure
that there are no fuel leakages as follows.
1) Turn ON ignition switch for 5 seconds (to operate fuel pump)
and then turn it OFF. Repeat this (ON and OFF) 3 or 4 times
ON and apply fuel pressure to fuel line (till fuel pressure is felt by
C
AC
hand placed on fuel return hose).
2) In this state, check to see that there are no fuel leakages
from any part of low pressure fuel system between fuel
pump and injection pump.
3) Check that there are no fuel leakages from any part of high
pressure fuel system between injection pump and fuel injec-
tor by performing the procedure below.
a) Start engine and warm up to normal operating temperature.
b) Check fuel leakage after turning off ignition switch.
c) Again, start engine and accelerate the vehicle up to 3500
rpm with L range (AT) or 1st gear (MT). Then stop vehicle.
d) Check fuel leakage after turning off ignition switch.
Engine Diagnosis
General Description
This vehicle is equipped with an engine and emission control system which are under control of ECM. The
engine and emission control system in this vehicle are controlled by ECM. ECM has an On-Board Diagnostic
system which detects a malfunction in this system and abnormality of those parts that influence the engine
exhaust emission. When diagnosing engine troubles, be sure to have full understanding of the outline of On-
Board Diagnostic System and each item in Precaution in Diagnosing Trouble and execute diagnosis accord-
ing to Engine Diagnostic Flow Table in this section.
There is a close relationship between the engine mechanical, engine cooling 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 malfunction indicator lamp (MIL) doesnt turn ON, it should be diagnosed according to this flow table.

ECM in this vehicle has the following functions.
When the ignition switch is turned ON with the engine at a
stop, MIL (1) turns ON to check the malfunction indicator
lamp (MIL) and its circuit.
When ECM detects a malfunction which gives an adverse
effect to vehicle emission while the engine is running, it
makes the malfunction indicator lamp in the meter cluster of
the instrument panel turn ON and stores the malfunction
1
area in its memory.
As a condition for detecting a malfunction in some areas in
the system being monitored by ECM and turning ON the
malfunction indicator lamp due to that malfunction, 2 driving
cycles detection logic is adopted to prevent erroneous detec-
tion.
When a malfunction is detected, engine and driving condi-
tions then are stored in ECM memory as freeze frame data.
(For the details, refer to description on Freeze frame data.)
2
It is possible to communicate by using not only SUZUKI scan
tool (2) but also generic scan tool. (Diagnostic information
can be accessed by using a scan tool.)
Warm-up Cycle
A warm-up cycle means sufficient vehicle operation such that
the coolant temperature has risen by at least 22C (40F) from
engine starting and reaches a minimum temperature of 70C
(160F).
Driving Cycle
A driving cycle consists of two parts, engine startup and engine
shutoff.
2 Driving Cycle Detection Logic
The malfunction detected in the first driving cycle is stored in
ECM memory (in the form of pending DTC) but the malfunction
indicator lamp does not light at this time. It lights up at the second
detection of same malfunction also in the next driving cycle.
Pending Diagnostic Trouble Code (DTC)
NOTE:
Pending diagnostic trouble code can be read using
generic scan tool or GST (Generic Scan Tool) mode of
SUZUKI scan tool.
Pending DTC means a DTC detected and stored temporarily at 1
driving cycle of the DTC which is detected in the 2 driving cycle
detection logic.
Freeze Frame Data
NOTE:
Freeze frame data can be read using generic scan tool or
GST (Generic Scan Tool) mode of SUZUKI scan tool.
ECM stores the engine and driving conditions (in the form of data
as shown in the figure) at the moment of the detection of a mal-
function in its memory. This data is called Freeze frame data.
Therefore, it is possible to know engine and driving conditions
(e.g., whether the engine was warm or not, where the vehicle was
running or stopped) when a malfunction was detected by check-
ing the freeze frame data.
[A]: An example of freeze frame data
[A]
Priority of Freeze Frame Data:

As ECM can store freeze frame data for one malfunction only, the
freeze frame data shown as 1 below has a priority for storage. (If
malfunction as described in the upper square 1 below is
detected while the freeze frame data in the lower square 2 has
been stored, the freeze frame data 2 will be updated by the
freeze frame data 1.)
PRIORITY FREEZE FRAME DATA
1 Freeze frame data at initial detection of diagnostic
trouble codes below.
P1166, P1113, P0088, P0094, P0087, P0089,
P0091, P0092, P0090, P0192, P0193, P0194,
P0261, P0262, P0201, P1372, P0264, P0265,
P0202, P1373, P0267, P0268, P0203, P1374,
P0204
2 Freeze frame data when a diagnostic trouble code
other than those in 1 above is detected.
Freeze Frame Data Clearance:

The freeze frame data is cleared at the same time as clearance of
diagnostic trouble code (DTC).
Data Link Connector (DLC)
DLC (1) in compliance with SAE J1962 in its installation position,

the shape of connector and pin assignment.
K (4) and L (3) lines of ISO 9141 is used for SUZUKI scan tool or
generic scan tool to communication with ECM, ABS control mod-
ule, BCM, HVAC control module and TCM.
SUZUKI serial data line (7) is used for SUZUKI scan tool to com-
municate with immobilizer control module.
2. B+
5. ECM ground
6. Body ground
1

Dont disconnect couplers from ECM, battery cable from battery, ECM ground wire harness from engine or
main fuse before confirming diagnostic information (DTC, freeze frame data, etc.) stored in ECM memory.
Diagnostic information stored in ECM memory can be cleared as well as checked by using SUZUKI scan
tool or generic scan tool. Before using scan tool, read its Operators (Instruction) Manual carefully to have
good understanding as to what functions are available and how to use it.
Priorities for diagnosing troubles
If troubleshooting priorities for multiple diagnostic code are given in the applicable diagnostic flow, these
should be followed.
If no instructions are given, troubleshoot diagnostic trouble codes according to the following priorities.
1. Fuel pressure (P0089 for Suzuki mode of SUZUKI scan tool/P0087, P0088, P0089, P0094, P1113,
P1166 for generic scan tool)
2. Diagnostic trouble codes other than listed below
DTC indicated by generic scan tool or GST mode of DTC indicated by Suzuki mode of SUZUKI scan tool
SUZUKI scan tool
P1166, P1113, P0088, P0094, P0087, P0089, P0089, P0090, P0190, P201, P202, P203, P0204
P0091, P0092, P0090, P0192, P0193, P0194,
P0261, P0262, P0201, P1372, P0264, P0265,
P0202, P1373, P0267, P0268, P0203, P1374,
P0204
3. Diagnostic trouble codes described in above list

Be sure to read Precautions for Electrical Circuit Service in Section 0A before inspection and observe what
is written there.
ECM replacement or substitution
When substituting a known-good ECM, check for the following conditions. Neglecting this check may cause
damage to known-good ECM.
Resistance value of all relays, actuators is as specified respectively.
MAF sensor is in good condition and none of power circuit of its sensor is shorted to ground.
ECU code registration
If ECM is replaced, register ECU code into ECM by performing procedure described in Procedure after
ECM Replacement of Section 8G. Otherwise, ECM dose not function as Immobilizer Control System.
Injector code registration
If ECM or injector is replaced, register injector code into ECM by performing procedure described in ECM
Registration of Section 6E3.
Otherwise, it has an adverse effect on engine.
E227 C51-1
E228 C51-2
E229 C51-3
G55 G54
G09 G87
Engine Diagnostic Flow Table

Numbers of each step correspond to the numbers of the items after this table.
Refer to Diagnostic Step Details following this table for the details of each step.
Step Action Yes No

1 Customer Complaint Analysis Go to Step 2. Perform customer
1) Perform customer complaint analysis. complaint analysis.
Was customer complaint analysis performed?
2 Diagnostic Trouble Code (DTC) and Freeze 1) Print DTC and freeze Go to Step 5.
Frame Data Check, Record and Clearance frame data or write
1) Check for DTC referring to Diagnostic Step then down and clear
Details. by referring to DTC
Is there any DTC(s)? Clearance in this sec-
tion.
2) Go to Step 3.
3 ECM Registration Data Check Go to Step 4. Register ECM according
1) Check injector class and transmission type to the registration proce-
of ECM registration data referring to ECM dure, referring to ECM
Registration in this section. Registration in Section
Are registered data in good condition? 6E3.
4 Visual Inspection 1) Repair or replace mal- Go to Step 6.
1) Perform Visual inspection referring to the function part.
Visual Inspection in this section. 2) Go to Step 12.
1) Perform visual inspection referring to the
Visual Inspection in this section.
1) Confirm trouble symptom referring to the
Trouble Symptom Confirmation in this sec-
tion.
7 Rechecking and Record of DTC/Freeze Frame Go to Step 10. Go to Step 9.
Data
8 Rechecking and Record of DTC/Freeze Frame Go to Step 11.
Data
Is there any malfunction DTC(s)?
Step Action Yes No

9 Engine Basic Inspection and Engine Diagnosis Go to Step 12. 1) Check and repair mal-
Table function part(s).
1) Check and repair according to Engine 2) Go to Step 12.
Basic Check and Engine Diagnosis Table
in this section.
DTC diag. flow table in this section.
11 Check for Intermittent Problems 1) Repair or replace mal- Go to Step 12.
1) Check for intermittent problems referring to function part(s).
the Diagnostic Step Details. 2) Go to Step 12.
2) Perform final confirmation test referring to
the Diagnostic Step Details.
Is there any problem symptom, DTC or
abnormal condition?
Diagnostic step details

1. CUSTOMER COMPLAINT ANALYSIS
Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this
purpose, use of such an inspection form will facilitate collecting information to the point required for proper anal-
ysis and diagnosis.
2. DIAGNOSTIC TROUBLE CODE (DTC)/FREEZE FRAME DATA CHECK, RECORD AND CLEARANCE
First, check DTC (including pending DTC), referring to DTC check in this section. If DTC is indicated, print it
and freeze frame data or write them down and then clear them by referring to DTC clearance in this section.
DTC indicates malfunction that occurred in the system but does not indicate whether it exists now or it occurred
in the past and the normal condition has been restored now. To check which case applies, check the symptom in
question according to Step 6 and recheck DTC according to Step 7 and 8.
Attempt to diagnose a trouble based on DTC in this step only or failure to clear the DTC (including pending DTC)
in this step will lead to incorrect diagnosis, trouble diagnosis of a normal circuit or difficulty in troubleshooting.
3. ECM REGISTRATION DATA CHECK

Refer to ECM Registration Data Check in Section 6E3 for checking procedure.
4 and 5. VISUAL INSPECTION
As a preliminary step, be sure to perform visual check of the items that support proper function of the engine
referring to Visual Inspection in this section.
6. TROUBLE SYMPTOM CONFIRMATION
Based on information obtained in Step 1 Customer complaint analysis and Step 2 DTC/freeze frame data check,
confirm trouble symptoms. Also, reconfirm DTC according to DTC Confirmation Procedure described in each
DTC flow.
7 and 8. DTC/FREEZE FRAME DATA RECHECK, RECORD AND CLEARANCE
Refer to DTC CHECK in this section for checking procedure.
9. ENGINE BASIC CHECK AND ENGINE DIAGNOSIS TABLE

Perform basic engine check according to the Engine Basic Check in this section first. When the end of the flow
table has been reached, check the parts of the system suspected as a possible cause referring to Engine Diag-
nosis Table in this section and based on symptoms appearing on the vehicle (symptoms obtained through
steps of customer complaint analysis, trouble symptom confirmation and/or basic engine check) and repair or
replace faulty parts, if any.
10. TROUBLESHOOTING FOR DTC (See each DTC Diag. Flow Table)
Based on the DTC indicated in Step 7 or 8 and referring to the applicable DTC diag. flow table in this section,
locate the cause of the trouble, namely in a sensor, switch, wire harness, connector, actuator, ECM or other part
NOTE:
If DTC P0089 (for Suzuki mode of SUZUKI scan tool) or P0087, P0088, P0089, P0094, P1113, P1166 (for
generic scan tool or GST mode of SUZUKI scan tool) together with other DTC are indicated in this
step, proceed to Diag. flow table for DTC P0089 (P0087, P0088, P0089, P0094, P1113, P1166) first.
11. CHECK FOR INTERMITTENT PROBLEM

12. FINAL CONFIRMATION TEST
Confirm that the problem symptom has gone and the engine is free from any abnormal conditions. If what has
been repaired is related to the DTC, clear the DTC once and perform DTC confirmation procedure and confirm
that no DTC is indicated.
NOTE:
The above form is standard sample. It should be modified according to conditions characteristic of
each market.
Malfunction Indicator Lamp (MIL) Check

1) Turn ON ignition switch (but the engine at stop) and check
that MIL lights.
If MIL does not light up or dims, go to Diagnostic Flow Table
A-1 for troubleshooting.
2) Start engine and check that MIL turns OFF.
If MIL remains ON, and no DTC is stored in ECM, go to
Diagnostic Flow Table A-2 for troubleshooting.

1) Prepare generic scan tool or SUZUKI scan tool.
2) Connect it to data link connector (DLC) (1) located on under-
side of instrument panel at drivers seat side.
1 Special tool
(A)
3) Turn ignition switch ON and confirm that MIL lights.
4) Read DTC, pending DTC and freeze frame data according to
instructions displayed on scan tool and print them or write
them down. Refer to scan tool operators manual for further
details.
If communication between scan tool and ECM is not possi-
ble, check if scan tool is communicable by connecting it to
ECM in another car. If communication is possible in this
case, scan tool is in good condition. Then check data link
connector and serial data line (circuit) in the car with which
communication was not possible.
5) After completing the check, turn ignition switch off and dis-
connect scan tool from data link connector.
Diagnostic Trouble Code (DTC) Clearance

1) Connect generic scan tool or SUZUKI scan tool to data link
connector in the same manner as when making this connec-
tion for DTC check.
2) Turn ignition switch OFF and then ON (but engine at stop).
3) Erase DTC and pending DTC according to instructions dis-
played on scan tool. Refer to scan tool operators manual for
further details.
NOTE:
When DTC clear command is executed using Suzuki
mode of SUZUKI scan tool with engine run, DTC can not
be cleared from ECM memory.
4) After completing the clearance, turn ignition switch OFF and
disconnect scan tool from data link connector.
Fail-Safe Table
When any of the following DTCs is detected, ECM enters fail-safe mode as long as malfunction continues to
exist but that mode is canceled when ECM detects normal condition after that.
P0190 Fuel pressure sensor Each control is performed based on 150 MPa (1500 bar) fuel pres-
(P0192) sure and engine speed is restricted to lower than specified value.
(P0193)
(P0194)
P0220 Throttle position sensor Each control is performed based on specified accelerator pedal
(P0222) opening and engine speed is restricted to lower than specified value.
(P0223)
(P0224)
P0225
(P0224)
(P0227)
(P0228)
(P2137)
P0115 Engine coolant tempera- Each control is performed based on 111C with engine run.
(P0115) ture sensor
(P0117)
(P0118)
P0180 Fuel temperature sensor Each control is performed based on 90C.
(P0182)
(P0183)
P0110 Intake air temperature Each control is performed based on 50C.
(P0112) sensor (in mass air flow)
(P0113)
P0235 Intake air pressure sensor Each control is performed based on the value measured by baro-
(P0069) metric pressure sensor (in ECM). If barometric pressure sensor fails,
(P0235) 900 mbar is used as intake air pressure and engine speed is
(P0237) restricted to lower than specified value.
(P0238)
(P1281)
P0105 Barometric pressure sen- Each control is performed based on the value measured by intake
(P0107) sor (in ECM) air pressure sensor. If intake air pressure sensor is failed, 900 mbar
(P0108) is used as barometric pressure.
P0100 Mass air flow sensor Each control uses the value calculated by barometric pressure and
(P0102) engine speed.
(P0103)
(P3007)
(P3008)
P0500 Vehicle speed sensor Each control is performed based on 80 km/h.
(P0500)
(P0501)

P0089 Fuel pressure sensor/ Engine speed is restricted to lower than specified value or engine
(P0087) pressure regulator stops.
(P0088)
(P0089)
(P0094)
(P1113)
(P1166)
P0401 EGR valve/solenoid Engine speed is restricted to lower than specified value.
(P0401)
P2141
(P2141)
P2144
(P2144)
P0561 Sensor supply voltage Engine speed is restricted to lower than specified value.
(P0642)
(P0643)
P0234 Turbo pressure solenoid Engine speed is restricted to lower than specified value.
(P0234) valve
P0245
(P0245)
P0090 Fuel pressure regulator Engine speed is restricted to lower than specified value.
(P0090)
(P0091)
(P0092)
P0201 Fuel injector No.1 Engine speed is restricted to lower than specified value or engine
(P0201) stops.
(P0261)
(P0262)
(P1372)
(P0202) stops.
(P0264)
(P0265)
(P1373)
(P0203) stops.
(P0267)
(P0268)
(P1374)
(P0204) stops.
(P0267)
(P0268)
(P1374)
P1613 ECM Engine speed is restricted to lower than specified value.
P0335 CKP sensor Engine stops and does not start.
P0604 ECM internal memory Engine speed is restricted to lower than specified value.
P0606 ECM Engine stops
P1169 ECM Engine stops and does not start.
P1170 ECM Engine stops and does not start.

P1517 ECM Engine does not start or normal operates depending on trouble con-
dition.
NOTE:
For ( ) marked No. in DTC column, it is indicated when generic scan tool is used.
Diagnostic Trouble Code (DTC) Table

DTC NO. DTC NO.
DTC
(SUZUKI (Generic DETECTING CONDITION
CYCLE
tool) tool)
P0087
P1113 Fuel rail pressure too low/too
P0088 high
P1166 Fuel pressure in common rail is 1 driving 1 driving
P0089
Fuel system leak detected - lower or higher than specification cycle cycle
P0094
small leak
Fuel pressure regulator per-
P0089
formance malfunction
P0091 Fuel pressure regulator con- Monitor signal of fuel pressure
P0092 trol circuit low/high regulator is different from com-
1 driving 1 driving
P0090 mand signal (circuit open or
Fuel pressure regulator con- cycle cycle
P0090 short), or poor performance of
trol circuit malfunction
regulator
P0102 Mass air flow circuit low Sensor output low or high voltage,
P0103 input/high input or air flow is lower or higher than 1 driving 3 driving
P0100
P3007 Mass air flow plausibility at specification under specified cycle cycles
P3008 low flow/high flow engine RPM
P0107 Barometric pressure sensor 1 driving 3 driving
P0108 circuit low input/high input cycle cycles
P0112 Intake air temperature sen- Intake air temperature sensor cir- 1 driving 3 driving
P0110
P0113 sor circuit low/high cuit low or high input cycle cycles
P0117 Engine coolant temperature Engine coolant temperature sen-
P0118 circuit low/high sor circuit low or high input, or 1 driving 3 driving
P0115
Engine coolant temperature poor performance of engine cool- cycle cycles
P0115
circuit malfunction ant temperature sensor
Exhaust gas recirculation
1 driving
P2142 throttle position control circuit
cycle
high Monitor signal of EGR throttle
P0120
Exhaust gas recirculation solenoid valve is different from
1 driving
P0487 throttle position control circuit command signal (circuit open or
cycle
malfunction short), or poor performance of
Exhaust gas recirculation valve
1 driving 1 driving
P2141 P2141 throttle position control circuit
cycle cycle
low
P0182 Fuel temperature sensor cir- Fuel temperature circuit low or 1 driving
P0180
P0183 cuit low/high high input cycle
P0192 Fuel rail pressure sensor cir- Fuel rail pressure sensor circuit
P0193 cuit low/high low or high input
1 driving 1 driving
P0190 Fuel rail pressure sensor supply
Fuel rail pressure sensor cir- cycle cycle
P0194 circuit voltage is out of specifica-
cuit intermittent
tion
DTC NO. DTC NO.

DTC
CYCLE
tool) tool)
Injector circuit - cylinder 1
P0261
low
P0262 is different from command signal
high 1 driving 1 driving
P0201 (circuit open or short), or poor
Injector circuit - cylinder 1 cycle cycle
P0201 performance of fuel Injector #1
malfunction
and ECM
P1372
short
P0264
low
malfunction
and ECM
P1373
short
P0267
low
malfunction
and ECM
P1374
short
P0267
low
malfunction
and ECM
P1374
short
1 driving
P0215 Engine shutoff solenoid Poor performance of double relay
cycle
P0222 Pedal position sensor No.1 Throttle position sensor circuit low
P0223 circuit low/high or high input
1 driving 1 driving
P0220 Throttle position sensor supply
Pedal position sensor No.1 cycle cycle
P0224 circuit voltage is out of specifica-
circuit intermittent
tion
P0227 Pedal position sensor No.2 Throttle position sensor 2 circuit

P0228 circuit low/high low or high input
Throttle position sensor 2 supply
Pedal position sensor No.2 1 driving 1 driving
P0225 P0224 circuit voltage is out of specifica-
circuit intermittent cycle cycle
tion
Pedal position sensor No.2 Poor performance of throttle posi-
P2137
circuit voltage correlation tion sensor
DTC NO. DTC NO.

DTC
CYCLE
tool) tool)
Fuel pump supply circuit low or
1 driving
P0230 Fuel pump primary circuit high input, poor performance of
cycle
fuel pump
Turbo charger over boost Intake air pressure is higher than 1 driving 1 driving
P0234 P0234
condition specification cycle cycle
P0237 Turbo charger boost sensor Intake air pressure sensor circuit
P0238 circuit low/high low or high input
P0235 Turbo charger boost sensor Intake pressure sensor supply cir-
1 driving 1 driving
P0235 P1281 circuit malfunction cuit voltage is out of specification
cycle cycle
Manifold absolute pressure -
Poor performance of intake air
P0069 barometric pressure correla-
pressure sensor
tion
Turbo charger waste gate
P0243
solenoid malfunction Monitor signal of turbo pressure 1 driving
P0243
Turbo charger waste gate regulator solenoid valve is differ- cycle
P0246
solenoid high ent from command signal (circuit
Turbo charger waste gate open or short) 1 driving 1 driving
P0245 P0245
solenoid low cycle cycle
Intake air pressure is higher than 1 driving
P0299 P0299 Turbo charger under boost
specification cycle
Monitor signal of crankshaft posi-
Crankshaft position sensor 1 driving
P0335 P0335 tion sensor is higher than specifi-
circuit cycle
cation
P0343
cuit high
P0344 Supply voltage low or high input,
cuit intermittent 1 driving
P0340 or poor performance of camshaft
Camshaft position sensor cir- cycle
P0341 or crankshaft position sensor
cuit performance
Crankshaft position - cam-
P0016
shaft position correlation
Glow plug circuit relay
P1352
jammed
Both pre/post heating relay and
Glow plug circuit excess volt- 1 driving
P0380 P1351 diagnostic signals are high or low
age cycle
level
P1349
Glow plug circuit short/open
P1350
Monitor signal of glow indicator
1 driving
P0381 Glow plug indicator circuit lamp circuit is different from com-
cycle
DTC NO. DTC NO.

DTC
CYCLE
tool) tool)
P2145 Exhaust gas recirculation 1 driving

P2143 vent control circuit high/open cycle
Exhaust gas recirculation Monitor signal of EGR solenoid
P0400 P0402
flow excessive detected valve is different from command 1 driving 3 driving
Exhaust gas recirculation signal (circuit open or short), or cycle cycles
P0400
flow malfunction excessive EGR flow
Exhaust gas recirculation 1 driving 1 driving
P2144 P2144
vent control circuit low cycle cycle
Exhaust gas recirculation 1 driving 1 driving
P0401 P0401 Insufficient EGR flow
flow insufficient detected cycle cycle
1 driving
P0480 Fan 1 control circuit (high) circuit is different from com-
cycle
1 driving
P0481 Fan 2 control circuit (high) circuit is different from com-
cycle
Radiator fan relay signal is not

1 driving
P0485 Fan power/ground circuit corresponding to radiator fan state
cycle
signal
Vehicle speed sensor mal- Vehicle speed is lower or higher
P0500
function than specification under certain 1 driving 3 driving
P0500
Vehicle speed sensor perfor- condition, or poor performance of cycle cycles
P0501
mance ECM
P0562 1 driving 3 driving
P0560 System voltage low/high Power supply low or high input
P0563 cycle cycles
P0642 Sensor reference voltage cir- 1 driving 1 driving
P0643 cuit low/high cycle cycle
Internal control module keep 1 driving 1 driving
P0603 P0603 Poor performance of ECM
alive memory (KAM) error cycle cycle
Internal control module ran-
1 driving 1 driving
P0604 P0604 dom access memory (RAM) Poor performance of ECM
cycle cycle
error
1 driving
P0606 P0606 ECM processor Poor performance of ECM
cycle
P0658 Actuator supply voltage cir- Sensor power supply low or high 1 driving 3 driving
P0608
P0659 cuit 1 low/high voltage cycle cycles
P2670 Actuator supply voltage cir- Sensor power supply 2 low or high 1 driving 3 driving
P0609
P2671 cuit 2 low/high voltage cycle cycles
Malfunction indicator lamp
P0650 (MIL) control circuit malfunc- Monitor signal of MIL circuit is dif-
1 driving
P0650 tion ferent from command signal (cir-
cycle
Malfunction indicator lamp cuit open or short)
P1642
(MIL) circuit open
DTC NO. DTC NO.

DTC
CYCLE
tool) tool)
Monitor signal of swirl control
solenoid valve circuit is different
P2009 Intake manifold runner con- 1 driving
P1107 from command signal more than
P2010 trol circuit low/high cycle
specified detecting times (circuit
open or short)
Condenser 1 voltage too low/ 1 driving
high cycle
Condenser 2 voltage too low/ 1 driving
high cycle
ECU function (ECU internal 1 driving
fault) cycle
Monitor signal of pre/post heating
1 driving
P1404 TL4226 circuit malfunction relay is different from command
cycle
signal
Fuel temperature or ECT is more
1 driving
P1507 Anti-boiling activated than specified with high engine
cycle
load
Ignition switch circuit mal- Ignition signal is not memorized in 1 driving
P1511
function ECM cycle
No signal or incorrect code input-
ted from immobilizer control mod-
Immobilizer system malfunc- 1 driving
P1517 ule to ECM
tion cycle
Temporary fault of internal mem-

ory (status memory) in ECM
Fuel injector class and transmis- 1 driving 1 driving
P1613 ECU not registered
sion type are not registered cycle cycle
Accelerator pedal position Simultaneous operation of the 1 driving
P2299
incompatible accelerator and the brake cycle

Monitor signal of injection pump
P3005 3rd piston deactivator circuit solenoid valve is different from 1 driving
P3004
P3006 short/open command signal (circuit open or cycle
short)
NOTE:
In case that ECM detects a fault (DTC) in column with mark, engine is hard to start unless DTC
is cleared from ECM memory.
DTC DRIVING CYCLE column indicates the number of driving cycle before DTC is stored in ECM
memory.
In case that ECM detects a fault (DTC) in column with mark, it means temporary fault of internal
memory (status memory) for communication to immobilizer control module detected. However, it is
no adverse affect for communication. Therefore, it dose not affect engine and emission control sys-
tem.
Visual Inspection
Engine oil - - - - - level, leakage Section 0B
Engine coolant - - - - - level, leakage Section 0B
Fuel - - - - - level, leakage Section 0B
A/T fluid - - - - - level, leakage Section 0B
Air cleaner element - - - - - dirt, clogging Section 0B
Drive belt - - - - - tension, damage Section 0B
Accelerator cable - - - - - play (after warm up engine), installation Section 6E3
Vacuum hoses of air intake system - - - - - disconnection, looseness,
deterioration, bend
Connectors of electric wire harness - - - disconnection, friction
Fuses - - - - - burning Section 8A
Parts - - - - - installation, bolt - - - - - looseness
Parts - - - - - deformation
Also add the following items at engine start, if possible.
Malfunction indicator lamp operation Section 6-1
Charge warning lamp operation Section 6H
Engine oil pressure warning lamp operation Section 8C
Engine coolant temperature warning lamp operation Section 8C
Engine coolant temperature meter operation Section 8C
Fuel level meter operation Section 8C
Abnormal air being inhaled from air intake system
Exhaust system - - - - - leakage of exhaust gas, noise
Engine Basic Check

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 table carefully.
Step Action Yes No

2 Check battery voltage. Go to Step 3. Charge or replace battery.
Is it 11 V or more?
3 Is engine cranked? Go to Step 4. Go to Diagnosis in
Section 6G.
4 Does engine start? Go to Step 5. Go to Step 6.
5 Check engine idle speed referring to Idle Go to Step 11 in Go to Improper Engine
speed Inspection in Section 6E3. Engine Diag. Flow Table Idling or Engine Fails to
Is check result as specified? in this section. Idle under Engine Diag-
nosis Table in this sec-
tion.
6 Do you have SUZUKI scan tool? Go to Step 7. Go to Diagnosis in Sec-
tion 8G. If OK, go to Step
8.
7 Check immobilizer system malfunction as fol- Go to Diagnosis in Sec- Go to Step 8.
lows. tion 8G.
1) Execute Data List mode of Suzuki mode
using ECM application of SUZUKI scan tool.
Dose Suzuki scan tool indicate communication
error message?
8 Check fuel supply as follows: Go to Step 10. Go to Step 9.
1) Check to make sure that enough fuel is
filled in fuel tank.
2) Turn ON ignition switch for 5 seconds and
then OFF. Repeat this a few times.
Is fuel return pressure (returning sounds) felt
from fuel return hose when ignition switch is
turned ON?
9 Check fuel pump for operating. Go to Low Pressure Fuel Go to Diag. Flow Table B-
1) Was fuel pump operating sound heard from Supply Inspection in Sec- 1 in this section.
fuel pump for about 5 seconds after ignition tion 6E3.
switch ON and stop?
10 Check fuel injector referring to Fuel Injector in Go to Engine Diagnosis Go to DTC P0201,
Section 6E3. Table in this section. P0202, P0203, P0204
Is it in good condition? Flow Table in this section.
Engine Diagnosis Table

Perform troubleshooting referring to the following table when ECM has detected no DTC and no abnormality has
been found in visual inspection and engine basic inspection previously.

Hard starting Lack of fuel in fuel tank Refill.
(Engine cranks OK) Dirty or clogged fuel filter Replace.
Fuel leakage from fuel injection pipe joints Correct.
Faulty ECM Replace.
Faulty CKP sensor (Engine speed sensor) Inspect and replace.
Faulty CMP sensor Inspect, adjust and replace.
Compression leak from valve seat Remove cylinder head and lap
valves.
Sticky valve stem Correct or replace valve.
Weak or damaged valve springs Replace valve springs.
Compression leak at cylinder head gasket Repair or replace.
Sticking or damaged piston ring Replace piston rings.
Worn piston, ring or cylinder Replace ring and piston. Rebore or
replace cylinder.
Immobilizer control system out of order. Refer to Section 8G.
Broken valve timing belt Replace timing belt and repair
valve train.
Faulty EGR throttle valve Inspect and replace.

Improper engine idling Clogged air cleaner element Clean or replace.
or engine fails to idle EGR throttle valve Inspect and replace.
Shortage of fuel in fuel tank Refill.
Faulty ECM Replace.
Faulty mass air flow sensor Inspect and replace.
deactivator)
Faulty TP sensor (accelerator stroke sensor) Inspect and replace.
Faulty VSS Inspect and replace.
system.
system.
system.
system.
Faulty A/T shift switch Inspect and replace.
Faulty A/C signal Inspect and replace.
Mal-adjusted accelerator cable Adjust.

Abnormal knocking Fuel injection pipe cracks Replace.
Faulty ECM Replace.
Faulty fuel injection pump Inspect and replace.
Faulty pre/post heating relay Inspect and replace.
Faulty fuel temperature sensor Inspect and replace.
Faulty EGR valve Inspect and replace.
Engine hesitates when Clogged air cleaner element Clean or replace.
accelerating Faulty turbocharger. Replace.
Dirty or clogged fuel hose or pipe Clean or replace.
Clogged fuel injector Inspect and replace.
Fuel injection pump internal damage Inspect and replace.
deactivator)
Faulty TP sensor (Accelerator stroke sensor) Inspect and replace.
system.
system.
system.
system.
Mal-adjusted accelerator cable Replace.

Overheating Insufficient coolant Replenish.
Loose water pump belt Adjust.
Inoperative thermostat Replace.
Poor water pump performance Replace.
Clogged or leaky radiator Flush, repair or replace.
Improper engine oil grade Replace with proper grade oil.
Clogged oil filter or oil strainer Replace or clean (oil strainer).
Poor oil pump performance Repair or replace.
Oil leakage Repair.
Dragging brakes Repair or replace.
Slipping clutch Repair or replace.
Excessive engine oil Loose oil drain plug Tighten.
consumption Loose oil pan bolts Tighten.
Deteriorated or broken oil pan sealant Replace sealant.
Leaky crankshaft oil seal Replace.
Leaky cylinder head cover gasket Replace.
Improper tightening of oil filter Tighten.
Loose oil pressure switch Tighten.
Leaky crankshaft pulley oil seal Replace.
Leaky camshaft oil seal Replace.
Loose turbocharger oil hose bolts Tighten.
Sticky piston ring Remove carbon and replace rings.
Worn piston and cylinder Replace or rebore cylinder, and
replace piston.
Worn piston ring groove and ring Replace piston and ring.
Improper location of piston ring gap Reposition ring gap.
Worn or damaged valve stem seal Replace.
Worn valve stem Replace.
Lower oil pressure Improper oil viscosity Use oil of proper viscosity.
Malfunctioning oil pressure switch Replace.
Clogged oil strainer Clean.
Functional deterioration of oil pump Replace.
Worn oil pump relief valve Replace.
Excessive clearance in various sliding parts Replace worn parts.

Engine noise Improper valve lash Adjust.
(See NOTE:) Worn valve stem and guide Replace.
Weak or broken valve spring Replace.
Warped or bent valve Replace.
Worn piston, ring and cylinder bore Rebore or replace cylinder.
Replace piston and ring.
Worn crankpin bearing Replace.
Worn crankpin Repair by grinding or replace
crankshaft.
Loose connecting rod nuts Tighten nuts to specification.
Low oil pressure Previously outlined.
Worn crankshaft journal bearing Replace.
Worn crankshaft journal Repair by grinding or replace
crankshaft.
Loose lower crankcase (bearing cap) bolts Tighten bolts to specification.
Excessive crankshaft thrust play Replace thrust bearing.
Engine and emission control system out of Refer to Section 6E3.
order
White or blue smoke Clogged air cleaner element Clean or replace.
Improper oil level Adjust.
Black smoke Faulty turbocharger Inspect and replace.
Clogged air cleaner element Clean or replace.
Faulty TP sensor Inspect and replace.
system.
system.
system.

Black smoke Faulty swirl control valve Inspect and repair or replace swirl
system.
NOTE:
Before checking the mechanical noise, make sure that:
Injection timing is properly adjusted.
Specified fuel is used.
Inspection of ECM and Its Circuits

ECM and its circuits can be checked at ECM wiring couplers by
CAUTION:
ECM cannot be checked by itself. It is strictly prohibited
to connect voltmeter or ohmmeter to ECM with couplers
Voltage check
CAUTION:
When measuring the terminal voltages of ECM, try not to
damage the waterproof gel applied on the connector ter-
minal of ECM by inserting a pin, whose diameter is less
than 0.3 mm, along with the wiring of the ECM terminal.
For further details, refer to the figure shown below.
Otherwise, ECM and terminals are damaged by entering
water into the connector and trouble may occur.
1) Remove ECM form ECM bracket referring to Engine Control

Module (ECM) in Section 6E3.
2) Remove harness clamps (1) from ECM harness connector
assemblies (2).
3) Remove connector covers (3) from ECM harness connector
assemblies loosing connector cover locks (4).
4) Connect ECM harness connectors to ECM using connector

lock lever (1).
5) Measure voltage at each terminal with ignition switch turned
ON according to Diag. Flow Table.
NOTE:
1 is ON.
2. Pin
2
6) After measuring, disconnect ECM harness connectors (1)

from ECM loosing connector lock lever (2).
7) Install connector covers (1) to ECM harness connectors

securely.
8) Tighten harness clamps (2) with ECM harness and ECM
harness connector securely.
9) Connect ECM connector assemblies to ECM using connec-
tor lock lever securely.
NOTE:
When clamp replacement is necessary, be sure to use a
clamp with width and thickness as specified below or
less. If a larger clamp is used, lock lever will be caught by
clamp and it will be impossible to install ECM connector
to ECM.
Width b: 2.3 mm
Thickness a: 1.2 mm
10) Install ECM to bracket referring to Engine Control Module
(ECM) in Section 6E3.
TERMINAL ARRANGEMENT OF ECM CONNECTOR VIEWED FROM HARNESS SIDE

Resistance check
1) Disconnect couplers from ECM with ignition switch OFF.
CAUTION:
Do not touch terminals of ECM itself or connect voltmeter
or ohmmeter (2).
2) Check resistance between each pair of terminals of discon-

nected couplers (1) as listed in the following table.
2
1
CAUTION:
Be sure to connect ohmmeter probe from terminal side
of coupler.
3 When measuring the circuit resistance, use a pin
(diameter is less than 0.3 mm) (3) for touching to the
connector terminal and be careful not to damage to the
terminal of the ECM connectors.
The directly connecting of ohmmeter probe to termi-
nals cause poor connection.
Resistance in table represents that when parts temper-
ature is 20C (68F).
STANDARD
TERMINAL CIRCUIT CONDITION
RESISTANCE
E228-4 to E228-3 CKP sensor 315 405 At 20C (68F)
Refer to Fuel Temperature Sensor
E228-21 to E228-20 Fuel temperature sensor
E228-1 to E228-14 Fuel pressure regulator 23 At 20C (68F)
Refer to Engine Coolant Temperature
E228-8 to E228-9 ECT sensor
Sensor (ECT Sensor) in Section 6E3.
Table A-1 Malfunction Indicator Lamp Circuit Check MIL Does Not Come
ON or Dims at Ignition Switch ON (But Engine at Stop)
Wiring Diagram
1. ECM 3. Main fuse 5. To radiator fan relay No.3

2. To ignition switch 4. Double relay
Circuit Description
When the ignition switch is turned ON, ECM causes the double relay to turn ON (close the contact point). Then,
ECM being supplied with the main power, turns ON the malfunction indicator lamp (MIL). When the engine
starts to run and no malfunction is detected in the system, MIL goes OFF but if a malfunction was or is detected,
MIL remains ON even when the engine is running.
Inspection
Step Action Yes No

1 MIL Power Supply Check: Go to Step 2. IG COIL fuse blown,
1) Turn ignition switch ON. main fuse blown, Ignition
Do other indicator/warning lights in combination switch malfunction, BLK/
meter comes ON? WHT circuit open and
poor coupler connection
at combination meter.
2 ECM Power and Ground Circuit Check: Go to Step 3. Go to Table A-3 ECM
Does engine start? Power and Ground Cir-
cuit Check in this section.
If engine is not cranked,
go to Diagnosis in Sec-
tion 6G.
3 MIL Circuit Check: Substitute a known-good Faulty combination meter
1) Turn ignition switch OFF. ECM and recheck. or PPL/YEL wire circuit
2) Remove ECM connector cover referring to open.
minal E227-30.
4) If OK, then using service wire, ground termi-
nal E227-30 in connector disconnected.
Does MIL turn on at ignition switch ON?
Table A-2 Malfunction Indicator Lamp Circuit Check MIL Remains ON after
Engine Starts
Wiring Diagram/Circuit Description
Inspection
Step Action Yes No

1 DTC Check. Go to Step 2 of Engine Go to Step 2.
1) With ignition switch OFF, install scan tool. Diag. Flow Table in this
2) Start engine and check DTC. section.
Is there any DTC(s).
2 MIL Circuit Check: PPL/YEL wire shorted to Substitute a known-good
1) Turn ignition switch to OFF position. ground circuit. ECM and recheck.
2) Disconnect ECM connector referring to
Does MIL turn ON at ignition switch ON?
Table A-3 ECM Power and Ground Circuit Check MIL Doesnt Light at Igni-
tion Switch ON and Engine Doesnt Start Though It Is Cranked Up.
Wiring Diagram
Circuit Description
When the ignition switch is turned ON, the double relay turns ON (the contact point closes) and the main power
is supplied to ECM.
Inspection
Step Action Yes No

1 Double Relay Operating Sound Check: Go to Step 5. Go to Step 2.
Is operating sound of double relay heard at igni-
tion switch ON?
2 Fuse Check: Go to Step 3. Check for short in circuits
Is main FI fuse in good condition? connected to this fuse.
3 Double Relay Check: Go to Step 4. Replace double relay.
1) Turn OFF ignition switch and remove double
relay.
2) Check for proper connection to double relay
at terminal 3 and 10.
3) If OK, check double relay referring to Dou-
ble Relay in Section 6E3.
4 ECM Power Circuit Check: Go to Step 5. BLK/WHT, YEL/GRN
1) Turn ignition switch to OFF position. or WHT/YEL circuit
2) Remove ECM connector covers referring to open.
3) Install double relay.
minals E227-11, E228-24, E228-1 and
E228-2.
5) If OK, then measure voltage between termi-
nal E227-11 and ground, E228-24 and
Is each voltage 10 14 V?
5 ECM Power Circuit Check: Check ground circuits Go to Step 6.
1) Using service wire, ground terminal E228- BLK for open.
24 and measure voltage between terminal If OK, then substitute a
E228-1 and ground, E228-2 and ground at known-good ECM and
ignition switch ON. recheck.
Is it 10 14 V?
6 Is operating sound of double relay heard in Step Go to Step 7. WHT/YEL or BLU/BLK
1? wire open.
7 Double Relay Check: WHT/YEL or BLU/BLK Replace double relay.
1) Check double relay according to procedure wire open.
in Step 3.
Is double relay in good condition?
DTC P0100 (P0102/P0103/P3007/P3008) Mass Air Flow Circuit (Low Input/High

Input/Plausibility at Low Flow/Plausibility at High Flow)
Wiring Diagram
E227 E228 E229
8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9 24 23 22 21 20 19 18 17 16 15 14 13 16 15 14 13 12 11 10 9
24 23 22 21 20 19 18 17 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 32 31 30 29 28 27 26 25
1. Mass air flow sensor 3. Ignition switch 5. Main fuse

2. ECM 4. IG COIL fuse (20 A)

P0100 (P0102): Mass air flow sensor circuit
When ECM detects open or shorted to ground in E228-29 Mass air flow sensor malfunction
wire circuit. ECM malfunction
P0100 (P0103): Clogged or leaky air intake system
cuit.
P0100 (P3008):
Engine speed between 700 and 5000 rpm and air flow
greater than 700 mg/stroke at 1000 rpm or 600 mg/stroke at
4000 rpm.
P0100 (P3007):
Engine speed between 700 and 5000 rpm and air flow below
320 mg/stroke.
NOTE:
cedure.

engine at idle speed.
3) Then keep engine running over 4000 rpm for 10 sec. or more.
Troubleshooting
Step Action Yes No

2 MAF sensor power supply Check: Go to Step 3. Faulty BLK/WHT, BLK
1) With ignition switch OFF, disconnect MAF wire.
sensor coupler.
between BLK/WHT wire terminal of MAF
sensor coupler and BLK wire terminal of
MAF sensor coupler.
Is voltage 10 14 V?
3 Wiring Harness Check: Poor E228-29 terminal PPL/WHT wire circuit
1) Turn ignition switch to OFF position. and PPL/WHT wire ter- open.
2) Remove ECM connector cover referring to minal connection.
Voltage Check in this section. If OK, go to Step 4.
3) Measure resistance between E228-29 ter-
PPL/WHT wire terminal of MAF sensor
connector.
4 Wiring Harness Check: Go to Step 5. PPL/WHT wire circuit
body ground.
Is it infinite?
5 Wiring Harness Check: Go to Step 6. PPL/WHT wire shorted
ECM connector and PPL/WHT wire termi-
Is voltage 0 V?
Step Action Yes No

6 Wiring Harness Check: Poor E228-30 terminal BRN/BLU wire circuit
1) Turn ignition switch to OFF position. and BRN/BLU wire ter- open.
2) Measure resistance between E228-30 terminal connection.
minal of disconnected ECM connector and If OK, go to Step 7.
BRN/BLU wire terminal of MAF sensor
connector.
7 Wiring Harness Check: Go to Step 8. BRN/BLU wire circuit
body ground.
Is it infinite?
8 Wiring Harness Check: Go to Step 9. BRN/BLU wire shorted
ECM connector and BRN/BLU wire termi-
Is voltage 0 V?
9 MAF Sensor Output Voltage Check: Faulty BLK wire connec- Clogged or leaky air
1) With ignition switch OFF, connect MAF sen- tion. intake system.
sor coupler and ECM connector. If OK, substitute a known- If all are OK, substitute a
2) Start engine and check voltage between good ECM and recheck. known-good MAF sensor
E228-29 and E228-30 terminals of ECM and recheck.
connector under following condition.
Engine speed at 3000 rpm: about 3 4 V
Engine speed at idling: about 2 3 V
Is each voltage within specified value?
DTC P0110 (P0112/P0113) Intake Air Temperature Sensor Circuit (Low/High)

Wiring Diagram
E227 E228 E229
8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9 24 23 22 21 20 19 18 17 16 15 14 13 16 15 14 13 12 11 10 9
24 23 22 21 20 19 18 17 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 32 31 30 29 28 27 26 25
1. Mass air flow sensor

2. ECM

P0110 (P0112): IAT sensor circuit
Voltage is below 0.1 V or E228-28 wire terminal of ECM. IAT sensor malfunction
P0110 (P0113): ECM malfunction
Voltage is greater than 4.8 V at E228-28 wire terminal of
ECM.

3) Turn OFF ignition switch, then ON.
Troubleshooting
Step Action Yes No

2 Check IAT Sensor and Its Circuit. Go to Step 3. Intermittent trouble.
1) Connect scan tool with ignition switch OFF. Check for intermittent
3) Check intake air temp. displayed on scan and Poor Connection in
tool. Section 0A.
Is 40C (40F) or 131C (268F) indicated?
3 Check Wire Harness. Go to Step 4. PPL/RED wire open or
1) Disconnect MAF sensor (built-in IAT sensor) shorted to power, or poor
connector with ignition switch OFF. E228-28 connection.
2) Check for proper connection to MAF sensor If wire and connection are
(built-in IAT sensor) at PPL/RED and OK, substitute a known-
BRN/BLU wire terminals. good ECM and recheck.
3) If OK, then with ignition switch ON, is volt-
age applied to PPL/RED wire terminal of
harness side about 5 V?
4 Does scan tool indicate 40 C (40 F) at Step Go to Step 6. Go to Step 5.
2?
5 Check Wire Harness. Replace MAF sensor PPL/RED wire shorted
1) Disconnect MAF sensor (built-in IAT sensor) (built-in IAT sensor). to ground.
connector. If wire is OK, substitute a
2) Check intake air temp. displayed on scan known-good ECM and
tool. recheck.
6 Check Wire Harness. Replace MAF sensor (built- BRN/BLU wire open or
1) Using service wire, connect MAF sensor in IAT sensor). poor E228-30 connection.
(built-in IAT sensor) connector terminals. If wire and connection are
(between PPL/RED wire terminal and OK, substitute a known-
BRN/BLU wire terminal of harness side) good ECM and recheck.
2) Turn ignition switch ON and check intake air
temp. displayed on scan tool.
DTC P0115 (P0115/P0117/P0118) Engine Coolant Temperature Circuit (Mal-

function/Low/High)
Wiring Diagram
1. Engine coolant temperature (ECT) sensor

2. ECM

P0115 (P0117): Engine coolant temperature sensor circuit
Voltage is below 0.1 V at E228-8 wire terminal of ECM. Engine coolant temperature sensor malfunc-
P0115 (P0118): tion
Voltage is greater than 5 V at E228-8 wire terminal of ECM. Thermostat malfunction
Engine coolant temp. fails to reach normal operating temper-
ature even after driving for specified time or engine coolant
temp. variation is less than specified value.

engine at idle speed for 20 min. or more.
Troubleshooting
Step Action Yes No

2 Check engine coolant temp. Intermittent trouble. Go to Step 3.
1) With ignition switch turned OFF, install scan Check for intermittent
tool to DLC. referring to Instermittent
2) Turn ON ignition switch and check engine and Poor Connection in
coolant temp. displayed on scan tool. Section 0A.
3) Warm up engine to normal operating temp.
and check engine coolant temp. displayed
on scan tool.
Does engine coolant temp. rise more than 5C
(41F) and is higher than 30C (86F)?
3 Check thermostat Check thermostat referring Go to Step 4.
Is there a symptom due to thermostat remain- to Thermostat in Section
ing open (it takes a long time before vehicle 6B.
heater becomes effective or before engine is
warmed to normal operating temp., etc.)?
4 Check Wire Harness. Go to Step 5. PPL/BLK wire open or
1) Remove intercooler referring to Intercooler shorted to power/ground.
in Section 6A3. BRN/WHT wire open.
2) Disconnect ECT sensor connector with igni- Poor E228-8 or E228-9
tion switch OFF. connection.
3) Check for proper connection to ECT sensor
at PPL/BLK and BRN/WHT wire termi-
nals.
4) If OK, check voltage between PPL/BLK
and BRN/WHT wire terminals of harness
side with ignition switch ON.
5 Check ECT Sensor Substitute a known-good Faulty ECT sensor.
1) Check ECT sensor referring to Engine ECM and recheck.
Coolant Temperature Sensor (ECT Sensor)
in Section 6E3.
DTC P0220 (P0222/P0223/P0224) Pedal Position Sensor No.1 Circuit (Low/

High/Intermittent)
DTC P2299 Accelerator Pedal Position Incompatible
Wiring Diagram
1. Throttle position sensor 3. Brake lamp switch

2. ECM 4. STOP fuse (20 A)

P0220 (P0222): Throttle position sensor circuit
Voltage is below 0.1 V at E227-15 wire terminal of ECM. Throttle position sensor malfunction
P0220 (P0223): Brake (stop) lamp switch
Voltage is greater than 4.7 V at E227-15 wire terminal of ECM malfunction
ECM.
P0220 (P0224):
ECM or voltage is less than 4.8 V at E227-23 wire terminal
of ECM.
P2299:
Simultaneous operation of the accelerator and the brake.

3) Start engine and warm up to normal operating temperature.
4) Drive vehicle at more than 1300 rpm. for 1 min.
5) Stop vehicle.
Troubleshooting
Step Action Yes No

Is DTC below also indicated? (P2670/P2671) Actuator
<Using Suzuki mode of SUZUKI scan tool> Supply Voltage Circuit 2
P0609 (Low/High) in this sec-
<Using Generic Scan tool or GST mode of tion.
SUZUKI scan tool>
P2670 or P2671
3 Check Wire Harness. Go to Step 4. LT GRN wire open,
each terminals. If wire and connection are
4 Check TP Sensor output voltage. Substitute a known-good GRN/BLU wire open,
1) Turn ignition switch to OFF position. ECM and recheck. GRN/BLU wire shorted
3) Connect ECM connectors to ECM. Poor TP sensor connec-
4) With ignition switch ON, check voltage tor.
between E227-15 and ground, when accel- If wire and connection are
erator pedal is at idle position to fully OK, substitute a known-
depressed position. good TP sensor and
Is voltage 0.5 3.35 V? recheck.
DTC P0180 (P0182/P0183) Fuel Temperature Sensor Circuit (Low/High)

Wiring Diagram

2. ECM

P0180 (P0182): Fuel temperature sensor circuit
Voltage is below 0.1 V at E228-20 wire terminal of ECM. Fuel temperature sensor malfunction
ECM.

Troubleshooting
Step Action Yes No

2 1) Remove intercooler referring to Inter- Go to Step 3. BLU/ORN wire open or
cooler in Section 6A3. shorted to power/ground.
2) Disconnect fuel temp. sensor connector BRN wire open.
with ignition switch OFF. Poor E228-20 or E228-21
3) Check for proper connection to fuel temp. connection.
sensor at BLU/ORN and BRN wire ter- If wire and connection are
minals. OK, substitute a known-
4) If OK, check voltage between BLU/ORN good ECM and recheck.
and BRN wire terminals with ignition
switch ON.
3 1) Check fuel temp. sensor for resistance Substitute a known-good Replace fuel temp. sen-
referring to Fuel Temperature Sensor ECM and recheck. sor.
DTC P0190 (P0192/P0193/P0194) Fuel Rail Pressure Sensor Circuit (Low/High/

Intermittent)
Wiring Diagram
1. Fuel pressure sensor

2. ECM

P0190 (P0192): Fuel rail pressure sensor circuit
Voltage is less than 0.3 V at E228-6 wire terminal of ECM. Fuel rail pressure sensor malfunction
ECM.
P0190 (P0194):
ECM or voltage is less than 4.8 V at E228-5 wire terminal of
ECM.

Troubleshooting
Step Action Yes No

1) Connect scan tool to DLC with ignition (P0658/P0659) Actuator
switch OFF and then turn ignition switch Supply Voltage Circuit 1
ON. (Low/High) in this sec-
2) Dose scan tool indicate DTC as shown tion.
below?
<Using Suzuki mode of SUZUKI scan tool>
P0608
SUZUKI scan tool>
P0658 or P0659
3 Check Wire Harness Go to Step 4. LT GRN/BLK wire open,
1) Remove intercooler and intercooler outlet LT GRN/BLK wire
hose. shorted to ground circuit/
2) Disconnect connector from fuel pressure power circuit, GRY wire
sensor with ignition switch OFF. open, poor E228-5 con-
3) Check for proper connection to fuel pres- nection, or poor E228-7
sure sensor at each terminals. connection.
4) If OK, then with ignition switch ON, check If wire and connection are
voltage between LT GRN/BLK wire and OK, substitute a known-
GRY wire terminals at connector of fuel good ECM and recheck.
pressure sensor.
4 Check Fuel Pressure Sensor Output Voltage Substitute a known-good ORN/WHT wire open,
1) Turn ignition switch to OFF position. ECM and recheck. ORN/WHT wire shorted
3) Connect ECM connectors to ECM. Poor fuel pressure sensor
4) Connect fuel pressure sensor connector. connector.
5) Install intercooler and intercooler outlet If wire and connection are
hose. OK, substitute a known-
6) Start engine and check voltage between good fuel pressure sensor
E228-6 and E227-32 terminal at idle speed. and recheck.
Is voltage about 1.3 V?
DTC P0089 (P0089/P0087, P1113/P0088, P1116/P0094) Fuel Pressure Regula-

tor Performance (Malfunction/Fuel Rail Pressure Too Low/Too High/Fuel Sys-
tem Leak Detected Small Leak)
Wiring Diagram
E227 E228 E229
8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9 24 23 22 21 20 19 18 17 16 15 14 13 16 15 14 13 12 11 10 9
24 23 22 21 20 19 18 17 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 32 31 30 29 28 27 26 25
1. Double relay 3. Fuel pressure sensor 5. Double relay fuse (30 A)

2. Fuel pressure regulator 4. ECM

P0089 (P1166): Double relay and its circuit
Fuel rail pressure is higher than 1450 bars. Fuel pressure sensor and its circuit
P0089 (P1113): Fuel line clogged or bended
Fuel rail pressure is below the minimum permissible pressure Injection pump malfunction
for a given engine speed. ECM malfunction
P0089 (P0088):
Measured fuel rail pressure minus reference fuel rail pressure
is greater than 250 bars and fuel pressure regulate ratio is
below 10%.
P0089 (P0094):
Reference fuel rail pressure minus measured fuel rail pres-
sure is greater than 250 bars and fuel pressure regulate ratio
is greater than 79%.
P0089 (P0087):
Reference fuel rail pressure minus measured fuel rail pres-
sure is greater than 250 bars and fuel pressure regulate ratio
is criterion.
P0089 (P0089):
The calculated value based on current measured on fuel
pressure regulator and engine speed does not correspond to
the pressure given by fuel pressure sensor on basis.

3) Then run engine at 1000 rpm or more for 10 sec.
Troubleshooting
Step Action Yes No

2 Check Fuel Shortage Go to Step 3. Supply fuel into fuel tank.
1) Is there enough fuel in fuel tank?
3 Check Wire Harness Go to Step 4. Faulty WHT/GRN wire,
1) Turn ignition switch OFF position. YEL wire or LT GRN/
2) Remove ECM connector covers referring to WHT wire.
Voltage Check in this section. If wire is OK, substitute a
3) Check for proper connection to ECM at known-good double relay
E228-2 and E228-14 terminals. or injection pump and
4) If OK, check resistance between E228-2 recheck.
and E228-14 terminals.
Is resistance 2 3 ?
4 Check Fuel Pressure Sensor Output Voltage Go to Step 5. ORN/WHT wire open,
1) Connect ECM connectors to ECM. ORN/WHT wire shorted
2) Start engine and check voltage between to ground circuit/power
E228-6 and E227-32 terminal at idle speed. circuit.
Is voltage about 1.3 V? Poor fuel pressure sensor
connector terminal con-
nection.
good fuel pressure sensor
and recheck.
5 Check Fuel Leakage Fuel line clogged or Repair or replace.
1) Perform step 1), 2) and 3) of DTC Confir- bended.
mation Procedure. Faulty fuel pressure
2) Check fuel leakage on Fuel System. regulator.
Is it in good condition? If OK, substitute a known-
DTC P0201 (P0201/P0261/P0262/P1372) Injector Circuit Cylinder 1 (Malfunc-

tion/Low/High/ Short)
Wiring Diagram


P0201 (P0261): Fuel injector circuit
Excessive high voltage at E229-9 wire terminal of ECM. Fuel injector malfunction
Excessive high voltage at E229-2 wire terminal of ECM. Battery or charging system malfunction
P0201 (P0201):
Insufficient current between E229-2 and E229-9 wire ter-
minals during injection command.
P0201 (P1372):
The current between E229-2 and E229-9 wire terminals is
still present after the injection.
NOTE:
When DTC P0201 (P0261/P0262), P0202 (P0264/P0265), P0203 (P0267/P0268) and P0204 (P0267/P0268)
are indicated together, it is possible that battery or charging system is malfunction.

Troubleshooting
Step Action Yes No

2 Check Charging Voltage Go to Step 3. Check charging system
1) Check battery referring to Battery under referring to Under-
Diagnosis in Section 6H. charged Battery or
2) If OK, start engine and check charging volt- Overcharged Battery in
age. Section 6H.
Is charging voltage 12 15 V?
3 Check Fuel Injector Circuit Go to Step 4. Open PNK wire or
1) Turn ignition switch to OFF position. RED wire.
2) Remove ECM connector cover referring to If wire is OK, substitute a
Voltage Check in this section. known-good fuel injector
3) Check for proper connection to ECM at and recheck.
nect connector from fuel injector No.1.
5) Check for proper connection to fuel injector
at PNK and RED wire terminals.
6) Connect connector to fuel injector.
7) Measure resistance between E229-2 and
E229-9 terminals of ECM connector.
Is resistance 0.56 (maximum)?
4 Check Fuel Injector Circuit Go to Step 5. PNK wire is shorted to
1) Disconnect connector from fuel injector RED wire.
No.1.
5 Check Fuel Injector Circuit Substitute a known-good RED wire is shorted to
1) Turn ignition switch to ON position. ECM and recheck. power circuit.
of ECM connector and engine ground.
Is voltage 0 V?

Wiring Diagram
Refer to DTC P0201 (P0201/P0261/P0262/P1372) Injector Circuit Cylinder 1 (Malfunction/Low/High/Short)
in this section.

P0202 (P0202):
Insufficient current between E229-17 and E229-25 wire
terminals during injection command.
P0202 (P1373):
The current between E229-17 and E229-25 wire terminals
is still present after the injection.
NOTE:

Troubleshooting
Step Action Yes No

age. Section 6H.
3 Check Fuel Injector Circuit Go to Step 4. Open PNK/BLK wire or
1) Turn ignition switch to OFF position. RED/BLK wire.
at PNK/BLK and RED/BLK wire termi-
nals.
4 Check Fuel Injector Circuit Go to Step 5. PNK/BLK wire is shorted
1) Disconnect connector from fuel injector to RED/BLK wire.
No.2.
5 Check Fuel Injector Circuit Substitute a known-good RED/BLK wire is
1) Turn ignition switch to ON position. ECM and recheck. shorted to power circuit.
Is voltage 0 V?

Wiring Diagram
in this section.

P0203 (P0203):
Insufficient current between E229-18 and E229-26 wire
terminals during injection command.
P0203 (P1374):
NOTE:

Troubleshooting
Step Action Yes No

age. Section 6H.
3 Check Fuel Injector Circuit Go to Step 4. Open PNK/GRN wire or
1) Turn ignition switch to OFF position. RED/GRN wire.
at PNK/GRN and RED/GRN wire termi-
nals.
4 Check Fuel Injector Circuit Go to Step 5. PNK/GRN wire is
1) Disconnect connector from fuel injector shorted to RED/GRN
No.3. wire.
5 Check Fuel Injector Circuit Substitute a known-good RED/GRN wire is
Is voltage 0 V?

Wiring Diagram
in this section.

P0204 (P0204):
Insufficient current between E229-10 and E229-1 wire ter-
minals during injection command.
P0204 (P1374):
NOTE:

Troubleshooting
Step Action Yes No

age. Section 6H.
3 Check Fuel Injector Circuit Go to Step 4. Open PNK/BLU wire or
1) Turn ignition switch to OFF position. RED/BLU wire.
at PNK/BLU and RED/BLU wire termi-
nals.
4 Check Fuel Injector Circuit Go to Step 5. PNK/BLU wire is
1) Disconnect connector from fuel injector shorted to RED/BLU
No.4. wire.
5 Check Fuel Injector Circuit Substitute a known-good RED/BLU wire is
Is voltage 0 V?
DTC P1169 Condenser 1 Voltage Too Low/High

DTC P1170 Condenser 2 Voltage Too Low/High
Wiring Diagram


Electromotive force of fuel injector is greater than 90 V or Fuel injector circuit
below 40 V with over 500 rpm. Fuel injector malfunction
ECM malfunction

Troubleshooting
Step Action Yes No

2 Check Fuel Injector Circuit for Short Go to Step 3. Short circuit between
1) Turn ignition switch to OFF position. PNK wire and RED
2) Remove ECM connector cover referring to wire, PNK/BLK wire and
Voltage Check in this section. RED/BLK wire, PNK/
3) Check for proper connection to ECM at GRN wire and RED/
E229-2, E229-9, E229-25, E229-17, E229- GRN wire, or PNK/BLU
26, E229-18, E229-1 and E229-10 termi- wire and RED/BLU wire.
nals.
nect connector at all fuel injectors.
5) Check for proper connection of all fuel injec-
tor connector.
6) If OK, measure resistance between the fol-
lowing terminals of fuel injector connectors.
PNK and RED:
Fuel injector No.1
PNK/BLK and RED/BLK:
Fuel injector No.2
PNK/GRN and RED/GRN:
Fuel injector No.3
PNK/BLU and RED/BLU:
Fuel injector No.4
Is resistance between terminals of all fuel injec-
tors infinity ()?
3 Check Fuel Injector Circuit for Short Go to Step 4. PNK wire, RED wire,
1) Measure resistance between PNK, RED, PNK/BLK wire, RED/
PNK/BLK, RED/BLK, PNK/GRN, RED/ BLK wire, PNK/GRN
GRN, PNK/BLU, RED/BLU wires and wire, RED/GRN wire,
engine ground. PNK/BLU wire or RED/
Is each resistance infinity? BLU wire shorted to
ground circuit.
4 Check Fuel Injector Circuit for Short Go to Step 5. PNK wire, RED wire,
1) Turn ignition switch to ON position. PNK/BLK wire, RED/
2) Measure voltage between PNK, RED, BLK wire, PNK/GRN
PNK/BLK, RED/BLK, PNK/GRN, RED/ wire, RED/GRN wire,
GRN, PNK/BLU, RED/BLU wires and PNK/BLU wire or RED/
engine ground. BLU wire shorted to
Is each voltage 0 V? other circuit.
Step Action Yes No

5 Check Fuel Injector Circuit for Open Substitute a known-good Substitute a known-good
1) Turn ignition switch to OFF position. ECM and recheck. fuel injector and recheck.
2) Connect connector to all fuel injectors.
3) Measure for resistance between the follow-
ing terminals of ECM connector.
E229-2 and E229-9: 0.56 (maximum)
E229-25 and E229-17: 0.56 (maximum)
E229-26 and E229-18: 0.56 (maximum)
E229-1 and E229-10: 0.56 (maximum)
DTC P0215 Engine Shutoff Solenoid

Wiring Diagram
1. Double relay 3. Ignition switch 5. Main fuse 7. Double relay fuse (30 A)
2. ECM 4. IG COIL fuse (20 A) 6. To radiator fan relay No.3

Cutting off the ECM supply (for double relay) with no ECM Double relay circuit
command or cutting off the ECM supply (for double relay) for Double relay malfunction
more than 2 seconds. ECM malfunction

Troubleshooting
Step Action Yes No

2 Check Double Relay Function Substitute a known-good Go to Step 3.
1) Turn ignition switch ON for 5 sec. and then ECM and recheck.
OFF.
Is click of double relay heard from double relay
at 2 sec. after ignition switch OFF?
3 1) Remove ECM connector covers referring to Poor E228-1/2 and/or Go to Step 4.
Voltage Check in this section. E227-11 connection.
2) Connect ECM connectors to ECM. If connection is OK,
3) Check voltage between E228-1/2 and substitute a known-good
ground, between E227-11 and ground. ECM and recheck.
5 1) Check voltage between E228-24 and Poor E228-24 connec- YEL/GRN wire open or
ground. tion. short.
Ignition switch ON: about 0 V BLU/BLK wire open/
Ignition switch OFF: 10 14 V short.
Is check result as specified? WHT/GRN wire open/
short.
DTC P0230 Fuel Pump Primary Circuit

Wiring Diagram


When ECM detects open or shorted to ground in E228- Fuel pump circuit
48 wire circuit. Fuel pump malfunction
or ECM malfunction
cuit.

Troubleshooting
Step Action Yes No

2 Is operating sound heard from fuel pump? Substitute a known-good Go to Step 3.
ECM and recheck.
4 Check Fuel Pump Output Circuit Poor E228-48 connec- GRN/ORN wire open/
1) Turn ignition switch to OFF position. tion short.
2) Remove ECM connector cover referring to BLK, PNK/BLK or
Voltage Check in this section. BRN/RED wire open/
3) Connect ECM connectors to ECM. short
4) Check voltage between E228-48 and Fuse broken
ground. Faulty fuel pump
Within 5 sec. after ignition switch ON: If all are OK, substitute a
about 0 V known-good ECM and
Over 5 sec. after Ignition switch OFF: recheck.
10 14 V
DTC P0243 (P0243/P0246) Turbo Charger Waste Gate Solenoid (Malfunction/

High)
DTC P0245 (P0245) Turbo Charger Waste Gate Solenoid Low
Wiring Diagram
1. Double relay 3. Boost pressure regulator solenoid valve 5. ENG fuse (15 A)

P0243 (P0243): Boost pressure regulator solenoid valve cir-
When ECM detects open in E229-31 wire circuit. cuit
P0243 (P0246): Boost pressure regulator solenoid valve mal-
When ECM detects shorted to power in E229-31 wire cir- function
P0245 (P0245):
When ECM detects shorted to ground in E229-31 wire cir-
cuit.

Troubleshooting
Step Action Yes No

Fuel Pump Primary Cir-
cuit in this section.
1) Disconnect boost pressure regulator sole- shorted to power/ground
noid valve connector with ignition switch or fuse broken.
OFF.
noid valve connector disconnected and
ground.
about 12 V
0V
4 Check Boost Pressure Regulator Solenoid GRN/BLK wire open or Faulty solenoid valve.
Valve shorted to power/ground.
1) Check solenoid valve referring to Boost Poor E229-31 connection.
Pressure Regulator Solenoid Valve in Sec- If wire and connection are
tion 6E3. OK, substitute a known-
Is check result as specified? good ECM and recheck.
DTC P0234 (P0243) Turbo Charger Over Boost Condition

DTC P0299 (P0299) Turbo Charger Under Boost
Wiring Diagram
Refer to DTC P0243 (P0243/P0246) Turbo Charger Waste Gate Solenoid (Malfunction/High) in this section.

P0299 (P0299): Vacuum circuit for leak, clogged and bended
Reference pressure minus the pressure measured is greater Boost pressure regulator solenoid valve mal-
than 200 mbars for more than 10 seconds. function
Reference pressure minus the pressure measured is less
than 300 mbars for more than 10 seconds.

3) Run engine for 10 sec. or more.
Troubleshooting
Step Action Yes No

2 Check Vacuum Circuit Go to Step 3. Repair or replace.
Check vacuum circuit for leak and clogging.
3 Check boost pressure regulator solenoid valve Substitute a known-good Replace boost pressure
for resistance referring to Boost Pressure Reg- ECM and recheck. regulator solenoid valve.
ulator Solenoid Valve in Section 6E3.
DTC P0380 (P1351/P1352/P1349/P1350) Glow Plug Circuit (Excess Voltage/

Relay Jammed/Short/Open)
DTC P1404 TL4226 Circuit Malfunction
Wiring Diagram
4 1
2
BRN
LT BLU E229-7
GRN/BLU E229-3
GRY GRY/WHT
GRY/BLU GRY/RED
3
BLK
E227 E228 E229
8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9 24 23 22 21 20 19 18 17 16 15 14 13 16 15 14 13 12 11 10 9
24 23 22 21 20 19 18 17 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 32 31 30 29 28 27 26 25
1. Pre/post heating relay (control unit) 3. Glow plugs

2. ECM 4. Main fuse

P0380 (P1352): Fuse broken
Pre/post heating relay is jammed open, E229-3 wire termi- Pre/post heating relay circuit
nal is low voltage or at least one of the 4 glow plugs is burnt- Pre/post heating relay malfunction
out. Glow plug malfunction
When ECM detects high voltage at E229-3 wire terminal.
P0380 (P1349):
When ECM detects shorted to power or ground in E229-7
wire circuit.
P0380 (P1350):
When ECM detects open in E229-7 wire circuit.
P1404:
When ECM detects open in both E229-3 and E229-7 wire
circuits or glow fuse (main fuse) broken.

3) Turn ignition switch ON for 30 sec. after OFF. Then run engine at idle speed for 30 sec.
Troubleshooting
Step Action Yes No

2 Check Wire Harness Go to Step 3. Main fuse broken.
1) Turn ignition switch to OFF position. BRN wire circuit open or
2) Check voltage between pre/post heating shorted to ground.
relay at BRN wire terminal and body
3 Check Wire Harness Poor glow plug GRY, GRY, GRY/BLU, GRY/
1) Turn ignition switch to OFF position. GRY/BLU, GRY/WHT WHT or GRY/RED wire
2) Check voltage between glow plug each wire or GRY/RED wire termi- (between pre/post heating
terminals with ignition switch ON. nals connection. relay and glow plug) open,
Is voltage about 12 V for limited time? If wire are OK, replace shorted to power/ground.
glow plug. If OK, go to Step 4.
4 Check Wire Harness Go to Step 5. BLK wire circuit
1) Turn ignition switch to OFF position. (between pre/post heating
2) Disconnect pre/post heating relay connec- relay and ground) open.
tor.
3) Check for proper connection of pro/post
heating relay connector at all terminals.
4) If OK, measure resistance between pre/post
heating relay connector at BLK wire termi-
nal and body ground.
5 Check Wire Harness Go to Step 6. LT BLU wire open or
1) Connect pre/post heating relay connector. shorted to ground.
3) Check voltage between E229-7 and ground
with ignition switch ON.
6 Check Wire Harness Poor E229-3 or E229-7 GRN/BLU wire open or
1) Check voltage between E229-3 and ground connection. shorted to ground.
with ignition switch ON. If connections are in good If OK, substitute a known-
Is it about 0 V? condition, substitute a good pre/post heating
known-good ECM and relay and recheck.
recheck.
DTC P0381 Glow Plug Indicator Circuit

Wiring Diagram
1. Glow indicator lamp (in combination meter)

2. ECM

When ECM detects open or shorted to ground in E227- Glow indicator lamp circuit
14 wire circuit. Glow indicator lamp (combination meter)
or malfunction
cuit.

3) Turn ignition switch ON for 30 sec. after OFF.
Troubleshooting
Step Action Yes No

2 Check Wire Harness Substitute a known-good RED/BLK wire open
<Not Using SUZUKI Scan Tool> ECM and recheck. or short.
1) Turn ignition switch to OFF position. Poor E227-14 connec-
2) Remove ECM connector cover referring to tion.
Voltage Check in this section. Replace combination
3) Supply battery power (12 V) to E227-14 meter.
wire terminal of disconnected ECM connec-
tor by using service wire.
Does glow indicator lamp turn ON?
<Using SUZUKI Scan Tool>
1) Connect SUZUKI scan tool to DLC.
2) Execute Glow Indicator Lamp in Misc Test.
Does glow indicator lamp flash?
Reference:
As soon as ignition is switched on, ECM turns on glow indicator lamp for a period which depends on engine
coolant temp. as shown below.
Engine coolant temp. (C) Time turning on glow indicator lamp (sec.)
30 20
10 5
0 0.5
18 0
DTC P0401 (P0401) Exhaust Gas Recirculation Flow Insufficient Detected


EGR flow gap between reference value and measured value EGR vacuum circuit
is greater than 75 mg/stroke, EGR solenoid valve reference EGR valve malfunction
value stable and air flow inconsistent. EGR solenoid valve malfunction
Intake air circuit
MAF sensor malfunction
ECM malfunction

3) Run engine between 700 and 2700 rpm for 10 sec. or more.
Troubleshooting
Step Action Yes No

2 Check EGR vacuum circuit and intake air circuit Go to Step 3. Repair or replace.
for leak.
3 Check EGR valve referring to EGR Valve and Go to Step 4. Replace EGR valve.
EGR cooler in Section 6E3.
4 Check EGR solenoid valve for resistance refer- Go to Step 5. Replace EGR solenoid
ring to EGR Solenoid Valve in Section 6E3. valve.
5 Check MAF sensor referring to Mass Air Flow Substitute a known-good Replace MAF sensor.
Sensor (MAF Sensor) in Section 6E3. ECM and recheck.
DTC P0400 (P0400/P0402/P2143/P2145) Exhaust Gas Recirculation Flow (Mal-

function/Excessive Detected/Exhaust Gas Recirculation Vent Control Circuit
Open/High)
DTC P2144 (P2144) Exhaust Gas Recirculation Vent Control Circuit Low
Wiring Diagram
E227 E228 E229
8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9 24 23 22 21 20 19 18 17 16 15 14 13 16 15 14 13 12 11 10 9
24 23 22 21 20 19 18 17 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 32 31 30 29 28 27 26 25
1. Double relay 3. EGR solenoid valve 5. ENG fuse (15 A)


When ECM detects short to power in E228-36 wire circuit. EGR solenoid valve circuit
P0400 (P2143): EGR solenoid valve malfunction
When ECM detects open in E228-36 wire circuit. ECM malfunction
P0400 (P0402): EGR valve malfunction
EGR flow gap between reference value and measured value Intake air circuit
is greater than 200 mg/stroke. MAF sensor malfunction
P0400 (P0400):
EGR flow variety when EGR valve opened and closed is
below 100 mg.
P2144 (P2144):
When ECM detects short to ground in E228-36 wire circuit.

3) Run engine between 700 and 2700 rpm for 10 sec. or more.
Troubleshooting
Step Action Yes No

1) Disconnect EGR solenoid valve connector shorted to power/ground
with ignition switch turned OFF. or fuse broken.
10 14 V
about 0 V
4 Check EGR Solenoid Valve LT GRN/RED wire Replace EGR solenoid
1) Check solenoid valve referring to EGR open or shorted to valve.
Solenoid Valve in Section 6E3. power/ground.
tion.
OK, go to Step 5.
5 Check EGR Valve Go to Step 6. Replace EGR valve.
1) Check EGR valve referring to EGR Valve
and EGR Cooler in Section 6E3.
6 Check Intake Air Circuit Go to Step 7. Repair or replace.
1) Check intake air circuit for leak.
7 Check MAF Sensor Substitute a known-good Replace MAF sensor.
1) Check MAF sensor referring to Mass Air ECM and recheck.
Flow Sensor (MAF Sensor) in Section 6E3.
DTC P0105 (P0107/P0108) Barometric Pressure Sensor Circuit (Low Input/

High Input)
DTC P0561 (P0642/P0643) Sensor Reference Voltage Circuit (Low/High)
DTC P0603 (P0603) Internal Control Module Keep Alive Memory (KAM) Error
DTC P0604 (P0604) Internal Control Module Random Access Memory (RAM)
Error
Wiring Diagram
1. Double relay 3. Ignition switch 5. Main fuse

2. ECM 4. IG COIL fuse 6. To radiator fan relay No.3
DTC DETECTING CONDITION

This DTC will be set when an internal fault is detected in the ECM.

3) Run engine at idle speed for 10 sec.
Troubleshooting
Step Action Yes No

1 Was Engine Diag. Flow Table performed? Substitute a known-good Go to Engine Diag. Flow
ECM and recheck. Table in this section.
DTC P1107 (P2009/P2010) Intake Manifold Runner Control Circuit (Low/High)

Wiring Diagram
E227 E228 E229
8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9 24 23 22 21 20 19 18 17 16 15 14 13 16 15 14 13 12 11 10 9
24 23 22 21 20 19 18 17 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 32 31 30 29 28 27 26 25
1. Double relay 3. Swirl control solenoid valve 5. ENG fuse (15 A)


When ECM detects open or shorted to ground in E228-47 Swirl control solenoid valve circuit
wire circuit. Swirl control solenoid valve malfunction
cuit.

Troubleshooting
Step Action Yes No

1) Disconnect swirl control solenoid valve con- shorted to power/ground
nector with ignition switch OFF. or fuse broken.
between BLU/WHT wire terminal of swirl
control solenoid valve connector and
ground.
10 14 V
about 0 V
4 Check Swirl Control Solenoid Valve RED/BLK wire open Faulty swirl control sole-
1) Check swirl control solenoid valve referring or shorted to power/ noid valve.
to Swirl Control Solenoid Valve in Section ground.
6E3. Poor E228-47 connec-
Is it in good condition? tion. If wire and con-
nection are OK,
substitute a known-
good ECM and
recheck.
DTC P0480 Fan 1 Control Circuit

Wiring Diagram
WHT/GRN 8
BLU
6 9 4
E228-2 WHT/GRN BLU/WHT

7
E227-18 YEL/WHT 7 BLU/BLK
BLK/WHT 1
E227-3 BLU/BLK
3
BLK/WHT
E227-4 YEL/BLU
BLU/GRN
2
BLK
BLU/BLK
BLU/BLK
BLK
E227 E228 E229
8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9 24 23 22 21 20 19 18 17 16 15 14 13 16 15 14 13 12 11 10 9
24 23 22 21 20 19 18 17 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 32 31 30 29 28 27 26 25
1. Radiator fan motor 1 4. Radiator fan relay 3 (Low) 7. From IG COIL fuse (20 A)
2. Radiator fan relay 1 (High/Low) 5. Radiator fan motor 2 8. From main fuse
3. Radiator fan relay 2 (High) 6. ECM 9. Double relay

18 wire circuit. Radiator fan high speed circuit
or Radiator fan relay 1 (high/low) or radiator fan
When ECM detects shorted to power in E227-18 wire cir- relay 2 (high) malfunction
cuit.

Troubleshooting
Step Action Yes No

Is it about 12 V?
3 Check Radiator Fan Relay YEL/WHT wire open Faulty radiator fan relay 1
1) Check radiator fan relay 1 and 2 referring to or short to ground. or 2.
Radiator Fan Relay 1 (High/Low) and BLK/WHT wire open
Radiator Fan Relay 2 (High) in Section or short to ground.
6E3. Fuse broken.

Wiring Diagram
Refer to DTC P0480 Fan 1 Control Circuit in this section.

When ECM detects open or shorted to ground in E227-4 Fuse broken
wire circuit. Radiator fan low speed circuit
or Radiator fan relay 3 (low) malfunction
cuit.

Troubleshooting
Step Action Yes No

Is it about 12 V?
3 Check Radiator Fan Relay YEL/BLU wire open or Faulty radiator fan relay 3.
1) Check radiator fan relay 3 referring to Radi- short to ground.
ator Fan Relay 3 (Low) in Section 6E3. WHT/GRN wire open
Is it in good condition? or short to ground.
Fuse broken.
DTC P3004 (P3005/P3006) 3rd Piston Deactivator Circuit (Short/Open)

Wiring Diagram
E227 E228 E229
8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9 24 23 22 21 20 19 18 17 16 15 14 13 16 15 14 13 12 11 10 9
24 23 22 21 20 19 18 17 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 32 31 30 29 28 27 26 25
1. Double relay 3. Injection pump solenoid valve (3rd piston deactivator) 5. ENG fuse (15 A)

When ECM detects open in E228-34 wire circuit. 3rd piston deactivator circuit
P3004 (P3005): Injection pump (solenoid valve) malfunction
cuit.

3) Run engine at idle speed.
Troubleshooting
Step Action Yes No

1) Disconnect injection pump solenoid valve short to power/ground or
connector with ignition switch turned OFF. fuse broken.
10 14 V
about 0 V
4 Check Injector Pump Solenoid Valve RED/GRN wire open Faulty injection pump
1) Check resistance between BLU/WHT wire or shorted to power/ solenoid valve.
terminal and RED/GRN wire terminal of ground.
valve. Poor E228-34 connec-
Is it resistance 25 30 ? tion.
DTC P0090 (P0090/P0091/P0092) Fuel Pressure Regulator Control Circuit (Mal-

function/Low/High)
DTC P0606 (P0606) ECM Processor
DTC P1171 ECU Function (ECU Internal Fault)
Wiring Diagram
E227 E228 E229
8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9 24 23 22 21 20 19 18 17 16 15 14 13 16 15 14 13 12 11 10 9
24 23 22 21 20 19 18 17 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 32 31 30 29 28 27 26 25
1. Double relay 2. ECM 3. Fuel pressure regulator

P0090 (P0091): Fuse pressure regulator circuit
When ECM detects shorted to power or ground in E228-14 Fuse pressure regulator malfunction
wire circuit. ECM malfunction
P0090 (P0092):
P0090 (P0090):
Engine runs on with 500 rpm over 1.5 sec. even though igni-
tion switch is turned OFF. (fuel pressure regulator faulty)
P0606 (P0606):
Engine speed does not drop fast enough when ignition switch
is turned OFF.
P1171:
Engine runs on with 500 rpm over 1.5 sec. even though ECM
is commanded cut-off of injection.

3) Run engine at idle speed for 10 sec. and stop it. Then, turn ignition switch ON.
Troubleshooting
Step Action Yes No

2 Check Wire Harness Go to Step 3. YEL wire open or shot to
1) Disconnect connector at fuel pressure regu- ground.
lator.
2) Check voltage between YEL terminal of
regulator connector and ground with ignition
switch ON.
3 Check Fuel Pressure Regulator LT GRN/WHT wire Faulty fuel pressure regu-
Check resistance between YEL wire terminal open or shorted to lator.
and LT GRN/WHT wire terminal of valve. power/ground.
Is it resistance 2 3 ? Poor E228-14 connec-
tion.
DTC P0120 (P0487/P2142) Exhaust Gas Recirculation Throttle Position Con-

trol Circuit (Malfunction/High)
DTC P2141 (P2141) Exhaust Gas Recirculation Throttle Position Control Cir-
cuit Low
Wiring Diagram
E227 E228 E229
8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9 24 23 22 21 20 19 18 17 16 15 14 13 16 15 14 13 12 11 10 9
24 23 22 21 20 19 18 17 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 32 31 30 29 28 27 26 25
1. Double relay 3. EGR throttle solenoid valve 5. ENG fuse (15 A)


When ECM detects open or shorted to power in E229-32 EGR throttle solenoid valve circuit
wire circuit. EGR throttle solenoid valve malfunction
When ECM detects inoperative EGR throttle valve.
P2141 (P2141):
When ECM detects shorted to ground in E229-32 wire cir-
cuit.

Troubleshooting
Step Action Yes No

1) Disconnect EGR throttle solenoid valve con- shorted to power/ground
nector with ignition switch turned OFF. or fuse broken.
10 14 V
about 0 V
4 Check EGR Throttle Solenoid Valve PPL/BLK wire open or Faulty EGR throttle sole-
1) Check solenoid valve referring to EGR shorted to power/ noid valve.
Throttle Solenoid Valve in Section 6E3. ground.
tion.
DTC P1511 Ignition Switch Circuit Malfunction

Wiring Diagram
1. Ignition switch 3. IG COIL fuse (20 A)

2. ECM 4. Main fuse

When ECM detects open or short to ground in E227-11 Fuse broken
wire circuit. Ignition switch circuit
or ECM malfunction
When ECM detects short to power in E227-11 wire cir-
cuit.

Troubleshooting
Step Action Yes No

2 Check Ignition Signal Poor E227-11 connection. BLK/WHT wire open,
1) Turn ignition switch to OFF position. If it is in good condition, shorted to power/ground
2) Remove ECM connector cover referring to substitute a known-good or fuse broken.
Voltage Check in this section. ECM and recheck.
ground.
Is it within specified value?
DTC P0485 Fan Power/Ground Circuit

Wiring Diagram
Refer to DTC P0480 Fun 1 Control Circuit in this section.
Troubleshooting
Proceed to DTC P0480 Fun 1 Control Circuit and P0481 Fan 2 Control Circuit in this section for TROUBLE-
SHOOTING.
DTC P0650 (P0650/P1642) Malfunction Indicator Lamp (MIL) Control Circuit

Malfunction (Malfunction/Open)
Wiring Diagram
E227 E228 E229
8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9 24 23 22 21 20 19 18 17 16 15 14 13 16 15 14 13 12 11 10 9
24 23 22 21 20 19 18 17 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 32 31 30 29 28 27 26 25
1. Malfunction indicator lamp (MIL) 4. METER fuse (10 A)

3. Ignition switch

When ECM detects shorted to power or ground in E227-30 MIL circuit
wire circuit. Combination meter malfunction

Troubleshooting
Step Action Yes No

2 MIL Circuit Check Go to Step 3. Go to Step 4.
3 MIL Circuit Check Poor E227-30 connection. PPL/YEL wire open,
3) Check voltage between PPL/YEL wire ter- meter.
ground.
DTC P0608 (P0658/P0659) Actuator Supply Voltage Circuit 1 (Low/High)

Wiring Diagram
1. Fuel rail pressure sensor 4. ECM

2. Intake air pressure sensor 5. Barometric pressure sensor

P0608 (P0658): Sensor power supply circuit
Voltage is less than 4.8 V at E228-23, E228-5 and E228- Fuel rail pressure sensor malfunction
17 terminal of ECM connector. Intake air pressure sensor malfunction
ECM detects less than 4.8 V at internal power supply of baro- Camshaft position (CMP) sensor malfunction
metric pressure sensor. ECM malfunction
P0608 (P0659):
Voltage is greater than 5.1 V at E228-23, E228-5 and
ECM detects greater than 5.1 V at internal power supply of
barometric pressure sensor.

Troubleshooting
Step Action Yes No

Step Action Yes No

2 Check Fuel Rail Pressure Sensor Circuit Go to Step 3. LT GRN/BLK wire
1) Disconnect connector from fuel rail pres- shorted to other circuits.
3) Check voltage between LT GRN/BLK wire recheck.
terminal in fuel rail pressure sensor connec-
3 Check Fuel Rail Pressure Sensor Circuit Go to Step 4. Faulty fuel rail pressure
1) Connect connector to fuel rail pressure sen- sensor.
ground.
4 Check Intake Air Pressure Sensor Circuit Go to Step 5. LT GRN wire shorted to
1) Disconnect connector from intake air pres- other circuits.
minal in intake air pressure sensor connec-
5 Check Intake Air Pressure Sensor Circuit Go to Step 6. Faulty intake air pressure
1) Connect connector to intake air pressure sensor.
sensor with ignition switch turned OFF.
6 Check CMP Sensor Circuit Go to Step 7. BRN/YEL wire shorted
1) Disconnect connector from CMP sensor to other circuits.
with ignition switch turned OFF. If wire are OK, substitute
3) Check voltage between BRN/YEL wire ter- recheck.
minal in CMP sensor connector and vehicle
body ground.
7 Check CMP Sensor Circuit Faulty ECM, substitute a Faulty CMP sensor.
1) Connect connector to CMP sensor with igni- known-good ECM and
tion switch turned OFF. recheck.
DTC P0609 (P2670/P2671) Actuator Supply Voltage Circuit 2 (Low/High)

Wiring Diagram
PPL/RED E228-28
3
1
LT GRN E227-23
2 BRN/ORN E228-20
BRN/WHT E228-8
4
E227 E228 E229
8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9 24 23 22 21 20 19 18 17 16 15 14 13 16 15 14 13 12 11 10 9
24 23 22 21 20 19 18 17 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 32 31 30 29 28 27 26 25
1. Throttle position sensor 4. Engine coolant temperature sensor

2. Fuel temperature sensor 5. ECM
3. Intake air temperature sensor

P0609 (P2670): Sensor power supply circuit
Voltage is less than 4.8 V at E227-23, E228-28, E228-8 Throttle position sensor malfunction
and E228-20 terminal of ECM connector Fuel temperature sensor malfunction
P0609 (P2671): Intake air temperature sensor (built-in mass
Voltage is greater than 5.1 V at E227-23, E228-28, E228- air flow sensor) malfunction
8 and E228-20 terminal of ECM connector. Engine coolant temperature sensor malfunc-
tion
ECM malfunction

Troubleshooting
Step Action Yes No

2 Check TP Sensor Circuit Go to Step 3. LT GRN wire shorted to
1) Disconnect connector from TP sensor with other circuits.
ignition switch turned OFF. If wire are OK, substitute
minal in TP sensor connector and vehicle
body ground.
3 Check TP Sensor Circuit Go to Step 4. Faulty TP sensor.
1) Connect connector to TP sensor with igni-
2) Remove ECM connector covers referring to
3) Connect ECM connectors from ECM.
4 Check Fuel Temperature Sensor Circuit Go to Step 5. BRN/ORN wire shorted
1) Disconnect connector from fuel rail pres- to other circuits.
3) Check voltage between BRN/ORN wire recheck.
terminal in fuel temperature sensor connec-
5 Check Fuel Temperature Sensor Circuit Go to Step 6. Faulty fuel temperature
1) Connect connector to fuel temperature sen- sensor.
ground.
6 Check Intake Air Temperature Sensor Circuit Go to Step 7. PPL/RED wire shorted
1) Disconnect connector from intake air tem- to other circuits.
perature sensor with ignition switch turned If wire are OK, substitute
OFF. a known-good ECM and
2) Turn ON ignition switch. recheck.
3) Check voltage between PPL/RED wire ter-
minal in intake air temperature sensor con-
nector and vehicle body ground.
Step Action Yes No

7 Check Intake Air Temperature Sensor Circuit Go to Step 8. Faulty intake air tempera-
1) Connect connector to intake air temperature ture sensor (built-in mass
sensor with ignition switch turned OFF. air flow sensor).
8 Check Engine Coolant Temperature Sensor Cir- Go to Step 9. BRN/WHT wire shorted
cuit to other circuits.
1) Disconnect connector from engine coolant If wire are OK, substitute
temperature sensor with ignition switch a known-good ECM and
turned OFF. recheck.
3) Check voltage between BRN/WHT wire
terminal in engine coolant temperature sen-
sor connector and vehicle body ground.
9 Check Engine Coolant Temperature Sensor Cir- Faulty ECM, substitute a Faulty engine coolant
cuit known-good ECM and temperature sensor.
1) Connect connector to engine coolant tem- recheck.
perature sensor with ignition switch turned
OFF.
DTC P0225 (P0224/P0227/P0228/P2137) Pedal Position Sensor No.2 Circuit

(Intermittent/Low/High/Voltage Correlation)
Wiring Diagram
Refer to DTC P0220 (P0222/P0223/P0224) Pedal Position Sensor No.1 Circuit (Low/High/Intermittent) in this
section.

P0225 (P0227): Throttle position sensor circuit
Voltage is below 0.1 V at E227-19 wire terminal of ECM Throttle position sensor malfunction
connector. ECM malfunction
P0225 (P0228):
ECM connector.
P0225 (P2137):
Voltages ratio between PPS 1 signal (voltage at E227-15
terminal) and PPS 2 signal (voltage at E227-19 terminal) is
greater than specified value.
P0225 (P0224):
ECM connector or voltage is below 4.8 V at E227-23 wire
terminal of ECM connector.

3) Run engine at idle speed for 10 sec. or more.
Troubleshooting
Step Action Yes No

below?
P0609
SUZUKI Scan tool>
(P2670/P2671)
3 Check Wire Harness Go to Step 4. LT GRN wire open,
each terminal. If wire and connection are
4 Check TP Sensor Output Voltage Substitute a known-good GRY/BLU wire open,
1) Turn ignition switch to OFF position. ECM and recheck. GRY/BLU, wire shorted
2) Remove ECM connector cover referring to to ground/power or poor
Voltage Check in this section. TP sensor connector.
3) Connect ECM connector from ECM. If wire and connection are
4) With ignition switch ON, check voltage OK, substitute a known-
between E227-19 and ground, when accel- good TP sensor and
erator pedal is at idle position to fully recheck.
depressed position.
DTC P0335 (P0335) Crankshaft Position Sensor Circuit

Wiring Diagram
1. Crankshaft position sensor (Engine speed sensor)

2. ECM

When ECM (E228-4 wire terminal) judged engine speed Crankshaft position sensor circuit
5500 rpm by the signal of crankshaft position sensor. Crankshaft position sensor rotor malfunction
Crankshaft position sensor malfunction
ECM malfunction

engine at idle speed for 10 sec.
Troubleshooting
Step Action Yes No

2 CKP Sensor and Its Circuit Resistance Check: Go to Step 4. Go to Step 3.
4) If OK, check resistance of the followings.
Resistance between E228-3 and E228-4
terminals:
315 405 at 20C, 68F
Resistance between each terminal and
ground:
1M or more
3 CKP Sensor Resistance Check: Faulty ORN/BLK wire or Faulty CKP sensor.
1) With ignition switch OFF, disconnect CKP BLU wire.
sensor coupler and remove CKP sensor.
2) Check resistance between terminals of CKP
sensor. (See Fig.)
Were measured resistance values as specified
in Step 2?
4 CKP Sensor Visual Inspection: Intermittent trouble or Replace or reinstall.
1) Check visually CKP sensor and sensing faulty ECM.
rotor for the followings. (See Fig.) Recheck for intermittent
Damage referring to Intermittent
No foreign material attached and Poor Connection in
Correct installation Section 0A.

[B]: Fig. for Step 4
DTC P0340 (P0341/P0343/P0344/P0016) Camshaft Position Sensor Circuit

(Performance/High/Intermittent/Crankshaft Position Camshaft Position Cor-
relation)
Wiring Diagram

2. ECM

P0340 (P0343): Camshaft position sensor circuit
Camshaft frequency is greater than 100 Hz. Camshaft position sensor maladjusted
P0340 (P0344): Camshaft position sensor malfunction
Voltage is less than 4.8 V at E228-17 wire terminal of ECM Camshaft hub malfunction
connector or voltage is greater than 5.1 V at E228-17 wire ECM malfunction
terminal of ECM connector. Crankshaft position sensor circuit
P0340 (P0016): Crankshaft position sensor malfunction
Engine speed calculated based on CMP sensor signal is dif-
ferent from actual engine speed (CKP sensor signal).
P0340 (P0341):
Camshaft position signal is out of specified angle.

3) Crank engine for 3 seconds or more and keep it at idle for 1 min. if engine start.
Troubleshooting
Step Action Yes No

below?
P0608
SUZUKI Scan tool>
P0658 or P0659
3 Is engine cranked? Go to Step 4. Go to Diagnosis in Sec-
tion 6G.
4 Is engine started? Go to Step 5. Check CKP sensor
and its circuit according to
DTC P0335 (P0335)
Crankshaft Position Sen-
sor Circuit in this section.
5 Check CMP Sensor and connector for proper Go to Step 6. Correct.
installation.
Is CMP sensor installed properly and connector
connected securely?
6 Check Wire Harness and Connection. Go to Step 7. ORN/BLU or GRY/
1) Disconnect connector from CMP sensor. RED wire open, short or
2) Check for proper connection to CMP sensor poor connection.
at each terminal.
3) If OK, turn ignition switch ON and check for
voltage between ORN/BLU and GRY/
RED terminals of sensor connector discon-
nected.
Is voltage 10 14 V?
7 Check for voltage between BRN/YEL and Go to Step 8. BRN/YEL wire open,
GRY/RED terminals of sensor connector dis- short or poor connection.
connected. If wire and connection are
Is voltage about 5 V? OK, substitute a known-
8 Check Camshaft Hub Check CMP sensor air Clean surfaces of cam-
1) Remove upper timing belt cover. gap referring to Camshaft shaft hub or replace cam-
2) Check camshaft hub for the following. Position Sensor (CMP shaft hub.
Damage Sensor) in Section 6E3.
No foreign material attached If check result is OK, sub-
Is it in good condition? stitute a known-good
CMP sensor and recheck.
[A]: Fig. for Step 6 and 7

DTC P0500 (P0500/P0501) Vehicle Speed Sensor (Malfunction/Performance)

Wiring Diagram
1. Vehicle speed sensor 4. IG COIL fuse (20 A) 7. BCM

2. ECM 5. Main fuse
3. Ignition switch 6. Combination meter

P0500 (P0500): Vehicle speed sensor circuit
When ECM (E228-15 wire terminal) judges vehicle speed Vehicle speed sensor drive and/or driven
327 km/h (203 mile/h) by the signal of vehicle speed sensor. gears malfunction
P0500 (P0501): Vehicle speed sensor malfunction
ECM detects vehicle speed signal (E228-15 terminal) below Combination meter malfunction
15 km/h (9 mil/h) although engine speed is greater than 2500 BCM malfunction
rpm and air flow is greater than 40 mm3/stroke. ECM malfunction
WARNING:

2) Turn ON ignition switch and clear DTC, pending DTC and freeze frame data by using scan tool and warm up
engine completely.
3) Increase vehicle speed to 100 110 km/h (60 70 mph).
4) Release accelerator pedal and with engine brake applied, keep vehicle coasting and then stop vehicle.
Troubleshooting
Step Action Yes No

2 Does speedometer indicate vehicle speed? Faulty BLU/YEL wire or Go to Step 3.
poor E228-15 connection.
OK, intermittent trouble or
faulty ECM.
Check for intermittent
referring to Intermittent
and Poor Connection in
Section 0A.
3 VSS Power Supply Voltage Check: Go to Step 4. BLK/WHT or BLK wire
1) With ignition switch OFF, remove VSS cou- open/short.
pler.
check voltage between BLK/WHT wire ter-
pler.
Is voltage 10 14 V?
4 VSS Signal Harness Check: Go to Step 5. Go to Step 6.
pler.
5 VSS Visual Inspection: Poor VSS connection or Replace VSS.
1) Remove VSS referring to Speed Sensor in VSS malfunction.
Section 7D. If connection is OK, sub-
2) Check VSS drive and driven gears for dam- stitute a known-good VSS
age and excessive wear. and recheck.
6 Speedometer Circuit Check: Substitute a known-good Go to Step 7.
1) With ignition switch OFF, disconnect G11 combination meter and
coupler from combination meter. recheck.
pler.
7 BCM Circuit Check Substitute a known-good BLU/YEL wire open/
1) With ignition switch OFF, disconnect G55 BCM and recheck. short or faulty ECM.
coupler from BCM. If wire and connection are
2) With ignition switch ON leaving engine OFF, OK, substitute a known-
check voltage between BLU/YEL wire ter- good ECM and recheck.
pler.
DTC P0235 (P0069/P0235, P1281/P0237/P0238) Turbo Charger Boost Sensor

Circuit (Manifold Absolute Pressure Barometric Pressure Correlation/Mal-
function/Low/High)
Wiring Diagram
1. Intake air pressure sensor 3. Barometric pressure sensor

2. ECM

P0235 (P0235, P1281): Intake air pressure sensor circuit
Voltage is greater than 5.1 V at E228-23 wire terminal of Intake air pressure sensor malfunction
ECM connector or voltage is less than 4.8 V at E228-23 ECM malfunction
wire terminal of ECM connector.
P0235 (P0237):
Voltage is less than 0.1 V at E228-45 wire terminal of ECM
connector.
P0235 (P0238):
ECM connector.
P0235 (P0069):
When ECM detects difference of 100 millibar or more
between intake air pressure and atmospheric pressure with
engine speed less than 850 rpm.
WARNING:
NOTE:
Check to make sure that the following conditions are satisfied when using this DTC CONFIRMATION
PROCEDURE.

3) Run engine at idle speed for 10 sec or more.
Troubleshooting
Step Action Yes No

below?
P0608
SUZUKI Scan tool>
P0658 or P0659
3 Intake Air Pressure Sensor Signal Check: Intermittent trouble or Go to Step 4.
1) Turn ignition switch to OFF position. faulty ECM.
2) Remove ECM connector cover referring to Check for intermittent
Voltage Check in this section. referring to Intermittent
4) Check voltage E228-45 and ground with Section 0A.
ignition switch ON.
Is voltage 0.1 5 V?
4 Intake Air Pressure Sensor Check: LT GRN, BRN/RED or Replace intake air pres-
1) Disconnect connector from intake air pres- GRN/ORN circuit open/ sure sensor.
sure sensor. short.
2) Check for proper connection to intake air If wire and connections
pressure sensor at each terminal. are OK, substitute a
3) If OK, check intake air pressure sensor for known-good ECM and
performance referring to Intake Air Pres- recheck.
sure Sensor (Manifold Absolute Pressure
Sensor) in Section 6E3.
DTC P0560 (P0562/P0563) System Voltage (Low/High)

Wiring Diagram
1. Double relay 3. Fuel pump 5. Main fuse 7. To ignition switch


P0560 (P0562): Power supply circuit
Voltage is below 7 V at E227-11, E228-1 and E228-2 ECM malfunction
wire terminals of ECM connector.
P0560 (P0563):
Voltage is greater than 17.5 V at E227-11, E228-1 and
E228-2 wire terminals of ECM connector.

2) Turn ON ignition switch and clear DTC/pending DTC and freeze frame data by using scan tool and run
engine at idle speed for 1 min.
Troubleshooting
Step Action Yes No

2 1) Turn ignition switch to OFF position. Intermittent trouble. BLK/WHT, BLU/BLK or
2) Remove ECM connector cover referring to Check for intermittent WHT/GRN circuit open
Voltage Check in this section. referring to Intermittent or short.
4) While engine running, check voltage Section 0A.
between following terminals. If wire and connections
E227-11 and ground are OK, substitute a
E228-1 and ground known-good ECM and
E228-2 and ground recheck.
Is each voltage 7 17.5 V?
DTC P1613 ECM Not Registered

This DTC will be set when fuel injector class and transmission type are not registered to ECM.
(When ECM replaced new one. etc.)
Troubleshooting
Step Action Yes No

1 1) Register ECM according to the registration Substitute a known-good End.
procedure, referring to ECM Registration ECM and recheck.
in Section 6E3.
2) Check DTC after performing ECM registra-
tion.
Is DTC P1613 still indicated?
DTC P1517 Immobilizer System Malfunction

Wiring Diagram
1
2
E227-10 PNK G09-1
G09-6
E227 E228 E229
8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9 24 23 22 21 20 19 18 17 16 15 14 13 16 15 14 13 12 11 10 9
24 23 22 21 20 19 18 17 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 32 31 30 29 28 27 26 25
1. ECM 2. Immobilizer control module
Detecting Condition and Trouble Area

This DTC will be set when temporary fault of internal mem- PNK wire circuit
ory (status memory) for communication to immobilizer con- Immobilizer control system malfunction
trol module detected in the ECM. ECM malfunction
No signal or incorrect code inputted from immobilizer con-
trol module to ECM.

2) Turn ON ignition switch and clear DTC by using scan tool.
3) Start engine.
Troubleshooting
Step Action Yes No

2 Does engine start? Temporary fault of internal Go to Step 3.
memory (status memory)
for communication to
immobilizer control mod-
ule.
However, it is no adverse
affect for communication.
Therefore, it does not
affect engine and emis-
sion control system.
3 Check Wire Harness and Connection Go to Step 4. PNK wire is open circuit.
E227-10 terminal.
4) Disconnect immobilizer control module con-
nector.
5) Check for proper connection to immobilizer
control module at G09-1 and G09-6 termi-
nals.
6) If each terminal connection is OK, measure
resistance between G09-1 terminal of
immobilizer control module and E227-10
terminal of ECM connector, between G09-6
terminal of immobilizer control module and
Is each resistance 1 or less?
1) Measure resistance between E227-10 ter- ground.
minal of ECM connector and vehicle body
ground.
1) Turn ignition switch to ON position. power circuit.
of ECM connector and vehicle body ground.
Is voltage 0 V?
6 Check Immobilizer Control System Substitute a known-good Faulty immobilizer control
1) Check immobilizer control system referring ECM and recheck. system.
to Immobilizer Control System Diagnostic
Flow Table in Section 8G.
TABLE B-1 Fuel Pump Circuit Inspection

Wiring Diagram

2. ECM 4. Fuel Pump fuse (15 A) 6. To radiator fan relay No.3
Inspection
Step Action Yes No

1 Fuel Pump Operation Check: Fuel pump circuit is in Go to Step 2.
1) Turn ON ignition switch. good condition.
Is fuel pump operation sound heard for 5 sec.
after ignition switch ON?
2 Fuel Pump Circuit Check: Go to Step 3. BLK, PNK/BLK or
1) With ignition switch OFF, remove double BRN/RED circuit open
relay from connector. or fuel pump malfunction.
2) Check for proper connection to relay at each
terminal.
3) If OK, using service wire, connect terminals
8 and 5 of relay connector. (See CAUTION.)
Is fuel pump heard to operate at ignition switch
ON?
3 Double Relay Check: GRN/ORN circuit open. Replace double relay.
CAUTION:
Check to make sure that connection is made between correct terminals. Wrong connection can cause
damage to ECM, wire harness etc.
TABLE B-2 Fuel Pressure Inspection

System Diagram
(A): Gauge 1. Fuel tank 4. Fuel temperature sensor

(B): Hose 2. Fuel pump 5. Fuel heater
(C): Attachment 3. Fuel filter
Inspection
NOTE:
Before using the following flow table, check to make sure that battery voltage is higher than 11 V. If
battery voltage is low, pressure becomes lower than specification even if fuel pump and line are in
good condition.
Step Action Yes No

1 1) Install fuel pressure gauge and check fuel Normal fuel pressure. Go to Step 2.
pressure referring to Low Pressure Fuel
Supply System in Section 6E3.
Is fuel pressure within specified value?
2 Was fuel pressure higher than spec. in Step 1? Clogged fuel heater, fuel Go to Step 3.
filter, fuel temperature or
fuel hose/pipe.
3 Was no fuel pressure applied in Step 1? Shortage of fuel Fuel leakage from fuel
Fuel pump and its cir- line.
cuit defective.
(Refer to Table B-1
Fuel Pump Circuit
Inspection in this sec-
tion.)
[A]
(A)
(B)
(C)
Special tool
(A): 09912-58442
(B): 09912-58432
(C): 09912-56530
Special Tool
09912-58442 09912-58432 Tech 2 kit (SUZUKI scan tool) 09912-56530

Pressure gauge Pressure hose (See NOTE B.) 3 way joint and hose
NOTE:
B: This kit includes the following items.
ENGINE MECHANICAL (RHW ENGINE) 6A3-1
SECTION 6A3
ENGINE MECHANICAL
(RHW ENGINE)
WARNING:
CAUTION:
Be sure to read Precaution in Section 6E before disconnecting fuel line or removing fuel system
part(s). Failure to follow Precautions could result unneeded fuel system repairs.
CONTENTS 6A3
Service Precaution........................................6A3-2 Oil Pump ................................................... 6A3-29

On-Vehicle Service........................................6A3-2 Camshafts and Valve Rockers.................. 6A3-33
Compression Check ....................................6A3-2 Valves and Cylinder Head ........................ 6A3-40
Oil Pressure Check .....................................6A3-3 Swirl Control Solenoid Valve..................... 6A3-47
Air Cleaner Element ....................................6A3-4 Piston, Piston Rings, Connecting Rods
Intercooler ...................................................6A3-5 and Cylinders ............................................ 6A3-49
Cylinder Head Cover ...................................6A3-6 Unit Repair Overhaul ..................................6A3-54
Turbocharger.............................................6A3-10 Engine Assembly ...................................... 6A3-54
Intake Manifold ..........................................6A3-12 Main Bearings, Crankshaft and
Exhaust Manifold.......................................6A3-12 Cylinder Block ........................................... 6A3-57
Timing Belt and Belt Tensioner .................6A3-15 Special Tools...............................................6A3-66
Oil Pressure Switch ...................................6A3-23 Required Service Materials ........................6A3-67
Oil Cooler ..................................................6A3-23
Tightening Torque Specifications .............6A3-68
Oil Pan and Oil Pump Strainer ..................6A3-24
6A3-2 ENGINE MECHANICAL (RHW ENGINE)
Service Precaution
CAUTION:
Be sure to use engine hooks (1) for hanging engine.
Never use engine hook (2) for this purpose. This prohibited service may damage fuel line.
On-Vehicle Service
Compression Check
1) Cool off engine if it is hot.
3) Disconnect ECM connectors from ECM.
4) Remove all glow plugs referring to Glow Plug in Section
6E3.
5) Place transmission gear shift lever in Neutral for M/T model
(shift selector lever to P range for A/T model), and set park-
ing brake and block drive wheels.
6) Install special tool to glow plug hole.
Special tool
(A): 09912-57820
(A) (B): 09916-96520
7) Connect negative cable at battery.
8) Depress clutch pedal fully (to lighten starting load on engine)
for M/T model.
9) Crank engine and inspect compression pressure.
Compression pressure specification
(at cranking engine (engine speed is 250 rpm or more))
(B)
Minimum: 2.5 MPa (25 kg/cm2, 356 psi)
Maximum difference between cylinders:
0.5 MPa (5 kg/cm2, 72 psi)
10) Carry out step 6) through 9) on each cylinder in order to
obtain 4 readings.
11) If compression in one or more cylinders is low, pour a small

amount of engine oil into the cylinder and recheck compres-
sion.
If compression increases, piston, piston rings or cylinder wall
may be worn.
If compression stays low, valve may be stuck or seating
improperly.
If compression in adjacent cylinders stays low, cylinder head
gasket may be damaged or cylinder head distorted.
13) Remove special tool and install all glow plugs referring to
Glow Plug in Section 6E3.
14) Connect ECM connectors to ECM.
Oil Pressure Check
WARNING:
To avoid danger of being burned, do not touch exhaust
manifold when exhaust system is hot.
NOTE:
Prior to checking oil pressure, check and perform the fol-
lowing.
Oil level in oil pan.
If oil level is low, add oil up to full level mark (2) on oil
level gauge (3).
Oil quality.
If oil is discolored, or deteriorated, change it.
For particular oil to be used, refer to Engine in Sec-
tion 0B.
Oil leaks.
If leak is found, repair it.
Be sure to place transmission gear shift lever in Neu-
tral for M/T model (shift selector lever to P range for
A/T model), and set parking brake and block drive
wheels.
1. Low level mark
1) Remove oil filter from oil filter stand referring to Engine Oil
and Filter in Section 0B.
(A)
2) Install special tool to oil cooler.
Special tool
(A): 09915-76530/OUT0000057
CAUTION:
Be careful not to make special tool touch exhaust mani-
fold when installing because exhaust manifold becomes
very hot.
3) Start engine and warm it up to normal operating tempera-

ture.
4) After warming up, raise engine speed to specified speed,
and measure oil pressure.
Oil pressure specification
Approx. 200 kPa (2.04 kg/cm2, 29.0 psi) at 1,000 r/min (rpm)
Approx. 400 kPa (4.08 kg/cm2, 58.0 psi) at 2,000 r/min (rpm)
5) Stop engine and remove oil pressure gauge.
6) Install new oil filter referring to Engine in Section 0B.
7) Start engine and check oil filter for oil leakage.
Air Cleaner Element

REMOVAL
1) Remove air cleaner case clamps.

2) Remove air cleaner element from case.
INSPECTION
Check air cleaner element for dirt. Replace excessively dirty ele-
ment.
CLEAN
Blow off dust by compressed air from air outlet side of element.
INSTALLATION
Reverse removal procedure for installation.
Intercooler
COMPONENTS
7
6
2 4.5 Nm (0.45 kg-m)
2 4.5 Nm (0.45 kg-m)

2 4.5 Nm (0.45 kg-m)
2 4.5 Nm (0.45 kg-m)
1. Intercooler 3. Intercooler outlet hose 5. Intercooler bolt 7. Intercooler duct bolt Tightening Torque
2. Clamp 4. Intercooler inlet hose 6. Intercooler duct 8. Intercooler duct crip
REMOVAL
1) Loosen intercooler hose clamps.
2) Remove intercooler.
INSTALLATION
Tighten hose clamp to specified torque.
Tightening torque
Intercooler outlet and inlet hose clamps:
4.5 Nm (0.45 kg-m, 3.5 lb-ft)
Cylinder Head Cover

REMOVAL
2) Detach fuse/relay box and TP sensor (Accelerator stroke
sensor) with air cleaner upper case.
3) Remove intake air pressure sensor and strut tower bar (1).
4) Remove intercooler and intercooler inlet hose referring to
Intercooler in this section.
5) Remove battery from vehicle.
4
5 6) Remove clamps (1) using special tool, and remove EGR
1
pipe (2) from EGR cooler (3).
2
Special tool
1
(A): 09919-46510/OUT0000110
(A) 7) Move aside EGR cooler (3) with heater outlet hose (4) and
heater outlet No.2 hose (5) removing EGR cooler bolt No.1
and No.2 (6).
3 6
1
2 8) Remove intercooler bracket (1) and vacuum pipe (2).
9) Disconnect fuel injector couplers, and move aside harness
for fuel injectors from cylinder head cover.
1 10) Remove engine front hook (1) on engine bracket, and

remove upper timing belt cover.
1
4
11) Disconnect breather hose (1) and oil filler hose (2) from cyl-
3
inder head cover (4) after removing clamps (5) using special
tool.
2
Special tool
(A): 09919-46510/OUT0000110
(A)
12) Disconnect CMP sensor connector.
13) Remove CMP sensor (3) from cylinder head cover.
5
1 14) Loosen cylinder head cover bolts in such order as indicated

7
11 in figure and remove them.
13
10 15) Remove cylinder head cover with its gasket.
2
6
8
12
9
5 3
INSTALLATION
1) Install new gasket (1) to cylinder head cover (2).

1
NOTE:
2
Ensure that new gasket is positioned correctly in groove
of cover.
2) Install cylinder head cover to cylinder head.
13
3) Tighten bolts in such order as indicated in figure a little at a
7 time till they are tightened to specified torque.
3
1
4 Tightening torque
12
8
6
Cylinder head cover bolt: 10 Nm (1.0 kg-m, 7.5 lb-ft)
2
5 NOTE:
9 11
When installing cylinder head cover, use care so that cyl-
inder head cover gasket will not get out of place or fall
10
off.
1 4) Connect breather hose (1) and oil filler hose (2) to cylinder
3
head cover, and fix hoses with new clamps using special
tool.
2
Special tool
(A): 09919-46510/OUT0000110
(A)
5) Install CMP sensor (3) to cylinder head cover.
6) Check CMP sensor air gap referring to Camshaft Position
Sensor in Section 6E3.
7) Install upper timing belt cover (1).

Apply sealant to timing belt cover bolts, and then tighten
bolts to specified torque.
1 A: Sealant LOCKTITE FRENETANCH
(a) Tightening torque
Timing belt cover bolt and nut (a):
10 Nm (1.0 kg-m, 7.5 lb-ft)
(a) 8) Connect fuel injector couplers, and fix harness for fuel injec-
tor to cylinder head cover.
1 9) Install engine front hook (1) to engine bracket, and tighten

engine front hook mounting bolt to specified torque.
Tightening torque
Engine front hook mounting bolt:
50 Nm (5.0 kg-m, 36.5 lb-ft)
1
2 10) Install vacuum pipe (2) and intercooler bracket (1).
11) Bring back EGR cooler (3) with heater outlet hose (4) and
4
5
1
heater outlet No.2 hose (5), and tighten EGR cooler bolt
2 No.1 and No.2 to specified torque.
1
Tightening torque
EGR cooler bolt No.1 (a): 10 Nm (1.0 kg-m, 7.5 lb-ft)
EGR cooler bolt No.2 (b): 23 Nm (2.3 kg-m, 16.5 lb-ft)
(A)
12) Install EGR pipe (2) and fix pipe with new clamps (1) using
special tool.
(b)
(a) 3 Special tool
(A): 09919-46510/OUT0000110
13) Install battery to vehicle.

14) Install intercooler inlet hose and intercooler referring to
15) Install strut tower bar, TP sensor (Accelerator stroke sensor)
with air cleaner upper case, and intake air pressure sensor.
16) Install fuse/relay box.
Turbocharger
WARNING:
To avoid danger of being burned, do not service exhaust system while it is still hot. Service should be
performed after system cools down.
COMPONENTS
17 25 Nm (2.5 kg-m)
16 25 Nm
(2.5 kg-m)
2 10 20 Nm (2.0 kg-m)
13 12 9 4.5 Nm (0.45 kg-m)
18 55 Nm (5.5 kg-m)
1
9 4.5 Nm
4 (0.45 kg-m)
3
8
14
6
5
14
11
15 10 Nm (1.0 kg-m)
1. Air cleaner outlet hose 6. Turbocharger bracket 11. Oil return pipe 16. Turbocharger nut
2. Turbocharger outlet pipe 7. Exhaust manifold 12. Lubrication pipe 17. Turbocharger outlet pipe nut
3. Seal ring 8. Turbocharger 13. Gasket 18. Exhaust No.2 pipe bolt
4. Gasket 9. Air cleaner outlet hose clamp 14. Turbocharger bracket bolt Tightening Torque
5. Oil return pipe gasket 10. Lubrication pipe union bolt 15. Oil return pipe bolt Do not reuse.
REMOVAL
2) Detach fuse/relay box and remove intake air pressure sen-
sor.
3) Remove strut tower bar.
4) Remove intercooler and intercooler inlet hose referring to
5) Detach air cleaner assembly with TP sensor (Accelerator
stroke sensor).
6) Remove air cleaner outlet hose from turbocharger.
7) Disconnect vacuum hose from waste gate actuator.
5 8) Remove turbocharger outlet pipe (4) from turbocharger (6).

9) Remove turbocharger bracket bolt (1) from turbocharger (6).
10) Disconnect oil return pipe (2) and lubrication pipe (3) from
3 turbocharger (6).
6
11) Remove turbocharger from exhaust manifold removing 3 tur-
4 bocharger nuts (5).
2
1
INSPECTION
Rotate turbine shaft (1) by hand and verify that it turns smoothly
without any abnormal noise and excessive runout.
If not as specified, replace the turbocharger.
INSTALLATION
Clean mating surfaces of turbocharger, turbocharger outlet
pipe and exhaust manifold.
Use new gaskets.
Use new turbocharger bolts.
Tighten each nuts and bolts to specified torque.

(b) Tightening torque
1, (a)
Turbocharger nut (a):
25 Nm (2.5 kg-m, 18.0 lb-ft)
Lubrication pipe union bolt (b):
20 Nm (2.0 kg-m, 14.5 lb-ft)
Turbocharger outlet pipe nut (c):
25 Nm (2.5 kg-m, 18.0 lb-ft)
Oil return pipe bolt (d):
10 Nm (1.0 kg-m, 7.5 lb-ft)
(c) Exhaust No.2 pipe bolt:
(d)
55 Nm (5.5 kg-m, 40.0 lb-ft)
Air cleaner outlet hose clamp:
4.5 Nm (0.45 kg-m, 3.5 lb-ft)
Tighten strut tower bar bolts to specified torque referring to
Strut Damper in Section 3D.
Intake Manifold
REMOVAL/INSTALLATION
Refer to Camshafts and Valve Lash Adjusters in this section.
Exhaust Manifold
WARNING:
To avoid danger of being burned, do not service exhaust system while it is still hot. Service should be
performed after system cools down.
COMPONENTS
19 10 Nm (1.0 kg-m)
15
14
16
13
12
7
10 10 Nm
(1.0 kg-m)
11 23 Nm (2.3 kg-m) 8
17
9 10 Nm
(1.0 kg-m) 2
18
20 30 Nm (3.0 kg-m) 6
1
5 30 Nm (3.0 kg-m)
4 25 Nm (2.5 kg-m)
1. Exhaust manifold 7. EGR valve 13. Heater outlet No.2 hose 19. EGR pipe bolt
2. Exhaust manifold gasket 8. EGR valve spacer 14. Heater outlet hose 20. EGR cooler bracket nut
3. Turbocharger 9. EGR valve spacer nut 15. EGR pipe Tightening Toque
4. Turbocharger nut 10. EGR cooler bolt No.1 16. Clamp Do not reuse.
5. Exhaust manifold nut 11. EGR cooler bolt No.2 17. EGR cooler bracket
6. Spacer 12. EGR cooler 18. EGR valve gasket
REMOVAL
1) Remove battery.
2) Remove turbocharger from exhaust manifold referring to
Turbocharger in this section.
3) Disconnect vacuum hose from EGR valve.
4) Remove swirl control solenoid valve referring to Swirl Con-
trol Solenoid Valve in Section 6E3.
5 5) Remove EGR cooler bolt No.1 (7), No.2 (8) and EGR valve
6
spacer nut (9).
6) Detach EGR cooler (1) with EGR valve (2), EGR valve
spacer (3), heater outlet hose (5) and heater outlet No.2
1 hose (6).
7) Remove EGR cooler bracket (4).
2
7
4 8 3
9
2 3 8) Remove exhaust manifold nuts (1) and spacers (2).

9) Remove exhaust manifold (3) and its gasket from cylinder
head.
INSTALLATION
1) Install new exhaust manifold gasket to cylinder head.
2 3 2) Install exhaust manifold (3) and spacers (2), and tighten
exhaust manifold nuts (1) to specified torque.
Tightening torque
Exhaust manifold nut (a): 30 Nm (3.0 kg-m, 22.0 lb-ft)
1, (a)
3) Install EGR cooler bracket (4), and tighten EGR cooler

bracket nut (5) to specified torque.
Tightening torque
EGR cooler bracket nut (a): 30 Nm (3.0 kg-m, 22.0 lb-ft)
1
4) Install new EGR valve spacer gasket.
5) Install EGR cooler (1) with EGR valve (2) and EGR valve
2 spacer (3), and tighten bolts and nuts to specified torque.
Tightening torque
(c)
5, (a) 4 3
EGR valve spacer nut (b): 10 Nm (1.0 kg-m, 7.5 lb-ft)
(d)
(b) EGR cooler bolt No.1 (c): 10 Nm (1.0 kg-m, 7.5 lb-ft)
EGR cooler bolt No.2 (d): 23 Nm (2.3 kg-m, 16.5 lb-ft)
6) Install swirl control valve referring to Swirl Control Solenoid
Valve in Section 6E3.
7) Connect vacuum hose to EGR valve.
8) Install turbocharger to exhaust manifold referring to Turbo-
charger in this section.
9) Install battery to vehicle.
Timing Belt and Belt Tensioner

COMPONENTS
1. Upper timing belt cover 5. Camshaft timing belt pulley 9. Timing belt cover bolt 13. Timing belt cover nut
:Apply LOCKTITE FRENE
TANCH to thread part of bolt.
2. Right timing belt cover 6. Camshaft hub 10. Camshaft timing belt pulley bolt Tightening Torque
3. Lower timing belt cover 7. Timing belt tensioner 11. Timing belt tensioner bolt
4. Timing belt 8. Roller 12. Roller bolt
REMOVAL
2) Remove A/C compressor belt, if equipped.
3) Remove generator belt referring to Generator Belt in Sec-
tion 6H.
4) Remove radiator referring to Radiator in Section 6B.
5) Remove crankshaft pulley bolt with crankshaft locked by
using flat end rod (1) or the like as shown in figure.
6) Remove crankshaft pulley.

If it is hard to remove, install crankshaft pulley bolt without
washer and use special tool after replacing fixing bolts
included special tool to specified bolts as follows.
Special tool fixing bolt size: M6, P1.0, L=75 mm (2.95 in.)
Special tool
(A): 09944-36011
1 7) Remove engine front hook (1) on engine bracket, and

remove timing belt covers.
8) Turn crankshaft so that crank timing pulley key (7) turns

upward, and then lock camshaft hub (1) inserting special tool
(A) into cylinder head hole (2) as shown in figure.
Special tool
(A): 09910-26540/OUT0000151
9) Lock flywheel (for M/T model) or drive plate (for A/T model)
inserting special tool (B) into holes in both cylinder block and
flywheel (for M/T model) (or drive plate (for A/T model)) with
crank timing pulley key turned upward.
Special tool
(B): 09910-26530/OUT0000160
10) Loosen timing belt tensioner bolt (3). Then remove timing
belt (8) turning timing belt tensioner (4) clockwise with spe-
cial tool (C).
Special tool
(C): 09919-56550/OUT0000141
11) Remove timing belt tensioner (4) and roller (5).
6. Starting motor
INSPECTION
Inspect timing belt for wear or crack.

Replace it as necessary.
Inspect timing belt tensioner and roller for smooth rotation.

INSTALLATION
1) Install timing belt tensioner (1) and roller (2).

Do not tighten timing belt tensioner bolt with wrench yet.
Tighten by hand only at this time.
Tightening torque
Roller bolt (a): 45 Nm (4.5 kg-m, 32.5 lb-ft)
2) Check that camshaft hub (5) is locked inserting special tool
(A) into cylinder head hole (6) as shown in figure.
Special tool
(A): 09910-26540/OUT0000151
3) Check that flywheel (for M/T model) or drive plate (for A/T
model) is locked inserting special tool (B) into holes in both
cylinder block and flywheel (for M/T model) (or drive plate
(for A/T model)) with crank timing pulley key (7) turned
upward.
Special tool
(B): 09910-26530/OUT0000160
4) Loosen camshaft timing belt pulley bolts (3) and check that
camshaft timing belt pulley (4) rotates freely on camshaft
hub (5).
NOTE:
Do not remove camshaft timing belt pulley bolts (3).
1 2
5) Turn camshaft timing belt pulley (1) clockwise until the
oblong hole (2) end contacts pulley bolt (3) as shown.
3
6) Install timing belt (1) with fully taut, in the following order.
a) Crankshaft timing belt pulley (2).
b) Roller (3).
c) Injection pump pulley (4).
d) Camshaft timing belt pulley (5).
NOTE:
Slightly turn camshaft timing belt pulley (5) counter
clockwise within one teeth width in order to engage tim-
ing belt on pulley.
e) Water pump pulley (7).
f) Timing belt tensioner (6).
7) Fit special tool as shown in figure.
NOTE:
Check that special tool is not touching anything in the
near vicinity.
Special tool
(A): 09919-56560/OUT0000138
8) Turn timing belt tensioner counterclockwise using special
tool (B) until special tool (A) indicates 98 2. Then tighten
timing belt tensioner bolt (2) to specified torque.
Special tool
(B): 09919-56550/OUT0000141
Tightening torque
Timing belt tensioner bolt (a): 25 Nm (2.5 kg-m, 18.0 lb-ft)
9) Remove special tool (A).
10) By removing one of camshaft timing belt pulley bolts (1),
check to make sure that bolt hole is not at the oblong hole
end in pulley.
If bolt hole is at the oblong hole end in pulley, repeat step 2)
through 9) after removing timing belt.
11) Install camshaft timing belt pulley bolt (1) removed at step
10).
Tighten bolts (1) to specified torque.
Tightening torque
Camshaft timing belt pulley bolt (b):
20 Nm (2.0 kg-m, 14.5 lb-ft)
12) Remove all special tools.

13) Install crankshaft pulley temporarily, and then turn crankshaft
8 rotations clockwise.
NOTE:
Never turn crankshaft counterclockwise.
14) Install special tools referring to step 2) and 3).
15) Loosen camshaft timing belt pulley bolts (1) and timing belt
tensioner bolt (2).
NOTE:
Do not remove camshaft timing belt pulley bolts (1).
16) Fit special tool as shown.
Special tool
(A): 09919-56560/OUT0000138
17) Turn timing belt tensioner clockwise using special tool (B)
until special tool (A) indicates 54 2. Then tighten timing belt
tensioner bolt (2) to specified torque.
Special tool
(B): 09919-56550/OUT0000141
Tightening torque
Timing belt tensioner bolt (a): 25 Nm (2.5 kg-m, 18.0 lb-ft)
18) Tighten camshaft timing belt pulley bolts (1) to specified
torque.
Tightening torque
Camshaft timing belt pulley bolt (b):
20 Nm (2.0 kg-m, 14.5 lb-ft)
19) Remove special tool (A), and then install it again.
20) Check that special tool (A) indicates between 51 and 57. If
indication of tool is out of specified value, perform step 2)
through 19) again after removing timing belt.
21) Remove all special tools, and then turn crankshaft 2 revolu-
tions in clockwise.
NOTE:
Never turn crankshaft counterclockwise.
22) Check timing belt installed properly by installing special tools

(A) and (B) as follows.
If special tool(s) can not install, preform step 2) through 21)
again after removing timing belt.
a) Camshaft timing belt pulley (1) is locked inserting special
tool (A) into cylinder head hole as shown in figure.
Special tool
(A): 09910-26540/OUT0000151
b) Flywheel (for M/T model) or drive plate (for A/T model) is
locked inserting special tool (B) into holes in both cylinder
block and flywheel (for M/T model) (or drive plate (for A/T
model)).
Special tool
(B): 09910-26530/OUT0000160
24) Remove special tools (A and B).
25) Install timing belt covers.

Apply sealant to timing belt cover bolts, and then tighten tim-
ing belt cover bolts and nut to specified torque.
A: Sealant LOCTITE FRENETANCH
Tightening torque
Timing belt cover bolt and nut (a):
10 Nm (1.0 kg-m, 7.5 lb-ft)
1 26) Install engine front hook (1) to engine bracket, and tighten
engine front hook mounting bolts to specified torque.
Tightening torque
Engine front hook mounting bolt:
50 Nm (5.0 kg-m, 36.5 lb-ft)
27) Install crankshaft pulley (1) with crankshaft locked by using

flat end rod (2) or the like, apply sealant to crankshaft pulley
bolt and tighten it gradually as follows.
a) Tighten bolt to 50 Nm (5.0 kg-m, 36.5 lb-ft)
b) Tighten bolt to 145 Nm (14.5 kg-m, 105 lb-ft)
Tightening torque
Crankshaft pulley bolt (a): 145 Nm (14.5 kg-m, 105 lb-ft)
A: Sealant LOCTITE 273
28) Install radiator referring to Radiator in Section 6B.
29) Refill cooling system referring to Cooling System Flush and
Refill in Section 6B.
30) Install generator belt referring to Generator Belt in Section
6H.
Oil Pressure Switch

REMOVAL
1) Detach degassing tank from its bracket.
2) Disconnect oil pressure switch connector.
3) Remove oil pressure switch (1).
2. Gasket
INSTALLATION
1) Install oil pressure switch (1) with new gasket (2).

2) Tighten oil pressure switch (1) to specified torque.
Tightening torque
Oil pressure switch (a): 32 Nm (3.2 kg-m, 23.5 lb-ft)
3) Connect oil pressure switch connector.
4) Install degassing tank to its bracket.
5) Start engine and check for oil leakage.
Oil Cooler
REMOVAL
1) Drain engine coolant.
2) Detach degassing tank from its bracket.
3) Remove oil filter (1).
4) Disconnect hoses and remove oil cooler (2).
3. Oil filter stud
INSTALLATION
1) Install oil cooler (2) with new gasket.

2) Tighten oil filter stud.
3) Connect hoses and tighten oil filter (1) referring to Engine
and Oil Filter Change in Section 0B.
4) Install degassing tank to its bracket.
5) Fill engine coolant.
6) Check engine oil level referring to Engine and Oil Filter
Change in Section 0B.
7) Check for oil leakage.
Oil Pan and Oil Pump Strainer

COMPONENTS
1. Oil pan 5. Strainer bolt Tightening Torque

:Apply sealant 1207F 99000-31250 to mating surface.
2. Strainer 6. Bracket bolt Do not reuse.
3. Gasket 7. Oil pan bolt

4. Drain plug
REMOVAL
1) Remove oil level gauge.
2) Raise vehicle and remove both front wheels.
3) Remove engine under cover.
4) Remove steering gear box (1) from vehicle referring to
Power Steering Gear Box Assembly in Section 3B1.
5) Remove front differential housing (2) with differential from
chassis referring to Dismounting in Section 7E.
6) Remove knuckle (1), drive shaft (2) and suspension control

arm (3) of either side after removing stabilizer bar.
Refer to Stabilizer Bar/Bushings, Knuckle/Wheel Spindle
and Suspension Control Arm/Bushings in Section 3D and
Drive Shaft in Section 4A2.
7) Detach suspension frame (4) from chassis.
8) Drain engine oil removing drain plug (1).
9) Remove transmission fastening bolts (1).
10) Remove oil pan bolts.
NOTE:
Bolt (1) at the rear of power steering pump bracket (2)
should be loosened only. It is not possible to remove it
due to interference with bracket.
11) Remove oil pan (1) from cylinder block as shown.
12) Remove oil pump strainer (1).
CLEANING
Clean oil pump strainer screen.

Clean mating surfaces of oil pan and cylinder block.

Remove oil, old sealant, and dust from mating surfaces and
inside of oil pan.
INSTALLATION
1) Using new gasket (1), install oil pump strainer (2) to oil
pump.
Tighten strainer bolts (3) first and then bracket bolt (4) to
specified torque.
Tightening torque
Oil pump strainer bolt (a): 9.0 Nm (0.9 kg-m, 6.5 lb-ft)
2) Apply sealant to oil pan mating surface continuously as

shown in figure.
A: Sealant 99000-31250
3) Fit oil pan to cylinder block using bolt (1) at the position as
shown in figure.
4) After fitting oil pan (1) to cylinder block, run in securing bolts
(2) and start tightening at the center: move wrench outward,
tightening one bolt at a time.
Tighten bolts to specified torque.
Tightening torque
Oil pan bolt (a): 16 Nm (1.6 kg-m, 11.5 lb-ft)
5) Install new gasket and drain plug (3) to oil pan.
Tighten drain plug to specified torque.
Tightening torque
Drain plug (b): 34 Nm (3.4 kg-m, 24.5 lb-ft)
6) Install suspension frame to chassis.

Tightening torque
Suspension flame bolt (a): 85 Nm (8.5 kg-m, 61.5 lb-ft)
7) Install knuckle (1), drive shaft (2) and suspension control
arm (3) and stabilizer bar referring to Knuckle/Wheel Spin-
dle, Suspension Control Arm/Bushings and Stabilizer
Bar/Bushings in Section 3D and Drive Shaft in Section
4A2.
8) Install front differential housing referring to Remounting in

Section 7E.
9) Refill front differential housing with gear oil referring to Main-
tenance Service in Section 7E.
10) Install steering gear box to vehicle referring to Power Steer-
ing Gear Box Assembly in Section 3B1.
11) Install engine under cover.
12) Install oil level gauge.
13) Refill engine with engine oil referring to Engine Oil and Fil-
ter in Section 0B.
14) Refill power steering system with specified fluid referring to
Power Steering Fluid Level Check in Section 3B1.
15) Check to make sure that there is no engine oil leakage, dif-
ferential oil leakage and power steering fluid leakage at each
connection.
Oil Pump
COMPONENTS
1. Gasket holder plate 5. Oil pump case No.2 9. Retainer Tightening Torque
:Apply sealant 1207F 99000-
31250 to mating surface.
2. Oil pump chain 6. Rotor 10. Gasket holder plate oil seal Do not reuse.
:Apply engine oil to oil seal lip.
3. Oil pump drive sprocket 7. Relief valve 11. Gasket holder plate bolt (long)
4. Oil pump case No.1 8. Relief spring 12. Gasket holder plate bolt (short)
REMOVAL
2) Remove timing belt referring to Timing Belt and Belt Ten-
sioner in this section.
3) Remove oil pan and oil pump strainer referring to Oil Pan
and Oil Pump Strainer in this section.
4) Remove generator.
5) Remove power steering pump bracket.
6) Remove crankshaft timing belt pulley (1) and then remove
gasket holder plate (2).
7) After removing sprocket key from crankshaft, remove oil

pump (1), oil pump chain (2) and oil pump drive sprocket (3)
all together.
DISASSEMBLY
Disassemble oil pump as shown in figure.
CAUTION:
Do not remove oil pump sprocket (5).
Otherwise, oil pump sprocket and/or oil pump rotor shaft
might be damaged.
INSPECTION
Check rotor (3) and oil pump cases (1 and 2) for excessive
wear or damage.
If any malcondition is found, replace oil pump assembly.
Check relief valve (4) for excessive wear or damage.
If any malcondition is found, replace relief valve.
Check teeth of oil pump drive sprocket for wear or damage.

If any malcondition is found, replace oil pump drive sprocket.
Check teeth of oil pump sprocket for wear or damage.

If any malcondition is found, replace oil pump assembly.
Check oil pump chain for wear or damage.

If any malcondition is found, replace oil pump chain.
Check gasket holder plate oil seal lip for fault or damage.
If any malcondition is found, replace gasket holder plate oil
seal.
ASSEMBLY
1) Wash, clean and then dry all disassembled parts.
2) Apply thin coat of engine oil to rotors and inside surface of
each oil pump case.
3) Assemble oil pump. After assembling oil pump, check to be

sure that rotor turns smoothly by hand.
INSTALLATION
1) Install oil pump (1), oil pump chain (2) and oil pump drive
sprocket (3) all together to cylinder block and crankshaft.
Tighten oil pump bolts to specified torque.
Tightening torque
Oil pump bolt (a): 16 Nm (1.6 kg-m, 11.5 lb-ft)
2) Install sprocket key to crankshaft.
3) Apply sealant to mating surface of gasket holder plate (1).

A: Sealant 99000-31250
4) Install gasket holder plate oil seal (1) by using special tools
and bolt (2) tapping them with plastic hammer, if removed.
Special tool
(A): 09916-51910/OUT0000132
5) Install gasket holder plate (1) to cylinder block.

Tighten gasket holder plate bolts to specified torque.
Tightening torque
Gasket holder plate bolt (a): 15 Nm (1.5 kg-m, 11.0 lb-ft)
6) Install crankshaft timing belt pulley (2).
7) Install power steering pump bracket.
8) Install generator referring to Generator in Section 6H.
9) Install oil pump strainer and oil pan referring to Oil Pan and
Oil Pump Strainer in this section.
10) Install timing belt referring to Timing Belt and Belt Ten-
Camshafts and Valve Rockers

COMPONENTS
2 10 Nm (1.0 kg-m) 13 10 Nm (1.0 kg-m)
14
11 3
15
10
5
16
4
11
9 25 Nm (2.5 kg-m)
6 10
8 45 Nm (4.5 kg-m)
12
1. Camshaft housing/intake manifold 6. Camshaft hub 11. Valve rocker 16. Camshaft chain guide
2. Camshaft housing/intake manifold 7. Camshaft timing belt 12. Cylinder head Tightening Torque
bolt pulley :Apply sealant 1207B 99000-31140
: For tightening order, refer to to mating surface of cylinder head.
Installation.
3. Exhaust camshaft 8. Camshaft hub bolt 13. Fuel infector pillar bolt Do not reuse.
4. Intake camshaft 9. Camshaft timing belt 14. Camshaft chain tensioner assembly Apply engine oil to slid-
pulley bolt ing surface of each part.
5. Camshaft oil seal 10. Ball valve rocker 15. Camshaft chain
:Apply engine oil to oil seal lip.
REMOVAL
3) Remove cylinder head cover referring to Cylinder Head
Cover in this section.
4) Remove vacuum pump from cylinder head referring to Vac-
uum Pump in Section 6E3.
5) Remove throttle valve assembly referring to Throttle Valve
6) Remove oil level gauge guide bolt.
7) Remove high pressure pipes and fuel injectors referring to
Fuel Injector in Section 6E3.
2 8) Remove fuel injector pillar bolts (1) from camshaft housing/

1 intake manifold (2).
2
9) Remove oil vapor breather tube (2).
10) Remove camshaft timing belt pulley bolts (1) and camshaft
hub bolt (2) with locking camshaft timing belt pulley (3) by
special tool.
Special tool
(A): 09910-26540/OUT0000151
11) Remove camshaft timing belt pulley (3) and camshaft hub
(4).
12) Remove camshaft chain tensioner assembly (1).

1 13) Remove oil level gauge guide bolt.
14) Detach intercooler left side bracket.
15) Loosen camshaft housing/intake manifold (1) bolts in such

order as indicated in figure and remove them.
16) Remove camshaft housing/intake manifold (1).
A: Camshaft timing belt pulley side
2 17) Remove camshaft oil seal (1) from exhaust camshaft (2).
4 18) Remove exhaust camshaft (2) and intake camshaft (3) with
1
camshaft chain (4) from cylinder head.
19) Remove valve rocker (1) with ball valve rocker (2).
NOTE:
Never disassemble ball valve rocker.
Dont apply force (4) to body of ball valve rocker, for oil
in high pressure chamber in it will leak.
Immerse removed ball valve rocker in clean engine oil
and keep it there till reinstalling it so as to prevent oil
leakage. If it is left in air, place it with its bucket body
facing down. Dont place on its side or with bucket
body facing up.
20) Remove camshaft chain guide (3) from cylinder head.
INSPECTION
Camshafts
Check teeth of sprocket for wear or damage.

Check journals and cam faces for wear or damage.
If any malcondition is found, replace camshaft.
Camshaft housing/intake manifold
Check camshaft housing/intake manifold for pitting, scratches,

wear or damage.
If any malcondition is found, replace cylinder head with cylinder
head with camshaft housing/intake manifold. Never replace cylin-
der head without replacing camshaft housing/intake manifold.
Ball valve rockers and valve rockers
Check ball valve rocker (1) and valve rocker (2) for pitting,
scratches, wear or damage.
2
If any malcondition is found, replace them.
Camshaft chain
Check camshaft chain for wear or damage.

If any malcondition is found, replace camshaft chain, camshaft
chain tensioner assembly and camshaft chain guide all together.
Camshaft chain tensioner assembly and camshaft chain

guide
Check shoe of tensioner and guide for wear or damage.

If any malcondition is found, replace camshaft chain, camshaft
2 chain tensioner assembly (1) and camshaft chain guide (2) all
together.
1
INSTALLATION
1 1) Apply engine oil around valve rocker and ball valve rocker,
2 and install valve rocker (1) with ball valve rocker (2) to cylin-
3 der head.
2) Install camshaft chain guide (3) to cylinder head.
3) Remove special tool (A).

Special tool
(A): 09910-26530/OUT0000160
4) Install crankshaft pulley temporarily, and turn crankshaft
counter clockwise through 90.
6) Install camshaft chain (1) to camshafts aligning plates (gold)

(2) of chain to marks or paint (3) on camshaft sprockets (4).
7) Fit camshafts and camshaft chain with cylinder head.
8) Apply a line of sealant around the edge of mating surfaces of

cylinder head.
A: Sealant 99000-31140
9) Fit camshaft hub (2), special tool (A) and camshaft housing/
intake manifold (1) to cylinder head, and tighten camshaft
housing/intake manifold bolts temporarily first. Then tighten
them by the following sequence as indicated in figure.
Tighten a little at a time and evenly among bolts and repeat
tightening sequence two or three times before they are tight-
ened to specified torque.
Special tool
(A): 09910-26540/OUT0000151
Tightening torque
Camshaft housing/intake manifold bolt (a):
10 Nm (1.0 kg-m, 7.5 lb-ft)
1, (a)
10) Install new fuel injector pillar bolts (1) to camshaft housing/
2
intake manifold (2). Tighten pillar bolts to specified torque.
Tightening torque
Fuel injector pillar bolt (a): 10 Nm (1.0 kg-m, 7.5 lb-ft)
11) Install intercooler left side bracket.
12) Install oil level gauge guide bolt.
13) After applying grease to oil seal lip, fit new camshaft oil seal
(1) using special tool.
Special tool
(A): 09913-56510/OUT0000152
14) Install camshaft hub (1) and special tool.

Tighten camshaft hub bolt (2) to specified torque with locking
hub (1) by special tool.
Special tool
(A): 09910-26540/OUT0000151
Tightening torque
Camshaft hub bolt (a): 45 Nm (4.5 kg-m, 32.5 lb-ft)
15) Install camshaft timing belt pulley and tighten bolts by hand.
16) Install camshaft chain tensioner assembly (1) to cylinder

1 head.
17) Install oil vapor breather tube (1).

1
18) Install fuel injectors and high pressure pipes referring to
Fuel Injector in Section 6E3.
19) Install throttle valve assembly referring to Throttle Valve
20) Install vacuum pump to cylinder head referring to Vacuum
Pump in Section 6E3.
21) Install cylinder head cover referring to Cylinder Head Cover
in this section.
22) Install timing belt referring to referring to Timing Belt and
Belt Tensioner in this section.
Valves and Cylinder Head

COMPONENTS
7
1
8
3
10
4
10
6
5
1. Valve cotters 6. Exhaust valve 9. Cylinder head

2. Valve spring retainer 7. Cylinder head bolt 10. Knock pin
3. Valve spring :Apply sealant MOLYKOTE G RAPID PLUS to threads and Tightening Torque
under bolt head.
4. Valve stem seal :Replace bolt if it is longer than specified value. Do not reuse.
For tightening procedure, refer to Installation.
5. Intake valve 8. Cylinder head gasket Apply engine oil to sliding sur-
:Thickness identification holes provided on gasket should face of each part.
come to oil filter side.
REMOVAL
2) Remove turbocharger referring to Turbocharger in this sec-
tion.
3) Remove camshaft from cylinder head referring to Camshaft
and Valve Rockers in this section.
1 2 4) Remove engine bracket (1) from cylinder head and cylinder
block.
5) Disconnect vent hose (2) from cylinder head.
8 1 6) Disconnect radiator inlet hose (1) from thermostat cap (8).

6
7
7) Disconnect radiator outlet No.2 hose (2), oil cooler inlet hose
(3) and oil cooler outlet hose (4) from water outlet box (7).
8) Disconnect vent hose (5) and heater inlet No.2 hose (6) from
5
intercooler bracket pipes.
3
4 2
9) Disconnect ECT sensor connector (1), glow plug supply wire

connector (2), swirl control solenoid valve connector (3) and
ground terminal (4).
2
10) Remove engine harness clamp nut from water outlet box.
4
1
11) Remove water inlet box (1) and water inlet pipe (2) with
water inlet hose (3) connected.
12) Remove common rail from cylinder head referring to Com-
mon Rail (High Pressure Fuel Injection Rail) in Section 6E3.
3 1
13) Loosen cylinder head bolts in such order as indicated in fig-

ure and remove them.
14) Check all around cylinder head for any other parts required
3 7 10 6 2 to be removed or disconnected and remove or disconnect
A whatever necessary.
15) Remove cylinder head with exhaust manifold, water outlet
box, glow plugs and swirl control solenoid valve using lifting
4 8 9 5 1
device.
A: Camshaft timing belt pulley side
DISASSEMBLY
1) For ease in servicing cylinder head, remove exhaust mani-

fold with water outlet box, swirl control solenoid valve and
glow plugs.
2) Check valve protrusion average as follows.
If average is out of specification, grind valve seat and then
lap valve on seat.
a) Clean valve face and then measure protrusion of each
valve using special tool and dial gauge as shown in figure.
Special tool
(A): 09910-26510/OUT0000005
Valve protrusion
Intake valve protrusion a: 0.5 1.0 mm (0.020 0.039 in.)
Exhaust valve protrusion b: 0.9 1.4 mm (0.035 0.055
in.)
2. Intake valve
3. Exhaust valve
3) Using special tool (Valve lifter), compress valve springs and

then remove valve cotters (1) using special tool (Forceps) as
shown.
Special tool
(A): 09916-14510
(B): 09916-14521
(C): 09916-84511
4) Release special tool, and remove spring retainer and valve
spring.
5) Remove valve from combustion chamber side.
INSPECTION
Cylinder Head
Remove all carbon from cylinder head surface.
NOTE:
Do not use any sharp-edged tool to scrape off carbon. Be
careful not to scuff or nick metal surfaces when decar-
boning. The same applies to valves and valve seats, too.
Check cylinder head for cracks in intake, exhaust ports and

head surface.
Flatness of gasketed surface:
Using a straightedge and thickness gauge, check surface at
6 locations in total. If distortion limit, given below, is
exceeded, correct gasketed surface with a surface plate and
abrasive paper of about #400 (Waterproof silicon carbide
abrasive paper): place paper on and over surface plate, and
rub gasketed surface against paper to grind off high spots.
Should this fail to reduce thickness gauge readings to within
limit, replace cylinder head.
Leakage of combustion gases from this gasketed joint is
often due to warped gasketed surface: such leakage results
in reduced power output.
Cylinder head gasket surface distortion limit:
0.03 mm (0.0012 in.)
ASSEMBLY
1) Install valve to valve guide.

Before installing valve to valve guide, apply engine oil to
stem seal, valve guide bore, and valve stem.
2) Install valve spring and spring retainer.
3) Using special tool (Valve lifter), compress valve spring and fit
two valve cotters (1) into groove in valve stem.
Special tool
(A): 09916-14510
(B): 09916-14521
(C): 09916-84511
4) Install exhaust manifold with water outlet box referring to
Exhaust Manifold in this section.
Valve in Section 6E3.
6) Install glow plugs referring to Glow Plug in Section 6E3.
INSTALLATION
1) Clean mating surface of cylinder head and cylinder block.
Remove oil, old gasket and dust from mating surface.
2) Prepare optimum cylinder head gasket according to the fol-
lowing procedure.
a) As shown in figure, piston (1) protrudes above cylinder
block (2) when it reaches top dead center. Using special
tool and dial gauge, measure protrusion b at two points
A and B and take an average. Repeat this procedure
with each piston.
Special tool
(A): 09910-26510/OUT 0000005
a: 10 mm (0.40 in.)
b) Using the largest value among averages obtained at step

a), prepare optimum cylinder head gasket (1) referring to
the following table and figure.
Measured piston Thickness of Identification of

protrusion gasket gasket
0.55 0.60 mm 1.21 1.29 mm
[A]
(0.022 0.023 in.) (0.048 0.050 in.)
0.61 0.65 mm 1.26 1.34 mm
[B]
(0.024 0.025 in.) (0.050 0.052 in.)
0.66 0.70 mm 1.31 1.39 mm
[C]
(0.026 0.027 in.) (0.052 0.054 in.)
0.71 0.75 mm 1.36 1.44 mm
[D]
(0.028 0.029 in.) (0.054 0.056 in.)
3) Lock flywheel (for M/T model) or drive plate (for A/T model)
inserting special tool (A) into holes in both cylinder block and
flywheel (for M/T model) or drive plate (for A/T model) with
crankshaft timing pulley key turned up.
Special tool
(A): 09919-26530/OUT0000160
4) Install knock pins (1) to cylinder block.

5) Install new cylinder head gasket (2) to cylinder block.
Thickness identification holes (3) provided on gasket should
come to oil filter side.
A: Crankshaft pulley side
B: Flywheel side
6) Check to make sure that length a of cylinder head bolts.

If length a exceeds specified value, replace cylinder head
bolt.
Cylinder head bolt length
a: Less than 134 mm (5.27 in.)
7) Install cylinder head to cylinder head block, and apply seal-
ant to threads and bottom of cylinder head bolt head.
A: Sealant MOLYKOTE G RAPID PLUS
8) Tighten cylinder head bolts gradually as follows.

a) Tighten all bolts to 20 Nm (2.0 kg-m, 14.5 lb-ft) according
to numerical order in figure.
b) In the same manner as in step a), tighten them to 60 Nm
(a)
(6.0 kg-m, 43.5 lb-ft).
c) Loosen all bolts 1 revolution according to numerical order in
8 4 1 5 9 figure.
A d) Repeat step a) and b).
e) Retighten all bolts 220 according to numerical order in fig-
ure.
7 3 2 6 10
Tightening torque
Cylinder head bolt (a):
60 Nm (6.0 kg-m, 43.5 lb-ft) and extra tightening 220
A: Crankshaft pulley side
9) Install common rail to cylinder head referring to Common

Rail (High Pressure Fuel Injection Rail) in Section 6E3.
10) Using new water inlet box gasket and new water inlet pipe O-
ring, install water inlet box (1) and water inlet pipe (2), water
inlet hose (3).
11) Install engine harness clamp nut to water outlet box.
3 1
12) Connect ECT sensor connector (1), glow plug supply wire
connector (2), swirl control solenoid valve connector (3) and
ground terminal (4).
1 4
8 1 13) Connect vent hose (5) and heater inlet No.2 hose (6) to inter-
6
7
cooler bracket pipes.
14) Connect radiator outlet No.2 hose (2), oil cooler inlet hose
(3) and oil cooler outlet hose (4) to water outlet box (7).
5
15) Connect radiator inlet hose (1) to thermostat cap (8).
3
4 2
A, (b) 2 16) Install engine bracket (1).

Tighten bolts to specified torque after applying sealant to
thread of bolt indicated in figure.
(a)
A: Sealant LOCKTITE FRENETANCH
1
Tightening torque
(b) Engine bracket bolts No.1 (a): 45 Nm (4.5 kg-m, 32.5 lb-ft)
Engine bracket bolt No.2 (b): 20 Nm (2.0 kg-m, 14.5 lb-ft)
17) Connect vent hose (2) to cylinder head.
18) Install valve rockers and camshafts to cylinder head referring

to Camshaft and Valve Rockers in this section.
19) Install turbocharger to exhaust manifold referring to Turbo-
charger in this section.
20) Adjust generator belt tension referring to Generator Belt in
Section 6H.
21) Adjust A/C compressor belt tension (if equipped) referring to
Compressor Drive Belt in Section 1B.
22) Check to ensure that all removed parts are back in place.
Reinstall any necessary parts which have not been rein-
stalled.
23) Refill cooling system with coolant referring to Cooling Sys-
tem Flush and Refill in Section 6B.
24) Refill A/T with specified A/T fluid (vehicle with A/T) referring
to Fluid Change in Section 7B.
26) Check to make sure that there is no fuel leakage, coolant
leakage, oil leakage, A/T fluid leakage (vehicle with A/T) and
exhaust gas leakage at each connection.
Swirl Control Solenoid Valve

COMPONENTS
10
9
8
6
1 3
7
4
5
1. Swirl control solenoid valve 5. Bumper 9. Nut

2. Swirl control solenoid valve shaft 6. Control lever 10. Swirl control solenoid valve
3. Swirl control solenoid valve mounting bolt 7. Stopper Do not reuse.
4. Gasket 8. Washer
REMOVAL
1) Remove cylinder head referring to Valves and Cylinder
Head in this section.
2) Remove swirl control solenoid valves (1) from swirl control
solenoid valve shaft (2).
NOTE:
Make matching mark on solenoid valves (1) to identify its
direction and location.
3) Remove bumper (1) and control lever (2) from solenoid valve
shaft (3).
4) Remove solenoid valve shaft (3) from cylinder head (4).
INSTALLATION
Install swirl control solenoid valve at proper direction and
location by matching mark made in REMOVAL.
Adjust swirl control solenoid valve as follow.

a) Close swirl control solenoid valves (1).
b) Actuate stopper (2) until swirl control solenoid valves (1)
become detached.
c) Tighten stopper (2).
d) Confirm that swirl control solenoid valve (1) close correctly
and do not any hard spots on opening.
Piston, Piston Rings, Connecting Rods and Cylinders

COMPONENTS
1. Top ring 5. Connecting rod 9. Piston pin circlip Do not reuse.
2. 2nd ring 6. Connecting rod bearing cap 10. Connecting rod bearing cap nut
:For tightening procedure, refer to Installa-
tion.
3. Oil ring 7. Connecting rod bearing Tightening Torque
4. Piston 8. Piston pin Apply engine oil to sliding surface of each

parts.
REMOVAL
2) Drain engine oil and engine coolant.
4) Remove oil pump referring to Oil Pump in this section.
5) Remove cylinder head referring to Valves and Cylinder
Head in this section.
6) Mark cylinder number on all pistons, connecting rods and
rod bearing caps using silver pencil or quick drying paint.
7) Remove oil level gauge lower guide (1) and oil partition (2).
8) Remove connecting rod bearing caps.
9) Install guide hoses (1) over threads of rod bolts. This is to

prevent damage to bearing journal and rod bolt threads
when removing connecting rod.
10) Decarbon top of cylinder bore before removing piston from
cylinder.
11) Push piston and connecting rod assembly out through the
top of cylinder bore.
DISASSEMBLY
1) Using piston ring expander, remove two compression rings
(Top and 2nd) and oil ring from piston.
2) Remove piston pin from connecting rod as follows.
a) Ease out piston pin circlips (1) as shown.
b) Force piston pin out.
CLEANING
Clean carbon from piston head and ring grooves using a suitable
tool.
INSPECTION
Cylinders
Inspect cylinder walls for scratches, roughness, or ridges
which indicate excessive wear. If cylinder bore is very rough
or deeply scratched, or ridged, rebore cylinder.
Pistons
Inspect piston for faults, cracks or other damaged.
Damaged or faulty piston should be replaced.
Piston Pin
Check piston pin, connecting rod small end bore and piston
bore for wear or damage, paying particular attention to con-
dition of small end bore bush. If pin, connecting rod small
end bore or piston bore is badly worn or damaged, replace
pin, connecting rod and/or piston.
Piston Rings
To measure end gap, insert piston ring (1) into cylinder bore and
then measure the gap by using thickness gauge (2).
If measured gap is out of specification, replace ring.
NOTE:
Decarbonize and clean top of cylinder bore before insert-
ing piston ring.
Piston ring end gap

Top ring: 0.20 0.35 mm (0.0079 0.0137 in.)
2nd ring: 0.80 1.00 mm (0.0315 0.0393 in.)
Oil ring: 0.25 0.50 mm (0.0099 0.0196 in.)
Piston ring thickness
Top ring: 3.50 mm (0.138 in.)
2nd ring: 2.00 mm (0.079 in.)
Oil ring: 3.00 mm (0.119 in.)
a : 120 mm (4.72 in.)
Rod bearing:
Inspect bearing shells for signs of fusion, pitting, burn or flak-
ing and observe contact pattern. Bearing shells found in
defective condition must be replaced.
Two kinds of rod bearing are available; standard size bearing
and 0.15 mm (0.0059 in.) undersize bearing. For identifica-
tion of undersize bearing, it is painted red (1) at the position
as indicated in figure, undersize bearing thickness is 1.978
1.988 mm (0.0779 0.0782 in.) at the center of it.
ASSEMBLY
1
4 1) Install piston pin to piston (1) and connecting rod (2):
After applying engine oil to piston pin and piston pin holes in
piston and connecting rod, fit connecting rod to piston so that
5
bearing lock tab (3) and arrow mark (4) come on the oppo-
2
site side and insert piston pin to piston and connecting rod,
and install piston pin circlips.
5. Camshaft pulley side
3
1 2) Install piston rings to piston:

As indicated in figure, 1st and 2nd rings have TOP mark
respectively. When installing these piston rings to piston,
1
direct marked side of each ring toward top of piston.
2
1st ring (1) differs from 2nd ring (2) in thickness and shape.
2
5
Distinguish 1st ring from 2nd ring by referring to figure.
3
When installing oil ring (3), install spiral ring (4) first and then
4
rail (5).
3) After installing three rings (1st, 2nd and oil rings), distribute
their end gaps as shown in figure.
1. Arrow mark
2. 1st ring end gap
3. 2nd ring end gap and oil ring spacer gap
4. Oil ring rail gap
5. Exhaust manifold side
6. Oil filter side
INSTALLATION
1) Apply engine oil to pistons, rings, cylinder walls, connecting
rod bearings and crankpins.
NOTE:
Do not apply oil between connecting rod and bearing or
between bearing cap and bearing.
2) Install guide hoses (1) over connecting rod bolts.

These guide hoses (1) protect crankpin and threads of rod
bolt from damage during installation of connecting rod and
piston assembly.
3) When installing piston and connecting rod assembly into cyl-

inder bore, point arrow mark on piston head to crankshaft
pulley side (1).
1
4) Install piston and connecting rod assembly into cylinder

bore. Use special tool (Piston ring compressor) to compress
rings. Guide connecting rod into place on crankshaft.
Using a hammer handle, tap piston head to install piston into
bore. Hold ring compressor firmly against cylinder block until
all piston rings have entered cylinder bore.
Special tool
(A): 09916-77310
5) Install bearing cap (1):

At this time, make sure that bearing lock tab (2) of bearing
cap faces oil filter side (3).
Tighten new cap nuts (4) gradually as follows.
a) Tighten all cap nuts to 20 Nm (2.0 kg-m, 14.5 lb-ft).
b) Retighten them by turning through 70.
Tightening torque
Connecting rod bearing cap nut (a):
20 Nm (2.0 kg-m, 14.5 lb-ft) and extra tightening 70.
6) Install oil partition (2) and oil level gauge lower guide (1).
7) Adjust generator belt tension referring to Generator Belt in
Section 6H.
8) Adjust A/C compressor belt tension, if equipped. Refer to
9) Check to ensure that all removed parts are back in place.
stalled.
10) Refill engine with engine oil referring to Engine Oil and Oil
Filter Change in Section 0B.
11) Refill cooling system referring to Cooling System Flush and
Refill in Section 6B.
12) Refill front differential housing with gear oil referring to
Transfer Gear Oil in Section 7E.
14) Check to make sure that there is no fuel leakage, coolant
leakage, oil leakage and exhaust gas leakage at each con-
nection.
Unit Repair Overhaul

Engine Assembly
REMOVAL
2) Remove engine hood after disconnecting windshield washer
hose.
3) Remove TP sensor (Accelerator stroke sensor) and intake
air pressure sensor.
4) Detach fuse/relay box and remove strut tower bar (1).
6) Drain cooling system.
7) Remove degassing tank and radiator with radiator fan motor
assembly referring to Radiator in Section 6B.
8) Remove air cleaner outlet hose.
9) Remove intercooler referring to Intercooler in this section.
10) Remove transmission assembly referring to Dismounting of
Transmission Unit in Section 7A2 or Automatic Transmis-
sion Assembly (with Transfer) in Section 7B1.
11) Disconnect the following electric wires:

Swirl control solenoid valve (1)
Camshaft position sensor (2)
Fuel pressure regulator (3)
1 4 7
Glow plug supply wire at the connector
5 Engine coolant temp. sensor (4)
11 Fuel pressure sensor (5)
10 Fuel injectors (6)
6 9
3 15 Fuel temp. sensor (7)
13 Injection pump solenoid valve (8)
14 Generator
Engine oil pressure switch
Double relay (9)
Pre post heating control unit (10)
Fuel heater (11)
2 8 12 Ground terminal from water outlet box
ECM (12)
EGR solenoid valve (14)
EGR throttle solenoid valve (15)
and then release wire harnesses from clamps.
12) Disconnect the following hoses:

2 5
1 Brake booster hose (1) from vacuum pipe
Vacuum hoses (6) from vacuum pipe (7)
Heater inlet hose (5) and outlet hose (2) from pipe
Fuel feed hose (3) and return hose (4) from each pipe
4 3
6
7
13) With hose connected, detach A/C compressor (1) (if

equipped) and power steering pump from bracket.
14) Drain engine oil, if necessary.
15) Install lifting device.

16) Remove engine side mounting bracket nuts (1).
17) Before lifting engine, check to ensure all hoses, electric wires
and cables are disconnected from engine.
18) Remove engine assembly from chassis.
INSTALLATION
1) Lower engine assembly into engine compartment.
2) Tighten engine side mounting bracket nuts (1).
Tightening torque
Engine side mounting bracket nut (a):
55 Nm (5.5 kg-m, 40.0 lb-ft)
3) Reverse removal procedure for installation noting the follow-

ing.
CAUTION:
Before installing intake air pressure sensor hose,
degrease connect part of hose and intercooler outlet
hose. Otherwise hose may become detached and cause
turbo system failure.
Install transmission assembly referring to Remounting of

Transmission Unit in Section 7A2 or Automatic Transmis-
sion Assembly (with Transfer) in Section 7B1.
Adjust generator belt tension, referring to Generator Belt in
Section 6H.
Adjust A/C compressor belt tension, if equipped. Refer to
Check to ensure that all removed parts are back in place.
stalled.
Refill engine with engine oil referring to Engine Oil and Fil-
ter in Section 0B.
Refill cooling system referring to Cooling System Refill in
Section 6B.
Check to make sure that there is no fuel leakage, coolant
leakage and exhaust gas leakage at each connection.
Main Bearings, Crankshaft and Cylinder Block

COMPONENTS
1. Cylinder block 7. Main bearing: 13. Main bearing cap bolt No.1 19. O-ring
Apply engine oil to bear- :Follow tightening procedure
ing inside surfaces. referring to Installation.
2. Oil jet 8. Main bearing cap No.1 14. Main bearing cap bolt No.2 Tightening Torque
:Follow tightening procedure
referring to Installation.
3. Oil jet bolt 9. Main bearing cap No.2 15. Input shaft bearing Do not reuse.
4. Crankshaft 10. Main bearing cap No.3 16. Flywheel

:Apply engine oil to slid-
ing surface.
5. Thrust bearing 11. Main bearing cap No.4 17. Flywheel bolt
ing surface.
6. Rear oil seal 12. Main bearing cap No.5 18. Bearing cap seal
ing surface.
REMOVAL
1) Remove engine assembly from body referring to Engine
Assembly in this section.
3) Remove exhaust manifold referring to Exhaust Manifold in
this section.
4) Remove cylinder head cover referring to Cylinder Head
Cover in this section.
5) Remove timing belt, belt tensioner, roller and crankshaft tim-
ing belt pulley and timing belt cover referring to Timing Belt
and Belt Tensioner in this section
6) Remove oil pump, oil pump drive sprocket and gasket holder
plate referring to Oil Pump in this section.
7) Remove camshafts referring to Camshafts and Valve Rock-
ers in this section.
8) Remove cylinder head assembly referring to Valve and Cyl-
inder Head in this section.
9) Remove piston and connection rod referring to Piston, Pis-
ton Rings, Connecting Rods, Connecting Rods and Cylin-
ders in this section.
10) Remove clutch cover, clutch disc and flywheel (for M/T
model) or drive plate (for A/T model) and CKP (Engine
speed) sensor ring.
CAUTION:
Do not use CKP sensor ring (1) to lock crankshaft rota-
tion. This prohibited service may damage CKP sensor
ring.
Special tool
(A): 09924-17811
11) Loosen crankshaft bearing cap bolts in such order as indi-

cated in figure a little at a time and remove bearing caps.
12) Remove thrust bearings (lower side) (1) and rear oil seal (2).
13) Remove crankshaft from cylinder block.
14) Remove thrust bearings (upper side).
15) Remove oil jet.
INSPECTION
Crankshaft thrust play
Measure this play with crankshaft set in cylinder block in the nor-
mal manner as follows.
1) Install upper thrust bearings (1) to cylinder block between
No.1 and No.2 cylinders, Face oil groove (2) sides to crank
webs.
2) Install crankshaft to cylinder block.
3) Install lower thrust bearing (1) contacting its oil grooved sur-
face crankshaft.
4) Install main bearing caps in the right place as shown figure.

5) Tighten main bearing cap bolts as follows.
a) Tighten bolts to 25 Nm (2.5 kg-m, 24.5 lb-ft) according to
numerical order in figure.
b) In the same manner as in step a), retighten them by turning
through 60.
Tightening torque
Crankshaft main bearing cap bolt (a):
6) Use a dial gauge to read displacement in axial (thrust) direc-

tion of crankshaft.
If measured value is out of specification, replace thrust bear-
ing with new standard one or oversize one to obtain standard
thrust play.
Crankshaft thrust play
: 0.07 0.32 mm (0.0028 0.0125 in.)
Crankshaft thrust bearing thickness
Standard: 2.28 mm (0.0898 in.)
Oversize: 2.33 mm (0.0917 in.)
Main Bearings
General information
Service main bearings are available in standard size and

0.15 mm (0.0059 in.) undersize.
Upper half of bearing (1) has oil groove (2) as shown in fig-
ure. Install this half with oil groove to cylinder block.
Lower half of bearing does not have oil groove.
On each main bearing cap, number is embossed as shown

in figure.
When installing each bearing cap to cylinder block, point
bearing lock tab toward oil filter side (1) and install each cap
from that side to crankshaft pulley side in ascending order of
numbers 1K, 2K, 3K, 4K and 5K.
Visual inspection
Check bearings for pitting, scratches, wear or damage.
If any malcondition is found, replace both upper and lower halves.
Never replace one half without replacing the other half.
Crankshaft
Regrind crankshaft journal to the following finished diameter,
if necessary.
Regrind crankshaft journal diameter
59.777 59.800 mm (2.3535 2.3543 in.)
Cylinder Block
Distortion of gasketed surface
Using straightedge and thickness gauge, check gasketed

surface for distortion.
If flatness exceeds its limit, correct it.
Cylinder block flatness
Limit: 0.03 mm (0.0012 in.)
Honing or reboring cylinders
1) When any cylinder needs reboring, all other cylinders must

also be rebored at the same time.
NOTE:
Before reboring, install all main bearing caps in place
and tighten to specification to avoid distortion of bear-
ing bores.
Cylinder block can rebore up to reboring limit below.
Cylinder reboring limit diameter a:
90.018 mm (3.544 in.)
1. No.1 cylinder
2. No.2 cylinder
3. No.3 cylinder
4. No.4 cylinder
2) Measure piston clearance after honing or reboring.
INSTALLATION
NOTE:
All parts to be installed must be perfectly clean.
Be sure to apply oil to crankshaft journals, journal
bearings, thrust bearings, crankpins, connecting rod
bearings, pistons, piston rings and cylinder bores.
Journal bearings, bearing caps, connecting rods, rod
bearings, rod bearing caps, pistons and piston rings
are in combination sets. Do not disturb such combina-
tion and make sure that each part goes back to where
it came from, when installing.
1) Install main bearings (1) to cylinder block.

One of two halves of main bearing has an oil groove (2).
Install it to cylinder block, and the other half without oil
groove to bearing cap.
2) Install oil jet (3) to cylinder block.

Tighten oil jet bolt to specified torque.
Oil jet bolt (a): 10 Nm (1.0 kg-m, 7.5 lb-ft)
3) Install thrust bearings (1) to cylinder block between No.1 and
No.2 cylinders. Face oil groove (2) sides to crank webs.
4) Install crankshaft to cylinder block.
5) Install thrust bearing (1) contacting its oil groved surface to

crankshaft.
6) Apply sealant to cylinder block hatched part as shown in fig-

ure.
A: Sealant 99000-31140
7) Install main bearing cap No.1 to cylinder block as follows.

a) Install special tool (A) to main bearing cap No.1 (4) tighten-
ing its clamp (3).
NOTE:
Shim slide (1) of special tool (A) must be in extension of
surface (2) of bearing cap No.1 (4).
Special tool
(A): 09911-16510/OUT0000002
3. Bolt and washer
(B) b) Install new bearing cap seals (1) to groove of bearing cap
with specified protrusion below.
a
Bearing cap seal protrusion
3 a: approximately 1.5 mm (0.059 in.)
c) Install special tool (B) to special tool (A) on the heel (2) of
2 bearing cap No.1 (3).
(A)
1
A Special tool
[A]
(B): 09913-96510/OUT0000012
(B) d) Apply engine oil to special tool (B) and their contact surface
2
on cylinder block.
1
[A]: View A
e) Engage bearing cap & special tools into cylinder block tilt-
ing them as shown.
f) Straighten bearing cap & special tools out.
g) Lower bearing cap & special tools slowly into cylinder block.
h) Remove bolt and washer (1) that holds special tool (A) to
bearing cap.
i) Tighten both bearing cap bolts (2) temporarily.
j) Remove special tools sideways.
k) Check protrusion of bearing cap seals with specified value

below.
If protrusion is out of specification, repeat step a) through j).
Bearing cap seal protrusion:
Approximately 1.5 mm (0.059 in.)
NOTE:
Bearing cap seal is supplied with correct length, thus it
must not be cut.
8) Install main bearing caps in the right place as shown figure.

9) Tighten main bearing cap bolts as follows.
a) Tighten bolts to 25 Nm (2.5 kg-m, 24.5 lb-ft) according to
numerical order in figure.
b) In the same manner as in step a), retighten them by turning
through 60.
Tightening torque
Crankshaft main bearing cap bolt (a):
NOTE:
After tightening cap bolts, check to be sure that crank-
shaft rotates smoothly.
10) Set new rear oil seal (1) on special tool as shown figure.
(A)
1 Special tool
(A): 09911-16520/OUT0000011
11) Install rear oil seal (1) tapping it with plastic hammer until it
(A) fully seats.
Special tool
(B) (A): 09911-16520/OUT0000011
(B): 09913-75510
1 12) Remove special tool by turning and pulling it out in direction

of engine rotation.
13) Check that visible lip of rear oil seal faces outside.
14) Install flywheel (for M/T model) or drive plate (for A/T model)
and CKP (Engine speed) sensor ring.
Using special tool, lock flywheel or drive plate.
CAUTION:
Do not use CKP sensor ring (1) to lock crankshaft rota-
tion. This prohibited service may damage CKP sensor
ring.
Special tool
(A): 09924-17811
Tightening torque
Flywheel or drive plate bolt (a):
50 Nm (5.0 kg-m, 36.5 lb-ft)
15) Install piston and connecting rod referring to Piston, Piston
Rings, Connecting Rods and Cylinders in this section.
16) Install cylinder head assembly referring to Valve and Cylin-
der Head in this section.
17) Install camshafts referring to Camshafts and Valve Rockers
in this section.
18) Install oil pump, oil pump drive sprocket and gasket holder
plate referring to Oil Pump in this section.
19) Install to timing belt, belt tensioner, roller, crankshaft timing
sprocket and timing belt cover referring to Timing Belt and
Belt Tensioner in this section.
20) Install cylinder head cover referring to Cylinder Head Cover
in this section.
21) Install exhaust manifold referring to Exhaust Manifold in
this section.
22) Install oil pan and oil pump strainer referring to Oil Pan and
Oil Pump Strainer in this section.
23) Install clutch to flywheel (for M/T model) referring to Clutch
Cover, Clutch Disc and Flywheel in Section 7C1.
24) Install engine mounting brackets.
Tightening torque
Engine side mounting bracket nuts (a):
55 Nm (5.5 kg-m, 40.0 lb-ft)
Frame side mounting bracket nuts (b):
55 Nm (5.5 kg-m, 40.0 lb-ft)
Frame side mounting bracket bolts (c):
93 Nm (9.3 kg-m, 67.5 lb-ft)
Engine side mounting bracket bolts (d):
40 Nm (4.0 kg-m, 29.0 lb-ft)
25) Install engine assembly to vehicle referring to Engine
Assembly in this section.
Special Tools
09910-26510 (OUT0000005) 09910-26530 (OUT0000160) 09910-26540 (OUT0000151) 09911-16510 (OUT0000002)

Dial gauge support TDC rod positioner Camshaft TDC positioner Rear oil seal installer
09911-16520 (OUT0000011) 09912-57820 09913-56510 (OUT0000152) 09913-75510

Rear main seal installer Compression gauge Oil seal installer Bearing installer
09913-96510 (OUT0000012) 09915-76530 (OUT0000057) 1. 09916-14510 09916-51910 (OUT0000132)

Bearing cap seal support Oil pressure gauge kit Valve lifter Fitting, crankshaft oil seal
2. 09916-14521
Valve lifter attachment
09916-77310 09916-84511 09916-96520 09919-46510 (OUT0000110)

Piston ring compressor Forceps Compression gauge attach- Clamp pliers
ment
09919-56550 (OUT0000141) 09919-56560 (OUT0000138) 09924-17811 09944-36011

Tension lever Tension measuring equipment Flywheel holder Steering wheel remover

Use
(Part Number)
Sealant 1207F 99000-31250 To apply to mating surfaces of cylinder of cylinder block and oil pan.
To apply to mating surfaces of cylinder block and gasket holder
plate.
Sealant 1207B 99000-31140 To apply to mating surface of camshaft housing intake manifold and
cylinder head.
To apply mating surfaces of cylinder block and main bearing cap
No.1.

Tightening torque
Fastening part
Nm kg-m lb-ft
Intercooler outlet and inlet hose clamps 4.5 0.45 3.5
Cylinder head cover bolt 10 1.0 7.5
Engine front hook mounting bolt 50 5.0 36.5
Timing belt cover bolt and nut 10 1.0 7.5
EGR pipe bolt 10 1.0 7.5
EGR cooler bolt No.1 10 1.0 7.5
EGR cooler bolt No.2 23 2.3 16.5
EGR cooler bracket nut 30 3.0 22.0
Strut tower bar bolt 50 5.0 36.5
Air cleaner outlet hose clamp 4.5 0.45 3.5
Turbocharger nut 25 2.5 18.0
Lubrication pipe union bolt 20 2.0 14.5
Turbocharger outlet pipe nut 25 2.5 18.0
Exhaust No.2 pipe bolt 55 5.5 40.0
Oil return pipe bolt 10 1.0 7.5
Exhaust manifold nut 30 3.0 22.0
EGR valve spacer nut 10 1.0 7.5
Roller bolt 45 4.5 32.5
Timing belt tensioner bolt 25 2.5 18.0
Camshaft timing belt pulley bolt 20 2.0 14.5
a) Tighten 50 Nm (5.0 kg-m, 36.5 lb-ft)
Crankshaft pulley bolt
b) Tighten 145 Nm (14.5 kg-m, 105 lb-ft)
Oil pressure switch 32 3.2 23.5
Oil pump strainer bolt 9.0 0.9 6.5
Oil pan bolt 16 1.6 11.5
Drain plug 34 3.4 24.5
Suspension frame bolt 85 8.5 61.5
Oil pump bolt 16 1.6 11.5
Gasket holder plate bolt 15 1.5 11.0
Camshaft housing/intake manifold bolt 10 1.0 7.5
Fuel injector pillar bolt 10 1.0 7.5
Camshaft hub bolt 45 4.5 32.5
For tightening procedure, refer to Valves
Cylinder head bolt
and Cylinder Head in this section
Engine bracket bolt No.1 45 4.5 32.5
Engine bracket bolt No.2 20 2.0 14.5
Connecting rod bearing cap nut
b) Tighten by turning through 70
Engine side mounting bracket nut 55 5.5 40.0
Crankshaft main bearing cap bolt
b) Tighten by turning through 60
Oil jet bolt 10 1.0 7.5
Flywheel or drive plate bolt 50 5.0 36.5
Engine side mounting bracket nut 55 5.5 40.0
Engine side mounting bracket bolt 40 4.0 29.0
Tightening torque
Fastening part
Nm kg-m lb-ft
Frame side mounting bracket nut 55 5.5 40.0
Frame side mounting bracket bolt 93 9.3 67.5
ENGINE COOLING 6B-1
SECTION 6B
ENGINE COOLING
WARNING:
authorized SUZUKI dealer. Refer to System Components and Wiring Location View under Gen-
eral Description in air bag system section in order to confirm whether you are performing service
on or near the air bag system components or wiring. Please observe all WARNINGS and Precau-
tions in air bag system section before performing service on or around the air bag system compo-
nents or wiring. Failure to follow WARNINGS could result in unintentional activation of the system
or could render the system inoperative. Either of these two conditions may result in severe injury.
CONTENTS
General Description ........................................6B-2 Coolant Level Check..................................... 6B-7
Cooling System Component .........................6B-2 Cooling System Service................................ 6B-7
Cooling System Circulation ...........................6B-3 Cooling System Flush ................................... 6B-8
Coolant Degassing Tank ...............................6B-4 On-Vehicle Service ..................................... 6B-10
Water Pump ..................................................6B-4 Cooling System Draining ............................ 6B-10
Thermostat ....................................................6B-4 Cooling System Refill.................................. 6B-10
Cooling Fan ...................................................6B-5 Cooling Water Pipes or Hoses.................... 6B-10
Coolant..........................................................6B-5 Thermostat.................................................. 6B-11 6B
Anti-freeze proportioning chart: .................6B-5 Radiator ...................................................... 6B-13
Coolant capacity........................................6B-5 Radiator Fan Relay ..................................... 6B-14
Diagnosis .........................................................6B-6 Water Pump ................................................ 6B-14
Diagnosis Table ............................................6B-6 Required Service Materials ..........................6B-16
Maintenance ....................................................6B-7 Tightening Torque Specifications ...............6B-16
Special Tool...................................................6B-16
6B-2 ENGINE COOLING
General Description
The cooling system consists of the degassing tank cap, radiator, degassing tank, hoses, water pump, cooling
fan, thermostat. The radiator is of tube-and-fin type.
Cooling System Component
1. Radiator 8. Radiator outlet No.2 hose 15. Heater outlet hose 22. To heater unit
2. Engine cooling fan 9. Heater outlet No.2 hose 16. Vent. hose (radiator to degassing) 23. To water pump
3. Degassing tank 10. Water box 17. Vent. hose (pipe to degassing) 24. To cylinder head
4. Radiator inlet hose 11. EGR cooler 18. Vent. hose (waterbox to pipe) No.1 25. To radiator upper tank
5. Radiator outlet hose 12. Inter cooler braket 19. Vent. hose (engine to pipe) 26. To timing belt cover
6. Degassing tank outlet hose 13. Heater inlet hose 20. Oil cooler hose 27. Water ventilation pipe
7. Water inlet pipe 14. Water inlet hose (engine to pipe) 21. To oil cooler 28. Vent. hose (waterbox to pipe) No.2
ENGINE COOLING 6B-3
Cooling System Circulation
[A] : When thermostat is open and close 1. Radiator 4. Engine 7. Water pump
[B] : When thermostat is open 2. Thermostat 5. Degassing tank 8. Heater
[C] : When thermostat is close 3. Engine oil cooler 6. Degassing tank cap (Radiator cap) 9. EGR cooler
6B-4 ENGINE COOLING
Coolant Degassing Tank

The degassing tank (1) consists of a see-through plastic tank, a
hose and a degassing tank cap (2).
During operation, the coolant circulates inside of the degassing
tank constantly. As the coolant warms up and expands, the cool-
ant level in the degassing tank rises. On the other hand, it lowers
as the coolant cools down and contracts. When the pressure
applied to the inside of the degassing tank constantly exceeds the
specified value, the pressure is relieved through the degassing
tank cap.
Thus, the radiator is kept filled with coolant to the desired level at
all times, resulting in increased cooling efficiency.
Coolant level should be between FULL (3) and LOW (4) marks
on the degassing tank.
Water Pump
The water pump (1) is driven by timing belt (2).
The water pump can not be disassembled.
Thermostat
A wax pellet type thermostat is used in the coolant outlet passage
to control the flow of engine coolant, to provide fast engine warm
up and to regulate coolant temperatures.
A wax pellet element is hermetically contained in a metal case,
and expands when heated and contracts when cooled.
When the pellet is heated and expands, the metal case pushed
down the valve to open it.
As the pellet is cooled, the contraction allows the spring to close
the valve.
Thus, the valve remains closed while the coolant is cold, prevent-
ing circulation of coolant through the radiator.
At this point, coolant is allowed to circulate only throughout the
engine to warm it quickly and evenly.
As the engine warms, the pellet expands and the thermostat
valve opens, permitting coolant to flow through the radiator.
Thermostat functional spec. 1.5 C (2.7 F)
Temp. at which valve begins to open 83 C (181 F)
Temp. at which valve becomes fully open 95 C (203 F)
ENGINE COOLING 6B-5
Cooling Fan
The cooling fan is driven by electric motor, and the motor is acti-
vated by ECM (and ECT sensor).
WARNING:
Keep hands, tools, and clothing away from engine cool-
2
ing fan to help prevent personal injury. This fan is electric
and can come on whether or not the engine is running.
The fan can start automatically in response to the relays
with the ignition switch in the ON position.
1
1. Radiator fan motor 1
2. Radiator fan motor 2
Coolant
When the system cools down, the coolant is drawn back into the radiator.
The cooling system has been filled at the factory with a quality coolant that is a 50/50 mixture of water and eth-
ylene glycol antifreeze.
This 50/50 mixture coolant solution provides freezing protection to 36 C (33 F).
Maintain cooling system freeze protection at 36 C (33 F) to ensure protection against corrosion and loss
of coolant from boiling.
This should be done even if freezing temperatures are not expected.
Add ethylene glycol base coolant when coolant has to be added because of coolant loss or to provide added
protection against freezing at temperature lower than 36 C (33 F).
Anti-freeze proportioning chart:
C 36
Freezing temperature
F 33
Antifreeze/Anticorrosion coolant concentration % 50
ltr. 4.75/4.75
Ratio of compound to cooling water US pt 10.04/10.04
Imp. pt. 8.36/8.36
Coolant capacity
Engine, radiator heater and degassing tank etc.

ltr. (US/Imp. pt.) 9.5 (20.1/16.72)
NOTE:
Alcohol or methanol base coolant or plain water alone should not be used in cooling system at any
time as damage to cooling system could occur.
Coolant must be mixed with demineraled water or distilled water.
6B-6 ENGINE COOLING
Diagnosis
Diagnosis Table
Engine overheats Not enough coolant Check coolant level and add as
necessary.
Faulty thermostat Replace.
Faulty water pump Replace.
Dirty or bent radiator fins Clean or remedy.
Coolant leakage on cooling system Repair.
Defective cooling fan motor or its circuit Check and replace as necessary.
Plugged radiator Check and replace radiator as nec-
essary.
Faulty degassing tank cap Replace.
Dragging brakes Adjust brake.
Slipping clutch Adjust or replace.
ENGINE COOLING 6B-7
Maintenance
Coolant Level Check
WARNING:
hot.
Scalding fluid and steam can be blown out under pres-
sure if cap is taken off too soon.
To check level, lift hood and look at see-through degassing tank
(1). It is not necessary to remove degassing tank cap (2) to check
coolant level.
When engine is cool, check coolant level in degassing tank (1).
A normal coolant level should be between FULL (3) and LOW
(4) marks on degassing tank (1).
If coolant level is below LOW mark, remove degassing tank cap
and add recommended coolant to tank to bring coolant level up to
FULL mark. Then, install degassing cap, making sure that the
ear of cap lines up with degassing tank pipe (5).
NOTE:
If recommended quality antifreeze is used, there is no
need to add extra inhibitors or additives that claim to
improve system. They may be harmful to proper opera-
tion of system, and are unnecessary expense.
Cooling System Service
WARNING:
hot.
Cooling system should be serviced as follows.
1) Check cooling system for leakage or damage.
2) Wash degassing tank cap and filler neck with clean water by
removing degassing tank cap when engine is cold.
3) Check coolant for proper level and freeze protection.
6B-8 ENGINE COOLING
4) Using a pressure tester (1), check system and degassing

tank cap (2) for proper pressure holding capacity 110 kpa
(1.1 kg/cm2, 15.6 psi). If replacement of cap is required, use
proper cap specified for this vehicle.
5) Install degassing tank cap (1) to degassing tank turning it

clockwise up to stop.
6) Tighten hose clamps and inspect all hoses. Replace hoses

whenever cracked, swollen or otherwise deteriorated.
7) Clean frontal area of radiator core.
Cooling System Flush
WARNING:
hot.
1) Remove degassing tank cap turning it counter clockwise
when engine is cool.
2) With degassing tank cap removed, run engine until upper
radiator hose is hot (this shows that thermostat is open and
coolant is flowing through system).
3) Stop engine, and remove engine under cover.
ENGINE COOLING 6B-9
4) Stop engine and open radiator drain plug (1) to drain coolant.
5) Close drain plug.
6) Fill the circuit slowly with water.

7) Remove intercooler referring to Intercooler in Section 6E3.
1
8) Loosen bleed screw (1) to bleed air and tighten it after confir-
mation of overflow.
2. Thermostat cap
3. Engine rear hook
2
9) Install intercooler referring to Intercooler in Section 6E3.

10) Run engine until upper radiator hose is hot again.
11) Stop engine, and repeat steps 4) and 10) several times until
drained liquid is nearly colorless.
12) Drain cooling system and then close radiator drain plug
tightly.
13) Disconnect hoses from degassing tank (1). Remove degas-
sing tank and pour out any fluid. Scrub and clean inside of
degassing tank (1) with soap and water. Flush it well with
clean water and drain.
Reinstall degassing tank and hose.
14) Refill cooling system referring to Cooling System Refill in
this section.
6B-10 ENGINE COOLING
On-Vehicle Service
WARNING:
Check to make sure that engine coolant temperature is
cold before removing any part of cooling system.
Also be sure to disconnect negative cord from battery
terminal before removing any part.
Cooling System Draining

1) Remove degassing tank cap.
2) Loosen drain plug (1) on radiator to drain coolant.
3) After draining coolant, be sure to tighten drain plug securely.
Cooling System Refill

1) Add 50/50 mixture of good quality ethylene glycol antifreeze
and water to degassing tank (1).
Fill to FULL level mark (2).
3) Loosen bleed screw to bleed air and tighten it after confirma-
tion of overflow.
4) Install intercooler referring to Intercooler in Section 6E3.
5) Run engine, with degassing tank cap (4) removed, until radi-
ator upper hose is hot.
6) With engine idling, add coolant to degassing tank (1) until
level reaches FULL mark.
Install degassing tank cap (4) turning it clockwise up to stop.
Cooling Water Pipes or Hoses

REMOVAL
1) Drain cooling system referring to Cooling System Draining
in this section.
2) To remove these pipes or hoses, loosen clamp on each hose
and pull hose end off.
ENGINE COOLING 6B-11
INSTALLATION
Install removed parts in reverse order of removal procedure not-
ing the following.
Tighten each clamp securely.
Refill cooling system with proper coolant referring to Cooling
System Refill in this section.
Thermostat
REMOVAL
1) Remove battery from vehicle.
2) Drain cooling system referring to Cooling System Draining
in this section.
4) Remove EGR pipe clamp (1) by using special tool.
Special tool
(A): 09919-46510/OUT0000110
5) Remove EGR pipe (2).
3. Strut tower bar
2
(A)
1 3
6) Remove Engine hunger bracket (1).
7) Remove thermostat cap (1) from water box (3).

8) Remove thermostat (2) from water box (3).
1
2
3
INSPECTION
Check to make sure that valve seat is free from foreign mat-
ters which would prevent valve from seating tight.
Check thermostat seal (1) for breakage, deterioration or any
other damage.
Check thermostatic movement of wax pellet as follows:

1) Immerse thermostat (1) in water, and heat water gradually.
2) Check that valve starts to open at specific temperature.
3) If valve starts to open at a temperature substantially below or
above specific temperature, thermostat unit should be
replaced with a new one. Such a unit, if reused, will bring
about overcooling or overheating tendency.
Temp. at which valve begins to open 83 C (181 F)
Temp. at which valve becomes fully open 95 C (203 F)
2. Thermometer
3. Heater
INSTALLATION
For installation, reverse removal procedure noting the following.
Tighten EGR pipe bolts to specified torque.
(a)
Tightening torque
EGR pipe bolts
(a): 10 Nm (1.0 Kg-m, 7.0 lb-ft)
Install new EGR pipe clamp using special tool.
Special tool
(A): 09919-46510/OUT0000110
(A)
this section.
Radiator
REMOVAL
2) Drain cooling system referring to Cooling System in this
section.
4) When servicing A/T vehicle, place oil pan under radiator (1),
1 and drain A/T fluid disconnecting A/T fluid hoses (2) from
radiator.
5) Detach P/S fluid reservoir (1) and disconnect radiator outlet

3 hose (2) from radiator (3) as shown in figure.
4 6) Disconnect radiator inlet hose (1) and degassing tank hose

(2) from radiator (3).
7) Remove P/S fluid reservoir bracket.
8) Remove P/S high pressure hose clamp.
9) Disconnect radiator fan motor couplers (4).
3 2 1
10) Remove radiator (1) with radiator fan motor assembly from
vehicle.
11) Remove radiator fan motor assembly from radiator (1).
1
INSPECTION
Check radiator for leakage or damage. Straighten bent fins, if any.
CLEANING
Clean frontal area of radiator cores.
INSTALLATION
Reverse removal procedures, noting the following.
Refill cooling system with proper coolant referring to Cooling
System Refill in this section.
After installation, check each joint for leakage.
With A/T vehicle, check A/T fluid level referring to Fluid
Change Section 7B1.
Radiator Fan Relay

INSPECTION
Refer to Radiator Fan Control System in Section 6E3.
Water Pump
CAUTION:
Do not disassemble water pump.
If any repair is required on pump, replace it as assembly.
REMOVAL
2) Drain cooling system referring to Coolant System Draining
in this section.
sioner in Section 6A3.
4) Remove water pump assembly (1).
1
INSPECTION
Rotate water pump by hand to check for smooth operation. If

pump does not rotate smoothly or makes abnormal noise,
replace it.
Inspect water pump impeller for damage.
Replace as necessary.
INSTALLATION
1) Install new pump gasket (2) to water pump (1).

2) Install water pump to cylinder block.
1 2 Tightening torque
Water pump bolt (a): 15 Nm (1.5 kg-m, 11.0 lb-ft)
(a)
3) Install timing belt and timing belt covers referring to Timing
Belt and Belt Tensioner in Section 6A3.
4) Connect negative () cable at battery.
5) Fill coolant referring to Coolant System Refill in this sec-
tion.
6) After installation, check each part for leakage.

Material Use
(Part Number)
Ethylene glycol base coolant Engine cooling system for improv-
(Anti-freeze/Anti-corrosion ing cooling efficiency and for protec-
coolant) tion against rusting.

Tightening torque
Fastening part
Nm kg-m lb-ft
EGR pipe bolt 10 1.0 7.0
Water pump bolt 15 1.5 11.0
Special Tool
09919-46510
(OUT0000110) Clamp pliers
ENGINE FUEL 6C-1
SECTION 6C
ENGINE FUEL
CAUTION:
Be sure to read Precaution in Section 6E before disconnecting fuel line or removing fuel system
part(s).
Failure to follow Precaution could result unneeded fuel system repairs.
CONTENTS
General Description ........................................6C-2 Fuel tank assembly components...............6C-6
Fuel System ..................................................6C-2 2-way check valve (tank pressure
On-Vehicle Service..........................................6C-2 control valve).............................................6C-6
Fuel tank ...................................................6C-7
Water Draining of Fuel Filter .........................6C-2
Fuel Pump and Fuel Level Gauge ................6C-8
Air Bleeding of Fuel System ..........................6C-2
Fuel pump .................................................6C-9
Fuel Filter Assembly......................................6C-2
Fuel level gauge......................................6C-10
Fuel filter assembly components...............6C-2
Injection Pump ............................................6C-10
Fuel filter element......................................6C-3
Fuel filter assembly ...................................6C-4 Tightening Torque Specifications ...............6C-11
Fuel Tank Assembly......................................6C-6 Special Tools.................................................6C-11
6C
6C-2 ENGINE FUEL
General Description
Fuel System
The main components of the fuel system are fuel tank, fuel pump, high pressure fuel pump, fuel filter and fuel
level gauge and it includes fuel feed line, fuel return line and vapor line.
On-Vehicle Service
Water Draining of Fuel Filter
3) Place container under bleed screw (1), and drain fuel loosen-
ing it.
4) Tighten bleed screw.
5) Install strut tower bar referring to Strut Damper in Section
3D.
1
Air Bleeding of Fuel System

Air bleeding must be carried out when fuel system has been dis-
assembled or when vehicle ran out of fuel.
Turn ignition switch ON to operate fuel pump and after about 5
seconds turn it OFF. Repeat this 6 times and then check engine
starts.
Fuel Filter Assembly

Fuel filter assembly components
2 3
5
7 10 Nm (1.0 kg-m)
1. Fuel filter fastener 4. Gasket 7. Fuel filter assembly mounting bolt

2. Fuel filter cap incorporate with fuel heater 5. Fuel filter case Do not reuse
3. Fuel filter element 6. Bleed screw Tightening torque

ENGINE FUEL 6C-3
Fuel filter element

REMOVAL
2) Place container under breed screw (1), and drain fuel loos-
ening breed screw.
1 3) Pull out fuel pipes (1) with pushing lock button (2).
4) Disconnect coupler (3) from fuel filter cap.
1
2
5) Turning fuel filter fastener (1) counterclockwise, remove fuel

filter fastener (1) from fuel filter case (4).
6) Remove fuel filter cap (2) and fuel filter element (3).
4
6C-4 ENGINE FUEL
INSTALLATION
Be sure to replace fuel filter element as new one.
Clean fuel filter case as follows.
a) Place container under breed screw, and drain fuel loosing
breed screw.
b) Tighten breed screw.
c) Remove fuel filter case.
d) Pour diesel substitute (kerdane, diltine or paraffin) into fuel
filter case.
e) Clean fuel filter case with brush.
f) Dry and wipe out fuel filter case.
1
Tighten fuel filter fastener (1) until its match mark (2)
becomes between MAXI and MINI.
Bleed air in system referring to Air Bleeding Procedure in
2 this section.
Start engine and check that there are no fuel leakage.
Fuel filter assembly

REMOVAL
1) Disconnect fuel pipes and install special tools to fuel filter
cap referring to Step 1) through 4) of Removal under Fuel
Filter Element in this section.
(A) 1
2) Install special tools to fuel filter cap (1) in order to prevent its
(A)
internal parts from dust.
For detail, refer to Precaution in Section 6E.
Special tool
(A) : 09916-50010
3) Remove fuel filter assembly mounting bolts (1).

4) Remove fuel filter assembly (2).
1
2
ENGINE FUEL 6C-5
INSTALLATION
Tighten fuel filter assembly mounting bolts (1) to specified
torque.
Tightening torque
Fuel filter mounting bolt (a) : 10 Nm (1.0 kg-m, 7.0 lb-ft)
this section.
1, (a)
6C-6 ENGINE FUEL
Fuel Tank Assembly

Fuel tank assembly components
11
9
10
12
13 8
6
11
1
3 5
3
2
2
14 50 Nm (5.0 kg-m)
4 15 50 Nm (5.0 kg-m)
1. Fuel tank 5. 2 way check valve 9. Fuel filler packing 13. Fuel tank breather pipe
2. Fuel tank fixer belt 6. Breather hose 10. Fuel filler cap 14. Fuel tank bolt
3. Fixer belt pad 7. Fuel tank filler hose 11. Hose 15. Fuel tank protector bolt
4. Fuel tank protector 8. Fuel filler neck 12. Fuel cut valve Tightening torque
2-way check valve (tank pressure control valve)

INSPECTION
WARNING:
Do not suck air through 2-way check valve.
Fuel vapor inside the valve is harmful.
1) Air should pass through 2-way check valve (1) smoothly from
fuel tank side (Black side (2) of 2-way check valve) to Orange
side (3) when blown hard.
2) From Orange side, even when blown softly, air should come
out of Black side.
3) If air doesn't pass through valve in step 1) or hard blow is
required in step 2), replace 2-way check valve.
ENGINE FUEL 6C-7
Fuel tank
REMOVAL
2) Remove fuel filler cap.
3) Insert hose of a hand operated pump into fuel filler hose (1)
and drain fuel in space A in the figure (drain fuel through it
till fuel stops).
CAUTION:
Do not force hose of a hand operated pump into fuel
tank, or inlet valve may be damage.
2. Fuel tank inlet (check) valve
4) Disconnect filler hose (1) from fuel tank and breather hoses
(2) from fuel filler neck.
5) Remove fuel tank inlet valve (3).
NOTE:
Use care not to damage inlet valve when removing.
6) Drain fuel tank by pumping fuel out through fuel tank filler.
Use hand operated pump device to drain fuel tank.
CAUTION:
Never drain or store fuel in an open container due to pos-
sibility of fire or explosion.
6C-8 ENGINE FUEL
7) Disconnect fuel pump inlet hose (1) from fuel pump and fuel
return hose (2) from pipes.
8) Remove fuel tank protector (if equipped) from vehicle.
9) Lower fuel tank gradually while holding it with jack horizon-
tally and pull out coupler (3) at fuel level gauge (4).
INSTALLATION
Tighten each bolt to specified torque.
Tightening torque
Fuel level gauge bolt (a): 5.0 Nm (0.5 kg-m, 3.5 lb-ft)
Fuel tank bolt (b): 50 Nm (5.0 kg-m, 36.0 lb-ft)
INSPECTION
After removing fuel tank, check hoses and pipes connected to fuel
tank for leaks, loose connections, deterioration or damage. Also
check fuel level gauge gaskets for leaks, visually inspect fuel tank
for leaks and damage.
Replace any damaged or malconditioned parts.
Fuel Pump and Fuel Level Gauge
3 5.0 Nm (0.5 kg-m)
7
2
6 4
6
8
1
1. Fuel tank 3. Fuel return hose 5. Fuel pump 7. Fuel pump outlet hose 9. Fuel return pipe
2. Fuel level gauge 4. Fuel pump inlet hose 6. Fuel pump bracket 8. Fuel feed pipe Tightening torque
ENGINE FUEL 6C-9
Fuel pump
REMOVAL
2) Hoist vehicle.
3) Disconnect fuel pump wire harness (1).
2
4) Pull outlet hose clamp (2) and disconnect outlet hose (3).
4
5) Disconnect inlet hose (4) from fuel pump (5).
3 6) Remove fuel pump (5).
6. Left side suspension lower arm
6
7) Remove inlet hose clamp (1) using special tool.

(A)
5 Special tool
(A) : 09919-46510/OUT 0000110
2
8) Disconnect inlet hose (2) from fuel pump (3).
9) Disconnect BLU/BLK wire terminal (4) and BLK wire ter-
minal.
4
(A)
1 3
INSPECTION
Connect battery and ammeter to starter as shown.

Check that fuel pump operation and ammeter indicates specified
current.
Fuel pump specified current: 8 A MAX. at 12 V
INSTALLATION
Connect BLU/BLK wire terminal (4) and BLK wire termi-
2 nal (2) to fuel pump using nuts securely as shown in figure.
1
6C-10 ENGINE FUEL
Install new inlet hose clamp (1) using special tool.

(A)
Special tool
(A) : 09919-46510/OUT 0000110
(A)
1
Be sure to install fuel pump (1) to proper direction as shown.

this section.
Fuel level gauge

REMOVAL
1) Remove fuel tank referring to Fuel tank in this section.
2) Remove fuel level gauge (1) from fuel tank.
INSPECTION
Check fuel level gauge (1) for evidence of dirt and contamination.
If present, clean and check for presence of dirt in fuel tank.
INSTALLATION
Use new gasket (2).
Tighten fuel level gauge bolts to specified torque.
Tightening torque
Fuel level gauge bolt (a): 5.0 Nm (0.5 kg-m, 3.5 lb-ft)
3. To supply pump
4. From return pipe
Injection Pump
For removal and installation, refer to Injection Pump in Section
6E3.
ENGINE FUEL 6C-11

Tightening torque
Fastening part
Nm kg-m lb-ft
Fuel filter mounting bolt 10 1.0 7.0
Fuel tank bolt 50 5.0 36.0
Fuel tank protector bolt 50 5.0 36.0
Fuel level gauge bolt 5 0.5 3.5
Special Tools
09916-50010 09919-46510
Fuel system, plug set (OUT0000110) Clamp pliers
6C-12 ENGINE FUEL
ENGINE AND EMISSION CONTROL SYSTEM (RHW ENGINE) 6E3-1
SECTION 6E3
6F1
7B1
ENGINE AND EMISSION CONTROL SYSTEM 7C1
7C1
(RHW ENGINE) 7D
7E
7A
WARNING: 7A1
For vehicles equipped with a Supplemental Restraint (Air Bag) System: 7B1
Service on and around the air bag system components or wiring must be performed only by an 7C1
authorized SUZUKI dealer. Refer to Air Bag System Components and Wiring Location View under 7D
General Description in air bag system section in order to confirm whether you are performing ser- 7E
vice on or near the air bag system components or wiring. Please observe all WARNINGS and Ser- 7F
8A
8B
8C
8D
6H
8D
NOTE:
Service information for two types of emission control system, Other Than EOBD Spec, and EOBD
Spec, is provided in this section. To distinguish between Other Than EOBD Spec and EOBD 10
Spec, refer to Identification of Emission Control System in this section. 10A
10B
CONTENTS
General Description ..................................... 6E3-3 Fuel Leakage Check ................................ 6E3-24 6E3
Identification of Emission Control Fuel pump ............................................ 6E3-24
System ....................................................... 6E3-3 Fuel heater ........................................... 6E3-24 6G
System Diagram......................................... 6E3-4 Fuel injector.......................................... 6E3-25
Electronic Control System .......................... 6E3-5 Common rail (High pressure fuel
System location diagram ........................ 6E3-5 injection rail) ......................................... 6E3-28
System wiring diagram ........................... 6E3-6 Injection pump...................................... 6E3-31
Air Intake System ..................................... 6E3-10 Electronic Control System........................ 6E3-34
Fuel Delivery System ............................... 6E3-11 Engine control module (ECM) .............. 6E3-34
On-Vehicle Service..................................... 6E3-12 ECM registration .................................. 6E3-35
Registration data check........................ 6E3-36
Accelerator Cable Adjustment.................. 6E3-12
Mass air flow sensor
Idle Speed Inspection............................... 6E3-12
(MAF sensor) ....................................... 6E3-36
Air Intake System ..................................... 6E3-13
Throttle position sensor (TP sensor)
Vacuum hose routing diagram ............. 6E3-13
(accelerator pedal position sensor) ...... 6E3-38
Throttle valve assembly........................ 6E3-14
Fuel temperature sensor assembly...... 6E3-39
EGR throttle solenoid valve.................. 6E3-15
Fuel (rail) pressure sensor ................... 6E3-40
Vacuum pump ...................................... 6E3-15
Engine coolant temperature sensor
Boost pressure regulator solenoid
(ECT sensor)........................................ 6E3-41
valve ..................................................... 6E3-18
VSS ...................................................... 6E3-42
Glow plug ............................................. 6E3-19
Camshaft position sensor
Fuel Delivery System ............................... 6E3-21
(CMP sensor) ....................................... 6E3-43
Precautions .......................................... 6E3-21
Crankshaft position sensor
Low pressure fuel supply system ......... 6E3-23
(engine speed sensor) ......................... 6E3-43
6E3-2 ENGINE AND EMISSION CONTROL SYSTEM (RHW ENGINE)
Intake air pressure sensor EGR System ............................................ 6E3-51

(manifold absolute pressure EGR valve component ......................... 6E3-51
sensor) ................................................. 6E3-45 EGR valve and EGR cooler ................. 6E3-52
Radiator fan control system ................. 6E3-46 Vacuum hose ....................................... 6E3-53
Radiator fan.......................................... 6E3-46 EGR solenoid valve ............................. 6E3-53
Radiator fan relay 1 (high/low) ............. 6E3-47 Swirl Control Solenoid Valve ................... 6E3-54
Radiator fan relay 2 (high).................... 6E3-48 Tightening Torque Specifications............ 6E3-56
Radiator fan relay 3 (low) ..................... 6E3-48 Special Tools ............................................. 6E3-57
Double relay ......................................... 6E3-49
Pre/post heating relay
(control unit) ......................................... 6E3-50
General Description
[A]
For EOBD spec, the wire harness type power supply line (1) for
1
glow plugs is used.
For other than EOBD spec, the metal plate type power supply line
(2) for glow plugs is used.
[A]: Other than EOBD spec
[B]: EOBD spec
[B]
2
System Diagram
29 3 32 1
30
14 32 4
32
6
13 32
33 9
5
15 32 10
7 32
16
35
32 32
8
27 11 17
32 12
28 34
32 18
32
20
19
23
25 32
24 22
21
32
26
31
1. Air Cleaner 13. Injector 25. Fuel pump

2. MAF sensor 14. Fuel temperature sensor 26. Fuel tank
3. Turbocharger 15. Fuel pressure sensor 27. Fuel feed line
4. Intercooler 16. Vacuum pump 28. Fuel return line
5. TP sensor (Accelerator stroke sensor) 17. EGR throttle solenoid valve 29. Waste gate actuator
6. Intake air pressure sensor 18. EGR solenoid valve 30. Catalytic converter
7. Throttle valve actuator 19. EGR valve 31. Fuel heater
8. Throttle valve assembly 20. Boost (Turbo) pressure regulator solenoid valve 32. To ECM
9. CMP sensor 21. Injection pump 33. Common rail (High pressure fuel injection rail)
10. Glow plug 22. Fuel pressure regulator 34. Swirl control solenoid valve
11. ECT sensor 23. Injection pump solenoid valve (3rd piston deactivator) 35. Swirl valve
12. CKP sensor (Engine speed sensor) 24. Fuel filter
Electronic Control System

System location diagram
g
f
1 C
11 e
D E
10
G
9 12
q 8 B
d b 6
c i
a 4
H
j p l
F k
h 5 A
3
m
2 n
7
INFORMATION SENSORS CONTROLLED DEVICES OTHERS

1. VSS (Installed on transfer) a: Injector A: ECM
2. MAF sensor (built-in intake air temp. sen- b: Radiator fan relay 1 (High/Low) B: Pre/post heating relay (control unit)
sor)
3. Accelerator stroke sensor c: Radiator fan relay 2 (High) C: Combination meter
4. Fuel (rail) pressure sensor d: Radiator fan relay 3 (Low) D: TCM
5. Intake air pressure sensor e: Engine coolant temperature warning lamp E: Data link connector
6. Fuel temperature sensor f: Malfunction indicator lamp F: Main fuse box
7. CMP sensor g: Glow indicator lamp G: Fuel box
8. ECT sensor h: Fuel pressure regulator H: Fuel heater
9. CKP sensor (Engine speed sensor) i: Double relay
10. Immobilizer control module j: EGR valve
11. A/C control module k: EGR solenoid valve
12. Brake lamp switch l: Boost (Turbo) pressure regulator solenoid valve
m: EGR throttle solenoid valve
n: Injection pump solenoid valve (3rd piston deactivator)
o: Fuel pump
p: Glow plug
q: Swirl control solenoid valve
System wiring diagram

Other than EOBD Spec
1 IG 1
+B
BLK/WHT
2
39 E227-2 PPL/GRN
20
LT BLU E229-7
BLK GRN/BLU E229-3

E228-40 GRN/BLU
26 +BB
E227-12 BLK/RED
27
E227-30 PPL/YEL
3 28
BLU/YEL E228-15 E227-14 RED/BLK
PPL/RED E228-28
BLK/WHT E227-11 IG 1
BLK E227-31
4 29
PPL/WHT E228-29 E227-25 GRN/WHT
BRN/BLU E228-30 +B
IG 1
GRN/BLU E227-15
GRY/BLU E227-19 24
5 LT GRN E227-23
BRN E227-16
21
GRY E228-7 IG 1 IG 1
6 ORN/WHT E228-6
LT GRN/BLK E228-5
23
22
LT GRN E228-23
7 BRN/RED E228-46 E227-18 YEL/WHT
GRN/ORN E228-45
E227-3 BLU/BLK
8 BRN E228-21
BLU/ORN E228-20 E227-4 YEL/BLU
9 PNK E229-2 25
RED E229-9
10 PNK/BLK E229-25
RED/BLK E229-17
11 PNK/GRN E229-26
RED/GRN E229-18 +BB
12 PNK/BLU E229-1
E229-10 31
RED/BLU
E228-24 YEL/GRN 10
E228-14 LT GRN/WHT
30 9 3
BRN/YEL E228-17
13 ORN/BLU E228-18 E228-1 BLU/BLK 2 11
GRY/RED E228-19 E228-2 WHT/GRN 1 15
E228-48 GRN/ORN 7 8
PPL/BLK IG 1
E228-8
14 BRN/WHT E228-9 34
E228-36 LT GRN/RED
15 BLU E228-4
35
ORN/BLK E228-3 E229-31 GRN/BLK 5
E229-32
36 4 32
PPL/BLK
GRN E227-28 37
16 PNK E227-10 E228-34 RED/GRN
E228-47 40
RED/BLK
YEL/BLK E227-29
17 E227-21 38
GRY/WHT
YEL/WHT E227-20
18 BRN E227-7 E228-38 BLK 33
E228-37 BLK
E227-32 BLK
19 BLU/WHT E229-28
WHT E228-11
EOBD Spec
1 IG 1
+BB
BLK/WHT
2
39 E227-2 PPL/GRN
20
LT BLU E229-7
BLK GRN/BLU E229-3

E228-40 GRN/BLU
26 +BB
E227-12 BLK/RED
27
E227-30 PPL/YEL
3 28
BLU/YEL E228-15 E227-14 RED/BLK
PPL/RED E228-28
BLK/WHT E227-11 IG 1
BLK E227-31
4 29
PPL/WHT E228-29 E227-25 GRN/WHT
BRN/BLU E228-30 +B
IG 1
GRN/BLU E227-15
GRY/BLU E227-19 24
5 LT GRN E227-23
BRN E227-16
21
GRY E228-7 IG 1 IG 1
6 ORN/WHT E228-6
LT GRN/BLK E228-5
23
22
LT GRN E228-23
7 BRN/RED E228-46 E227-18 YEL/WHT
GRN/ORN E228-45
E227-3 BLU/BLK
8 BRN E228-21
BLU/ORN E228-20 E227-4 YEL/BLU
9 PNK E229-2 25
RED E229-9
10 PNK/BLK E229-25
RED/BLK E229-17
11 PNK/GRN E229-26
RED/GRN E229-18 +BB
12 PNK/BLU E229-1
E229-1C 31
RED/BLU
E228-24 YEL/GRN 10
E228-14 LT GRN/WHT
30 9 3
BRN/YEL E228-17
13 ORN/BLU E228-18 E228-1 BLU/BLK 2 11
GRY/RED E228-19 E228-2 WHT/GRN 1 15
E228-48 GRN/ORN 7 8
PPL/BLK IG 1
E228-8
14 BRN/WHT E228-9 34
E228-36 LT GRN/RED
15 BLU E228-4
35
ORN/BLK E228-3 E229-31 GRN/BLK 5
E229-32
36 4 32
PPL/BLK
GRN E227-28 37
16 PNK E227-10 E228-34 RED/GRN
E228-47 40
RED/BLK
YEL/BLK E227-29
17 E227-21 38
GRY/WHT
WHT/YEL E227-20
18 BRN E227-7 E228-38 BLK 33
E228-37 BLK
E227-32 BLK
19 BLU/WHT E229-28
WHT E228-11
ECM Connector (Terminal Arrangement Viewed from Harness Side)
1. Pre/post heating relay (control unit) 15. Crankshaft position sensor 29. Brake lamp switch
2. Glow plug 16. Immobilizer control module 30. Fuel pressure regulator
3. Vehicle speed sensor 17. A/C control module 31. Double relay
4. Mass air flow sensor (built-in intake air temp. 18. Combination meter 32. Ignition switch
sensor)
5. Throttle position sensor (Accelerator stroke 19. Transmission control module (TCM) 33. Battery
sensor)
6. Fuel (rail) pressure sensor 20. Data link connector 34. EGR solenoid valve
7. Intake air pressure sensor (MAP sensor) 21. Radiator fan motor 1 (Left side) 35. Boost (Turbo) pressure regulator solenoid valve
8. Fuel temperature sensor 22. Radiator fan relay 1 (High/Low) 36. EGR throttle solenoid valve
9. Fuel injector No.1 23. Radiator fan relay 2 (High) 37. Injection pump solenoid valve (3rd piston deactivator)
10. Fuel injector No.2 24. Radiator fan relay 3 (Low) 38. Fuel pump
11. Fuel injector No.3 25. Radiator fan motor 2 (Right side) 39. Engine control module (ECM)
12. Fuel injector No.4 26. Engine coolant temperature warning lamp 40. Swirl control solenoid valve
13. Camshaft position sensor 27. Malfunction indicator lamp
14. Engine coolant temperature sensor 28. Glow indicator lamp
TERMINAL CIRCUIT TERMINAL CIRCUIT TERMINAL CIRCUIT

1 7 Ground for fuel pressure sensor 45 Signal for intake air pressure sensor
2 Data link connector 8 Engine coolant temperature sensor () 46 Ground for intake air pressure sensor
E228
3 Radiator fan state 9 Engine coolant temperature sensor (+) 47 Swirl control solenoid valve
4 Radiator fan relay (low) 10 48 Double relay (Fuel pump relay)
5 11 Engine torque signal (A/T) 1 Fuel injector No.4 (+)
6 12 2 Fuel injector No.1 (+)
7 Engine speed signal (Combination meter) 13 3 Pre post heating diagnostic
8 14 Fuel pressure regulator 4
9 15 Vehicle speed sensor 5
10 Immobilizer control module signal 16 6
11 Power supply for mass air flow sensor 17 Power supply for camshaft position sensor 7 Pre/post heating relay
12 Engine coolant temperature warning lamp 18 Signal for camshaft position sensor 8
13 19 Ground for camshaft position sensor 9 Fuel injector No.1 ()
14 Glow indicator lamp 20 Signal for fuel temperature sensor 10 Fuel injector No.4 ()
15 Throttle position sensor No.1 21 Ground for fuel temperature sensor 11
(Accelerator stroke sensor)
16 Sensor ground 22 12
E227 17 23 Power supply for intake air pressure sensor 13
18 Radiator fan relay (high) 24 Double relay (Main relay) 14
19 Throttle position sensor No.2 25 15
(Accelerator stroke sensor)
20 Signal for engine coolant temperature sen- E228 26 16
sor
21 Cut off signal for A/C control module 27 17 Fuel injector No.2 ()
E229
22 28 Intake air temperature sensor 18 Fuel injector No.3 ()
23 5 V power supply output 29 Mass air flow sensor (+) 19
24 30 Mass air flow sensor () 20
25 Brake lamp switch 31 21
26 32 22
27 33 23
28 Immobilizer control module wake-up signal 34 Injection pump solenoid valve 24
(3rd position deactivator)
29 A/C control module signal 35 25 Fuel injector No.2 (+)
30 Malfunction indicator lamp 36 ERG solenoid valve 26 Fuel injector No.3 (+)
31 Ground for mass air flow sensor 37 Ground 27
32 Ground 38 Ground 28 Throttle position signal (A/T)
1 Power source 39 29
2 Double relay (Main relay) 40 Data link connector 12 V 30
3 Crankshaft position (Engine speed) sensor 41 31 Boost (Turbo) pressure regulator solenoid
() valve
E228
4 Crankshaft position (Engine speed) sensor 42 32 ERG throttle solenoid valve
(+)
5 Power supply for fuel pressure sensor 43
6 Signal for fuel pressure sensor 44
Correspondence Table of Harness Connector


E227 C51-1
E228 C51-2
E229 C51-3
Air Intake System
4 1
3
2
7
12
13 14
6
11
8
9
10
1. Air cleaner 6. Intercooler 11. Intake manifold / camshaft housing

2. MAF sensor 7. Intake air pressure sensor 12. Breather hose
3. Air cleaner outlet hose 8. Intercooler outlet hose 13. Exhaust manifold
4. Turbocharger 9. EGR throttle valve assembly 14. PCV hose
5. Intercooler inlet hose 10. Swirl control solenoid valve
Fuel Delivery System
1. Fuel tank 5. Injection pump [A]: Fuel feed line

2. Fuel pump 6. Common rail (High pressure fuel injection rail) [B]: Fuel return line
3. Fuel filter 7. Injector
4. Fuel temperature sensor 8. Fuel heater
On-Vehicle Service
Accelerator Cable Adjustment
1) Check accelerator pedal play which should be within the follow-
ing specification.
1
If measured value is out of specification, adjust it to specifi-
cation with cable adjusting nut (1).
Accelerator pedal play
a: 2 7 mm (0.08 0.27 in.)
2) With accelerator pedal depressed fully, check clearance

between throttle lever and lever stopper (throttle body).
If measured value is out of specification, adjust it to specifi-
cation by changing height of pedal stopper bolt.
Accelerator cable adjustment clearance (With pedal
depressed fully)
b: 0.5 2.0 mm (0.02 0.07 in.)
Idle Speed Inspection

1) Shift transmission into Neutral (for M/T) or P range (for A/T).
2) Start engine and warm it up to normal operating tempera-
ture.
3) Turn all electrical loads off.
4) Using tachometer, verify that idle speed is within specifica-
tion.
Engine speed: 825 875 rpm (M/T)
805 855 rpm (A/T)
5) Operate A/C and verify that engine speed is within specifica-
tion.
Engine speed: 825 875 rpm (M/T or A/T)
6) If not, refer to troubleshooting Improper engine idle under
Engine Diagnosis Table in Section 6-1.
Air Intake System

Vacuum hose routing diagram
10
9
4
2
8 7
e
d
6
a
5
b
c
1
f e c
8
d b
g
9
2
10
d a
a: To EGR throttle valve g: To swirl control solenoid valve 5. EGR throttle solenoid valve
b: To EGR valve h: To brake booster 6. EGR solenoid valve
c: To waste gate actuator 1. Vacuum pump 7. Boost (turbo) pressure regulator solenoid valve
d: To EGR throttle solenoid valve and EGR solenoid valve 2. EGR throttle valve assembly 8. Waste gate actuator (turbocharger)
e: To boost (turbo) pressure regulator solenoid valve 3. Intake air pressure sensor 9. Swirl control solenoid valve
f: To swirl control solenoid valve, brake booster and each sole- 4. EGR valve 10. Brake booster
noid valve
Throttle valve assembly

Inspection
1) Remove intercooler and intercooler outlet hose.
(A) 2) Connect a vacuum pump gauge (Special Tool) to throttle
valve assembly (1).
Special tool
(A): 09917-47910
3) Gradually increase vacuum and check for throttle valve (2)
operation.
If not as specified, replace throttle valve assembly (1).
1
Valve operation starting vacuum:
0 About 10.7 kPa (80 mmHg)
Valve operation completion vacuum:
2
About 50.6 66.5 kPa (380 500 mmHg)
Removal
2) Disconnect vacuum hose (1) from throttle valve assembly
(2).
3) Remove throttle valve assembly from intake manifold/cam-
shaft housing (3).
3 1 CAUTION:
Dont disassemble throttle valve assembly.
2
Installation

Clean mating surfaces of throttle valve assembly and intake
manifold/camshaft housing.
Check O-ring for damage and replace throttle valve assem-
bly if necessary.
Connect vacuum hose securely.

EGR throttle solenoid valve

Removal
2) Remove EGR throttle solenoid valve (1) from bracket.
3) Disconnect connector from EGR throttle solenoid valve.
4) Disconnect vacuum hoses from EGR throttle solenoid valve.
1
Inspection
Measure resistance between each two terminals.

If resistance is out of specification, replace EGR throttle solenoid
valve.
EGR throttle solenoid valve resistance
12 18 at 25 C (77 F)
Installation
For installation, reverse removal procedure.
Vacuum pump
Removal
1) Remove battery.
2) Remove intercooler from intercooler bracket.
3) Remove EGR pipe (1) from EGR cooler and intake manifold/
camshaft housing.
1
4) Remove left side intercooler bracket (1).
5) Remove swirl control solenoid valve mounting nuts (1).
6) Disconnect vacuum hose (1) from vacuum pump.

7) Remove vacuum pump (2) from cylinder head.
2
Installation
1) Install new O-rings (1) to vacuum pump.
2) Install vacuum pump (2) to cylinder head.
Fit the dogs of vacuum pump coupling into the slot of cam-
shaft.
3) Tighten vacuum pump bolts and nut to specified torque.
Tightening torque
Vacuum pump bolt and nut
(a): 20 Nm (2.0 kg-m, 14.5 lb-ft)
4) Connect vacuum hose (3) to vacuum pump.
3
1
2
(a)
5) Tighten swirl control solenoid valve nuts (1).
6) Install left side intercooler bracket (1).
1
7) Install EGR pipe (1) to EGR cooler and intake manifold/cam-

shaft housing.
8) Install new EGR pipe clamp by using special tool.
Special tool
(A): 09919-46510/OUT0000110
1
NOTE:
Do not reuse EGR pipe clamp.
9) Install intercooler from intercooler bracket.
(A)
10) Install battery.
Boost pressure regulator solenoid valve

Removal
2) Remove boost pressure regulator solenoid valve (1) from
bracket.
1
3) Disconnect connector from boost pressure regulator sole-
noid valve.
4) Disconnect vacuum hoses from boost pressure regulator
solenoid valve.
Inspection

If resistance is out of specification, replace boost pressure regula-
tor solenoid valve.
Boost pressure regulator solenoid valve resistance
12 18 at 25 C (77 F)
Installation
Glow plug
Removal
CAUTION:
Do not damage heating section of the glow plug.
Do not use glow plug that has been dropped.
When removing glow plug, first loosen it by using a
tool so that one or more screw threads remain
engaged, then loosen and remove by hand.

2) Drain cooling system and tighten drain plug.
3) Remove intercooler referring to Intercooler in Section 6A3.
4) Disconnect vacuum hoses (1) from vacuum pipe.
1 5) Remove vacuum pipe (2) from intercooler bracket.
6) Remove EGR valve and EGR cooler referring to EGR Valve

and EGR Cooler in this section.
7) Disconnect glow plug connector (1) (other than EOBD spec
only).
1
[A] 8) Remove glow plug metal plate (1) (other than EOBD spec) or
glow plug wires (2) (EOBD spec) from glow plugs.
[A]: Other than EOBD spec
1 [B]: EOBD spec
[B]
9) Remove glow plugs (1) from cylinder head.
Installation
Tightening glow plug to specified torque.
Tightening torque
(a) Glow plug (a): 10 Nm (1.0 km-m, 7.5 lb-ft)
Use new EGR gasket.

Tighten EGR connection bolts and nuts to specified torque
referring to EGR Valve Component in this section.
Connect vacuum hoses securely.
Section 6B.
Fuel Delivery System
WARNING:
Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel. Fuel line spills and leaks are dangerous. Fuel can ignite and
cause serious injuries or death and damage.
Fuel can also irritate skin and eyes. To prevent this, always complete the following Precautions.
Precautions
When disconnecting a fuel hose or pipe, wrap rag around it to protect against fuel leakage. Plug discon-
nected hose.
Before disconnecting a fuel hose or pipe, wait 30 seconds or more after engine stop to release pressure in
fuel system.
When disconnecting fuel line from injection pump, injector, delivery pipe and/or fuel filter, install new plug or
new cap including in fuel system plug set (special tool) to fittings immediately in order to prevent its internal
part from dust.
1. Fuel injector 3. Injection pump : Use special tool with clip which fixing fuel
return hose to injector.
2. Common rail 4. Fuel filter : Do not reuse
Special tool
(A): 09916-50010
6
7
12
13
14
5
, [D]
1
1
, [C]
11 25 Nm (2.5 kg-m)
4, [A]
16
15 40 Nm (4.0 kg-m)
26 Nm (2.6 kg-m)
2,
9,
3,
, [B]
10
[A]: Tighten fuel injector nut to 4 Nm (0.4 kg-m) and then 3. Copper seal 9. High pressure supply 15. Fuel pressure sensor
turn fuel injector nut at 45 pipe
[B]: Tighten union nut to 24 Nm (2.4 kg-m) and then turn 4. Nut 10. Injection pump 16. Fuel temperature sensor
tighten union nut to 26 Nm (2.6 kg-m)
[C]: Tighten union nut to 24 Nm (2.4 kg-m) and then turn 5. Return hose 11. Bolt : Tightening torque
tighten union nut to 26 Nm (2.6 kg-m)
[D]: Tighten union nut to 8 Nm (0.8 kg-m) and then turn 6. High pressure pipe (for 12. Fuel feed hose : Do not reuse.
tighten union nut to 27.5 Nm (2.8 kg-m) No.1 & No.2)
1. Fuel injector 7. High pressure pipe (for 13. Fuel return hose
No.3 & No.4)
2. Sealing ring 8. Common rail (high pres- 14. Fuel filter assembly
sure (including fuel heater)
Low pressure fuel supply system

Inspection
CAUTION:
A small amount of fuel may be released when fuel feed
hose is removed. Place container under the fuel feed
hose or fuel feed pipe with a shop cloth so that released
fuel is caught in container or absorbed in cloth. Place
that cloth in an approved container.
1) Disconnect fuel feed hose (1) from fuel feed pipe.

(A) 2) Connect special tools and hose (2) between fuel feed hose
(B)
and fuel feed pipe as shown in figure, and clamp hose
1
securely to ensure no leaks occur during checking.
Special tool
(A): 09912-58442
(B): 09912-58432
(C): 09912-56530
3) Check that battery voltage is above 11 V.
2
4) Check for the maximum fuel pressure by repeating the fol-

lowing procedure for 5 times.
a) Turn ignition switch to ON position for about 5 seconds.
b) Turn ignition switch to OFF position.
5) Start engine.
6) Measure fuel pressure at idling.
If measured specified fuel pressure is not obtained, refer to
Table B-2 Fuel Pressure Inspection in Section 6-1 and
check each possibly defective part. Replace if found defec-
tive.
7) Make sure that the fuel pressure is decreased after turning
the ignition switch to OFF position.
If not decreased, make sure if the fuel pipe is clogged up. If
clogged up, replace the original pipe with the new one.
Fuel pressure specification
CONDITION FUEL PRESSURE

With fuel pump operating and about 300 kPa
engine stopped (See Step 4)) 3.0 kg/cm2,
42.7 psi
At specified idle speed about 320 kPa
(See Step 6)) 3.2 kg/cm2,
45.5 psi
With fuel pump stopped 0 kPa
(See Step 7)) 0 kg/cm2,
0 psi
8) After checking fuel pressure, remove special tool and hose

from fuel feed pipe.
9) Connect fuel feed hose and clamp it securely.
10) With engine OFF and ignition switch ON, check for fuel
leaks.
Fuel Leakage Check

2) Check for the fuel leakage in each part, which was serviced.
3) Start the engine, and then check for the fuel leakage in each
part, which was serviced.
4) Run vehicle at 1000 rpm with the 3rd gear, accelerate the
vehicle to 3500 rpm with the same gear, and stop the vehi-
cle. Check for the fuel leakage in each part, which was ser-
viced.
Fuel pump
On-Vehicle Inspection
1) Check that fuel pump operating sound is heard from fuel
pump for 5 seconds and then stop when turning ignition
switch to ON position.
If above check result is not satisfactory, advance to Table B-
1 Fuel Pump Circuit Inspection in Section 6-1.
2) Check that fuel pressure is felt at fuel feed hose (1) for about
5 seconds after ignition switch ON.
If fuel pressure is not felt, advance to Low Pressure Fuel
Supply System in this section.
Removal/Inspection/Installation
Refer to Fuel Pump in Section 6C.
Fuel heater
Refer to Fuel Heater in Section 6C for removal, installation and
inspection.
Fuel injector
NOTE:
B There are three types of the fuel injector type, whose are
distinguished as A, B and C.
The distinction mark is stamped on the near the connec-
tor. When replacing the fuel injector(s) with new one(s),
make sure that type of new fuel injector(s) is same as the
one of the replaced fuel injector(s) because the engine
vibration or noise might occur if any fuel injector(s),
which is different type, installed onto the engine.
1) Using sound scope or such, check operating sound of injec-

tor when engine is running or cranking.
Cycle of operating sound should vary according to engine
speed.
If no sound or an unusual sound is heard, check injector cir-
cuit (wire or coupler) or injector.
2) Disconnect coupler from injector, connect ohmmeter

between terminals of injector and check resistance.
If resistance is out of specification, replace.
Resistance of injector
0.56 (MAX.) (at 20 C, 68 F)
3) Connect coupler to injector securely.
Removal
2) Remove strut tower bar referring to Strut Tower Bar in Sec-
tion 3D.
4) Remove fuel filter referring to Fuel Filter Assembly in Sec-
tion 6C.
5) Remove fuel filter bracket from cylinder head.
(A) 6) Remove clip (1), and then disconnect return hose (2) from
fuel injector.
7) Install special tool to fuel injector as shown in the figure.
Fix special tool using removed clip (1).
1
Special tool
2
(A): 09916-50010
8) Remove high pressure pipe.

When loosening union nut of high pressure pipe, holding
union nut of fuel injector with wrench as shown.
Special tool
(A): 09950-76510/OUT0000148
(A)
9) Install special tool to fuel injector and common rail to prevent

them from entering dust.
Special tool
(A): 09916-50010
(A)
10) Remove fuel injector from cylinder head.

11) Remove sealing ring (1) and copper seal (2), then install
special tool from fuel injector.
1
Special tool
(A): 09916-50010
2 (A)
Installation
CAUTION:
Do not reuse high pressure pipe (3) because it has the
possibility that fuel leaks out.
2 1) Remove special tool from fuel injector and then install new
copper seal (1) and new sealing ring (2).
2) Install fuel injector to cylinder head.
3) Install new high pressure pipe (3) tighten each union nut
1 temporarily by hand.
4) Tighten fuel injector nuts in Steps below.
(a) 3
a) Tighten fuel injector nuts to 4 Nm (0.4 kg-m, 3.0 lb-ft)
b) Tighten fuel injector nuts by turning through 45
Tightening torque
Fuel injector nut (a): 4 Nm (0.4 kg-m, 3.0 lb-ft) and then
turn fuel injector nut at 45
5) Tighten high pressure pipe union nut of fuel injector side to

specified torque in Steps below, holding union nut of fuel
injector with wrench as shown.
a) Tighten high pressure pipe union nut to 8 Nm (0.8 kg-m,
6.0 lb-ft).
b) Tighten high pressure pipe union nut to 27.5 Nm (2.8 kg-m,
20.0 lb-ft).
Special tool
(A): 09950-76510/OUT0000148
(a)
Tightening torque
High pressure pipe union nut (Fuel injector side)
(a): 27.5 Nm (2.8 kg-m, 20.0 lb-ft)
6) Tighten high pressure pipe union nut of common rail side in

Steps below.
(a) a) Tighten high pressure pipe union nut to 24 Nm (2.4 kg-m,
17.5 lb-ft).
b) Tighten high pressure pipe union nut to 26 Nm (2.6 kg-m,
19.0 lb-ft).
Tightening torque
High pressure pipe union nut (Common rail side)
(a): 26 Nm (2.6 kg-m, 19.0 lb-ft)
7) Connect return hose (1) to fuel injector and then install clip
(2) to fuel injector.
8) Connect fuel injector connector (3).
9) Install fuel filter bracket to cylinder head.
10) Install fuel filter to fuel filter bracket referring to Fuel Filter
2
Assembly in Section 6C.
3
11) Install intercooler and intercooler outlet hose.
12) Install strut tower bar referring to Strut Tower Bar in Section
3D.
1 In case that the fuel injector(s) was replaced, perform Reg-
istration Data Check in this section to check the fuel injector
type registered to ECM.
14) Check fuel leakage referring to Fuel Leakage Check in this
section.
Common rail (High pressure fuel injection rail)
Removal
1) Disconnect negative cable from battery.
tion 3D.
tion 6C.
1 6) Remove high pressure supply pipe (1) from injection pump

and common rail.
When loosening union nut of high pressure supply pipe,
holding union nut of injection pump with wrench as shown.
Special tool
(A): 09950-76510/OUT0000148
(A)
7) Install special tool to injection pump and common rail to pre-
vent them from entering dust.
Special tool
(B): 09916-50010
8) Remove high pressure pipes from fuel injectors and common
rail referring to Step 8) to 9) of Removal under Fuel Injec-
tor in this section.
(B)
9) Disconnect fuel hoses from fuel temperature sensor.

10) Install special tool to fuel temperature sensor to prevent

them from entering dust.
Special tool
(A): 09916-50010
(A)
11) Disconnect fuel pressure sensor and fuel temperature sen-

sor connectors.
12) Remove common rail (1) from cylinder head.
13) Remove fuel pressure sensor (1) and fuel temperature sen-
sor (2) from common rail (3).
3
1
2
Installation
CAUTION:
Do not reuse high pressure supply pipe and high pres-
sure pipes because it has the possibility that fuel leaks
out.
1) Install fuel pressure sensor (2) and fuel temperature sensor
(1) to common rail.
Tightening torque
Fuel pressure sensor
(a): 40 Nm (4.0 kg-m, 29.0 lb-ft)
1
2, (a) Fuel temperature sensor mounting bolt
(b) (b): 8.5 Nm (0.9 kg-m, 6.5 lb-ft)
2) Install common rail (1) and tighten bolts (2) temporarily by hand.
3) Connect fuel pressure sensor and fuel temperature sensor
connectors, then remove special tool from common rail, fuel
temperature sensor and injection pump.
4) Connect fuel hoses to fuel temperature sensor.
2, (a)
5) Install new high pressure supply pipe (3) and new high pres-
sure pipes (4), tighten each union nuts temporarily by hand.
6) Tighten common rail bolts to specified torque.
1
Tightening torque
Common rail bolt (a): 25 Nm (2.5 kg-m, 18.0 lb-ft)
4
7) Tighten high pressure pipes union nuts to specified torque
referring to Step 5) to 6) of Installation under Fuel Injector
in this section.
8) Tighten high pressure supply pipe union nut of injection

pump side to specified torque, holding union nut of injection
(a)
pump with wrench as shown.
Special tool
(A): 09950-76510/OUT0000148
(A) Tightening torque
High pressure supply pipe union nut (Injection pump side)
(a): 26 Nm (2.6 kg-m, 19.0 lb-ft)
9) Tighten high pressure supply pipe union nut of common rail

side in Steps below.
(a)
a) Tighten high pressure supply pipe union nut to 24 Nm (2.4
kg-m, 17.5 lb-ft).
b) Tighten high pressure supply pipe union nut to 26 Nm (2.6
kg-m, 19.0 lb-ft).
Tightening torque
High pressure supply pipe union nut (Common rail side)
(a): 26 Nm (2.6 kg-m, 19.0 lb-ft)
11) Install fuel filter referring to Fuel Filter Assembly in Section
6C.
12) Install intercooler and intercooler outlet hose.
13) Install strut tower bar referring to Strut Tower Bar in Section
3D.
section.
Injection pump
Removal
tion 6C.
5) Loosen injection pump pulley nut (1) with pulley locked by using
1 special tool.
(B) Special tool

(A): 09919-56570/OUT0000157
(A) 6) Remove injection pump pulley (2) by using special tool.
Special tool
2
(B): 09919-56580/OUT0000158
7) Disconnect inlet fuel hose (1) and return fuel hose (2), then cap
2 injection pump opening with special tool.
1 Special tool
(A): 09919-46510/OUT0000110
(B) (B): 09916-50010
(A)
8) Remove high pressure supply pipe referring to Step 6) to 7)

of Removal under Common Rail (High Pressure Fuel
Injection Rail in this section.
9) Remove injection pump (1).
1
Inspection
Fuel Pressure Regulator
Check resistance between terminals of fuel pressure regulator.

If found faulty, replace injection pump.
Resistance of fuel pressure regulator
23
Installation
1) Install injection pump.

Tighten injection pump bolts to specified torque.
Injection pump bolt (a): 22.5 Nm (2.3 kg-m, 16.5 lb-ft)
2) Install injection pump pulley.

Tighten injection pump pulley nuts to specified torque.
(a)
Tightening torque
Injection pump pulley nut (a): 50 Nm (5.0 kg-m, 36.5 lb-ft)
3) Remove special tool, then install high pressure supply pipe (1)
to injection pump and common rail.
Tighten each union nuts temporarily by hand.
1
4) Tighten high pressure supply pipe referring to Step 8) to 9) of

Installation under Common Rail (High Pressure Fuel Injec-
tion Rail) in this section.
5) Remove special tool, then connect inlet fuel hose (1) and return
fuel hose (2) to injection pump.
6) Install new fuel hose clamps (3) by using special tool.
2
Special tool
1 (A): 09919-46510/OUT0000110
7) Install timing belt referring to Timing Belt and Belt Ten-
(A)
9) Install fuel filter referring to Fuel Filter Assembly in Section
3 6C.
(A) 10) Connect negative () cable at battery.
section.
Electronic Control System

Engine control module (ECM)
CAUTION:
As ECM consists of precision parts, be careful not to
expose it to excessive shock.
Be careful not to spill coolant from degassing tank
when relocating degassing tank to engine side.
ECM may be damaged by spill coolant.
Removal
2) Remove degassing tank mounting bolts (1).
1 3) Relocate degassing tank (1) to engine side away.

4) Disconnect solenoid valve connectors (2).
5) Remove vacuum pipe mounting bolts.
2
6) Detach ECM cover (1) from ECM bracket (2).

7) Remove ECM (3) from ECM bracket (3).
1 2 3
8) Disconnect ECM connectors from ECM by pulling off the lock

(1).
Installation
NOTE:
If ECM is replaced, register fuel injector type and trans-
mission type into ECM referring to ECM Registration in
this section.
1) Connect connectors to ECM securely.
2) Install ECM to bracket.
3) Install ECM cover to ECM bracket.
4) Install vacuum pipe to ECM bracket.
5) Connect solenoid valve connectors.
6) Install degassing tank to ECM cover.
ECM registration
NOTE:
If the registration of the fuel injector type is not per-
formed correctly, engine noise or vibration might occur.
1) Connect SUZUKI scan tool to data link connector (DLC) (1)
located on under side of instrument panel at drives seat
1 side.
Special tool
(A)
2) Check the fuel injector for the type A, B or C stamped on

the fuel injector.
B
4) Select ECM registration command in SELECT MODE
menu of SUZUKI scan tool.
5) Follow the instructions indicated on the SUZUKI scan tool.
NOTE:
For further details, refer to the operators manual for
SUZUKI scan tool.
6) Check DTC referring to DTC Check in this section.

If DTC is displayed on SUZUKI scan tool, go to applicable
DTC diag. flow for troubleshooting.
7) Clear DTC referring to DTC Clearance in this section if any.
Registration data check

located on underside of instrument panel at drivers seat
side.
Special tool
1
(A)
3) Select ECM registration command in SELECT MODE
menu of SUZUKI scan tool.
4) Confirm whether fuel injector type and transmission type
installed on correspond to specification displayed on
SUZUKI scan tool.
Register fuel injector type and transmission type into ECM
referring to ECM Registration in this section when it does
not correspond.
5) Push EXIT button of SUZUKI scan tool.
Mass air flow sensor (MAF sensor)

Inspection
NOTE:
Use voltmeter with high-impedance (10 k/V minimum)
or digital type voltmeter.
1) Connect voltmeter to BLK/WHT wire terminal of MAF sen-
sor coupler disconnected and ground.
2) Turn ignition switch ON and check that voltage is battery volt-
age.
If not, check if wire harness is open or connection is poor.
3) Connect MAF sensor coupler to MAF sensor.

4) Check voltage at MAF sensor output terminal E228-29 of
ECM referring to Voltage Check in Section 6-1.
Voltage: About 0.6 V
5) Start engine and check that voltage is lower than 5 V and it
rises as engine speed increases.
(Reference data: about 2.6 V at specified idle speed)
If check result is not as specified above, cause may lie in
wire harness, coupler connection, MAF sensor or ECM.
Removal
1) Disconnect negative cable at battery and coupler (1) from

MAF sensor (2).
2) Remove air cleaner outlet hose (3) from turbocharger and
MAF sensor.
3) Remove MAF sensor from air cleaner case.
CAUTION:
Dont disassemble MAF sensor.
Do not expose MAF sensor to any shock.
Do not blow compressed air by using air gun or the
like.
Do not put finger or any other object into MAF sensor.
Malfunction may occur.
Installation
1) Check MAF sensor seal for deterioration and damage.

2) Install MAF sensor to air cleaner case.
3) Install air cleaner outlet hose.
4) Connect MAF sensor coupler securely.
5) Connect battery negative cable to battery.
Throttle position sensor (TP sensor) (accelerator

pedal position sensor)
Inspection
Check throttle position sensor referring to Diag. flow table of each
emission control system spec in Section 6-1 as follows.
Other than EOBD spec
DTC P0121 (P0121) Throttle Position Circuit Range/Per-
formance Problem
DTC P0221 (P0220) Throttle Position Range/Performance
Problem 2
DTC P0604 (P0120) Throttle Position Sensor Monitoring
System Malfunction
EOBD spec
DTC P0220 (P0222/P0223/P0224) Pedal Position Sensor
No.1 Circuit (Low/High/Intermittent)
DTC P0225 (P0224/P0227/P0228/P2137) Pedal Position
Sensor No.2 Circuit (Intermittent/Low/High/Voltage Corre-
lation)
If malfunction is found, replace throttle position sensor.
Removal
2) Disconnect accelerator cable (1) from TP sensor (2).
3) Disconnect coupler (3) from TP sensor.
3 1 4) Disconnect air cleaner outlet hose from MAF sensor.
1
5) Remove air cleaner upper case (1).
6) Remove TP sensor (2) from air cleaner upper case.
Installation
Adjust accelerator cable play to specification referring to Acceler-
ator Cable Adjustment in this section.
Fuel temperature sensor assembly

Removal
2) Remove common rail referring to Common Rail (High Pres-
sure Fuel Injection Rail) in this section.
3) Remove fuel temperature sensor assembly (1) from common
rail.
Inspection
1) Remove fuel temperature sensor from its assembly.
2) Place sensor and a thermometer in water. Heat water gradu-
ally and verify that resistance between fuel temperature sen-
sor terminals at following temperatures is as specified.
If not as specified, replace fuel temperature sensor assem-
bly.
Water temperature C (F) Resistance (k)
40 (40) 93.63
20 (4) 25.76
0 (32) 8.62
25 (77) 2.39
40 (104) 1.24
60 (140) 0.56
80 (176) 0.27
100 (212) 0.14
120 (248) 0.08
Installation
Connect each fuel hoses and connectors securely.
Install common rail referring to Common Rail (High Pres-
sure Fuel Injection Rail) in this section.
Fuel (rail) pressure sensor

Removal
tion 3D.
tion 6C.
5) Disconnect connector from fuel pressure sensor (1).
6) Remove fuel pressure sensor from common rail (2).
Inspection
Inspect the fuel pressure sensor visually for the followings.

Thread of fuel pressure sensor for deformed.
Fuel pressure sensor for clogged.
Terminal of fuel pressure sensor for damaged.
If defective is found, replace fuel pressure sensor.
Installation
Connect each fuel hoses and connectors securely.
Check joints of fuel line for leakage referring to Fuel Leak-
age Check in this section.
Engine coolant temperature sensor (ECT sensor)

Removal
1) Remove battery.
2) Drain cooling system.
2 4) Remove ground wire mounting nut (1).
2. Vacuum pump
5) Disconnect ECT sensor connector (1) with unlocked connec-

tor lock.
6) Remove ECT sensor (3) from water box by removing clip (4).
1
2
3 4
Inspection
Immerse temperature sensing part of ECT sensor in water and

measure resistance between sensor terminals (1) and (2) while
heating water gradually.
If measured resistance doesnt shown such characteristic as shown,
replace ECT sensor.
Installation
Reverse removal procedure noting the following.
Clean mating surfaces of sensor and water outlet box.
Check O-ring for damage and replace ECT sensor if neces-
sary.
Install ECT sensor and then install ECT sensor clip securely.
Connect coupler to sensor securely.
Refill cooling system.
VSS
Check VSS referring to DTC P0500 (P0500) Vehicle Speed Sen-
sor Circuit Malfunction (other than EOBD spec) or DTC P0500
(P0500/P0501) Vehicle Speed Sensor (Malfunction/Perfor-
mance) (EOBD spec) in Section 6-1.
If malfunction is found, replace.
Removal, Inspection and Installation
Refer to Speed Sensor in Section 7D.

Camshaft position sensor (CMP sensor)

Check CMP sensor referring to DTC P0340 (P0335/P0340)
Camshaft Position Sensor Circuit Malfunction (other than EOBD
spec) or DTC P0340 (P0341/P0343/P0344/P0016) Camshaft
Position Sensor Circuit (Performance/High/Intermittent/Crank-
shaft Position-Camshaft Position Correlation) (EOBD spec) in
Section 6-1.
Air Gap Inspection/Adjustment
1) Remove upper timing belt cover.
2) Check clearance between CMP sensor (1) and camshaft
hub (2), using thickness gauge (3).
Clearance between CMP sensor and camshaft hub
a: 1.2 mm (0.047 in.)
If clearance is out of specification, move the CMP sensor and
adjust the clearance.
Tightening torque
CMP sensor bolt (a): 2 Nm (0.2 kg-m, 2.8 lb-ft)
3
(a)
Crankshaft position sensor (engine speed sensor)

Removal
1) Remove battery.
2) Remove swirl control solenoid valve referring to Swirl Con-
trol Solenoid Valve in this section.
3) Disconnect connector from crankshaft position sensor.
4) Remove crankshaft position sensor (1) from transmission
case (2).
Inspection
Verify that resistance between terminals of CKP sensor is

within specification.
Resistance: 315 405
If not as specified, replace CKP sensor.
Check to make sure that crankshaft position sensor (1) and

sensor rotor tooth (2) is free from any metal particles and dam-
age.
Installation
1) Install crankshaft position sensor to transmission case (1).

2) Tighten crankshaft position sensor mounting bolt.
3) Connect connector to it securely.
Valve in this section.
5) Install battery.
Intake air pressure sensor (manifold absolute pres-

sure sensor)
Removal
2) Disconnect connector from intake air pressure sensor (1)
and then pull off vacuum hose (2).
3) Remove intake air pressure sensor from strut tower bar.
Inspection
1) Arrange 3 new 1.5 V batteries (2) in series and connect its

positive terminal to Vin (4) terminal of coupler and negative
terminal to Ground (5) terminal. Then check voltage
between Vout (6) and Ground.
Also, check if voltage reduces when vacuum is slowly
applied up to 400 mmHg by using vacuum pump (3).
CAUTION:
As connection to wrong terminal will cause damage to
intake air pressure sensor, make absolutely sure to con-
nect properly as shown in the figure.
Output voltage (When sensor input voltage is 4.5 5.5 V, ambient
temp. 20 30 C, 68 86 F)
ALTITUDE BAROMETRIC OUTPUT
(Reference) PRESSURE VOLTAGE
(ft) (m) (mmHg) (kPa) (V)
0 0 760 100
| | | | 1.9 2.7
2 000 610 707 94
2 001 611 94
Under 707
| | | 1.8 2.6
over 634
5 000 1 524 85
5 001 1 525 85
Under 634
| | | 1.7 2.4
over 567
8 000 2 438 76
8 001 2 439 76
Under 567
| | | 1.6 2.3
over 526
10 000 3 048 70
If check result is not satisfactory, replace intake air pressure sen-
sor (1).
Installation
CAUTION:
Before installing intake air pressure sensor hose,
degrease connect part of hose and intercooler outlet
hose. Otherwise, hose may become detached and cause
turbo system failure.
1
1) Install intake air pressure sensor (1) to strut tower bar.
2) Connect connector and hose to intake air pressure sensor
securely.
Radiator fan control system

System Inspection
WARNING:
9 Keep hands, tools, and clothing away from engine cool-
ing fan to help prevent personal injury. This fan is electric
9
BLU and can come on whether or not the engine is running.
4
WHT/GRN The fan can start automatically in response to the ECT
BLU/WHT sensor with the ignition switch in the ON position.
7 8
BLU/BLK Check system for operation fererring to Diag. flow table of each
BLK/WHT 8 emission control system spec in Section 6-1 as follows.
5
3 Other than EOBD spec
BLK/WHT
DTC P1108 Radiator Fan High Speed Circuit Malfunction
BLU/GRN
1
WHT/GRN 2 DTC P1109 Radiator Fan Low Speed Circuit Malfunction
DTC P1519 Radiator Fan Circuit Malfunction
E228-2
BLK EOBD spec
E227-18 YEL/WHT DTC P0480 Fan 1 Control Circuit
BLU/BLK
E227-3 BLU/BLK
BLU/BLK DTC P0485 Fan Power/Ground Circuit
E227-4 YEL/BLU If radiator fan fails to operate properly, check relay, radiator fan
6
and electrical circuit.
BLK
1. ECM 4. Radiator fan relay 3 (Low) 7. Double relay
2. Radiator fan relay 1 (High/low) 5. Radiator fan motor 1 8. From IG COIL fuse
3. Radiator fan relay 2 (High) 6. Radiator fan motor 2 9. From main fuse
Radiator fan
Inspection
1) Check continuity between each two terminals.

If there is no continuity, replace radiator fan motor.
2) Connect battery (1) to radiator fan motor coupler (2) (black

connector for radiator fan motor 1, white connector for radia-
tor fan motor 2) as shown in figure, then check that the radia-
tor fan motor operates smoothly.
If radiator fan motor does not operate smoothly, replace
motor.
Radiator fan relay 1 (high/low)

Inspection
2) Remove radiator fan relay 1 (1) from fuse/relay box (2).
2 1
3) Check that there is no continuity between terminal c and

d.
4) Connect battery positive (+) terminal to terminal b of relay.
Connect battery negative () terminal a of relay.
Check continuity between terminal c and d.
If there is no continuity when relay is connected to the battery,
replace relay.
Radiator fan relay 2 (high)

Inspection
2 1

d.
replace relay.
Radiator fan relay 3 (low)

Inspection
2 1

d.
replace relay.
Double relay
Removal
2) Remove double relay (1) from bracket.
3) Disconnect connector from double relay by pulling off lock

(1).
Inspection
1) Connect connector to double relay.
2) Remove FUEL PUMP fuse from fuse box.
3) Disconnect ECM connector.
5) Check voltage between each terminal and ground.
If not as specified, replace double relay.
Terminal 1, 2, 4 and 9: 0 V
6) Using service wire, ground terminal 7 and terminal 10.

7) Check voltage between each terminal and ground.
If not as specified, replace double relay.
Terminal 1, 2, 4 and 9: Battery voltage
Installation
Pre/post heating relay (control unit)

Removal
Other than EOBD spec
2) Remove pre/post heating control unit (1) from bracket.
3) Disconnect connector from pre/post heating control unit by

pushing lock (1).
4) Disconnect WHT wire terminal (2) and BLK wire terminal (3).
EOBD spec
2) Disconnect connector from pre/post heating control unit (1)
by pulling off lock lever (2).
3) Remove pre/post heating control unit from bracket.
1
Installation
EGR System
EGR valve component
10 Nm (1.0 kg-m)
5 23 Nm (2.3 kg-m)
8
7
7
2 3
10 Nm (1.0 kg-m)
8
10 Nm (1.0 kg-m)
30 Nm (3.0 kg-m)
6
10 Nm (1.0 kg-m)
1. EGR valve 3. EGR cooler 5. EGR pipe No.2 7. EGR pipe clamp Tightening torque
:
2. EGR valve spacer 4. EGR pipe No.1 6. EGR bracket 8. Gasket Do not reuse
:
EGR valve and EGR cooler

Removal
2) Drain cooling system and tighten drain plug.
4) Disconnect vacuum hoses (1) from vacuum pipe.
1 5) Remove vacuum pipe (2) from intercooler bracket.
6) Disconnect EGR cooler hoses (1) from EGR cooler.
7) Remove EGR assembly (1) from exhaust manifold and

intake manifold/camshaft housing.
8) Remove EGR valve (1) from EGR cooler (2).

2 1 9) Remove EGR pipe (3) from EGR cooler by using special
tool.
3 Special tool
(A): 09919-46510/OUT0000110
(A)
Inspection
1) Using a vacuum pump, apply vacuum to diaphragm cham-

ber.
(A)
Check EGR valve for operation.
Vacuum less than about 24 kPa (180 mmHg):
EGR valve close
Vacuum about 24 kPa (180 mmHg) or more:
EGR valve open
Special tool
A
B
(A): 09917-47910
If not as specified, replace EGR valve.
Installation

Clean mating surfaces of EGR valve and exhaust manifold.
Install new EGR pipe clamps (2) by using special tool.
Special tool
2 2
(A): 09919-46510/OUT0000110
1
Use new gasket (1).
Tighten EGR valve nuts to specified torque.
(A)
Tightening torque
EGR valve nut (a): 10 Nm (1.0 kg-m, 7.5 lb-ft)
EGR cooler mounting bolt (b): 23 Nm (2.3 kg-m, 16.5 lb-ft)
EGR cooler mounting bolt (c): 10 Nm (1.0 kg-m, 7.5 lb-ft)
(d) EGR pipe joint bolt (d): 10 Nm (1.0 kg-m, 7.5 lb-ft)
(a)
EGR pipe mounting bolt (e): 10 Nm (1.0 kg-m, 7.5 lb-ft)
(e)
(c) (b)
Vacuum hose
Inspection
Check hose for connection, leakage, clogs and deterioration.
Replace as necessary.
EGR solenoid valve
Removal
2) Remove EGR solenoid valve (1) from bracket.

3) Disconnect connector from EGR solenoid valve (1).
4) Disconnect vacuum hoses from EGR solenoid valve.
1
Inspection

If resistance is out of specification, replace EGR solenoid valve.
EGR solenoid valve resistance
12 18 at 25 C (77 F)
Installation
Swirl Control Solenoid Valve

Removal
1) Remove battery.
2) Remove vacuum pump (1) referring to Vacuum Pump in
this section.
3) Remove EGR pipe bracket (2) from water box.
4) Disconnect vacuum hose (3) from vacuum pipe (4).
4
5) Disconnect connector from swirl control solenoid valve.
6) Remove swirl control solenoid valve assembly (5) from cylin-
der head.
2 1
5
Installation
Install vacuum pump referring to Vacuum Pump in this sec-
tion.
Connect connector to swirl control solenoid valve securely.
Connect vacuum hose securely.
Inspection
Swirl control solenoid valve
1) Connect 12 V battery to swirl control solenoid valve termi-

nals as shown in the figure.
2) Check that swirl control solenoid valve opens when battery
voltage is added.
If check result is not satisfactory, replace swirl control sole-
noid valve.
Swirl control actuator
1) Disconnect vacuum hose (1) from swirl solenoid valve.

2) Using a vacuum pump, apply vacuum to diaphragm cham-
ber.
1
3) Confirm that actuator rod of swirl control valve moves and it
keeps the position when vacuum is added.
If check result is not satisfactory, replace swirl control sole-
noid valve.

Tightening torque
Fastening part
Nm kg-m lb-ft
Vacuum pump bolt and nut 20 2.0 14.5
Glow plug 10 1.0 7.5
EGR valve nut 10 1.0 7.5
EGR cooler mounting bolt 8 mm 23 2.3 16.5
EGR cooler mounting bolt 6 mm 10 1.0 7.5
EGR pipe joint bolt 10 1.0 7.5
EGR pipe mounting bolt 10 1.0 7.5
4 Nm (0.4 kg-m, 3.0 lb-ft)
Fuel injector nut
and then turn to 45 once.
Fuel injector side high pressure pipe union nut 27.5 2.8 20.0
Common rail side high pressure pipe union nut 26 2.6 19.0
Fuel pressure sensor 40 4.0 29.0
Fuel temperature sensor mounting bolt 8.5 0.9 6.5
Common rail bolt 25 2.5 18.0
Injection pump side high pressure supply pipe union nut 26 2.6 19.0
Common rail side high pressure supply pipe union nut 26 2.6 19.0
Injection pump bolt 22.5 2.3 16.5
Injection pump pulley nut 50 5.0 36.5
CMP sensor bolt 2 0.2 2.8
Special Tools
09912-58432 09912-58442 09912-56530 09916-50010

Pressure hose Pressure gauge 3 way joint and hose Fuel system, plug set
09917-47910 09919-46510 09919-56570 09919-56580

Vacuum pump gauge (OUT0000110) Clamp pliers (OUT0000157) (OUT0000158)
Injection pump pulley lock Injection pump pulley remover
09950-76510
(OUT0000148) Tech 2 kit (SUZUKI scan tool)
Pipe spanner (See NOTE)
NOTE:
CRANKING SYSTEM 6G-1
SECTION 6G
6F1
7A
CRANKING SYSTEM 7A1
(2.0 kW Reduction Type) 7C1
NOTE: 7A
7A1
7C1
7D
CONTENTS
7F
General Description ....................................... 6G-2 Inspection............................................................ *

Inspection..................................................6G-7 8A
Cranking Circuit............................................ 6G-2
Starting Motor Circuit ................................... 6G-2 Performance Test ............................................... * 8B
Starting Motor............................................... 6G-3 Performance test.....................................6G-10 8C
Diagnosis ........................................................ 6G-4 Specifications................................................6G-11 8D
Unit Repair Overhaul ..................................... 6G-5 1.2 kW type (1.4 kW type)............................... * 8E
Generator ..................................................... 6G-5 0.9 kW type ..................................................... *
Dismounting and Remounting ............................. * 2.0 kW reduction type .............................6G-11
9
Dismounting ............................................. 6G-5 Required Service Materials ..........................6G-11
Remounting .............................................. 6G-5 Special Tool........................................................... *
Disassembly ........................................................ * 10
Tightening Torque Specifications ...............6G-12
Reassembly ........................................................ * 10A
Disassembly and reassembly................... 6G-6 10B
6G
6G
6K
6G-2 CRANKING SYSTEM
General Description
Cranking Circuit
The cranking circuit consists of the battery, starting motor, ignition switch, and related electrical wiring. These
components are connected electrically.
Only the starting motor will be covered in this section.
Starting Motor Circuit

The magnetic switch coils are magnetized when the ignition switch is closed.
The resulting plunger and pinion drive lever movement causes the pinion to engage the engine flywheel gear
and the magnetic switch main contacts to close, and cranking takes place.
When the engine starts, the pinion over-running clutch protects the armature from excessive speed until the
switch is opened, at which time the return spring causes the pinion to disengage.
1. Pinion driver lever 5. Plunger 9. Starting motor

2. Pinion and Over running clutch 6. Magnetic switch contacts 10. A/T: Transmission range switch (shift lever switch)
3. Magnetic switch 7. Pull in coil 11. Ignition and Starting motor switch
4. Hold in coil 8. Return spring 12. Battery
Starting Motor
The starting motor consists of parts shown in below.
The magnetic switch assembly and parts in the starting motor are enclosed in the housings so that they will be
protected against possible dirt and water splash.
1. Magnetic switch 6. Planetary carrier shaft 11. Front housing 16. Bearing
2. Plunger 7. Internal gear 12. Rear bracket 17. Armature
3. Lever 8. Over-running clutch 13. Brush holder 18. Yoke
4. Ball 9. Pinion gear 14. Brush spring
5. Planetary gear 10. Bush 15. Brush
Diagnosis
Motor not running Operating sound of magnetic switch heard
Battery run down Recharge battery.
Battery voltage tool low due to battery deterio- Replace battery.
ration
Loose battery cable connections Retighten.
Burnt main contact point, or poor contacting Replace magnetic switch.
action of magnetic switch
Brushes are seating poorly or worn down Repair or replace.
Weakened brush spring Replace.
Burnt commutator Replace armature.
Poor grounding of field coil Repair.
Layer short-circuit of armature Replace.
Crankshaft rotation obstructed Repair.
Starting motor run- If battery and wiring are satisfactory, inspect
ning but too slow starting motor
(small torque) Insufficient contact of magnetic switch main Replace magnetic switch.
contacts
Layer short-circuit of armature Replace.
Disconnected, burnt or worn commutator Repair commutator or replace
armature.
Poor grounding of field coil Repair.
Worn brushes Replace brush.
Weakened brush springs Replace spring.
Burnt or abnormally worn end bush Replace bush.

Generator
Dismounting
3) Disconnect magnetic switch lead wire (S terminal) (1) and
battery cable (2) from starting motor terminal (B terminal).
4) Drain coolant.
5) Hoist vehicle.
6) Remove water outlet pipe mounting bolts from left side
engine mounting.
7) Disconnect radiator outlet hose No.1 from water outlet box.
8) Remove starting motor mount bolts (3) and remove starting
motor (4).
Remounting
Reverse dismounting procedure to install starting motor, noting
the following points.
Tighten starting motor mount bolt and battery cable nut.
Tightening torque
Starting motor mount bolt
(a): 45 Nm (4.5 kg-m, 32.5 lb-ft)
Battery cable nut
(b): 11 Nm (1.1 kg-m, 8.0 lb-ft)
Refill cooling system with proper coolant referring to Cool-

ant and Cooling System Flush and Refill in Section 6B.
Disassembly and reassembly
NOTE:
Disassemble in order shown in figure.
For reassembly, reverse disassembly procedure.
Tighten bolt and nut to specified torque.
Upon completion of reassembly, carry out Perfor-
mance Test later in this section.
1. Magnetic switch 8. Over-running clutch 15. Brush

2. Plunger 9. Pinion gear 16. Bearing
3. Pinion drive lever 10. Front bush 17. Armature
4. Ball 11. Front housing 18. Yoke
5. Planetary gear 12. Rear bracket Apply grease (99000-25010)
6. Planetary carrier shaft 13. Brush holder Tightening torque
7. Internal gear 14. Brush spring

Inspection
BRUSH
Check brushes for wear.

Measure length of brushes and if below limit, replace brush.
Brush length
Standard 18.0 mm (0.71 in.)
Limit 11.0 mm (0.43 in.)
1. Wear limit
Install brushes to each brush holder and check for smooth

movement.
SPRING
Inspect brush springs for wear, damage or other abnormal condi-

tions. Replace if necessary.
Brush spring tension
Standard 3.1 kg (6.8 Ib)

Limit 1.5 kg (3.3 Ib)
BRUSH HOLDER
Check movement of brush in brush holder. If brush move-
ment within brush holder is sluggish, check brush holder for
distortion and sliding faces for contamination. Clean or cor-
rect as necessary.
Check for continuity between insulated brush holder and
brush holder plate. Replace brush and brush holder if there
is continuity.
ARMATURE
Inspect commutator for dirt or burn. Correct with sandpaper

or lathe, if necessary.
1. Sandpaper (#300~400)
Check commutator for uneven wear with armature (1) sup-

ported on V-blocks (2). If deflection of dial gauge (4) pointer
exceeds limit, repair or replace.
NOTE:
Below specification presupposes that armature is free
from bend. Bent armature must be replaced.
Commutator out of round
Standard: 0.05 mm (0.002 in.) or less
Limit: 0.1 mm (0.004 in.)
3. Magnetic stand
Inspect commutator for wear. If diameter is below limit,

replace armature.
Commutator outside diameter
Limit: 31.4 mm (1.24 in.)
Inspect commutator for insulator (2) depth. Correct or

replace if below limit.
Commutator insulator depth a
Standard: 0.5 0.8 mm (0.02 0.031 in.)
A: Correct
B: Incorrect
1. Commutator segment
Ground Test
Check commutator and armature core. If there is continuity, arma-

ture is grounded and must be replaced.
Open Circuit Test
Check for continuity between segments. If there is no continuity at

any test point, there is an open circuit and armature must be
replaced.
FIELD COIL
Check for continuity between brushes (1) and between con-

nector (2) and brush (1). Replace field coil if there is continu-
ity.
Check for continuity between connector (2) and yoke (1).

Replace field coil if there is continuity.
Performance test
CAUTION:
Each test must be performed within 3 5 seconds to
avoid coil from burning.
PULL-IN TEST
Connect battery to magnetic switch as shown.

Check that plunger and pinion move outward.
If plunger and pinion dont move, replace magnetic switch.
NOTE:
Before testing, disconnect lead wire from terminal M.
1. Terminal S
2. Terminal M
3. Lead wire (switch to motor)
HOLD-IN TEST
While connected as above with plunger out, disconnect negative

lead from terminal M.
Check that plunger and pinion remain out.
If plunger and pinion return inward, replace magnetic switch.
1. Terminal S
2. Terminal M
3. Terminal B
PLUNGER AND PINION TEST
Disconnect negative lead from switch body.

Check that plunger and pinion return inward,
If plunger and pinion dont return, disassemble and inspect start-
ing motor.
1. Terminal S
2. Terminal M
3. Terminal B
NO-LOAD PERFORMANCE TEST
a) Connect battery and ammeter to starter as shown.

b) Check that starter rotates smoothly and steadily with pinion
moving out. Check that ammeter indicates specified cur-
rent.
Specified current: 130 A MAX. at 11 V
NOTE:
Use wires as thick as possible and tighten each terminal
fully.
1. Terminal S
2. Terminal B
Specifications
2.0 kW reduction type
Voltage 12 volts
Output 2.0 kW
Rating 30 seconds
Direction of rotation Clockwise as viewed from pinion side
Brush length 18.0 mm (0.71 in.)
Number of pinion teeth 10
Performance Condition Guarantee
130 A maximum
No load characteristic 11.0 V
3,600 rpm minimum
7.7 V 10.6 Nm (1.06 kg-m, 7.67 Ib-ft) minimum
Around at Load characteristic
400 A 1,280 rpm minimum
20 C (68 F)
1,000 A maximum
Locked characteristic 3.0 V
29.4 Nm (2.94 kg-m, 21.3 Ib-ft) minimum
Magnetic switch operating voltage 8 volts maximum

Material Recommended SUZUKI product Use
Front bush
Plunger
Pinion drive lever
SUZUKI SUPER GREASE A
Lithium grease Internal gear
(99000-25010)
Planetary carrier shaft
Planetary gear
Ball

Tightening torque
Fastening part
Nm kg-m lb-ft
Starting motor mounting bolt 45 4.5 32.5
B terminal nut 11 1.1 8
Magnetic switch screw 7 0.7 5.0
Starting motor housing screw 11 1.1 8
CHARGING SYSTEM 6H-1
SECTION 6H
6F1
6F2
CHARGING SYSTEM 7F
8A
WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System
7A
7A1
7C1
7D
unintentional activation of the system or could render the system inoperative. Either of these two 7F
Technical service work must be started at least 90 seconds after the ignition switch is turned to the 8A
LOCK position and the negative cable is disconnected from the battery. Otherwise, the system 8B
may be activated by reserve energy in the Sensing and Diagnostic Module (SDM). 8C
8D
NOTE: 8E
ual mentioned in FOREWORD of this manual. 9
10
CONTENTS 10A
10B
General Description .............................................. * Remounting..................................................... *
Battery ................................................................. * Generator......................................................6H-2
Carrier and hold-down..................................... * Generator belt ...........................................6H-2
Electrolyte freezing.......................................... * Unit Repair Overhaul ......................................6H-4
Sulfation .......................................................... * Generator......................................................6H-4
Built-in indicator (If equipped).......................... * Dismounting .................................................... *
Care of battery................................................. * Remounting..................................................... * 6H
Generator ............................................................ * Disassembly [60 A type].................................. * 6K
Diagnosis ............................................................... * Disassembly [70 A and 80 A types] ................ *
Battery ................................................................. * Inspection [60 A type]...................................... *
Common causes of failure............................... * Inspection [70 A and 80 A types] .................... *
Visual inspection ............................................. * Replace brush ................................................. *
Hydrometer test............................................... * Reassembly [60 A type] .................................. *
Generator ............................................................ * Reassembly [70 A and 80 A types] ................. *
Undercharged battery...................................... * Specifications..................................................6H-7
Overcharged battery........................................ * Battery................................................................. *
On-Vehicle Service..........................................6H-2 Generator......................................................6H-7
Battery ................................................................. * Tightening Torque Specifications .................6H-7
Jump starting in case of emergency................ * Special Tools...................................................6H-7
Dismounting .................................................... *
Handling .......................................................... *
6H-2 CHARGING SYSTEM
On-Vehicle Service
Generator
Generator belt
WARNING:
Disconnect negative cable at battery before inspection,
removing and installing Generator belt.
INSPECTION
Verify that belt engages with pulley groove correctly.

Visually check for wear and damage on belt and pulley con-
tact surface and damage on pulley.
1. Generator belt
2. Generator
Inspect belt for cracks, cuts, deformation, wear and cleanli-

ness using mirror under enough lighting.
If any defect exists, replace.
Check that belt wear check mark (1) (tension indicator) is
within range a using mirror (4) under enough lighting.
If wear check mark (1) is aligned with maximum wear mark
(2) or out of range a, replace generator belt with a new one.
3. Zero wear mark
REMOVAL
1) Using special tool (A) for dynamic roller tensioner, turn

dynamic roller tensioner counterclockwise to loosen it.
Special tool
(A): 09919-56610/OUT0000143
2) With dynamic roller tensioner holes aligned by turning

dynamic roller tensioner, insert special tool (B) into them.
Special tool
(B): 09919-56590/OUT0000142
1. Zero wear mark
2. Maximum wear mark
3) Loosen roller tensioner bolt (1) using special tool (C).

Special tool
(C): 09919-56620
4) Remove generator belt.
INSTALLATION
1) Using special tool (C) for roller tensioner, turn roller tensioner
clockwise to loosen it.
2) While holding the tensioner, install generator belt.
3) Using special tool (C), turn roller tensioner counterclockwise

to until special tool (B) becomes free. With roller tensioner
kept in that state, fix it by tightening roller tensioner bolt (1) to
specified torque.
Special tool
(B): 09919-56590/OUT0000142
(C): 09919-56620
Tightening torque
Roller tension bolt
(a): 45 Nm (4.5 kg-m, 32.5 lb-ft)
4) Remove special tool (B) and (C), turn crankshaft pulley 4
revolutions.
5) Using special tool (B), check that dynamic roller tensioner
holes are aligned. If they are not aligned, repeat step 3) to 5).

Generator
DISMOUNTING
2) Drain engine oil and remove engine oil element.
3) Detach degassing tank (1) and P/S pump reservoir (2).
4) Remove ECM, referring to Engine Control Module (ECM) in

Section 6A3.
5) Remove ECM bracket (1).
1
6) Detach P/S pump (1) from P/S pump bracket.
7) Remove Generator (1).
REMOUNTING
Install removed parts in reverse order of dismounting procedure,
noting the following.
a
Tighten generator bolts and B terminal outer nut.
Tightening torque
c
d Generator upper bolt
b
a (a): 23 Nm (2.3 kg-m, 17.0 lb-ft)
Generator lower bolt
(b): 48 Nm (4.8 kg-m, 35.0 lb-ft)
B terminal outer nut
(c): 16 Nm (1.6 kg-m, 11.5 lb-ft)
b
L terminal outer nut
(d): 6 Nm (0.6 kg-m, 4.5 lb-ft)
Install engine oil filter and refill engine oil referring to Engine
Oil and Oil Filter Change in Section 0B.
DISASSEMBLY AND REASSEMBLY

Disassemble in numerical order shown in figure below and note the following.
For reassembly, reverse disassembly procedure.
1. Rear cover 4. Regulator 7. Pulley

2. D+ contact with capacitor 5. Cover 8. Rotor
3. Rectifier 6. Stator 9. Front bearing
When removing stator lead wire from rectifier, carry out sol-
dering quickly.
CAUTION:
Overheating can damage semiconductor components
such as regulator and rectifier.
NOTE:
Hold lead wire with pliers during soldering to prevent
applying heat to rectifier.
Hold rotor (2) with soft jawed vise (3) and remove pulley (1)
by using special tool.
Special tool
(A): 09932-96510
Specifications
Generator
Type 150 A type
Rated voltage 12 V
Nominal output 150 A

Tightening torque
Fastening part
Nm kg-m lb-ft
Roller tension bolt 45 4.5 32.5
Generator upper bolt 23 2.3 17.0
Generator lower bolt 48 4.8 35.0
B terminal outer nut 16 1.6 11.5
L terminal outer nut 6 0.6 4.5
Special Tools
09919-56610/OUT0000143 09919-56590/OUT0000142 09919-56620 09932-96510

Belt tension lever Belt tensioner pin Belt tension adjuster wrench Pulley remover attachment
EXHAUST SYSTEM 6K-1
SECTION 6K
EXHAUST SYSTEM
CONTENTS
General Description ........................................6K-2 On-Vehicle Service .........................................6K-4
Exhaust System Components .......................6K-2 Exhaust Manifold .......................................... 6K-4
Maintenance ....................................................6K-3 Muffler ........................................................... 6K-4
6K
6K-2 EXHAUST SYSTEM
General Description
The exhaust system consists of an exhaust manifold, a turbo charger, a turbocharger outlet pipe, an exhaust
No.1 pipe, an exhaust No.2 pipe, a muffler and seal, gaskets and etc., and the exhaust No.1 and No.2 pipe has
the catalytic converter for oxidation.
The catalytic converter for oxidation is an emission control device added to the exhaust system to lower the lev-
els of Hydrocarbon (HC) and Carbon Monoxide (CO) pollutants in the exhaust gas.
Exhaust System Components
7 25 Nm (2.5 kg-m) 9
9 6
8 55 Nm
(5.5 kg-m)
2
1 8 55 Nm (5.5 kg-m)
3 9
3
9
4-1
8 55 Nm (5.5 kg-m)
9
9
8 55 Nm (5.5 kg-m)
6-1
1. Exhaust pipe gasket 5. Blank 9. Mounting

2. Exhaust No.1 pipe 6. Muffler for 3door model Tightening torque
3. Exhaust pipe seal ring 6-1. Muffler for 5door model Do not reuse
4. Exhaust No.2 pipe for M/T model 7. Exhaust No.1 pipe nut
4-1. Exhaust No.2 pipe for A/T model 8. Exhaust pipe bolt
EXHAUST SYSTEM 6K-3
Maintenance
WARNING:
To avoid the danger of being burned, do not touch the
exhaust system when the system is hot. Any service on
the exhaust system should be performed when the sys-
tem is cool.
At every interval of periodic maintenance service, and when vehi-
cle is raised for other service, check exhaust system as follows:
Check rubber mountings for damage, deterioration, and out
of position.
Check exhaust system for leakage, loose connection, dent

and damage.
If bolts or nuts are loosened, tighten them to specified
torque.
Refer to Exhaust System Components in this section for
torque data.
Check nearby body areas damaged, missing, mispositioned
part, open seam, hole connection or any other defect which
could permit exhaust fumes to seep into vehicle.
Make sure that exhaust system components have enough
clearance from underbody to avoid overheating and possible
damage to passenger compartment carpet.
Any defect should be fixed at once.
6K-4 EXHAUST SYSTEM
On-Vehicle Service
WARNING:
To avoid the danger of being burned, do not touch the
exhaust system when the system is hot. Any service on
the exhaust system should be performed when the sys-
tem is cool.
Exhaust Manifold
Refer to Turbocharger in Section 6E3 for removal and installa-
tion procedures. Before installation, check gasket and seal for
deterioration or damage. Replace them as necessary.
Muffler
CAUTION:
As exhaust No.2 pipe has catalytic converter in it, it
should not be exposed to any impulse. Be careful not to
drop it or hit it against something.
Tighten bolts and nuts to specified torque when reassem-

bling. Refer to Exhaust System Components in this section
for location of bolts and nuts.
After installation, start engine and check each joint of
exhaust system for leakage.
MANUAL TRANSMISSION (TYPE 3) 7A2-1
SECTION 7A2
7A2
MANUAL TRANSMISSION (TYPE 3)
CONTENTS
General Description ......................................7A2-2 Back Up Light Switch .................................. 7A2-4

System Description .....................................7A2-2 Engine Rear Mounting ................................ 7A2-4
Diagnosis .......................................................7A2-2 Dismounting of Transmission Unit .............. 7A2-4
Remounting of Transmission Unit............... 7A2-6
On-Vehicle Service........................................7A2-3
Unit Repair.....................................................7A2-8
Transmission Gear Oil ................................7A2-3
Transmission Shift Control Lever ................7A2-4 Tightening Torque Specifications ...............7A2-8
7A2-2 MANUAL TRANSMISSION (TYPE 3)
General Description
System Description
The manual transmission consists of the input shaft, main shaft, countershaft and reverse idle gear shaft which
are installed in the die-cast aluminum alloy and cast-iron cases. This transmission provides five forward speeds
and one reverse speed.
The 1st, 2nd and 3rd speeds are for speed reduction drive, 4th speed is for direct drive and 5th speed is for over
drive.
The low speed (1st and 2nd) synchronizer is mounted on middle of the main shaft and engaged with the main
shaft 1st or 2nd gear. The high speed (3rd and 4th) synchronizer is mounted on forefront of the main shaft and
engaged with the main shaft 3rd gear or input shaft. The 5th speed synchronizer is mounted on the countershaft
and engaged with the countershaft 5th gear. The 5th speed synchronizer is also equipped with the prevention
device from gear cracking noise when shifting gear into the reverse gear. The triple cone synchronizer mecha-
nism is provided to the 1st, 2nd and 3rd gear synchromesh devices for high performance of shifting into the 1st,
2nd and 3rd gear.
The gear shift lever case is located at the upper behind the transmission case and has a cam which prevents
direct gear shifting from the 5th speed gear into the reverse gear.
As the die-cast aluminum alloy and cast-iron cases are sealed with liquid type gasket, it is necessary to use gen-
uine sealant or its equivalent on its mating surface when reassembling them. Also, the case fastening bolts must
be tightened to specified torque by means of the torque wrench and tightening over or below the specified
torque should be avoided.
Diagnosis
Gear slipping out of Worn shift fork shaft Replace
mesh Worn shift fork or synchronizer sleeve Replace
Weak or damaged locating spring Replace
Worn bearings on input shaft or main shaft Replace
Worn chamfered tooth on sleeve or gear Replace sleeve and gear
Missing or disengagement of circlip(s) Install or replace
Gears refusing to dis- Weakened or broken synchronizer spring Replace
engage Distorted shift shaft or shift fork Replace
Hard shifting Improper clutch pedal free travel Adjust
Distorted or broken clutch disc Replace
Damaged clutch pressure plate Replace clutch cover
Worn synchronizer ring Replace
Worn chamfered tooth on sleeve or gear Replace sleeve and gear
Distorted shift shaft Replace
Noise Inadequate or insufficient lubricant Replenish
Damaged or worn bearing(s) Replace
Damaged or worn gear(s) Replace
Damaged or worn synchronizer ring Replace
Damaged or worn chamfered tooth on sleeve or gear Replace
On-Vehicle Service
Transmission Gear Oil
INSPECTION AND CHANGE
1) Before changing or inspecting oil, be sure to stop engine and

lift vehicle horizontally.
2) With vehicle lifted up, check oil level and leakage. If leakage
exists, correct or repair it.
3) Drain old oil removing drain plug (1).
NOTE:
Do not drain transmission oil from plug (4).
Whenever vehicle is hoisted for any service work other
than oil change, check for oil leakage.
4 If water or rust is mixed in drained oil, be sure to check
1, (a) 3 breather hose and boot of transmission.
4) Fill new specified oil as shown by specified amount (up to

level hole).
NOTE:
It is highly recommended to use SAE 75W-90 gear oil.
Gear Oil Specification
2, (a)
Oil grade: API GL-4
Viscosity: SAE 75W-85, 75W-90 or 80W-90
Oil Capacity:
2.3 liters (4.9/4.0 US/Imp. pt)
5) Torque drain plug (1) and level/filler plug (2) as specified.
CAUTION:
Transmission oil must not be poured through gear shift
control lever part.
Tightening torque
Transmission oil filler/level and drain plugs
(a): 37 Nm (3.7 kg-m, 27.0 lb-ft)
[A]: Viscosity chart SAE
Transmission Shift Control Lever

Refer to Transmission Shift Control Lever in Section 7A of the
Service Manual mentioned in Foreword of this manual.
Back Up Light Switch

Refer to Back Up Light Switch in Section 7A of the Service Man-
ual mentioned in Foreword of this manual.
Engine Rear Mounting

When replacement of mounting parts are necessary, torque bolts
as specified below.
Tightening torque
Engine rear mounting bolts
(a): 55 Nm (5.5 kg-m, 40.0 lb-ft)
Engine rear mounting member bolts
(a)
(a) (b): 55 Nm (5.5 kg-m, 40.0 lb-ft)
1. Engine rear mounting member
2. Engine rear mounting
(a)
(b)
(a)
(b)
Dismounting of Transmission Unit

1) Remove battery.
2) Detach fuse/relay box, remove strut tower bar.
3) Remove CKP sensor from clutch housing referring to CKP
Sensor in Section 6E3.
4) Remove starting motor bolts.
5) Remove transmission to engine nuts (1).
1
6) Remove transmission shift control lever referring to Trans-

mission Shift Control Lever in Section 7A of the Service
Manual mentioned in Foreword of this manual.
7) Remove transfer shift control lever referring to Transfer Shift
Control Lever in Section 7D of the Service Manual men-
tioned in Foreword of this manual.
8) Hoist vehicle.
9) Drain transmission gear oil referring to Transmission Gear
Oil in this section.
10) Drain transfer gear oil referring to Transfer Gear Oil in Sec-
tion 7D of the Service Manual mentioned in Foreword of
this manual.
11) Remove propeller shafts referring to Propeller Shaft in Sec-
tion 4B of the Service Manual mentioned in Foreword of
this manual.
12) Remove exhaust No.2 pipe (1).
1 13) Remove clutch operating cylinder (1) from transmission. It is

not necessary to disconnect clutch hose from operating cyl-
inder.
14) Apply transmission jack (1) and remove engine rear mount-
ing member (2) taking off its bolts.
15) Lower the transmission jack (1) slowly.
16) Disconnect couplers from 4WD switch, back up light switch
and speed sensor assembly and release their harness from
clamps.
[A] 17) Remove transmission fastening bolts (1 and 2).

1 [A] : Upper side
[B] : Lower side
3. Oil pan
NOTE:
If bolt (2) cannot be removed, loosen it only completely.
2 18) Move rearward transmission and transfer assemblies placed
[B] on jack and then lower them.
1
19) Remove breather hoses (1).

20) Separate gear shift lever case (2) and transfer assembly (3)
1 2
from transmission assembly (4).
Remounting of Transmission Unit

1) Set transmission fasting bolt (1) to transmission assembly (2)
as shown beforehand, if transmission fasting bolt (1) could
not be removed at step 16) of Dismounting of Transmission
Unit in this section.
2
2) Reverse dismounting procedure for remounting noting the

following.
Slant the rear of the engine down, using support device (1)
and install transmission to engine.
Use specified torques as given below.

Transmission to engine bolts and nuts
(a): 55 Nm (5.5 kg-m, 40.0 lb-ft)
(a) (b): 55 Nm (5.5 kg-m, 40.0 lb-ft)
Turbocharger outlet pipe to exhaust No.2 pipe bolt
(a)
(c): 55 Nm (5.5 kg-m, 40.0 lb-ft)
(d): 55 Nm (5.5 kg-m, 40.0 lb-ft)
Exhaust No.2 pipe to muffler bolts or nuts
(e): 55 Nm (5.5 kg-m, 40.0 lb-ft)
Clutch operating cylinder bolts
(f) (f): 50 Nm (5.0 kg-m, 36.5 lb-ft)
Set each clamp for wiring and hoses securely.
Set clamp for shift control lever boots securely.
Fill gear oil to transmission and transfer as specified referring
to Transmission Gear Oil in this section and Transfer Gear
Oil in Section 7D of the Service Manual mentioned in Fore-
word of this manual.
(a)
Install propeller shafts referring to Propeller Shaft in Sec-
tion 4B of the Service Manual mentioned in Foreword of
this manual.
Install strut tower bar referring to Strut Damper in Section
3D of the Service Manual mentioned in Foreword of this
manual.
(b) (b) Install battery and check function of engine, clutch, transmis-
sion and transfer.
(d) (b)
(b)
(c)
(e)
Unit Repair
Refer to the same section of Unit Repair Manual mentioned in Foreword of this manual.

Tightening torque
Fastening part
Nm kg-m lb-ft
Transmission oil filler/level and drain plugs 37 3.7 27.0
Transmission to engine bolts and nuts 55 5.5 40.0
Engine rear mounting member bolts 55 5.5 40.0
Turbocharger outlet pipe to exhaust No.2 pipe bolts 50 5.0 36.5
Exhaust No.2 pipe to muffler bolts or nuts 50 5.0 36.5
Engine rear mounting bolts 55 5.5 40.0
Clutch operating cylinder bolts 50 5.0 36.5
AUTOMATIC TRANSMISSION (4 A/T) 7B1-1
SECTION 7B1
6H
7B1
AUTOMATIC TRANSMISSION (4 A/T) 7A

7A1
WARNING:
7B1
For vehicles equipped with Supplemental Restraint (Air Bag) System : 7A
Service on and around the air bag system components or wiring must be performed only by an 7A1
authorized SUZUKI dealer. Refer to Air Bag System Components and Wiring Location View under 7B1
General Description in air bag system section in order to confirm whether you are performing ser- 7C1
7D
7E
7F
8A
8A
8D
8E
CONTENTS
9
General Description ......................................7B1-3 Table B-2: O/D OFF Lamp Circuit
Clutch/Brake Functions ...............................7B1-5 Check (O/D OFF Lamp Comes 10
Table of Component Operation ...................7B1-6 On Steadily) .............................................. 7B1-39
10A
Electronic Shift Control System...................7B1-7 Inspection of TCM and Its Circuits ............ 7B1-40
Change mechanism ................................7B1-9 Wire Harness and Connectors.................. 7B1-41 10B
Operation of shift solenoids and Scan Tool Data ......................................... 7B1-42
TCC solenoid...........................................7B1-9 Scan Tool Data Definition ......................... 7B1-43
Diagnosis .....................................................7B1-11 DTC P0705 (DTC NO.34) Transmission
Range Sensor (Switch) Circuit
On-Board Diagnostic System ....................7B1-11
Malfunction................................................ 7B1-44
Precaution in Diagnosing Trouble .............7B1-12
DTC P0710 (DTC NO.36/38)
Automatic Transmission Diagnostic
Transmission Fluid Temperature Sensor
Flow Table.................................................7B1-13
Circuit Malfunction .................................... 7B1-47
O/D OFF Lamp Check ............................7B1-16
DTC P0715 (DTC NO.37) Input/Turbine
Diagnostic Trouble Code (DTC) Check.....7B1-16
Speed Sensor Circuit Malfunction............. 7B1-49
Diagnostic Trouble Code Clearance .........7B1-18
DTC P0720 (DTC NO.31) Output Speed
Diagnostic Trouble Code Table.................7B1-19
Sensor Circuit Malfunction ........................ 7B1-52
Fail Safe Table ..........................................7B1-21
DTC P0725 (DTC NO.35) Engine Speed
Visual Inspection .......................................7B1-22
Input Circuit Malfunction ........................... 7B1-55
A/T Basic Check........................................7B1-23
DTC P0743 (DTC NO.25/26) TCC
Trouble Diagnosis Table 1 ........................7B1-24
(Lock-Up) System Electrical...................... 7B1-57
DTC P0748 (DTC NO.41/42) Pressure
Control Solenoid Electrical........................ 7B1-59
Engine Brake Test.....................................7B1-31
DTC P0753 (DTC NO.21/22)/
Stall Test ...................................................7B1-31
P0758 (DTC NO.23/24) Shift Solenoid-A/
Time Lag Test ...........................................7B1-33
Shift Solenoid-B Electrical......................... 7B1-61
Line Pressure Test ....................................7B1-34
DTC P1700 (DTC NO.32/33)
P Range Test ..........................................7B1-35
Acceleration Stroke Signal Input
Table A-1: No Gear Shift to O/D ...............7B1-36
Malfunction................................................ 7B1-63
Table A-2: No Lock-Up Occurs .................7B1-37
DTC P1702 (DTC NO.52) Internal
Table B-1: O/D OFF Lamp Circuit
Malfunction of TCM................................... 7B1-65
Check (O/D OFF Lamp Doesnt
Light at Ignition Switch On) .......................7B1-38
7B1-2 AUTOMATIC TRANSMISSION (4 A/T)
DTC P1730 (DTC NO.64) Engine Unit Repair .................................................. 7B1-89

Torque Signal Circuit Malfunction ............. 7B1-66 Precautions............................................... 7B1-89
On-Vehicle Service .....................................7B1-68 Part Inspection and Correction Table ....... 7B1-90
Maintenance Service ................................ 7B1-68 Unit Disassembly ...................................... 7B1-91
Fluid level .............................................. 7B1-68 Subassembly .......................................... 7B1-108
Fluid change.......................................... 7B1-69 Oil pump assembly ............................. 7B1-108
Oil Cooler Hoses....................................... 7B1-70 O/D clutch assembly and O/D
Manual Selector Assembly ....................... 7B1-70 planetary gear assembly..................... 7B1-112
Select Cable.............................................. 7B1-72 O/D brake assembly ........................... 7B1-118
Transmission Range Sensor (Switch)....... 7B1-73 Direct clutch assembly ........................ 7B1-122
Input Shaft Speed Sensor......................... 7B1-74 Forward clutch assembly .................... 7B1-126
Output Shaft Speed Sensor ...................... 7B1-75 Sun gear and one-way No.3 clutch
A/T Fluid Temperature Sensor.................. 7B1-77 assembly............................................. 7B1-131
O/D Off Switch .......................................... 7B1-77 Forward brake assembly..................... 7B1-133
Solenoid Valves (Shift Solenoid Valves, Rear planetary gear carrier assembly
TCC Solenoid Valve and Pressure and output shaft .................................. 7B1-136
Control Solenoid Valve) ............................ 7B1-78 Valve body assembly .......................... 7B1-141
Throttle Position Sensor............................ 7B1-81 Unit Assembly......................................... 7B1-142
Transmission Control Module (TCM) ........ 7B1-81 Tightening Torque Specifications........... 7B1-161
4WD LOW Switch ..................................... 7B1-82 Required Service Material........................ 7B1-162
Oil Cooler Pipes ........................................ 7B1-82 Special Tool .............................................. 7B1-162
Automatic Transmission Assembly
(with Transfer)........................................... 7B1-83
General Description
This automatic transmission is a full automatic type with 3-speed plus overdrive (O/D).
The torque converter is a 3-element, 1-step and 2-phase type and is equipped with an electronically controlled
lock-up mechanism. The gear shift device consists of 3 sets of planetary gear units, 3 disc type clutches, 3 disc
type brakes, 1 band type brake and 3 one-way clutches. The gear shift is done by selecting one of 6 positions
(P, R, N, D, 2 and L) of the select lever installed on the floor. On the shift knob, there is an overdrive (O/
D) off switch which prevents shift-up to the overdrive mode. The optimum line pressure of fluid is obtained based
on throttle pressure of fluid. The throttle pressure of fluid which corresponds to engine load (engine torque) is
adjusted by the electronically controlled linear solenoid.
1 2
3 4 5 6 7 8 9 10 11 12 13 14 15
16 17 18
1. Torque converter 6. O/D planetary gear 11. 2nd brake 16. O/D input shaft
2. Oil pump 7. Direct clutch 12. One-way No. 3 clutch 17. Intermediate shaft
3. O/D brake 8. 2nd coast brake 13. One-way No. 2 clutch 18. Output shaft
4. O/D clutch 9. Forward clutch 14. Reverse brake
5. One-way No.1 clutch 10. Front planetary gear 15. Rear planetary gear
Item Specifications
Torque con- Type 3-element, 1-step, 2-phase type (with TCC (lock-up) mecha-
verter nism)
Stall torque ratio 1.75 0.1
Oil pump Type Trochoid type oil pump
Drive system Engine driven
Gear Type Forward 4-step, reverse 1-step planetary gear type
change Shift position P range Gear in neutral, output shaft fixed, engine start
device R range Reverse
N range Gear in neutral, engine start
D range Forward 1st 2nd 3rd 4th (O/D)
(O/D ON) automatic gear change
D range Forward 1st 2nd 3rd
(O/D OFF) automatic gear change
2 range Forward 1st 2nd 3rd automatic gear change
L range Forward 1st 2nd reduction, and fixed at 1st gear
Gear ratio 1st 2.804
(low gear)
2nd 1.531
(second gear)
3rd 1.000
(top gear)
4th 0.705
(overdrive gear)
Reverse 2.393
(reverse gear)
Control elements Wet type multi-disc clutch . . . 3 sets
Wet type multi-disc brake. . . . 3 sets
Band type brake. . . . . . . . . . . 1 set
One-way clutch . . . . . . . . . . . 3 sets
Transfer Hi : 1.000
Lo : 1.816 (4WD model only)
Final gear reduction ratio 4.300
(Differential)
Lubrication Lubrication system Forced feed system by oil pump
Cooling Cooling system Radiator assisted cooling (water-cooled)
Fluid used An equivalent of DEXRONIII
Clutch/Brake Functions
2 1 8 5 4 3 6 10 7 9
11 14 12 15 16 13
5 6
2 7
4
1
9
3
8
10
11 12
15 16 13
14
1. O/D clutch 5. 2nd coast brake 9. One-way No. 2 clutch 13. Output shaft
2. O/D brake 6. 2nd brake 10. One-way No. 3 clutch 14. O/D planetary gear
3. Forward clutch 7. Reverse brake 11. O/D input shaft 15. Front planetary gear
4. Direct clutch 8. One-way No.1 clutch 12. Intermediate shaft 16. Rear planetary gear
Part Name Function

O/D clutch Meshes overdrive carrier incorporated with overdrive input shaft and over-
drive sun gear.
O/D brake Fixes overdrive sun gear.
One-way No.1 clutch Meshes overdrive carrier and overdrive sun gear only when driven by
engine.
Forward clutch Meshes forward clutch input shaft and front planetary carrier.
Direct clutch Meshes forward clutch input shaft with front sun gear and rear sun gear.
Second coast brake Fixes front sun gear and rear sun gear.
Second brake Fixes outer race of one-way No.3 clutch, to prevent front sun gear and
rear sun gear from turning counterclockwise (reverse direction of engine
input rotation direction).
Reverse brake Fixes rear planetary carrier.
One-way No.3 clutch Prevents front sun gear and rear sun gear from turning counterclockwise
only when second brake is at work.
One-way No.2 clutch Prevents rear planetary carrier from turning counterclockwise.
Table of Component Operation

Solenoid Solenoid TCC O/D Forward Direct O/D Second Second Reverse One-way One-way One-way
valve-A valve-B solenoid clutch clutch clutch brake coast brake brake No.1 No.3 No.2
(No.1) (No.2) valve brake clutch clutch clutch
P
R
(Rev<9
km/h)
R
(Rev9
km/h)
N
D 1st
2nd
3rd ()
4th ()
2 1st
2nd
3rd
L 1st
2nd
: ON
: OFF
() : ON when TCC is in lock-up condition
: ON when vehicle is accelerating
: OFF when vehicle is coasting
Electronic Shift Control System

The gear ratio change in D, 2 or L range and torque converter clutch operation are controlled by Transmission
Control Module (TCM).
Engine Torque converter with Planetary gear Final gear

torque converter clutch unit reduction unit
Clutches and
Regulator valves brakes
Oil pump
in valve body
Control valves
Pressure control in valve body
solenoid valve (1) Shift solenoid valves (2)
andTCC solenoid valve (3)
A
Engine control module (ECM)
B Transmission control module (TCM) (4)
A: Acceleration stroke signal
B: Engine speed signal C
C: Engine torque signal
Input shaft speed sensor (5)
Throttle position sensor
O/D OFF lamp (10)
(Acceleration stroke Output shaft speed sensor (6)
sensor) (12)
Data link connector Transmission range sensor (7)
Crank shaft position
sensor (Engine speed Monitor connector (11) O/D off switch (8)
sensor) (13)
Transmission fluid
temperature sensor (9)
Power transmission
Fluid pressure circuit Transfer 4L switch (14)
Electric signal
Brake light switch (15)
2 12V 1
12V
13
E203-6 YEL 14
E227-7 BLU/WHT E202-15
3
12V
12V
E229-28 BLU/WHT E202-6 E203-7 PPL/RED
12V
15
12V
E228-11 WHT E202-23 16
E203-4 GRN
12V 17
4
E203-3 GRN/RED
WHT E202-4
ORN E202-16
2.5V 12V
18
5
BLU/YEL E202-5 E203-12 GRN/YEL
BLU/GRN E202-17
BB 2.5V 12V
19
6
GRN/WHT E203-16 E203-11 BLU/ORN
7
12V E203-8 BLU/RED
8
5V 20
ORN/WHT E203-1
E203-5 RED/BLU
12V
9
E203-14 RED/GRN
10 GRN/RED E202-3 21
P 22
ORN/GRN E202-2
E202-10 WHT/BLK
IG11 R
11 RED E202-1
N E203-20 BLK/WHT
ORN/BLU E202-9
D E203-13 WHT IG11 IG1 BB
YEL/GRN E202-8 23
2
GRN/ORN E202-21
L 25
GRN/BLU E202-20
24
IG1
E203-15 BLK
12 E203-19 BLK
E203 E202 22
4 3 2 1 7 6 5 4 3 2 1
13 12 11 10 9 8 7 6 5 19 18 17 16 15 14 13 12 11 10 9 8
20 19 18 17 16 15 14 28 27 26 25 24 23 22 21 20
1. TCM 8. 4WD low switch 15. A/T 22. Ignition switch

2. To tachometer 9. O/D off switch 16. Shift solenoid-A (Shift solenoid No.1) 23. Inhibitor switch
(In transmission range sensor)
3. ECM 10. Transmission range sensor 17. Shift solenoid-B (Shift solenoid No.2) 24. Starter relay
4. Output shaft speed sensor 11. Backup lamp 18. TCC (Lock-up) solenoid 25. Battery
5. Input shaft speed sensor 12. Shift indicator 19. Pressure control solenoid 26. Terminal arrangement of TCM cou-
pler (Viewed from harness side)
6. Brake light switch 13. Monitor connector 20. Transmission fluid temp. sensor
7. Brake light 14. Data link connector (DLC) 21. O/D OFF lamp
Change mechanism
The same select pattern shift lever is used as the floor type and
frequently used N and D ranges are made selectable freely.
[A] : Shift the select lever with its button pushed in.
[B] : Shift the select lever without pushing its button.
Operation of shift solenoids and TCC solenoid
RANGE D 2 L N R P
GEAR 4th Neu- Rev Rev
1st 2nd 3rd 1st 2nd 1st
(O/D) tral (>9 km/h) (9 km/h)
Shift solenoid-A (NO.1)
SOLENOIDS
()
Shift solenoid-B (NO.2) ()
TCC solenoid valve
() ()
: ON (Turn power on)
: OFF (Turn power off)
() : ON only when TCC is in lock-up condition
() : Gear is at neutral position regardless of solenoid status
Valve status
Turn power ON Turn power OFF
Shift solenoid-A (NO.1) Open Close
Shift solenoid-B (NO.2) Open Close
TCC solenoid Close Open
AUTOMATIC GEAR SHIFT DIAGRAM

Automatic shift schedule as a result of shift control is shown below. In case that select lever is shifted to L at a
higher than 35 km/h or 22 mile/h speed, 2nd or 3rd gear is operated and then down shifts to 1st at a speed lower
than that. No up shift is available in L.
Likewise, when the select lever is shifted to 2 at a higher than 69 km/h (43 mile/h) speed, 3rd gear is operated
and then down shifts to 2nd at a speed lower than that.
Shift
12 23 34 43 32 21
Throttle Full throttle km/h (mile/h) 35 69 110 102 62 27
opening (22) (43) (69) (64) (39) (17)
Closed throttle km/h (mile/h) 13 24 38 34 21 7
(8) (15) (24) (21) (13) (4)
GEAR SHIFT DIAGRAM [A] AND TCC LOCK-UP DIAGRAM [B]
% 1 2 1 2 2 32 3 3 4 3 4
[A] 100
[C] 50
: E
: F
0
0 50 100 Km/h
0 50 MPH
[D]
%
[B] 100
: G
: H
[C] 50
I J
0
0 50 100 Km/h
0 50 MPH
[D]
[C] : Throttle valve opening [G] : TCC ON

[D] : Vehicle speed [H] : TCC OFF
[E] : Up shift [I] : 4th gear
[F] : Down shift [J] : 3rd gear
Diagnosis
This vehicle is equipped with an electronic transmission control system, which controls the automatic shift up
and shift down timing, TCC operation, etc. suitably to vehicle driving conditions.
TCM has an On-Board Diagnosis system which detects a malfunction in this system and abnormality of those
parts. When diagnosing a trouble in the transmission including this system, be sure to have full understanding of
the outline of On-Board Diagnostic System and each item in Precaution in Diagnosing Trouble and execute
diagnosis according to Automatic Transmission Diagnostic Flow Table to obtain correct result smoothly.

For automatic transmission control system, TCM has the following
functions.
When TCM detects a malfunction in A/T control system while
the engine is running, it flashes O/D OFF lamp (3) and
stores the malfunction area in its memory.
It is possible to communicate with TCM through DLC (2) by
using SUZUKI scan tool (1). (Diagnostic information can be
accessed by using a scan tool (1).)
2 It is also possible to output by flashing of O/D OFF lamp (3)
1 with diagnosis switch terminal (5) of monitor connector (4)
grounded.
If no DTC is stored in TCM memory, DTC No.12 is outputted
repeatedly.
If one or more DTCs are stored in TCM memory, they are
outputted three times per one code starting from smallest
code number in increasing order.
3 After all DTCs are outputted, they are outputted again in the
same manner.
4

Dont disconnect couplers from TCM, battery cable from bat-
tery, TCM ground wire harness from engine or main fuse
before checking DTC stored in TCM memory. Such discon-
nection will clear memorized information in TCM memory.
Using SUZUKI scan tool, the diagnostic information stored in
TCM memory can be checked and cleared as well. Before its
use, be sure to read Operators (Instruction) Manual supplied
with it carefully to have good understanding of its functions
and usage.
Be sure to read Precautions for Electrical Circuit Service in
Section 0A before inspection and observe what is written
there.
TCM replacement
When substituting a known-good TCM, check for the follow-
ing condition.
Neglecting this check may result in damage to a good TCM.
All relays and actuators have resistance of specified value.
Automatic Transmission Diagnostic Flow Table

Refer to the following items for the details of each step.
Step Action Yes No

1 Customer Complaint Analysis Go to Step 2. Perform customer com-
1) Perform customer complaint analysis. plaint analysis.
Was customer complaint analysis performed
according to instruction?
2 Diagnostic Trouble Code (DTC) Check, Record Print DTC or write them Go to Step 4.
and Clearance down and clear them by
1) Check for DTC referring to DTC Clear-
Is there any DTC(s)? ance in this section.
Go to Step 3.
3 Visual Inspection Repair or replace mal- Go to Step 5.
1) Perform visual inspection. function part.
Is there any faulty condition? Go to Step 11.
1) Perform visual inspection.
1) Confirm trouble symptom.
6 Rechecking and Recording of DTC Go to Step 9. Go to Step 8.
1) Recheck for DTC referring to DTC Check
in this section.
7 Rechecking and Recording of DTC Go to Step 9. Go to Step 10.
1) Recheck for DTC referring to DTC Check
in this section.
8 Automatic Transmission Basic Inspection and Go to Step 11. Check and repair mal-
Trouble Diagnosis Table function part(s).
1) Check and repair according to A/T Basic Go to Step 11.
Check and Trouble Diagnosis Table in this
section.
Are check and repair completed?
DTC Diagnostic Flow Table.
Are check and repair completed?
10 Check for Intermittent Problems Repair or replace mal- Go to Step 11.
1) Check for intermittent problems. function part(s).
Is there any faulty condition? Go to Step 11.
2) Perform final confirmation test.
Is there any problem symptom, DTC or abnor-
mal condition?
STEP 1. CUSTOMER COMPLAINT ANALYSIS

Record details of the problem (failure, complaint) and how it occurred as described by the customer.
For this purpose, use of such an inspection form as shown in the following page as an example will facilitate col-
lecting information to the point required for proper analysis and diagnosis.
STEP 2. DIAGNOSTIC TROUBLE CODE (DTC) CHECK, RECORD AND CLEARANCE
First, referring to DTC Check in this section, check DTC. If DTC exists, print or write down DTC and then clear
it by referring to DTC Clearance in this section. DTC indicates malfunction in the system but it is not possible to
know from it whether the malfunction is occurring now or it occurred in the past and normal condition has been
restored. In order to know that, check symptom in question according to Step 5 and then recheck DTC accord-
ing to Step 6.
Diagnosing a trouble based on the DTC in this step only or failure to clear the DTC in this step may result in a
faulty diagnosis, trouble diagnosis of a normal circuit or difficulty in troubleshooting which is otherwise unneces-
sary.
STEP 3 and STEP 4. VISUAL INSPECTION
As a preliminary step, be sure to perform visual check of the items that support proper function of the A/T and
engine referring to Visual Inspection in this section.
STEP 5. TROUBLE SYMPTOM CONFIRMATION
Check trouble symptoms based on information obtained in Step 1 CUSTOMER COMPLAINT ANALYSIS and
Step 2 DTC Check.
Also, recheck DTC according to DTC Confirmation Procedure described in each DTC FLOW TABLE.
STEP 6 and STEP 7. RECHECKING AND RECORDING OF DTC
Refer to DTC Check in this section for checking procedure.
STEP 8. A/T BASIC CHECK AND TROUBLE DIAGNOSIS TABLE
Perform A/T basic check according to A/T Basic Check in this section first. When the end of the flow table has
been reached, check the parts of the system suspected as a possible cause referring to Trouble Diagnosis
Table in this section and based on symptoms appearing on the vehicle (symptoms obtained through steps of
customer complaint analysis, trouble symptom confirmation and/or A/T basic check) and repair or replace faulty
parts, if any.
STEP 9. DIAGNOSTIC TROUBLE CODE FLOW TABLE
Based on the DTC indicated in Step 6 and 7 and referring to Diagnostic Trouble Code Table in this section,
locate the cause of the trouble, namely in a sensor, switch, wire harness, connector, actuator, TCM or other part
STEP 10. CHECK FOR INTERMITTENT PROBLEM
STEP 11. FINAL CONFIRMATION TEST
Confirm that the problem symptom has gone and the A/T is free from any abnormal conditions.
If what has been repaired is related to the malfunction DTC, clear the DTC once, set conditions under which
DTC was detected and A/T and/or vehicle was repaired and confirm that no DTC is indicated.
NOTE:
The above form is a standard sample. It should be modified according to conditions characteristic of
each market.
O/D OFF Lamp Check

1) Turn ignition switch ON.
2) Check that O/D OFF lamp lights for about 2 4 sec. and
then goes OFF.
If anything faulty is found, advance to Table B-1: O/D OFF
Lamp Circuit Check (O/D OFF Lamp Doesnt Light at Igni-
tion Switch ON) or Table B-2: O/D OFF Lamp Circuit
Check (O/D OFF Lamp Comes ON Steadily) in this sec-
tion.

[CHECK DTC USING SUZUKI SCAN TOOL]
1) Turn ignition switch OFF.
2) Connect SUZUKI scan tool to data link connector (DLC) (1).
Special tool
1
(A) 3) Turn ignition switch ON.
4) Read DTC according to instructions displayed on SUZUKI
scan tool and print it down. Refer to SUZUKI scan tool oper-
ators manual for further details.
5) After completing DTC check, turn ignition switch OFF and
disconnect SUZUKI scan tool from data link connector (DLC)
(1).
[CHECK DTC WITHOUT USING SUZUKI SCAN TOOL]
1
1) Turn ignition switch ON and make sure that O/D OFF lamp
(1) is OFF in combination meter (with O/D off switch OFF).
3) Remove steering column hole cover (5).
4) Using service wire, ground diagnosis switch terminal (2) of
monitor connector (4).
6) Read DTC from flashing pattern of O/D OFF lamp (1).
7) After completing DTC check, turn ignition switch OFF and
disconnect service wire from monitor connector (4).
3. Ground terminal
3
Diagnostic Trouble Code Clearance

[CLEAR DTC USING SUZUKI SCAN TOOL]
located in underside of instrument panel at driver's seat side.
Special tool
1 (A): SUZUKI scan tool
(A)
4) Erase DTC according to instructions displayed on SUZUKI
scan tool. Refer to SUZUKI scan tool operator's manual for
further details.
5) After completing erasing, turn ignition switch OFF and dis-
connect SUZUKI scan tool from data link connector (DLC)
(1).
[CLEAR DTC WITHOUT USING SUZUKI SCAN TOOL]
2) After 6 seconds or more, repeat connecting and disconnect-
ing diagnosis switch terminal (2) and ground terminal (3) of
monitor connector (1) 5 times at about 1 second interval
within 10 seconds, using service wire.
3) Perform DTC Check in this section and confirm that only
DTC No.12 (normal DTC) is displayed. If not, repeat Step 1)
and 2) and check again.
3
Diagnostic Trouble Code Table

EXAMPLE: When Shift Solenoid-B Electrical (Code No.21) Is Set
[A] : O/D OFF lamp is turned ON [C] : Code No.21

[B] : O/D OFF lamp is turned OFF [D] : Time (Sec.)
DTC O/D OFF Lamp

Detecting Condition (DTC will
Using Not using Flashing of DTC Detecting Items
set when detecting)
scan tool scan tool (Not using scan tool)

12 Normal
No sensor signal is inputted.
Transmission range
or
P0705 34 sensor circuit malfunc-
2 or more signals are inputted
tion
simultaneously.
Sensor output voltage is too high
36 (Circuit open or shorted power cir-
Transmission fluid tem-
P0710 cuit)
perature sensor circuit
Sensor output voltage is too low
38
(Circuit shorted to ground)
No sensor signal is inputted
Input/Turbine speed
P0715 37 although output shaft speed sensor
sensor circuit
signal is inputted.
Output speed sensor
P0720 31 although input shaft speed sensor
circuit
signal is inputted.
Engine speed input cir-
P0725 35 although input shaft speed sensor
cuit
signal is inputted.
Voltage of TCC solenoid terminal is
25 too high although TCM commands
Torque converter clutch TCC solenoid to turn OFF.
P0743
circuit electrical Voltage of TCC solenoid terminal is
26 too low although TCM commands
TCC solenoid to turn ON.
No electric flow is detected in pres-
41
Pressure control sole- sure solenoid circuit.
P0748
noid electrical Too much electric flow is detected
42
in pressure control solenoid circuit.
DTC O/D OFF Lamp

Detecting Condition (DTC will
Using Not using Flashing of DTC Detecting Items
set when detecting)
scan tool scan tool (Not using scan tool)
Voltage of shift solenoid terminal is
Shift solenoid-A (No.1) shift solenoid to turn OFF.
P0753
electrical Voltage of shift solenoid terminal is
shift solenoid to turn ON.
Voltage of shift solenoid terminal is
Shift solenoid-B (No.2) shift solenoid to turn OFF.
P0758
electrical Voltage of shift solenoid terminal is
shift solenoid to turn ON.
Too short low signal of pulse signal
32 from ECM to TCM continues to be
Acceleration stroke sig- out of specification.
P1700
nal input malfunction Too long low signal of pulse signal
33 from ECM to TCM continues to be
out of specification.
Calculation of current data stored
Internal malfunction of in TCM is not correct comparing
P1702 52
TCM with pre-stored checking data in
TCM.
Too short or too long low signal of
Engine torque signal cir-
P1730 64 pulse signal from ECM to TCM
cuit malfunction
continues to be out of specification.
Fail Safe Table

This function is provided by the safe mechanism that assures safe driveability even when the solenoid valve,
sensor or its circuit fails.
The table below shows the fail safe function for each fail condition of solenoid, solenoid or its circuit.
DTC No. Trouble Area Fail Safe Operation

In case of circuit open, selected range is set as D range.
In case of circuit short (In case that 2 or more sensor signals are
Transmission range sen- inputted), selected range is set in following priority order.
P0705 34
sor or its circuit D>2>L>R>N>P
Reverse control operation, which inhibits reverse driving at R range
while vehicle runs forward at more than 11 km/h (7 mile/h), is inhibited.
Transmission fluid tem- Lock-up function is inhibited to operate.
36
P0710 perature sensor or its cir- Line pressure control which defuses shift shock is inhibited.
38
cuit
Maximum value of line pressure is outputted.
Input shaft speed sensor
P0715 37 Lock-up function is inhibited to operate.
or its circuit
Line pressure control which defuses shift shock is inhibited.
4th gear (O/D) shift-up function is inhibited to operate.
Output speed sensor or Lock-up function is inhibited to operate.
P0720 31
its circuit Line pressure control which defuse shift shock is inhibited.
Reverse control operation, which inhibits reverse driving at R range
while vehicle runs forward at more than 11 km/h (7 mile/h), is inhibited.
Engine speed input cir- Maximum value of line pressure is outputted.
P0725 35
cuit or ECM Lock-up function is inhibited to operate.
Lock-up function is inhibited to operate.
When TCC solenoid circuit is shorted to power circuit and vehicle
25 TCC solenoid valve or its speed is less than 10 km/h (6 mile/h), gear position is fixed in 1st
P0743
26 circuit gear for prevention of engine stall.
Up shift to 4th gear is inhibited when A/T fluid temperature is 140
C (284 F) or higher.
41 Pressure control solenoid Line pressure control which defuses select shock is inhibited.
P0748
42 valve or its circuit Power supply to shift solenoid, TCC solenoid and pressure control
solenoid is cut.
21 Shift solenoid-A valve or Lock-up function is inhibited to operate.
P0753
22 its circuit Line pressure control which defuses select shock is inhibited.
23 Shift solenoid-B valve or Power supply to shift solenoid, TCC solenoid and pressure control
P0758
24 its circuit solenoid is cut.
Line pressure control which defuses shift shock is inhibited.
32 Throttle position (TP)
P1700 Throttle position which is used for A/T control (Shift schedule etc.)
33 sensor or its circuit
is supposed to be 0%.
Power supply to shift solenoid, TCC solenoid and pressure control
P1702 52 TCM
solenoid is cut.
Engine torque signal cir- Maximum value of line pressure is outputted.
P1730 64
cuit or ECM Lock-up function is inhibited to operate.
Shift solenoid fail safe table
Select lever position Normal Gear position to be fixed

1
2
D O/D
3
O/D
1
2 2 3
3
1
L 1
2
Visual Inspection

A/T fluid - - - - - level, leakage, color SECTION 0B
A/T fluid hoses - - - - - disconnection, looseness, deterioration SECTION 7B1
Accelerator cable - - - - - play, installation SECTION 6E3
A/T select cable - - - - - installation, operation SECTION 7B1
Engine oil - - - - - level, leakage SECTION 0B
Engine coolant - - - - - level, leakage SECTION 0B
Connectors of electric wire harness - - - - - disconnection, friction SECTION 6
Fuses - - - - - burning SECTION 8
Parts - - - - - installation, damage
Bolt - - - - - looseness
Also check the following items at engine start, if possible.
O/D OFF lamp - - - - - Operation SECTION 7B1
Malfunction indicator lamp - - - - - Operation SECTION 6
Charge warning lamp - - - - - Operation SECTION 6H
Engine oil pressure warning lamp - - - - - Operation SECTION 8 (SECTION 6A3 for
pressure check)
A/T Basic Check

This inspection is important for troubleshooting when TCM has detected no DTC and no abnormality has been
noted in visual inspection. Follow flow table carefully.
Step Action Yes No

1 Was Automatic Transmission Diagnostic Flow Go to Step 2. Go to Automatic Transmis-
Table in this section performed? sion Diagnostic Flow
2 Perform Road Test in this section. Go to Step 3. Proceed to Road Test in
Is it OK? this section.
3 Perform Manual Road Test in this section. Go to Step 4. Proceed to Manual Road
Is it OK? Test in this section.
4 Perform Engine Brake Test in this section. Go to Step 5. Proceed to Engine Brake
5 Perform Stall Test in this section. Go to Step 6. Proceed to Stall Test in
Is it OK? this section.
6 Perform Time Lag Test in this section. Go to Step 7. Proceed to Time Lag
7 Perform Line Pressure Test in this section. Go to Step 8. Proceed to Line Pressure
8 Proceed to Trouble Diagnosis Table 1" in this Repair or replace defective Go to Step 9.
section. parts.
Is trouble identified?
9 Proceed to Trouble Diagnosis Table 2" in this Repair or replace defective Proceed to Trouble Diag-
section. parts. nosis Table 3" in this sec-
Is trouble identified? tion.
Trouble Diagnosis Table 1

ELECTRICAL REPAIR

Poor 1 2 shift and Acceleration stroke sensor circuit faulty Inspect circuit for open, short and intermittent
2 1 shift trouble referring to Section 6. If NG, repair.
Transmission range sensor circuit faulty Inspect circuit for open, short and intermittent
Output shaft speed sensor circuit faulty trouble. If NG, repair.
Shift solenoid-B valve circuit faulty
TCM Inspect referring to DTC FLOW TABLE of
P0705, P0720, P0748, P0753, P0758, P1700
and P1702 in this section. If NG, replace.
Poor 2 3 shift and Acceleration stroke sensor circuit faulty Inspect circuit for open, short and intermittent
3 2 shift trouble referring to Section 6. If NG, repair.
Shift solenoid-A valve circuit faulty
P0705, P0720, P0743, P0748, P0753,
P0758, P1700 and P1702 in this section. If
NG, replace.
Poor 3 O/D shift and Acceleration stroke sensor circuit faulty Inspect circuit for open, short and intermittent
O/D 3 shift trouble referring to Section 6. If NG, repair.
O/D off switch circuit faulty Refer to DIAGNOSTIC FLOW TABLE A-1 in
4WD low switch circuit faulty this section.
P0705, P0720, P0743, P0748, P0753,
NG, replace.
Incorrect gear shift Acceleration stroke sensor circuit faulty Inspect circuit for open, short and intermittent
point trouble referring to Section 6. If NG, repair.
Pressure control solenoid valve circuit
faulty
P0705, P0720, P0743, P0748, P0753,
NG, replace.
TCC (lock-up) system Acceleration stroke sensor circuit faulty Inspect circuit for open, short and intermittent
does not operate trouble referring to Section 6. If NG, repair.
TCC solenoid valve circuit faulty
Transmission fluid temperature sensor
circuit faulty
Brake light switch circuit faulty
P0710, P0715, P0720, P0743 and P1700 in
this section. If NG, replace.

Higher or lower stall Pressure control solenoid valve circuit Inspect circuit for open, short and intermittent
speed faulty trouble. If NG, repair.
P0748 in this section. If NG, replace.
Higher or lower line Pressure control solenoid valve circuit Inspect circuit for open, short and intermittent
pressure faulty trouble. If NG, repair.
P0748 in this section. If NG, replace.
Excessive shock at Acceleration stroke sensor circuit faulty Inspect circuit for open, short and intermittent
N D trouble referring to Section 6. If NG, repair.
Transmission fluid temperature sensor Inspect circuit for open, short and intermittent
circuit faulty trouble. If NG, repair.
faulty
P0710, P0715, P0720, P0725, P0748,
P0753, P0758, P1700 and P1730 in this sec-
tion. If NG, replace.
N R trouble referring to Section 6. If NG, repair.
Transmission fluid temperature sensor Inspect circuit for open, short and intermittent
circuit faulty trouble. If NG, repair.
P0710, P0715, P0720, P0725, P0748,
shift up and down trouble referring to Section 6. If NG, repair.
Output shaft speed sensor circuit faulty Inspect circuit for open, short and intermittent
Input shaft speed sensor circuit faulty trouble. If NG, repair.
Transmission fluid temperature sensor
circuit faulty
faulty
P0710, P0715, P0720, P0725, P0748,

ON-VEHICLE REPAIR

Unable to run in all Faulty valve body component Replace valve body assembly.
range
Poor 1 2 shift, Engine abnormal condition Inspect and repair engine.
excessive shock or Malfunction of acceleration stroke sensor Inspect. If NG, replace.
slippage Malfunction of transmission range sensor
Malfunction of transmission fluid tempera-
ture sensor
Malfunction of output shaft speed sensor
Malfunction of input shaft speed sensor
Malfunction of shift solenoid-B valve cir-
cuit
Malfunction of pressure control solenoid Inspect. If NG, replace valve body
assembly.
Faulty valve body component Replace valve body assembly.
Poor 2 3 shift, Engine abnormal condition Inspect and repair engine.
ture sensor
Malfunction of shift solenoid-A valve cir-
cuit
assembly.
Poor 3 O/D shift, Engine abnormal condition Inspect and repair engine.
ture sensor
assembly.
Incorrect shift point Engine abnormal condition Inspect and repair engine.
Malfunction of acceleration stroke sensor Inspect. If NG, replace.
Malfunction of transmission range sensor
assembly.

TCC (lock-up) system Malfunction of acceleration stroke sensor Inspect. If NG, replace.
does not operate Malfunction of transmission range sensor
ture sensor
Malfunction of TCC solenoid valve
Malfunction of brake light switch
Excessive N D Faulty valve body component Replace valve body assembly.
or N R

OFF-VEHICLE REPAIR

Unable to run in all Faulty oil pump Inspect. If NG, replace.
ranges Seized or broken planetary gear
Damaged drive plate
Faulty torque converter Replace.
Poor 1 2 shift, Faulty 2nd brake Inspect. If NG, replace.
excessive shock or Faulty one-way No.3 clutch
slippage Faulty torque converter
Poor 2 3 shift, Faulty direct clutch Inspect. If NG, replace.
excessive shock or Faulty torque converter
slippage
Poor 3 O/D shift, Faulty O/D brake Inspect. If NG, replace.
excessive shock or Faulty torque converter
slippage
TCC (lock-up) system Faulty torque converter Replace.
does not operate
Excessive N D Clogged oil strainer Replace.
time lag Faulty oil pump Inspect. If NG, replace.
Faulty forward clutch
Faulty one-way No.1 clutch
Leakage from D range fluid pressure Replace valve body assembly.
circuit
Excessive N R Clogged oil strainer Replace.
time lag Faulty oil pump Inspect. If NG, replace.
Faulty direct clutch
Faulty reverse brake
Leakage from R range fluid pressure Replace valve body assembly.
circuit
Poor engine brake in Faulty second coast brake Inspect. If NG, replace.
downshift to 2range
Poor engine brake in Faulty reverse brake Inspect. If NG, replace.
downshift to L range
ROAD TEST
This test is to check if upshift and downshift take place at specified speed while actually driving vehicle on a level
road.
WARNING:
Carry out test in very little traffic area to prevent an accident.
Test requires 2 persons, a driver and a tester.
1) Warm up engine.
2) With engine running at idle, shift select lever to D.
3) Accelerate vehicle speed by depressing accelerator pedal gradually.
4) While driving in D range, check if gear shift and lock-up occur properly as shown in Automatic Gear Shift
Diagram in this section.
TROUBLESHOOTING

Unable to run in all Faulty valve body component Replace valve body assembly.
ranges Faulty oil pump Inspect. If NG, replace.
Seized or broken planetary gear
Damaged drive plate
Faulty torque convertor Replace.
1 2 up shift fails to Malfunction of shaft solenoid-B valve Inspect. If NG, replace.
occur Malfunction of acceleration stroke sensor
Faulty 2nd brake Inspect. If NG, replace.
2 3 up shift fails to Malfunction of shift solenoid-A valve Inspect. If NG, replace.
occur Malfunction of acceleration stroke sensor
Faulty direct clutch Inspect. If NG, replace.
3 O/D up shift fails Malfunction of acceleration stroke sensor Inspect. If NG, replace.
to occur Malfunction of transmission range sensor
Faulty O/D brake Inspect. If NG, replace.
Gear shift point is Malfunction of acceleration stroke sensor Inspect. If NG, replace.
incorrect Malfunction of transmission range sensor
Malfunction of pressure control solenoid
valve

TCC (lock-up) function Malfunction of TCC solenoid valve Inspect. If NG, replace.
does not operate Malfunction of acceleration stroke sensor
ture sensor
Malfunction of brake light switch
Faulty torque converter Replace.
MANUAL ROAD TEST

This test is to check the gear being used in L, 2 or D range
when driven with gear shift control system unoperated. Test drive
vehicle on a level road.
NOTE:
Before this test, check diagnostic trouble code (DTC).
WARNING:
To avoid danger of being burned, do not touch hot
exhaust system when disconnecting or reconnecting
shift solenoid coupler (1).
1) Disconnect shift solenoid connector (1) on transmission.
1
2) With select lever in P range, start engine and warm it up.
3) With select lever in L range, start vehicle and accelerate to
20 km/h (12.5 mile/h). Check in this state that 1st gear is
being used.
4) At 20 km/h (12.5 mile/h), shift select lever to 2 range and
accelerate to 40 km/h (25 mile/h). Check in this state that 3rd
gear is being used.
5) At 40 km/h (25 mile/h), shift select lever to D range and
check that O/D gear is used when speed is higher than 40
km/h (25 mile/h).
6) After above checks, stop vehicle then engine, and connect
shift solenoids coupler (1) with ignition switch OFF.
7) Clear DTC with scan tool.
TROUBLESHOOTING

Selected gear is not Defective valve body component Replace valve body assembly.
correct Defective clutch or brake Inspect clutch and brake. If any part
is found faulty, replace it.
Engine Brake Test
WARNING:
Before this test, make sure that there is no vehicle behind so as to prevent rear-end collision.
1) While driving vehicle in 3rd gear of D range, shift select lever down to 2 range and check if engine brake
operates.
2) In the same way as in Step 1, check engine brake for operation when select lever is shifted down to L
range.
3) If engine brake fails to operate in above tests, possible causes for such failure are as follows. Check each
part which is suspected to be the cause.
TROUBLESHOOTING

Failure to operate Defective second coast brake Replace.
when shifted down to
2 range
Failure to operate Defective reverse brake Replace.
when shifted down to
L range
Stall Test
This test is to check overall performance of automatic transmission and engine by measuring stall speed at D
and R ranges. Be sure to perform this test only when transmission fluid is at normal operating temperature and
its level is between FULL and LOW marks.
CAUTION:
Do not run engine at stall more than 5 seconds continuously, for fluid temperature may rise exces-
sively high.
After performing stall test, be sure to leave engine running at idle for longer than 60 seconds before
another stall test.
1) Apply parking brake and block wheels.

2) Install tachometer.
3) Start engine with select lever shifted to P range.
4) Depress brake pedal fully range.
5) Shift select lever to D and depress accelerator pedal fully while watching tachometer. Read engine rpm
quickly when it has become constant (stall speed).
6) Release accelerator pedal immediately after stall speed is checked.
7) In the same way, check stall speed in R range.
8) Stall speed should be within the following specification.
Stall speed:
2,250 - 2,550 rpm
TROUBLESHOOTING

Lower than standard Engine output torque failure faulty Inspect and repair engine.
level Defective one-way clutch of torque converter Replace.
Higher than standard Defective pressure control solenoid valve (Low Inspect.
level in D range line pressure) If NG, replace valve body assem-
bly.
Primary regulator valve (Low line pressure) Replace valve body assembly.
Slippery forward clutch Replace.
Defective one-way No.2 clutch Replace.
Leakage from D range fluid pressure circuit Replace valve body assembly.
Higher than standard Defective pressure control solenoid valve (Low Inspect.
level in R range line pressure) If NG, replace valve body assem-
bly.
Defective primary regulator valve (Low line Replace valve body assembly.
pressure)
Slippery direct clutch Replace.
Slippery reverse brake Replace.
Leakage from R range fluid pressure circuit Replace valve body assembly.
High than standard Defective pressure control solenoid valve (Low Inspect.
level in both D and line pressure) If NG, replace valve body assem-
R ranges bly.
pressure)
Clogged oil strainer Wash strainer.
Defective O/D clutch and one-way No.1 clutch Replace.
Malfunction of oil pump Replace.
Leakage from fluid pressure circuit Replace valve body assembly.
Time Lag Test

This test is to check conditions of clutch, reverse brake and fluid pressure. Time lag means time elapsed since
select lever is shifted with engine idling till shock is felt.
1) With chocks placed before and behind front and rear wheels respectively, depress brake pedal.
2) Start engine.
3) With stop watch ready, shift select lever from N to D range and measure time from that moment till shock
is felt.
4) Similarly measure time lag by shifting select lever from N to R range.
Specification for time lag:
N D Less than 1.0 sec.

N R Less than 1.4 sec.
NOTE:
When repeating this test, be sure to wait at least one minute after select lever is shifted back to N
range.
Engine should be warmed up fully for this test.
TROUBLESHOOTING

N D time lag Defective pressure control solenoid valve Inspect.
exceeds specification (Low line pressure) If NG, replace valve body assembly.
pressure)
Defective oil pump Inspect. If NG, replace.
Leakage from D range fluid pressure circuit Replace valve body assembly.
Defective forward clutch Replace.
Defective one-way No.2 clutch Replace.
N R time lag Defective pressure control solenoid valve Inspect.
exceeds specification (Low line pressure) If NG, replace valve body assembly.
pressure)
Leakage from R range fluid pressure circuit Replace valve body assembly.
Defective direct clutch Replace.
Defective reverse brake Replace.
Line Pressure Test

Purpose of this test is to check operating conditions of each part
by measuring fluid pressure in fluid pressure line. Line pressure
test requires the following conditions.
Automatic fluid is at normal operating temperature (70 to 80
C/158 176 F).
Fluid is filled to proper level (between FULL HOT and LOW
HOT on dipstick).
Air conditioner switch is turned OFF.
1) Apply parking brake securely and place chocks against
wheels.
2) Attach oil pressure gauge to fluid pressure check plug bolt
(1) hole in transmission case.
2. Transmission identification number plate
1, (a) Special tool

(A): 09925-37811
CAUTION:
2
After attaching oil pressure gauge, check that no fluid
leakage exists.
3) Depress foot brake fully, run engine at idle and stall.
4) Check fluid pressure in D and R ranges. Measured values
should be as specified below.
CAUTION:
Do not continue running engine at stall speed longer
than 5 seconds.
D range R range
(A)
Idle speed 4.0 4.6 kg/cm2 7.7 8.7 kg/cm2
57 65 psi 109 124 psi
Stall speed 9.1 10.5 kg/cm2 12.5 15.9 kg/cm2
129 150 psi 177 226 psi
5) If check result is OK, disconnect special tool, then tighten fluid
pressure check plug bolt to specified torque.
Tightening torque
Fluid pressure check plug bolt
(a): 7.5 Nm (0.75 kg-m, 5.5 lb-ft)
TROUBLESHOOTING

Higher than standard level in Defective pressure control solenoid Inspect.
each range valve If NG, replace valve body assembly.
Defective primary regulator valve Replace valve body assembly.
Lower than standard level in Defective pressure control solenoid Inspect.
each range valve If NG, replace valve body assembly.
Defective primary regulator valve Replace valve body assembly.
Leakage from fluid pressure circuit Overhaul or replace valve body
assembly.
Defective O/D clutch and one way No.1 Replace.
clutch
Lower than standard level Leakage from D range fluid pressure Overhaul or replace valve body
only in D range circuit assembly.
Defective forward clutch Replace.
Lower than standard level Leakage from R range fluid pressure Overhaul or replace valve body
only in R range circuit assembly.
Defective direct clutch Replace.
Defective reverse brake Replace.
P Range Test
1) Stop vehicle on a slope of 5 degrees or more, shift select lever to P range and at the same time apply park-
ing brake.
2) After stopping engine, depress brake pedal and release parking brake.
3) Then, release brake pedal gradually and check that vehicle remains stationary.
4) Depress brake pedal and shift select lever to N range.
5) Then, release brake pedal gradually and check that vehicle moves.
WARNING:
Before this test, check to make sure no one is around vehicle or down on a slope and keep watchful
for safety during test.
Table A-1: No Gear Shift to O/D

SYSTEM DESCRIPTION
TCM does not shift to O/D gear under any of the following conditions.
O/D off switch is ON. (O/D OFF lamp ON.)
4WD low switch is ON.
Output shaft speed sensor is in faulty condition. (P0720)
TROUBLESHOOTING
WARNING:
Road test should be carried out with 2 persons, a driver and tester, on a level road.
Step Action Yes No
1 Was Automatic Transmission Diagnostic Flow Go to Step 2. Go to Automatic Trans-
Table in this section performed? mission Diagnostic Flow
2 Check DTC. Go to DTC P0720 (DTC Go to Step 3.
Is DTC P0720 detected? No.31) Output Speed
Sensor Circuit Malfunc-
tion in this section to
repair and retry.
3 Perform running test under the following Faulty shift solenoid valve, GRN or GRN/RED
conditions and check voltage between circuit or transmission. circuit shorted to power
terminal E203-4 of TCM connector and circuit. If wire is OK, go to
ground, terminal E203-3 of TCM connector and Step 4.
ground.
O/D off switch is OFF.
Selector lever is in D range.
Transfer lever is in 2H position.
Drive vehicle with 4th gear condition referring
to Automatic Gear Shift Diagram in this sec-
tion.
Is each terminal voltage 0 1 V?
4 O/D off switch signal inspection. Go to Step 5. Faulty O/D off switch or its
With ignition switch ON, check voltage circuit.
between terminal E202-3 of TCM connector If OK, substitute a known-
and ground. good TCM and recheck.
O/D off switch OFF : 10 14 V
O/D off switch ON : 0 1 V
5 4WD low switch signal inspection. Substitute a known-good Faulty 4WD low switch or
With ignition switch ON, check voltage between TCM and recheck. its circuit.
terminal E202-1 of TCM connector and ground. If OK, substitute a known-
Transfer gear position 4L or N: 0 1 V good TCM and recheck.
Transfer gear position 2H or 4H: 10 14 V
Table A-2: No Lock-Up Occurs

SYSTEM DESCRIPTION
TCM turns TCC solenoid OFF under any of the following conditions.
Brake light switch is ON.
4WD low switch is ON.
Transmission fluid temperature sensor circuit is in faulty condition. (P0710)
Input shaft speed sensor is in faulty condition. (P0715)
Output shaft speed sensor is in faulty condition. (P0720)
TCC (lock-up) system circuit is in faulty condition. (P0743)
Pressure control solenoid circuit is in faulty condition. (P0748)
Shift solenoid circuit is in faulty condition. (P0753/P0758)
Acceleration stroke signal circuit is in faulty condition. (P1700)
TROUBLESHOOTING
WARNING:
Road test should be carried out with 2 persons, a driver and tester, on a level road.
Step Action Yes No
2 Check DTC. Go to applicable DTC Go to Step 3.
Is DTC P0710, P0715, P0720, P0743, P0748, diagnosis flow table to
P0753, P0758 or P1700 detected? repair and retry.
3 Perform running test under the following condi- Faulty TCC solenoid Go to Step 4.
tions and check voltage between terminal valve, circuit or
E203-12 of TCM connector and ground. transmission.
Selector lever is in D range.
Transfer lever is in 2H position.
Brake pedal is released.
Drive vehicle with TCC ON condition refer-
ring to Automatic Gear Shift Diagram in this
section.
Is terminal voltage 10 14 V?
4 Brake light switch signal inspection. Go to Step 5. Maladjusted brake light
With ignition switch ON, check voltage switch, faulty brake light
between terminal E202-16 of TCM connector switch or its circuit.
and ground. If OK, substitute a known-
Brake pedal is released: 0 1 V good TCM and recheck.
Brake pedal is depressed: 10 14 V
5 4WD low switch signal inspection. Substitute a known-good Faulty 4WD low switch or
With ignition switch ON, check voltage TCM and recheck. its circuit.
between terminal E202-1 of TCM connector If OK, substitute a known-
and ground. good TCM and recheck.
Transfer gear position 4L or N: 0 1 V
Transfer gear position 2H or 4H: 10 14 V
Table B-1: O/D OFF Lamp Circuit Check (O/D OFF Lamp Doesnt Light at
Ignition Switch On)
WIRING DIAGRAM
1
12V 4
3
GRN/RED E202-3 E202-10 WHT/BLK
[A]
E203 E202
3
10
1. O/D OFF lamp 4. To ignition switch

2. TCM [A] : Terminal arrangement of TCM connector (viewed from harness side)
3. O/D off switch
TROUBLESHOOTING
Step Action Yes No

1 O/D OFF lamp circuit check: Poor E202-10 terminal Bulb burned out or faulty
1) With ignition switch OFF, disconnect cou- connection. WHT/BLK or BLK/
plers from TCM. If OK, substitute a know- WHT wire.
2) Using service wire, connect E202-10 termi- good TCM and recheck.
nal of disconnected TCM harness side con-
nector and ground.
Does O/D OFF light turn ON at ignition switch
ON?
Table B-2: O/D OFF Lamp Circuit Check (O/D OFF Lamp Comes On
Steadily)
WIRING DIAGRAM
Refer to Table B-1: O/D OFF Lamp Circuit Check (O/D OFF Lamp Doesnt Light at Ignition Switch ON) in
this section.
TROUBLESHOOTING
Step Action Yes No

1 Check O/D OFF switch status. Go to Step 2. System is OK.
1) Press O/D OFF switch button (1) at igni-
tion switch ON.
Does O/D OFF lamp come ON steadily?
2 O/D OFF light circuit check: WHT/BLK wire shorted Go to Step 3.
1) Turn ignition switch OFF, disconnect cou- to ground circuit. If OK,
plers from TCM. replace combination meter.
Does O/D OFF lamp come ON steadily?
3 O/D OFF light circuit check: Go to Step 4. YEL/RED wire shorted to
1) Turn ignition switch to OFF position. ground circuit.
2) Disconnect O/D OFF switch connector.
3) Check continuity between YEL/RED wire
terminal of disconnected O/D OFF switch
connector and body ground.
Is it infinity?
4 Check O/D OFF switch for operation: Substitute a known-good Replace knob assembly.
1) With ignition switch OFF, remove console TCM and recheck.
box.
2) Disconnect O/D OFF switch connector.
3) Check continuity between switch terminals
under each of following conditions.
O/D OFF switch operation
With O/D OFF switch button (1) released:
No continuity
With O/D OFF switch button (1) pressed:
Continuity
[A] : Fig. for Step 1

[B] : Fig. for Step 4
Inspection of TCM and Its Circuits

TCM and its circuits can be checked at TCM wiring connectors by
CAUTION:
TCM cannot be checked by itself, it is strictly prohibited
to connect voltmeter or ohmmeter to TCM with connector
INSPECTION
1) Remove TCM (1) from vehicle referring to Transmission
Control Module (TCM) in this section.
2) Connect TCM connectors (2) to TCM.
3) Check voltage at each terminal of connectors connected.
NOTE:
As each terminal voltage is affected by battery voltage,
1
confirm that it is 11 V or more when ignition switch is
2
ON.
Pulse signal cannot be measured by voltmeter. It can
be measured by duty meter or oscilloscope.
3. Body ground
3
Connector : E202
Terminal Wire Normal

Circuit Condition
Number Color Voltage
R position signal for transmission 10 14 V Ignition switch turned ON, select lever shifted at R range.
1 RED
range switch 02V Ignition switch turned ON, select lever shifted at other than R range.
P position signal for transmission 10 14 V Ignition switch turned ON, select lever shifted at P range.
2 ORN/GRN
range switch 02V Ignition switch turned ON, select lever shifted at other than P range.
O/D switch signal for selector 02V Ignition switch turned ON, O/D OFF switch at O/D OFF.
3 YEL/RED
switch 10 14 V Ignition switch turned ON, O/D OFF switch at O/D ON.
4 WHT Output shaft speed sensor signal (+) 23V Ignition switch turned ON.
5 BLU/YEL Input shaft speed sensor signal (+) 23V Ignition switch turned ON.
Ignition switch turned ON (Output signal is 100 Hz active low duty pulse. Duty
01V
Throttle position sensor (Accelera- ratio varies as throttle valve is opened gradually.)
6 BLU/WHT
tor stroke sensor) signal Throttle opening 0% = 5 10% ON duty
10 14 V
Throttle opening 100% = 80 90% ON duty
7
D position signal for transmission 10 14 V Ignition switch turned ON, select lever shifted at D range.
8 YEL/GRN
range switch 02V Ignition switch turned ON, select lever shifted at other than D range.
N position signal for transmission 10 14 V Ignition switch turned ON, select lever shifted at N range.
9 ORN/BLU
range switch 02V Ignition switch turned ON, select lever shifted at other than N range.
02V Ignition switch turned ON, O/D OFF switch at O/D OFF.
10 WHT/BLK O/D OFF lamp signal
10 14 V Ignition switch turned ON, O/D OFF switch at O/D ON.
11
12
13
14

Circuit Condition
01V
While engine running. (Output signal is pulse.
15 BRN Engine speed signal
Pulse frequency varies depending on engine speed.) (3000r/min=100Hz)
10 14 V
16 ORN Output shaft speed sensor signal () 23V Ignition switch turned ON.
17 BLU/GRN Input shaft speed sensor signal () 23V Ignition switch turned ON.
18
19
L position signal for transmission 10 14 V Ignition switch turned ON, select lever shifted at L range.
20 GRN/BLU
range switch 02V Ignition switch turned ON, select lever shifted at other than L range.
2 position signal for transmission 10 14 V Ignition switch turned ON, select lever shifted at 2 range.
21 GRN/ORN
range switch 02V Ignition switch turned ON, select lever shifted at other than 2 range.
22
Ignition switch turned ON (Output signal is 100 Hz active low duty pulse. Duty
01V
ratio varies depending on engine output torque.)
23 WHT Engine torque signal
Engine torque 100Nm=2 9% ON duty
10 14 V
Engine torque 300Nm=92 98% ON duty
24
25
26
27
28
Connector : E203

Circuit Condition
1 ORN/WHT 4WD low switch signal 02V Ignition switch turned ON, select lever at 4WD low position.
2
Shift solenoid valve-B (Shift solenoid
3 GRN/RED 02V Ignition switch turned ON, select lever at P range.
No.2)
Shift solenoid valve-A (Shift solenoid
4 GRN/RED 10 14 V Ignition switch turned ON, select lever at P range.
No.1)
Transmission fluid temperature sen-
5 RED/BLU 3.2 3.8 V Ignition switch turned ON, fluid temperature is 60 C (140 F).
sor signal
6 YEL Diagnosis switch 10 14 V Ignition switch turned ON.
7 PPL/RED Data link connector 10 14 V Ignition switch turned ON.
Pressure control solenoid valve
8 BLU/RED 0.6 1.0 V Ignition switch turned ON.
(ground)
9
10
11 BLU/ORN Pressure control solenoid valve (+) Voltage varies depending on throttle opening. (Output signal is duty pulse.)
12 GRN/YEL TCC (lock-up) solenoid valve 02V Ignition switch turned ON.
13 WHT Power source for back-up 10 14 V Constantly.
Transmission fluid temperature sen-
14 RED/GRN 02V Ignition switch turned ON.
sor signal (ground)
15 BLK Ground 02V Ignition switch turned ON.
10 14 V Ignition switch turned ON, brake pedal depressed.
16 GRN/WHT Brake light switch
02V Ignition switch turned ON, brake pedal released.
17
18
19 BLK Ground 02V Ignition switch turned ON.
20 BLK/WHT Power source 10 14 V Ignition switch turned ON.
Wire Harness and Connectors

Refer to Section 8A (WIRING DIAGRAM manual).
Scan Tool Data

As the data values given below are standard values estimated on the basis of values obtained from the normally
operating vehicles by using a scan tool when the vehicle is under the following conditions, use them as refer-
ence values. Even when the vehicle is in good condition, there may be cases where the checked value does not
fall within each specified data range. Therefore, judgment as abnormal should not be made by the those
detected by TCM and output from TCM as commands and there may be cases where the automatic transaxle or
actuator is not operating in the condition as indicated by the scan tool.
Apply parking brake and block wheels.

Ignition switch ON.
Turn OFF air conditioner (if equipped).
Apply no load to power steering (if equipped). (Dont turn it)
Turn OFF all electric loads (except ignition).
Scan Tool Data Standards Condition

GEAR POSITION 1st Vehicle stop when select lever in D,
2 or L range
P or N/R When select lever in P, N or R range
ENGINE SPEED Specified idle speed At specified idle speed in P range
INPUT SHAFT REV 0 RPM Vehicle stop at specified idle speed
in D range
Specified idle speed At specified idle speed in P range
OUTPUT SHAFT REV 0 RPM Vehicle stop
BATTERY VOLTAGE 10 14 V Engine stop
ATF TEMP 70 80 C
SHIFT SOL #1 ON Vehicle stop
SHIFT SOL #2 OFF Vehicle stop
TCC SOL OFF Vehicle stop
PRESS CONT SOL 100 % Throttle valve at idle position engine
stop
ENGINE TORQUE Display of engine torque
VEHICLE SPEED 0 Km/h, 0 MPH Vehicle stop
O/D OFF SWITCH ON O/D OFF switch ON
OFF O/D OFF switch OFF
TRANS RANGE P When select lever in P range
THROTTLE POS 0 1.0 % Throttle valve at idle position with
engine running
90 100 % Throttle valve fully open
BRAKE SWITCH ON Brake pedal depressed
OFF Brake pedal released
4WD LOW SW ON Transfer lever at 4L
OFF Transfer lever at 4H or 2H
Scan Tool Data Definition

GEAR POSITION (R/P or N/1/2/3/4):
This parameter indicates the current gear position. It is computed by the throttle position coming from ECM and
vehicle speed.
ENGINE SPEED (RPM):
Engine speed is obtained by computing the CKP signal from ECM and it is used for trouble diagnosis of the AT
system and fail-safe control.
INPUT SHAFT REV (RPM):
Input shaft revolution is computed based on pulse signal from input shaft speed sensor in the transmission.
OUTPUT SHAFT REV (RPM):
Output shaft revolution is computed based on pulse signal from output shaft speed sensor in the transmission.
BATTERY VOLTAGE (VOLTS):
Battery voltage is an analog input signal read by TCM.
ATF TEMP (C, F):
This parameter is decided by signal from transmission fluid temperature sensor in the transmission.
SHIFT SOL #1, SHIFT SOL #2 (ON, OFF):
Shift solenoid is used for shifting the transmission up and down. It is turned ON or OFF by a signal from TCM.
Gear position is decided by combination of ON or OFF.
TCC SOL (ON, OFF):
TCC solenoid is used for the TCC control mode. It is turned ON or OFF by a signal from TCM.
PRESSURE CONT SOL (%):
Pressure control solenoid is used for the shift change control in the transmission. It is operated by timing pulses
coming from TCM.
ENGINE TORQUE (Nm):
Engine torque value at the engine crankshaft output is transmitted from ECM.
VEHICLE SPEED (Km/h, MPH):
Vehicle speed is a TCM internal parameter. It is computed by timing pulses coming from the vehicle speed sen-
sor for A/T. Vehicle speed is used for the solenoid control in TCM.
O/D OFF SWITCH (ON, OFF):
O/D OFF switch is used for the over drive control. When this signal is ON, the gear position is not shifted to 4th.
TRANS RANGE (P/R/N/D/2/L/FAIL):
Transmission range is fed to TCM from the transmission range switch. This signal indicates when the gear is
shifted to each range.
THROTTLE POS (%):
Throttle position is a TCM internal parameter. It is computed by duty signal coming from ECM. Throttle position
is used for the shift solenoid control in TCM.
BRAKE SWITCH (ON, OFF):
This switch signal informs TCM whether the brake is active or not.
4WD LOW SW (ON, OFF):
4WD-L signal is fed to TCM from the 4WD-L switch. This switch signal is used for timing of shift change.
DTC P0705 (DTC NO.34) Transmission Range Sensor (Switch) Circuit Malfunc-
tion
WIRING DIAGRAM
1. TCM 3. Fuse box

2. Transmission range sensor (switch) 4. To ignition
DTC DETECTING CONDITION AND TROUBLE AREA

Transmission range sensor (switch) signal (P, R, N, Transmission range sensor (switch) maladjusted
D, 2 or L) is not inputted for 30 sec. at more than 30 Transmission range sensor (switch) or its circuit
km/h (19 mile/h) vehicle speed and more than 1500 TCM
rpm engine speed.
Multiple signals are inputted simultaneously for 10
sec.
DTC CONFIRMATION PROCEDURE
WARNING:

2) Clear DTC in TCM memory by using scan tool and start engine.
3) Shift A/T select lever to each of L, 2, D, N, R and P ranges for 20 seconds each.
4) Increase vehicle speed to about 40 km/h (25 mile/h) and engine speed to 1500 rpm or more in D range.
5) Keep driving above vehicle speed for 40 seconds.
6) Release accelerator pedal, decrease vehicle speed and stop vehicle.
7) Check DTC.
TROUBLESHOOTING
Step Action Yes No

2 Do you have SUZUKI scan tool? Go to Step 3. Go to Step 4.
3 Check transmission range sensor (switch) cir- Intermittent trouble. Go to Step 5.
cuit for operation. Check for intermittent
Check by using SUZUKI scan tool: referring to Intermittent
1) Connect SUZUKI scan tool to DLC with igni- and Poor Connection in
tion switch OFF. Section 0A.
2) Turn ignition switch ON and check transmis-
sion range signal (P, R, N, D, 2 or L) on dis-
play when shifting select lever to each
range.
Is applicable range indicated?
Are check results satisfactory?
4 Check transmission range sensor (switch) cir- Intermittent trouble. Go to Step 5.
cuit for operation. Check for intermittent
Check without using SUZUKI scan tool: referring to Intermittent
1) Turn ignition switch ON. and Poor Connection in
2) Check voltage at terminals E202-1, E202-2, Section 0A.
E202-8, E202-9, E202-20 and E202-21
respectively with select lever shifted to each
range.
Taking terminal E202-21 as an example, is bat-
tery voltage indicated only when select lever is
shifted to 2 range and 0 V for other ranges as
shown in the figure.
Check voltage at other terminals likewise, refer-
ring to the figure.
5 Check transmission range sensor (switch) for Go to Step 6. Adjust transmission range
installation position. sensor (switch) and
1) Shift select lever to N range. recheck.
2) Check that N reference line on sensor and
center line on shaft are aligned.
Are they aligned?
6 Check select cable for adjustment referring to Go to Step 7. Adjust select cable and
Select Cable Adjustment in this section. recheck.
Is it adjusted correctly?
7 Check transmission range sensor (switch) refer- YEL, ORN/GRN, Replace transmission
ring to Transmission Range Sensor (Switch) in RED, ORN/BLU, YEL/ range sensor.
this section. GRN, GRN/ORN or
Are check results satisfactory? GRN/BLU circuit open
or short.
If wires and connections
are OK, substitute a
known-good TCM and
recheck.
Fig. for Step 3
Terminal
E202-2 E202-1 E202-9 E202-8 E202-21 E202-20
Select lever position P 10 14 V 0V 0V 0V 0V 0V
R 0V 10 14 V 0V 0V 0V 0V
N 0V 0V 10 14 V 0V 0V 0V
D 0V 0V 0V 10 14 V 0V 0V
2 0V 0V 0V 0V 10 14 V 0V
L 0V 0V 0V 0V 0V 10 14 V
DTC P0710 (DTC NO.36/38) Transmission Fluid Temperature Sensor Circuit

Malfunction
WIRING DIAGRAM
1. Transmission fluid temperature sensor

2. TCM
3. Terminal arrangement of TCM connector (viewed from harness side)

Transmission fluid temperature sensor output volt- Transmission fluid temperature sensor or its circuit
age is continuously too high in R, D, 2 or L TCM
range for 15 minutes after engine is started.
Transmission fluid temperature sensor output volt-
age is too low for 5 minutes continuously.
WARNING:

2) Clear DTC in TCM memory by using scan tool.
3) Start engine and drive vehicle for 25 minutes or more.
4) Stop vehicle and check DTC by using scan tool.
TROUBLESHOOTING
Step Action Yes No

2 Check transmission fluid temperature sensor Intermittent trouble or Go to Step 3.
circuit. faulty TCM.
1) Turn ignition switch OFF and disconnect Check for intermittent
TCM connectors. referring to Intermittent
2) Check for proper connection to output trans- and Poor Connection in
mission fluid temperature sensor at terminal Section 0A.
E203-5 and E203-14. If OK, substitute a known-
3) If OK, check resistance between terminal good TCM and recheck.
E203-5 and E203-14 of disconnected har-
ness side TCM connector.
Is it Approx. 12 k (at 20 C (68 F))?
Resistance of transmission fluid tempera-
ture sensor
Reference: Approx. 12 k (at 20 C (68 F))
Approx. 1.7 k (at 80 C (176 F))
3 Check transmission fluid temperature sensor RED/BLU or RED/ Faulty transmission fluid
resistance. GRN circuit open, temperature sensor.
1) With ignition switch OFF, disconnect trans- shorted each other, inter-
mission fluid temperature sensor connector. mittent trouble or faulty
2) Check resistance transmission fluid temper- TCM.
ature sensor connector. If wire and connection are
Is it Approx. 12 k (at 20 C (68 F))? OK, substitute a known-
Resistance of transmission fluid tempera- good TCM and recheck.
ture sensor
Reference: Approx. 12 k (at 20 C (68 F))
Approx. 1.7 k (at 80 C (176 F))
[A] : Fig. for Step 3
3
DTC P0715 (DTC NO.37) Input/Turbine Speed Sensor Circuit Malfunction

WIRING DIAGRAM
BLU/GRN
1. TCM
2. Input shaft speed sensor

The following condition is detected for one minute con- Input shaft speed sensor or its circuit
tinuously in the period between ignition switch ON and TCM
OFF.
No pulse signal out of input shaft speed sensor is
inputted although 12 pulses out of output shaft
speed sensor are inputted.
and
Transmission range sensor signal is detected as
D, 2 or L range.
and
Gear position is not 4th.
and
Output shaft revolution is more than 775 rpm.
WARNING:

2) Clear DTC by using scan tool.
3) Start engine and turn O/D off switch ON.
4) Shift select lever to D range.
5) Start vehicle and keep vehicle speed at 50 km/h (31 mile/h) with 3rd gear in D range for 60 sec. or more.
6) Stop vehicle.
7) Check DTC.
TROUBLESHOOTING
Step Action Yes No

2 Input shaft speed sensor circuit check: Go to Step 4. Go to Step 3.
1) With ignition switch OFF, disconnect TCM
connectors.
2) Check for proper connection to input shaft
speed sensor at E202-5 and E202-17 termi-
nals.
3) If OK, check resistance of sensor circuit.
Input shaft speed sensor resistance:
Resistance between E202-5 and E202-17:
560 680 (at 20 C (68 F))
Resistance between E202-5/E202-17 and
ground:
1 M or more
3 Input shaft speed sensor check: BLU/YEL or Replace input shaft speed
1) With ignition switch OFF, disconnect input BLU/GRN wire open or sensor.
shaft speed sensor connector. shorted to ground.
2) Check for proper connection to input shaft
speed sensor at each terminal.
3) If OK, then check resistance of input shaft
speed sensor.
Are measured values as specified in Step 2?
4 Check visually input speed shaft sensor and Intermittent trouble or Clean, repair or replace.
overdrive clutch drum for the followings. faulty TCM.
No damage Check for intermittent
No foreign material attached referring to Intermittent
Correct installation and Poor Connection in
Are they in good condition? Section 0A.
If OK, substitute a known-
good TCM and recheck.
REFERENCE
[A] Connect oscilloscope between E202-5 (+) and E202-17 () of
5V/Div
TCM connector connected to TCM and check input shaft speed
sensor signal.
[A] : Oscilloscope waveforms at specified idle speed in P range
4ms/Div
DTC P0720 (DTC NO.31) Output Speed Sensor Circuit Malfunction

WIRING DIAGRAM
WHT
1. TCM
2. Output shaft speed sensor

[When gear position is 1st, 2nd or 3rd gear] Output shaft speed sensor or its circuit
The following condition is detected for five hundred TCM
times continuously in the period between ignition
switch ON and OFF.
No pulse signal out of output shaft speed sensor is
inputted although 45 pulses out of input shaft speed
sensor are inputted.
and
D, 2 or L range.
and
Vehicle speed is more than 5 km/h (3 mile).
[When gear position is 4th gear]
Detected (calculated) output shaft revolution is 0
rpm and 1500 rpm or more less than last detected
(calculated) revolution.
and
D, 2 or L range.
and
Vehicle speed is more than 5 km/h (3 mile).
WARNING:

3) Start engine, warm it up to normal operating temperature and shift transfer lever to 2H or 4H range.
4) Drive vehicle at 50 km/h (31 mile/h) or more with 3rd gear in D range for longer than 60 sec. and at 60 km/
h (38 mile/h) or more with 4th gear for about 10 sec.
TROUBLESHOOTING
Step Action Yes No

2 Output shaft speed sensor circuit check: Go to Step 4. Go to Step 3.
1) Remove TCM cover.
2) With ignition switch OFF, disconnect TCM
connectors.
3) Check for proper connection to output shaft
speed sensor at E202-4 and E202-16 termi-
nals.
4) If OK, check resistance of sensor circuit.
Resistance between E202-4 and E202-16:
560 680 (at 20 C (68 F))
Resistance between E202-4/E202-16 and
ground:
1 M or more
3 Output shaft speed sensor check: ORN or WHT wire Replace output shaft
1) With ignition switch OFF, disconnect output open or shorted to speed sensor.
shaft speed sensor connector. ground.
2) Check for proper connection to output shaft
speed sensor at each terminal.
3) If OK, then check resistance of output shaft
speed sensor.
Are measured values as specified in Step 2?
4 Check visually output shaft speed sensor and Intermittent trouble or Clean, repair or replace.
sensor rotor for the followings. faulty TCM.
No damage Check for intermittent
No foreign material attached referring to Intermittent
Correct installation and Poor Connection in
Are they in good condition? Section 0A.
REFERENCE
Connect oscilloscope between E202-4 (+) and E202-16 () of

TCM connector connected to TCM and check output shaft speed
sensor signal.
[A] : Oscilloscope waveforms at about 40 km/h (25 mile/h)
DTC P0725 (DTC NO.35) Engine Speed Input Circuit Malfunction

WIRING DIAGRAM
1. TCM 3. Terminal arrangement of TCM connector (viewed from harness side)

2. ECM 4. Terminal arrangement of ECM connector (viewed from harness side)

No engine speed signal is inputted although input shaft Engine speed input circuit
speed sensor signals indicate 2000 rpm or more for five TCM
seconds (other than 4th gear). ECM
WARNING:

3) Start engine and O/D off switch is turned OFF.
4) Shift selector lever in D range and drive vehicle, keeping vehicle speed of about 65 km/h (41 mile/h) at 3rd
gear for 10 second.
TROUBLESHOOTING
Step Action Yes No

2 Check engine speed input circuit. Go to Step 3. BRN circuit open.
1) Turn ignition switch OFF and disconnect
TCM and ECM connectors.
2) Check for proper connection of TCM con-
nector at E202-15 wire and ECM connec-
tor at E227-7 wire terminals.
3) If OK, measure resistance between terminal
E202-15 of disconnected harnesses side
TCM connector and terminal E227-7 of
disconnected harness side ECM connector.
3 Check engine speed input circuit. Go to Step 4. BRN circuit shorted to
Measure between terminal E202-15 of discon- ground.
nected harness side TCM connector and
ground.
Is it infinity?
4 Check TCM terminal voltage. Intermittent trouble, faulty Substitute a known-good
1) With ignition switch OFF, connect TCM con- TCM or faulty ECM. TCM and recheck.
nector. Check for intermittent
3) Measure voltage between terminal E227-7 and Poor Connection in
of disconnected harness side ECM connec- Section 0A.
tor and ground. If OK, substitute a known-
Is it 10 14 V? good TCM or ECM and
recheck.
DTC P0743 (DTC NO.25/26) TCC (Lock-Up) System Electrical

WIRING DIAGRAM
GRN/YEL
1. A/T 3. TCM
2. TCC (Lock-up) solenoid 4. Terminal arrangement of TCM connector (viewed from harness side)

The following condition is detected 8 times of gear TCC (lock-up) solenoid valve or its circuit
change continuously. TCM
Voltage at terminal E203-12 of TCM is too high
while TCC solenoid OFF is commanded or too low
while TCC solenoid ON is commanded.
WARNING:

3) Start engine, warm it up to normal operating temperature and shift transfer lever to 2H or 4H range.
4) Shift selector lever in D range and start vehicle.
5) Increase vehicle speed to about 80 km/h (50 mile/h) in 4th gear and in D range.
7) Repeat step 4) to step 6) one time.
TROUBLESHOOTING
Step Action Yes No

2 Check TCC solenoid circuit for short. Go to Step 3. GRN/ORN circuit
1) Turn ignition switch OFF and disconnect shorted to power circuit.
TCM connectors.
2) Check for proper connection to TCM at ter-
minal E203-12.
3) If OK, then turn ignition switch ON and mea-
sure voltage between terminal E203-12 of
disconnected TCM harness side connector
and ground.
Is it about 0 V?
3 Check TCC solenoid circuit for open or short. Intermittent trouble or GRN/ORN circuit open
1) Turn ignition switch OFF. faulty TCM. or shorted to ground.
2) Measure resistance between terminal Check for intermittent If wire and connections
E203-12 of disconnected TCM harness side referring to Intermittent are OK, replace TCC
connector and ground. and Poor Connection in solenoid.
Is it 11 15 ? (at 20 C (68 F))? Section 0A.
DTC P0748 (DTC NO.41/42) Pressure Control Solenoid Electrical

WIRING DIAGRAM
1. Pressure control solenoid valve

2. TCM

Pressure control solenoid output voltage is too high Pressure control solenoid valve
comparing with TCM command value. Pressure control solenoid valve circuit
or TCM
Pressure control solenoid output voltage is too low
comparing with TCM command value.
WARNING:

3) Start engine and shift select lever in D range.
4) Start vehicle and increase vehicle speed to about 60 km/h in D range.
5) Keep driving at above vehicle speed for 30 second.
TROUBLESHOOTING
Step Action Yes No

2 Check pressure control solenoid circuit for Go to Step 3. BLU/ORN or
short. BLU/RED circuit
1) Turn ignition switch OFF and disconnect shorted to power
TCM connectors. circuit.
minals E203-11 and E203-8.
3) If OK, measure voltage between terminal
E203-8 of disconnected harness side TCM
connectors and ground.
Is it about 0 V?
3 Check pressure control solenoid circuit for Go to Step 4. BLU/ORN or
short. BLU/RED circuit shorted
Measure resistance between terminal E203-11 to ground.
or disconnected harness side TCM connector
and ground.
Is it infinity?
4 Check pressure control solenoid circuit for Intermittent trouble or Faulty pressure control
short. faulty TCM. solenoid valve.
Measure resistance between terminal E203-8 Check for intermittent Replace valve body
and E203-11 of disconnected harness side referring to Intermittent assembly.
TCM connector. and Poor Connection in
Is it 3.3 3.7 (20 C (68 F))? Section 0A.
good TCM or ECM and
recheck.
DTC P0753 (DTC NO.21/22)/ P0758 (DTC NO.23/24) Shift Solenoid-A/ Shift
Solenoid-B Electrical
WIRING DIAGRAM
1. A/T 4. TCM
2. Shift solenoid-A 5. Terminal arrangement of TCM connector (viewed from harness side)
3. Shift solenoid-B

DTC P0753: Shift solenoid valve-A or its circuit
The following condition is detected 8 times of gear TCM
change continuously.
Voltage at terminal E203-4 of TCM is too high while
shift solenoid OFF is commanded or too low while
shift solenoid ON is commanded
DTC P0758: Shift solenoid valve-B or its circuit
The following condition is detected 8 times of gear TCM
change continuously.
Voltage at terminal E203-3 of TCM is too high while
shift solenoid OFF is commanded or too low while
shift solenoid ON is commanded
WARNING:

3) Start engine and shift transfer lever to 2H or 4H range.
4) Shift select lever in D range and start vehicle.
5) Increase vehicle speed to about 80 km/h (50 mile/h) with 4th gear in D range.
7) Repeat step 4) to step 6) five times.
TROUBLESHOOTING
Step Action Yes No

2 Check shift solenoid circuit for short. Go to Step 3. GRN or GRN/RED cir-
1) Turn ignition switch OFF and disconnect TCM cuit shorted to power cir-
connectors. cuit.
minal E202-3 or E203-4.
3) If OK, then turn ignition switch ON and mea-
sure voltage between terminal E203-3 or
E203-4 of disconnected harness side TCM
connector and ground.
Is it about 0 V?
3 Check shift solenoid circuit for open or short. Intermittent trouble or GRN or GRN/RED cir-
1) Turn ignition switch OFF. faulty TCM. cuit open or shorted to
2) Measure resistance between terminal Check for intermittent ground.
E203-3 or E203-4 of disconnected harness referring to Intermittent If wire and connections
side TCM connector and ground. and Poor Connection in are OK, replace malfunc-
Is it 11 15 (at 20 C (68 F))? Section 0A. tion shift solenoid.
DTC P1700 (DTC NO.32/33) Acceleration Stroke Signal Input Malfunction

WIRING DIAGRAM


Continuous time of low voltage acceleration stroke Acceleration stroke signal circuit from ECM to TCM
signal is too long. open or short.
or Throttle position sensor (acceleration stroke sensor)
Continuous time of low voltage acceleration stroke or its circuit malfunctioning.
signal is too short. TCM
or ECM
No acceleration stroke signal is inputted from ECM.

3) Start engine and keep on idling for 20 seconds.
4) Stop engine and check DTC by using scan tool.
TROUBLESHOOTING
Step Action Yes No

2 Is there DTC related to throttle position sensor Go to corresponding DTC Go to Step 3.
(P0121, P0221)? Flow Table in Section 6.
3 Check acceleration stroke signal input circuit for Go to Step 4. BLU/WHT circuit open.
open.
2) Check for proper connection to TCM con-
nector at E202-6 wire and ECM connector
at E229-28 wire terminals.
E202-6 of disconnected harness side
4 Check acceleration stroke signal input circuit for Go to Step 5. BLU/WHT circuit
short. shorted to ground.
Measure between terminal E202-6 of discon-
nected harness side TCM connector and
ground.
Is it infinity?
5 Check acceleration stroke signal input circuit for Go to Step 6. BLU/WHT circuit
short to power circuit. shorted to power circuit.
1) With ignition switch OFF, connect ECM con-
nector.
3) Measure voltage between terminal E202-6
of disconnected harness side TCM connec-
tor and ground.
Is it about 0 V?
nector and disconnect ECM connector. Check for intermittent
3) Measure voltage between terminal E229- and Poor Connection in
28 of disconnected harness side ECM con- Section 0A.
nector and ground. If OK, substitute a known-
recheck.
DTC P1702 (DTC NO.52) Internal Malfunction of TCM


Calculations of current data stored in TCM is not cor- TCM
rect comparing with pre-stored checking data in TCM.

3) Turn ignition switch ON, and OFF.
TROUBLESHOOTING
Step Action Yes No
1 Is DTC P1702 outputted after performing DTC Faulty TCM Could be a temporary
confirmation procedure? malfunction of TCM.
DTC P1730 (DTC NO.64) Engine Torque Signal Circuit Malfunction

WIRING DIAGRAM


Continuous time of low voltage engine torque signal Engine torque signal circuit
is too long. TCM
or ECM
Continuous time of low voltage engine torque signal
is too short.
or
No engine torque signal is inputted from ECM.

3) Start engine and keep on idling for 10 seconds.
4) Stop engine and check DTC by using scan tool.
TROUBLESHOOTING
Step Action Yes No

2 Check engine torque signal circuit for open. Go to Step 3. WHT circuit open.
2) Check for proper connection to TCM con-
nector at E202-23 wire and ECM connec-
tor at E228-11 wire terminals.
E202-23 of disconnected harnesses side
3 Check engine torque signal circuit for short. Go to Step 4. WHT circuit shorted to
Measure between terminal E202-23 of ground.
disconnected harness side TCM connector and
ground.
Is it infinity?
4 Check engine torque signal circuit for short to Go to Step 5. WHT circuit shorted to
power circuit. power circuit.
1) With ignition switch OFF, connect ECM con-
nector to ECM.
3) Measure voltage between terminal E202-
23 of disconnected harness side TCM con-
nector and ground.
Is it about 0 V?
nector and disconnect ECM connector. Check for intermittent
3) Measure voltage between terminal E228- and Poor Connection in
11 of disconnected harness side ECM con- Section 0A.
nector and ground. If OK, substitute a known-
recheck.
On-Vehicle Service
Maintenance Service
Fluid level
LEVEL CHECK AT NORMAL OPERATING TEMPERATURE
1) Stop vehicle and place it level.
2) Apply parking brake and place chocks against wheels.
3) With select lever at P range, start engine.
4) Warm up engine till A/T fluid temperature reaches normal
operating temperature (70 80 C (158 176 F)). As a
guide to check fluid temperature, warm up engine to normal
operating temperature.
5) Keep engine idling and shift select slowly to L and back to
P range.
[A]: Shift select lever with its button pushed in.
[B]: Shift select lever without pushing its button.
6) With engine idling, pull out dipstick (1), wipe it off with a
clean cloth and put it back into place.
7) Pull out dipstick (1) again and check fluid level indicated on
it. Fluid level should be between FULL HOT and LOW HOT.
If it is below LOW HOT, add equivalent of DEXRON-III up to
FULL HOT.
A/T fluid specification
Equivalent of DEXRON-III
NOTE:
DO NOT RACE ENGINE while checking fluid level, even
after engine is started.
DO NOT OVERFILL. Overfilling can causes foaming
and loss of fluid through breather. Then slippage and
transmission failure can result.
Bringing fluid level from LOW HOT to FULL HOT
requires 0.3 liters (0.64/0.53 US/Imp. pt.).
If vehicle was driven under high load such as pulling a
trailer, fluid level should be checked about half an hour
after it is stopped.
2. FULL HOT 4. FULL COLD
3. LOW HOT 5. LOW COLD
LEVEL CHECK AT ROOM TEMPERATURE
The fluid level check at room temperature performed after repair

or fluid change before test driving is just preparation for level
check of normal operating temperature. The checking procedure
itself is the same as that described in Level Check at Normal
Operating Temperature under Fluid Level in this section. If the
fluid level is between FULL COLD and LOW COLD, proceed to
test drive. And when the fluid temperature has reached the nor-
mal operating temperature, check fluid level again and adjust it as
necessary.
1. Dipstick
2. FULL COLD
3. LOW COLD
Fluid change
1) Lift up vehicle.
2) When engine is cool, remove drain plug from oil pan and
drain A/T fluid using oil gutter (1).
3) Install drain plug.
Tightening torque
A/T fluid drain plug: 20 Nm (2.0 kg-m, 14.5 lb-ft)
4) Lower vehicle and fill proper amount of specified fluid.

5) Check fluid level referring to Level Check Normal Operating
Temperature under Fluid Level in this section.
A/T fluid specification
Equivalent of DEXRON-III
A/T fluid capacity reference value
When draining from drain plug hole:
Approx. 4.0 liters (8.45/7.04 US/Imp. pt.)
When overhauling:
Approx. 9.0 liters (19.02/15.84 US/Imp. pt.)
1. Dipstick 4. FULL COLD
2. FULL HOT 5. LOW COLD
3. LOW HOT
Oil Cooler Hoses

When replacing them, make sure to note the followings.
to replace clamps at the same time
1 2-1
to insert hose as far as bulge of pipe
to clamp hose securely
Tightening torque
2
3 Oil hose clamp bracket bolt
(a): 23 Nm (2.3 kg-m, 17.0 lb-ft)
1. Radiator 3. Outlet hose
2. Inlet hose 4. Oil hose clamp bracket bolt
4, (a) 1 2-1. Inlet hose for left hand steering vehicle
Manual Selector Assembly

COMPONENTS
1. Manual lever assembly 5. Bulb

2. Select indicator assembly 6. Knob assembly
3. Illumination lamp assembly 7. Manual selector assembly mounting bolt
4. Bulb filter Tightening torque
REMOVAL
2) Remove console box.
3) Disconnect connector for illumination lamp and O/D off
switch.
4) Remove manual selector assembly mounting bolts.
5) Disconnect select cable (1) from manual selector assembly

(2) expanding select cable clip (3).
INSTALLATION
Reverse removal procedure to install manual selector assembly
noting the following instructions.
Make sure that select cable clip (3) holds select cable (1) on
manual selector assembly (2) securely.
Tighten manual selector assembly mounting bolts to speci-
fied torque.
Tightening torque
Manual selector assembly mounting bolts:
18 Nm (1.8 kg-m, 13.5 lb-ft)
INSPECTION
Check select lever for smooth and clear-cut movement and posi-
tion indicator for correct indication.
For operation of select lever, refer to the figure.
[A]: Shift select lever with its button pushed in.
[B]: Shift select lever without pushing its button.
Select Cable
LOCATION
1 3
2 18 Nm (1.8 kg-m)
4
9 13 Nm (1.3 kg-m)
6
7 19 Nm (1.9 kg-m)
5 13 Nm (1.3 kg-m)
1. Manual selector assembly 5. Manual select lever nut 9. Transmission range sensor bolt
2. Manual selector assembly mounting bolt 6. Manual select lever Tightening torque
3. Select cable 7. Select cable end nut

4. Select cable bracket 8. Transmission range sensor
ADJUSTMENT
1) Loosen select cable end nut (1).

2) Shift selector lever to N.
3) Align center line (2) on manual shift shaft (3) to N reference
4
line (4) as shown in figure.
3 4) Tighten select cable end nut (1) to specified torque.
Tightening torque
Select cable end nut (a): 19 Nm (1.9 kg-m, 14.0 lb-ft)
2 1, (a)
5) After select cable was installed, check for the following.

Push vehicle with select lever shifted to P.
Vehicle should not move.
Vehicle can not be driven in N.
Vehicle can be driven in D, 2, and L.
Vehicle can be backed in R.
Transmission Range Sensor (Switch)

INSPECTION AND ADJUSTMENT
1) Shift select lever to N range.

3 2) Check that center line on manual shift shaft (2) and N refer-
ence line (1) on sensor are aligned. If not, loosen sensor bolt
1
(3) and align them.
3) Check that engine starts in N and P ranges but it doesnt
start in D, 2, L or R range. Also, check that back-up
lamp lights in R range.
If faulty condition cannot be corrected by adjustment, disconnect
2
transmission range sensor connector and check that continuity
exists as shown by moving select lever.
[B]
4 3 2 1
4 1 3 5 2 6 8 7 9
9 8 7 6 5
P
R
N
[A]
D
2
L
[A]: Sensor position

[B]: Terminal No.
REMOVAL
2) Hoist vehicle.
3) Disconnect transmission range sensor connector (1).
1 4) Disconnect select cable (2) from manual select lever (3).
5) Remove manual select lever (3) from transmission range
2
sensor (4).
4
6) Unbend bend parts of lock washer (1), then remove manual

4
shift shaft nut (2), lock washer (1) and grommet.
7) Remove transmission range sensor (3) by removing sensor
bolt (4).
1
3
2
INSTALLATION
1) Install transmission range sensor (3) and tighten sensor bolt

(4) temporarily.
2) Install grommet, lock washer (1) and manual shift shaft nut
(2). Tighten nut to specified torque. After tightening it, bend
5 4, (b) claws of lock washer (1).
Tightening torque
Manual shift shaft nut (a): 7 Nm (7.0 kg-m, 5.0 lb-ft)
1 3) After turning manual shift shaft fully counterclockwise, turn it
6
3 clockwise by 2 notches and set it to N range.
2, (a) 4) With N reference line (5) on range sensor and shaft center
(6) aligned, tighten transmission range sensor bolt (4) to
specified torque.
Tightening torque
Transmission range sensor bolt
(b): 13 Nm (1.3 kg-m, 9.5 lb-ft)
5) Install manual select lever (3) to transmission range sensor

1 (4). Tighten nut to specified torque.
Tightening torque
2
(a) Manual select lever nut
4
(a): 13 Nm (1.3 kg-m, 9.5 lb-ft)
3
(b) 6) Connect select cable (2) to manual select lever (3). Tighten
select cable end nut to specified torque referring to Adjust-
ment of Select Cable in this section.
7) Connect transmission range sensor connector (1).
8) Lower hoist.
Input Shaft Speed Sensor

INSPECTION
2) Hoist vehicle.
3) Disconnect input shaft speed sensor connector.
4) Check input shaft speed sensor (1) for resistance between
1
terminals of sensor.
Input shaft speed sensor resistance
560 680 (at 20 C, 68 F)
REMOVAL
2) Hoist vehicle.
3) Disconnect input shaft speed sensor connector.
4) Remove input shaft speed sensor (1) from transmission.
1
INSTALLATION
1) Check that sensor is free from any metal particles and dam-
1, (a)
age.
2) Apply A/T fluid to O-ring and then install input shaft speed
sensor (1) to transmission. Tighten sensor bolt to specified
torque.
Tightening torque
Input shaft speed sensor bolt
(a): 5.5 Nm (0.55 kg-m, 4.0 lb-ft)
3) Connect input shaft speed sensor connector.

4) Lower hoist.
Output Shaft Speed Sensor

REMOVAL
2) Remove transfer shift lever referring to Step 2) to 4) of Dis-
mounting under Automatic Transmission assembly (with
Transfer) in this section.
3) Hoist vehicle.
4) Remove exhaust No.2 pipe.
5) Disconnect propeller shafts from differential flanges referring
to Propeller Shafts in Section 4B.
6) To facilitate work, increase clearance between transmission

1 and floor panel according to procedure described below.
2
a) Support transmission with jack and lower transmission 2
3 cm (1 in.).
CAUTION:
Do not lower transmission more than instructed value.
That may cause trouble to engine or transmission.
b) Disconnect output shaft speed sensor connector (1) and
then remove output shaft speed sensor (2) from transmis-
sion.
INSPECTION
Check output shaft speed sensor (1) for resistance between ter-
1 minals of sensor.
Output shaft speed sensor resistance
560 680 (at 20 C, 68 F)
INSTALLATION
(a) Reverse removal procedure for installation noting the followings.

Check that sensor is free from any metal particles and dam-
age.
Apply A/T fluid to O-ring and then install input shaft speed
sensor (1) to transmission. Tighten sensor bolt to specified
torque.
Tightening torque
(a): 5.5 Nm (0.55 kg-m, 4.0 lb-ft)
Tighten rear mounting member bolts to specified torque.

Tightening torque
(a) Rear mounting member bolt
(a) (a): 55 Nm (5.5 kg-m, 40.0 lb-ft)
(a)
(a)
Connect propeller shaft referring to Propeller Shaft in Sec-

tion 4B.
Install exhaust No.2 pipe referring to Exhaust System Com-
ponents in Section 6K.
A/T Fluid Temperature Sensor

REMOVAL
2) Hoist vehicle.
1 3) Disconnect A/T fluid temperature sensor connector (1).

2 4) Remove A/T fluid temperature sensor (2) from transmission.
INSPECTION
Immerse temperature sensing part of A/T fluid temperature sen-

sor in water. Check A/T fluid temperature sensor for resistance
between terminals of sensor. Thus make sure its resistance
decreases as temperature rises.
A/T fluid temperature sensor resistance
Temperature Resistance
20 C (68 F) Approx. 12 k
80 C (176 F) Approx. 1.7 k
1. A/T fluid temperature sensor connector
INSTALLATION
1 1) Apply A/T fluid to O-ring, install A/T fluid temperature sensor

2, (a) (2) to transmission. Tighten sensor to specified torque.
Tightening torque
A/T fluid temperature sensor
(a): 14.7 Nm (1.5 kg-m, 11.0 lb-ft)
2) Connect A/T fluid temperature sensor connector (1).
3) Lower hoist.
O/D Off Switch

INSPECTION
Check O/D off switch for operation referring to Step 4 of Diagnos-
tic Flow Table B-2 in this section.
Solenoid Valves (Shift Solenoid Valves, TCC

Solenoid Valve and Pressure Control Sole-
noid Valve)
REMOVAL
1) Disconnect negative cable from battery.
2) Pull out fluid level gauge and lift up vehicle.
7
3) Remove exhaust No.2 pipe (1).
2
4) Disconnect front propeller shaft (2) from front differential.
1
5) Apply transmission jack (3) under transfer and take off rear
mounting member (4).
6) Remove engine rear mounting (5).
6 7) Remove drain plug (6) and drain A/T fluid.
4
8) Install drain plug (6).
Tightening torque
A/T fluid drain plug (a): 20 Nm (2.0 kg-m, 14.5 lb-ft)
3 5
9) Remove A/T oil pan (7).
10) Disconnect shift solenoid-A valve, shift solenoid-B valve,
TCC solenoid valve and pressure control solenoid valve con-
nectors referring to Unit Disassembly in this section.
11) Remove shift solenoid-A valve, shift solenoid-B valve, TCC
solenoid valve and pressure control solenoid valve referring
to Unit Disassembly in this section.
INSPECTION
Solenoid Valves (Shift Solenoid Valves and TCC Solenoid
Valve)
Resistance Check
Measure resistance between terminal (2) and solenoid valve
body. If resistance is out of specification, replace solenoid valve.
Shift solenoid valve and TCC solenoid valve resistance
Standard: 11 15 (at 20 C (68 F))
1. Shift solenoid or TCC solenoid valve
Operation Check
With solenoid connected to battery (2) as shown in the fig-
ure, check that solenoid valve is actuated with click sound.
1. Shift solenoid or TCC solenoid valve
With shift solenoid valve (1) connected to battery (2), confirm

that shift solenoid valve is open by blowing air (50 200 kpa,
0.5 2.0 kg/cm2, 7 28.5 psi) into solenoid valve as shown
in the figure.
With shift solenoid valve (1) not connected to battery (2),
confirm that shift solenoid valve is closed by blowing air (50
200 kpa, 0.5 2.0 kg/cm2, 7 28.5 psi) into solenoid valve
as shown in the figure.
CAUTION:
Do not insert air gun against strainer installed on inlet of
solenoid valve too deeply, when blowing air into solenoid
valve. If not, the strainer will be damaged.
With TCC solenoid valve (1) connected to battery (2), con-

firm that shift solenoid valve is closed by blowing air (50
With TCC solenoid valve (1) not connected to battery (2),
confirm that TCC solenoid valve is open by blowing air (50
CAUTION:
Do not insert air gun against strainer installed on inlet of
solenoid valve too deeply, when blowing air into solenoid
valve. If not, the strainer will be damaged.
Pressure Control Solenoid Valve

Resistance Check
Measure resistance between pressure control solenoid valve (1)
terminals. If resistance is out of specification, replace valve body
assembly.
Pressure control solenoid valve resistance
Standard: 5.0 5.6 (at 20 C (68 F))
Operation Check
Check pressure control solenoid valve (1) operation in either of
the following methods.
[Using regulated DC power supply]
1) Connect pressure control solenoid valve (1) with regulated
DC power supply (2) as shown in the figure.
2) Turn regulated DC power supply switch ON, increase voltage
of power supply keeping current within 1.0 A.
3) Check that valve (3) moves gradually in arrow A direction
as voltage increases.
4) Check that valve (3) moves in arrow B direction as voltage
decreases.
5) Turn power supply switch OFF.
CAUTION:
Do not feed current 1.0 A or more, or pressure control
solenoid will be burned out.
[Not using regulated DC power supply]

1) Connect pressure control solenoid valve (1) to battery (4)
setting 8 10 W bulb (2) in between as shown in the figure.
2) Check that valve (3) moves in arrow A direction.
3) Disconnect pressure control solenoid valve (1) from battery
(4) and check that valve (3) moves in arrow B direction as
shown in the figure.
CAUTION:
Set 8 10 W bulb in between, or pressure control sole-
noid valve will be burned out.
INSTALLATION
Reverse removal procedure to install solenoid valves, noting the
following points.
For details of solenoid valves and their connectors installa-
tion, refer to Unit Disassembly in this section. Use new O-
ring.
For details of A/T oil pan installation, refer to Unit Disassem-
bly in this section.
Tighten universal joint flange bolts & nuts, engine rear
mounting bolts, exhaust pipe bolts & nuts and rear mount
member bolts.
Fill A/T fluid and check fluid level according to procedure

described in Fluid Change in this section.
Check for fluid leakage after warming up A/T.
Throttle Position Sensor

INSPECTION
Refer to DTC P0121 (DTC P0120) TP Circuit Range/Perfor-
mance Problem, DTC P0221 (DTC P0220) TP Range/Perfor-
mance Problem and DTC P0604 (DTC P0120) TP Sensor
Monitoring System Malfunction in Section 6-1.
Transmission Control Module (TCM)
CAUTION:
TCM consists of highly precise parts, so when handling
it, be careful not to expose it to excessive shock.
REMOVAL
2) Disable air bag system.
Refer to Disabling Air Bag System in Section 10B.
4) Disconnect couplers (2) from TCM (1).
5) Loosen screws and remove TCM (1).
INSTALLATION
Reverse removal procedure noting the following points.
Connect TCM couplers securely.
Be sure to enable air bag system after TCM is back in place.
Refer to Enabling Air Bag System in Section 10B.
4WD LOW Switch

INSPECTION
1) Disconnect negative cable () at battery.
2) Hoist vehicle.
3) Disconnect 4WD LOW switch coupler (2).
4) Check continuity between 4WD LOW switch (1) terminals.
There should be continuity when transfer lever is shifted to
4L position and it should be infinity when transfer lever is
shifted to 4H or 2H position.
If not, replace 4WD LOW switch (1).
5) Connect 4WD LOW switch coupler (2).
6) Lower hoist and connect negative () cable.
Oil Cooler Pipes

REMOVAL
1) Lift up vehicle.
2) Make sure to wash dirt off from around pipe joints.
3) When engine is cool, loosen oil cooler pipe union bolts with
oil outlet union locked and remove oil cooler pipes (1) from
oil outlet unions and hoses.
NOTE:
To avoid fluid leakage, plug open ends of oil outlet
unions and hoses right after they are disconnected.
3 INSTALLATION
1) Use new union gaskets and connect oil cooler pipes to oil
outlet unions.
2) Connect hoses to pipes and clamp them securely.
1
3) Tighten union bolts (2) to specified torque with oil outlet
2, (a)
union locked.
Tightening torque
Oil cooler pipe union bolts
(a): 25 Nm (2.5 kg-m, 18.0 lb-ft)
4) Tighten pipe clamp bolt (3) securely.
5) Check A/T fluid level according to procedure described in

Maintenance Service in this section.
6) Check for fluid leakage after warming up A/T.
Automatic Transmission Assembly

(with Transfer)
DISMOUNTING
Vehicle Compartment
2) Remove console box.
3) Detach boot cover (1) and boot No.2 (2).
4) Remove boot clamp (1) and then remove boot No.1 (2) from
transfer gear shift lever case.
5) With transfer shift control case cover (1) pushed down with
fingers, turn it counterclockwise and take out shift control
lever (2).
In Engine Room
1) Remove battery.
2) Detach fuse/relay box and remove strut tower bar.
3) Remove CKP sensor from torque converter housing referring
to CKP sensor in Section 6E3.
4) Remove starter motor bolts.
5) Remove nuts (1) fixing transmission to engine.
1
On Lift
1) Drain transfer oil.

1. Drain plug
2. Level and filler plug
2) Before removing propeller shaft, give match marks (1) on

joint flange and propeller shaft as shown in the figure.
3) Remove universal joint flange bolts and take out rear propel-
ler shaft.
4) Likewise, take out front propeller shaft.

5) Remove nut from the end of select cable and bracket to set
cable free.
6) Remove select cable bracket by removing its 2 bolts.
7) Remove exhaust No.2 pipe.
8) Remove stabilizer bar mount bush bracket bolts.
9) Unclamp and disconnect oil cooler hoses from pipes.
NOTE:
To avoid leakage of transmission fluid, plug open ends of
oil cooler pipes and hoses right after they are discon-
nected.
10) Remove torque converter housing cover.

12) Holding crankshaft pulley bolt stationary with wrench,
remove torque converter mounting bolts (1) with wrench.
CAUTION:
Do not use CKP sensor ring (2) to lock drive plate when
loosening bolts.
13) Apply transmission jack and take off rear mounting member
by removing its bolts.
2 14) Remove rear mounting (1) by removing its bolts (2).
NOTE:
If automatic transmission is overhauled later on, draining
A/T fluid at this point will facilitate work.
1. Drain plug
(a)
15) Lower transmission jack slowly. Remove it from transmis-

sion, then install auxiliary arm (2) to transmission jack (1).
16) Raise transmission jack until it contacts transmission.
17) Disconnect connectors from VSS, output shaft speed sen-

sor, input shaft speed sensor, transmission range sensor,
shift & TCC solenoid valves, A/T fluid temperature sensor,
4WD low switch and 4WD switch, and release their wire har-
nesses from clamps.
18) Remove breather hose and harness clamp mounting bolt

from transmission.
19) Remove mass damper from transfer.
[A] 20) Remove bolts (1) fixing engine to transmission and loosen
1
bolt (2) which can not removed due to interference with vehi-
cle body.
[B]
21) With transmission assembly held up on jack, move them to

the rear and lower them including torque converter.
As necessary, insert a rod into the gap between CKP sensor
rotor (1) and torque converter (2), then separate CKP sensor
rotor (1) from torque converter (2).
WARNING:
Transmission assembly may tilt rearward on jack. It is
recommended to use an auxiliary arm of jack for the pur-
pose of safety.
[A]: Transmission upper side
[B]: Transmission lower side
After Dismounting
WARNING:
Be sure to keep transmission and transfer assembly hor-
izontal throughout the work. Should they be tilted, torque
converter may fall off and cause personal injury and A/T
fluid may flow out.
1) Remove transfer by removing its bolts.
REMOUNTING
WARNING:
When moving transmission assembly with torque con-
verter equipped in it, be sure to keep it horizontal. Tilting
it with its front facing down may allow converter to fall
off, thereby an injury may result.
Reverse dismounting procedure for remounting noting the follow-

ing points.
When installing transmission and transfer to engine, lift the
front of engine about 10 cm (3.94 in) by using hoist.
Fit transmission assembly to engine cylinder block with bolt
(1) inserted to transmission. After fitting, bolt (1) can not be
installed.
Check drive plate (1) for runout by using magnetic stand and
(A)
dial gauge.
If runout is not within specification or ring gear is damaged,
replace drive plate.
Drive plate runout limit
0.2 mm (0.0079 in.)
(B)
Special tool
(A): 09900-20606
1
(B): 09900-20701
Install torque converter (2) to drive plate (1) by using torque

converter mounting bolt (3) of correct length.
[A] [B]
2 2 [A]: Incorrect length bolt
[B]: Correct length bolt
4. TCC
3 3
1 1
4 4
Tighten bolts and nuts to specified torque.

Tightening torque
Torque converter mounting bolts
(a): 65 Nm (6.5 kg-m, 47.0 lb-ft)
Transmission to engine bolts and nuts
(b): 61 Nm (6.1 kg-m, 44.0 lb-ft)
Drive plate bolts
(c): 50 Nm (5.0 kg-m, 36.5 lb-ft)
(d): 55 Nm (5.5 kg-m, 40.0 lb-ft)
(e): 55 Nm (5.5 kg-m, 40.0 lb-ft)
Torque converter housing cover bolts:
10 Nm (1.0 kg-m, 7.5 lb-ft)
Exhaust No.2 pipe to turbocharger outlet pipe bolts:
55 Nm (5.5 kg-m, 40.0 lb-ft)
Muffler to exhaust No.2 pipe bolts or nuts:
55 Nm (5.5 kg-m, 40.0 lb-ft)
Front propeller shaft universal joint flange bolts:
50 Nm (5.0 kg-m, 36.5 lb-ft)
Rear propeller shaft universal joint flange bolts:
55 Nm (5.5 kg-m, 40.0 lb-ft)
Stabilizer bar mount bush bracket bolts:
23 Nm (2.3 kg-m, 17.0 lb-ft)
Strut tower bar bolts:
50 Nm (5.0 kg-m, 36.5 lb-ft)
1. Drive plate 4. Transfer
2. Torque converter 5. Engine rear mounting
3. Automatic transmission 6. Engine rear mounting member
Clamp wire harness and hoses securely.

Refer to Select Cable in this section for adjusting procedure
of select cable.
Follow fluid level check procedure for refilling automatic
transmission fluid and adjusting its level.
Install battery, and confirm that engine and transmission
function acceptably.
When remounting drive plate, use specified bolts.
Unit Repair
When repairing automatic transmission, it is necessary to conduct the on-vehicle test to investigate where the
cause of the trouble lies first.
Then whether overhaul should be done or not is determined. If the transmission is disassembled without such
preliminary procedure, not only the cause of the trouble would be unknown, but also a secondary trouble may
occur and often time would be wasted.
Precautions
As the automatic transmission consists of high precision components, the following cautions should be strictly
observed when handling its parts in disassembly and reassembly.
Disassembling valve body assembly is prohibited in principle. However, a few parts can be disassembled.
When disassembling valve body component parts, confirm whether these parts are allowed to disassemble
or not referring to Valve Body Assembly in this section.
Make sure to wash dirt off from the transmission so that no such dirt will enter the transmission during dis-
mounting and remounting.
Select a clean place free from dust and dirt for overhauling.
Place a rubber mat on the work bench to protect parts from damage.
Work gloves or shop cloth should not be used. (Use nylon cloth or paper towel.)
When separating the case joint, do not pry with a screwdriver or such but tap with a plastic hammer lightly.
Make sure to wash dirt off from the transmission so that no such dirt will enter the transmission during disas-
sembly and reassembly.
Wash the disassembled parts in ATF (Automatic Transmission Fluid) or kerosene (using care not to allow
ATF or kerosene to get on your face, etc.) and confirm that each fluid passage is not clogged by blowing air
into it. But use ATF to wash the disc, resin washers and rubber parts.
Replace each gasket, oil seal and O-ring with a new one.
Apply ATF to sliding or rotating parts before reassembly.
A new disc should be soaked in ATF at least 15 minutes before use.
Part Inspection and Correction Table

Part Inspect for Correction
Casted part, machined Small flaw, burr Remove with oil stone.
part Deep or grooved flaw Replace part.
Clogged fluid passage Clean with air or wire.
Flaw on installing surface, residual gasket Remove with oil stone or replace
part.
Crack Replace part.
Bearing Unsmooth rotation Replace.
Streak, pitting, flaw, crack Replace.
Bushing, thrust washer Flaw, burr, wear, burning Replace.
Oil seal, gasket Flawed or hardened seal ring Replace.
Worn seal ring on its periphery or side Replace.
Piston seal ring, oil seal, gasket, etc. Replace.
Gear Flaw, burr Replace.
Worn gear tooth Replace.
Splined part Burr, flaw, torsion Correct with oil stone or replace.
Snap ring Wear, flaw, distortion Replace.
No interference Replace.
Thread Burr Replace.
Damage Replace.
Spring Settling, sign of burning Replace.
Clutch disc, brake disc Wear, burning, distortion, damaged claw Replace.
Clutch plate, brake plate Wear, burning, distortion, damaged claw Replace.
Sealing surface (where Flaw, rough surface, stepped wear, foreign Replace.
lip contacts) material
Unit Disassembly
CAUTION:
Keep component parts in group for each subassembly and avoid mixing them up.
Clean all parts with cleaning solvent thoroughly and air dry them.
Use kerosene or automatic transmission fluid as cleaning solvent.
Do not use wiping cloths or rags to clean or dry parts.
All oil passages should be blown out and checked to make sure that they are not obstructed.
Keep face and eyes away from solvent spray while air blowing parts.
Check mating surface for irregularities and remove them, if any, and clean it again.
Soak new clutch discs and brake discs in transmission fluid for at least 15 minutes before assem-
bly.
Replace all gaskets and O-rings with new ones.
Apply automatic transmission fluid to all O-rings.
When installing seal ring, be careful so that it is not expanded excessively, extruded or caught.
Replace oil seals that are removed and apply grease to their lips.
Before installing, be sure to apply automatic transmission fluid to sliding, rolling and thrusting sur-
face of all component parts. Also after installation, make sure to check each part for proper opera-
tion.
Always use torque wrench when tightening bolts.
COMPONENTS
20
18 19
16
15 28
11 13
27
21 24
9
14 22
23
17 25 Nm (2.5 kg-m) 25 26
12
1 4 10
3
7 8
6
46
45
5
43
42
49
2 22 Nm (2.2 kg-m) 40 48
47
39
38
44
34 41
33
29 32
31
30
36 37
35
60
59
58
57
56
50 55
54
53
52
51
1. Oil pump assembly 22. Spring 43. Forward brake flange

2. Oil pump bolt 23. 2nd coast brake piston assembly 44. Forward brake disc
3. O/D thrust bearing No.1 race 24. 2nd coast brake piston cap 45. Forward brake No.1 plate
4. O/D thrust No.1 bearing 25. O-ring 46. Forward brake No.2 plate
5. O/D clutch assembly and O/D planetary 26. Snap ring 47. Forward brake sleeve
gear assembly
6. O/D thrust bearing No.2 race 27. Direct clutch assembly 48. Snap ring
7. O/D thrust No.2 bearing 28. Forward clutch thrust washer 49. Forward brake drum
8. O/D planetary ring gear 29. Forward clutch assembly 50. Reverse brake plate
9. Snap ring 30. Input shaft rear thrust bearing front race 51. Reverse brake disc
10. O/D brake flange 31. Input shaft rear thrust bearing 52. Reverse brake flange
11. O/D brake disc 32. Input shaft rear thrust bearing rear race 53. Rear planetary carrier assembly and output shaft
12. O/D brake plate 33. Front planetary ring gear 54. Rear planetary thrust bearing
13. O/D thrust bearing No.3 race 34. Front ring gear thrust bearing 55. Snap ring
14. Snap ring 35. Front ring gear thrust bearing rear race 56. Reverse brake return spring
15. O/D thrust No.3 bearing 36. Snap ring 57. Reverse brake No.1 piston
16. O/D case 37. Front planetary carrier assembly 58. Reverse brake piston sleeve
17. O/D case bolt 38. Front planetary thrust bearing race 59. Reverse brake No.2 piston
18. Direct clutch thrust washer 39. Front planetary thrust bearing 60. Front ring gear thrust bearing front race
19. Input shaft front thrust bearing race 40. Input sun gear drum, sun gear and one-way Tightening torque
No.3 clutch
20. Input shaft thrust bearing 41. Forward brake return thrust washer Do not reuse.
21. 2nd coast brake band 42. Snap ring

BEARING AND RACE INSTALLATION DIAGRAM
5 6 7 8 9 10 11
1 2 3 4
12 13 14 15 16 17 18
Bearing and race dimensions
No. Bearing and race Inner diameter Outer diameter

1 O/D thrust bearing No.1 race 28.45 mm (1.120 in.) 47.20 mm (1.858 in.)
2 O/D thrust No.1 bearing 29.20 mm (1.150 in.) 50.20 mm (1.976 in.)
7 Input shaft front thrust bearing race 36.80 mm (1.449 in.) 50.90 mm (2.004 in.)
8 Input shaft front thrust bearing 33.70 mm (1.327 in.) 47.60 mm (1.874 in.)
9 Input shaft rear thrust bearing front race 26.00 mm (1.024 in.) 48.90 mm (1.925 in.)
10 Input shaft rear thrust bearing 26.00 mm (1.024 in.) 46.75 mm (1.841 in.)
11 Input shaft rear thrust bearing rear race 26.80 mm (1.055 in.) 47.02 mm (1.851 in.)
12 Front ring gear thrust bearing 35.00 mm (1.378 in.) 53.75 mm (2.116 in.)
13 Front ring gear thrust bearing rear race 34.30 mm (1.350 in.) 47.30 mm (1.862 in.)
14 Front planetary thrust bearing race 33.70 mm (1.327 in.) 47.60 mm (1.874 in.)
15 Front planetary thrust bearing 35.50 mm (1.398 in.) 47.70 mm (1.878 in.)
16 Sun gear thrust bearing race 28.50 mm (1.122 in.) 44.20 mm (1.740 in.)
17 Sun gear thrust bearing 27.70 mm (1.091 in.) 44.20 mm (1.740 in.)
18 Rear planetary thrust bearing 39.38 mm (1.550 in.) 58.10 mm (2.287 in.)
DISASSEMBLY
1) Pull out torque converter (1) from transmission.
CAUTION:
1 Remove torque converter as much straight as possible.
Leaning it may cause damage to oil seal lip.
2) Remove breather hose from transmission.
3) Remove output shaft speed sensor (1), input shaft speed

2 3
1 sensor (2) and transmission case plug (3).
2 3 4) Remove A/T fluid temperature sensor (1).

5) Remove manual select lever from transmission range sensor
(2).
1
6) Unbend bent parts of lock washer (3), and then remove man-
ual shift shaft nut, lock washer and grommet.
7) Remove transmission range sensor (2) by removing sensor
bolt.
8) Remove converter housing (1) by removing 6 bolts.
1
2 9) Remove adapter case (1) by removing 7 bolts.
CAUTION:
Use care not to cause damage to adapter case oil seal
1
(2).
1 10) Remove C-ring (1) and then remove speed sensor rotor (2).
2 NOTE:
Use care not to loose rotor stop key.
11) Remove oil pan (2) using special tool and plastic hammer.
2 1
CAUTION:
Hold oil pan with transfer side down to prevent foreign
material in oil pan from entering valve body.
If iron powder is found, it is possible that bearing, gear
or clutch plate is worn.
Special tool
(A): 09921-96510
(A)
2
1 12) Remove oil strainer (1) from valve body assembly.

13) Disconnect connectors from shift solenoid-A (2), shift sole-
noid-B (3), TCC solenoid (4) and pressure control solenoid
(5).
2 3 5 4
1 14) After removing bolt (1), pull out solenoid wire harness con-
nector (2) from transmission case.
1 2 15) Remove spring plate (1) and manual shift lever spring (2).
16) Remove valve body assembly (3) by removing 20 bolts.
3
1 17) Remove check ball body (1) and spring (2).
2
18) Remove forward brake and direct clutch accumulator pistons

1 (1) and (3) by blowing compressed air (lower than 392 kPa,
2
4.0 kg/cm2, 57 psi) into oil hole (2).
3
NOTE:
Cover accumulator piston (1) with shop cloth while blow-
ing because A/T fluid will spatter.
19) Remove forward brake accumulator piston spring (Yellow)
from transmission case.
20) Remove direct clutch accumulator piston springs (Pink and
Pink/White) from transmission case.
1 21) Remove forward clutch accumulator piston (1) by blowing

compressed air (lower than 392 kPa, 4.0 kg/cm2, 57 psi) into
hole (2).
NOTE:
2
22) Remove forward clutch accumulator piston (1) by blowing air

into hole (2).
23) Remove O/D clutch accumulator piston springs (Orange and

Yellow) from O/D clutch accumulator piston.
24) Remove O/D clutch accumulator piston (1) by blowing com-
pressed air (lower than 392 kPa, 4.0 kg/cm2, 57 psi) into hole
2
(2).
1
NOTE:
1 25) Remove parking pawl bracket (1).

2 1 26) Remove parking lock rod (2) from manual shift lever (1).
2 27) Pull out parking pawl pin (1) to oil pump side and then
remove parking lock pawl (2) and parking pawl spring (3).
1 3
28) Remove manual shift shaft and lever as follows.

a) Undo caulking of sleeve cover (1) by using flat end rod or
the like and hammer.
1
b) Drive out manual shift lever pin (1) by using special tool and
hammer.
Special tool
(A)
(A): 09922-89810
c) Pull out manual shift shaft (2) from transmission case, and
2
then remove manual shift lever (3) and sleeve cover (4).
3 4 1
29) Remove manual shift shaft oil seals (1) from transmission
case.
1
30) Place transmission on the stand facing oil pump upward.
NOTE:
To prevent transmission case from getting damaged,
protect its contacting surface with stand by using shop
cloth or the like.
A stand of such size as shown in the figure will facili-
tate work.
(A) 31) After removing oil pump bolts, remove oil pump assembly (1)
by using special tool.
Special tool
(A): 09918-48211
1
32) Remove O/D thrust bearing No.1 race (1) from oil pump
assembly.
33) Remove O/D planetary gear assembly (1), O/D clutch

assembly (2) and one-way No.1 clutch assembly from trans-
2
mission case.
34) Remove O/D thrust No.1 bearing (1) and O/D thrust bearing
1 3
No.2 race (2) from O/D clutch assembly (3) and O/D plane-
tary gear assembly (4).
4
35) Remove O/D planetary ring gear (1) from transmission case.
1
36) Remove O/D thrust No.2 bearing (1) and O/D thrust bearing
3
No.3 race (2) from O/D planetary ring gear (3).
2 37) Remove snap ring (1) by using flat end rod or the like.
CAUTION:
1 Use care not to cause damage to transmission case
3 when removing snap ring.
4 38) Remove O/D brake flange (2), O/D brake discs (3) and O/D
brake plates (4).
39) Remove 2 bolts (1) of O/D case assembly from transmission

case.
40) Remove snap ring and then remove O/D case assembly (1)
(A)
by using special tools.
Special tool
(A): 09918-48211
(B): 09918-48220
(B)
1
41) Remove O/D thrust No.3 bearing (1) and input shaft front
2 thrust bearing race (2) from O/D case assembly.
42) Remove 2nd coast brake piston cap snap ring.

1 43) Remove 2nd coast brake piston cap and 2nd coast brake
2
piston assembly (1) and spring by blowing air into oil hole
(2).
2 44) Remove direct clutch assembly (1) with forward clutch

assembly (2) from transmission case.
1
45) Remove direct clutch assembly (1) from forward clutch

2
assembly (2).
1
46) Remove forward clutch thrust washer (1), input shaft front
thrust bearing (2) and input shaft rear thrust bearing (3) from
1
3 forward clutch assembly.
2
2
47) Remove E-ring (1) and 2nd coast brake pin (2).
1
48) Remove 2nd coast brake band (1) from transmission case.
49) Remove front planetary ring gear (1) from transmission case.
1
50) Remove input shaft rear thrust bearing rear race (1), front
4
ring gear thrust bearing front race (2) and front ring gear
thrust bearing (3) from front planetary ring gear (4).
1
3
2
1
1
51) Remove front ring gear thrust bearing rear race (1) from front
planetary carrier assembly.
52) Place wooden block or the like under output shaft and hold it.
1 53) Remove snap ring (1).
2 54) Remove front planetary carrier assembly (2) from transmis-
sion case.
2 55) Remove front planetary thrust bearing race (1) and front
1
planetary thrust bearing (2) from front planetary carrier
assembly (3).
56) Remove input sun gear drum (1), sun gear (2) and one-way
1
No.3 clutch (3) all together from transmission case.
3 57) Remove forward brake return thrust washer (4) from forward
2 brake return spring retainer.
4
2 58) Remove snap ring (1).

59) Remove forward brake flange (2), forward brake discs (3),
1 forward brake No.1 plates (4) and forward brake No.2 plate
(5) from transmission case.
3 4
5
1 60) Remove forward brake sleeve (1) from transmission case.
61) Remove snap ring (1).
62) Remove forward brake drum assembly (1), reverse brake

disc/plate/flange (2), rear planetary carrier assembly, rear
1 planetary ring gear (3) and output shaft (4) from transmis-
2 sion case.
3
63) Disassemble forward brake drum assembly (1), reverse

4
brake disc/plate/flange (5), rear planetary carrier assembly
3 2 5
(2), rear planetary rear thrust washer (3) and rear planetary
1
ring gear (4) from output shaft.
1 64) Remove rear planetary thrust bearing (1) from transmission

case.
1 65) Remove forward clutch/reverse brake guide spring (1) from

transmission case.
66) Remove reverse brake drum gasket (1) from transmission

case.
67) Compress reverse brake return spring (2) by using special

tool and then remove snap ring (1).
CAUTION:
Stop compressing when spring seat is pushed down to 1
(A)
2 mm (0.039 0.078 in.) lower than snap ring groove, so
as to prevent spring seat from being deformed.
1 1
2 Special tool
2
(A): 09922-86010
68) Remove reverse brake return spring (2).
69) Remove reverse brake No.1 piston (1) by blowing com-

pressed air (392 kPa, 4.0 kg/cm2, 57 psi) into oil hole (2) of
1 transmission case.
70) Remove O-ring from reverse brake No.1 piston (1).
71) Remove reverse brake piston sleeve (1) by using special

tool.
(A)
Special tool
1 (A): 09920-20310
72) Remove reverse brake No.2 piston (1) by using special tools.
Special tool
(A): 09920-20310
1 1
(A)
INSPECTION
Front planetary ring gear
Measure inner diameter of front planetary ring gear bushing.

If inside diameter exceeds limit, replace front planetary ring gear.
Front planetary ring gear bushing inner diameter limit
24.08 mm (0.948 in.)
Front planetary carrier assembly
Measure planetary pinion gear thrust clearance by using thick-

ness gauge.
If clearance exceeds limit, replace front planetary carrier assem-
bly.
Front planetary gear thrust clearance
Standard: 0.20 0.60 mm (0.0079 0.0236 in.)
Limit: 0.65 mm (0.0255 in.)
Clutch discs, clutch plates or brake band
Check that sliding surfaces of discs, plates or band are not worn
or burnt. If necessary, replace them.
NOTE:
If disc or band lining is exfoliated, discolored or worn
excessively, replace all discs or band.
Even if only a part of printed numbers is corroded,
replace all discs or band.
Before assembling new discs or band, soak them in A/
T fluid for at least 15 minutes.
Reverse brake return spring
Measure free length of reverse brake return spring together with

spring seat.
Reverse brake return spring free length
a: 12.9 mm (0.507 in.)
a
Transmission case
Measure inner diameter of transmission case rear bushing.

If inner diameter exceeds limit, replace transmission case.
Transmission case rear bushing inner diameter limit
38.19 mm (1.5035 in.)
Subassembly
Oil pump assembly
COMPONENTS
8 10 Nm (1.0 kg-m)
3
2 5
1. Oil pump body oil seal 3. Oil pump cover O-ring 5. Driven gear 7. Stator shaft seal Tightening torque Apply A/T fluid
2. Oil pump body 4. Drive gear 6. Stator shaft assembly 8. Oil pump cover bolt Do not reuse.
DISASSEMBLY
1) Remove oil pump body oil seal (2) from oil pump body by
2
using flat end rod or the like.
CAUTION:
Be careful not to damage bushing and oil pump body.
2) Remove stator shaft assembly (1) from oil pump body by

removing 13 bolts.
1
2 1 3 3) Give marks (1) on drive gear (2) and driven gear (3) by using
water proof paint.
4) Remove drive gear (2) and driven gear (3) from oil pump
body.
INSPECTION
Measure inner diameter of oil pump body bushing.

If inner diameter exceeds limit, replace oil pump body.
Oil pump body bushing inner diameter limit
38.19 mm (1.5035 in.)
Measure inner diameter of stator shaft bushing.

If inner diameter exceeds limit, replace stator shaft assem-
bly.
Stator shaft bushing inner diameter limit
Torque converter side: 21.58 mm (0.8496 in.)
Output shaft side: 27.08 mm (1.0661 in.)
Check body clearance of driven gear.

Push driven gear (2) to one side of oil pump body (3). Using
a feeler gauge, measure clearance between driven gear (2)
and body (3).
If clearance exceeds standard value, replace oil pump
assembly.
Clearance between driven gear and body
Standard: 0.07 0.15 mm (0.00276 0.0059 in.)
Limit: 0.20 mm (0.0078 in.)
1. Drive gear
Check tip clearance of driven gear.

Measure radial clearance between gear tooth tip and cres-
cent (1).
assembly.
Tip clearance between driven gear and crescent
Standard: 0.004 0.248 mm (0.0002 0.0097 in.)
Limit: 0.300 mm (0.012 in.)
Check side clearance of both gears.

Using a straightedge (1) and a feeler gauge, measure side
clearance between gears and pump body.
assembly.
Side clearance between gears and oil pump body
Standard: 0.02 0.05 mm (0.0008 0.0019 in.)
Limit: 0.1 mm (0.004 in.)
ASSEMBLY
(A)
1) Press-fit new oil pump body oil seal (1) to oil pump body till
its end face is flush with oil pump body end face, using spe-
cial tool.
1 Special tool
(A): 09913-75520
2 1 3 2) Install drive gear (2) and driven gear (3) to oil pump body
aligning marks and directing marked surface (1) toward sta-
tor shaft assembly side. Apply A/T fluid to gears and oil
pump body.
3) Install stator shaft assembly (1) to oil pump. Tighten 13 bolts

(a)
to specified torque.
1
Tightening torque
Oil pump cover bolt (a): 10 Nm (1.0 kg-m, 7.5 lb-ft)
4) Apply A/T fluid to new stator shaft seals (1).

1
5) Squeeze ends of seals together with wrap distance 8 mm
(0.314 in.) or less and then install new stator shaft seals (1)
to stator shaft groove.
CAUTION:
Do not spread seal ends excessively.
6) Check that seals rotate smoothly.
7) Check that drive gear and driven gear rotate smoothly by

turning drive gear with two flat end rods or the like.
CAUTION:
Be careful not to damage oil pump body oil seal.
8) Apply A/T fluid to new O-ring and then install oil pump cover
O-ring (1) to oil pump body.
1
O/D clutch assembly and O/D planetary gear assembly

COMPONENTS
5
3
2
1 10
9
8
6
19
14 18
13
12 17
11 16
15
1. O/D clutch drum 7. O/D clutch plate 13. One-way No.1 clutch outer race 19. Snap ring
2. O/D clutch piston 8. O/D clutch disc 14. One-way No.1 clutch Do not reuse.
3. Inner O-ring 9. O/D clutch flange 15. O/D planetary thrust washer Apply A/T fluid
4. Outer O-ring 10. Snap ring 16. O/D planetary gear assembly
5. O/D clutch return spring 11. Snap ring 17. O/D ring gear
6. Snap ring 12. One-way No.1 clutch retainer 18. O/D ring gear flange
DISASSEMBLY
O/D Clutch Assembly
1) Remove O/D clutch drum (1) from O/D planetary gear

assembly (2).
2
2) Remove snap ring (1) by using flat end rod or the like.
3
2 1
3) Remove O/D clutch flange (3), 2 O/D clutch discs (2) and 2
O/D clutch plates (5) from O/D clutch drum (2).
4) Compress O/D clutch return spring (1) by using special tool

and hydraulic press, and then remove snap ring (2).
(A)
CAUTION:
1 Special tool
2 (A): 09926-96010
5) Remove O/D clutch return spring (1).
6) Remove O/D clutch piston from O/D clutch drum (1) by blow-
1
ing compressed air (392 kPa, 4.0 kg/cm2, 57 psi) into oil hole
(2) of O/D clutch drum (1) as shown in figure.
7) Remove inner and outer O-rings from O/D clutch piston.
O/D Ring Gear
2) Remove O/D ring gear flange (2) from O/D ring gear.
1
2
O/D Planetary Gear Assembly

3
2) Remove one-way No.1 clutch retainer (2), one-way No.1
2
5 clutch outer race (3) with one-way No.1 clutch (4) and O/D
planetary thrust washer (5).
4
INSPECTION
O/D Clutch Assembly
Check that sliding surfaces of discs, plate and flange are not
worn or burnt. If necessary, replace them.
NOTE:
If disc lining is exfoliated, discolored or worn exces-
sively, replace all discs.
replace all discs.
Before assembling new discs, soak them in A/T fluid
for at least 15 minutes.
Measure free length of O/D clutch return spring together with

spring seat.
O/D clutch return spring free length
a: 15.8 mm (0.622 in.)
a
Shake O/D clutch piston lightly and check that check ball (1)
is not stuck. Check that valve does not have leaks by apply-
ing low-pressure compressed air.
Measure inner diameter of O/D planetary gear assembly

bushing.
If inner diameter exceeds limit, replace O/D planetary gear
assembly.
O/D planetary gear assembly bushing inner diameter limit
11.27 mm (0.443 in.)
Measure planetary pinion gear thrust clearance by using

thickness gauge.
If clearance exceeds limit, replace O/D planetary gear
assembly.
O/D planetary gear thrust clearance
Standard: 0.20 0.60 mm (0.0079 0.0236 in.)
Limit: 0.65 mm (0.0255 in.)
ASSEMBLY
1 1) Install O/D planetary thrust washer (5) with groove to one-
3
way No.1 clutch side.
2
5 2) Install one-way clutch No.1 (4) into one-way No.1 clutch
outer race (3) with flange side of one-way No.1 clutch
4 directed to torque converter side.
3) Install one-way No.1 clutch with one-way No.1 clutch outer
race to O/D planetary gear assembly.
4) Install one-way No.1 clutch retainer (2).
5) Install snap ring (1) by using flat end rod or the like.
O/D Ring Gear
1) Install O/D ring gear flange (2) to O/D ring gear.

1
2
O/D Clutch Assembly

1
1) Apply A/T fluid to new inner O-ring and new outer O-ring,
2
and then install them to O/D clutch piston.
2) Press-fit O/D clutch piston (1) into O/D clutch drum (2) by
hands.
CAUTION:
Do not twist or deviate O-rings during installation.
3) Place O/D clutch return spring (1) onto O/D clutch piston.
(A)
4) Compress O/D clutch return spring (1) by using special tool
and hydraulic press.
CAUTION:
1 as to prevent spring seat from being deformed.
2
Special tool
(A): 09926-96010
5) Install snap ring (2) making sure not to align snap ring end
3
gap with claw (3) of O/D clutch return spring retainer (4).
3
6) Make sure that O/D clutch piston moves smoothly when

1
applying and not applying low-pressure compressed air into
oil hole (2) of O/D clutch drum (1).
2
7) Install O/D clutch plates P and O/D clutch discs D in the

following order.
PDPD
1
8) Install O/D clutch flange (1) with flat end facing to clutch disc
side.
10) Measure O/D clutch piston stroke by using thickness gauge.
D
O/D clutch piston stroke
P Standard: 1.85 2.15 mm (0.0729 0.0846 in.)
If piston stroke is out of specification, select another O/D clutch
flange with suitable thickness from the list below and replace it.
Available O/D clutch flange thickness
2 Identification Identification
Thickness Thickness
No. No.
3.6 mm 3.2 mm
06 02
(0.142 in.) (0.126 in.)
3.5 mm 3.1 mm
05 01
(0.138 in.) (0.122 in.)
3.4 mm
04
(0.134 in.)
3.3 mm
03
(0.130 in.)
3
2 1
12) Remove O/D clutch flange (3), 2 O/D clutch discs (4) and 2
O/D clutch plates (5) from O/D clutch drum (2).
1 13) Install O/D clutch drum (1) to O/D planetary gear assembly
(2) securely.
2
14) Install O/D clutch plates P and O/D clutch discs D in the
1 following order.
PDPD
15) Install selected O/D clutch flange (1) with flat end facing to
clutch disc side.
D 16) Install snap ring by using flat end rod or the like.
P
17) Hold O/D clutch drum and turn O/D planetary gear assembly.
Check that O/D planetary gear assembly can be turned
freely (1) clockwise and locked (2) counterclockwise.
1
O/D brake assembly

COMPONENTS
6 8
7
5
3
2
1
11
12
10
1. Snap ring 5. O/D brake piston 9. Snap ring Do not reuse.
2. O/D brake return spring 6. O/D case 10. O/D brake flange Apply A/T fluid
3. Inner O-ring 7. Direct clutch thrust washer 11. O/D brake disc
4. Outer O-ring 8. O/D case seal 12. O/D brake plate
DISASSEMBLY
1) Remove O/D case seals (1) and direct clutch thrust washer
(2).
2
2) Remove O/D brake return spring (1) from O/D case (3) as
follows.
CAUTION:
(A) 146 mm
1
a) Set special tool to O/D brake return spring.

b) Compress return spring by using special tool and hydraulic
press.
c) Remove snap ring and then return spring.
NOTE:
3 2
Set special tool to 146 mm (5.748 in.) in width as shown
in figure.
Special tool
(A): 09941-51010
3) Remove O/D brake piston (1) from O/D case (2) by blowing
compressed air (392 kPa, 4.0 kg/cm2, 57 psi) into oil hole (3)
of O/D case (2) as shown in figure.
2
3
1 4) Remove outer O-ring (1) and inner O-ring (2) from O/D brake
piston.
2
INSPECTION
Measure free length of O/D brake return spring together with

spring seat.
O/D brake return spring free length
a: 17.03 mm (0.670 in.)
a
NOTE:
replace all discs.
ASSEMBLY
1 1) Apply A/T fluid to new outer O-ring (1) and new inner O-ring
(2), and then install O-rings to O/D brake piston.
1
2) Align O/D brake piston (1) and notch of O/D case (3) as
shown in figure and then press O/D brake piston (1) into O/D
case subassembly (2) by hands.
CAUTION:
2
3
3 1
2
3) Place O/D brake return spring (1) onto O/D brake piston (2).
NOTE:
Make sure that O/D brake return spring is inserted in O/D
brake piston return spring boss (3).
4) Install O/D brake return spring (1) to O/D case as follows.
CAUTION:
(A) 1
a) Set special tool to O/D brake return spring.
b) Compress return spring by using special tool and hydraulic
press.
c) Install snap ring by using flat end rod or the like making
sure not to align snap ring end gap (2) with cutout portion of
3 O/D brake piston (3).
NOTE:
2
Set special tool to 146 mm (5.748 in.) in width as shown
in figure.
Special tool
(A): 09941-51010
5) Make sure O/D brake piston (1) moves smoothly when blow-
ing compressed air (392 kPa, 4.0 kg/cm2, 57 psi) into oil hole
(3) of O/D case (2) as shown in figure.
2
3
6) Install new O/D case seals (1) and direct clutch thrust
washer (2).
2
1
Direct clutch assembly

COMPONENTS
10
1
5
1. Direct clutch drum 5. Direct clutch return spring 9. Direct clutch flange
2. Direct clutch piston 6. Snap ring 10. Snap ring
3. Inner O-ring 7. Direct clutch plate Do not reuse.
4. Outer O-ring 8. Direct clutch disc Apply A/T fluid
DISASSEMBLY
2) Remove direct clutch flange (2), 4 direct clutch discs (3) and
4 direct clutch plates (4) from direct clutch drum (5).
1
3
4
5
3) Compress direct clutch return spring (1) by using special tool

(A)
and hydraulic press, and then remove snap ring (2).
CAUTION:
1
2
Special tool
(A): 09926-96010
1 4) Remove direct clutch return spring (1).
3 5) Place direct clutch drum (1) onto O/D case (2).

6) Remove direct clutch piston (3) from direct clutch drum (1)
1
by blowing compressed air (392 kPa, 4.0 kg/cm2, 57 psi) into
oil hole (4) of direct clutch drum (1) as shown in figure.
2
4
7) Remove inner O-ring (1) and outer O-ring (2) from direct
2 clutch piston.
1
INSPECTION
NOTE:
replace all discs.
Measure free length of direct clutch return spring together

with spring seat.
Direct clutch return spring free length
a: 21.32 mm (0.839 in.)
a
Shake direct clutch piston lightly and check that check ball
(1) is not stuck. Check that valve does not have leaks by
blowing low-pressure compressed air.
Measure inner diameter of direct clutch drum bushing.

If inner diameter exceeds limit, replace direct clutch drum.
Direct clutch drum bushing inner diameter limit
53.99 mm (2.1255 in.)
ASSEMBLY
3
1) Apply A/T fluid to new outer O-ring (1) and new inner O-ring
2 1 (2), and then install them to direct clutch piston (3).
2) Press-fit direct clutch piston (3) into direct clutch drum (4) by
hands.
CAUTION:
4
3) Place direct clutch return spring (1) onto direct clutch piston.
(A) 4) Compress direct clutch return spring (1) by using special tool
and hydraulic press.
1
CAUTION:
2 as to prevent spring seat from being deformed.
Special tool
(A): 09926-96010
3
gap with claw (3) of direct clutch return spring retainer (4).
3
1 6) Install direct clutch plates P and direct clutch discs D in

following order.
PDPDPDPD
7) Install direct clutch flange (1) with flat end facing to clutch
D disc side.
P 8) Install snap ring (2) by using flat end rod or the like being
2
sure not to align snap ring end gap with cut portion of direct
clutch drum.
9) Measure direct clutch piston stroke by blowing compressed

air (392 kPa, 4.0 kg/cm2, 57 psi) into oil hole (1) of direct
clutch drum (2) as shown in figure.
Direct clutch piston stroke
0.30 0.60 mm (0.012 0.023 in.)
If piston stroke is out of specification, select another direct clutch
1 flange with suitable thickness from the list below and replace.
Available direct clutch flange thickness
Identification Identification
Thickness Thickness
No. No.
3.3 mm 3.7 mm
53 57
(0.130 in.) (0.146 in.)
3.4 mm 3.8 mm
2 54 58
(0.134 in.) (0.150 in.)
3.5 mm 4.0 mm
55 60
(0.138 in.) (0.157 in.)
3.6 mm 4.2 mm
56 62
(0.142 in.) (0.165 in.)
Forward clutch assembly

COMPONENTS
10
13
12
11
6
5
3 4
1 2
1. Input shaft seal 5. Inner O-ring 9. Forward clutch cushion plate 13. Snap ring
2. Forward clutch drum 6. Outer O-ring 10. Forward clutch plate Do not reuse.
3. O-ring 7. Forward clutch return spring 11. Forward clutch disc Apply A/T fluid
4. Forward clutch piston 8. Snap ring 12. Forward clutch flange

DISASSEMBLY
1 2) Remove forward clutch flange (2), 5 forward clutch discs (3)
3
and 5 forward clutch plates (4).
3) Remove forward clutch cushion plate (1).

1
4) Compress forward clutch return spring (1) by using special

tool and hydraulic press, and then remove snap ring (2).
CAUTION:
(A)
1 Special tool
2 (A): 09926-96010
5) Remove forward clutch return spring (1).
6) Place forward clutch drum (3) onto O/D case (2).

7) Remove forward clutch piston (1) from forward clutch drum
3
1
(1) by blowing compressed air (196 kPa, 2.0 kg/cm2, 28.5
psi) into oil hole (4) of O/D case (2) as shown in figure.
2
4
8) Remove O-ring (1) and seals (2) from forward clutch drum.
1
2
INSPECTION
NOTE:
replace all discs.
Shake forward clutch piston lightly and check that check ball
(1) is not stuck. Check that valve does not have leaks by
blowing low-pressure compressed air.
Measure inner diameter of forward clutch drum bushing.

If inner diameter exceeds limit, replace forward clutch drum.
Forward clutch drum bushing inner diameter limit
24.08 mm (0.948 in.)
ASSEMBLY
1) Apply A/T fluid to new O-ring (1) and new seals (2).
2) Squeeze ends of seals together with wrap distance 8 mm
1
2 (0.314 in.) or less and then install new seals to forward clutch
drum groove.
CAUTION:
3) Check seals rotate smoothly.
4) Apply A/T fluid to new outer O-ring (1) and new inner O-ring
(2), and then install them to forward clutch piston (3).
1
3
1 5) Press-fit forward clutch piston (1) into forward clutch drum

(2) by hands.
CAUTION:
2
6) Place forward clutch return spring (1) onto forward clutch pis-
ton.
(A) 7) Compress forward clutch return spring (1) by using special
tool and hydraulic press.
CAUTION:
1
2
Special tool
3 (A): 09926-96010
3 8) Install snap ring (2) making sure not to align snap ring end
gap with claw (3) of forward clutch return spring retainer (4).
4
9) Install forward clutch cushion plate (1) in correct direction.

1
3 1 10) Install forward clutch plates P and forward clutch discs D

2 in the following order.
D
PDPDPDPDPD
11) Install forward clutch flange (1) facing flat end surface (3) to
clutch disc side.
P 12) Install snap ring (2) by using flat end rod or the like making
sure not to align snap ring end gap with cut portion of for-
ward clutch drum.
13) Measure forward clutch piston stroke by blowing com-

pressed air (392 kPa, 4.0 kg/cm2, 57 psi) into oil hole (1) of
forward clutch drum (2) as shown in figure.
Direct clutch piston stroke
0.50 0.90 mm (0.020 0.035 in.)
If piston stroke is out of specification, select another forward
clutch flange with suitable thickness from the list below and
replace.
Available forward clutch flange thickness
Thickness Thickness
No. No.
3.0 mm 3.8 mm
90 94
(0.118 in.) (0.150 in.)
3.2 mm 4.0 mm
91 95
(0.126 in.) (0.157 in.)
3.4 mm 4.2 mm
92 96
(0.134 in.) (0.165 in.)
3.6 mm 4.4 mm
93 97
(0.142 in.) (0.173 in.)
Sun gear and one-way No.3 clutch assembly

COMPONENTS
6
5
3 4
2
1. Snap ring 5. Snap ring

2. Sun gear 6. One-way No.3 clutch thrust washer
3. Seal 7. One-way No.3 clutch assembly
4. Sun gear input drum
DISASSEMBLY
1) Remove one-way No.3 clutch assembly (1) and one-way

1 No.3 clutch thrust washer (2) from sun gear input drum (3).
2) Remove seals (1) from sun gear (2).

2
3) After removing snap ring (3), remove sun gear (2) from sun
1 gear input drum (4).
4) Remove snap ring (1) from sun gear by using flat end rod or
the like.
1
INSPECTION
Measure inner diameter of sun gear bushing.

If inner diameter exceeds limit, replace sun gear.
Sun gear bushing inner diameter limit
27.08 mm (1.066 in.)
ASSEMBLY
1) Install snap ring (1) to sun gear by using flat end rod or the
like.
2) Install sun gear (2) to sun gear input drum (4) by installing
2
snap ring (3).
1 3) After applying A/T fluid to new seals (1), install them to sun
gear (2).
3
CAUTION:
4
4) Check that seals rotate smoothly.
5) Install one-way No.3 clutch thrust washer (2) to sun gear

1 input drum (3).
4
2
NOTE:
Make sure that tab shapes of thrust washer fit into holes
3
of sun gear input drum.
6) Install one-way No.3 clutch assembly (1) to sun gear input
drum (3) directing deeper side upward (4).
7) Hold sun gear and turn one-way No.3 clutch assembly.

2
Check that one-way No.3 clutch assembly can be turned
1 freely (1) clockwise and locked (2) when turned counter-
clockwise.
Forward brake assembly

COMPONENTS
7
6 8
5
3
2
1
13
11
10
14
12
1. Forward brake return thrust washer 5. Forward brake piston 9. Forward brake sleeve 13. Forward brake No.1 plate
2. Snap ring 6. Inner O-ring 10. Snap ring 14. Forward brake No.2 plate
3. Forward brake return spring retainer 7. Outer O-ring 11. Forward brake flange Do not reuse.
4. Forward brake return spring 8. Forward brake drum 12. Forward brake disc Apply A/T fluid
DISASSEMBLY
1) Compress forward brake return spring (1) by using special

tool and hydraulic press, and then remove snap ring (2).
CAUTION:
Special tool
(A): 09926-96520
2) Remove forward brake return spring retainer (3) and forward
(A)
brake return spring (1).
1
3
2
3) Remove forward brake piston (1) from forward brake drum

1 2
(2) by blowing low pressure compressed air into oil hole (3)
of forward brake drum (2) as shown in figure.
4) Remove inner and outer O-rings from forward brake piston.
INSPECTION
NOTE:
replace all discs.
Measure free length of forward brake return spring including

spring seat.
Forward brake return spring free length
a: 16.05 mm (0.6318 in.)
a
ASSEMBLY
1) After applying A/T fluid to new O-rings, install them to for-

1
ward brake piston.
2) Press-fit forward brake piston (1) into forward brake drum (2)
by hands.
CAUTION:
3) Put forward brake return spring (1) and forward brake return
1
spring retainer (3) on forward brake piston.
4) Compress forward brake return spring (1) by using special
tool and hydraulic press, and then install snap ring (2).
CAUTION:
Special tool
(A) (A): 09926-96520
3
2
5) Make sure that forward brake piston (1) moves smoothly

1 2
when blowing and not blowing low pressure compressed air
into oil hole (3) of forward brake drum (2) as shown figure.
1 6) Fit thrust washer (1) to forward brake assembly (2) with

petroleum jelly so that washer does not fall off when assem-
bling A/T unit.
2
NOTE:
Make sure that cutout portions of thrust washer fit into
teeth of forward brake return spring retainer.
Rear planetary gear carrier assembly and output shaft

COMPONENTS
13
11
10
9
12
8 6
7 5
1. One-way No.2 clutch inner race 5. Rear planetary carrier assembly 9. Rear planetary ring gear 13. Seal
2. Snap ring 6. Rear planetary rear thrust washer 10. Rear planetary ring gear flange Do not reuse.
3. One-way No.2 clutch 7. Sun gear thrust bearing race 11. Snap ring
4. Rear planetary front thrust washer 8. Sun gear thrust bearing 12. Output shaft
DISASSEMBLY
1) Remove rear planetary carrier assembly (1) with rear plane-

tary ring gear (2) from output shaft (3).
1
2) Remove rear planetary carrier assembly (1) from rear plane-

tary ring gear (2).
3) Remove one-way No.2 clutch inner race (1) from rear plane-
tary carrier assembly (2).
4) After removing snap ring (1), remove one-way No.2 clutch

(2) and rear planetary front thrust washer (3) from rear plan-
etary carrier assembly (4).
5) Remove rear planetary rear thrust washer (1) from rear plan-
1
etary carrier assembly (2).
6) Remove sun gear thrust bearing race (1) and sun gear thrust
1
bearing (2) from rear planetary ring gear (3).
2
7) After removing snap ring (1), remove rear planetary ring gear
1 flange (2) from rear planetary ring gear (3).
INSPECTION
Measure planetary pinion gear thrust clearance by using

thickness gauge.
If clearance exceeds limit, replace rear planetary gear carrier
assembly.
Rear planetary gear thrust clearance
Standard: 0.20 0.60 mm (0.0079 0.0236 in.)
Limit: 0.65 mm (0.0255 in.)
ASSEMBLY
1) After applying A/T fluid to new seal (1), install it to output

shaft (2).
1
CAUTION:
2 Do not spread seal ends excessively.
2) Check that seal rotates smoothly.
3) Install rear planetary ring gear flange (2) to rear planetary

1 ring gear (3) by installing snap ring (1).
4) Apply petroleum jelly to sun gear thrust bearing race (1) and
1
sun gear thrust bearing (2), and then install them to rear
2 planetary ring gear (3).
3
5) Apply petroleum jelly to rear planetary rear thrust washer (1),

1
and then install it to rear planetary carrier assembly (2).
NOTE:
Make sure that tab shapes of thrust washer fit into cutout
portions of rear planetary carrier assembly.
2
1 6) Apply petroleum jelly to rear planetary front thrust washer

(3), and then install it to rear planetary carrier assembly (4).
5
2
NOTE:
3
Make sure that tab shapes of thrust washer fit into cutout
portions of rear planetary gear carrier assembly.
7) Install one-way No.2 clutch (2) to rear planetary gear carrier
4
assembly (4) directing open ends of guides (5) on one-way
No.2 clutch to snap ring side.
9) While turning one-way No.2 clutch inner race (1) counter-

clockwise, install it to rear planetary carrier assembly (2).
10) Hold rear planetary carrier assembly (1), and turn one-way
1 No.2 clutch inner race (2).
Check that one-way No.2 clutch inner race (2) can be turned
4
3 freely (3) counterclockwise and locked (4) when turned
clockwise.
11) Install rear planetary carrier assembly (1) to rear planetary

ring gear (2).
2
12) Install rear planetary carrier assembly (1) with rear planetary
ring gear (2) to output shaft (3).
1
Valve body assembly

COMPONENTS
2 6
10
5
4 6
9 10 Nm (1.0 kg-m)
3
7
8
9 10 Nm (1.0 kg-m)
1. Valve body assembly 6. O-ring Apply A/T fluid
2. Manual valve 7. TCC (lock-up) solenoid valve Tightening torque.
3. Detent spring 8. Pressure control solenoid valve Do not reuse.
4. Detent spring plate 9. Solenoid valve bolt

5. Shift solenoid-B (No.2) valve 10. Shift solenoid-A (No.1) valve
NOTE:
When replacing pressure control solenoid valve (8), it is strictly required to replace it together with
valve body assembly (1) as a set.
DISASSEMBLY
1) Remove manual valve (1).
2) Remove shift solenoid-A (No.1) valve (1) and shift solenoid-B

(No.2) valve (2).
1
3) Remove TCC solenoid valve (3) and pressure control sole-
noid valve (4).
2 4 3
ASSEMBLY
Reverse disassembling procedure noting the following points.
Use new O-ring for shift solenoid valves and TCC solenoid
valve.
Tighten solenoid bolts (1) to specified torque.
1, (a) Tightening torque
Solenoid valve bolts (a): 10 Nm (1.0 kg-m, 7.5 lb-ft)
1, (a)
Unit Assembly
ASSEMBLY
1 1) After applying A/T fluid to new O-rings, install them to

reverse brake No.2 piston (1) and reverse brake piston
sleeve (2).
2) Install reverse brake No.2 piston (1) to reverse brake piston
sleeve (2).
2
3) Install reverse brake No.2 piston (1) with reverse brake pis-
ton sleeve (2) to transmission case.
2
CAUTION:
3 Be careful not to damage O-ring (3).
4) After applying A/T fluid to new O-ring, install it to reverse

brake No.1 piston (1).
5) Install reverse brake No.1 piston (1) in transmission case.
6) Place reverse brake return spring (2) on reverse brake No.1
piston (1).
(A)
7) Place snap ring (3) on reverse brake return spring retainer
and compress reverse brake return spring (2) by using spe-
3
cial tool.
1
2
CAUTION:
Special tool
(A): 09922-86010
gap with claw of reverse brake return spring retainer.
9) Make sure that reverse brake No.1 piston (1) and reverse
brake No.2 piston (1) move smoothly when blowing and not
1 blowing low pressure compressed air into oil hole of trans-
mission case.
2
10) After applying A/T fluid to rear planetary thrust bearing (1),
1
install it to transmission case.
1
11) Install forward clutch/reverse brake guide spring (1) to trans-
mission case.
12) Install rear planetary gear assembly and rear planetary ring
gear (1) to output shaft (2) referring to Rear Planetary Car-
rier Assembly in this section.
3
13) Install reverse brake flange F with chamfering side (4) fac-
ing to reverse brake disc side, reverse brake discs D and
P
D reverse brake plates P to rear planetary gear assembly in
following order.
1
4
FDPDPDPDPDPDP
2 14) Align teeth of reverse brake flange and reverse brake plates.
F 15) Face snap ring toward torque converter side and install for-
ward brake drum assembly (3) to rear planetary gear assem-
bly.
16) Install assembled output shaft (1) to transmission case while

aligned teeth fit in grooves in transmission case facing oil
hole of forward brake drum toward valve body side.
17) Place wooden block or the like under output shaft and hold it.
18) Install snap ring (1) facing round edge side (2) upward.
19) Measure clearance between reverse brake plate (1) and for-
ward brake drum by using thickness gauge.
If clearance is out of specification, select another reverse
brake flange with suitable thickness from the list below and
replace it.
Clearance between reverse brake plate and forward brake
drum
Standard: 0.60 1.12 mm (0.0237 0.0440 in.)
Available reverse brake flange thickness
Thickness Thickness
No. No.
1
5.4 mm 4.6 mm
67 52
(0.213 in.) (0.181 in.)
5.2 mm 4.4 mm
66 53
(0.205 in.) (0.173 in.)
5.0 mm 4.2 mm
50 54
(0.197 in.) (0.165 in.)
4.8 mm 4.0 mm
51 55
(0.189 in.) (0.157 in.)
1 20) Install forward brake sleeve (1) onto forward brake piston.
21) After applying A/T fluid to new reverse brake drum gasket
(1), install it to transmission case.
22) Install forward brake return thrust washer (1) onto forward
1 brake return spring retainer.
NOTE:
Make sure that cutout portions of thrust washer fit into
teeth of forward brake return spring retainer.
1 23) Install one-way No.3 clutch (1) directing shallower side

2
upward (2).
2 24) Install forward brake No.2 plate (1.8 mm, 0.071 in. thickness)
(1) with chamfering side (4) of plate facing to forward brake
5 disc side.
3
25) Install forward brake discs D and forward brake plates P
in following order.
P D
DPDPDPDPDP
26) Install forward brake flange (2) with chamfering side (5) of
flange facing to forward brake disc side.
4
27) Install snap ring (3).
1
28) Measure clearance between snap ring (1) and forward brake
flange (2) by using thickness gauge.
If clearance is out of specification, check them for installa-
1
tion.
Clearance between snap ring and forward brake flange
Standard: 0.62 1.98 mm (0.0244 0.0779 in.)
2
29) Install one-way No.3 thrust washer (1) to sun gear input
3 drum (3) securely after applying petroleum jelly so that
washer does not fall off.
2 30) Install sun gear (2) with sun gear input drum (3) into one-way
1 No.3 clutch by turning sun gear (2) clockwise.
3
2 31) After applying petroleum jelly to front planetary thrust bear-
1
ing race (1) and front planetary thrust bearing (2), install
them to front planetary carrier assembly (3).
1
32) Install front planetary carrier assembly (2) to sun gear input
2 drum
34) Remove wooden block or the like under output shaft.

1
35) After applying petroleum jelly to front ring gear thrust bearing
2 rear race (1), install it to front planetary carrier assembly (2).
1
36) Install 2nd coast brake band (1) to transmission case.
2
37) Install 2nd coast brake pin (2) and fix with E-ring (1).
2 38) Install forward clutch thrust washer (1) to forward clutch

3
assembly.
1 39) Install direct clutch assembly (2) to forward clutch assembly
(3).
40) After applying petroleum jelly to input shaft rear thrust bear-
ing (1), install them to forward clutch assembly.
1
41) After applying petroleum jelly to input shaft rear thrust bear-
1
ing rear race (1), install it to front planetary ring gear facing
rim side (2) of washer downward.
2
42) Align teeth of forward clutch discs and install front planetary
ring gear (1) to forward clutch assembly (2).
43) After applying petroleum jelly to front ring gear thrust bearing
(1) and front ring gear thrust bearing front race (2), install
them to front planetary ring gear.
2
1
44) Install assembled direct clutch assembly (1), forward clutch

1 2 3 assembly (2) and front planetary ring gear (3) as a unit to
transmission case.
2 45) Measure distance between sun gear input drum (1) and
direct clutch drum (2).
If distance is out of specification, check them for installation.
Distance between sun gear input drum and direct clutch
2 drum
1 a: 1.8 4.8 mm (0.071 0.188 in.)
a
1
1 46) After applying petroleum jelly to input shaft front thrust bear-
ing (1), install it to forward clutch.
47) After applying A/T fluid to O-rings, install spring (1), 2nd
coast brake piston assembly (2) and 2nd coast brake piston
assembly cover (3) by installing snap ring (4).
1
2
3
4
48) Measure 2nd coast brake piston stroke as follows.

a) Place a mark (1) on piston rod with waterproof pen.
b) Measure piston stroke while blowing compressed air (392
kPa, 4.0 kg/cm2, 57 psi) into oil hole (2).
2nd coast brake piston stroke
2
a: 1.5 3.0 mm (0.059 0.118 in.)
c) If stroke is more than specification, select another 2nd
coast brake piston assembly (3) with suitable length from
the list below and replace.
1
NOTE:
There are two kinds of 2nd coast brake piston assembly
and those are distinguished by the number of piston rod
groove (4).
a
Available 2nd coast brake piston rod length b
Piston rod groove Piston rod length
3
4 0 78.40 mm (3.087 in.)
1 79.90 mm (3.146 in.)
d) If stroke is still more than specification, replace 2nd coast
brake band with a new one.
b
2 49) After applying petroleum jelly to O/D thrust No.3 thrust bear-
ing (1) and input shaft front thrust bearing race (2), install
them to O/D case assembly.
1
3
50) Install direct clutch thrust washer (1) to O/D case assembly.
NOTE:
1
2
Make sure that tab (2) of thrust washer fits into notch (3)
of O/D case assembly.
51) Install O/D case assembly (1) to transmission case aligning

1
bolt holes of O/D case with bolt holes of transmission case,
and then tighten O/D case bolts temporarily.
52) Install snap ring facing round edge (1) upward and position-
ing its end gap as specified below.
Snap ring installation position
1 a: 24 mm (0.94 in.)
53) Tighten O/D case bolts to specified torque.

Tightening torque
O/D case bolt (a): 25 Nm (2.5 kg-m, 18.0 lb-ft)
(a)
54) Measure end play of output shaft.

If end play is out of specification, check it for installation.
Output shaft end play
0.30 1.04 mm (0.0119 0.0409 in.)
55) Check that output shaft rotates smoothly.
1 56) Install O/D brake plates P and O/D brake discs D in fol-
lowing order.
3
PDPDPD
2 57) Install O/D brake flange (1) with flat side (3) of flange facing
to O/D brake disc side.
D
P
59) Measure O/D brake piston stroke between O/D brake piston
and O/D brake plate by using thickness gauge.
If piston stroke is less than specification, parts may have
been assembled incorrectly, so check and reassemble them
again. If piston stroke is more than specification, select
another O/D brake flange with suitable thickness from the list
below and replace it.
O/D brake piston stroke
1.32 1.62 mm (0.052 0.0637 in.)
Available O/D brake flange thickness
Thickness Thickness
No. No.
3.3 mm 3.8 mm
33 38
(0.130 in.) (0.150 in.)
3.5 mm 3.9 mm
35 39
(0.138 in.) (0.154 in.)
3.6 mm 4.0 mm
36 40
(0.142 in.) (0.157 in.)
3.7 mm
37
(0.146 in.)
60) After applying petroleum jelly to O/D thrust No.2 bearing (1)
3
and O/D thrust bearing No.3 race (2), install them to O/D
planetary ring gear (3).
61) Install O/D planetary ring gear (1) to transmission case.

1
62) After applying petroleum jelly to O/D thrust No.1 bearing (1)
1 3
and O/D thrust bearing No.2 race (2), install them to O/D
clutch assembly (3) and O/D planetary gear assembly (4).
63) Install O/D planetary gear assembly (1), O/D clutch assem-
bly (2) and one-way No.1 clutch assembly to transmission
2
case.
64) Check height difference between transmission case (1) and

O/D clutch drum (2) by measuring as shown in the figure.
If measured value is out of specification, check them for
installation.
Standard height difference between transmission case
and O/D clutch drum
a: 15.5 16.5 mm (0.611 0.649 in.)
2 65) After applying petroleum jelly to O/D thrust bearing No.1

race (1), install it to oil pump assembly.
1
66) After applying A/T fluid to new O-ring (2), install it to oil pump
assembly.
67) Install oil pump assembly aligning bolt holes in transmission

(a) case with oil pump assembly.
Tighten oil pump bolts by certain amount of torque at each
time one after another till specified torque is attained.
Tightening torque
Oil pump bolt (a): 22 Nm (2.2 kg-m, 16.0 lb-ft)
68) Make sure input shaft rotates smoothly.
3 2 1 4 69) Blow compressed air into oil holes indicated in the figure.
If there is no sound, disassemble and check installation con-
dition of parts.
NOTE:
5
When inspecting O/D clutch, check that O/D clutch accu-
mulator piston hole is closed.
1. O/D brake 5. 2nd coast brake
6
2. Direct clutch 6. Forward brake
3. Forward clutch 7. Reverse brake
4. O/D clutch
7
70) Install manual shift shaft oil seals (1) to transmission case by
using special tools.
Special tool
(A): 09917-98221
(B): 09916-57330
(B) 1
(A)
71) Install new sleeve cover (1) to manual shift lever (2).
72) Install manual shift shaft (3) to transmission case through
manual shift lever.
(A) 73) Drive in manual shift lever pin (4) by using special tool and
hammer.
Special tool
3
(A): 09922-85811
2
1 4
74) Align hole in sleeve cover with dent in manual shift lever and
caulk securely with pin punch (1). Then check that manual
shift shaft turns smoothly.
2
75) Install parking lock pawl (2), parking pawl pin (1) and parking
pawl spring (3).
1 3
1 2 76) Connect parking lock rod (1) to manual shift lever (2).
(a) 1 2 77) Install parking pawl bracket (1).

Tightening torque
Parking pawl bracket bolt
(a): 7.4 Nm (0.74 kg-m, 5.5 lb-ft)
4
78) Turn manual shift lever (2) to P position, confirm that rear
4
planetary ring gear (3) is correctly locked up by parking lock
3 pawl (4).
79) After applying A/T fluid to new O-rings, install them to accu-
mulator pistons.
80) Install springs to transmission case.
Accumulator piston spring specification
Free Outside Identification
4 3 Accumulator spring
length diameter painting
2
46.0 mm 14.02 mm
O/D clutch Inner Yellow
(1.811 in.) (0.552 in.)
accumulator
1 74.6 mm 20.9 mm
(1) Outer Orange
(2.937 in.) (0.823 in.)
Forward clutch 63.6 mm 16.0 mm
Red
accumulator (2) (2.504 in.) (0.630 in.)
42.1 mm 14.7 mm
Direct clutch Inner Pink
(1.657 in.) (0.579 in.)
accumulator
64.0 mm 20.2 mm
(3) Outer White/Pink
(2.520 in.) (0.795 in.)
Forward brake 70.5 mm 19.7 mm
Green
accumulator (4) (2.776 in.) (0.776 in.)
1 81) Install spring (2) and check ball body (1) to transmission
case.
2
82) After confirming that accumulator piston is pushed all the

way down, match pin (1) of manual shift lever with groove in
manual valve (2).
83) Install valve body assembly (3) by using bolts noting their
length shown below.
Tightening torque
Valve body bolt (a): 10 Nm (1.0 kg-m, 7.5 lb-ft)
Valve body bolt length
Bolt Length Pieces

A 23 mm (0.91 in.) 4
B 28 mm (1.10 in.) 10
C 36 mm (1.42 in.) 6
84) Install manual shift lever spring (4) and spring plate (5).
1, (a) 85) After applying A/T fluid to O-ring, install solenoid wire har-
ness connector (2).
Tighten stopper plate bolt (1) to specified torque.
2
Tightening torque
Stopper plate bolt (a): 5.5 Nm (0.55 kg-m, 4.0 lb-ft)
86) Connect shift solenoid-A (No.1) connector (2), shift solenoid-

B (No.2) connector (3), TCC solenoid connector (4) and
pressure control solenoid connector (5) to each solenoid
valve.
Shift solenoid valve connector and harness color
Harness
Solenoid valve Connector color
C, (a) B, (a) 1 color
A, (a) Shift solenoid-A (No.1) White White
Shift solenoid-B (No.2) Black Black
TCC solenoid Black Yellow
Green and
Pressure control solenoid Black
Orange
87) Install oil strainer (1) to valve body assembly. Tighten bolts to
specified torque.
2 3 5 4
Oil strainer bolt length
Bolt Length
A 14 mm (0.55 in.)
B 20 mm (0.79 in.)
C 23 mm (0.91 in.)
Tightening torque
Oil strainer bolt (a): 10 Nm (1.0 kg-m, 7.5 lb-ft)
a 88) Install magnets (1) to oil pan.

1 89) Apply sealant continuously to oil pan mating surface as
1 shown in figure.
A Sealant: 99000-31230
Sealant amount for oil pan
Width a: 2 3 mm (0.08 0.11 in.)
90) Install oil pan to transmission case.

(a) Tighten bolts to specified torque.
Tightening torque
Oil pan bolt (a): 7.4 Nm (0.74 kg-m, 5.5 lb-ft)
1 91) With key attached to output shaft, install speed sensor rotor
(2) by aligning key groove with key and install C-ring (1).
2
92) If oil seal was removed, install new one (1) to adapter case
(A)
by using special tool and hammer.
Special tool
1
(A): 09913-75520
93) Apply sealant continuously to adapter case (1) mating sur-

face as shown in figure.
A Sealant: 99000-31230
1, A
94) Install adapter case (1) to transmission case.
Tightening torque
Adapter case bolt (a): 34 Nm (3.4 kg-m, 24.5 lb-ft)
2, (a) 2. Adapter case bolt 50 mm (1.969 in.)

2, (a)
3. Adapter case bolt 40 mm (1.575 in.)
3, (a) 3, (a)
95) Clean threads of converter housing bolts and bolt holes of

transmission case, install converter housing (1) to transmis-
sion case.
96) Tighten bolts to specified torque.
2, (a) 2, (a)
NOTE:
Make sure to use new converter housing bolts (2) and (3).
1
Tightening torque
Converter housing bolt M10
(a): 34 Nm (3.4 kg-m, 24.5 lb-ft)
Converter housing bolt M12
(b): 57 Nm (5.7 kg-m, 41.5 lb-ft)
3, (b) 3, (b) 2. Converter housing bolt M10
3. Converter housing bolt M12
97) Install output shaft speed sensor (1), input shaft speed sen-
(b) 3 1
sor (2) and transmission case plug (3).
(a)
Tightening torque
Output shaft speed sensor bolt
(a): 5.5 Nm (0.55 kg-m, 4.0 lb-ft)
(b): 5.5 Nm (0.55 kg-m, 4.0 lb-ft)
2 (c)
Transmission case plug
(c): 5.5 Nm (0.55 kg-m, 4.0 lb-ft)
98) Apply A/T fluid to O-rings, install oil pipe unions, if removed.
Tighten unions to specified torque.
Tightening torque
Oil pipe union
(a)
(a): 29 Nm (2.9 kg-m, 21.0 lb-ft)
(a)
99) Install transmission range sensor (1) and tighten sensor bolt
temporarily.
100) Install grommet, lock washer (2) and manual shift shaft nut
1 2 (3).
Tighten nut to specified torque. After tightening it, bend
claws of lock washer.
6, (c)
Tightening torque
Manual shift shaft nut
(a): 7 Nm (7.0 kg-m, 5.0 lb-ft)
101) After turning manual shift shaft fully counterclockwise, turn it
clockwise by 2 notches and set it to N range.
3, (a)
102) With neutral reference line (4) and groove (5) in transmission
range sensor aligned, tighten transmission range sensor bolt
to specified torque.
(b)
Tightening torque
4 Transmission range sensor bolt
(b): 13 Nm (1.3 kg-m, 9.5 lb-ft)
5
103) Apply A/T fluid to O-ring and install A/T fluid temperature
sensor (6).
Tighten A/T fluid temperature sensor to specified torque.
Tightening torque
A/T fluid temperature sensor
(c): 14.7 Nm (1.5 kg-m, 11.0 lb-ft)
104) Install torque converter (1) to input shaft.
CAUTION:
1 Install torque converter, using care not to damage oil seal
lip of oil pump.
105) Confirm that torque converter is fully fitted in transmission.

1
2 Confirmation can be done by measuring dimension between
end surface of converter housing (1) and drive plate installa-
tion seat (3).
a
Torque converter installing position
a: 56.4 mm (2.22 in.)
106) Check that torque converter turns smoothly and feeds
3 grease to centerpiece (2) of torque converter.
107) Connect breather hose to transmission case.


Tightening torque
Fastening part
Nm kg-m lb-ft
A/T fluid drain plug 20 2.0 14.5
Oil hose clamp bracket bolt 23 2.3 17.0
Manual selector assembly mounting bolt 18 1.8 13.5
Manual select lever nut 13 1.3 9.5
Select cable end nut 19 1.9 14.0
Transmission range sensor bolt 13 1.3 9.5
Manual shift shaft nut 7 0.7 5.0
Input shaft speed sensor bolt 5.5 0.55 4.0
Output shaft speed sensor bolt 5.5 0.55 4.0
Rear mounting member bolt 55 5.5 40.0
Front propeller shaft universal joint flange bolt 50 5.0 36.5
Rear propeller shaft universal joint flange bolt 55 5.5 40.0
Exhaust No.2 pipe to turbocharger outlet pipe bolt 55 5.5 40.0
Muffler to exhaust No.2 pipe bolt or nut 55 5.5 40.0
A/T fluid temperature sensor 14.7 1.5 11.0
Oil cooler pipe union bolt 25 2.5 18.0
Torque converter mounting bolt 65 6.5 47.0
Transmission to engine bolt and nut 61 6.1 44.0
Drive plate bolt 50 5.0 36.5
Engine rear mounting bolt 55 5.5 40.0
Engine rear mounting member bolt 55 5.5 40.0
Stabilizer bar mount bush bracket bolt 23 2.3 17.0
Oil pump cover bolt 10 1.0 7.5
Shift solenoid-A (No.1) valve bolt 10 1.0 7.5
Shift solenoid-B (No.2) valve bolt 10 1.0 7.5
TCC (lock-up) solenoid valve bolt 10 1.0 7.5
O/D case bolt 25 2.5 18.0
Oil pump bolt 22 2.2 16.0
Parking pawl bracket bolt 7.4 0.74 5.5
Valve body bolt 10 1.0 7.5
Stopper plate bolt 5.5 0.55 4.0
Oil strainer bolt 10 1.0 7.5
Oil pan bolt 7.4 0.74 5.5
Adapter case bolt 34 3.4 24.5
Converter housing bolt M10 34 3.4 24.5
Converter housing bolt M12 57 5.7 41.5
Transmission case plug 5.5 0.55 4.0
Oil pipe union 29 2.9 21.0
Strut tower bar bolt 50 5.0 36.5

Material Use
(Part Number)
Refer to Section 0B Automatic transmission
Parts lubrication when installing
A/T fluid
Solenoid valve O-ring
A/T fluid temperature sensor O-ring
SUZUKI SUPER GREASE C Retaining parts in place when
(99000-25030) assembling
Oil seal lips
Lithium grease
Oil pump O-ring
SUZUKI SUPER GREASE A Cable ends
(99000-25010)
SUZUKI BOND NO.1216B Mating surface of adapter case
Sealant
(99000-31230) Mating surface of oil pan
Special Tool
09920-76010 09922-89810 09918-48211 09918-48220

Snap ring opener Spring pin remover Oil pump remover Oil pump remover attachment
(M8)
09922-86010 09913-75520 09900-20607 09900-20701

Clutch piston compressor Bearing installer Dial gauge Magnetic stand
09926-96010 09925-37811-001 09917-98221 09922-85811

Clutch spring compressor Oil pressure gauge Valve stem seal installer Spring pin remover
09916-57330 09926-96520 09920-20310 09941-51010

Valve guide installer Spring compressor Clutch spring hook Lock ring wrench
09921-96510
Tech 2 kit (SUZUKI scan tool) Oil pan seal cutter
See MOTE below.
NOTE:
This kit includes the following items and substitutes for the Tech 1 kit.
1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE16/19 adapter, 5. Cigarette cable,
CLUTCH 7C1-1
SECTION 7C1
CLUTCH 7C1
NOTE:
CONTENTS
General Description .............................................. * Clutch Operation Cylinder................................... *
Diagnosis ............................................................... * Unit Pepair .....................................................7C1-2
On-Vehicle Service................................................ * Clutch Cover, Clutch Disc and Flywheel.....7C1-2
Fluid Inspection ................................................... * Tightening Torque Specifications ...............7C1-5
Clutch Pedal Height ............................................ * Required Service Material ............................7C1-6
Clutch Pedal Free Travel .................................... * Special Tool...................................................7C1-6
Clutch Fluid Pipe and Hose................................. *
Clutch Master Cylinder ........................................ *
7C1-2 CLUTCH
Unit Pepair
Clutch Cover, Clutch Disc and Flywheel
COMPONENTS
1. Input shaft bearing 4. Clutch cover 7. Clutch release fork 10. Clutch release fork support
Apply grease 99000-25010 to contact Apply grease 99000-25010 to contact
part with release bearing part with clutch release fork
2. Flywheel 5. Bolt 8. Boot 11. Flywheel bolt
3. Clutch disc 6. Release bearing 9. Clip Tightening torque
DISMOUNTING/REMOUNTING
Refer to Dismounting/Remounting of Transmission Unit in Sec-
tion 7A2.
CLUTCH 7C1-3
REMOVAL
1) Hold flywheel stationary with special tool (A) and remove

clutch cover bolts (1), clutch cover (2) and clutch disc.
Special tool
(A): 09924-17810
2) Pull out input shaft bearing (1) by using special tool (B) and
wrench (2).
Special tool
(B): 09923-73210
3) Remove release bearing and release fork.
INSPECTION
Input Shaft Bearing and Release Bearing
Check bearing for smooth rotation and replace it if abnormality is
found.
Clutch Disc
Measure depth of rivet head depression, i.e. distance between

rivet head and facing surface. If depression is found to have
reached service limit at any of holes, replace disc assembly.
Rivet head depth
Standard: 1.6 mm (0.06 in.)
Service limit: 0.5 mm (0.02 in.)
Clutch Cover
1) Check diaphragm spring for abnormal wear or damage.
2) Inspect pressure plate for wear or heat spots.
3) If abnormality is found, replace it as assembly. Do not disas-
semble it into diaphragm and pressure plate.
Flywheel
Check surface contacting clutch disc for abnormal wear or heat
spots. Replace or repair as required.
7C1-4 CLUTCH
INSTALLATION
NOTE:
Before assembling, make sure that flywheel surface and
pressure plate surface have been cleaned and dried thor-
oughly.
1) Install flywheel (1) to crankshaft and tighten bolts (2) to spec-

ified torque.
Special tool
(A): 09924-17810
Tightening torque
Flywheel bolt (a): 50 Nm (5.0 kg-m, 36.5 lb-ft)
2) Using special tool (B), install input shaft bearing to flywheel

(1).
Special tool
(B): 09925-98210
3) Aligning clutch disc to flywheel center by using special tool

(C), install clutch cover (1) and bolts (2). Then tighten bolts to
specification.
NOTE:
While tightening clutch cover bolts (2), compress
clutch disc with special tool (C) by hand so that disc
centered.
Tighten cover bolts little by little evenly in diagonal
order.
Special tool
(A): 09924-17810
(C): 09923-36320
Tightening torque
Clutch cover bolt (a): 23 Nm (2.3 kg-m, 16.5 lb-ft)
CLUTCH 7C1-5
4) Install clip (2) to release fork (1), and apply grease to release
fork (1).
Then install release fork (1) and release bearing (4) as
shown in figure.
A: Grease 99000-25010
5) Slightly apply grease to spline of input shaft (3). Then join
transmission assembly with engine referring to Remounting
of Transmission in Section 7A2.
B: Grease 99000-25210
NOTE:
Insert transmission input shaft (3) to clutch disc turning
crankshaft pulley with wrench so that splines mesh.

Tightening torque
Fastening part
Nm kg-m lb-ft
Flare nut 16 1.6 11.5
Master cylinder nut 13 1.3 9.5
Lock nut 18 1.8 13.0
Flywheel bolts 50 5.0 36.5
Flywheel bolts (J20, H25 and H27 engines) 70 7.0 50.5
Clutch cover bolts 23 2.3 16.5
Clutch release fork support 29 2.9 21.0
Clutch hose union bolt 23 2.3 16.5
Clutch operating cylinder bolt 50 5.0 36.5
7C1-6 CLUTCH

Material Use
(Part Number)
Lithium grease SUZUKI SUPER GREASE A Clutch master cylinder clevis pin.
(99000-25010) Release fork.
Push rod tip of clutch operating cyl-
inder.
SUZUKI SUPER GREASE I Input shaft spline front end.
(99000-25210)
Clutch fluid (Brake fluid) DOT3 or SAE J1703 Clutch reservoir.
Clutch master cylinder.
Clutch operating cylinder.
Sealant SUZUKI BOND No.1215 Flywheel bolts
(99000-31110)
Special Tool
09923-73210 09923-36320 09924-17810 09925-98210

Bearing remover Clutch center guide Flywheel holder Input shaft bearing installer
DIFFERENTIAL (FRONT) 7E-1
SECTION 7E
DIFFERENTIAL (FRONT)
7E
NOTE:
CONTENTS
General Description ........................................7E-1 Inspection............................................................ *
4WD Control System.....................................7E-2 4WD control system ........................................ *
System circuit and operation .....................7E-3 Actuator........................................................... *
Components and functions........................7E-4 Air pump assembly.......................................... *
Diagnosis .........................................................7E-5 Removal and Installation............................. 7E-10
Differential mountings ............................. 7E-10
Diagnosis Table ............................................7E-5
Rear mounting
Differential assembly .................................7E-5
(for front differential carrier)..................... 7E-12
4WD control system diagnostic
Dismounting ................................................ 7E-12
flow table ...................................................7E-5
Remounting................................................. 7E-14
4WD Control Circuit Inspection .....................7E-8
Voltage check............................................7E-8 Unit Repair..................................................... 7E-15
On-Vehicle Service..........................................7E-9 Tightening Torque Specifications ............... 7E-15
Maintenance Service.....................................7E-9 Required Service Material ............................ 7E-15
Gear oil change .........................................7E-9 Special Tool................................................... 7E-15
General Description
The differential assembly using a hypoid bevel pinion and gear is installed to the front axle.
4WD control system controls drive force to be transmitted to front axles or not. The reduction ratio varies
depending on transmission or engine type.
The differential assembly is decisive in that the drive power is concentrated there. Therefore, use of genuine
parts and specified torque is compulsory. Further, because of sliding tooth meshing with high pressure between
bevel pinion and gear, it is mandatory to lubricate them by hypoid gear oil.
7E-2 DIFFERENTIAL (FRONT)
4WD Control System

When the 4WD switch is turned ON by shifting the transfer shift lever, 4WD controller actuates (energizes) the
air pump assembly. Then positive pressure is sent from the air pump assembly to the actuator installed to the
differential case and causes the axle lock clutch and the free axle hub in the differential case to be engaged,
resulting in the 4WD mode. Only when running in the 4WD mode, front axles are joined to differential case, and
they become free when 2WD mode is used (or when transfer shift lever is shifted to N position), thereby reduc-
ing the power loss.
1. 4WD switch 4. Steering support member 7. Axle lock clutch

2. Transfer 5. Air pump assembly 8. Free axle hub
3. 4WD controller 6. Actuator 9. 4WD indicator lamp
System circuit and operation
1. 4WD switch 4. Release valve 7. Front differential 10. To ignition switch

2. Air pump assembly 5. Pressure switch 8. Air hose and pipe 11. 4WD controller
3. Pump motor 6. Transfer 9. 4WD indicator lamp
Components and functions
Component Function
4WD switch When the transfer shift lever is shifted to 4L or 4H position, this switch
turns ON and causes the 4WD control system to turn ON, unless it is
shifted to N or 2H within 1 second.
4WD controller When the 4WD switch turns ON [unless it turns OFF within 1 second], this
controller actuates the air pump assembly. If the pressure in the air pump
assembly fails to increase higher than the set level even after the pump
motor has run more than 10 seconds, this controller stops the motor to
protect the air pump assembly.
Air pump assembly The air pump assembly consists of a pump motor, release valve and a
Pump motor pressure switch.
Release valve Pump motor :
Pressure switch Produces positive pressure which actuates the actuator.
Release valve :
Closes when transfer shift lever is shifted to 4H or 4L so that the positive
pressure is applied to the actuator, and opens when N or 2H to release
the pressure to the atmosphere.
Pressure switch :
Turns ON and OFF depending on the pressure level in the pump assem-
bly (whether higher or lower than the set pressure level). 4WD controller
detects the pressure level through this switch.
Differential case assembly The free axle hub, axle lock clutch and actuator are installed in the differ-
Free axle hub ential left case. The positive pressure produced in the air pump assembly
Axle lock clutch is applied to the actuator which then pushes the axle lock clutch to be
Actuator engaged with the free axle hub. In this state, the drive force is transmitted
to the front axle, resulting in the 4WD mode.
When the actuator is free from the positive pressure [when it is under the
atmospheric pressure], the axle lock clutch is pushed back by the return
spring force and cannot be engaged with the free axle hub, resulting in
the 2WD mode.
4WD indicator lamp It lights up when 4WD control system is in the 4WD mode.
Diagnosis
Diagnosis Table
Differential assembly

Gear noise Deteriorated or water mixed lubricant Repair and replenish.
Inadequate or insufficient lubricant Repair and replenish.
Maladjusted backlash between bevel pinion and Adjust.
gear
Improper tooth contact in the mesh between Adjust or replace.
bevel pinion and gear
Loose bevel gear securing bolts Replace or retighten.
Damaged side gear(s) or side pinion(s) Replace.
Bearing noise (Constant noise) Deteriorated or water mixed Repair and replenish.
lubricant
(Constant noise) Inadequate or insufficient Repair and replenish.
lubricant
(Noise while coasting) Damaged bearing(s) of Replace.
bevel pinion
(Noise while turning) Damaged diff. side bear- Replace.
ing(s) or axle bearing(s)
Oil leakage Worn or damaged oil seal Replace.
Excessive oil Adjust oil level.
Loose differential carrier bolts Replace or retighten.
2WD/4WD switching Defective actuator Replace.
error Abnormality in 4WD control system Inspect referring to 4WD control
system diagnostic flow table.
4WD control system diagnostic flow table

Before performing the trouble diagnosis, check that the transfer and front differential are in good condition.
[NOTES ON SYSTEM CIRCUIT INSPECTION]

Be sure to read Precautions for Electrical Circuit Service in Section 0A before circuit inspection and
observe what is written there.
For system circuit, refer to the figure of System circuit and operation in this section.
For terminal arrangement, refer to 4WD Control Circuit Inspection in this section.
Step Action Yes No

1 Inspect 4WD control system for air leakage and Go to step 2. Inspect for air leakage
operation referring to 4WD control system from air hoses. If OK, go
under Inspection in this section. to Step 3.
Is the result OK?
Step Action Yes No

2 Inspect actuator for air leakage and operation 4WD control system and Inspect for air leakage
referring to Actuator under Inspection in this actuator are OK. Recheck from air hoses. If OK,
section. transfer and front differen- inspect differential assem-
Is the result OK? tial. bly referring to Section 7E
in UNIT REPAIR MAN-
UAL.
3 Inspect air pump assembly for air leakage and Go to step 4. Replace air pump assem-
operation referring to Air pump assembly bly.
under Inspection in this section.
Is the result OK?
4 Check ground circuit. Go to step 5. BLK wire is open.
1) Disconnect connector from 4WD controller
with ignition switch OFF.
2) Check for proper connection to 4WD con-
troller at all terminal.
3) If OK, check continuity between terminal
E23-6 and body ground.
Is there continuity between terminal E23-6 and
body ground?
5 Check power circuit. Go to step 6. BLK/WHT circuit is open
1) Disconnect connector from 4WD controller. or short.
3) Check voltage between terminal E23-2 and
ground.
Is it 10 14 V?
6 Check 4WD switch circuit. Go to step 7. Check 4WD switch (refer-
1) Connect coupler to 4WD controller. ring to 4WD switch and
2) Turn ignition switch ON and check voltage back up light switch
between terminal E23-4 and ground. inspection under
Transfer lever is in N or 2H: 6 8 V Switches.), BLK/ORN
Transfer lever is in 4L or 4H: 0 1 V and BLK circuit of 4WD
Is the result OK? switch. If OK, substitute a
known-good 4WD control-
ler and recheck.
7 Check 4WD controller. Go to step 8. Substitute a known-good
1) Turn ignition switch ON. 4WD controller and
2) Check voltage between terminal E23-3 and recheck.
ground.
Transfer lever is in N or 2H: 0 1 V
Transfer lever is in 4L or 4H: 10 14 V
(1 second after transfer lever is shifted to
4H or 4L.)
Is the result OK?
Step Action Yes No

8 Check 4WD controller. Go to step 9. Substitute a known-good
1) Check for proper connection to air pump 4WD controller and
assembly at all terminals. recheck.
3) Check voltage between terminal E23-7 and
ground.
Transfer lever is in N or 2H: 0 1 V
Transfer lever is in 4L or 4H: 10 14 V
(4 seconds after transfer lever is shifted to
4H or 4L.)
Is the result OK?
9 Check 4WD indicator lamp circuit. Substitute a known-good Check ORN/BLK circuit
1) Turn ignition switch ON. 4WD controller and (including indicator lamp
2) Check voltage between terminal E23-1 and recheck. and combination meter). If
ground. OK, substitute a known-
Transfer lever is in N or 2H: 10 14 V good 4WD controller and
Transfer lever is in 4L or 4H: 0 1 V recheck.
(4 seconds after transfer lever is shifted to
4H or 4L.)
Is the result OK?
4WD Control Circuit Inspection

Voltage check
Check for input or output voltage (voltage between each circuit and body ground) of 4WD controller with 4WD
controller connector connected and ignition switch turned ON.
TERMI- WIRE NORMAL VOLT-

CIRCUIT CONDITION
NAL COLOR AGE
10 14 V Transfer shift lever: 2H or N
E23-1 4WD indicator lamp ORN/BLK 4 seconds after transfer shift lever
01V
shifted to 4H or 4L
E23-2 Ignition switch BLK/WHT 10 14 V Ignition switch: ON
01V Transfer shift lever: 2H or N
Air pump assembly (Pump
E23-3 RED 1 seconds after transfer shift lever
motor and release valve) 10 14 V
shifted to 4H or 4L
E23-4 4WD switch BLK/ORN
01V Transfer shift lever: 4H or 4L
E23-6 Ground BLK 01V
Air pump assembly (pres-
E23-7 PNK 4 seconds after transfer shift lever
sure switch) 10 14 V
shifted to 4H or 4L
1. 4WD controller connector terminal arrangement

On-Vehicle Service
Maintenance Service
NOTE:
When having driven through water, check immediately
if water has entered (if so, oil is cloudy). Water mixed
oil must be changed at once.
Whenever vehicle is hoisted for any other service work
than oil change, also be sure to check for oil leakage
and status of breather hoses.
Gear oil change
NOTE:
Hypoid gear oil must be used for differential.
It is highly recommended to use SAE 75W-90 (API GL-
4) viscosity.
1) Before oil change or inspection, be sure to stop engine and

lift up vehicle horizontally.
2) Check for oil level and leakage. If leakage is found, find the
cause of the leakage and fix it.
3) Drain old oil and pour proper amount of gear oil as specified
as shown (roughly up to level hole).
4) Apply sealant to thread of differential oil drain plug (b) and

torque plugs to specification.
Sealant 99000-31110
Tightening torque
Differential oil level/filler plug
(a) : 23 Nm (2.3 kg-m, 17.0 lb-ft)
Differential oil drain plug
(b) : 23 Nm (2.3 kg-m, 17.0 lb-ft)
Specified gear oil :

Hypoid gear oil API GL-4
SAE 75W-90
For oil viscosity, refer to left chart.
Oil capacity :
1.0 liter (2.1/1.8 US pt/lmp. pt)
Removal and Installation

Differential mountings
1) Lift up vehicle and turn steering wheel all the way to the right.
2) Separate mounting bracket R (2) from differential housing (3)
by removing mounting bracket bolts (1) from its lower part.
3) Remove mounting bracket R (2) by removing mounting front
bolt (4) from its upper part.
4) Remove mounting bracket L (3) from differential housing (1)

by removing upper and lower mounting bracket bolts (4).
2. Front mounting bolt
5) Check conditions of each bush. If it is damaged or deterio-

rated, drive it out with special tools and hydraulic press for
replacement.
Special tool
(A) : 09951-26010
(B) : 09951-16080
1. Mounting bracket
6) Position slit in each bush as shown when press-fitting it.

1. Mounting bracket L
2. Bush
3. Mounting bracket R
A : Slit alignment 45
7) Position each bush to bracket as shown.

Length a : 3.0 mm (0.12 in.)
8) Use following torque for reinstallation.

Tightening torque
Mounting front bolt (a) : 85 Nm (8.5 kg-m, 61.5 lb-ft)
Mounting bracket bolts (b) : 50 Nm (5.0 kg-m, 36.5 lb-ft)
Rear mounting (for front differential carrier)

1) Lift up vehicle and remove rear mounting bracket (3) by
removing rear mounting bolt (1) and rear mounting bracket
bolts (2).
2) Check mounting rubber for damage or deterioration and
replace as necessary.
3) Tighten rear mounting bolts (1) and rear mounting bracket
bolts (2) to specified torque for reinstallation.
Tightening torque
Rear mounting bolt (a) : 85 Nm (8.5 kg-m, 61.5 lb-ft)
Rear mounting bracket bolts (b) :
60 Nm (6.0 kg-m, 43.5 lb-ft)
Dismounting
1) Lift up vehicle and drain oil.
2) Disconnect air hose and breather hose from differential
housing.
joint flange and propeller shaft as shown.
4) Remove propeller shaft flange by removing its 4 bolts and
suspend propeller shaft with cord or the like.
NOTE:
In case of pulling out propeller shaft, transfer oil must be
drained before pulling out.
5) Remove mounting bracket bolts (1) for left mounting bracket

and flange bolts and nuts (2) for drive shaft flange to set left
side of differential free.
6) Remove rear mounting bolt (1), rear mounting bracket bolts

(2) and rear mounting bracket (3).
7) Remove rear mounting bracket No.2 bolts (4) and rear
mounting bracket No.2 (5).
8) With differential housing assembly held with transmission

jack, remove mounting bracket bolts (1) on right end of differ-
ential housing (3).
9) Using two large screwdrivers (4) as levers, pull out right side
drive shaft joint (1) from differential housing (2) and dismount
differential housing assembly from vehicle by using transmis-
sion jack (3).
CAUTION:
During above work, use care not to damage drive shaft
boot and oil seal.
Remounting
For remounting, reverse dismounting procedure and use following
tightening torque.
Tightening torque
Propeller shaft flange bolts
(a) : 50 Nm (5.0 kg-m, 36.5 lb-ft)
Front drive shaft flange bolts
(b) : 50 Nm (5.0 kg-m, 36.5 lb-ft)
Mounting bracket bolts
(c) : 50 Nm (5.0 kg-m, 36.5 lb-ft)
Rear mounting bracket bolts
(d) : 60 Nm (6.0 kg-m, 43.5 lb-ft)
Rear mounting bolt
(e) : 85 Nm (8.5 kg-m, 61.5 lb-ft)
Rear mounting bracket No.2 bolts
(f) : 85 Nm (8.5 kg-m, 61.5 lb-ft)
After tightening all fasteners properly, fill hypoid gear oil as speci-
fied and check tightening of plugs with specification.
Unit Repair
Refer to the same section of Unit Repair Manual mentioned in FOREWORD of this manual.

Tightening torque
Fastening part
Nm kg-m lb-ft
Differential oil level/filler plug 23 2.3 17.0
Differential oil drain plug 23 2.3 17.0
Mounting front bolts 85 8.5 61.5
Mounting bracket bolts 50 5.0 36.5
Front drive shaft flange bolts 50 5.0 36.5
Propeller shaft flange bolts 50 5.0 36.5
Pump assembly bolts 13 1.3 9.5
Rear mounting bolt 85 8.5 61.5
Rear mounting bracket bolts 60 6.0 43.5
Rear mounting bracket No.2 bolts 85 8.5 61.5

Material Use
(Part Number)
Sealant SUZUKI BOND NO. 1215 Front differential drain plug
(99000-31110)
Special Tool
09951-16080 09951-26010 09918-18110

Bearing installer Bush remover plate Air pressure regulator
09367-04002
3-way joint
DIFFERENTIAL (REAR) 7F-1
SECTION 7F
DIFFERENTIAL (REAR)
CONTENTS 7F
General Description ........................................ 7F-2 Sub-Assembly Adjustment and

Diagnosis ......................................................... 7F-2 Reassembly .................................................. 7F-9
On-vehicle Service .......................................... 7F-3 Differential carrier...................................... 7F-9
Differential case ........................................ 7F-9
Maintenance Service..................................... 7F-4
Differential side bearing .......................... 7F-11
Changing oil .............................................. 7F-4
Drive bevel pinion.................................... 7F-12
Rear Differential Assembly............................ 7F-5
Assembling Unit .......................................... 7F-16
Dismounting .............................................. 7F-5
Remounting ............................................... 7F-5 Tightening Torque Specification ................. 7F-19
Unit Repair ....................................................... 7F-6 Required Service Material ............................ 7F-19
Disassembling Unit ....................................... 7F-6 Special Tool................................................... 7F-20
Component Inspection .................................. 7F-9
7F-2 DIFFERENTIAL (REAR)
General Description
The differential assembly using a hypoid bevel pinion and gear is installed to the rear axle. It is set in the conven-
tional type axle housing.
The differential assembly is decisive in that the drive power is concentrated there. Therefore, use of genuine
parts and specified torque is compulsory. Further, because of sliding tooth meshing with high pressure between
bevel pinion and gear, it is mandatory to lubricate them by hypoid gear oil.
Diagnosis
Gear noise Deteriorated or water mixed lubricant Repair and replenish.
Inadequate or insufficient lubricant Repair and replenish.
Maladjusted backlash between drive bevel pinion and gear Adjust as prescribed.
Improper tooth contact in the mesh between drive bevel pin- Adjust or replace.
ion and gear
Loose drive bevel gear securing bolts Replace or retighten.
Damaged differential gear(s) or differential pinion(s) Replace.
Bearing noise (Constant noise) Deteriorated or water mixed lubricant Repair and replenish.
(Constant noise) Inadequate or insufficient lubricant Repair and replenish.
(Noise while coasting) Damaged bearing(s) of drive bevel Replace.
pinion
(Noise while turning) Damaged differential side bearing(s) Replace.
or axle bearing(s)
Oil leakage Clogged breather plug Clean.
Worn or damaged oil seal Replace.
Excessive oil Adjust oil level.
On-vehicle Service
1. Universal joint flange 10. Differential pinion 19. Pinion shaft No.2 : Do not reuse.
2. Hypoid gear set 11. Differential gear 20. Pinion joint : Tightening torque
3. Bevel pinion spacer 12. Pinion shaft No.1 21. Spring washer : Apply differential oil.
4. Shim 13. Differential left case 22. Washer
5. Rear bearing 14. Differential right case 23. Bevel gear bolt:
Apply thread lock cement 99000-
32110 to thread part of bolt.
6. Front bearing 15. Thrust washer 24. Bolt
7. Oil seal: 16. Differential side bearing 25. Bolt
Apply grease 99000-25010 to oil
seal lip.
8. Flange nut: 17. Bearing adjuster 26. Bolt
After tightening nut so as rotation
torque of bevel pinion shaft to be in
specified value, caulk nut securely.
9. Differential carrier assembly 18. Lock plate 27. Differential case screw:
Apply thread lock cement 99000-
32110 to thread part of bolt.
Maintenance Service
NOTE:
When having driven through water, check immediately
if water has entered (if so, oil is cloudy). Water mixed
oil must be changed at once.
Whenever vehicle is hoisted for any other service work
than oil change, also be sure to check for oil leakage
and status of breather hoses.
Changing oil
NOTE:
Hypoid gear oil must be used for differential.
It is highly recommended to use SAE 80W-90 viscosity.
1) Before oil change or inspection, be sure to stop engine and
lift up vehicle horizontally.
2) Check oil level and existence of leakage. If leakage is found,

correct its cause.
3) Drain old oil and pour proper amount of gear oil as specified
(roughly up to level hole).
4) Torque drain (3) and level/filler plugs (2) to specification.

A: Sealant 99000-31110
Tightening torque
Differential oil level/filler plug
(a): 50 Nm (5.0 kg-m, 36.5 lb-ft)
Differential oil drain plug
(b): 28 Nm (2.8 kg-m, 20.5 lb-ft)
1. Breather hose
Specified gear oil :

Hypoid gear oil API GL-5 SAE 80W-90
For oil viscosity, refer to the chart at the left.
Oil capacity: 2.5 liters (5.3/4.4 US/Imp. pt.)
[A]: Viscosity chart SAE
Rear Differential Assembly

Dismounting
1) Lift up vehicle and drain oil from rear differential housing.
2) Remove rear brake drums and pull out right and left rear axle
shafts. (Refer to Rear Axle Shaft in Section 3E.)

joint flange and propeller shaft as shown.
4) Remove propeller shaft by removing its flange bolts.
5) Remove differential assembly by removing its 8 fastening

bolts (1).
Remounting
1) Clean mating surfaces of rear axle and differential assembly
and apply sealant to axle side evenly.
A: Sealant 99000-31110
2) Install differential assembly to axle and fix it with bolts (1)

tightened to specified torque.
Tightening torque
Differential carrier bolts
(a): 55 Nm (5.5 kg-m, 40.0 lb-ft)
3) Install propeller shaft to joint flange aligning match marks

and torque flange bolts to specification. Apply thread lock
cement to thread part of bolt if reused.
A: Cement 99000-32110
Tightening torque
Propeller shaft flange bolts
(a): 50 Nm (5.0 kg-m, 36.5 lb-ft)
4) Install right and left rear axle shafts and drums.

(Refer to Rear Axle in Section 3E and Rear Brake Drum
in Section 5.)
5) Install wheels.
6) Fill hypoid gear oil as specified and tighten plug to specifica-
tion.
7) Lower lift.
Unit Repair
Disassembling Unit
1) Hold differential assembly securely and put identification
marks on differential side bearing caps (6).
2) Take off differential side bearing lock plates (4) and differen-
tial side bearing caps (6) by removing their bolts and then
take out bearing adjusters (5), side bearing outer races and
drive bevel gear with differential case.
1. Differential carrier
2. Drive bevel gear assembly
3. Differential case
A: Identification mark
3) Remove drive bevel gear (hypoid gear), differential gears,

differential pinions and pinion shafts.
a) With aluminum plates (2) placed on vise first, grip differen-
tial case with it and remove drive bevel gear (hypoid gear)
(3) by removing its bolts (1).
b) Remove differential left case (2) from differential right case

(1).
c) Remove pinion shafts, differential gears, washers, differen-

tial pinions, spring washers, thrust washers.
4) Using special tools, pull out differential side bearings (1).

Special tool
(C): 09913-85230
(D): 09913-61510
5) Remove drive bevel pinion (hypoid gear) assembly.

a) Hold universal joint flange with special tool and then
remove flange nut by using power wrench (4 10 magnifi-
cation) (2).
Special tool
(E): 09922-66021
1. Socket wrench
b) Make mating marks (1) on drive bevel pinion and compan-

ion flange.
CAUTION:
Dont make mating mark on the coupling surface of the
flange.
c) Press drive bevel pinion (2) by using rod (4) (approx. 22
mm (0.866 in.) in diameter) and press (5) then remove drive
bevel pinion (2) and companion flange (3).
CAUTION:
Do not drop drive bevel pinion by holding its gear part by
hand from beneath.
d) Remove drive bevel pinion rear bearing (2) by using bear-

ing puller (3) and press.
1. Drive bevel pinion
6) Using a hammer and brass bar (1), drive out front bearing
outer race with bearing (2) and oil seal (3).
7) Drive out rear bearing outer race in the same way as in the
Step 6).
Component Inspection
Check companion flange for wear or damage.
Check bearings for wear or discoloration.
Check differential carrier for cracks.
Check drive bevel pinion and drive bevel gear for wear or
cracks.
Check differential gears, pinions and pinion shafts for wear
or damage.
Check differential gear spline for wear or damage.
Sub-Assembly Adjustment and Reassembly

Judging from faulty conditions noted before disassembly and
what is found through visual check of bearing and gear tooth etc.
after disassembly, prepare replacing parts and proceed to reas-
sembly according to procedures as described below.
CAUTION:
Drive bevel gear and pinion must be replaced as a set
when either replacement becomes necessary.
When replacing taper roller bearing, replace as inner
race & outer race assembly.
Differential carrier
For press-fitting drive bevel pinion bearing outer races, use spe-
cial tools as shown in the figure.
Special tool
(A): 09924-74510
(B): 09926-68310
(C): 09913-75510
1. Differential carrier
Differential case
1) After applying differential oil to differential gear (4), pinions
(5), pinion shafts (6), thrust washer (2) and spring washer
(1), install them in differential right case (3).
For correct installing direction of thrust washer (2) and spring
washer (1), refer to the figure.
2) When installing pinion shaft No.2 (2) (shorter) into differential

case and pinion, insert its a side into pinion joint (1).
NOTE:
a is longer than b. (a > b)
3) Check differential pinion gear (1) for smooth rotation.
4) In the same manner as described in Step 1), install thrust

washer (2), spring washer (1) and differential gear (4).
3. Differential left case
5. Differential pinion
5) Install differential left case (1) and then tighten screws (2) to
specified torque.
A: Cement 99000-32110
Tightening torque
Differential case screw
(a): 9 Nm (0.9 kg-m, 6.5 lb-ft)
3. Differential right case
6) Clean and degrease mating surface of drive bevel gear

(hypoid gear) (1).
7) Apply thread lock cement to hatched part of drive bevel gear
(1) as shown in the figure.
A: Cement 99000-32110
8) Put drive bevel gear (3) on differential case (1) and fasten
them with bolts (2) by tightening them to specified torque.
Use thread lock cement for bolts (2).
CAUTION:
Use of any other bolts than that specified is prohibited.
A: Cement 99000-32110
Tightening torque
Bevel gear bolts (a): 105 Nm (10.5 kg-m, 76.0 lb-ft)
9) Install special tool to differential case assembly (2) and

check that preload is within specification below. If preload
exceeds specified value, check if foreign matter is caught or
gear is damaged.
Special tool
(B): 09928-06510
Side gear preload
: Max. 2.5 Nm (0.25 kg-m, 1.8 lb-ft)
1. Torque wrench
3. Aluminum plate
4. Vise
Differential side bearing

1) Press-fit side bearing (1) with special tool and press.
Special tool
(A): 09944-66020
2) Hold bearing press-fitted in Step 1) with holder and press-fit

side bearing on the other side.
NOTE:
Be sure to use bearing holder for the purpose of protect-
ing lower bearing.
Special tool
(A): 09944-66020
(B): 09951-16060
Drive bevel pinion

To engage drive bevel pinion and gear correctly, it is pre-required to install drive bevel pinion to differential car-
rier properly by using adjusting shim as described on the followings. Shown below is relative positions of drive
bevel pinion, differential carrier and mounting dummy.
(A): 09900-20606
(B): 09926-78320
(C): 09922-75222
(D): 09922-76570
(E): 09951-46010
(F): 09926-78311-002
1. Universal Joint flange 5. Rear bearing a: Pinion dummy height + Attachment height d: Drive bevel pinion mounting distance
(P/No. 27110-60A00) 110.00 mm/4.3307 in.
2. Nut 6. Spacer b: Axle dummy radius e: Shim size for mounting distance
adjustment (= c)
3. Front bearing 7. Drive bevel pinion a + b: Mounting dummy size 110.00 mm/4.3307 in.
4. Differential carrier 8. Drive bevel gear c: Measured dimension
1) Install special tools with bearings and universal joint flange

(2) to differential carrier (1).
NOTE:
This installation requires no spacer or oil seal.
Special tool
(E): 09951-46010
(F): 09926-78311-002
2) Tighten flange nut (1) so that specified bearing preload is

obtained.
NOTE:
Before taking measurement with spring balance (2) or
torque wrench (3), check for rotation by hand and
apply small amount of differential oil to bearings.
On measuring preload, rotate the drive bevel pinion
about 1 rotation per 2 seconds.
Special tool
(C): 09922-75222
(F): 09926-78311-002
Pinion bearing preload:
0.9 1.7 Nm (9.0 17.0 kg-cm, 7.8 14.7 lb-in.)
Spring measure reading with special tool:
18 34 N (1.8 3.4 kg, 4.0 7.5 lb)
4. Socket with adapter
3) Set dial gauge to mounting dummy and make 0 (zero)

adjustment on surface plate (1).
NOTE:
When setting dial gauge to mounting dummy, tighten
screw (2) lightly. Be careful not to overtighten it, which
will cause damage to dial gauge.
With dial gauge set, turn dummy back and force by
hand a couple of times and attain accurate 0 (zero)
adjustment.
It is desirable that short pointer indicates beyond 2 mm
when long one is at 0 (zero).
Special tool
(A): 09900-20606
(B): 09926-78320
4) Place zero-adjusted mounting dummy and dial gauge set on

pinion mounting dummy and take measurement between
zero position and extended dial gauge measuring tip.
NOTE:
Repeat turning back and force of dummy and measure
distance as far as top surface of pinion dummy accu-
rately.
When dial gauge measuring tip extends from 0 (zero)
position, pointer turns counterclockwise.
Measured value may exceed 1 mm. Therefore, it is also
necessary to know reading of short pointer.
Special tool
(A): 09900-20606
(B): 09926-78320
(D): 09922-76570
(F): 09926-78311-002
5) Obtain adjusting shim thickness by using measured value by
dial gauge in previous step.
Necessary Dial gauge
shim thickness = measured
e value c
6) Select adjusting shim(s) (2) closest to calculated value from

among following available sizes and put it in place and then
press-fit rear bearing (1).
Calculated valve f:
Closest value to e (refer to Step 5).)
Special tool
(G): 09925-18011
(H): 09927-66010
Available shim thickness:
1.12, 1.15, 1.18, 1.21, 1.24, 1.27, 1.30 and 0.3 mm
(0.044, 0.045, 0.046, 0.047 0.048, 0.049, 0.050 and 0.012 in.)
7) With new pinion spacer (3) inserted as shown in the figure,

install front bearing (5) to differential carrier (4).
NOTE:
Make sure to use new spacer for reinstallation.
Apply differential oil to bearings.
2. Rear bearing
8) Using special tool and plastic hammer, drive oil seal (2) into
differential carrier (1) till it becomes flush with carrier end.
Then apply grease A to oil seal lip.
A: Grease 99000-25010
Special tool
(I): 09951-18210
9) While tightening flange nut gradually with special tool and

power wrench (4 10 magnification) (1), set preload of pin-
ion to specification.
NOTE:
torque wrench (4), check for smooth rotation by hand.
Be sure to tighten gradually and carefully till specified
starting torque is obtained. Turning back overtight-
ened flange nuts should be avoided.
Pinion bearing preload:
0.9 1.7 Nm (9.0 17.0 kg-cm, 7.8 14.7 lb-in.)
16 30 N (1.6 3.0 kg, 3.5 6.6 lb)
Special tool
(C): 09922-75222
(J): 09922-66021
2. Socket wrench
Assembling Unit
1) Place bearing outer races on their respective bearings.
Used left and right outer races are not interchangeable.
2) Install case assembly in carrier.
3) Install side bearing adjusters on their respective carrier,
making sure adjuster are threaded properly.
4) Align match marks (1) on cap and carrier. Screw in 2 side

bearing cap bolts 2 or 3 turns and press down bearing cap
by hand.
NOTE:
If bearing cap does not fit tightly on carrier, side bearing
adjuster is not threaded properly. Reinstall adjuster.
5) Tighten cap bolts (provisional torque).
Tightening torque
Bearing cap bolt (Provisional torque)
(a): 15 Nm (1.5 kg-m, 11.0 lb-ft)
6) Tighten both bearing adjusters (2) so as to obtain specified

gear backlash and at the same time, obtain preload of side
bearing.
NOTE:
Be sure to apply measuring tip of dial gauge at right
angles to convex side of tooth.
As a practical measure the following would be recom-
mended to obtain specified backlash and side bearing
preload at the same time.
Obtain specified backlash by turning both adjusters
inward lightly.
Tighten both adjusters further by one notch at a
time.
Measure at least 4 points on drive bevel gear periph-
ery.
Standard backlash:
0.13 0.18 mm (0.005 0.007 in.)
Special tool
(A): 09930-40120
(B): 09930-40113
(C): 09900-20701
1. Bearing cap bolt
7) Measure preload of pinion bearing with spring balance (1) or

torque wrench (2) and check composite preload of pinion
bearing and side bearing.
NOTE:
torque wrench (2), check for smooth rotation by hand.
Composite preload of pinion bearing and side bearing:
1.1 2.0 Nm (11.0 20.0 kg-cm, 9.5 17.4 lb-in.)
19.5 35.5 N (1.95 3.55 kg, 4.30 7.83 lb)
Special tool
(D): 09922-75222
3. Universal joint flange
4. Socket with adapter
8) Torque bearing cap bolts (2) to specification and install bear-

ing lock plates.
Tightening torque
Lock plate bolt (b): 12 Nm (1.2 kg-m, 9.0 lb-ft)
Bearing cap bolt (c): 85 Nm (8.5 kg-m, 61.5 lb-ft)
1. Lock plate bolt
9) As final step, check gear tooth contact as follows.

a) After cleaning 10 drive bevel gear teeth, paint them with
gear marking compound evenly by using brush (1) or
sponge etc.
b) Turn gear to bring its painted part in mesh with drive bevel
pinion and turn it back and forth by hand to repeat their con-
tact.
c) Bring painted part up and check contact pattern, referring
to following chart. If contact pattern is not normal, readjust
or replace as necessary according to instruction in chart.
NOTE:
Be careful not to turn drive bevel gear more than one full
revolution, for it will hinder accurate check.
A: Paint gear marking compound evenly
TOOTH CONTACT PATTERN DIAGNOSIS AND REMEDY

NORMAL
HIGH CONTACT
Pinion is positioned too fat from the center of
drive bevel gear.
1) Increase thickness of pinion height adjusting
shim and position pinion closer to gear center.
2) Adjust drive bevel gear backlash to specifica-
tion.
LOW CONTACT
Pinion is positioned too close to the center of
drive bevel gear.
1) Decrease thickness of pinion height adjusting
shim and position pinion farther from gear
center.
2) Adjust drive bevel gear backlash to specifica-
tion.
If adjustment is impossible, replace differential carrier.
1) Check seating of bevel gear or differential case.

(Check bevel gear for runout)
2) If adjustment is impossible, replace drive bevel gear & pinion
set or differential carrier.
Replace drive bevel gear & pinion set or differential case.

10) Upon completion of gear tooth contact check in Step 9),

caulk flange nut (2) with caulking tool (1) and hammer.

Tightening torque
Fastening part
Nm kg-m lb-ft
Differential oil level/filler plug 50 5.0 36.5
Differential oil drain plug 28 2.8 20.5
Propeller shaft flange bolts 50 5.0 36.5
Differential carrier bolts 55 5.5 40.0
Bevel gear bolts 105 10.5 76.0
Bearing cap bolts 85 8.5 61.5
Lock plate bolts 12 1.2 9.0
Differential case screws 9 0.9 6.5

Material Use
(Part Number)
Thread lock cement THREAD LOCK CEMENT SUPER 1322 Bevel gear bolts
(99000-32110) Differential case bolts
Bevel gear mating surface
Propeller shaft flange bolt
Lithium grease SUZUKI SUPER GREASE A Oil seal lips
(99000-25010)
Sealant SUZUKI BOND NO.1215 Rear differential drain plug
(99000-31110) Mating surface of differential housing
Mating surface of rear axle housing
Special Tool
09900-20606 09900-20701 09913-61510 09922-76570

Dial gauge Magnetic stand Bearing puller Attachment
09913-75510 09913-85230 09922-66021 09922-75222

Bearing installer Bearing removing jig Flange holder Preload checking tool
09924-74510 09925-18011 09926-68310 09926-78311-002

Installer attachment Bearing installer Bearing installer Pinion mounting dummy
(See NOTE.)
09926-78320 09927-66010/J-23082-01 09928-06510 09930-40113

Mounting dummy Oil pump aligner Differential torque checking Rotor holder
tool
09930-40120 09944-66020 09951-16060 09951-18210

Attachment Bearing installer Lower arm bush remover Oil seal remover & installer
No.2
09951-46010
Drive shaft oil seal installer
NOTE:
This tool (09926-78311-002) is one of components for 09926-78311.
INSTRUMENTATION/DRIVER INFORMATION 8C-1
SECTION 8C
6F1
6F2
INSTRUMENTATION/DRIVER INFORMATION
7A
7A1
WARNING:
For vehicles equipped with a Supplemental Restraint (Air Bag) System
7A
7A1
6G
8C
on or around the air bag system components or wiring. Failure to follow WARNINGS could result in 6K
unintentional activation of the system or could render the system inoperative. Either of these two 7F
Technical service work must be started at least 90 seconds after the ignition switch is turned to the 8A
LOCK position and the negative cable is disconnected from the battery. Otherwise, the system 8B
may be activated by reserve energy in the Sensing and Diagnostic Module (SDM). 8C
8D
NOTE: 8E
ual mentioned in FOREWORD of this manual. 9
10
CONTENTS 10A
OTHER THAN CANVAS TOP MODEL .................. * Brake Warning Lamp .......................................... * 10B
General Description ........................................8C-2 Windshield Washer Level Indicator Lamp........... *
Cautions in Servicing .......................................... * Clock/Temp. Display (in BCM)............................ *
Symbols and Marks............................................. * Radio................................................................... *
Abbreviations ...................................................... * CD Player............................................................ *
Wiring Color Symbols.......................................... * Tape Player......................................................... *
Joint Connector ................................................... * Remote Audio Control Switch ............................. *
Fuse Box and Relay ............................................ * On-Vehicle Service .........................................8C-4
Power Supply Diagram ....................................... * BCM-METER Signal Circuit ................................ *
BCM-METER Signal Circuit Construction ........... * Ignition (Main) Switch.......................................... *
Combination Meter ........................................8C-2 Combination Meter.............................................. *
Combination meter internal circuits and Vehicle Speed Sensor (VSS).............................. *
couplers.....................................................8C-2 Fuel Meter/Fuel Gauge Unit..........................8C-4
Diagnosis ............................................................... * Fuel level gauge........................................8C-4
Speedometer and VSS ....................................... * Engine Coolant Temperature (ECT)
Tachometer ......................................................... * Sensor...........................................................8C-4
Engine Coolant Temperature (ECT) Meter ......... * Oil Pressure Switch.......................................8C-4
Main Beam (High Beam) Indicator Lamp ............ * Brake Fluid Level Switch..................................... *
Turn signal Indicator............................................ * Parking Brake Switch.......................................... *
4WD Indicator ..................................................... * Windshield Washer Level Switch........................ *
Low Fuel Warning Lamp ..................................... * Door Switch......................................................... *
Driver Side Seat Belt Reminder .......................... * Seat Belt Buckle Switch ...................................... *
Open Door Warning Lamp .................................. * Audio System...................................................... *
Engine Oil Pressure Indicator ............................. * Radio assembly............................................... *
A/T Selector Position Indicator ............................ * Front speaker .................................................. *
Charge Warning Indicator Lamp ......................... * Sub woofer speaker ........................................ *
O/D OFF Indicator Lamp ..................................... * Remote audio control switch ........................... *
POWER Indicator Lamp ...................................... * Tightening Torque Specification ......................... *
8C-2 INSTRUMENTATION/DRIVER INFORMATION
General Description
Combination Meter
Combination meter internal circuits and couplers
4 4 16 16 16 16 16 16 3
1 2 14
G10-8 G11-12 G11-1 G11-11 G11-10 G10-10 G10-22 G10-21 G10-20 G10-19G10-18G10-17 G10-1
10 11
4WD
7
CPU
8
9
LCD
G11-13 G11-16 G11-6 G11-7 G11-5 G11-8 G10-15 G11-2 G11-3 G11-14 G10-16 G10-9 G10-13 G10-3 G10-6
19 18
20 12 3 3 20 21 15 13 22 13 3 17 3
1. RADIO DOME fuse 7. Fuel meter 13. To ABS control module 19. To lighting switch
2. METER fuse 8. Engine coolant temperature meter 14. Fuel level gauge 20. To BCM
3. To ECM 9. ODO-TRIP meter 15. To SDM 21. To data link connector
4. To turn signal relay 10. Back light 16. To transmission range sensor 22. To TCM
5. Tachometer 11. Meter pointer 17. To 4WD controller
6. Speedometer 12. To VSS 18. Oil pressure switch
COMBINATION METER TERMINAL ARRANGEMENT TABLE

Terminal Wire Color Circuit
G10-1 RED/BLK To ECM (Glow indicator control signal)
G10-2
G10-3 ORN/BLK To 4WD controller (4WD indicator control signal)
G10-4
G10-5
G10-6 PPL/YEL To ECM (MIL indicator control signal)
G10-7
G10-8 GRN/YEL To combination switch (Turn R signal indicator control signal)
G10-9 BLU/ORN To ABS control module (ABS indicator control signal)
G10-10 BLU/WHT To fuel level gauge
G10-11
G10-12
G10-13 BLK/RED To ECM (Engine coolant temperature warning indicator control signal)
G10-14
G10-15 PPL/RED To data link connector
INSTRUMENTATION/DRIVER INFORMATION 8C-3
Terminal Wire Color Circuit

G10-16 WHT/BLK To TCM (O/D OFF indicator control signal)
G10-17 GRN/BLU To transmission range sensor (L range indicator control signal)
G10-18 GRN/ORN To transmission range sensor (2 range indicator control signal)
G10-19 YEL/GRN To transmission range sensor (D range indicator control signal)
G10-20 ORN/BLU To transmission range sensor (N range indicator control signal)
G10-21 RED To transmission range sensor (R range indicator control signal)
G10-22 ORN/GRN To transmission range sensor (P range indicator control signal)
G11-1 WHT To RADIO DOME fuse
G11-2 BLU To SDM (AIR BAG indicator control signal)
G11-3 ORN To ABS control module (EBD warning indicator control signal)
G11-4
G11-5 YEL/WHT To ECM (Engine coolant temperature meter signal)
G11-6 BLU/YEL To VSS (Speedometer signal)
G11-7 BRN To ECM (Tachometer signal)
To BCM (brake fluid level, parking brake, charge warning, washer
G11-8 YEL
level indicator and light switch cognition signal)
G11-9
G11-10 BLK/YEL To fuel level gauge ground
G11-11 BLK/WHT To METER fuse
G11-12 GRN/RED To combination switch (Turn L signal indicator control signal)
G11-13 RED To combination switch (High beam indicator control signal)
G11-14 YEL/BLK To oil pressure switch
G11-15
G11-16 BLK/RED To door switch
G11-17
G11-18
G11-19
G11-20
G10 G11
10 9 2 1
10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3
20 19 12 11
22 21 20 19 18 17 16 15 14 13 12 11 18 17 16 15 14 13
8C-4 INSTRUMENTATION/DRIVER INFORMATION
On-Vehicle Service
Fuel Meter/Fuel Gauge Unit
Fuel level gauge
INSPECTION
Remove fuel level gauge referring to Fuel Level Gauge in Sec-
tion 6C of this manual.
Using an ohmmeter, confirm that resistance of level gauge unit
2 3
changes with change of float position.
Fuel level gauge specification
Float Position
Fuel Meter Resistance
Short Body Long Body
1 Position ()
a Vehicle Vehicle
90.1 mm 55 mm
a F 17 19
b (3.55 in.) (2.17 in.)
157.2 mm 139.6 mm
b 1/2 62 68
c (6.19 in.) (5.50 in.)
254.9 mm 254.9 mm
c E 111 113
(10.04 in.) (10.04 in.)
If measured valve is out of specification, replace fuel lever gauge.
1. Fuel level gauge
2. Fuel level gauge (+) terminal
4 3. Fuel level gauge () terminal
4. Float
Engine Coolant Temperature (ECT) Sensor

REMOVAL, INSPECTION AND INSTALLATION
Refer to Engine Coolant Temperature (ECT) Sensor in Section
6E3.
Oil Pressure Switch

REMOVAL AND INSTALLATION
Refer to Oil Pressure Switch in Section 6A3 of this manual for
details.
INSPECTION
Check oil pressure switch (1) for continuity using an ohmmeter.

If check result is not satisfactory, replace oil pressure switch.
During Engine Running No continuity ( )
At Engine Stop Continuity (0 )
2. Cylinder block
IMMOBILIZER CONTROL SYSTEM 8G-1
SECTION 8G
IMMOBILIZER CONTROL SYSTEM

WARNING:
8G
CONTENTS
General Description ....................................... 8G-2 DTC31 Transponder Code Not

Wiring Circuit ................................................ 8G-3 Registered...................................................8G-10
Ignition Key .................................................. 8G-4 DTC12 Fault in Immobilizer
Coil Antenna................................................. 8G-4 Control Module............................................8G-11
Immobilizer Control Module.......................... 8G-4 DTC13 No Transponder Code
ECM ............................................................. 8G-4 Transmitted from Ignition Key .....................8G-11
On-board Diagnostic System DTC14 Coil Antenna Circuit Malfunction ....8G-11
(Self-diagnosis Function) ............................. 8G-5 DTC41 ECM Not Registered.......................8G-13
Diagnosis ........................................................ 8G-6 DTC42 Serial Data Circuit Malfunction
(Between Immobilizer Control Module
Precautions in Diagnosing Troubles ............ 8G-6
and ECM)....................................................8G-14
Precautions in identifying diagnostic
DTC43 ECU Code Not Matched .................8G-15
trouble code.............................................. 8G-6
Inspection of Immobilizer Control Module
Notes on system circuit inspection ........... 8G-6
and Its Circuit ..............................................8G-16
Precaution after Replacing ECM or
Immobilizer Control Module.......................... 8G-6 On-Vehicle Service .......................................8G-18
Immobilizer Control System Diagnostic Precautions in Handling Immobilizer
Flow Table.................................................... 8G-7 Control System ...........................................8G-18
Diagnostic Trouble Code (DTC) Check Immobilizer Control Module ........................8G-19
(Immobilizer Control Module) ....................... 8G-8 Coil Antenna ...............................................8G-19
Diagnostic Trouble Code Table.................... 8G-8 How to Register Ignition Key.......................8G-20
Table A Scan Tool Can Not Procedure after Immobilizer Control
Communicate with Immobilizer Module Replacement ..................................8G-21
Control Module ............................................. 8G-9 Procedure after ECM Replacement ............8G-22
DTC11 Transponder Code Not Special Tools.................................................8G-23
Matched ..................................................... 8G-10
8G-2 IMMOBILIZER CONTROL SYSTEM
General Description
The immobilizer control system is designed to prevent vehicle burglar and consists of following components.
Engine Control Module (ECM)
Immobilizer Control Module
Ignition key (with built-in transponder)
Coil antenna
Operation of this system is as follows.

i) Each ignition key has its own Transponder code stored in memory. When the ignition switch is turned ON,
Immobilizer Control Module tries to read the Transponder code through the coil antenna installed to the
steering lock assembly.
ii) Immobilizer Control Module compares the Transponder code read in (i) and that registered in Immobilizer
Control Module and checks if they match.
iii) When it is confirmed that two Transponder codes match in Step (ii), Immobilizer Control Module and ECM
check if ECU codes registered in them respectively match.
iv) Only when it is confirmed that ECU codes match, engine can be started (immobilizer system unlocked).
If Transponder codes in Step (ii) or ECU codes in Step (iii) do not match, ECM will stop operation of the
injectors.
ii)
i) Immobilizer
Transponder Control
Code Module
iii)
iv)
5
1. Coil antenna 4. Immobilizer Control Module

2. Ignition key 5. ECM
3. Data link connector (DLC)
Wiring Circuit
4
WHT G09-3
5
7 G09-7 GRN E227-28
BLK/WHT G09-8
G09-1 PNK PNK E227-10
6 G09-6 PNK
BLK G08-1
BLK G08-3
G09-5 PPL/WHT 8
BLK G09-4
1
2 3
1. Coil antenna 5. Ignition switch

2. Immobilizer Control Module 6. Main fuse
3. ECM 7. IG METER fuse
4. DOME fuse 8. To data link connector
Ignition Key
The ignition key (1) for the immobilizer control system has a built-
in transponder. Each transponder in the key has an each trans-
mitting code (Transponder code). The code will transmitted from
the key via the coil antenna to Immobilizer Control Module when
the ignition switch is turned ON.
Coil Antenna
The coil antenna (1) is installed to the steering lock assembly. As
it is energized by Immobilizer Control Module, it transmits the
transponder code of the ignition key to Immobilizer Control Mod-
ule.

Immobilizer Control Module (1) is installed to the underside of the
instrument panel at the drivers seat side.
As main functions, Immobilizer Control Module checks matching
not only between the Transponder Code transmitted from the igni-
tion key and that registered in Immobilizer Control Module (Up to
four different Transponder codes can be registered.) but also
between the ECU code transmitted from ECM and that registered
in Immobilizer Control Module. In addition, it has an on-board
1 diagnostic system (self-diagnosis function) which is described in
the following page.
ECM
ECM checks matching of ECU code transmitted from Immobilizer
Control Module and ECU code registered in ECM. After confirma-
tion of ECU codes, ECM is ready to start engine.
On-board Diagnostic System

(Self-diagnosis Function)
Immobilizer Control Module diagnoses troubles which may occur
in the area including the following parts when the ignition switch is
ON. It indicates the diagnosis result on SUZUKI scan tool.
Ignition key (Transponder code)

Coil antenna
Serial data circuit between Immobilizer Control Module and
ECM
Immobilizer Control Module (Transponder code or ECU
code)
ECM (ECU code)
Diagnosis
Immobilizer Control Module have on-board diagnostic system (self-diagnosis function) as described previously.
Investigate where the trouble is by referring to Immobilizer Control System Diagnostic Flow Table and Diag-
nostic Trouble Code Table in this section.
Precautions in Diagnosing Troubles

Precautions in identifying diagnostic trouble code
Take a note of diagnostic trouble code indicated first.
Note on system circuit inspection

Refer to Precautions for Electrical Circuit Service and Intermittents and Poor Connection in Section 0A.
Precautions after Replacing ECM or Immobilizer Control Module

When ECM was replaced the ECM codes must be registered in ECM and Immobilizer Control Module by
performing procedure described in Procedure after ECM Replacement in this section. If it is not registered,
ECM would not function as Immobilizer Control System and accurate trouble diagnosis would not be
assured.
When Immobilizer Control Module was replaced, including when replaced because rechecking by using a
known-good Immobilizer Control Module was necessary during trouble diagnosis, the Transponder code and
ECM code must be registered in Immobilizer Control Module by performing procedure described in Proce-
dure after Immobilizer Control Module Replacement in this section. If they are not registered, the engine
would not start and accurate trouble diagnosis would not be assured.
Immobilizer Control System Diagnostic Flow Table
NOTE:
After replacing with Immobilizer Control Module and/or ECM, register Transponder code and ECU
code according to Procedure after Immobilizer Control Module Replacement or Procedure after
ECM Replacement. Otherwise, Immobilizer control system will not be in operation.
Step Action Yes No
1 Turn ignition switch to start engine. Immobilizer control Go to Step 2.
Dose engine run? system is in good con-
dition.
2 Check DTC stored in Immobilizer Control Mod- Go to flow table for Go to Step 3.
ule referring to Diagnostic Trouble Code (DTC) DTC No.
Check in this section.
Are there DTC Nos 13 and/or 14?
3 Is there DTC No.12? Go to flow table for Go to Step 4.
DTC No.
4 Are there DTC Nos 11 and/or 31? Go to flow table for Go to Step 5.
DTC No.
5 Are there DTC No.41, 42 or 43? Go to flow table for Substitute a known-good
DTC No. Immobilizer Control Module.
Then, perform Procedure
after Immobilizer Control
Module Replacement in this
section.
6 Turn ignition switch to start engine. Immobilizer control Go to Engine Diagnosis
Dose engine run? system is in good con- Table in Section 6-1.
dition.

(Immobilizer Control Module)
2) After setting program card to SUZUKI scan tool, connect it to
data link connector (DLC) (1) located on underside of instru-
ment panel at drivers seat side.
Special tool
3) Turn ignition switch OFF for 10 seconds and then ON.
NOTE:
When the ignition switch is turned off and then on again
1
within 10 seconds, DTC41 is stored in the Immobilizer
Control Module.
4) Read DTC stored in Immobilizer Control Module according
(A)
to instructions displayed on SUZUKI scan tool.
If SUZUKI scan tool indicates ECU NO RESPONSE, go to
Diagnostic Flow Table A.
NOTE:
For operation procedure of SUZUKI scan tool, refer to
operators manual for SUZUKI scan tool.
5) After completing the check, turn ignition switch OFF and dis-
connect SUZUKI scan tool from data link connector (DLC).
Diagnostic Trouble Code Table

IMMOBILIZER CONTROL MODULE
DIAGNOSTIC
TROUBLE DTC DESCRIPTION DIAGNOSIS
CODE NO.
This code appears when none of the
NO DTC
other codes are identified.
11 Transponder code not matched
12 Fault in Immobilizer Control Module
13 No transponder code transmitted from ignition key
14 Coil antenna circuit malfunction Diagnose trouble according to Immobi-
31 Transponder code not registered lizer Control System Diagnostic Flow
41 ECM not registered Table corresponding to each code No.
Serial data circuit (between Immobilizer Control
42
Module and ECM)
43 ECU code not matched
NOTE:
When the ignition switch is turned off and then on again within 10 seconds, DTC 41 is stored in the
Immobilizer Control Module.
If any DTC other than DTC 41 is stored in the Immobilizer Control Module, the immobilizer system is
locked (engine unable to start).
Table A Scan Tool Can Not Communicate with Immobilizer Control Module
6
WHT G09-3
G09-5 PPL/WHT
2 5
BLK/WHT G09-8
1
4
BLK G09-4
3 2 1
8 7 6 5 4 3 2 1
G09 G08
1. Main fuse 4. Data link connector (DLC)

2. Ignition switch 5. IG METER fuse
3. Immobilizer Control Module 6. DOME fuse
NOTE:
Before inspection, make sure if SUZUKI scan tool is free from any malfunction and if correct PC card
is used. Also, make sure if SUZUKI scan tool is properly connected to DLC.
INSPECTION:
Step Action Yes No

1 Check voltage between G09-8 terminal Go to Step 2. BLK/WHT wire
and body ground with ignition switch ON. open
Is it 10 14 V? IG METER fuse
broken
2 Check voltage between G09-3 terminal Go to Step 3. WHT wire open
and body ground. DOME fuse bro-
Is it 10 14 V? ken
3 Is there continuity between G09-4 Go to Step 4. BLK wire open
terminal and body ground?
4 Check voltage between PPL/WHT wire Poor G09-8, G09-3, G09-4 or G09- PPL/WHT wire
terminal of DLC and body ground with 5 connection. open
ignition switch ON. If connection and line are OK,
Is it 4 5 V? substitute a known-good Immobilizer
Control Module and recheck.
DTC11 Transponder Code Not Matched

DTC31 Transponder Code Not Registered
DESCRIPTION:
Immobilizer Control Module checks if Transponder code transmitted from ignition key and that registered in
Immobilizer Control Module match when ignition switch is ON. If they do not, DTC 11 and 31 are set.
INSPECTION:
Step Action Yes No

1 Was Immobilizer Control System Diagnostic Go to Step 2. Go to Immobilizer
Flow Table performed? Control System Diag-
nostic Flow Table.
2 Check that knob shape of ignition key being Register ignition key in Replace ignition key.
used is the same as shown in Fig. 1. Immobilizer Control Module
Is it ignition key with built-in transponder (1)?
according to the procedure
described in How to
Register Ignition Key. Then,
go to Step 3.
3 Read DTC according to Diagnostic Trouble Replace ignition key. Go to Immobilizer
Code Check section. Control System Diag-
Does SUZUKI scan tool indicate DTC 11 and/or nostic Flow Table.
31 again?
Fig. 1 for Step 2
1
DTC12 Fault in Immobilizer Control Module

DESCRIPTION:
This DTC is set when an internal fault is detected in Immobilizer Control Module.
INSPECTION:
Step Action Yes No

nostic Flow Table.
2 1) Ignition switch OFF. Substitute a known-good Repair or replace
2) Disconnect connectors from Immobilizer Immobilizer Control Module
Control Module. and recheck.
3) Check for proper connection to Immobilizer
Control Module at all terminals.
DTC13 No Transponder Code Transmitted from Ignition Key

DTC14 Coil Antenna Circuit Malfunction
BLK G08-1
BLK G08-3
1. Immobilizer Control Module

2. Coil antenna
DESCRIPTION:
Immobilizer Control Module energizes the coil antenna when the ignition switch is ON and reads Transponder
code from the ignition key. When Immobilizer Control Module cannot read Transponder code from the ignition
key even when the coil antenna is energized, DTC 13 and 14 are set.
INSPECTION:
Step Action Yes No

nostic Flow Table.
2 1) Disconnect coil antenna coupler with igni- Go to Step 3. Coil antenna open.
2) Is there continuity between coil antenna
coupler terminals G08-1 and G08-3? (See
Fig. 1)
3 Measure resistance between terminals of coil Go to Step 4. Coil antenna shorted
antenna coupler and body ground. (See Fig. 2) to ground.
Is it (infinity) ?
4 Poor G08-1 or G08-3 connection. Substitute a known-good Faulty coil antenna.
1) If connections are OK, substitute a known- Immobilizer Control Module
good coil antenna. and recheck.
2) Is DTC 13 and/or 14 also indicated with
ignition switch turned ON?
[A] Fig. 1 for Step 2 / [B] Fig. 2 for Step 3
1. Coil antenna coupler

DTC41 ECM Not Registered
1 2
G09-7 GRN E227-28
1. ECM
DESCRIPTION:
Immobilizer Control Module checks whether immobilizer control system is locked with ignition switch OFF. If the
system is unlocked, DTC 41 is set.
INSPECTION:
Step Action Yes No

nostic Flow Table.
2 1) Disconnect ECM coupler. Go to Step 3. GRN wire open or,
2) Disconnect coupler at Immobilizer Control Poor G09-7 terminal
Module. connection.
3) Is there continuity between G09-7 of Immo-
bilizer Control Module coupler and E227-28
in coupler of ECM?
See Fig. 1.
3 1) Check resistance between G09-7 of Immo- Poor G09-7 and E227-28 GRN wire shorted to
bilizer Control Module coupler and body terminal connection. ground.
ground. See Fig.1. If all above are OK, register
Is it infinity ()? ECU code in ECM according
to Procedure after ECM
Replacement section. And
then go to Step 4.
4 1) Read DTC according to Diagnostic Trouble Substitute a known-good Go to Immobilizer
Code Check section. ECM and recheck. Control System Diag-
Does SUZUKI scan tool indicate DTC 41 nostic Flow Table.
again?
Fig. 1 for Step 2 and 3
1. ECM coupler
2. Immobilizer Control Module connector
DTC42 Serial Data Circuit Malfunction (Between Immobilizer Control Module

and ECM)
1 2
G09-1 PNK PNK E227-10
G09-6 PNK

2. ECM
DESCRIPTION:
If ECU code is not transmitted from ECM, Immobilizer Control Module sets DTC42.
INSPECTION:
Step Action Yes No

nostic Flow Table.
2 1) Disconnect coupler at Immobilizer Control Substitute a known-good PNK wire open
Module. Immobilizer Control Module shorted to ground.
2) Check for proper connection to Immobilizer and recheck. or
Control Module at each terminal. Poor C51-36 or
If OK, check voltage between coupler termi- E227-10 terminal
nal below and body ground with ignition connection.
switch ON. See Fig.1. If all above are OK,
G09-6 and body ground substitute a known-
G09-1 and body ground good ECM and
Are they 10 14 V? recheck.
Fig. 1 for Step 2
1. Immobilizer Control Module coupler
DTC43 ECU Code Not Matched

DESCRIPTION:
Immobilizer Control Module and ECM check if ECU codes registered in them respectively match. If the codes do
not match, Immobilizer Control Module sets DTC 43.
INSPECTION:
Step Action Yes No

nostic Flow Table.
2 1) Register ECU code in Immobilizer Control Faulty ECM. Go to Immobilizer
Module according to Procedure after Control System Diag-
Immobilizer Control Module Replacement nostic Flow Table.
section.
2) Read DTC according to Diagnostic Trouble
Code Check section.
Does SUZUKI scan tool indicate DTC 43
again?
Inspection of Immobilizer Control Module and

Its Circuit
Immobilizer Control Module and its circuit can be checked at
Immobilizer Control Module wiring coupler by measuring voltage
and resistance. Described here is only inspection of Immobilizer
Control Module.
CAUTION:
Immobilizer Control Module cannot be checked by itself.
It is strictly prohibited to connect voltmeter or ohmmeter
to Immobilizer Control Module with coupler disconnected
from it.
VOLTAGE CHECK
1) Remove Immobilizer Control Module (1) from body with igni-

tion switch OFF referring to Immobilizer Control Module in
this section.
2) Connect Immobilizer Control Module couplers (2) to Immobi-
lizer Control Module (1).
3) Check voltage at each terminal of couplers connected.
NOTE:
is ON.
3. Body ground
Terminal Circuit Normal Voltage Condition

G08-1 Coil antenna + 0V Ignition switch ON
G08-2
G08-3 Coil antenna 0V Ignition switch ON
Serial data line between ECM and
G09-1 10 14 V Ignition switch ON and OFF
G09-2
G09-3 Power supply 10 14 V Ignition switch ON and OFF
G09-4 GND
Serial data line between SUZUKI scan
G09-5 45V Ignition switch ON and OFF
tool and Immobilizer Control Module
Serial data line between ECM and
G09-6 10 14 V Ignition switch ON and OFF
G09-7 Power control of ECM 0V Ignition switch ON and OFF
0V Ignition switch OFF
G09-8 Ignition signal
10 14 V Ignition switch ON
NOTE:
When measuring voltage at G08-1 and G08-3 terminals with ignition switch turned ON, be sure to turn
ignition switch ON before connecting positive probe of voltmeter to G08-1 or G08-3 terminal. If it is not
turned ON first, DTC13 (Diagnostic Trouble Code 13) may be indicated.
RESISTANCE CHECK
1) Disconnect Immobilizer Control Module coupler from Immo-

bilizer Control Module with ignition switch OFF.
CAUTION:
Do not touch terminals of Immobilizer Control Module
itself or connect voltmeter or ohmmeter.
2) Check resistance between each terminal of coupler discon-

nected.
CAUTION:
Be sure to connect ohmmeter probe from wire harness
side of coupler.
Resistance in table below represents that when parts
temperature is 20 C (68 F).
1. Immobilizer Control Module coupler disconnected
2. Ohmmeter
Terminal Circuit Normal Resistance Condition

G08-1 G08-3 Coil antenna Continuity
On-Vehicle Service
Precautions in Handling Immobilizer Control
System
Dont turn ON ignition switch with ignition key for immobilizer
control system put together with another one or placed quite
close to another one. Or the system may detect abnormal
condition and prevent engine from starting.
Do not turn ON ignition switch by using ignition key with any

type of metal wound (1) around its grip or in contact with it.
Or the system may detect abnormal condition and prevent
engine from starting.
1
Do not leave ignition key where high temperature is antici-

pated. High temperature will cause transponder in ignition
key to be abnormal or damaged.
Do not turn ON ignition switch with a radio antenna placed

near coil antenna or its harness to Immobilizer Control Mod-
ule. Or the system may detect abnormal condition and pre-
vent engine from starting.

REMOVAL
2) Remove steering column hole cover.
3) Disconnect couplers.
4) Remove Immobilizer Control Module (1).
INSTALLATION
NOTE:
After replacing Immobilizer Control Module, be sure to
register Transponder code and ECU code in Immobilizer
1
Control Module by performing procedure described in
Procedure after Immobilizer Control Module Replace-
ment.
Coil Antenna
REMOVAL

2) Remove steering column upper and lower cover (1) by
removing three screws.
3) Remove steering column hole cover.
4) Remove coil antenna (1).
INSTALLATION
How to Register Ignition Key

Register the ignition key with a built-in transponder in Immobilizer
Control Module by using the following procedure.
1) Prepare SUZUKI scan tool.
2) With ignition switch OFF, connect SUZUKI scan tool to data
link connector (DLC) (1) located on underside of instrument
panel at drivers seat side.
Special tool
NOTE:
1
For operation procedure of SUZUKI scan tool, refer to
operators manual for SUZUKI scan tool.
(A)
3) Prepare ignition key with a built-in transponder (1). And then

turn ignition switch ON by using it.
4) Number of Transponder codes for ignition key with a built-in
transponder that can be registered in Immobilizer Control
Module is limited to four. If needed, clear all Transponder
codes for ignition key with a built-in transponder that have
been registered in Immobilizer Control Module by using
1 SUZUKI scan tool.
NOTE:
When clearing Transponder code(s) while no DTC is
stored in the immobilizer control module, the immobilizer
system remains unlocked. The immobilizer system
changes into the locked state if the ignition switch is
turned off for 10 seconds or longer and then turned on.
5) Using SUZUKI scan tool, register Transponder code in
6) Make sure that no DTC is displayed on SUZUKI scan tool
after ignition switch is turned OFF for 10 seconds or more
and then ON.
7) If any other Transponder code for ignition key with a built-in
transponder needs to be registered, repeat above Steps 3),
5) and 6).
NOTE:
Up to four Transponder codes for ignition key with a
built-in transponder can be registered.
It is not possible to register the Transponder code
which is already registered in Immobilizer Control
Module.
Procedure after Immobilizer Control Module

Replacement
When Immobilizer Control Module was replaced, including when
replaced because rechecking by using a known-good Immobilizer
Control Module was necessary during trouble diagnosis, register
Transponder code and ECU code in Immobilizer Control Module
by performing following procedure.
1) Perform Steps 1) and 2) described in How to Register Igni-
tion Key in this section.
2) Prepare ignition key with a built-in transponder. And then
turn ignition switch ON by using it.
3) Using SUZUKI scan tool, clear all transponder codes regis-
tered in Immobilizer Control Module.
NOTE:
When clearing Transponder code(s) while no DTC is
stored in the immobilizer control module, the immobilizer
system remains unlocked. The immobilizer system
changes into the locked state if the ignition switch is
turned off for 10 seconds or longer and then turned on.
4) Using SUZUKI scan tool, register Transponder code in
5) Using SUZUKI scan tool, register ECU code in Immobilizer
Control Module.
CAUTION:
In the process of the code registration, SUZUKI scan tool
requires VIN to be entered. When entering VIN, make
sure to follow the procedure described in operators man-
ual for SUZUKI scan tool. Incorrect VIN will cause the
immobilizer system to be locked (engine does not start
up).
and then ON.
7) If any other Transponder code for ignition key with a built-in
transponder needs to be registered, repeat above Steps 2),
4) and 6).
NOTE:
Up to four Transponder codes for ignition key with a
built-in transponder can be registered.
It is not possible to register the Transponder code
which is already registered in Immobilizer Control
Module.
Procedure after ECM Replacement
CAUTION:
After replacing the ECM with a new one whose ECU code
has not been registered, be sure to register it according
to the following procedure. Without registration, the
immobilizer system does not operate properly.
NOTE:
ECU code can be registered to the ECM only once.
If both Immobilizer Control Module and ECM are
replaced at the same time, execute Procedure after
Immobilizer Control Module Replacement first and
then Procedure after ECM Replacement.
When ECM was replaced, register ECU code in ECM by perform-

ing following procedure.
1) Perform Steps 1) and 2) described in How to Register Igni-
tion Key in this section, and then turn ignition switch ON.
2) Using SUZUKI scan tool, register ECU code in ECM.
NOTE:
Turn on and off the ignition switch according to the
instructions that appear on the screen of SUZUKI scan
tool.
It takes 1 minute (max) until registration of ECU code
to the ECM is completed.
and then ON.
Special Tools
Tech 2 kit (SUZUKI scan tool)

See NOTE below.
NOTE:
1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE16/19 adapter, 5. Cigarette cable, 6. DLC loopback
adapter, 7. Battery power cable, 8. RS232 cable, 9. RS232 adapter, 10. RS232 loopback connector, 11.
Storage case, 12. Power supply
Prepared by
1st Ed. Jan, 2004
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What are some important warnings mentioned in the manual?

What are some important warnings mentioned in the manual?

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Important

Manual Name Manual No.

COPYRIGHT SUZUKI MOTOR CORPORATION 2004

Before starting any service work, cover fenders, seats

When performing service to electrical parts that does

When removing the battery, be sure to disconnect the

When removing parts that are to be reused, be sure to

Whenever you use oil seals, gaskets, packing, O-rings,

Make sure that all parts used in reassembly are perfectly

Be sure to use special tools when instructed.

When disconnecting vacuum hoses, attach a tag

After servicing fuel, oil, coolant, vacuum, exhaust or

For vehicles equipped with fuel injection systems, never

Be sure to use engine hooks (1) for hanging engine.

Engine Identification Number

Transmission Identification Number

Warning, Caution and Information Labels

MAINTENANCE AND LUBRICATION

Maintenance Schedule ...................................0B-2 Clutch .............................................................. *

Maintenance Recommended Under Severe Driving Conditions

GENERATOR DRIVE BELT INSPECTION

GENERATOR DRIVE BELT REPLACEMENT

AIR CONDITIONING COMPRESSOR DRIVE BELT INSPEC-

AIR CONDITIONING COMPRESSOR DRIVE BELT

Camshaft timing belt

Engine oil and oil filter

It is recommended to use the following engine oil or higher quality

4) Apply engine oil to new oil filter O-ring.

6) Tighten filter (1) to specified torque.

1) Remove degassing tank cap when engine is cool.

4) Fill cooling system with specified coolant through degassing

Check exhaust system as follows:

Heater (Glow) plugs

1) Unclamp air cleaner case clamps.

Fuel lines and connections

WATER DRAINING OF FUEL FILTER

Chassis and Body

Automatic transmission fluid

1) Inspect transmission case for evidence of fluid leakage.

FLUID COOLER HOSE INSPECTION

Check automatic transmission fluid cooler hose for fluid leakage,

Power steering (P/S) system (if equipped)

1) Visually check power steering system for fluid leakage and

2) With engine stopped, check fluid level indicated on fluid tank,

3) Visually check pump drive belt for cracks and wear.

Recommended Fluids and Lubricants

HEATER AND VENTILATION 1A

Condition Possible Cause Correction

5) Remove passenger lower member (1).

6) Remove A/C controller with bracket from blower unit.

8) Disconnect air intake actuator coupler.

Check for continuity between terminal to terminal as shown

Connect battery to the blower motor as shown, and then

Check if there is continuity between supplementary heater

Supplementary heater No.2

5) Disconnect supplementary heater No.2 lead wire (1) at cou-