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MARUTI SUZUKI Wagon R, Manual

The Maruti Suzuki Wagon R user manual is essential for any Wagon R owner. Easily accessible and free to download from manualshive.com, this comprehensive manual provides detailed instructions, troubleshooting tips, and valuable insights to maximize the driving experience. Get your hands on this must-have manual today!

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Table of Contents 0- i

0

Section 0

CONTENTS

General Information

General Information ................................ 0A-1

General Description .............................................0A-1

Abbreviations ...................................................... 0A-1
Symbols .............................................................. 0A-2
Wire Color Symbols ............................................ 0A-3
Fasteners Information ......................................... 0A-3
Vehicle Lifting Points........................................... 0A-6
Vehicle Identification Number ............................. 0A-8
Engine Identification Number.............................. 0A-8
LPG Compliance Plate........................................ 0A-8

Component Location ...........................................0A-9

Warning, Caution and Information Labels 

Location ............................................................ 0A-9

Maintenance and Lubrication................. 0B-1

Precautions...........................................................0B-1

Precautions for Maintenance and Lubrication..... 0B-1

Scheduled Maintenance ......................................0B-1

Maintenance Schedule under Normal Driving 

Conditions (Petrol Model) ................................. 0B-1

Periodic Maintenance Schedule (Bi-Fuel LPG 

Model) ............................................................... 0B-3

Repair Instructions ..............................................0B-3

Accessory Drive Belt Inspection...........................0B-*
Accessory Drive Belt Replacement......................0B-*
Valve Lash (Clearance) Inspection ......................0B-*
Engine Oil and Filter Change...............................0B-*
Engine Coolant Change .......................................0B-*
Exhaust System Inspection..................................0B-*
Spark Plug Replacement .....................................0B-*
Air Cleaner Filter Inspection.................................0B-*

Air Cleaner Filter Replacement ........................... 0B-*

Fuel Lines and Connections Inspection ..............0B-3
Fuel Tank Inspection...........................................0B-3
Fuel Filter Replacement ......................................0B-3

PCV Valve Inspection ......................................... 0B-*

LPG Leakage Inspection.....................................0B-3
LPG Fuel Filter Replacement..............................0B-3

Receptacle O-Ring Replacement........................ 0B-*

LPG Cylinder Inspection .....................................0B-4
LPG Fuel Pressure Regulator Filter 

Replacement .....................................................0B-4

Fuel Evaporative Emission Control System 

Inspection.......................................................... 0B-*

Brake Discs and Pads Inspection ....................... 0B-*
Brake Drums and Shoes Inspection.................... 0B-*
Brake Hoses and Pipes Inspection ..................... 0B-*
Brake Fluid Replacement.................................... 0B-*
Parking Brake Lever and Cable Inspection......... 0B-*
Clutch Pedal Inspection ...................................... 0B-*
Tires Inspection................................................... 0B-*
Wheel Inspection................................................. 0B-*
Wheel Bearing Inspection ................................... 0B-*
Suspension System Inspection ........................... 0B-*
Steering System Inspection ................................ 0B-*
Drive Shaft (Axle) Boots Inspection .................... 0B-*
Manual Transaxle Oil Inspection......................... 0B-*
Manual Transaxle Oil Replacement .................... 0B-*
All Latches, Hinges and Locks Inspection........... 0B-*
Final Inspection for Maintenance Service ........... 0B-*

Special Tools and Equipment ............................. 0B-*

Recommended Fluids and Lubricants................. 0B-*

NOTE
For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual 
mentioned in the “FOREWORD” of this manual.

Summary of Contents for Wagon R

Page 1: ...es 4C Parking Brake 4D ABS 4E Transmission Transaxle 5 Precautions 5 Manual Transmission Transaxle 5B Clutch 5C Steering 6 Precautions 6 Steering General Diagnosis 6A Steering Wheel and Column 6B Power Assisted Steering System 6C HVAC 7 Precautions 7 HVAC System 7B Restraint 8 Precautions 8 Seat Belts 8A Air Bag System 8B Body Cab and Accessories 9 i Precautions 9 Wiring Systems 9A 1 Lighting Syst...

Page 2: ......

Page 3: ...ling Mobile Communication Equipment 00 6 Precaution for CAN Communication System 00 6 Precaution for Installing Wiring Harness 00 6 Precautions for Electrical Circuit Service 00 7 Air Bag Warning 00 9 LPG Warning 00 9 Fastener Caution 00 9 Suspension Caution 00 9 Wheels and Tires Caution 00 9 ABS Caution 00 10 Brake Caution 00 10 Repair Instructions 00 10 Electrical Circuit Inspection Procedure 00...

Page 4: ...during a paint baking process remove the air bag system components beforehand to avoid component damage or unintended air bag system activation Diagnosis When troubleshooting air bag system be sure to follow Diagnosis in Air Bag System section Bypassing these procedures may result in extended diagnostic time incorrect diagnosis and incorrect parts replacement Never use electrical test equipment ot...

Page 5: ...ust be carefully torqued and the arrow must be pointing toward the front of the vehicle to ensure proper operation of the air bag system The SDM could be activated when powered while not rigidly attached to the vehicle which could cause deployment and result in personal injury Even when the accident was light enough not to cause air bags to activate be sure to inspect system parts and other relate...

Page 6: ... LPG pipes or hoses should not be repaired in all cases they should be replaced Welding brazing and the application of heat should not be carried out on any part of the LPG cylinder subsequent to manufacture Make sure to relieve LPG pressure before removing LPG pipes or hoses Check for fuel leakage after installing them The LPG cylinder piping and all components of the system should be examined fo...

Page 7: ... of these service materials It would cause diarrhea or nausea Keep all these materials out of children s reach 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 du...

Page 8: ...pecial tools when instructed Special tool A 09917M98221 B 09916M58210 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 Never disconnect the fuel line between the fuel pump and injector without first...

Page 9: ...mpty Precautions for Installing Mobile Communication Equipment AENAR90A0000006 When installing mobile communication equipment such as CB Citizens Band radio or cellular telephone be sure to observe the following precautions Failure to follow cautions may adversely affect electronic control system Keep the antenna as far away as possible from the vehicle s electronic control unit Keep the antenna f...

Page 10: ...ctor lock first and then pull them apart by holding connectors themselves When connecting connectors also hold connectors and put them together until they lock securely a click is heard When installing the wiring harness fix it with clamps so that no slack is left When installing vehicle parts be careful so that the wiring harness is not interfered with or caught by any other part To avoid damage ...

Page 11: ...ital type voltmeter When taking measurements at electrical connectors using a tester probe be sure to insert the probe 2 from the wire harness side backside of the connector 1 When connecting meter probe 2 from terminal side of connector 1 because it can t be connected from harness side use extra care not to bend male terminal of connector of force its female terminal open for connection In case o...

Page 12: ...he same location from which they were removed If a fastener needs to be replaced use the correct part number fastener for that application If the correct part number fastener is not available a fastener of equal size and strength or stronger may be used Fasteners that are not reused and those requiring thread locking compound will be called out The correct torque value must be used when installing...

Page 13: ...for the open circuit are as follows As the cause is in the connector or terminal in many cases they need to be checked particularly carefully Loose connection of connector Poor contact of terminal due to dirt corrosion or rust on it poor contact tension entry of foreign object etc Wire harness being open When checking system circuits including an electronic control unit such as ECM ABS control mod...

Page 14: ...s shown in the figure and results were as listed in the following it means that the circuit is open between terminals B 1 and A 1 Voltage between C 1 and body ground Approx 5 V B 1 and body ground Approx 5 V A 1 and body ground 0 V b Also if measured values were as listed in the following it means that there is a resistance abnormality of such level that corresponds to the voltage drop in the circ...

Page 15: ...rt or corrosion on the terminals The terminals must be clean and free of any foreign material which could impede proper terminal contact However cleaning the terminal with a sand paper or the like is prohibited Damaged connector body exposing the terminals to moisture and dirt as well as not maintaining proper terminal orientation with the component or mating connector Improperly formed or damaged...

Page 16: ...e insulation This condition could cause continuity check to show a good circuit but if only 1 or 2 strands of a multi strand type wire are intact resistance could be far too high If any abnormality is found repair or replace Special Tools and Equipment Recommended Service Material AENAR90A0008001 Special Tool AENAR90A0008002 I2RH01010059 01 I2RH01010060 01 Material SUZUKI recommended product or Sp...

Page 17: ...r Cleaner Filter Replacement 0B Fuel Lines and Connections Inspection 0B 3 Fuel Tank Inspection 0B 3 Fuel Filter Replacement 0B 3 PCV Valve Inspection 0B LPG Leakage Inspection 0B 3 LPG Fuel Filter Replacement 0B 3 Receptacle O Ring Replacement 0B LPG Cylinder Inspection 0B 4 LPG Fuel Pressure Regulator Filter Replacement 0B 4 Fuel Evaporative Emission Control System Inspection 0B Brake Discs and ...

Page 18: ...le Code E EBD Electronic Brake Force Distribution ECM Engine Control Module ECT Engine Coolant Temperature ECU Electronic Control Unit EEPROM Electrically Erasable Programmable Read Only Memory EFE Heater Early Fuel Evaporation Heater EGR Exhaust Gas Recirculation EGT Exhaust Gas Temperature ELR Emergency Locking Retractor EOP Engine Oil Pressure EPS Electronic Power Steering ESP Electronic Stabil...

Page 19: ...arm Up Three Way Catalytic converter Other 2WD 2 Wheel Drive 4WD 4 Wheel Drive NOTE DPF is a trademark of HJS Fahrzeugtechnik GmbH Co KG and Suzuki is the trade mark licensee ESP is registered trademark of Daimler AG Symbols AENAR90A0101002 Symbol Definition Symbol Definition Tightening torque SUZUKI Bond No 1207B 99000 31140 Apply oil engine transmission transfer differential A C compressor etc S...

Page 20: ...steners When replacing any fasteners it is most important that replacement fasteners be the correct diameter thread pitch and strength CAUTION Even when the nominal diameter 1 of thread is the same the thread pitch 2 or the width across flats 3 may vary between ISO and JIS Refer to JIS TO ISO Main Fasteners Comparison Table below for the difference Installing a mismatched bolt or nut will cause da...

Page 21: ...olts and nuts of the same strength or greater than the original fasteners the same number marking or higher It is likewise important to select replacement fasteners of the correct diameter and thread pitch Correct replacement bolts and nuts are available through the parts division Metric bolts Identification class numbers or marks correspond to bolt strength increasing numbers represent increasing...

Page 22: ... 5 48 0 77 5 118 0 A equivalent of 6 8 strength fastener without flange N m 2 4 4 7 8 4 20 42 80 125 193 280 kgf m 0 24 0 48 0 86 2 0 4 3 8 2 12 7 19 7 28 6 lbf ft 2 0 3 5 6 5 15 0 31 0 59 0 92 5 142 5 206 5 A equivalent of 6 8 strength fastener with flange Self lock nut 6 strength N m 2 4 4 9 8 8 21 44 84 133 203 298 kgf m 0 24 0 50 0 90 2 1 4 5 8 6 13 6 20 7 30 4 lbf ft 2 0 4 0 6 5 15 5 32 5 62 ...

Page 23: ...pe bracket or any other part When using frame contact hoist apply hoist as shown right and left at the same position Lift up the vehicle till 4 tires are a little off the ground and make sure that the vehicle will not fall off by trying to move vehicle body in both ways Work can be started only after this confirmation Make absolutely sure to lock hoist after vehicle is hoisted up When Using Frame ...

Page 24: ...be sure to use an air type floor jack with the following specified height or a manual type floor jack of the following size Otherwise the jack may cause the bumper or vehicle body panel damage Jake size Height h under 145 mm under 5 71 in Length l longer 900 mm under 35 4 in In raising front or rear vehicle end off the floor by jacking be sure to put the jack against front suspension frame 1 or ce...

Page 25: ...t side of cowl top panel in engine compartment Engine Identification Number AENAR90A0101007 The number is punched on cylinder block LPG Compliance Plate AENAR90A0101008 The plate is attached on the upper side of fuel filler lid A Front B Rear 1 2 1 2 A B I9R90A010003 01 I9R90A010004 01 I3RH01010003 01 I9R90A010005 01 ...

Page 26: ...re 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 4 3 1 2 I9R90A010006 01 1 Air bag label on sun visor if equipped 3 Steering shaft joint cover label 2 Engine cooling fan label 4 Jack label ...

Page 27: ...ation 0A 10 LPG Labels NOTE These labels are attached on vehicle equipped with bi fuel LPG system only 3 1 2 I9R90A010008 01 1 LPG label on windshield glass 2 LPG label on rear end door glass 3 LPG label on glove box ...

Page 28: ...I I I I I I I I I I Engine bolts All cylinder head and manifold fixings T T T T Engine mounting loose damage T T T T Exhaust system noise leakage otherwise defective I I I I PCV valve Hoses connections and valve I I I I Ignition system Ignition wiring damage deterioration I I I I Spark plugs R R R Fuel system Air cleaner filter R I Paved road Clean after every 5 000 Kms Replace after every 40 000 ...

Page 29: ...I I I Electrical Battery electrolyte level leakage I I I I I I I I I I Wiring harness connection looseness damage I I I I I I I I I Lighting system operation stains damage I I I I I I I I I I Horn operation I I I I I I I I I I System voltage I I I I I I I I I Body All latches hinges and locks I I I L I L I L I L I L I L I L I L I L All chassis bolts and nuts tighten I T T T T T T T T Suspension sy...

Page 30: ... Check fuel tank Reference Fuel Tank Inspection Petrol Model in Section 1G in related manual mentioned in the Foreword of this manual Bi Fuel LPG model Check fuel tank Fuel Filter Replacement AENAR90A0206012 Petrol model Replace fuel filter Reference Fuel Filter Removal and Installation Petrol Model in Section 1G in related manual mentioned in the Foreword of this manual Bi Fuel LPG model Replace ...

Page 31: ...Maintenance and Lubrication 0B 4 LPG Cylinder Inspection AENAR90A0206017 Check LPG cylinder LPG Fuel Pressure Regulator Filter Replacement AENAR90A0206018 Replace LPG fuel pressure regulator filter ...

Page 32: ...0B 5 Maintenance and Lubrication ...

Page 33: ...formation and Procedures 1A 20 Engine and Emission Control System Check 1A 20 MIL Check 1A LPG Warning Light Check 1A 23 DTC Check 1A 24 DTC Clearance 1A 25 DTC Table 1A 26 Fail Safe Table 1A 29 Scan Tool Data 1A 31 Visual Inspection 1A 38 Engine Basic Inspection 1A 39 Engine Symptom Diagnosis 1A 40 MIL Does Not Come ON with Ignition Switch in ON Position and Engine Stopped but Engine Can Be Start...

Page 34: ...Installation 1C Knock Sensor Inspection 1C IAT Sensor Removal and Installation 1C IAT Sensor Inspection 1C LPG MAP and Temperature Sensor Removal and Installation Bi Fuel LPG Model 1C 3 LPG MAP and Temperature Sensor Inspection Bi Fuel LPG Model 1C 3 Fuel Filler Lid Switch Removal and Installation Bi Fuel CNG Model 1C Fuel Filler Lid Switch Inspection Bi Fuel CNG Model 1C Specifications 1C Tighten...

Page 35: ...n Control System Circuit Diagram 1F Diagnostic Information and Procedures 1F 2 Engine Cooling System Symptom Diagnosis 1F 2 Radiator Cooling Fan Control System Check 1F 2 Repair Instructions 1F 5 Cooling System Components 1F 5 Coolant Level Check 1F Engine Cooling System Inspection 1F Cooling System Draining 1F Cooling System Flushing 1F Cooling System Refilling 1F 5 Cooling Water Pipes or Hoses R...

Page 36: ...1 Diagnostic Information and Procedures 1H 1 Ignition System Check 1H 1 Ignition Spark Test 1H Repair Instructions 1H Spark Plug Removal and Installation 1H Spark Plug Inspection 1H Ignition Coil Assembly Removal and Installation 1H Ignition Coil Assembly Inspection 1H Ignition Timing Inspection 1H Specifications 1H Tightening Torque Specifications 1H Special Tools and Equipment 1H Special Tool 1H...

Page 37: ...on for ECM and LPG Control Module Circuits Inspection Bi Fuel LPG model in Section 1A Precautions for LPG Control Module Circuit Inspection Refer to Precaution for ECM and LPG Control Module Circuits Inspection Bi Fuel LPG model in Section 1A Precautions for Fuel System Service Refer to Precautions for Fuel System Service LPG in Section 1G Precaution for CAN Communication System Refer to Precautio...

Page 38: ...le and how to use it Be sure to read Precaution for CAN Communication System in Section 00 before inspection and observe what is written there ECM Replacement When ECM is replaced with new one or substituted one check the following conditions Neglecting this check may cause damage to ECM Resistance value of all relays and actuators are as specified respectively TP sensor MAP sensor and A C refrige...

Page 39: ...ized At the time of installation they should be installed in the same locations with the same combinations as those before removal Battery cable should be disconnected before performing any major work on the engine Failure to disconnect cable may result in damage to wire harness or other electrical parts Engine Diagnosis General Description AENAR90A1101002 The engine and emission control systems i...

Page 40: ... of the 2 driving cycle detection logic Freeze Frame Data ECM stores the engine and driving conditions in the form of data as shown at the moment of the detection of a malfunction in its memory This data is called Freeze frame data It is possible to know engine and driving conditions e g whether the engine was warm or not where the vehicle was running or stopped where air fuel mixture was lean or ...

Page 41: ...ding system and changes the status of system readiness test from Incomplete to Complete NOTE Complete will be displayed on scan tool for all items as this vehicle does not have system readiness test function LPG Control Module General description LPG control module in this vehicle has the following functions When the ignition switch is turned to ON position with the engine stopped LPG warning ligh...

Page 42: ... rich when a malfunction was detected by checking the freeze frame data Also LPG control module has a function to store each freeze frame data for three different malfunctions in the order of their detection Utilizing this function it is possible to know the order of detection of these malfunctions This is helpful when rechecking or diagnosing a trouble For details of freeze frame data that can be...

Page 43: ...m Vehicle runs using either petrol or LPG For detail about fuel system refer to Fuel System Description LPG in Section 1G Bi fuel LPG system is equipped with fuel select switch and operating mode can be selected from three modes by fuel select switch as follows When ignition switch is turned to ON position operating mode is Petrol MODE or AUTO MODE Petrol MODE During Petrol MODE engine runs on pet...

Page 44: ...em based on signal from fuel select switch and ECM and then indicates selected fuel system by petrol LPG indicator on fuel select switch LPG warning light lights up or blinks when LPG control module detects malfunction related to bi fuel LPG system 4 5 6 A1 A2 A3 B1 B2 B3 C1 C2 C3 1 18 19 22 2 7 8 9 10 11 12 13 14 16 17 20 23 24 3 25 26 27 21 15 IAR90A110031 01 A1 Fuel injector No 1 control signal...

Page 45: ...onic Control System Description AENAR90A1101011 The electronic control system consists of various sensors switches ECUs which detect the state of engine and driving conditions ECM and LPG control module which controls various electric control devices according to the signals from various sensors and various electric control devices Electronic control system performs the following controls ECM Fuel...

Page 46: ... A C refrigerant pressure sensor TP sensor MAP sensor IAT sensor EVAP canister purge valve Generator field coil monitor signal Battery voltage Brake light switch VSS LPG control module Generator control Generator control signal Ignition switch Starter switch ECT sensor CKP sensor TP sensor MAP sensor IAT sensor Generator field coil monitor signal Battery voltage Brake light switch VSS HO2S heater ...

Page 47: ...h VSS Radiator cooling fan control Radiator cooling fan relay Ignition switch ECT sensor CKP sensor A C refrigerant pressure sensor A C switch VSS Fuel pump control Fuel pump relay Ignition switch Starter switch CKP sensor Starting motor control relay control Starting motor control relay Ignition switch Main relay control Main relay Function Output Input Fuel select control ECM Ignition switch ECT...

Page 48: ... Flow Diagram AENAR90A1102001 LPG injection control LPG fuel injector Ignition switch ECT sensor MAP sensor LPG pressure and temperature sensor Fuel select switch ECM LPG shut off valve control Shut off valve of LPG pressure regulator LPG tank valve Ignition switch Fuel select switch LPG valve control relay Function Output Input ...

Page 49: ...hrottle body assembly DLC Radiator cooling fan relay Starting motor Fuel EVAP valve Fuel tank Fuel pump EVAP canister EVAP canister purge valve Exhaust gas Air Fuel Petrol Vapor Generator Combination meter MIL Coolant temperature Immobilizer indicator light Speedometer Odometer MAP sensor ISC valve Electric signal CAN signal A C switch LPG tank LPG level sensor Shut off valve LPG pressure regulato...

Page 50: ...A 13 Engine General Information and Diagnosis Bi Fuel LPG model Engine Control System Circuit Diagram AENAR90A1102002 NOTE For identification of each cylinder refer to Cylinder Identification Description ...

Page 51: ...01 16 C01 29 C01 28 E01 4 E01 6 C01 38 C01 12 C01 17 C01 19 C01 24 C01 20 C01 13 C01 23 12 11 C01 9 C01 32 E01 22 C01 37 E01 26 E01 20 GRY RED C01 11 GRY BLU C01 26 GRY RED BLU RED E01 9 E01 13 BRN WHT YEL RED C01 10 BRN BLK GRN BLK 35 C01 31 4 20 20 E01 19 9 ORN BLU WHT WHT GRN E01 3 E01 24 WHT BLU E01 7 WHT BLK RED BLK GRN ORN E01 5 RED WHT C01 40 C01 39 C01 2 C01 14 GRN ORN C01 16 GRN BLU BLK O...

Page 52: ...y 46 Immobilizer control module 7 ECT sensor 27 Fuel pump 47 RDTR fuse 8 A C refrigerant pressure sensor 28 Radiator cooling fan relay 48 CPRSR fuse 9 A C evaporator outlet air temp sensor 29 Radiator cooling fan motor 49 Starting motor 10 HO2S 30 A C compressor relay 50 Main fuse box 11 Shield wire 31 A C compressor magnet clutch 51 Battery 12 Knock sensor 32 Generator 52 Engine ground 13 Blower ...

Page 53: ... 6 C13 14 BLU WHT C13 1 WHT BLK GRY C13 10 BLU RED C13 5 C13 18 WHT BLU RED WHT RED WHT BLK RED BLK RED BLK RED BLK RED BLK RED E485 21 BLK WHT BLK WHT E485 29 LT GRN E485 4 BLK ORN E485 34 BLU BLK WHT BLK E485 26 BLU WHT IAR90A110034 01 a To ECM C01 2 2 CPU 8 LPG fuse 14 LPG valve control relay b To ECM C01 1 3 LPG pressure and temperature sensor 9 LPG fuel injector No 1 15 Shut off valve of LPG ...

Page 54: ...terminal voltage refer to Inspection of LPG Control Module and Its Circuit Bi Fuel LPG model 3 4 5 6 7 9 2 1 8 A A 12 13 14 15 16 11 10 17 C13 E485 20 21 22 23 24 26 19 18 25 29 30 31 32 33 28 27 34 3 4 5 6 7 9 2 1 8 12 13 14 15 16 11 10 17 20 21 22 23 24 26 19 18 25 29 30 31 32 33 28 27 34 IAR90A110035 01 A LPG control module connector View A ...

Page 55: ...tion and Diagnosis Bi Fuel LPG model 1A 18 Component Location Electronic Control System Component Location AENAR90A1103001 5 a w 9 t 3 r q 4 10 12 3 1 s 5 d b e c f 2 g 2 7 8 n o p h i j 11 m l k 6 4 u 13 1 v IAR90A110036 01 ...

Page 56: ...sor installed in LPG tank valve m LPG fuel injector No 1 n Ignition coil assembly No 3 o Ignition coil assembly No 2 p Ignition coil assembly No 1 q MIL r Immobilizer indicator light s LPG warning light t Fuel pump u Shut off valve of LPG tank valve installed in LPG tank valve v Shut off valve of LPG pressure regulator installed in LPG pressure regulator w ISC valve Step Action Yes No 1 Customer c...

Page 57: ...p 9 Go to Step 10 8 Engine basic inspection and engine symptom diagnosis 1 Perform engine basic inspection and engine symptom diagnosis Is there any faulty condition Check and repair faulty part s and go to Step 11 Go to Step 10 9 Troubleshooting for DTC 1 Perform troubleshooting for applicable DTC Are check and repair complete Go to Step 11 Check and repair faulty part s and go to Step 11 10 Inte...

Page 58: ... and how it occurred as described by the customer For this purpose use of such an inspection form will facilitate collecting information required for proper analysis and diagnosis Customer problem inspection form Example NOTE This form is a standard sample It should be modified according to conditions characteristic of each market I7V20A111010 01 ...

Page 59: ...PG model based on symptom found in vehicle checking in the following steps Customer complaint analysis Trouble symptom confirmation Step 9 Troubleshooting for DTC Perform applicable DTC troubleshooting and repair or replace faulty parts Step 10 Intermittent Problem Check In case that there is no DTC at Step 2 Check for intermittent problem Refer to Intermittent and Poor Connection Inspection in Se...

Page 60: ...n tool SUZUKI SDT 2 Turn ignition switch to ON position and confirm that LPG warning light lights 3 Read DTC and freeze frame data according to instructions displayed on scan tool and print them or write them down Refer to scan tool operator s manual for details If communication between scan tool and LPG control module is not possible go to Troubleshooting for Communication Bus Off in Section 10H ...

Page 61: ... not detected in its circuit of ECM 2 D C Applicable P0107 Manifold Absolute Pressure Barometric Pressure Circuit Low Voltage of MAP sensor signal circuit is lower than 0 3 V for 5 sec 2 D C Applicable P0108 Manifold Absolute Pressure Barometric Pressure Circuit High Voltage of MAP sensor signal circuit is higher than 4 88 V for 5 sec 2 D C Applicable P0112 Intake Air Temperature Sensor1 Circuit L...

Page 62: ...it High Voltage of A C refrigerant pressure sensor signal circuit is higher than 4 93 V for 5 sec 2 D C Not applicable P0560 System Voltage Voltage of backup power supply circuit is lower than specification for 5 sec 2 D C Applicable P0601 Internal Control Module Memory Check Sum Error Data write error or check sum error 2 D C Applicable P0602 Control Module Programming Error Data programming erro...

Page 63: ...rature Sensor A Circuit High Voltage of LPG temperature sensor signal circuit is higher than 4 9 V for 5 sec 2 D C Applicable P0192 Fuel Rail Pressure Sensor A Circuit Low Voltage of LPG pressure sensor signal circuit is lower than 0 15 V for 5 sec 2 D C Applicable P0193 Fuel Rail Pressure Sensor A Circuit High Voltage of LPG pressure sensor signal circuit is higher than 4 9 V for 5 sec 2 D C Appl...

Page 64: ... 1 D C Applicable P2667 Fuel Shutoff Valve B Control Circuit High Monitor voltage of shut off valve of LPG tank valve is higher than specified voltage for 5 sec even if its command signal is output and LPG valve control relay is ON 1 D C Applicable P2668 Fuel Mode Indicator Lamp Control Circuit Fuel select switch ON signal is input continuously for more than 120 sec 1 D C Applicable U0073 Control ...

Page 65: ...mph ECM stops ISC feedback control P0505 Idle Air Control System P0532 A C Refrigerant Pressure Sensor A Circuit Low ECM stops A C control P0533 A C Refrigerant Pressure Sensor A Circuit High P0560 System Voltage P0601 Internal Control Module Memory Check Sum Error P0602 Control Module Programming Error P0616 Starter Relay Circuit Low P0617 Starter Relay Circuit High P0620 Generator Control Circui...

Page 66: ...n LPG control module closes shut off valve of LPG pressure regulator LPG control module stops LPG control and then shifts operating mode to Petrol MODE P2667 Fuel Shutoff Valve B Control Circuit High P2668 Fuel Mode Indicator Lamp Control Circuit U0073 Control Module Communication Bus Off LPG control module stops LPG control and then shifts operating mode to Petrol MODE U0100 Lost Communication wi...

Page 67: ... 5 C 9 F environmental temperature to 40 C 72 F environmental temperature Barometric Pres Barometric pressure EVAP Canist Prg Duty Specified idle speed after warming up 0 IAC Flow Duty Specified idle speed with no load after warming up Approx 5 to 40 Engine condition Specified idle speed after warming up A C switch ON Blower fan switch at 3rd position Approx 10 to 50 TP Sensor 1 Volt Engine condit...

Page 68: ...s of short term fuel trim and long term fuel trim 0 No correction Above 0 Enrichment correction Below 0 Lean mixture correction Inj Pulse Width CNG LPG Engine condition Specified idle speed with no load after warming up Fuel select mode Petrol MODE 0 msec Engine condition Specified idle speed with no load after warming up Fuel select mode Forced LPG MODE Approx 3 5 5 5 msec Fuel Select Mode Fuel s...

Page 69: ...100 EVAP canister purge valve is fully opened IAC Flow Duty Idle Air Control Flow Duty This parameter indicates the calculated opening rate of ISC valve based on ISC valve control signal 0 Minimum idle air flow 100 Maximum idle air flow TP Sensor 1 Volt TP Sensor Output Voltage V This parameter indicates the signal voltage of throttle position sensor Throttle Position Absolute Throttle Position Th...

Page 70: ...njection being cut output signal to injector is stopped OFF Fuel injection not being cut Closed Throttle Pos Closed Throttle Position ON OFF This parameter indicates the state of throttle valve position ON Throttle valve position is idle position fully closed OFF Throttle valve position is opened position O2S B1 S1 ACT HO2S Active Inactive This parameter indicates the activation condition of HO2S ...

Page 71: ...g up Approx 20 to 60 Engine Speed Engine condition Specified idle speed after warming up All electrical parts OFF Shift lever Neutral position Approx 830 to 930 rpm Vehicle Speed Vehicle running Vehicle speed MAP Specified idle speed with no load after warming up Approx 20 55 kPa ECT Specified idle speed after warming up Approx 80 100 C 176 212 F Intake Air Temperature Specified idle speed after w...

Page 72: ...ure kPa inHg inH2O mmHg psi This parameter indicates the calculated manifold pressure based on MAP sensor signal ECT Engine Coolant Temperature C F This parameter indicates the calculated engine coolant temperature based on ECT sensor signal Intake Air Temperature C F This parameter indicates the calculated intake air temperature based on IAT sensor signal Throttle Position Absolute Throttle Posit...

Page 73: ...ve of LPG tank valve ON Shut off valve of LPG tank valve is opened OFF Shut off valve of LPG tank valve is closed Shut Off V Reg Shut Off Valve Regulator ON OFF This parameter indicates the state of shut off valve of LPG pressure regulator ON Shut off valve of LPG pressure regulator is opened OFF Shut off valve of LPG pressure regulator is closed Power Supply Relay LPG Valve Control Relay ON OFF T...

Page 74: ...on LPG level indicator Operation Fuel select switch Operation Exhaust system Leakage of exhaust gas noise Exhaust System Check in Section 1K Abnormal air being inhaled at air intake system Other parts that can be checked visually Step Action Yes No 1 Was Engine and Emission Control System Check performed Go to Step 2 Go to Engine and Emission Control System Check Bi Fuel LPG model 2 Check battery ...

Page 75: ...turn pressure returning sounds felt from fuel return hose when ignition switch is turned ON Go to Step 13 Go to Step 12 12 Check fuel pump for operation Was fuel pump operating sound heard from fuel filler for about 2 seconds after ignition switch ON and stop Go to Fuel Pressure Check LPG in Section 1G Go to Fuel Pump and Its Circuit Check LPG in Section 1G 13 Check ignition spark 1 Check ignition...

Page 76: ...Air drawn in through intake manifold gasket or throttle body gasket Check air intake system Faulty throttle body assembly Throttle Body On Vehicle Inspection in Section Faulty ECT sensor or MAP sensor ECT Sensor Inspection in Section or MAP Sensor Inspection in Section Faulty ECM Inspection of ECM and Its Circuit Bi Fuel LPG model Faulty LPG control module Inspection of LPG Control Module and Its ...

Page 77: ...re that Specified spark plug is used Specified fuel is used Worn piston piston ring and cylinder bore Cylinder Piston and Piston Ring Inspection in Section Worn connecting rod bearing Crankshaft Pin and Connecting Rod Bearings Inspection in Section 1D Worn crank pin Crankshaft Pin and Connecting Rod Bearings Inspection in Section 1D Loose connecting rod bolts Piston Piston Ring and Connecting Rod ...

Page 78: ...nspection in Section Faulty petrol fuel injector s and or LPG fuel injector s Fuel Injector Circuit Check in Section Faulty ECM Inspection of ECM and Its Circuit Bi Fuel LPG model Faulty LPG control module Inspection of LPG Control Module and Its Circuit Bi Fuel LPG model Low compression Compression Check in Section Poor valve seating Valve and Valve Guide Inspection in Section Dragging brakes Bra...

Page 79: ...uel LPG model Engine overheating Condition Engine overheating Low compression Compression Check in Section Surge Engine power variation under steady throttle or cruise Feels like vehicle speeds up and down with no change in accelerator pedal Faulty spark plug excess carbon deposits improper gap burned electrodes etc Spark Plug Inspection in Section Variable petrol and or LPG fuel pressure Fuel Pre...

Page 80: ... Dirty or clogged petrol fuel hose or pipe Faulty petrol fuel pressure regulator Faulty fuel pump Fuel Pressure Check LPG in Section 1G LPG fuel pressure out of specification Dirty LPG fuel filter Dirty or clogged LPG fuel hose or pipe Faulty LPG pressure regulator Fuel Pressure Check LPG in Section 1G Engine has no power Faulty spark plug Spark Plug Inspection in Section Faulty ignition coil with...

Page 81: ...l with ignitor Ignition Coil Assembly Inspection in Section Low compression Compression Check in Section Lead contamination of three way catalytic converter Check for absence of filler neck restrictor Faulty evaporative emission control system EVAP Canister Purge System Inspection in Section 1B Petrol and or LPG fuel pressure out of specification Fuel Pressure Basic Check LPG in Section 1G Faulty ...

Page 82: ...valve control relay Check LPG valve control relay Faulty ECM Inspection of ECM and Its Circuit Bi Fuel LPG model Faulty LPG control module Inspection of LPG Control Module and Its Circuit Bi Fuel LPG model Unusable LPG Fuel can not change over to LPG in AUTO MODE Faulty IAT sensor IAT Sensor Inspection in Section Faulty ECT sensor ECT Sensor Inspection in Section Faulty TP sensor TP Sensor On Vehi...

Page 83: ...WHT E485 10 12V 5V RED WHT C13 25 C13 33 C01 39 C01 40 RED WHT 14 15 3 4 5 6 7 1 8 A 12 13 14 15 16 11 10 17 C13 E485 20 21 22 23 24 26 19 18 25 29 30 31 32 33 28 27 34 3 4 5 6 7 1 8 12 13 14 15 16 11 10 17 20 21 22 23 24 26 19 18 25 29 30 31 32 33 28 27 34 2 9 2 9 BLK RED E01 11 C01 8 BLK 31 32 33 34 35 36 37 38 39 40 41 42 43 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 2...

Page 84: ...s 4 MTR fuse check 1 Turn ignition switch to OFF position 2 Check if MTR fuse in junction block is blown Is MTR fuse in good condition Go to Step 5 Replace MTR fuse and check for short 5 Combination meter power supply circuit check 1 Remove combination meter Instrument Panel Disassembly and Reassembly in Section 2 Check for proper connection to combination meter connector at combination meter powe...

Page 85: ...nd Communication Bus Off Table in Section 10H Step Action Yes No 1 DTC check 1 Start engine and recheck DTC of LPG control module while engine running Is there any DTC s Go to troubleshooting for applicable DTC Substitute a known good combination meter and recheck If LPG warning light still remains ON substitute a known good LPG control module and recheck DTC detecting condition Trouble area P0601...

Page 86: ... sec even if its command signal is output and LPG valve control relay is ON 1 D C detection logic 12V 5V B E485 1 E485 10 BLK RED IG1 BLK WHT BLK BLK BLK C13 9 C13 17 C13 26 WHT RED WHT BB2 3 4 5 6 7 1 8 A A 12 13 14 15 16 11 10 17 C13 E485 20 21 22 23 24 26 19 18 25 29 30 31 32 33 28 27 34 3 4 5 6 7 1 8 12 13 14 15 16 11 10 17 20 21 22 23 24 26 19 18 25 29 30 31 32 33 28 27 34 2 9 2 9 1 2 3 4 5 6...

Page 87: ... ignition switch 2 Check if LPG RLY fuse in relay block is blown Is LPG RLY fuse in good condition Repair or replace defective wire harness Check that LPG valve control relay power supply circuit switch side is shorted to ground If OK replace LPG RLY fuse 5 LPG valve control relay check 1 Check LPG valve control relay Refer to Control Relay Inspection in related service manual mentioned in forewor...

Page 88: ...ssure regulator control circuit B3 is as follows Wiring harness resistance of shut off valve of LPG pressure regulator control circuit is less than 1 Ω Insulation resistance of shut off valve of LPG pressure regulator control circuit between shut off valve of LPG pressure regulator connector and vehicle body ground is infinity Insulation resistance of wire harness is infinity between shut off valv...

Page 89: ...erature sensor signal circuit is higher than 4 9 V for 5 sec 2 D C detection logic 5V 12V 1 B1 B2 C1 A1 3 4 5 6 7 1 8 A A 12 13 14 15 16 11 10 17 C13 E485 20 21 22 23 24 26 19 18 25 29 30 31 32 33 28 27 34 3 4 5 6 7 1 8 12 13 14 15 16 11 10 17 20 21 22 23 24 26 19 18 25 29 30 31 32 33 28 27 34 2 9 2 9 5V LT GRN RED 2 GRY GRY RED BLU RED IAR90A110045 01 A LPG control module connector View A B2 LPG ...

Page 90: ...ircuit is 0 1 V with ignition switch in ON position Are they in good condition Go to Step 3 Repair or replace LPG temperature sensor signal circuit and or LPG pressure and temperature sensor ground circuit 3 LPG temperature sensor signal circuit voltage check 1 Connect connectors to LPG control module 2 Turn ignition switch to ON position 3 Check that voltage between LPG temperature sensor signal ...

Page 91: ... disconnect connectors from LPG control module 2 Check for proper terminal connection to LPG control module connectors 3 If connections are OK check that LPG pressure sensor power supply circuit A1 is as follows Wiring harness resistance of LPG pressure sensor power supply circuit is less than 1 Ω Insulation resistance LPG pressure sensor power supply circuit between LPG pressure and temperature s...

Page 92: ... they in good condition Go to Step 6 Repair or replace LPG pressure sensor signal circuit 6 LPG Pressure and temperature sensor check 1 Check LPG pressure and temperature sensor LPG MAP and Temperature Sensor Inspection Bi Fuel LPG Model in Section 1C Is it in good condition Substitute a known good LPG control module and recheck Replace LPG pressure and temperature sensor LPG MAP and Temperature S...

Page 93: ... connector View A D1 LPG fuel injector No 1 control circuit 5 Petrol fuel injector No 1 B ECM connector View A D2 LPG fuel injector No 2 control circuit 6 Petrol fuel injector No 2 A1 Petrol fuel injector No 1 power supply circuit D3 LPG fuel injector No 3 control circuit 7 Petrol fuel injector No 3 A2 Petrol fuel injector No 2 power supply circuit E1 Fuel injector No 1 control signal from ECM cir...

Page 94: ...le connectors 3 If connections are OK check that LPG fuel injector control circuits D1 D2 and D3 are as follows Wiring harness resistance of each LPG fuel injector control circuit is less than 1 Ω Insulation resistance of each LPG fuel injector control circuit between LPG fuel injector connector and vehicle body ground is infinity Insulation resistance of wire harness is infinity between each LPG ...

Page 95: ...k 1 Disconnect connectors from LPG control module 2 Check for proper terminal connection to LPG control module connectors 3 If connections are OK check that LPG valve control relay drive circuit B1 is as follows Wiring harness resistance of LPG valve control relay drive circuit is less than 1 Ω Insulation resistance of LPG valve control relay drive circuit between LPG valve control relay connector...

Page 96: ...ning on LPG Monitor signal of either of fuel control relays is LPG side for 5 sec with engine running on petrol 2 D C detection logic Fuel injector control circuit between ECM and LPG control module LPG control module ECM Step Action Yes No 1 Was Engine and Emission Control System Check performed Go to Step 2 Go to Engine and Emission Control System Check Bi Fuel LPG model 2 DTC recheck 1 Replace ...

Page 97: ...age of LPG level sensor signal circuit is lower than 0 1 V for 5 sec 1 D C detection logic LPG level sensor and or its circuit LPG control module P1433 Remaining Fuel Sensor High Voltage Voltage of LPG level sensor signal circuit is higher than 4 9 V for 5 sec 1 D C detection logic A1 A2 1 5V 3 4 5 6 7 1 8 A A 12 13 14 15 16 11 10 17 C13 E485 20 21 22 23 24 26 19 18 25 29 30 31 32 33 28 27 34 3 4 ...

Page 98: ...Insulation resistance of wire harness is infinity between LPG level sensor signal circuit terminal and ground circuit terminal at LPG level sensor connector Are they in good condition Go to Step 3 Repair or replace LPG level sensor signal circuit or LPG level sensor ground circuit 3 LPG level sensor check 1 Check LPG level sensor LPG Tank with Tank Valve On Vehicle Inspection LPG in Section 1G Is ...

Page 99: ...uit Open Monitor voltage of shut off valve of LPG tank valve is lower than specified voltage for 5 sec even if its command signal is output and LPG valve control relay is ON 1 D C detection logic Shut off valve of LPG tank valve and or its circuit LPG valve control relay and or its circuit LPG control module P2667 Fuel Shutoff Valve B Control Circuit High Monitor voltage of shut off valve of LPG t...

Page 100: ...om LPG control module 2 Check for proper terminal connection to LPG control module connectors 3 If connection are OK check that shut off valve of LPG tank valve control circuit B2 is as follows Wiring harness resistance of shut off valve of LPG tank valve control circuit is less than 1 Ω Insulation resistance of shut off valve of LPG tank valve control circuit between shut off valve of LPG tank va...

Page 101: ...ector View A B1 Fuel select switch ground circuit 2 Fuel select switch A1 Fuel select switch signal circuit 1 LPG control module Step Action Yes No 1 Was Engine and Emission Control System Check performed Go to Step 2 Go to Engine and Emission Control System Check Bi Fuel LPG model 2 Fuel select switch ground circuit check 1 Turn ignition switch to OFF position and then disconnect connector from f...

Page 102: ...f fuel select switch signal circuit is less than 1 Ω Insulation resistance of fuel select switch signal circuit between fuel select switch connector and vehicle body ground is infinity Insulation resistance of wire harness is infinity between fuel select switch signal circuit terminal and each terminal at fuel select switch connector Voltage of fuel select switch signal circuit is 0 1 V with ignit...

Page 103: ... 15 16 17 18 19 20 21 22 23 24 25 26 A C01 E01 A 2928 I9R90A112029 01 A ECM connector View A Terminal No Wire color Circuit Normal voltage Condition C01 1 BRN Fuel injector No 2 control circuit 10 14 V Ignition switch ON 0 1 V 10 14 V Engine Idle speed after warming up C01 2 BRN YEL Fuel injector No 1 control circuit 10 14 V Ignition switch ON 0 1 V 10 14 V Engine Idle speed after warming up C01 3...

Page 104: ... ON ECT 50 C 122 F 0 42 0 52 V Ignition switch ON ECT 100 C 212 F C01 20 RED BLK MAP sensor signal circuit 3 70 4 52 V Ignition switch ON Barometric pressure 100 kPa 760 mmHg 0 80 1 81 V Engine Idle speed after warming up Barometric pressure 100 kPa 760 mmHg C01 21 BLU ORN ECT sensor ground circuit Below 0 3 V Ignition switch ON C01 22 C01 23 BRN WHT HO2S shield ground circuit Below 0 3 V Ignition...

Page 105: ... C01 41 ORN HO2S ground circuit Below 0 3 V Ignition switch ON C01 42 PNK BLU Generator control signal circuit 0 1 V 5 7 V Engine Idle speed after warming up C01 43 WHT BLU Generator field coil monitor signal circuit 0 1 V 10 14 V Engine Idle speed after warming up Terminal No Wire color Circuit Normal voltage Condition E01 1 BLK RED Main power supply circuit 1 0 1 V Ignition switch OFF 10 14 V Ig...

Page 106: ... relay drive circuit 0 1 V Ignition switch ON 10 14 V Ignition switch OFF E01 13 BLU RED A C refrigerant pressure sensor signal circuit 1 31 1 60 V Engine Running A C switch OFF Blower speed selector OFF A C refrigerant pressure 0 8 MPa 2 04 2 50 V Engine Running A C switch OFF Blower speed selector 1st position or higher A C refrigerant pressure 1 4 MPa 2 53 3 09 V Engine Running A C switch OFF B...

Page 107: ... less Ignition switch ON A C switch ON Blower speed selector 1st position or higher E01 20 GRN WHT Brake light switch signal circuit 0 1 V Ignition switch ON Brake pedal Not depressed 10 14 V Ignition switch ON Brake pedal Fully depressed position E01 21 E01 22 RED CAN high communication circuit 2 5 3 5 V Ignition switch ON E01 23 E01 24 ORN A C evaporator outlet air temp sensor ground circuit Bel...

Page 108: ...urement condition Engine Idle speed after warming up Fuel select mode Petrol MODE Generator control signal and generator field coil monitor signal Generator field coil monitor signal 1 Channel Probe Terminal No 2 C01 30 C01 8 Channel Probe Terminal No 3 C01 35 C01 8 Channel Probe Terminal No 4 C01 33 C01 8 5 Camshaft 360 angle 6 Crankshaft 720 angle Channel Probe Terminal No 1 C01 1 C01 8 Channel ...

Page 109: ...gnal 2 Measurement condition Engine Idle speed after warming up Measurement condition Engine Racing after warming up Ignition coil signal Measurement condition Engine Idle speed after warming up ISC valve signal Channel Probe Terminal No 1 C01 43 C01 8 Channel Probe Terminal No 2 C01 42 C01 8 Channel Probe Terminal No 1 C01 24 C01 8 Channel Probe Terminal No 2 C01 13 C01 8 I9L60A110030 01 I9L60A11...

Page 110: ... S control module Measurement condition Engine Drive vehicle at 30 km h 19 mph after warming up CKP sensor signal and CMP sensor signal CMP sensor signal 1 CKP sensor signal 2 Measurement condition Engine Idle speed after warming up 1 ISC valve signal Channel Probe Terminal No 1 C01 12 C01 8 1 EVAP canister purge valve signal Channel Probe Terminal No 1 C01 37 C01 8 I9C50A110031 01 I7V20A111065 02...

Page 111: ...CAN communication signal High 1 CAN communication signal Low 2 Measurement condition Engine Stop Ignition switch ON Channel Probe Terminal No 1 C01 9 C01 10 1 Knock sensor signal Channel Probe Terminal No 1 E01 7 C01 8 1 Fuel pump relay signal 3 Ignition switch ON 2 Ignition switch OFF 4 Ignition switch ON START I9L60A110034 01 I9C50A110033 01 I9L60A110035 01 Channel Probe Terminal No 1 E01 10 C01...

Page 112: ...5 29 30 31 32 33 28 27 34 IAR90A110049 01 A LPG control module connector View A Terminal No Wire color Circuit Normal voltage Condition C13 1 WHT BLK LPG fuel injector No 1 control circuit 10 14 V Ignition switch ON 0 1 V 10 14 V Engine Idle speed after warming up Fuel select mode Forced LPG MODE C13 2 C13 3 C13 4 C13 5 BLU RED Petrol fuel injector No 3 control circuit 10 14 V Ignition switch ON 0...

Page 113: ... 10 14 V Ignition switch ON 0 1 V 10 14 V Engine Idle speed after warming up Fuel select mode Forced LPG MODE C13 19 C13 20 C13 21 C13 22 C13 23 C13 24 C13 25 RED CAN high communication circuit 2 5 3 5 V Ignition switch ON C13 26 BLK LPG control module ground circuit Below 0 3 V Ignition switch ON C13 27 C13 28 C13 29 C13 30 C13 31 C13 32 C13 33 WHT CAN low communication circuit 1 5 2 5 V Ignition...

Page 114: ... Ignition switch ON LPG tank Emptied E485 16 E485 17 E485 18 E485 19 E485 20 E485 21 BLK WHT Ignition switch signal circuit 10 14 V Ignition switch ON 0 1 V Ignition switch OFF E485 22 LT GRN BLK Fuel select switch signal circuit 0 1 V Ignition switch ON Fuel select switch Pushed 8 13 V Ignition switch ON Fuel select switch Not pushed E485 23 GRN BLK LPG level sensor ground circuit Below 0 3 V Ign...

Page 115: ...or control signal from ECM 1 LPG fuel injector control signal 2 E485 34 BLU BLK Shut off valve of LPG tank valve control circuit 0 1 V Ignition switch ON 10 15 V Engine Running Fuel select mode Petrol MODE 0 1 V Engine Running Fuel select mode Forced LPG MODE Terminal No Wire color Circuit Normal voltage Condition A Waveform of channel 1 C VOLT DIV of each channel B Ground level of each channel D ...

Page 116: ...nt condition Ignition switch ON Fuel select mode Petrol control in AUTO MODE Remaining LPG Low CAN communication signal CAN communication signal High 1 CAN communication signal Low 2 Measurement condition Engine Stop Ignition switch ON ECM Power and Ground Circuit Check AENAR90A1104054 Channel Probe Terminal No 3 C13 6 No 1 C13 14 No 2 C13 5 No 3 C13 9 Channel Probe Terminal No 1 E485 29 C13 9 IAR...

Page 117: ...1 C01 8 BLK H2 31 32 33 34 35 36 37 38 39 40 41 42 43 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 30 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 A C01 E01 A 2928 I9R90A111055 01 A ECM connector View A E1 TP sensor power supply circuit 5 DOME fuse A1 Backup power supply circuit F1 MAP sensor power supply circuit 6 IG COIL fuse B1 Ignition switch ...

Page 118: ...en E01 2 terminal of ECM connector and body ground Is voltage 10 14 V Go to Step 3 Ignition switch signal circuit between battery and ECM is open and or short circuit 3 ECM ground circuit check 1 Measure the following circuits resistance between ECM connectors and vehicle body ground ECM ground circuit 1 H1 ECM ground circuit 2 H2 ECM ground circuit 3 H3 Are resistance 1 Ω or less Go to Step 4 Rep...

Page 119: ...C refrigerant pressure sensor power supply circuit D1 TP sensor power supply circuit E1 MAP sensor power supply circuit F1 Are resistance 1 Ω or less Check internal short circuit of TP sensor MAP sensor and or A C refrigerant pressure sensor Repair or replace defective wire harness Step Action Yes No A 3 4 5 6 7 1 8 A 12 13 14 15 16 11 10 17 C13 E485 20 21 22 23 24 26 19 18 25 29 30 31 32 33 28 27...

Page 120: ...ition signal check 1 Turn ignition switch to OFF position and then disconnect connectors from LPG control module 2 Turn ignition switch to ON position 3 Measure ignition switch signal circuit A1 voltage between LPG control module connector and body ground Is voltage 10 14 V Go to Step 2 Ignition switch signal circuit between battery and LPG control module is open and or short circuit 2 LPG control...

Page 121: ...ft lever in Neutral and set parking brake and block drive wheels 1 Turn ignition switch to OFF position and then connect SUZUKI scan tool to DLC 1 Special tool A SUZUKI scan tool SUZUKI SDT 2 Warm up engine to normal operating temperature 3 Check engine idle speed and IAC Flow Duty using Data List mode on scan tool Engine idle speed A C OFF 830 930 rpm IAC Flow Duty 5 40 A C ON 800 900 rpm IAC Flo...

Page 122: ...is Bi Fuel LPG model Special Tools and Equipment Special Tool AENAR90A1108001 SUZUKI scan tool SUZUKI SDT This kit includes following items 1 SUZUKI SDT 2 DLC cable 3 USB cable 4 AC DC power supply 5 Voltage meter probe 6 Storage case 1 2 3 4 5 6 ...

Page 123: ... HO2S inspection should be performed when system is cool HO2S Circuit Insulation Check 1 Disconnect connector from HO2S with ignition switch turned OFF 2 Using ohmmeter check the following circuits of HO2S for insulation If faulty condition is found replace HO2S Resistance between HO2S signal circuit terminal 2 and each of terminals 3 and 4 is infinity Resistance between HO2S ground circuit termin...

Page 124: ...ensor affects resistance value largely Make sure that sensor heater is at specified temperature HO2S heater resistance 5 0 6 4 Ω at 20 C 68 F CMP Sensor On Vehicle Inspection AENAR90A1306012 1 Disconnect connector of CMP sensor with ignition switch turned OFF 2 Turn ignition switch to ON position and check that voltage of CMP sensor connector vehicle side between terminals 1 and 2 is battery volta...

Page 125: ...move LPG MAP and temperature sensor 1 from LPG fuel delivery pipe 3 Installation Reverse removal procedure noting the following Clean mating surface of LPG MAP and temperature sensor and LPG delivery pipe LPG MAP and Temperature Sensor Inspection Bi Fuel LPG Model AENAR90A1306030 LPG Temperature Sensor Inspection 1 Remove LPG MAP and temperature sensor 2 Check O ring 1 for damage and deterioration...

Page 126: ...er Data List mode on scan tool Check LPG pressure displayed on scan tool 6 Check that fuel pressure on pressure gauge and LPG Pressure on SUZUKI scan tool are similarly decreased when fuel pressure is relieved If check result not satisfactory replace LPG MAP and temperature sensor Special Tools and Equipment Special Tool AENAR90A1308001 A Resistance 5 Temperature gauge B Temperature 2 24 2 75 A B ...

Page 127: ...f all electric switches 4 Remove air cleaner assembly 5 Remove PCV hose 1 from PCV valve 2 6 Connect special tool to PCV hose 1 Special tool A 09915M67311 7 Close PCV valve 2 using tape 3 or the like 8 Install air cleaner assembly 9 Start engine and confirm that all electric loads switches are turned off 10 Read vacuum gauge Vacuum should be specification at specified idle speed Petrol model Refer...

Page 128: ...it to specification Valve clearance specification Intake 0 14 0 23 mm 0 0063 0 0094 in When cold ECT 15 25 C 59 77 F Exhaust 0 30 0 40 mm 0 0123 0 0153 in When cold ECT 15 25 C 59 77 F Adjustment 1 Remove tappet to be replaced 2 Select proper size of tappet as follows a Using a micrometer measure the thickness of the removed tappet 1 b Calculate the thickness of new tappet by formula below NOTE If...

Page 129: ...sen intake manifold stiffener bolt 2 and then move intake manifold stiffener 3 as shown figure 9 Remove intake manifold 1 and intake manifold gasket 10 Remove cooling water pipe 1 11 Remove spacer 2 and gasket from cylinder head Installation Reverse removal procedure for installation noting the following Use new gaskets Refill cooling system Check for coolant leakage Check for LPG fuel leakage for...

Page 130: ...se the following bolt for timing chain tensioner fixing bolt Do not use wrench when tightening timing chain tensioner fixing bolt to avoid damage of timing chain tensioner a Tighten timing chain tensioner fixing bolt 2 by hand to fix timing chain tensioner 1 b While turning crankshaft 20 a counterclockwise tighten timing chain tensioner fixing bolt 2 by hand again c While turning crankshaft 20 a c...

Page 131: ...ed link 2 of timing chain b Direct dowel pin 3 of exhaust camshaft upward 3 Install camshaft housings 1 to specified places indicated by character 2 number 3 and arrow direction 4 on each camshaft housing 4 After applying engine oil to camshaft housing bolts tighten camshaft housing bolts temporarily first Then tighten camshaft housing bolts by the numerical order in figure Tighten camshaft housin...

Page 132: ...ing torque Exhaust camshaft timing sprocket bolt a 60 N m 6 1 kgf m 44 5 lbf ft CAUTION In case of extension special tool combined with torque wrench reading value of torque wrench is smaller than specified tightening torque When using extension special tool reading value should be calculated according to formula below M T X L L a M Reading value using extension special tool T Specified torque L T...

Page 133: ...normal 11 Check valve clearance 12 Install cylinder head cover Engine Assembly Removal and Installation AENAR90A1406017 Removal 1 Relieve fuel pressure in fuel feed line Petrol model Reference Fuel Pressure Relief Procedure Petrol Model in Section 1G in related manual mentioned in the Foreword of this manual Bi Fuel LPG model 2 Remove battery 3 Remove EVAP canister 4 For bi fuel LPG model remove L...

Page 134: ... 15 Remove engine harness clamps 16 With A C hoses connected remove A C compressor from its bracket CAUTION Hold removed A C compressor at a place where no damage will be caused during removal and installation of engine assembly 17 Remove clutch cable from clutch release arm 18 Disconnect gear shift control cable from transaxle 19 Remove exhaust pipe 20 Disconnect steering lower shaft from pinion ...

Page 135: ...ch cover and disc Flywheel Installation 1 Install following components to engine assembly if removed Flywheel Clutch cover and clutch disc Transaxle Engine harness 2 Install front suspension frame engine mountings engine mounting brackets and engine mounting bracket components and then tighten bolts to specified torque if removed Tighten engine harness ground bolt 1 with engine harness ground cabl...

Page 136: ...ir cleaner assembly 22 Make sure that all electric wires connectors are installed at original locations 23 Make sure that all removed components are installed at original locations 24 Fill following oils Engine oil Manual transaxle oil 25 For petrol model install battery bracket For bi fuel LPG model install battery bracket with pipe component 26 Install engine coolant reservoir 27 For bi fuel LPG...

Page 137: ... range 30 90 as shown in figure before rotating camshaft 1 Remove timing chain cover 2 By turning crankshaft align camshafts and crankshaft at specific position as follows a Align both match marks 1 on intake and exhaust camshaft timing sprocket with notches 2 on cylinder head respectively b Position crankshaft sprocket key 3 with notch on cylinder block 4 3 Remove timing chain tensioner adjuster ...

Page 138: ...ly engine oil to sliding surface of timing chain tensioner 2 8 Install timing chain tensioner 2 and tighten tensioner bolt to specified torque Tightening torque Timing chain tensioner bolt b 25 N m 2 5 kgf m 18 5 lbf ft 9 Make sure all blue plates 2 are aligned with match marks 1 on corresponding timing sprockets 10 Screw in plunger 2 of timing chain tensioner adjuster 1 clockwise and install a re...

Page 139: ...osen cylinder head No 1 bolts in numerical order 1 8 evenly and gradually NOTE Use 12 point socket wrench for cylinder head No 1 bolts 6 Check all around cylinder head for any other parts required to be removed or disconnected and remove or disconnect 7 Remove cylinder head with its gasket intake manifold and exhaust manifold from cylinder block 8 Remove following components cylinder head if neces...

Page 140: ...stall timing chain 8 Install timing chain cover 9 Install cylinder head cover 10 Install oil pan 11 Install thermostat assembly if removed 12 Install spark plugs 13 Install exhaust manifold if removed 14 Install intake manifold if removed 15 Install petrol fuel injectors if removed Petrol model Reference Fuel Injector Removal and Installation Petrol Model in Section 1G in related manual mentioned ...

Page 141: ...piston and oil hole 5 of connecting rod 2 at specified position as shown in figure c Insert piston pin to piston and connecting rod d Install new piston pin circlips 3 NOTE Install so that circlip end gap comes within the range indicated by arrow 6 3 Install piston rings to piston noting the following As indicated in figure 1st and 2nd rings have direct discrimination mark 1 respectively When inst...

Page 142: ...und 1 2 Limit 0 01 mm 0 0003 in Connecting Rod Bearing General Information Service connecting rod bearings are available in five standard sizes and 0 25 mm 0 0098 in undersize bearing The difference of those sizes is thickness Specified colors for identification of sizes are painted at specified location 1 as shown in figure Connecting Rod Bearing Visual Inspection Check bearing shells for signs o...

Page 143: ...than standard Replace bearings with one size thicker or regrind crankshaft pin to under size and use 0 25 mm 0 0098 in undersize bearings Less than standard Replace bearings with one size thinner or regrind crankshaft pin to under size and use 0 25 mm 0 0098 in undersize bearings Selection of Connecting Rod Bearings Standard size 1 Check connecting rod big end inside diameter according to the foll...

Page 144: ...cting rod bearing inside diameter a 2 Grind crankshaft pin to target diameter 3 Check connecting rod bearing oil clearance Main Bearings Crankshaft and Cylinder Block Removal and Installation AENAR90A1406039 CAUTION Keep the following parts in order They must go back in the position from which they were removed Main bearing Thrust bearing NOTE For identification of each cylinder refer to Cylinder ...

Page 145: ...h spring pin 2 to crankshaft 3 NOTE Use spring pin which is genuine SUZUKI part 09205 05006 b Install sensor plate to crankshaft CAUTION Align spring pin hole 4 on sensor plate with spring pin on crankshaft Inside edge 5 of sensor plate is bent Install sensor plate properly Tightening torque Sensor plate screw a 11 N m 1 1 kgf m 8 5 lbf ft 2 Install main bearings to cylinder block and lower crankc...

Page 146: ...ly b In the same manner as Step a retighten them to 40 N m 4 1 kgf m 29 5 lbf ft c In the same manner as Step a retighten them to 60 Tightening torque Main bearing cap bolt 20 N m 40 N m 60 2 0 kgf m 4 1 kgf m 60 14 5 lbf ft 29 5 lbf ft 60 9 Check that crankshaft rotates smoothly when turning it by hand 10 Apply engine oil to new rear oil seal 1 and install it to engine rear crankshaft oil seal ho...

Page 147: ...001 NOTE For fastener s with asterisk below refer to the specified procedure in Repair Instructions Reference For the tightening torques of fasteners not specified in this section refer to a A A 1 2 b I7V20A141111 01 3 Crankshaft side 1 2 a A A 3 I7V20A141112 01 Fastening part Tightening torque Note N m kgf m lbf ft Camshaft housing bolt 5 0 N m 8 0 N m 11 N m 0 51 kgf m 0 82 kgf m 1 1 kgf m 4 0 l...

Page 148: ...t SUZUKI Bond No 1217G P No 99000 31260 09911M05120 09911M16300 Box end wrench 14 mm Oil seal installer 09911M97720 09914M06310 Oil seal installer Guide camshaft sprocket 09915M67311 SUZUKI scan tool SUZUKI SDT Vacuum gauge This kit includes following items 1 SUZUKI SDT 2 DLC cable 3 USB cable 4 AC DC power supply 5 Voltage meter probe 6 Storage case 1 2 3 4 5 6 ...

Page 149: ...rature 7 Raise engine speed to 4 000 rpm and measure oil pressure Oil pressure specification 300 500 kPa 3 1 5 1 kgf cm2 43 5 72 5 psi at 4 000 rpm 8 After checking oil pressure stop engine and remove special tools 9 Apply thread lock cement to thread portion of oil pressure switch 1 and then tighten switch to specified torque CAUTION Do not apply cement to oil pressure switch hole A Thread lock c...

Page 150: ...nce For the tightening torques of fasteners not specified in this section refer to Recommended Service Material AENAR90A1508001 Special Tool AENAR90A1508002 Fastening part Tightening torque Note N m kgf m lbf ft Oil pressure switch 13 1 3 9 5 Material SUZUKI recommended product or Specification Note Thread lock cement Thread Lock Cement Super 1322 P No 99000 32110 09915M77311 09915M78211 Oil press...

Page 151: ...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 temperatures lower than 15 C 5 F NOTE Ethanol 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 demineralized water or distilled water...

Page 152: ... Reference Item Engine overheats Radiator fan operates Loose or broken water pump generator drive belt Check water pump generator drive belt Not enough coolant Check coolant level and add as necessary Faulty thermostat Check thermostat Faulty water pump Check water pump Dirty or bent radiator fins Clean or remedy Coolant leakage on cooling system Check cooling system for leakage Clogged radiator R...

Page 153: ... to radiator cooling fan relay at each terminal 3 If OK measure voltage between radiator cooling fan relay power supply circuit A1 and vehicle body ground Is it 10 14 V Go to Step 4 Repair or replace radiator cooling fan relay power supply circuit switch side 4 Radiator cooling fan relay check 1 Check radiator cooling fan relay Is it in good condition Go to Step 5 Replace radiator cooling fan rela...

Page 154: ...B 15 I9R90A160003 02 A Petrol model 8 Gasket 17 To heater core B Bi Fuel LPG model 9 Thermostat 18 To LPG pressure regulator 1 Radiator 10 ECT sensor 19 To cylinder block 2 Radiator cap 11 Thermostat case 11 N m 1 1 kgf m 8 5 lbf ft 3 Drain plug 12 O ring 12 N m 1 2 kgf m 9 0 lbf ft 4 Radiator fan assembly 13 Water pump assembly Apply sealant 99000 31250 referring to Water Pump Removal and Install...

Page 155: ...mp pt 4 Run engine at idle speed until radiator fan motor is operated 5 Stop engine and wait until engine comes cooled down to avoid getting burned 6 Add coolant to radiator up to bottom of radiator filler neck and install radiator cap 7 Repeat Step 4 through 6 several times 8 Confirm that coolant level in reservoir is at FULL level mark If coolant is insufficient add coolant 9 Check for coolant l...

Page 156: ...nd replace radiator cooling fan motor Reference Radiator cooling fan motor specified current at 12 V 8 3 1 5 A Radiator Cooling Fan Relay Inspection AENAR90A1606011 Refer to Control Relay Inspection in Section 10B in related manual mentioned in the Foreword of this manual Special Tool AENAR90A1608002 1 I9R90A160012 01 SUZUKI scan tool SUZUKI SDT This kit includes following items 1 SUZUKI SDT 2 DLC...

Page 157: ...t CAUTION Use unleaded fuel only Leaded or low lead fuel can result in engine damage and reduce the effectiveness of the emission control system General Description Fuel System Description AENAR90A1701001 This model employs a bi fuel system capable of utilizing two types of fuel petrol and LPG appropriately This system operates in three fuel modes Petrol MODE Forced LPG MODE and AUTO MODE each of ...

Page 158: ... filling capacity in the luggage compartment The tank valve located in the center of LPG tank is equipped with a safety mechanism Specifications LPG Tank Valve Description AENAR90A1701009 The tank valve which is attached in the center of the LPG tank is equipped with Non return Valve with LPG inlet 80 fill limiter Service valve with excess flow check valve Pressure relief valve Pressure relief dev...

Page 159: ...which is kept in close position Gas pressure pushes this piston open by overcoming the spring tension till its stem is set on the cam When the float reaches 80 the piston stem slides down the cam and the flow of gas to the tank is restricted LPG Fuel Filter Description AENAR90A1701007 The LPG fuel filter is located downstream from the LPG pressure regulator to remove any impurities mostly oil from...

Page 160: ...lve 3 Regulator Body 4 Gas outlet connector 5 Gas Inlet 6 Coolant Connectors 9 10 11 12 1 3 5 6 7 4 5 8 2 IAR90A170003 01 1 LPG tank 5 Shut off valve 9 LPG fuel filter 2 LPG Filler Valve 6 LPG pressure gauge 10 LPG fuel delivery pipe 3 LPG tank valve 7 LPG pressure sensor 11 MAP and temperature sensor 4 Manual valve 8 LPG pressure regulator 12 LPG fuel injector ...

Page 161: ... 33 34 35 36 37 38 39 40 41 42 43 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 30 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 A C01 E01 2928 C01 8 C01 29 BLK C01 28 BLK BLK I9R90A172068 01 A ECM connector View A C2 Fuel injector No 2 control circuit 8 LPG fuse B LPG control module connector View A C3 Fuel injector No 3 control circuit 9 Petrol fu...

Page 162: ...l injector turned off confirm that engine speed falls lower than specified idle speed 8 If rates of engine speed decrease are not in scale check following items Fuel injector circuit Petrol fuel injector LPG fuel injector Spark plug Ignition coil circuit Ignition coil Engine compression Not Using SUZUKI Scan Tool 1 Place gear shift lever in Neutral and apply parking brake 2 Start engine and warm u...

Page 163: ...al valve 7 LPG pressure sensor 10 MAP and temperature sensor 2 LPG Filler Valve 5 Shut off valve 8 LPG pressure regulator 11 LPG fuel injector 3 LPG tank valve 6 LPG pressure gauge 9 LPG fuel delivery pipe Step Action Yes No 1 DTC check 1 Check DTC Is there DTC s Go to applicable DTC troubleshooting and recheck Go to Step 2 2 LPG fuel feed line check 1 1 Check LPG fuel pipe LPG fuel hose and joint...

Page 164: ... pressure is within normal specification check LPG fuel filter for evidence of dirt and contamination If measured pressure is out of specification there is possibility of the following cause LPG fuel leakage Vacuum hose fault LPG pressure regulator fault LPG pressure specification At specified idle speed 110 160 kPa 1 1 1 6 kg cm2 16 0 23 2 psi 7 Relieve LPG pressure 8 Remove special tools from LP...

Page 165: ...injector 2 by using sound scope 1 or the like increase engine speed to higher than 3 000 rpm 4 Check that injector operation sound stops when throttle valve is closed instantly and it is heard again when engine speed is reduced to approx 2 000 rpm or less 5 If injector sound is not heard perform Fuel Injector Circuit Check Repair Instructions Fuel System Components AENAR90A1706001 2 1 I9R90A171007...

Page 166: ...l System LPG 1G 10 LPG System 48 49 1 2 3 5 7 6 9 8 29 11 10 28 24 25 41 18 View A View A 17 4 15 22 44 23 26 40 39 19 27 30 45 38 12 13 20 21 16 14 31 37 32 46 47 36 42 33 34 35 43 a b c d IAR90A170005 02 ...

Page 167: ...G Injector Hose Clip Intake side 4 LPG Clamp Bracket 24 LPG Hose Water Tube Inlet no 2 44 LPG Water tube Clamp 5 LPG Pipe Clamp 25 LPG Hose Water Tube Inlet no 3 45 LPG Vacuum hose clamp 6 LPG Regulator assembly 26 LPG Hose Water Tube Inlet no 4 46 LPG MAP sensor bolt 7 Regulator Bracket 27 Throttle Body Outlet Hose 47 LPG Rail Bolt 8 LPG Vaporiser Bolt 28 Vacuum Hose LPG Regulator no 1 48 LPG tan...

Page 168: ...k the inspection points on LPG feed line which are pointed by arrows in figure for LPG fuel leakage using gas leak detection liquid or gas detector as follows For inspection points of low pressure LPG fuel feed line a Start engine and run it at idle speed b Check the inspection points for LPG fuel leakage For Inspection points of high pressure LPG fuel feed line a Start engine and run it at idle s...

Page 169: ...exhaust gas as gas detectors will react to it Let gas detectors absorb gas for at least 10 seconds in each location Because of way they are constructed there is small time lag before gas detectors react to gas Fuel Line On Vehicle Inspection AENAR90A1706005 LPG System Inspect LPG fuel feed lines for LPG fuel leakage Visually inspect LPG fuel feed lines for LPG fuel hose crack deterioration and dam...

Page 170: ...ition switch to ON position and select Forced LPG MODE with selector switch 3 Using sound scope 1 or the like check operating sound of LPG fuel injector 2 when engine is running or cranking Cycle of operating sound should vary according to engine speed If no sound or unusual sound is heard check LPG fuel injector circuit or LPG fuel injector Fuel Injector Removal and Installation AENAR90A1706009 L...

Page 171: ...gulator On Vehicle Inspection AENAR90A1706011 1 Check LPG pressure regulator for coolant leak deformation and damage If any faulty condition is found replace LPG pressure regulator 2 Check LPG pressure regulator for LPG fuel leakage If faulty condition is found replace LPG pressure regulator 3 Check the shut off valve operation sound as follows a Turn ignition switch to ON position b Select Forced...

Page 172: ...attery 4 Remove LPG fuel pipe 1 5 Disconnect the following pipe hoses and connectors from LPG pressure regulator Coolant hoses 1 LPG fuel hose 2 Vacuum hose 3 LPG fuel pipe 4 Manual shut off valve connector 5 6 Remove LPG pressure regulator 1 with LPG pressure regulator bracket 2 7 Remove LPG pressure regulator bracket from LPG pressure regulator if necessary Installation Reverse removal procedure...

Page 173: ...eck result is not satisfactory replace LPG pressure regulator filter Filter Check LPG pressure regulator filter for evidence of dirt and contamination If filter is faulty replace LPG pressure regulator filter LPG Pressure Regulator Filter Removal and Installation AENAR90A1706014 Removal 1 Relieve LPG pressure in LPG fuel feed line 2 Remove Assembly Screw 1 with O ring 2 Separate O ring 2 from Asse...

Page 174: ... Relieve LPG pressure in LPG fuel feed line 2 Remove Fuel Pressure Regulator 3 Mount LPG pressure regulator on nylon bench vise 4 Remove Coil cap 1 with O ring 2 5 Remove Coil 3 and Elastic washer 4 6 Unscrew Coil Support 5 from Solenoid valve body 7 Remove Coil Support 5 with O ring 6 8 Remove Solenoid Valve Core Group 7 9 Clean components like Body Coil support Coil Cap Coil etc Installation Rev...

Page 175: ...oup 4 5 Remove Solenoid valve 1 with O ring 3 from Inlet fitting group 4 6 Unscrew Inlet fitting group 4 and remove it with Water Elbow fork 24 7 Unscrew two screws 5 and remove Fork 9 8 Unscrew screw 6 by Torx 10 wrench and remove Outlet Pipe Holder 7 with O ring 8 9 Unscrew six screws 10 using Torx 30 wrench 10 Remove Cover High Pressure side 11 11 Mount LPG pressure regulator on nylon bench vis...

Page 176: ...torque Screw a 2 5 N m 0 25 kgf m 1 84 lbf ft Tighten screw 6 to specified torque Tightening torque Screw a 1 0 N m 0 1 kgf m 0 73 lbf ft Tighten Nut 2 to specified torque Tightening torque Nut a 16 N m 1 6 kgf m 11 8 lbf ft Check for LPG fuel leaks LPG Valve Control Relay Inspection AENAR90A1706023 Refer to Control Relay Inspection in Section 10B in related manual mentioned in the Foreword of thi...

Page 177: ...13 4 Disconnect LPG solenoid and electronic fuel indicator connectors 5 Remove LPG fuel pipe No 1 and service line connections 6 Remove LPG filler valve pipe connected to tank valve 7 Remove bolts 10 anchoring the LPG tank on frame 8 Remove LPG tank 9 with tank valve 8 from the frame 4 Installation Reverse removal procedure for installation noting the following 1 Tighten LPG fuel pipe No 1 to spec...

Page 178: ... valve 3 4 Remove LPG Filler Valve screws 1 followed by LPG Filler Valve assembly 2 from vehicle 5 Remove Vent hose connector 2 Protection tube LPG joint 3 and LPG pipe clamp 4 LPG filler pipe No 1 and LPG filler pipe No 2 Installation 1 Install LPG Filler Valve by reversing the removal procedure 2 Install new O rings to LPG filler pipes 3 Install LPG joint to specified torque Tightening torque LP...

Page 179: ... 82 6 0 LPG fuel injector hose clamp 1 4 0 14 1 0 LPG fuel pipe nut 17 1 7 12 5 Assembly Screw 15 1 5 11 06 Coil Support 18 1 8 13 27 Coil Cap 12 1 2 8 85 Screw 9 5 0 95 7 00 Inlet Fitting Group 20 2 0 14 75 Screw 2 5 0 25 1 84 Screw 1 0 0 1 0 73 Nut 16 1 6 11 8 LPG fuel pipe nut 13 1 3 9 6 Bolt Bracket 45 4 5 33 19 LPG joint 13 1 3 9 6 09912M56720 09912M58432 3 way joint Fuel pressure gauge hose ...

Page 180: ...tory Go to Step 3 Go to Step 4 3 Ignition timing check 1 Check ignition timing Is check result satisfactory Ignition system is in good condition Repair or replace malfunctioning part 4 Confirmation of malfunction detected cylinder 1 Confirm any cylinder that the malfunction is detected on ignition spark test Are there malfunctions in all cylinders Go to Step 8 Go to Step 5 5 Ignition spark test 2 ...

Page 181: ...its in good condition Go to Step 8 Repair or replace malfunctioning part 8 Ignition coil assembly power supply and ground circuit check 1 Check power supply and ground circuits of ignition coil assembly for open short and poor connection Are circuits in good condition Substitute a known good ECM and recheck Repair or replace malfunctioning part Step Action Yes No ...

Page 182: ...on meter ECM faulty Check ECM Petrol model ECM Power and Ground Circuit Check Petrol model in Section 1A in related manual as mentioned in FOREWORD on this manual Bi Fuel LPG model Wiring faulty Repair wiring IC regulator faulty Replace IC regulator Charge warning light does not go out with engine running battery requires frequent recharging Drive belt loose or worn Adjust or replace drive belt Co...

Page 183: ... reservoir 2 Remove EVAP canister 3 Detach LPG fuel filter bracket 4 Bi fuel using LPG model Detach pipe component 5 Bi fuel using LPG model Installation 1 Reverse removal procedure 2 Tighten battery cables securely NOTE Check to be sure that ground cable has enough clearance to hood panel by terminal 1 2 1 4 3 I9R90A1A0005 02 2 1 5 3 4 I9R90A1A0006 01 ...

Page 184: ...1J 3 Charging System ...

Page 185: ...2B Special Tool 2B Rear Suspension 2C 1 General Description 2C Rear Suspension Description 2C Repair Instructions 2C 1 Rear Wheel Alignment Inspection 2C Rear Suspension Components 2C Rear Shock Absorber Removal and Installation 2C Rear Shock Absorber Inspection 2C Rear Coil Spring Bump Stopper and Spring Upper Seat Removal and Installation 2C 1 Rear Coil Spring Bump Stopper and Spring Upper Seat ...

Page 186: ...ck working place shop cloth on top of the jack to protect paint surface of the lifted portion from damaging 3 Detach rear shock absorbers 1 both sides 4 Lower rear axle gradually as far down as where coil spring 2 can be removed 5 Remove rear coil spring 6 Remove bump stopper 2 and spring upper seat 1 from vehicle body Installation 1 Install spring upper seat 1 to vehicle body 2 Install bump stopp...

Page 187: ...OTE Before jack working place shop cloth on top of the jack to protect paint surface of the lifted portion from damaging 5 Remove floor jacks from rear axle 6 Install rear wheel and tighten wheel nuts to specified torque 7 Lower hoist and bounce vehicle up and down several times to stabilize suspension 8 Tighten rear shock absorber upper bolts and lower nuts to specified torque 1 I9R90A230002 01 ...

Page 188: ...ircuit Diagram 9A A 9 CAN Circuit Diagram 9A 38 A 10 Security Control System Circuit Diagram 9A B 1 Windshield Wiper and Washer Circuit Diagram 9A B 2 Rear Wiper and Washer Circuit Diagram 9A B 3 Rear Defogger Circuit Diagram 9A B 4 Power Window Circuit Diagram 9A B 5 Power Door Lock Circuit Diagram 9A B 6 Power Mirror Circuit Diagram 9A B 7 Horn Circuit Diagram 9A C 1 Combination Meter Circuit Di...

Page 189: ... Schematic and Routing Diagram 9C 3 Combination Meter Circuit Diagram 9C 3 Selector Switch Circuit Diagram Bi Fuel LPG Model 9C 4 Diagnostic Information and Procedures 9C 4 Combination Meter System Check 9C Inspection of Combination Meter and Its Circuit 9C 4 Inspection of Selector Switch and Its Circuit Bi Fuel Model 9C 6 Repair Instructions 9C 7 Instrument Panel Removal and Installation 9C Instr...

Page 190: ...Description If Equipped 9F Keyless Entry System Description If Equipped 9F Dome Light Control System Description If Equipped 9F Security System Description If Equipped 9F Rear End Door Window Defogger Control System Description If Equipped 9F Schematic and Routing Diagram 9F Power Door Lock Circuit Diagram 9F Component Location 9F Power Door Lock System Component Location 9F Diagnostic Information...

Page 191: ...y Dimensions 9K Repair Instructions 9K Panel Clearance 9K Silencer Sheet Installation Area 9K Paint Coatings 9L Precautions 9L Precautions for Working on Air Bag System 9L General Description 9L Anti Corrosion Treatment Construction 9L Description of Plastic Parts Finishing 9L Repair Instructions 9L Sealant Application Areas 9L Undercoating Application Areas 9L Anti Corrosion Compound Application ...

Page 192: ...ic systems observe the cautions described in Precautions for Electrical Circuit Service in Section 00 to protect electrical parts and to prevent a fire General Description Abbreviations AENAR90A9101001 Refer to the Abbreviations in Section 0A for the general abbreviations Wire Connector Color Symbols AENAR90A9101002 Refer to Wire Color Symbols in Section 0A ...

Page 193: ...n relay Normally closed relay Normally open switch Normally closed switch I2RH01910910 01 IYSQ01910915 01 IYSQ01910916 01 IYSQ01910917 01 IYSQ01910918 01 IYSQ01910919 01 IYSQ01910920 01 IYSQ01910921 01 IYSQ01910922 01 IYSQ01910923 01 IYSQ01910924 01 IYSQ01910925 01 IYSQ01910926 01 H I2RH01910911 01 I5JB0B910995 02 IYSQ01910929 01 IYSQ01910930 01 IYSQ01910931 01 IYSQ01910932 01 IYSQ01910933 01 IYSQ...

Page 194: ...Side air bag R Side air bag L Side curtain air bag R Side curtain air bag L Glow plug I2RH01910912 01 I3JA01910902 01 I5RH01910901 01 I2RH01910915 01 I2RH01910916 01 I3JA01910904 01 I3JA01910905 01 I3JA01910906 01 I3JA01910907 01 I2RH01910921 01 I2RH01910922 01 I3JA01910908 01 I2RH01910924 01 XX Cont M I2RH01910925 01 I3JA01910909 01 I3JA01910910 01 I3JA01910911 01 I3JA01910912 01 I2RH01910930 01 ...

Page 195: ...Interior light harness Roof wire Roof radio antenna wire Rear speaker wire L Floor harness Floor antenna wire Coupling harness Accessory socket wire G sensor wire M Rear bumper wire O Rear end area harness wires except Rear bumper wire Q Side curtain air bag wire Side air bag harness Pretensioner wire R Fuel pump wire S Contact coil A 2 Connector Number B Ground Point No 12 11 B B Connector code A...

Page 196: ...in the illustration Refer to List of Connectors NOTE Molded terminal numbers that are different from the above can be found on some connectors in rare cases These molded numbers are not applied in this manual 2 Connector type A40 View Z View Z 1 1 2 3 4 5 6 7 8 2 3 4 5 6 7 8 D18 5 D18 A40 Connector code Connector code Terminal No CONNECTOR LIST Male terminal Female terminal Z View Z I5RS0A910901 0...

Page 197: ...rdinary connector but a part of the continuous wire in the harness 5 Weld splice W S Several different wires with the same wire color are joined by welding at a W S B15 B15 B14 B16 5 7 B14 B16 5 7 I2RH01910904 01 BLK RED YEL WHT BLK J C Example A A A A B B C C C C A A A A B B B B C C C WHT BLK WHT BLK RED YEL RED YEL BLK BLK BLK WHT BLK WHT BLK WHT BLK WHT BLK A A A A A A J C I9Y10A910A59 02 Weld ...

Page 198: ...A A B 15A 2 6 5 13 J B Connector No Terminal No BCM IG1 MTR Power etc A B CONT K LINE K LINE A B SIGNAL A B SIGNAL A B SIG A B SIG IG Sig 10A EPS AT MTA 4 6 1 3 2 4 8 11 9 12 9 11 23 25 30 29 Example J B BLK WHT J B ORN GRN BLU J B J B inner circuit I4RS0A910903 01 SYSTEM CIRCUIT DIAGRAM Connector code and terminal No CONNECTOR LAYOUT DIAGRAM Connector location CROSS REFERENCE CONNECTOR LIST Conne...

Page 199: ...TEM CIRCUIT DIAGRAM GROUND POINT CROSS REFERENCE Windoshield washer motor Individual circuit fuse box 20 15A Windoshield wiper motor E40 E09 E20 16 2 1 Off On Circuit breaker 60A B003 YEL BLU 1 20 5 2 1 3 4 6 7 BLU BLK BLK 10 BLK BLK 9 10 10 BLK M BLU BLU WHT BLU RED M Device body grounding is not given the ground point number I4JA01910985 01 ...

Page 200: ...L BLK PNK BLK LT GRN YEL GRN YEL BLU BLK WHT WHT BLK WHT GRN RED GRN WHT WHT BLU WHT RED WHT BLU WHT YEL WHT GRN WHT GRN WHT GRN BLU BLU RED RED YEL BLU RED Individual circuit fuse box Main fuse box Supplementary fuse box 11 11 2 4 3 12 13 14 15 16 17 18 19 20 21 29 32 12 13 14 15 16 17 18 19 20 21 15A 15A 15A 20A 20A 15A 15A 15A 15A 15A 15A E44 3 2 1 B01 1 E45 1 E40 2 1 Fuse RED YEL YEL WHT GRN 1...

Page 201: ... to two pages before You will find the same symbol with the arrows directing opposite in the referenced page The circuit continues between the symbols C Circuit Jumping Point Direction NOTE The circuit continues to the same symbol with opposite direction within the page You will find the other symbol in the direction of the arrow D Terminals in One Connector Mark E Wire Color F Shield Wire G Groun...

Page 202: ...1 2 8 BRN RED E52 1 2 E52 1 BRN RED RED 2 BRN RED BRN RED Motor Motor M M 6 5 5 A B A B 5 6 1 2 5 6 4 6 4 4 DOOR 2 DOOR 2 C71 E03 E34 O06 C31 E19 A B C F G H Other system circuit D I K L E33 7 5 E34 1 2 1 4 3 E08 ORN WHT YEL RED YEL YEL RED 4 3 YEL BLK RED ORN GRN GRN GRN B A GRN GRN 3 15A 2 J E N O M GB GR Y Y GB P 3 4 2 L50 1 GR Y GR BLK BLK 3 G20 XX Cont M GRN RED I8RW0A910A46 02 ...

Page 203: ...S C33 C37 C123 C38 C30 C83 C121 C282 C283 C343 To E371 C01 C32 C165 3 4 5 2 1 C A IAR90A910901 01 No Color Connective position Remarks C01 BLK ECM C13 GRY LPG control module Bi fuel using LPG model C30 BLK MAP sensor Bi fuel using LPG model C31 GRY CKP sensor C32 BLU CMP sensor C33 GRY VSS C35 BLK TP sensor C36 BLK MAP sensor C37 GRY Knock sensor C38 BLK IAT sensor C39 BLK ECT sensor C42 GRY HO2S ...

Page 204: ...e box C343 N Main harness To E371 No Color Connective position Remarks E485 E63 E62 E68 W S E165 E281 E282 E302 E303 E163 E304 E210 E65 E164 E64 E183 E151 E161 E159 E311 E312 E36 E222 W S E225 E221 E371 To C343 E166 E227 E265 E229 E234 E01 E267 E69 E152 E162 E160 E134 6 8 7 E IAR90A910902 02 No Color Connective position Remarks E01 BLK ECM E485 GRY LPG control module Bi fuel using LPG model E36 BL...

Page 205: ...al light R E166 N Side turn signal light L E183 GRY Brake fluid level switch E210 BLK Security hood switch If equipped E221 BLK Main relay E222 BLK Radiator cooling fan relay E225 BLK Starting motor relay E227 BLK Fuel pump relay E229 BLK A C compressor relay E234 BLK Front fog light relay If equipped E265 BLK Fuel shutoff valve relay Bi fuel using LPG model E267 N Option 2 Option E281 BLK Horn E2...

Page 206: ...R90A910904 01 No Color Connective position Remarks E181 N Brake light switch E266 N Option 1 Option E268 BLK Option 3 Option E317 BRN Individual circuit fuse box No 2 Bi fuel using LPG model E323 N J B E324 N J B E381 BLU Instrument panel harness To G333 E382 N Instrument panel harness To G334 E387 GRY Floor harness To L371 ...

Page 207: ... G28 GRY Keyless security control module If equipped G32 N Evaporator temperature sensor G61 N Blower motor G101 N Blower motor resistor G115 BLK LPG select switch Bi fuel using LPG model G141 BLK Combination switch G144 N Combination switch G146 N Main switch key G147 N Ignition switch G151 GRN Front fog light switch If equipped G152 N Headlight leveling switch G153 N Hazard switch G154 GRN HVAC ...

Page 208: ...el harness To G347 If equipped No Color Connective position Remarks 16 15 13 14 L390 To O231 L164 L134 L103 L61 L165 L133 L32 L135 L432 To K159 L381 To J217 L376 To G343 L380 To J216 L161 L167 L170 L04 L31 L382 To J218 L379 To J215 L371 To E387 L374 To G341 L162 L163 L131 L314 L313 L315 L10 L09 L L104 IAR90A910903 02 No Color Connective position Remarks L09 GRY Door lock control module If equipped...

Page 209: ...J B L371 GRY Main harness To E387 L374 N Instrument panel harness To G341 L376 YEL Instrument panel harness To G343 L379 N Front door wire Driver side To J215 If equipped L380 N Front door wire Passenger side To J216 L381 N Rear door wire R To J217 L382 N Rear door wire L To J218 L390 N Rear end door harness To O231 L432 N Rear roof wire To K159 If equipped No Color Connective position Remarks 37 ...

Page 210: ...sor relay 6 Fuel pump relay 8 BLANK No Fuse Description on the cover Protected circuit 30 A IGN Ignition switch 10 A CPRSR A C compressor relay 7 5 A LPG VLV Fuel shutoff valve relay Bi fuel using LPG model 15 A FR FOG Front fog light relay 30 A RDTR Radiator cooling fan relay BLANK BLANK BLANK 15 A H L L Headlight L 15 A H L R Headlight R BLANK BLANK BLANK 30 A ST Starting motor relay 15 A FI Mai...

Page 211: ...tch Audio 10 A RR FOG Combination switch 10 A TAIL Combination switch 10 A BACK Back up light switch HVAC control unit 10 A ABS ABS control module 10 A MTR Combination meter Flasher relay Keyless security control module Door lock control module 15 A IG COIL ECM Generator Immobilizer control module Ignition coil 1 Ignition coil 2 Ignition coil 3 LPG control module Bi fuel using LPG model LPG select...

Page 212: ...switch Power window sub switch Rear power window sub switch R Rear power window sub switch L 7 5 A LPG LPG control module Bi fuel using LPG model Fuel injector 1 Bi fuel using LPG model Fuel injector 2 Bi fuel using LPG model Fuel injector 3 Bi fuel using LPG model BLANK BLANK BLANK Abbreviation Full term Abbreviation Full term AS Assistant Front passenger LP Light CTR Center O H Over head DR Driv...

Page 213: ...NT SDL ENG GND BCM FLOOR DOME CONT BACK UP LP SW A C SW SPEEDOMETER 3 1 18 4 SPEEDOMETER A B CONT 17 2 MAIN SW FL BOX BAT 2 14 8 2 2 24 12 1 BACK 10A 2 1 Continued Individual circuit fuse box No 2 In J B 24 23 27 21 2 1 1 2 3 4 5 3 2 4 5 10 12 9 8 13 6 1 11 14 7 1 2 3 4 5 6 9 10 11 12 13 14 7 8 15 16 17 18 19 20 21 22 23 24 1 2 3 4 5 6 7 8 25 26 27 28 29 9 10 11 12 13 30 31 32 14 15 16 1 2 3 IAR90...

Page 214: ...S CONT SDL ENG GND BCM FLOOR DOME CONT BACK UP LP SW A C SW SPEEDOMETER 3 1 1 18 4 SPEEDOMETER A B CONT 17 2 MAIN SW FL BOX BAT 2 14 9 8 2 2 24 12 1 ABS 10A BACK 10A 2 1 Continued Individual circuit fuse box No 2 In J B 24 23 28 27 22 21 2 1 1 2 3 4 5 3 2 4 5 10 12 9 8 13 6 1 11 14 7 1 2 3 4 5 6 9 10 11 12 13 14 7 8 15 16 17 18 19 20 21 22 23 24 1 2 3 4 5 6 7 8 25 26 27 28 29 9 10 11 12 13 30 31 3...

Page 215: ...URN LH RR COMB LP L COMB SW LP COMB SW LP COMB SW LP POSN LP NR FL BOX BAT 3 B D L 20A BCM FLOOR 3 RR COMB LP L POSN LP NL 3 2 Continued Individual circuit fuse box No 2 In J B 30 Continued 4 3 2 1 4 Connector No Terminal No L313 L315 L314 G271 E323 E324 2 1 1 2 3 4 5 3 2 4 5 10 12 9 8 13 6 1 11 14 7 1 2 3 4 5 6 9 10 11 12 13 14 7 8 15 16 17 18 19 20 21 22 23 24 1 2 3 4 5 6 7 8 25 26 27 28 29 9 10...

Page 216: ...ircuit fuse box No 2 In J B 4 3 1 2 1 16 BLW FAN MOT H L LVL BLOWER MOTOR RLY BLW 30A 16 4 3 1 2 Connector No Terminal No 25 RADIO 5 ECU MAIN 1 DOME L313 L315 L314 G271 E323 E324 2 1 1 2 3 4 5 3 2 4 5 10 12 9 8 13 6 1 11 14 7 1 2 3 4 5 6 9 10 11 12 13 14 7 8 15 16 17 18 19 20 21 22 23 24 1 2 3 4 5 6 7 8 25 26 27 28 29 9 10 11 12 13 30 31 32 14 15 16 5 9 22 INST GND POWER GND LVL SW 3 DOME GND 4 28...

Page 217: ...dual circuit fuse box No 2 In J B 31 MAIN SW Connector No Terminal No MAIN SW L313 L315 L314 G271 E323 E324 2 1 1 2 3 4 5 3 2 4 5 10 12 9 8 13 6 1 11 14 7 1 2 3 4 5 6 9 10 11 12 13 14 7 8 15 16 17 18 19 20 21 22 23 24 1 2 3 4 5 6 7 8 25 26 27 28 29 9 10 11 12 13 30 31 32 14 15 16 5 32 10 MAIN SW R B ST RLY COIL ST SIG 10A 17 E324 L313 G271 E323 L315 L314 1 2 3 I9R90A910919 03 ...

Page 218: ... Refer to B 6 Power Mirror Circuit Diagram Refer to B 7 Horn Circuit Diagram Refer to C 1 Combination Meter Circuit Diagram Refer to D 1 Headlight System Circuit Diagram Refer to D 2 Position Tail and Licence Plate Light System Circuit Diagram Refer to D 3 Front Fog Light System Circuit Diagram Refer to D 4 Illumination Light System Circuit Diagram Refer to D 5 Interior Light System Circuit Diagra...

Page 219: ...s 17 E371 C343 2 G333 E381 BLK WHT BLK WHT 80A Main fuse box C192 J B 1 C283 IG COIL 35 15A 24 1 E323 13 C194 2 4 1 3 WHT BLU PNK BLU BLU WB PB WB ECM A 5 C 1 15 WHT BLU WHT BLU BLK Generator IC regulator IAR90A910905 01 ...

Page 220: ... 1 4 3 15A 24 15A 11 10A 2 GRN YEL GY CPRSR Compressor relay E229 Relay Compressor C141 1 E323 13 E371 C343 11 HO2S W S W S W S W S BRN WHT BRN BLK ORN WHT BLK RED C01 1 2 41 24 23 PNK WHT ECM 1 3 2 4 BLK RED BLU YEL BLK RED BLK RED BLK RED BLK RED BLK RED E01 4 12 7 1 2 GRY E227 4 2 3 1 2 10 BLK RED 11 16 Individual circuit fuse box No 1 32 9 13 YEL RED GRN BLU Knock sensor C37 1 C42 3 2 4 I9R90A...

Page 221: ...CM C91 1 2 C92 1 2 C93 1 2 2 1 3 BLK ORN BLU RED BLU WHT BLU YEL BLK RED BLK RED BLK RED ECT sensor 1 C38 RED GRN 2 IAT sensor A 4 LgR 30A RDTR 5 Relay motor BLU RED LT GRN RED BR 6 E01 1 14 1 2 19 21 18 36 3 E371 C343 4 3 BLK RED GRY BLK RED BLK RED BLK RED BLK RED Individual circuit fuse box No 1 4 3 2 1 E222 2 Open Close C35 2 3 1 TP sensor I9R90A910925 03 ...

Page 222: ... switch 1 3 ECM 3 CMP sensor C01 C01 C01 BLK BLK 3 4 8 3 C32 35 E01 16 15 14 RED YEL BLU BLK BLK YEL BLK BLK BLK 42 PNK BLU 28 29 BLK BLK BLK RED 1 2 YG YEL GRN YEL BLK WHT RED YEL RED Immobilizer control module W S BLK RED W S W S W S A 7 Generator A 2 YB YR PB 43 BLU WB 17 Starting motor relay A 1 BLK RED EVAP canister purge valve C123 1 2 C121 2 1 3 ISC valve IAR90A910906 02 ...

Page 223: ... GRN YEL BRN B R W RB WB P S Cont M F 4 PPL GW GY Ignition coil 2 31 GRN BLK GB Ignition coil 3 Ignition coil 1 HVAC control unit A 3 A 9 C 1 E 1 P GRN ORN GRY RED BLU RED Evaporator temperature sensor 1 2 G32 17 ORN E381 G333 WG refrigerant pressure sensor E36 2 3 WHT GRN BLU WHT 15 7 G333 E381 18 19 BLU WHT ORN WHT GRN 1 E08 10 8 I9R90A910927 03 ...

Page 224: ...E221 2 1 4 3 15A 24 15A 11 10A 2 GRN YEL GY CPRSR Compressor relay E229 Relay Compressor C141 1 E323 13 E371 C343 11 HO2S W S W S W S W S BRN WHT BRN BLK YEL RED ORN WHT BLK RED C01 1 2 41 24 23 PNK WHT ECM 1 3 2 4 BLK RED BLU YEL BLK RED BLK RED BLK RED BLK RED BLK RED E01 4 12 7 1 2 GRY E227 4 2 3 1 2 10 BLK RED 11 16 Individual circuit fuse box No 1 32 9 13 GRN BLU Knock sensor C37 1 C42 3 2 4 ...

Page 225: ...HT RED WHT BLK RED ECT sensor 1 C38 RED GRN BLK ORN 2 IAT sensor A 4 30A RDTR 5 Relay motor BLU RED LT GRN RED BR 6 E01 1 5 C81 1 2 1 WHT BLK 1 C82 1 2 2 GRY 10 C83 1 2 3 WHT BLU 18 RED WHT 1 RED WHT 10 14 6 C01 WHT GRN BRN BRN YEL 14 WHT 39 RED BLK BLK BLK 40 1 2 19 21 18 36 3 E371 C343 4 3 BLK RED GRY BLK RED BLK RED BLK RED BLK RED Individual circuit fuse box No 1 7 5A LPG 40 Individual circuit...

Page 226: ... switch 1 3 ECM 3 CMP sensor C01 C01 C01 BLK BLK 3 4 8 3 C32 35 E01 16 15 14 RED YEL BLU BLK BLK YEL BLK BLK BLK 42 PNK BLU 28 29 BLK BLK BLK RED 1 2 YG YEL GRN YEL BLK WHT RED YEL RED Immobilizer control module W S BLK RED W S W S W S A 7 Generator A 2 YB YR PB 43 BLU WB 17 Starting motor relay A 1 BLK RED EVAP canister purge valve C123 1 2 C121 2 1 3 ISC valve IAR90A910908 01 ...

Page 227: ...D Evaporator temperature sensor 1 2 G32 17 ORN E381 G333 WG refrigerant pressure sensor E36 2 3 WHT GRN BLU WHT 15 7 G333 E381 18 20 E371 C343 19 12 13 E387 L371 5 E382 G334 G333 E381 3 15 10 21 19 BLU WHT ORN WHT GRN 1 L104 2 1 E323 13 LPG Cont M 7 5A LPG VLV 3 Individual circuit fuse box No 1 15A IG COIL 24 J B Fuel shutoff valve relay 1 2 4 3 E265 4 LT GRN 29 LT GRN BLK LT GRN LT GRN BLK 22 21 ...

Page 228: ...nt M CAN CAN CAN DLC 8 G333 E381 18 7 RB WB R W R W Bi fuel using LPG model IAR90A910910 01 C01 C13 C30 C31 Bi fuel using LPG model Bi fuel using LPG model C32 C33 C35 C36 C37 C38 C39 C42 C81 C82 C83 C91 2 1 13 12 3 4 5 6 7 8 9 10 11 15 14 27 16 17 18 19 20 21 22 23 24 25 26 29 28 31 30 43 42 32 33 34 35 36 37 38 39 40 41 MCONF430001 01 18 19 20 21 22 23 24 25 26 10 11 12 13 15 14 16 17 27 28 29 3...

Page 229: ...030103 02 1 2 3 MCONF030085 01 1 2 MCONF020176 01 1 MCONF010076 01 1 MCONF010029 01 1 2 MCONF020176 01 1 MCONF010078 01 2 1 4 3 MCONF040127 01 1 MCONF010021 01 1 MCONF010022 01 1 MCONF010078 01 1 MCONF010082 01 3 2 5 6 10 12 9 8 13 4 1 14 15 16 17 18 19 20 11 7 MCONF200008 01 2 1 3 4 5 6 7 8 12 11 10 9 16 15 13 14 18 17 19 20 21 22 23 24 25 26 MCONF260029 01 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 ...

Page 230: ...0008 01 1 2 MCONF020008 01 1 MCONF010130 01 1 MCONF010130 01 1 MCONF010130 01 1 MCONF010130 01 1 2 MCONF020277 01 1 2 MCONF020169 01 1 2 MCONF020170 01 4 3 2 1 MCONF040176 01 1 2 3 4 5 6 9 10 11 12 13 14 7 8 15 16 MCONF160037 01 2 1 MCONF020202 01 4 5 2 1 10 8 11 12 7 3 6 20 19 18 17 16 15 14 9 13 MCONM200004 01 11 10 9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13 12 MCONM220003 01 13 12 11 10 8 ...

Page 231: ...7 8 17 18 19 20 21 22 11 12 9 10 13 14 15 23 24 25 28 29 26 27 30 31 32 16 MCONF320007 01 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 MCONF200012 01 2 1 MCONF020207 01 1 MCONM010040 01 17 18 19 20 21 22 23 24 1 2 3 4 5 6 7 8 25 26 27 28 29 9 10 11 12 13 30 31 32 14 15 16 MCONF320021 01 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 MCONF220009 01 11 12 13 14 6 7 8 9 2 3 4 10 5 1 M...

Page 232: ...CONM280004 01 22 21 20 19 26 25 14 13 12 11 6 5 4 3 2 1 10 9 18 17 8 7 16 15 24 23 28 27 MCONM280004 01 8 3 7 9 10 11 4 5 6 2 1 MCONF110014 01 8 3 7 9 10 11 4 5 6 2 1 MCONF110014 01 1 2 3 MCONF030134 01 1 2 3 MCONF030134 01 1 2 7 8 9 10 11 12 13 14 20 21 15 16 17 18 19 22 23 3 4 5 6 MCONF230004 01 2 3 4 5 6 7 15 1 14 16 17 18 19 20 10 11 12 23 24 25 13 26 8 9 21 22 MCONF260026 01 2 3 4 5 6 7 15 1 ...

Page 233: ...2 1 6 7 9 10 20 19 18 17 16 15 14 13 12 11 8 MCONM200008 01 4 3 2 1 MCONF040099 01 14 13 12 11 4 3 22 21 20 19 28 27 26 25 24 23 18 17 10 9 16 15 8 7 2 1 6 5 MCONF280006 01 14 13 12 11 4 3 22 21 20 19 28 27 26 25 24 23 18 17 10 9 16 15 8 7 2 1 6 5 MCONF280006 01 11 7 3 10 9 8 6 5 4 1 2 MCONM110006 01 11 7 3 10 9 8 6 5 4 1 2 MCONM110006 01 11 7 3 10 9 8 6 5 4 1 2 MCONM110006 01 3 2 1 MCONM030021 01...

Page 234: ...rating mode is switched to AUTO MODE Selector Switch Indications Petrol MODE Petrol indicator lights up and LPG pressure indicator green or red remains OFF Forced LPG MODE LPG indicator lights up When amount of remaining LPG is full approx 22 4 Lts all LPG level indicators green light up When amount of remaining LPG is less than approx 7 Lts LPG level indicator red lights up NOTE The number of LPG...

Page 235: ...PG LPG LPG LPG LPG LPG LPG IAR90A930003 01 A Petrol MODE F Abnormal condition B Forced LPG MODE LPG is full a Lighting up C Forced LPG MODE LPG is less than approx 7 Lts b Blinking D AUTO MODE in petrol system c Lighting up depending on the remaining amount of LPG E AUTO MODE in LPG system ...

Page 236: ...40 1 RED WHT IG IG IG B G240 27 BRN YEL 12 IG A C D B IG 8 2 3 G240 11 BLU YEL I9R90A930003 04 A ABS model 8 Fuel level sensor 19 Rear fog light if equipped B Air bag model 9 Lighting switch 20 Tachometer if equipped C Bi fuel model 10 SDM if equipped 21 Buzzer if equipped D EPS model 11 Key reminder switch 22 Parking brake switch 1 Combination meter 12 Seat belt switch 23 Brake fluid level switch...

Page 237: ...ecause it is pulse signal Check it with oscilloscope if necessary G240 View A LT GRN BLK E485 22 LT GRN E485 29 G115 1 G115 2 G115 4 BLK BLK WHT 1 12V 2 3 4 3 4 5 6 7 8 A B A 12 13 14 15 16 11 10 17 C13 G115 E23 20 21 22 23 24 26 19 18 25 29 30 31 32 33 28 27 34 3 4 5 6 7 8 12 13 14 15 16 11 10 17 20 21 22 23 24 26 19 18 25 29 30 31 32 33 28 27 34 2 1 9 2 1 9 6 1 2 5 4 3 G115 5 IAR90A930001 01 A L...

Page 238: ...ght switch Approx 12 0 V Rear fog light switch at ON position 0 V Rear fog light switch at OFF position G240 21 Fuel level sensor ground 0 V Ignition switch is at all positions G240 22 Door warning light control signal to driver side door switch Approx 12 0 V Driver side door is closed 0 V Driver side door is opened G240 23 Door warning light control signal to other than driver side door switch Ap...

Page 239: ...minal voltage is affected by the battery voltage confirm that it is 12 V or more when the ignition switch is turned to ON position Terminal with asterisk can not be measured by voltmeter because it is pulse signal Check it with oscilloscope if necessary G115 View A A Waveform of channel 1 C VOLT DIV of each channel B Ground level of each channel D TIME DIV Channel Probe Terminal No 1 G240 5 G240 2...

Page 240: ...ator light up for approx 2 seconds and then start to blink If switch does not operate or any abnormality is found replace abnormal selector switch G115 2 Indicator signal circuit 0 1 V 10 14 V Ignition switch ON Refer to reference waveform Selector switch indicator signal under Inspection of ECM and Its Circuit Bi Fuel LPG model in Section 1A G115 4 Power supply 10 14 V Ignition switch ON G115 5 G...

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