IMPORTANT

WARNING/CAUTION/NOTE
Please read this manual and follow its instructions carefully. To emphasize special information, the words
! WARNING , ! CAUTION and NOTE have special meanings. Pay special attention to the messages high-
lighted by these signal words.

! WARNING
Indicates a potential hazard that could result in death or injury.

! CAUTION
Indicates a potential hazard that could result in vehicle damage.

NOTE:
Indicates special information to make maintenance easier or instructions clearer.

! WARNING

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This service manual is intended for authorized Suzuki dealers and qualified service technicians only.
Inexperienced technicians or technicians without the proper tools and equipment may not be able to
properly perform the services described in this manual.

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Improper repair may result in injury to the technician and may render the vehicle unsafe for the driver
and passengers.

! WARNING
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For vehicles equipped with a Supplemental Restraint (Air Bag) System:
• Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under
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“General Description” in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser-
vice Precautions” under “On-Vehicle Service” in air bag system section before performing service
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on or around the air bag system components or wiring. Failure to follow WARNINGS could result in
unintentional activation of the system or could render the system inoperative. Either of these two
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conditions may result in severe injury.

• If the air bag system and another vehicle system both need repair, Suzuki recommends that the air
bag system be repaired first, to help avoid unintended air bag system activation.
• Do not modify the steering wheel, instrument panel or any other air bag system component on or
around air bag system components or wiring. Modifications can adversely affect air bag system
performance and lead to injury.
• If the vehicle will be exposed to temperatures over 93 °C (200 °F), for example, during a paint baking
process, remove the air bag system components, that is air bag (inflator) modules, SDM and/or seat
belt with pretensioner, beforehand to avoid component damage or unintended activation.
The circle with a slash in this manual means “Don’t do this” or “Don’t let this happen”.
 FOREWORD
This SUPPLEMENTARY SERVICE MANUAL is a supplement to Jimny (SN413/SN415D) SERVICE MANUAL.
It has been prepared exclusively for the following applicable model.

Applicable models: Jimny M13 Engine Vehicles (SN413) and Jimny K9K Engine Vehicles (SN415D) with
the following vehicle identification numbers (VINs).

M13 engine model K9K engine model

JSAFJB43V#0 300001 ~ JSAFJB53V00 300001 ~
JSAFJB43V#4 300001 ~
JS3JB43V #4 300001 ~

: Check digit (0 – 9 and X)

This supplementary service manual describes only different service information of the above applicable model
as compared with Jimny (SN413) SERVICE MANUAL. Therefore, whenever servicing the above applicable
models, consult this supplement first. And for any section, item or description not found in this supplement, refer

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to the related manual below.

When replacing parts or servicing by disassembling, it is recommended to use SUZUKI genuine parts, tools and

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service materials as specified in each description.

All information, illustrations and specifications contained in this literature are based on the latest product infor-
.
mation available at the time of publication approval. And used as the main subject of description is the vehicle of
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standard specifications among others.
Therefore, note that illustrations may differ from the vehicle being actually serviced.
The right is reserved to make changes at any time without notice.
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NOTE:
“SUZUKI Dealers” means Authorized Suzuki Service Workshop (in Europe).
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RELATED MANUAL:
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M13 K9K
Manual Name Manual No. engine engine
model model
Jimny (SN413) SERVICE MANUAL 99500-81A10-01E Applicable Applicable
Jimny (SN415D) SUPPLEMENTARY SERVICE MANUAL Not
99501-84A00-01E Applicable
(with K9K engine) applicable
Jimny (SN413/SN415D) SUPPLEMENTARY SERVICE MANUAL 99501-81A10-01E Applicable Applicable
Jimny (SN413/SN415D) WIRING DIAGRAM MANUAL 99512-81A50-015 Applicable Applicable

© COPYRIGHT SUZUKI MOTOR CORPORATION 2006

RECOMMENDATON OF GENUINE SUZUKI PARTS AND ACCESSORIES USE

SUZUKI strongly recommends the use of genuine SUZUKI parts* and accessories. Genuine SUZUKI parts and
accessories are built to the highest standards of quality and performance, and are designed to fit the vehicle's
exact specifications.

A wide variety of non-genuine replacement parts and accessories for SUZUKI vehicles are currently available in
the market. Using these parts and accessories can affect the vehicle performance and shorten its useful life.
Therefore, installation of non-genuine SUZUKI parts and accessories is not covered under warranty.

Non-Genuine SUZUKI Parts and Accessories

Some parts and accessories may be approved by certain authorities in your country.
Some parts and accessories are sold as SUZUKI authorized replacement parts and accessories. Some genu-
ine SUZUKI parts and accessories are sold as re-use parts and accessories. These parts and accessories are
non-genuine Suzuki parts and accessories and use of these parts are not covered under warranty.

Re-use of Genuine SUZUKI Parts and Accessories

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The resale or re-use of the following items which could give rise to safety hazards for users is expressly forbid-
den:

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1) Air bag components and all other pyrotechnic items, including their components (e.g. cushion, control
devices and sensors)
2) Seatbelt system, including their components (e.g. webbing, buckles, and retractors)
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The air bag and seat belt pretensioner components contain explosive chemicals. These components should be
removed and disposed of properly by SUZUKI authorized service shop or scrap yard to avoid unintended explo-
sion before scrapping.
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*The parts remanufactured under SUZUKI's approval can be used as genuine SUZUKI parts in Europe.
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 TABLE OF CONTENTS
GENERAL INFORMATION Engine and Emission Control System 0A 6E
6E
General Information 0A (M13 Engine) 0B 6E2
Maintenance and Lubrication 0B Engine and Emission Control System 6F
6E2
HEATING AND AIR CONDITIONING (K9K Engine) 1A 6G
Heater and Ventilation 1A Ignition System (Electronic Ignition System) 6F 1B 6G2
Air Conditioning (Optional) 1B Cranking System (M13 Engine) 6G 6H
STEERING, SUSPENSION, WHEELS AND Cranking System (K9K Engine) 6G2 3 6H2
TIRES Charging System (M13 Engine) 6H 3A 6K
Steering, Suspension, Wheels and Tires 3 Charging System (K9K Engine) 6H2 3B 6K2
Front Wheel Alignment 3A Exhaust System (M13 Engine) 6K 3B1
Steering Gear Box (Manual Type) and Exhaust System (K9K Engine) 6K2 3C 7A
3B
Linkage TRANSMISSION, CLUTCH AND DIFFEREN- 3D 7A2
Power Steering (P/S) System (if equipped) 3B1 TIAL 3E 7B
Steering Wheel and Column 3C Manual Transmission (M13 Engine Model) 7A 3F 7C
Front Suspension 3D Manual Transmission (K9K Engine Model) 7A2 7C2

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Rear Suspension 3E Automatic Transmission 7B 4B 7D
Wheels and Tires 3F Clutch (M13 Engine Model) 7C 7E

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DRIVE SHAFT AND PROPELLER SHAFT Clutch (K9K Engine Model) 7C2 5 7F
Propeller Shafts 4B Transfer 7D 5E
BRAKE SYSTEM . Front Differential 7E 8
Brakes 5 Rear Differential 7F 6-1 8G
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Antilock Brake System (ABS) 5E ELECTRICAL SYSTEM 6-2 8G2
ENGINE Body Electrical System 8 6-3
Engine General Information and Diagnosis Immobilizer Control System (M13 Engine 6A1 9
6-1 8G
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(M13 Engine without VVT) Model) (if equipped) 6A2

Engine General Information and Diagnosis Immobilizer Control System (K9K Engine 6A3 10
6-2 8G2
(K9K Engine) Model) 6B 10B
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Engine General Information and Diagnosis BODY SERVICE 6B2

6-3
(M13 Engine with VVT) Body Service 9 6C
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Engine Mechanical (M13 Engine without RESTRAINT SYSTEM 6C2

6A1
VVT) Restraint System 10
Engine Mechanical (K9K Engine) 6A2 Air Bag System 10B
Engine Mechanical (M13 Engine with VVT) 6A3
Engine Cooling (M13 Engine) 6B
Engine Cooling (K9K Engine) 6B2
Engine Fuel (M13 Engine) 6C
Engine Fuel (K9K Engine) 6C2

NOTE:
For the screen toned Section in the above table, refer to the same section of the Service Manuals men-
tioned in FOREWORD of this manual.
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 GENERAL INFORMATION 0A-1

SECTION 0A
0A

GENERAL INFORMATION
NOTE:
For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the Service Man-
ual mentioned in “FOREWORD” of this Manual.

CONTENTS
How to Use This Manual................................ 0A- * Identification Information.............................. 0A- *
Precautions......................................................0A-2 Body Number ................................................0A- *
Precaution for Vehicles Equipped with a Engine Identification Number........................0A- *
Supplemental Restraint (Air Bag) System.... 0A- * Transmission Identification Number..............0A- *

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Diagnosis.................................................. 0A- * Warning, Caution and Information
Servicing and handling ............................. 0A- * Labels.............................................................. 0A- *
General Precautions .....................................0A-2 Vehicle Lifting Points .................................... 0A- *

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Precaution for CAN Communication When Using Frame Contact Hoist ................0A- *
System ......................................................... 0A- * When Using Floor Jack.................................0A- *
Precautions For Catalytic Converter ............ 0A- *
Abbreviations May Be Used In This
Precautions For Electrical Circuit Service .... 0A- *
. Manual............................................................. 0A- *
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Electrical Circuit Inspection Procedure......... 0A- *
Open circuit check.................................... 0A- * Abbreviations ................................................0A- *
Short circuit check (wire harness to Fasteners Information ................................... 0A- *
ground) ..................................................... 0A- * Metric Fasteners ...........................................0A- *
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Intermittent and Poor Connection ................ 0A- * Fastener Strength Identification ....................0A- *
Precaution For Installing Mobile Standard Tightening Torque .........................0A- *
Communication Equipment .......................... 0A- *
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0A-2 GENERAL INFORMATION

Precautions
General Precautions
The WARNING and CAUTION below describe some general precautions that you should observe when servic-
ing a vehicle. These general precautions apply to many of the service procedures described in this manual, and
they will not necessarily be repeated with each procedure to which they apply.

WARNING:
• Whenever raising a vehicle for service, be sure to follow the instructions under “Vehicle Lifting
Points” in this section.
• When it is necessary to do service work with the engine running, make sure that the parking brake
is set fully and the transmission is in Neutral (for manual transmission vehicles) or Park (for auto-
matic transmission vehicles), Keep hands, hair, clothing, tools, etc. away from the fan and belts
when the engine is running.
• When it is necessary to run the engine indoors, make sure that the exhaust gas is forced outdoors.
• Do not perform service work in areas where combustible materials can come in contact with a hot
exhaust system. When working with toxic or flammable materials (such as gasoline and refriger-

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ant), make sure that the area you work in is well-ventilated.
• To avoid getting burned, keep away from hot metal parts such as the radiator, exhaust manifold,
tailpipe, muffler, etc.

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• New and used engine oil can be hazardous. Children and pets may be harmed by swallowing new or
used oil. Keep new and used oil and used engine oil filters away from children and pets.
Continuous contact with used engine oil has been found to cause [skin] cancer in laboratory ani-
.
mals. Brief contact with used oil may irritate skin. To minimize your exposure to used engine oil,
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wear a long-sleeve shirt and moisture-proof gloves (such as dish washing gloves) when changing
engine oil. If engine oil contacts your skin, wash thoroughly with soap and water. Launder any
clothing or rags if wet with oil, recycle or properly dispose of used oil and filters.
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• Be sure to observe following instructions when handling service materials such as fuel, oil, fluid,
coolant, grease, sealant, thread lock cement, etc. Otherwise, your health may be ruined.
– Whenever handling any of these service materials, wear safety glasses to protect your eyes.
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If it gets into your eye, it may cause inflammation.

– Whenever handling any of these service materials, wear moisture-proof gloves to protect your
skin. If it adheres to your skin, it may cause inflammation.
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– Do not swallow any 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 during servicing. Also, be aware that what you
wear (e.g, buttons) may cause damage to the vehicle’s
finish.
 GENERAL INFORMATION 0A-3

• When performing service to electrical parts that does

not require use of battery power, disconnect the nega-
tive cable of the battery.
• When disconnecting the negative cable from the battery,
be careful to the following.
– Check and record DTCs in ECM and immobilizer con-
trol module if necessary before disconnecting.
– Record displayed contents of the clock and/or audio
system, etc. before disconnecting and reset it as
before after connecting.

• When removing the battery, be sure to disconnect the

negative cable first and then the positive cable. When
reconnecting the battery, connect the positive cable first
and then the negative cable, and replace the terminal
cover.

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• When removing parts that are to be reused, be sure to
keep them arranged in an orderly manner so that they
.
may be reinstalled in the proper order and position.
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• Whenever you use oil seals, gaskets, packing, O-rings,

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locking washers, split pins, self-locking nuts, and cer-

tain other parts as specified, be sure to use new ones.
Also, before installing new gaskets, packing, etc., be
sure to remove any residual material from the mating
surfaces.

• Make sure that all parts used in reassembly are perfectly

clean.
• When use of a certain type of lubricant, bond or sealant
is specified, be sure to use the specified type.
“A”: Sealant 99000-31150
0A-4 GENERAL INFORMATION

• Be sure to use special tools when instructed.

Special tool
(A): 09917-98221
(B): 09916-58210

• When disconnecting vacuum hoses, attach a tag

describing the correct installation positions so that the
hoses can be reinstalled correctly.

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• After servicing fuel, oil, coolant, vacuum, exhaust or
brake systems, check all lines related to the system for
.
leaks.
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• For vehicles equipped with petrol engine, never discon-

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nect the fuel line between the fuel pump and injector
without first releasing the fuel pressure, or fuel can be
sprayed out under pressure.
Refer to “Fuel Pressure Relief Procedure” in Section 6
for fuel pressure releasing.
• For vehicles equipped with diesel engine, never discon-
nect fuel high-pressure line between injection pump and
injectors under pressure, or fuel can be sprayed out
under pressure.
Be sure to confirm that fuel high-pressure line is not
under pressure referring to “Fuel pressure relief confir-
mation procedures” in Section 6E2 before disconnect-
ing.
If it is under pressure, wait till it is not under pressure.
 GENERAL INFORMATION 0A-5

• When performing a work that produces a heat exceeding

80°C (176°F) in the vicinity of the electrical parts, remove
the heat sensitive electrical part(s) beforehand.

• Use care not to expose connectors and electrical parts

to water which will be a cause of a trouble.

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• Always be careful not to handle electrical parts (com-
puter, relay, etc.) in a rough manner or drop them.
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0A-6 GENERAL INFORMATION

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 MAINTENANCE AND LUBRICATION 0B-1

SECTION 0B
0B

MAINTENANCE AND LUBRICATION

WARNING:
For vehicles equipped with a Supplemental Restraint (Air Bag) System:
• Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under
“General Description” in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser-
vice Precautions” under “On-Vehicle Service” in air bag system section before performing service
on or around the air bag system components or wiring. Failure to follow WARNINGS could result in
unintentional activation of the system or could render the system inoperative. Either of these two
conditions may result in severe injury.

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• Technical service work must be started at least 90 seconds after the ignition switch is turned to the
“LOCK” position and the negative cable is disconnected from the battery. Otherwise, the system
may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).

NOTE:

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For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the Service Man-
ual mentioned in “FOREWORD” of this Manual.
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CONTENTS
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M13 Engine Model PCV (Positive Crankcase Ventilation)

Maintenance Schedule ...................................0B-3 Valve ........................................................ 0B- *
Fuel Evaporative Emission Control
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Maintenance Schedule Under Normal

Driving Conditions .........................................0B-3 System ..................................................... 0B- *
Maintenance Recommended Under Chassis and Body ....................................... 0B-11
Clutch ....................................................... 0B- *
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Severe Driving Conditions.............................0B-6

Brake Discs and Pads.............................. 0B- *
Maintenance Service.......................................0B-8
Brake Drums and Shoes .......................... 0B- *
Engine ......................................................... 0B- * Brake Hoses and Pipes............................ 0B- *
Drive Belt................................................. 0B- * Brake Fluid ............................................... 0B- *
Valve Lash............................................... 0B- * Parking Brake Lever and Cable ............... 0B- *
Engine Oil and Filter................................ 0B- * Tires/Wheels ............................................ 0B- *
Engine Coolant........................................ 0B- * Suspension System ................................. 0B- *
Exhaust System ...................................... 0B- * Propeller Shafts........................................ 0B- *
Ignition System............................................ 0B- * Manual Transmission Oil...........................0B- *
Spark Plugs ............................................. 0B- * Automatic Transmission Fluid ................. 0B-11
Fuel System ................................................. 0B- * Transfer and Differential Oil ......................0B- *
Air Cleaner Filter ..................................... 0B- * Steering System....................................... 0B- *
Fuel Lines and Connections.................... 0B- * Steering Knuckle Seal.............................. 0B- *
Fuel Filter ................................................. 0B- * Power Steering (P/S) System
Fuel Tank ................................................ 0B- * (if equipped) ............................................. 0B- *
Emission Control System ............................ 0B- * All Hinges, Latches and Locks ................. 0B- *
Crankcase Ventilation Hoses and
Final Inspection............................................. 0B- *
Connections ............................................ 0B- *
Recommended Fluids and Lubricants......... 0B- *
0B-2 MAINTENANCE AND LUBRICATION

K9K Engine Model Clutch....................................................... 0B- *

Maintenance Schedule ...................................0B-3 Brake Discs and Pads.............................. 0B- *
Maintenance Schedule Under Normal Brake Drums and Shoes.......................... 0B- *
Driving Conditions......................................... 0B-3 Brake Hoses and Pipes ........................... 0B- *
Maintenance Recommended Under Brake Fluid............................................... 0B- *
Severe Driving Conditions ............................ 0B-6 Parking Brake Lever and Cable ............... 0B- *
Tires/Wheels ............................................ 0B- *
Maintenance Service ......................................0B-8
Suspension System ................................. 0B- *
Engine (K9K)................................................. 0B-8 Propeller Shafts ....................................... 0B- *
Drive Belt.................................................. 0B- * Manual Transmission Oil .......................... 0B- *
Engine oil and filter (K9K Engine) ............. 0B-8 Transfer and Differential Oil ...................... 0B- *
Engine Coolant......................................... 0B- * Steering System....................................... 0B- *
Exhaust System ....................................... 0B- * Steering Knuckle Seal.............................. 0B- *
Fuel System ................................................ 0B-10 Power Steering (P/S) System
Air Cleaner Filter ...................................... 0B- * (if equipped) ............................................. 0B- *
Fuel Lines and Connections..................... 0B- * All Hinges, Latches and Locks................. 0B- *
Fuel Filter ................................................ 0B-10
Final Inspection ............................................. 0B- *
Water Draining of Fuel Filter ................... 0B-10
Fuel Tank ................................................. 0B- * Recommended Fluids and Lubricants .........0B- *
Chassis and Body .........................................0B- *

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 MAINTENANCE AND LUBRICATION 0B-3

Maintenance Schedule
Maintenance Schedule Under Normal Driving Conditions

NOTE:
• This interval should be judged by odometer reading or months, whichever comes first.
• This table includes service as scheduled up to 90,000 km (54,000 miles) mileage. Beyond 90,000 km
(54,000 miles), carry out the same services at the same intervals respectively.

M13 Engine Model:

Km (x 1,000) 15 30 45 60 75 90
Interval Miles (x 1,000) 9 18 27 36 45 54
Months 12 24 36 48 60 72
ENGINE
Drive belt V-belt I R I R I R
V-rib belt (Flat type) – – I – – R

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Valve lash (clearance) – I – I – I
Engine oil and oil filter R R R R R R
Engine coolant – – R – – R

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Exhaust system – I – I – I
IGNITION SYSTEM
✱Spark plugs When Vehicle without Nickel spark
unleaded HO2S
. plug
– R – R – R
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fuel is used Iridium spark
– – R – – R
plug
Vehicle with Nickel spark
– – R – – R
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HO2S plug
Iridium spark
– – – R – –
plug
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When leaded fuel is used, refer to “Maintenance Recommended Under Severe Driving Condi-
tions” in this section.
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FUEL SYSTEM
Air cleaner filter I I R I I R
Fuel lines and connections – I – I – I
Fuel filter Replace every 210,000 km (126,000 miles).
Fuel tank – – I – – I
EMISSION CONTROL SYSTEM
Crankcase ventilation hoses and connections
– – I – – I
(Vehicle without HO2S)
✱PCV valve Vehicle without HO2S – – I – – I
Vehicle with HO2S – – – – – I
✱Fuel evaporative emission Vehicle without HO2S – I – I – I
control system Vehicle with HO2S – – – – – I
0B-4 MAINTENANCE AND LUBRICATION

NOTE:
“R”: Replace or change
“I”: Inspect and correct, replace or lubricate if necessary
• For Sweden, items with ✱ (asterisk) should be performed by odometer reading only.
• For spark plugs, replace every 50,000 km if the local law requires.
• Nickel spark plug: BKR6E-11 (NGK) or K20PR-U11 (DENSO)
• Iridium spark plug: IFR5E11 (NGK) or SK16PR-A11 (DENSO)

K9K Engine Model:

Km (x 1,000) 15 30 45 60 75 90
Interval Miles (x 1,000) 9 18 27 36 45 54
Months 12 24 36 48 60 72
ENGINE
Engine accessory drive belt – – – – R –
Camshaft timing belt and tensioner – – – – R –

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Engine oil and oil filter
R R R R R R
*1
Engine coolant – R – R – R

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Exhaust system – I – I – I
FUEL SYSTEM
Air cleaner filter I I R I I R
Fuel lines and connections
. – I – I – I
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Fuel filter – – R – – R
Drain water every 15,000 km or 9,000 miles
Fuel tank – – I – – I
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NOTE:
“R”: Replace or change
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“I”: Inspect and correct, replace or lubricate if necessary

• Some maintenance items are required to be serviced at times other than the regular maintenance
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times shown at the top of above table. These items can be serviced at an earlier service opportunity
according to customer’s maintenance convenience. Their next maintenance service should be done
within the specified period.
• *1: Inspect every 2,000 km (1,200 miles) until mileage of 5,000 km (3,000 miles)
 MAINTENANCE AND LUBRICATION 0B-5

M13 and K9K Engine Models:

Km (x 1,000) 15 30 45 60 75 90
Interval Miles (x 1,000) 9 18 27 36 45 54
Months 12 24 36 48 60 72
CHASSIS AND BODY
Clutch (pedal height and travel for cable type / fluid leakage and
– I – I – I
level for hydraulic type)
Brake discs and pads (thickness, wear, damage) I I I I I I
Brake drums and shoes (wear, damage) – I – I – I
Brake hoses and pipes (leakage, damage, clamp) – I – I – I
Brake fluid – R – R – R
Brake lever and cable (damage, stroke, operation) Inspect at first 15,000 km (9,000 miles) only.
Tires (wear, damage, rotation) I I I I I I
Wheel discs (damage) I I I I I I
Suspension system (tightness, damage, rattle, breakage) – I – I – I
Propeller shafts – – I – – I

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Manual transmission oil (leakage, level) (I: 1st 15,000 km only) I – R – – R
Automatic transmission Fluid level – I – I – I
Fluid change Replace every 165,000 km (99,000 miles).

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Fluid hose – – – I – –
Transfer oil (leakage, level) I – I – I –
Differential oil (leakage, level) (R: 1st 15,000 km only) R or I – I – I –
.
Steering system (tightness, damage, breakage, rattle) – I – I – I
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Power steering (if equipped) I I I I I I
All latches, hinges and locks – I – I – I
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NOTE:
“R”: Replace or change
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“I”: Inspect and correct, replace or lubricate if necessary

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0B-6 MAINTENANCE AND LUBRICATION

Maintenance Recommended Under Severe Driving Conditions

If the vehicle is usually used under the conditions corresponding to any severe condition code given below, it is
recommended that applicable maintenance operation be performed at the particular interval as shown in the fol-
lowing table.
Severe condition code
A : Repeated short trips
B : Driving on rough and/or muddy roads
C : Driving on dusty roads
D : Driving in extremely cold weather and/or salted roads
E : Repeated short trips in extremely cold weather
F : Leaded fuel use
G : Low quality fuel use (For K9K diesel engine only)
H : Trailer towing (if admitted)

M13 Engine Model:

Severe Maintenance

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Maintenance Maintenance Interval
Condition Code Operation
Every 15,000 km
I

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(9,000 miles) or 12 months
–BCD–––– Drive belt (V-rib belt)
Every 45,000 km
R
. (27,000 miles) or 36 months
A–CDEF–H Engine oil and oil filter R Every 7,500 km (4,500 miles) or 6 months
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Every 15,000 km
–B–––––– Exhaust pipe mountings I
(9,000 miles) or 12 months
I Every 2,500 km (1,500 miles)
––C––––– Air cleaner filter ✱1 Every 30,000 km
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R
(18,000 miles) or 24 months
Nickel spark plug R Every 10,000 km (6,000 miles) or 8 months
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ABC–EF–H Spark plugs Iridium spark plug Every 30,000 km

R
(18,000 miles) or 24 months
Every 15,000 km
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–BCD–––H Wheel bearing I

(9,000 miles) or 12 months
Every 15,000 km
–B–––––– Suspension bolts and nuts T
(9,000 miles) or 12 months
Every 15,000 km
–B–DE––H Propeller shafts I
(9,000 miles) or 12 months
First time only:
15,000 km (9,000 miles) or 12 months
Manual transmission,
–B––E––H R Second time and after: Every 30,000 km
transfer and differential oil
(18,000 miles) or 24 months reckoning from
0 km (0 mile) or 0 month
Every 30,000 km
–B––E––H Automatic transmission fluid R
(18,000 miles) or 24 months
Every 15,000 km
–BCD–––– Steering knuckle seal I
(9,000 miles) or 12 months
 MAINTENANCE AND LUBRICATION 0B-7

NOTE:
• “I”: Inspect and correct, replace or lubricate if necessary
• “R”: Replace or change
• “T”: Tighten to the specified torque
• ✱1: Inspect or replace more frequently if necessary

K9K Engine Model:

Severe Maintenance
Maintenance Maintenance Interval
Condition Code Operation
Every 30,000 km
–BCD–––– Engine accessory drive belt R
(18,000 miles) or 24 months
Camshaft timing belt and ten- Every 60,000 km (36,000 miles)
A–CDE––– R
sioner or 48 months
A–CDE––H Engine oil and oil filter R Every 7,500 km (4,500 miles) or 6 months
Every 15,000 km
–B–––––– Exhaust pipe mountings I

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(9,000 miles) or 12 months
I Every 2,500 km (1,500 miles)
––C––––– Air cleaner filter *1 Every 30,000 km

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R
(18,000 miles) or 24 months
––––––G– Fuel filter R Every 5,000 km (3,000 miles)
Every 15,000 km
–BCD–––H Wheel bearing I
. (9,000 miles) or 12 months
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Every 15,000 km
–B–––––– Suspension bolts and nuts T
(9,000 miles) or 12 months
Every 15,000 km
–B–DE––H Propeller shafts I
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(9,000 miles) or 12 months

First time only:
15,000 km (9,000 miles) or 12 months
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Manual transmission,
–B––E––H R Second time and after: Every 30,000 km
transfer and differential oil
(18,000 miles) or 24 months reckoning from
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0 km (0 mile) or 0 month
Every 15,000 km
–BCD–––– Steering knuckle seal I
(9,000 miles) or 12 months

NOTE:
• “I”: Inspect and correct, replace or lubricate if necessary
• “R”: Replace or change
• “T”: Tighten to the specified torque
• *1: Inspect or replace more frequently if necessary
0B-8 MAINTENANCE AND LUBRICATION

Maintenance Service
Engine (K9K)
Engine oil and filter (K9K Engine)
Change

WARNING:
• New and used engine oil can be hazardous.
Be sure to read “WARNING” in General Precaution in
Section 0A and observe what in written there.
• Step 1) – 7) outlined below must be performed with
ENGINE NOT RUNNING. For step 8), be sure to have
adequate ventilation while engine is running.

Before draining engine oil, check engine for oil leakage. If any evi-
dence of leakage is found, make sure to correct defective part
before proceeding to the following work.

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1) Drain engine oil by removing drain plug.
2) After draining oil, wipe drain plug clean. Reinstall drain plug,

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and tighten it securely as specified below.
Tightening torque
(a): 35 N·m (3.5 kg-m, 25.5 lb-ft)
.
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3) Loosen oil filter (1) by using oil filter wrench (special tool).
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Special tool
(A): 09915-46510
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NOTE:
Before fitting new oil filter, be sure to oil its O-ring. Use
engine oil for this purpose.

4) Screw new filter on oil filter stand by hand until the filter
O-ring contacts the mounting surface.

CAUTION:
To tighten oil filter properly, it is important to accurately
identify the position at which filter O-ring first contacts
the mounting surface.
 MAINTENANCE AND LUBRICATION 0B-9

5) Tighten the filter (1) 3/4 turn from the point of contact with
the mounting surface using an oil filter wrench (special tool).
Special tool
(A): 09915-46510

6) Replenish oil until oil level is brought to FULL level mark on

[A] dipstick. (about 4.9 liters (8.6 lmp pt.)). The filler inlet is at the
top of the cylinder head cover.
Use engine oil of ACEA standard B3/B4 grade.
10W-40, 10W-50
Select the appropriate oil viscosity according to the proper
5W-40, 5W-50
engine oil viscosity chart [A].
0W-40
However, it is recommended to use 0W-40 oil under ambient

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o
C -30 -20 -10 0 10 20 30 40
o
F -22 -4 14 32 50 68 86 104 temperatures below –15 °C (5 °F)

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NOTE:
Note that the amount of oil required when actually chang-
ing oil may somewhat differ from the data depending on
.
various conditions (temperature, viscosity, etc.)
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7) Check oil filter and drain plug for oil leakage.

8) Start engine and run it for three minutes. Stop it and wait five
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minutes before checking oil level. Add oil, as necessary, to

bring oil level to FULL level mark (1) on oil level gauge (3).
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2. Low level mark

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Inspection
1) Check engine for oil leakage. If any evidence of leakage is
found, repair defective part.
2) Check engine oil for level according to step 8) of “Engine Oil
and filter change” in this section.
0B-10 MAINTENANCE AND LUBRICATION

Fuel System
Fuel Filter
Replacement

WARNING:
This work must be performed in a well ventilated area
and away from any open flames (such as gas hot water
heaters).

Replace fuel filter (1) with new one periodically, referring to “Fuel
Filter Removal and Installation” in Section 6C2.
1

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Water Draining of Fuel Filter
Bleed fuel filter of water referring to “Water Draining of Fuel Filter”
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in Section 6C2.
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 MAINTENANCE AND LUBRICATION 0B-11

Chassis and Body

Automatic Transmission Fluid
Inspection
1) Inspect transmission case for evidence of fluid leakage.
Repair leaky point, if any.
2) Make sure that vehicle is placed level for fluid level check.

3) Check fluid level.

For fluid level checking procedure, refer to “Fluid Level
Check” in Section 7B and be sure to perform it under speci-
fied conditions. If fluid level is low, replenish specified fluid.
1. Dipstick
2. “FULL HOT” mark
3. “LOW HOT” mark

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Change

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1) Inspect transmission case for evidence of fluid leakage.
Repair leaky point, if any.
2) Make sure that vehicle is placed level for fluid level check.
3) Change fluid. For its procedure, refer to “Changing Fluid” in
.Section 7B.
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CAUTION:
Use of specified fluid is absolutely necessary.
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1 1. Drain plug
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Fluid Cooler Hose Inspection

Check automatic transmission fluid cooler hoses for fluid leakage,

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cracks, damage and deterioration. Replace hose and/or clamp if

any faulty condition is found.
0B-12 MAINTENANCE AND LUBRICATION

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 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE) 6-2-1

SECTION 6-2
6F1
6F2
ENGINE GENERAL INFORMATION AND
DIAGNOSIS
(K9K ENGINE) 7A
7A1
7B1
WARNING: 7C1
For vehicles equipped with a Supplemental Restraint (Air Bag) System: 7D
• Service on and around the air bag system components or wiring must be performed only by an 7E
authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under 7F
“General Description” in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Pre- 8B

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cautions” under “On-Vehicle Service” in air bag system section before performing service on or 8B
around the air bag system components or wiring. Failure to follow WARNINGS could result in unin- 8C

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tentional activation of the system or could render the system inoperative. Either of these two condi- 8D
tions may result in severe injury.
8E
• Technical service work must be started at least 90 seconds after the ignition switch is turned to the
“LOCK” position and the negative cable is disconnected from the battery. Otherwise, the system
.
may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).
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6-2
10
10A
CONTENTS
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10B
General Information ....................................... 6-2-3 DTC P0087 Fuel rail/system pressure
Statement of Cleanliness and Care ............. 6-2-3 too low.................................................... 6-2-24
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General Information on Engine Service ....... 6-2-3 DTC P0089 Fuel pressure regulator
Precaution on fuel system service............ 6-2-4 performance problem ............................. 6-2-25
Fuel pressure relief confirmation DTC P0100 Mass air flow circuit ............ 6-2-26
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procedure ................................................. 6-2-4 DTC P0115 Engine coolant temperature

Fuel leakage check procedure ................. 6-2-4 circuit malfunction .................................. 6-2-27
Engine Diagnosis ........................................... 6-2-5 DTC P0170 Fuel trim ............................. 6-2-28
DTC P0180 Fuel temperature sensor
General Description ..................................... 6-2-5
circuit malfunction .................................. 6-2-30
On-Board Diagnostic System ....................... 6-2-5
DTC P0190 Fuel pressure sensor
Precaution in Diagnosing Trouble ................ 6-2-7
circuit malfunction .................................. 6-2-31
Engine Diagnostic Flow Table...................... 6-2-9
DTC P0200 Injector circuit ..................... 6-2-32
Diagnostic step details ........................... 6-2-11
DTC P0201 Injector circuit malfunction –
Diagnostic Trouble Code (DTC) Check...... 6-2-12
cylinder 1................................................ 6-2-34
Diagnostic Trouble Code (DTC)
DTC P0202 Injector circuit malfunction –
Clearance ................................................... 6-2-12
cylinder 2................................................ 6-2-36
Diagnostic Trouble Code (DTC) Table ....... 6-2-13
DTC P0203 Injector circuit malfunction –
Indicator lamp operation table .................... 6-2-16
cylinder 3................................................ 6-2-38
Visual Inspection ........................................ 6-2-19
DTC P0204 Injector circuit malfunction –
Engine Basic Check ................................... 6-2-20
cylinder 4................................................ 6-2-40
Fault Finding – Fault Interpretation ............ 6-2-21
DTC P0225 Pedal position sensor 1
DTC P0016 Crankshaft position –
circuit...................................................... 6-2-42
camshaft position correlation.................. 6-2-21
DTC P0231 Fuel pump secondary
DTC P0045 Turbo charger boost
circuit low ............................................... 6-2-44
control solenoid circuit/open................... 6-2-22
DTC P0235 Turbo pressure sensor
DTC P0070 External air temperature
circuit malfunction .................................. 6-2-45
sensor circuit malfunction....................... 6-2-23
6-2-2 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE)

DTC P0263 Cylinder 1 contribution/ DTC P0651: Sensor reference voltage 2

balance................................................... 6-2-47 circuit/open .............................................6-2-74
DTC P0266 Cylinder 2 contribution/ DTC P0685 Main relay control circuit
balance................................................... 6-2-48 malfunction .............................................6-2-76
DTC P0269 Cylinder 3 contribution/ DTC P1641 Additional heater relay
balance................................................... 6-2-49 circuit 1 ...................................................6-2-77
DTC P0272 Cylinder 4 contribution/ DTC P1642 Additional heater relay
balance................................................... 6-2-50 circuit 2 ...................................................6-2-78
DTC P0325 Knock sensor circuit DTC P2120 Pedal position sensor 2
malfunction............................................. 6-2-51 circuit ......................................................6-2-79
DTC P0335 Crankshaft position sensor DTC P2226 Barometric pressure circuit
circuit malfunction .................................. 6-2-52 malfunction .............................................6-2-81
DTC P0340 Camshaft position sensor DTC P2263: Turbo charger boost
circuit malfunction .................................. 6-2-53 system performance ...............................6-2-81
DTC P0380 Glow plug/heater circuit Fault Finding – Customer Complaints ........6-2-83
malfunction............................................. 6-2-54 Table 1 No dialogue with the ECM .........6-2-84
DTC P0670 Glow plug module control Table 2 The engine does not start ..........6-2-85
circuit...................................................... 6-2-54 Table 3 The engine starts with difficulty
DTC P0382 Glow plug/heater circuit B or starts then stalls..................................6-2-86
malfunction............................................. 6-2-55 Table 4 Starting difficult with warm

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DTC P0400 Exhaust gas recirculation engine .....................................................6-2-87
flow......................................................... 6-2-56 Table 5 Rough idle speed (pumping)......6-2-88
DTC P2413 Exhaust gas recirculation Table 6 Idle speed too high/too low ........6-2-89

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system performance............................... 6-2-56 Table 7 Unexpected acceleration/
DTC P0403 Exhaust gas recirculation deceleration and engine stalling .............6-2-90
control circuit .......................................... 6-2-58 Table 8 Response fault ...........................6-2-91
DTC P0409 Exhaust gas recirculation Table 9 Engine stop/stalling....................6-2-92
.
sensor circuit .......................................... 6-2-59 Table 10 Engine jerking ..........................6-2-93
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DTC P0480 Radiator cooling fan low Table 11 Lack of power...........................6-2-94
speed control system malfunction.......... 6-2-60 Table 12 Too much power ......................6-2-95
DTC P0481 Radiator cooling fan high Table 13 Excessive consumption ...........6-2-96
speed control system malfunction.......... 6-2-61 Table 14 Overspeed when lifting off
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DTC P0487 Exhaust gas recirculation accelerator or changing gear ..................6-2-97

throttle position control circuit................. 6-2-62 Table 15 Engine dies on pulling away ....6-2-98
DTC P0500 Vehicle speed sensor Table 16 Engine rattling, noisy................6-2-99
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circuit malfunction .................................. 6-2-63 Table 17 Blue, white or black smoke ....6-2-100
DTC P0513 Incorrect immobilizer key.... 6-2-64 Table 18 Blue, black or white smoke
DTC P0530 A/C refrigerant pressure when accelerating .................................6-2-101
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sensor circuit .......................................... 6-2-65 Fault Finding – Tests ................................6-2-102

DTC P0560 System voltage................... 6-2-66 Test 1: Low Pressure Circuit Check......6-2-103
DTC P0571 Brake switch circuit............. 6-2-67 Test 2: Electrical Circuit Check .............6-2-103
DTC P0604 Control module internal Test 3: Injector Check ...........................6-2-104
fail........................................................... 6-2-68 Test 4: Parameter Check ......................6-2-104
DTC P0605 Control module program Test 5: Air Inlet Circuit Check ...............6-2-104
error........................................................ 6-2-69 Test 6: ECM Check...............................6-2-104
DTC P0606 Control module program Test 7 High Pressure System Check ....6-2-105
error........................................................ 6-2-69 Test 8 High Pressure Circuit Sealing
DTC P062F Control module EEPROM Test .......................................................6-2-105
failure ..................................................... 6-2-70 Test 9 Injector Sealing Check ...............6-2-106
DTC P0641 Sensor reference voltage 1 Test 11: Diesel filter check....................6-2-108
circuit/open............................................. 6-2-71 Special Tool ................................................6-2-109
DTC P0645 A/C compressor relay
control circuit .......................................... 6-2-73
 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE) 6-2-3

General Information
Statement of Cleanliness and Care
An automobile engine is a combination of many machined,
honed, polished and lapped surfaces with tolerances that are
measured in the thousands of an millimeter (ten thousands of
inch). Accordingly, when any internal engine parts are serviced,
1
2 care and cleanliness are important. Throughout this section, it
3 should be understood that proper cleaning and protection of
4
machined surfaces and friction areas is part of the repair proce-
dure. This is considered standard shop practice even if not specif-
ically stated.
• A liberal coating of engine oil should be applied to friction
areas during assembly to protect and lubricate the surface
on initial operation.
• Whenever valve train components, pistons, piston rings, con-
necting rods, rod bearings and crankshaft journal bearings

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are removed for service, they should be retained in order. At
the time of installation, they should be installed in the same

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locations and with the same mating surfaces as when
removed.
• Battery cables should be disconnected before any major
work is performed on the engine. Failure to disconnect
.
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cables may result in damage to wire harness or other electri-
cal parts.
• Throughout this manual, the four cylinders of the engine are
identified by numbers: No.1 (1), No.2 (2), No.3 (3) and No.4
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(4) as counted from flywheel side to crankshaft pulley side.

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General Information on Engine Service

The following information on engine service should be noted
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carefully, as it is important in preventing damage, and in contribut-

ing to reliable engine performance.
• When raising or supporting engine for any reason, do not
use a jack under oil pan. Due to small clearance between oil
pan and oil pump strainer, jacking against oil pan may cause
it to be bent against strainer resulting in damaged oil pick-up
unit.
• It should be kept in mind, while working on engine, that 12-
volt electrical system is capable of violent and damaging
short circuits. When performing any work where electrical
terminals could possibly be grounded, ground cable of the
battery should be disconnected at battery.
• Any time the air cleaner, air cleaner outlet hose, turbo-
charger, intercooler, intercooler outlet hose, or intake mani-
fold is removed, the intake opening should be covered. This
will protect against accidental entrance of foreign material
which could follow intake passage into cylinder and cause
extensive damage when engine is started.
6-2-4 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE)

Precaution on fuel system service

• Work must be done with no smoking, in a well-ventilated
area and away from any open flames.
• A small amount of fuel may be released after fuel line is dis-
connected.
In order to reduce the chance of personal injury, cover fitting
to be disconnected with a shop cloth. Put that cloth in an
approved container when disconnection is completed.
• Never run engine with main relay disconnected when engine
and exhaust system are hot.
• Fuel or fuel vapor hose connection varies with each type of
pipe. When reconnecting fuel or fuel vapor hose, be sure to
connect and clamp each hose correctly referring to the fig-
ure.
After connecting, make sure that it has no twist or kink.
[A]: With short pipe, fit hose as far as it reaches pipe joint as shown.

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[B]: With following type pipe, fit hose as far as its peripheral projection as shown.
[C]: With bent pipe, fit hose as its bent part as shown or till pipe is about 20 to 30 mm
(0.79 – 1.18 in.) into the hose.
[D]: With straight pipe, fit hose till pipe is, about 20 to 30 mm (0.79 – 1.18 in.) into the hose.

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1. Hose
2. Pipe
3. Clamp
4. Clamp securely at a position 3 to 7 mm (0.12 – 0.27 in.) from hose end.
. 5. 20 to 30 mm (0.79 – 1.18 in.)
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• Before starting any service on fuel system, refer to “Precau-
tions in Fuel Delivery System” in Section 6E2.
• When installing fuel filter union bolt or plug bolt, always use
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new gasket and tighten it to specified torque.

• When installing injector, fuel feed pipe or fuel pressure regu-
lator, lubricate its O-ring with spindle oil or fuel.
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• When connecting fuel pipe flare nut, first tighten flare nut by
hand and then tighten it to specified torque, using back-up
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wrench.

Fuel pressure relief confirmation procedure

The fuel system installed on the engine injects the high pressure
fuel into the engine. Therefore, before starting fuel system ser-
vice, confirm that fuel high pressure line is not under pressure
referring to “Fuel Pressure Relief Confirmation Procedure” in Sec-
tion 6E2.

Fuel leakage check procedure

After performing any service on fuel system, refer to “Fuel Leak-
age Check” in Section 6E2 to see if there is any fuel leakage.
 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE) 6-2-5

Engine Diagnosis
General Description
The engine and emission control system in this vehicle are controlled by ECM. ECM has an On-Board Diagnos-
tic system which detects a malfunction in this system and abnormality of those parts that influence the engine
exhaust emission. When diagnosing engine troubles, be sure to have full understanding of the outline of “On-
Board Diagnostic System” and each item in “Precaution in Diagnosing Trouble” and execute diagnosis accord-
ing to “Engine Diagnostic Flow Table” in this section.
There is a close relationship between the engine mechanical, engine cooling system, exhaust system, etc. and
the engine and emission control system in their structure and operation. In case of an engine trouble, even when
the warning light (MIL, injection warning light, and/or red stop warning light) doesn’t turn ON, it should be diag-
nosed according to this flow table.

On-Board Diagnostic System

ECM in this vehicle has the following functions.
• When the ignition switch is turned ON with the engine at a

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stop, MIL (1), injection warning light (gravity 1 fault) (2) and/
2
or red stop warning light (gravity 2 fault) (3) turns ON to
check the warning lights and its circuit.

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• When ECM detects a malfunction which gives an adverse
effect to vehicle emission while the engine is running, it
STOP
. makes the malfunction indicator lamp in the meter cluster of
the instrument panel turn ON and stores the malfunction
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area in its memory.
3 1
• When a malfunction is detected, a malfunction in some
STOP
areas in the system and driving cycles then are stored in
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ECM memory (For the details, refer to description on “Indica-

tor Lamp Operation Table” in this section.)
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6-2-6 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE)

Warm-Up Cycle
A “warm-up cycle” means sufficient vehicle operation such that
the coolant temperature has risen by at least 22 °C (40 °F) from
engine starting and reaches a minimum temperature of 70 °C
(160 °F).
Driving Cycle
A “driving cycle” consists of two parts, engine startup and engine
shutoff.
3 Driving Cycle Detection Logic
The malfunction detected in the first driving cycle is stored in
ECM memory (in the form of pending DTC) but the malfunction
indicator lamp does not light at this time. It does not light up at the
second detection of same malfunction also in the next driving
cycle. It lights up at the third detection of same malfunction also in
the third driving cycle.

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Pending Diagnostic Trouble Code (DTC)
Pending DTC means a DTC detected and stored temporarily at
first or second driving cycle of the DTC which is detected in the 3

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driving cycle detection logic.

Data Link Connector (DLC)

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DLC (1) is in compliance with SAE J1962 in its installation posi-
tion, the shape of connector and pin assignment.
2 6
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16 15 14 13 12 11 10 9 K line (3) of ISO 9141 is used for SUZUKI scan tool to communi-
cation with ECM, ABS control module and immobilizer control
8 7 6 5 4 3 2 1
module.
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5
4
3 CAN lines (6) and (7) are used to write program in ECM using
1 7
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SUZUKI scan tool. For details of writing program in ECM, refer to

“ECM Registration (Programming)” in Section 6E2.
2. B+
4. ECM ground
5. Body ground
 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE) 6-2-7

Precaution in Diagnosing Trouble

• Don’t disconnect couplers from ECM, battery cable from battery, ECM ground wire harness from engine or
main fuse before confirming diagnostic information (DTC) stored in ECM memory.
• Diagnostic information stored in ECM memory can be cleared as well as checked by using SUZUKI scan
tool. Before using scan tool, read its Operator’s (Instruction) Manual carefully to have good understanding as
to what functions are available and how to use it.
• Be sure to read “Precautions for Electrical Circuit Service” in Section 0A before inspection and observe what
is written there.
• For the connector number and the terminal number described in fault finding procedure, refer to “Wiring Dia-
gram Manual” described in FOREWORD of this manual.
• Fuel Injector Registration
If fuel injector is replaced, register fuel injector calibration code into ECM by performing procedure described
in “Fuel Injector Registration” under “ECM Registration (Programming)” of Section 6E2.
• Registration for ECM Replacement
Engine control program is not written in new ECM (i.e., blank ECM) bought from a part supplier.
Therefore, when using a new ECM, it is necessary to write engine control program in it. For details, refer to
“Registration for ECM Replacement” under “ECM Registration (Programming)” in Section 6E2.

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• High Pressure Pump Data Initialization
If high pressure pump is replaced with new one, initialize fuel pressure data in ECM by performing procedure

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described in “High Pressure Pump Data Initialization” under “ECM Registration (Programming)” of Section
6E2.
• EGR Valve Data Initialization
If EGR valve is replaced with new one, initialize EGR valve data in ECM by performing procedure described
.
in “EGR Valve Data Initialization” under “ECM Registration (Programming) of Section 6E2.
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• ECM substitution
– The data of immobilizer control system registered with ECM cannot be reprogrammed. Therefore, check
for engine control system can not be performed using known-good ECM installed in other normal vehicle.
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– In case that new ECM, on which the data of immobilizer control system is not programmed, is used for
inspecting the engine control system, the ECM cannot be used for the other vehicles because the data of
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immobilizer control system registered with the ECM cannot be reprogrammed.

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6-2-8 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE)

Malfunction Indicator Lamp (MIL) Check

Malfunction indicator lamp (1) signals an antipollution system fail-

ure.
Check that it lights up for 3 seconds after the ignition switch is
turned on, and then it goes off (automatic test procedure).
If light remains ON after an automatic test procedure, go to “Diag-
nostic Trouble Code (DTC) Check” in this section.
1 After the ignition switch is turned on, if light does not light up or
remains ON, check that malfunction indicator lamp circuit.

Glow Indicator Light and Injection Warning Light (Gravity

1 Fault) Check

This light serves to indicate that the glow plugs are working and to
signal system failures.
• Glow plug indicator light (2):

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Check that it lights while glow plugs are operating.
• Injection warning light (3):
Check that it lights up for 3 seconds after the ignition switch

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is turned on, and then it goes off (automatic test procedure).
If lights (glow indicator light and injection warning light) remain
ON after end of the preheating period and an automatic test pro-
3
.
cedure, go to “Diagnostic Trouble Code (DTC) Check” in this sec-
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2
tion.
After the ignition switch is turned on, if lights (glow indicator light
and injection warning light) does not light up or remains ON,
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check that glow indicator light circuit or injection warning light

(gravity 1 fault) circuit.
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Red Stop Warning Light (Gravity 2 Fault) Check

Red stop warning light (4) serves to indicate proper functioning

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and to signal system failures.

Check that it lights up for 3 seconds after the ignition switch is
turned on, and then it goes off (automatic test procedure).
STOP

If light remains ON after an automatic test procedure, go to “Diag-

nostic Trouble Code (DTC) Check” in this section.
4 After the ignition switch is turned on, if light does not light up or
STOP remains ON, check that red stop warning light (gravity 2 fault) cir-
cuit.
 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE) 6-2-9

Engine Diagnostic Flow Table

Numbers of each step correspond to the numbers of the items after this table.
Refer to “Diagnostic Step Details” following this table for the details of each step.

Step Action Yes No

1 Customer Complaint Analysis Go to Step 2. Perform customer com-
Perform customer complaint analysis. plaint analysis.
Was customer complaint analysis performed?
2 Visual Inspection Repair or replace mal- Go to Step 3.
Perform visual inspection referring to “Visual function part and then go
Inspection” in this section. to Step 3.
Is there any faulty condition?
3 Diagnostic Trouble Code Check and Record 1) Record and clear DTC Go to Step 4.
and clearance referring to “Diagnos-
Check for DTC referring to “Diagnostic Step tic Trouble Code
Details”. (DTC) Clearance” in
Is there any DTC(s)? this section.

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2) Go to Step 5.
4 Engine Basic Check and Fault Finding – Cus- Repair or replace mal- Go to Step 8.
tomer Complaints function part and then go

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Check and repair according to “Engine Basic to Step 8.
Check” and “Fault Finding – Customer Com-
plaints” in this section.
Is there any faulty condition?
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5 Recheck DTC Go to Step 6. Go to Step 7.
Recheck DTC referring to “Diagnostic Step
Details”.
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Is there any DTC(s)?

6 Troubleshooting for DTC Repair or replace mal- Go to Step 7.
Check and repair according to applicable DTC function part and then go
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diagnostic flow table in this section. to Step 8.

Is there any faulty condition?
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7 Check for intermittent problems Repair or replace mal- Go to Step 8.

Check for intermittent problems referring to function part and then go
“Diagnostic Step Details”. to Step 8.
Is there any faulty condition?
8 Final Confirmation Test Go to Step 5. End.
1) Clear DTC if any.
2) Perform final confirmation test referring to
“Diagnostic Step Details”.
3) Is there any problem symptom, DTC or
abnormal condition?
6-2-10 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE)

Customer Problem Inspection Form (Example)

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NOTE:
The above form is standard sample. It should be modified according to conditions characteristic of
each market.
 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE) 6-2-11

Diagnostic step details

1. Customer Complaint Analysis
Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this
purpose, use of such an inspection form will facilitate collecting information to the point required for proper anal-
ysis and diagnosis.

2. Visual Inspection
As a preliminary step, be sure to perform visual check of the items that support proper function of the engine
referring to “Visual Inspection” in this section.

3. Diagnostic Trouble Code (DTC) Check, Record and Clearance

First, check DTC, referring to “Diagnostic Trouble Code (DTC) Check” in this section. If DTC is indicated, record
and clear DTC by referring to “Diagnostic Trouble Code (DTC) Clearance” in this section.
Attempt to diagnose a trouble based on DTC in this step only or failure to clear the DTC in this step will lead to
incorrect diagnosis, trouble diagnosis of a normal circuit or difficulty in troubleshooting.

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4. Engine Basic Check and Fault Finding – Customer Complaints
Perform basic engine check according to the “Engine Basic Check” in this section first. When the end of the flow
table has been reached, check the parts of the system suspected as a possible cause referring to “Fault Finding

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– Customer Complaints” in this section and based on symptoms appearing on the vehicle (symptoms obtained
through steps of customer complaint analysis, trouble symptom confirmation and/or basic engine check) and
repair or replace faulty parts, if any.
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5. Recheck DTC
Refer to “Diagnostic Trouble Code (DTC) Check” in this section for checking procedure.
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6. Troubleshooting for DTC (See each DTC Diag. Flow Table)

Based on the DTC indicated in Step 5 and referring to the applicable DTC diag. flow table in this section, locate
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the cause of the trouble, namely in a sensor, switch, wire harness, connector, actuator, ECM or other part and
repair or replace faulty parts.
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7. Check for Intermittent Problem

Check parts where an intermittent trouble is easy to occur (e.g., wire harness, connector, etc.), referring to
“Intermittent and Poor Connection” in Section 0A and related circuit of DTC recorded in Step 5.

8. Final Confirmation Test

Confirm that the problem symptom has gone and the engine is free from any abnormal conditions. If what has
been repaired is related to the DTC, clear the DTC once and then recheck DTC and confirm that no DTC is indi-
cated.
6-2-12 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE)

Diagnostic Trouble Code (DTC) Check

1) Prepare SUZUKI scan tool.
2) Connect it to data link connector (DLC) (1) located on under-
side of instrument panel at driver’s seat side.
Special tool
(A): SUZUKI scan tool

1 3) Turn ignition switch ON.

4) Read DTC according to instructions displayed on scan tool
(A) and print them or write them down. Refer to scan tool opera-
tor’s manual for further details.
If communication between scan tool and ECM is not possi-
ble, check if scan tool is communicable by connecting it to
ECM in another vehicle. If communication is possible in this
case, scan tool is in good condition. Then check data link
connector and serial data line (circuit) in the vehicle with
which communication was not possible.

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5) After completing the check, turn ignition switch off and dis-
connect scan tool from data link connector.

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Diagnostic Trouble Code (DTC) Clearance
1) Connect SUZUKI scan tool to data link connector in the
. same manner as when making this connection for Diagnostic
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Trouble Code (DTC) Check.
2) Turn ignition switch OFF and then ON (but engine at stop).
3) Erase DTC according to instructions displayed on scan tool.
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Refer to scan tool operator’s manual for further details.

4) After completing the clearance, turn ignition switch OFF and
disconnect scan tool from data link connector.
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 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE) 6-2-13

Diagnostic Trouble Code (DTC) Table

DTC No. DTC No.
Detecting Condition
(Generic (SUZUKI Detecting Item
(DTC will set when detecting:)
scan tool) scan tool)
Crankshaft Position – Camshaft Camshaft position sensor signal is incorrect input
P0016 P0016
Position Correlation
Turbo Charger Boost Control Boost pressure control solenoid circuit is open or
P0045 P0045
Solenoid Circuit/Open short
External Air Temperature Sen- IAT sensor circuit is open or short
P0070 P0070
sor Circuit Malfunction
Fuel Rail/System Pressure Too Fuel flow is too low or too high
– P0087
Low
Fuel Pressure Regulator Perfor- Fuel rail pressure is too low or too high
P0089 P0089
mance Problem
*P0100 P0100 Mass Air Flow Circuit MAF sensor signal is low or high input
Engine Coolant Temperature Engine coolant temperature sensor circuit is open or
P0115 P0115

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Circuit Malfunction short
Fuel Trim Learned value of fuel injection amount is not
– P0170
updated for longer than a certain period.

P0180

*P0190
P0180

P0190
cuit Malfunction
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Fuel Temperature Sensor Cir-

Fuel Rail Pressure Sensor Cir-

cuit Malfunction
. Fuel temperature circuit is open or short

Fuel pressure signal is low or high input

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P0200 P0200 Injector Circuit Fuel injector circuit voltage is too low or too high
Injector Circuit Malfunction – Fuel injector No.1 current is low or high input
*P0201 P0201
Cylinder 1
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Injector Circuit Malfunction – Fuel injector No.2 current is low or high input
*P0202 P0202
Cylinder 2
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Injector Circuit Malfunction – Fuel injector No.3 current is low or high input
*P0203 P0203
Cylinder 3
Injector Circuit Malfunction – Fuel injector No.4 current is low or high input
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*P0204 P0204
Cylinder 4
Pedal Position Sensor 1 Circuit Accelerator pedal position sensor 1 signal is low or
*P0225 P0225
high input
Fuel Pump Secondary Circuit Fuel flow actuator circuit is open or short
P0231 P0231
Low
Turbo Pressure Sensor Circuit Boost pressure signal is low or high input
P0235 P0235
Malfunction
Cylinder 1 Contribution/Balance Detection of engine speed fluctuation (problem on
P0263 P0263
cylinder No.1)
Cylinder 2 Contribution/Balance Detection of engine speed fluctuation (problem on
P0266 P0266
cylinder No.2)
Cylinder 3 Contribution/Balance Detection of engine speed fluctuation (problem on
P0269 P0269
cylinder No.3)
Cylinder 4 Contribution/Balance Detection of engine speed fluctuation (problem on
P0272 P0272
cylinder No.4)
Knock Sensor Circuit Malfunc- Knock sensor signal is low or high input
P0325 P0325
tion
6-2-14 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE)

DTC No. DTC No.

Detecting Condition
(Generic (SUZUKI Detecting Item
(DTC will set when detecting:)
scan tool) scan tool)
Crankshaft Position Sensor Cir- Crankshaft position sensor signal is not inputted or
– P0335
cuit Malfunction incorrect signal is inputted
Camshaft Position Sensor Cir- Camshaft position sensor signal is not inputted
P0340 P0340
cuit Malfunction
Glow Plug Module Control Cir- Glow plug control circuit is open or short
P0670 P380
cuit
Glow Plug / Heater Circuit B Pre / post-heating control circuit is open or short
P0382 P0382
Malfunction
Exhaust Gas Recirculation Flow Excessive or insufficient EGR flow
P0400
Malfunction
P0400
Exhaust Gas Recirculation Sys- Poor performance of EGR valve
P2413
tem Performance
Exhaust Gas Recirculation Con- EGR valve control circuit is open or short
P0403 P0403
trol Circuit

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Exhaust Gas Recirculation Sen- EGR valve position sensor signal is low or high input
P0409 P0409
sor Circuit

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Radiator Cooling Fan Low Radiator low speed cooling fan control circuit is low
– P0480 Speed Control System Malfunc- or high input
tion
Radiator Cooling Fan High Radiator high speed cooling fan control circuit is low
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– P0481 Speed Control System Malfunc- or high input
tion
Exhaust Gas Recirculation EGR valve position sensor circuit open or short
P0487 P0487
Throttle Position Control Circuit
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Vehicle Speed Sensor Circuit Vehicle speed sensor signal is not input or incorrect
– P0500
Malfunction signal is input
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Incorrect Immobilizer Key Communication error with immobilizer control mod-

– P0513
ule
A/C Pressure Sensor Circuit A/C pressure sensor circuit is open or short
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– P0530
Malfunction
– P0560 System Voltage Power supply voltage is low or high input
– P0571 Brake Switch Circuit Brake switch signal is not input
– P0604 Control Module Internal Fail Engine control module internal faulty (system error)
– P0606 Control Module Program Error Engine control module internal faulty (system error)
Control Module EEPROM Fail- Engine control module internal faulty (system error)
*P062F P062F
ure
Sensor Reference Voltage 1 Cir- Sensor power source 1 voltage is too low or too high
– P0641
cuit/Open
– P0645 A/C Relay Control Circuit A/C relay control circuit is open or short
Sensor Reference Voltage 2 Cir- Sensor power source 2 voltage is too low or too high
P0651 P0651
cuit/Open
Main Relay Control Circuit Mal- Main relay control signal is low or high input
*P0685 P0685
function
Additional Heater Relay Circuit Additional heater relay 1 signal circuit is open or
– P1641
1 short
Additional Heater Relay Circuit Additional heater relay 2, 3 signal circuit is open or
– P1642
2 short
 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE) 6-2-15

DTC No. DTC No.

Detecting Condition
(Generic (SUZUKI Detecting Item
(DTC will set when detecting:)
scan tool) scan tool)
Pedal Position Sensor 2 Circuit Accelerator pedal position sensor 2 signal is low or
P2120 P2120
high input
P2226 P2226 Barometric Pressure Circuit Barometric pressure signal is low or high input
Turbo Charger Boost System Boost pressure is too low or too high
P2263 P2263
Performance

NOTE:
In the case of DTC No. of generic scan tool with * mark, DTC is not displayed on generic scan tool
depending on DTC detecting conditions. For details, refer to corresponding “Faulty Finding – Fault
Interpretation” in this section.

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6-2-16 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE)

Indicator lamp operation table

DTC No. DTC No.
Malfunction Injection Red Stop
(Generic (SUZUKI
Detecting Item Indicator Lamp Warning Light Warning Light
scan scan
(MIL) (Gravity 1 Fault) (Gravity 2 Fault)
tool) tool)
Crankshaft Position – Cam-
P0016 P0016 – – –
shaft Position Correlation
Turbo Charger Boost Control
P0045 P0045 – 1 driving cycle –
Solenoid Circuit/Open
External Air Temperature Sen-
P0070 P0070 3 driving cycles – –
sor Circuit Malfunction
Fuel Rail/System Pressure
– P0087 – – *1 driving cycle
Too Low
Fuel Pressure Regulator Per-
P0089 P0089 – – 1 driving cycle
formance Problem
P0100 P0100 Mass Air Flow Circuit *3 driving cycles – –

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Engine Coolant Temperature
P0115 P0115 – 1 driving cycle –
Circuit Malfunction
– P0170 Fuel Trim – – –

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Fuel Temperature Sensor Cir-
P0180 P0180 – – –
cuit Malfunction
Fuel Pressure Sensor Circuit
P0190 P0190
Malfunction
. – – *1 driving cycle
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P0200 P0200 Injector Circuit 3 driving cycles – 1 driving cycle
Injector Circuit Malfunction –
P0201 P0201 *3 driving cycles *1 driving cycle –
Cylinder 1
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Injector Circuit Malfunction –

P0202 P0202 *3 driving cycles *1 driving cycle –
Cylinder 2
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Injector Circuit Malfunction –

P0203 P0203 *3 driving cycles *1 driving cycle –
Cylinder 3
Injector Circuit Malfunction –
P0204 P0204 *3 driving cycles *1 driving cycle –
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Cylinder 4
Pedal Position Sensor 1 Cir-
P0225 P0225 – 1 driving cycle –
cuit
Fuel Pump Secondary Circuit
P0231 P0231 – – 1 driving cycle
Low
Turbo Pressure Sensor Cir-
P0235 P0235 – *1 driving cycle –
cuit Malfunction
Cylinder 1 Contribution/Bal-
P0263 P0263 – 1 driving cycle –
ance
Cylinder 2 Contribution/Bal-
P0266 P0266 – 1 driving cycle –
ance
Cylinder 3 Contribution/Bal-
P0269 P0269 – 1 driving cycle –
ance
Cylinder 4 Contribution/Bal-
P0272 P0272 – 1 driving cycle –
ance
Knock Sensor Circuit Malfunc-
P0325 P0325 – 1 driving cycle –
tion
 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE) 6-2-17

DTC No. DTC No.

Malfunction Injection Red Stop
(Generic (SUZUKI
Detecting Item Indicator Lamp Warning Light Warning Light
scan scan
(MIL) (Gravity 1 Fault) (Gravity 2 Fault)
tool) tool)
Crankshaft Position Sensor
– P0335 – *1 driving cycle *1 driving cycle
Circuit Malfunction
Camshaft Position Sensor Cir-
P0340 P0340 – – –
cuit Malfunction
Glow Plug Module Control Cir-
P0670 P0380 – – –
cuit
Glow Plug / Heater Circuit B
P0382 P0382 – – –
Malfunction
Exhaust Gas Recirculation
P0400 – – –
Flow Malfunction
P0400
Exhaust Gas Recirculation
P2413 3 driving cycles 1 driving cycle –
System Performance
Exhaust Gas Recirculation

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P0403 P0403 *3 driving cycles – –
Control Circuit
Exhaust Gas Recirculation
P0409 P0409 – – –

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Sensor Circuit
Radiator Cooling Fan Low
– P0480 Speed Control System Mal- – – –
function
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Radiator Cooling Fan High
– P0481 Speed Control System Mal- – – –
function
Exhaust Gas Recirculation
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P0487 P0487 Throttle Position Control Cir- 3 driving cycles – –

cuit
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Vehicle Speed Sensor Circuit

– P0500 – – –
Malfunction
– P0513 Incorrect Immobilizer Key – – –
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A/C Pressure Sensor Circuit

– P0530 – – –
Malfunction
– P0560 System Voltage – 1 driving cycle –
– P0571 Brake Switch Circuit – – –
– P0604 Control Module Internal Fail – – 1 driving cycle
– P0606 Control Module Program Error – *1 driving cycle *1 driving cycle
Control Module EEPROM Fail-
P062F P062F *3 driving cycles *1 driving cycle –
ure
Sensor Reference Voltage 1
– P0641 – – 1 driving cycle
Circuit/Open
– P0645 A/C Relay Control Circuit – – –
Sensor Reference Voltage 2
P0651 P0651 – 1 driving cycle –
Circuit/Open
Main Relay Control Circuit
P0685 P0685 – – –
Malfunction
Additional Heater Relay Cir-
– P1641 – – –
cuit 1
6-2-18 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE)

DTC No. DTC No.

Malfunction Injection Red Stop
(Generic (SUZUKI
Detecting Item Indicator Lamp Warning Light Warning Light
scan scan
(MIL) (Gravity 1 Fault) (Gravity 2 Fault)
tool) tool)
Additional Heater Relay Cir-
– P1642 – – –
cuit 2
Pedal Position Sensor 2 Cir-
P2120 P2120 – 1 driving cycle –
cuit
P2226 P2226 Barometric Pressure Circuit – – –
Turbo Charger Boost System
P2263 P2263 – *1 driving cycle –
Performance

NOTE:
• For indicator/warning light operation of items with *, refer to corresponding “Faulty Finding – Fault
Interpretation” in this section.
• “–” marked in above table indicates that indicator/warning light does not light.

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 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE) 6-2-19

Visual Inspection
Visually check the following parts and systems.

INSPECTION ITEM REFERRING SECTION

Engine oil - - - - - level, leakage Section 0B
Engine coolant - - - - - level, leakage Section 0B
Fuel - - - - - level, leakage Section 0B
Air cleaner element - - - - - dirt, clogging Section 0B
Battery - - - - - fluid level, corrosion of terminal
Drive belt - - - - - tension, damage Section 0B
Vacuum hoses of air intake system - - - - - disconnection, looseness,
deterioration, bend
Connectors of electric wire harness - - - disconnection, friction
Fuses - - - - - burning
Parts - - - - - installation, bolt - - - - - looseness
Parts - - - - - deformation
Other parts that can be checked visually

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Also add the following items at engine start, if possible.
Malfunction indicator lamp operation Check that malfunction indicator lamp

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circuit.
Glow plug indicator light and injection warning light operation Check that glow plug indicator light and
injection warning light circuit.
Red stop warning light Check that red stop warning light circuit.
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Charge warning lamp operation Section 6H2
Engine oil pressure warning lamp operation Section 8
Engine coolant temperature meter operation Section 8
Fuel level meter operation Section 8
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Abnormal air being inhaled from air intake system

Exhaust system - - - - - leakage of exhaust gas, noise
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Other parts that can be checked visually

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6-2-20 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE)

Engine Basic Check

This check is very important for troubleshooting when ECM has detected no DTC and no abnormality has been
found in visual inspection.
Follow the flow table carefully.

Step Action Yes No

1 Check battery voltage. Go to Step 2. Go to “Diagnosis” in Sec-
Is it 11 V or more? tion 6H2.
2 Is engine cranked? Go to Step 3 Go to “Diagnosis” in Sec-
tion 6G2.
3 Does engine start? Go to Step 4. Go to Step 5.
4 Was the trouble symptom able to be confirmed? Go to the corresponding Go to Step 7 of “Engine
item(s) in “Fault Finding- Diagnosis Flow Table” in
Customer Complaints” in this section.
this section.
5 Check immobilizer system referring to “Diag- Go to the corresponding Repair malfunction part.
nostic Flow Table” in Section 8G2. item(s) in “Fault Finding-

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Is it in good condition? Customer Complaints” in
this section.

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 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE) 6-2-21

Fault Finding – Fault Interpretation

DTC P0016 Crankshaft position – camshaft position correlation

NOTE:
Conditions for applying fault finding procedures to stored DTC:
The DTC is detected when the starter motor is operating or the engine is running at idle speed.

Wiring Diagram
For wiring circuit and connector number, refer to “A-4 Engine Control System (DSL Type 5)” in Section 8A.

Troubleshooting

Check the connection and condition of the CMP sensor connector.

Repair if necessary.
Check the connection and condition of the ECM “C47” connector.
Repair if necessary.

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Check for 12 V after ignition feed on “C90-1” terminal of the CMP sensor connector.
Check for earth on “C90-3” terminal of the CMP sensor connector.
Repair if necessary.

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Check the insulation, continuity and the absence of interference resistance on the following connections:
• Between “C90-2” terminal of CMP sensor connector and “C47-24” terminal of ECM connector
• Between “C90-3” terminal of CMP sensor connector and “C47-34” terminal of ECM connector
.
Repair if necessary.
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Check the valve timing referring to “Timing Belt Removal and Installation” in Section 6A2.
Repair if necessary. If DTC P0016 is still detected, replace the CMP sensor.
If DTC P0016 is still detected, replace the ECM.
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After Repair
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Deal with any faults detected by SUZUKI scan tool.

Clear the DTC.
Carry out a road test followed by another check with the SUZUKI scan tool.
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6-2-22 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE)

DTC P0045 Turbo charger boost control solenoid circuit/open

NOTE:
If DTC P0045 is detected, air flow regulation switched off, EGR valve closed and turbo charger regula-
tion switched off.

Wiring Diagram
For wiring circuit and connector number, refer to “A-4 Engine control system (DSL Type5):” in Section 8A.

Detecting Condition

Status displayed on Indicator/warning light

Detecting condition
SUZUKI scan tool operation
CO 0 Open circuit or short circuit to ground Injection warning light (gravity 1
CC 1 Short circuit to 12 V fault) lights up

Troubleshooting

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Check the connection and condition of the boost pressure control solenoid valve connector.

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Repair if necessary.
Check the connection and condition of the ECM “C47” connector.
Repair if necessary.
Check for the 12 V after ignition feed on “C97-2” terminal of the boost pressure control solenoid valve connec-
tor.
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Check boost pressure control solenoid valve for resistance referring to “Boost Pressure Control Solenoid Valve
Inspection” in Section 6E2.
Replace the boost pressure control solenoid valve if necessary.
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Check for insulation, continuity and absence of interference resistance of the connections:
• Between “C97-1” terminal of boost pressure control solenoid valve connector and “C47-3” terminal of ECM
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connector.
Repair If necessary.
If DTC P0045 is still detected, replace the ECM.
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After Repair
Deal with any faults detected by SUZUKI scan tool.
Clear the DTC.
Carry out a road test followed by another check with the SUZUKI scan tool.
 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE) 6-2-23

DTC P0070 External air temperature sensor circuit malfunction

Wiring Diagram
For wiring circuit and connector number, refer to “A-4 Engine Control System (DSL Type 5)” in Section 8A.

Detecting Condition

Status displayed on Indicator/warning light

Detecting condition
SUZUKI scan tool operation
CO 0 Short circuit to ground
MIL lights up
CC 1 Open circuit or short circuit to 12 V

Troubleshooting

Check the connection and condition of the MAF and IAT sensor connector.
Repair if necessary.
Check the connection and condition of the ECM “C47” connector.
Repair if necessary.

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Check IAT sensor for resistance referring to “MAF and IAT Sensor Inspection” in Section 6E2.
Replace MAF and IAT sensor if necessary.

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Check the insulation, continuity and absence of interference resistance of the connections:
• Between “C98-1” terminal of MAF and IAT sensor connector and “C47-19” terminal of ECM connector
• Between “C98-2” terminal of MAF and IAT sensor connector and “C47-38” terminal of ECM connector
Repair if necessary.
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If DTC P0070 is still detected, replace the ECM.

After Repair
Deal with any faults detected by SUZUKI scan tool.
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Clear the DTC.

Carry out a road test followed by another check with the SUZUKI scan tool.
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6-2-24 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE)

DTC P0087 Fuel rail/system pressure too low

NOTE:
• This DTC indicated only with SUZUKI scan tool.
• Fault finding procedure application conditions for stored DTC:
The DTC is detected with the engine running.

Detecting Condition

Status displayed on Indicator/warning light

Detecting condition
SUZUKI scan tool operation
D5 Trim minimum for high fuel Red stop warning light (gravity 2
fault) light up.
D6 Trim maximum for high fuel

Troubleshooting

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Check the connection and condition of the fuel flow actuator connector.
Repair if necessary.
Check the connection and condition of the ECM “C47” connector.

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Repair if necessary.
Check for the 12 V after ignition feed on “C40-1” terminal of the fuel flow actuator connector.
Repair if necessary.
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Check the insulation, continuity and absence of interference resistance of the connection:
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• Between “C47-7” terminal of ECM connector and “C40-2” terminal of fuel flow actuator
Repair if necessary.
Check fuel flow actuator for resistance referring to “Fuel Flow Actuator Inspection” in Section 6E2.
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Replace the fuel flow actuator if necessary.

Check for fuel in the tank.
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Carry out Test 1: Low Pressure Circuit Check in this section.

Repair if necessary.
If the fault persists, carry out “Test 7: High Pressure System Check” in this section.
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If DTC P0087 is still detected, replace the ECM.

After Repair
Deal with any faults detected by SUZUKI scan tool.
Clear the DTC.
Carry out a road test followed by another check with the SUZUKI scan tool.
 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE) 6-2-25

DTC P0089 Fuel pressure regulator performance problem

NOTE:
• Priority when dealing with a number of DTCs:
If DTC P0089 and either one of DTC P0180 or P0190 are present, deal with DTC P180 Fuel Tempera-
ture Sensor Circuit Malfunction or DTC P0190 Fuel Pressure Sensor Circuit Malfunction first.
• Fault finding procedure application conditions for stored DTC:
The DTC is detected with the engine running.
• This DTC may be detected when driving with insufficient fuel in fuel tank. Be sure to bear this in
mind during troubleshooting.

Detecting Condition

Status displayed on Indicator/warning light

Detecting condition
SUZUKI scan tool operation
D1 Parameter at limit minimum
D2 Parameter at limit maximum

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D3 Below minimum threshold
D4 Above maximum threshold Red stop warning light (gravity 2
D5 Trim minimum for high fuel fault) light up
D6
D7
D8 co
Trim maximum for high fuel
Trim minimum for low fuel
Trim maximum for low fuel
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Troubleshooting

Check amount of fuel in fuel tank.

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If fuel in fuel tank is around empty, refill and recheck.

Check the connection and condition of the fuel flow actuator connector.
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Repair if necessary.
Check the connection and condition of the ECM “C47” connector.
Repair if necessary.
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Check for the 12 V after ignition feed on “C40-1” terminal of the fuel flow actuator connector.
Repair if necessary.
Check the insulation, continuity and absence of interference resistance of the connection:
• Between “C47-7” terminal of ECM connector and “C40-2” terminal of fuel flow actuator
Repair if necessary.
Check fuel flow actuator for resistance referring to “Fuel Flow Actuator Inspection” in Section 6E2.
Replace fuel flow actuator if necessary.
Check for fuel in the tank.
Carry out Test 1: Low Pressure Circuit Check in this section.

After Repair
Deal with any faults detected by SUZUKI scan tool.
Clear the DTC.
Carry out a road test followed by another check with the SUZUKI scan tool.
6-2-26 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE)

DTC P0100 Mass air flow circuit

Wiring Diagram
For wiring circuit and connector number, refer to “A-4 Engine Control System (DSL Type 5)” in Section 8A.

Detecting Condition

NOTE:
Generic scan tool displays status with * mark only.

Status displayed on Indicator/warning light

Detecting condition
SUZUKI scan tool operation
D1 Parameter at limit minimum
Does not light
D2 Parameter at limit maximum
*D3 Parameter low level
MIL light up
*D4 Parameter high level

Troubleshooting

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Check the connection and condition of the MAF and IAT sensor connector.
Repair if necessary.

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Visually check that the turbocharger circuit sealing.
Repair if necessary.
Check that the air filter is not blocked.
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Clean or replace air cleaner filter if necessary.
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Check turbo charger referring to “Turbocharger Inspection” in Section 6A2.
Replace if necessary.
Check that the air inlet system is not blocked between the air filter outlet and the intake manifold.
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Repair if necessary.
Check the connection and condition of the ECM “C47” connector.
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Repair if necessary.
Check for the 5 V after ignition feed on “C98-5” terminal of MAF and IAT sensor connector.
Repair if necessary.
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Check for insulation, continuity and absence of interference resistance of the connections:
• Between “C98-2” terminal of MAF and IAT sensor connector and “C47-38” terminal of ECM connector
• Between “C98-6” terminal of MAF and IAT sensor connector and “C47-28” terminal of ECM connector
Repair If necessary. If DTC P0100 is still detected, replace the MAF and IAT sensor.

After Repair
Deal with any faults detected by SUZUKI scan tool.
Clear the DTC.
Carry out a road test followed by another check with the SUZUKI scan tool.
 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE) 6-2-27

DTC P0115 Engine coolant temperature circuit malfunction

NOTE:
• If DTC P0115 is detected, radiator cooling fan motor is operated.
• The preheating time is 10 seconds or longer.

Wiring Diagram
For wiring circuit and connector number, refer to “A-4 Engine Control System (DSL Type 5)” in Section 8A.

Detecting Condition

Status displayed on Indicator/warning light

Detecting condition
SUZUKI scan tool operation
CC0 Short circuit to ground Injection warning light (gravity 1
CO1 Open circuit or short circuit to 12 V fault) light up.

Troubleshooting

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Check the connection and condition of the coolant temperature sensor connector.

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Repair it if necessary.
Check the connection and condition of the ECM “C47” connector.
Repair if necessary.
Check ECT sensor for resistance referring to “Engine Coolant Temperature Sensor (ECT sensor) Inspection” in
Section 6E2.
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Check the insulation, continuity and absence of interference resistance of the connections:
• Between “BLU/WHT” wire of engine coolant temperature sensor connector and “C47-31” terminal of ECM
connector
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• Between “BLU/RED” wire of engine coolant temperature sensor connector and “C47-21” terminal of ECM
connector
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Repair if necessary.
If DTC P0115 is still detected, replace the ECM.
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After Repair
Deal with any faults detected by SUZUKI scan tool.
Clear the DTC.
Carry out a road test followed by another check with the SUZUKI scan tool.
6-2-28 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE)

DTC P0170 Fuel trim

NOTE:
• This DTC indicated only with SUZUKI scan tool.
• Priority when dealing with a number DTCs:
If DTC P0170 and either one of DTC P0089, P0200, P0201, P0202, P0203 or P0204 are detected, deal
with DTC “P0089 Fuel pressure regulator performance problem”, “P0200 Injector control circuit”,
“P0201 Cylinder 1 injector control circuit, P0202 Cylinder 2 injector control circuit”, “P0203 Cylinder
3 injector control circuit” or “P0204 Cylinder 4 injector control circuit” first.

Wiring Diagram
For wiring circuit and connector number, refer to “A-4 Engine control system (DSL Type5):” in Section 8A.

Driving cycle for troubleshooting

Before starting troubleshooting, carry out the following driving cycle.

Perform the following: (idle)

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• Engine running at idle speed for 30 seconds
• Engine speed < 1000 rpm
• Injected quantity < 10 mg/stroke
• Rail pressure: between 270 bar and 300 bar
• Vehicle speed < 3 km/h
• Engine coolant temperature > 79 °C
.
• Intake air temperature: between 10 °C and 50 °C
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• Fuel temperature: between 10 °C and 57 °C
• Battery voltage: between 10 V and 16 V
• Barometric pressure > 90kPa
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Perform the following: (Running)

• Engine running at idle speed for 30 seconds
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• Engine speed: between 1250 rpm and 3500 rpm

• Injected quantity: betwee15 mg/stroke and 30 mg/stroke
• Rail pressure: between 350 bar and 1450 bar
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• Vehicle speed: no limit

• Engine coolant temperature > 65 °C
• Intake air temperature: between 0 °C and 150 °C
• Fuel temperature: between –50 °C and 150 °C
• Battery voltage: between 10 V and 16 V
• Barometric pressure > 80kPa
If DTC P0170 is still detected, go to trouble shooting.

Troubleshooting

Check that the fuel injector calibration codes are correctly entered on the ECM.
Check the connection and condition of the ECM “C47” connector and “C47-9” terminal of knock sensor shield-
ing.
Check that the knock sensor is secured on the engine.
After retightening the knock sensor, initialize the fuel pressure value by using “Initialize High Pressure Pump”
under “Miscellaneous test” (“MISC TEST”) of SUZUKI scan tool.
 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE) 6-2-29

After Repair
Deal with any faults detected by SUZUKI scan tool.
Clear the DTC.
Carry out a road test followed by another check with the SUZUKI scan tool.

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6-2-30 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE)

DTC P0180 Fuel temperature sensor circuit malfunction

Wiring Diagram
For wiring circuit and connector number, refer to “A-4 Engine control system (DSL Type5):” in Section 8A.

Detecting Condition

Status displayed on Indicator/warning light

Detecting condition
SUZUKI scan tool operation
CO0 Short circuit to ground
Does not light
CC1 Open circuit or short circuit to 12 V

Troubleshooting

Check the connection and condition of the fuel temperature sensor connector.
Repair if necessary.
Check the connection and condition of the ECM “C47” connector.
Repair if necessary.

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Check fuel temperature sensor for resistance referring to “Fuel Temperature Sensor Inspection” in Section
6E2.

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Check the insulation, continuity and absence of interference resistance of the connections:
• Between “C41-2” terminal of fuel temperature sensor connector and “C47-22” terminal of ECM connector
• Between “C41-1” terminal of fuel temperature sensor connector and “C47-32” terminal of ECM connector
Repair if necessary.
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If DTC P0180 is still detected, replace the ECM.

After Repair
Deal with any faults detected by SUZUKI scan tool.
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Clear the DTC.

Carry out a road test followed by another check with the SUZUKI scan tool.
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 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE) 6-2-31

DTC P0190 Fuel pressure sensor circuit malfunction

NOTE:
• Priority when dealing with a number of faults:
If DTC P0190 and DTC P0641 are detected, deal with DTC P0641 Sensor Reference Voltage 1 Circuit/
Open first.
• Fault finding procedure application conditions for stored DTC:
The DTC is detected after the engine started.
• If DTC P0190 is detected, the engine stops and impossible to restart.

Detecting Condition

NOTE:
Generic scan tool displays status with * mark only.

Status displayed on Indicator/warning light

Detecting condition
SUZUKI scan tool operation

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*CC0 Short circuit to ground Red stop warning light (gravity 2
*CO1 Open circuit or short circuit to 12 V fault) light up
*D1 Inconsistency Does not light

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*D2 Above maximum threshold Red stop warning light (gravity 2
*D3 Below minimum threshold fault) light up
D4 Value out of range Does not light
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Troubleshooting

Check the connection and condition of the connector of the fuel pressure sensor.
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Repair if necessary.
Check the connection and condition of ECM “C47” connector.
Repair if necessary.
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Check for 5 V on “C91-1” terminal of the fuel pressure sensor connector.

Check for earth on “C91-2” terminal of the fuel pressure sensor connector.
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Repair if necessary.
Check for insulation, continuity and absence of interference resistance of the connections:
• Between “ORN” wire of fuel pressure sensor connector and “C47-15” terminal of ECM connector
• Between “RED/BLK” wire of fuel pressure sensor connector and “C47-25” terminal of ECM connector
• Between “BLK” wire of fuel pressure sensor connector and “C47-35” terminal of ECM connector
Repair if necessary.
If DTC P0190 is still detected, replace the rail.
If DTC P0190 is still detected, replace the ECM.

After Repair
Deal with any faults detected by SUZUKI scan tool.
Clear the DTC.
Carry out a road test followed by another check with the SUZUKI scan tool.
6-2-32 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE)

DTC P0200 Injector circuit

NOTE:
• Conditions for applying the fault finding procedure to the DTC stored:
The DTC is detected when engine is running at idle speed.
• Priority when dealing with a number of DTCs:
If DTC P0200 and either one of DTC P0201, DTC P0202, DTC P0203 or DTC P0204 are detected, the
fault finding procedure remains the same, but the faulty injector has to be identified.
• If DTC P0200 is detected, engine noise, unstable engine speed and reduced engine performance.

Wiring Diagram
For wiring circuit and connector number, refer to “A-4 Engine control system (DSL Type5):” in Section 8A.

Detecting Condition

Status displayed on Indicator/warning light

Detecting condition
SUZUKI scan tool operation

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CC1 Short circuit to 12 V MIL and red stop warning light
CC0 Short circuit to ground (gravity 2 fault) light up

Troubleshooting

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Switch off the ignition and check the connection and condition of the injector connectors.
Repair if necessary.
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Switch off the ignition, disconnect the injectors (or the injector identified by DTC P0201, DTC P0202, DTC
P0203 or DTC P0204) and switch the ignition back on.
Check DTC.
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If DTC P0200 is detected, carry out troubleshooting for detected DTC P0200.
If DTC P0200 is not detected, carry out troubleshooting for not detected DTC P0200.
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Troubleshooting for detected DTC P0200

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The injectors are not faulty.

Check the condition and connection of the ECM “C47” connector.
Repair if necessary.
Check for insulation, continuity and absence of interference resistance of the connections:
• Between “C47-48” terminal of ECM connector and “C36-1” terminal of injector No.1 connector
• Between “C47-47” terminal of ECM connector and “C36-2” terminal of injector No.1 connector
• Between “C47-42” terminal of ECM connector and “C37-1” terminal of injector No.2 connector
• Between “C47-41” terminal of ECM connector and “C37-2” terminal of injector No.2 connector
• Between “C47-46” terminal of ECM connector and “C38-1” terminal of injector No.3 connector
• Between “C47-45” terminal of ECM connector and “C38-2” terminal of injector No.3 connector
• Between “C47-44” terminal of ECM connector and “C39-1” terminal of injector No.4 connector
• Between “C47-43” terminal of ECM connector and “C39-2” terminal of injector No.4 connector
Repair if necessary.
If DTC P0200 is still detected, replace the ECM.
 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE) 6-2-33

Troubleshooting for not detected DTC P0200

Injector(s) fault.
Replace the injector, identified by DTC P0201 to DTC P0204 if detected.
If none of the faults identifying the faulty injector circuit are detected.
• Switch off the ignition
• Reconnect one of the four injectors
• Switch on the ignition again
If DTC is detected, replace the reconnected injector.
Carry out the same procedure for the remaining injectors.

After Repair
Deal with any faults detected by SUZUKI scan tool.
Clear the DTC.
Carry out a road test followed by another check with the SUZUKI scan tool.

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6-2-34 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE)

DTC P0201 Injector circuit malfunction – cylinder 1

NOTE:
• Cylinder number is counted from flywheel side.
• Fault finding procedure application conditions for stored DTC:
The DTC is detected when engine is running at idle speed.
• When DTC P0201 occurs, the idle speed is locked at 1000 rpm, there is engine noise, the engine
speed is unstable, and engine performance is reduced to 75%.

Wiring Diagram
For wiring circuit and connector number, refer to “A-4 Engine control system (DSL Type5):” in Section 8A.

Detecting Condition

NOTE:
Generic scan tool displays status with *mark only.

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Status displayed on Indicator/warning light
Detecting condition
SUZUKI scan tool operation
*CO Open circuit MIL and injection warning light

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*CC Short circuit (gravity 1 fault) light up
D1 Parameter at limit minimum Injection warning light (gravity 1
D2 Parameter at limit maximum fault) light up
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Troubleshooting for CO: Open circuit, CC: Short circuit

Switch off the ignition and wait 15 seconds.

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Check the connection and condition of the injector connector.

Repair if necessary.
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Check the connection and condition of the ECM “C47” connector.

Repair if necessary.
Using SUZUKI scan tool, carry out the “Cylinder 1 Injector” (in output test on scan tool).
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If injector 1 cannot be heard operating five times in a cycle, connect the wire of the injector of cylinder 2 to the
injector of cylinder 1 and carry out the “Cylinder 2 Injector” (in output test on scan tool).
Does this injector actuation cycle work?
Yes Injector 1 is not defective; the fault is in the injector 1 control circuit.
Check for continuity and absence of interference resistance of the connections:
• Between “C47-48” terminal of ECM connector and “C36-1” terminal of injector No.1 connector
• Between “C47-47” terminal of ECM connector and “C36-2” terminal of injector No.1 connector
Repair if necessary.
If DTC P0201 is still detected, replace the ECM.
No Injector 1 is faulty, replace the cylinder 1 injector.
 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE) 6-2-35

Troubleshooting for D1: At minimum stop, D2: At maximum stop

Check that the injector calibration codes are registered correctly in the ECM.
Check the connection and condition of the “C47-9” terminal of ECM connector.
Repair if necessary.
Check that the knock sensor is secured on the engine.
Repair if necessary.
After retightening the knock sensor, initialize the fuel pressure value by using “Initialize High Pressure Pump”
under “Miscellaneous test” (“MISC TEST”) of SUZUKI scan tool.
If DTC P0201 is still detected, replace the cylinder 1 injector.

After Repair
Deal with any faults detected by SUZUKI scan tool.
Clear the DTC.
Carry out a road test followed by another check with the SUZUKI scan tool.

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6-2-36 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE)

DTC P0202 Injector circuit malfunction – cylinder 2

NOTE:
• Cylinder number is counted from flywheel side.
• Fault finding procedure application conditions for stored DTC:
The DTC is detected when engine is running at idle speed.
• When DTC P0202 occurs, the idle speed is locked at 1000 rpm, there is engine noise, the engine
speed is unstable, and engine performance is reduced to 75%.

Wiring Diagram
For wiring circuit and connector number, refer to “A-4 Engine control system (DSL Type5):” in Section 8A.

Detecting Condition

NOTE:
Generic scan tool displays status with *mark only.

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Status displayed on Indicator/warning light
Detecting condition
SUZUKI scan tool operation
*CO Open circuit MIL and injection warning light

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*CC Short circuit (gravity 1 fault) light up
D1 Parameter at limit minimum Injection warning light (gravity 1
D2 Parameter at limit maximum fault) light up
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Troubleshooting for CO: Open circuit, CC: Short circuit

Switch off the ignition and wait 15 seconds.Check the connection and condition of the injector connector.
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Repair if necessary.
Check the connection and condition of the ECM “C47” connector.
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Repair if necessary.
Using SUZUKI scan tool, carry out the “Cylinder 2 Injector” (in output test on scan tool).
If injector 2 cannot be heard operating five times in a cycle, connect the wire of the injector of cylinder 3 to the
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injector of cylinder 2 and carry out the “Cylinder 3 Injector” (in output test on scan tool).
Does this injector actuation cycle work?
Yes Injector 2 is not defective; the fault is in the injector 1 control circuit.
Check for continuity and absence of interference resistance of the connections:
• Between “C47-42” terminal of ECM connector and “C37-1” terminal of injector No.2 connector
• Between “C47-41” terminal of ECM connector and “C37-2” terminal of injector No.2 connector
Repair if necessary.
If DTC P0202 is still detected, replace the ECM.
No Injector 2 is faulty, replace the cylinder 2 injector.
 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE) 6-2-37

Troubleshooting for D1: At minimum stop, D2: At maximum stop

Check that the injector calibration codes are registered correctly in the ECM.
Check the connection and condition of the “C47-9” terminal of ECM connector.
Repair if necessary.
Check that the knock sensor is secured on the engine.
Repair if necessary.
After retightening the knock sensor, initialize the fuel pressure value by using “Initialize High Pressure Pump”
under “Miscellaneous test” (“MISC TEST”) of SUZUKI scan tool.
If DTC P0202 is still detected, replace the cylinder 2 injector.

After Repair
Deal with any faults detected by SUZUKI scan tool.
Clear the DTC.
Carry out a road test followed by another check with the SUZUKI scan tool.

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6-2-38 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE)

DTC P0203 Injector circuit malfunction – cylinder 3

NOTE:
• Cylinder number is counted from flywheel side.
• Fault finding procedure application conditions for stored DTC:
The DTC is detected when engine is running at idle speed.
• When DTC P0203 occurs, the idle speed is locked at 1000 rpm, there is engine noise, the engine
speed is unstable, and engine performance is reduced to 75%.

Wiring Diagram
For wiring circuit and connector number, refer to “A-4 Engine control system (DSL Type5):” in Section 8A.

Detecting Condition

NOTE:
Generic scan tool displays status with *mark only.

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Status displayed on Indicator/warning light
Detecting condition
SUZUKI scan tool operation
*CO Open circuit MIL and injection warning light

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*CC Short circuit (gravity 1 fault) light up
D1 Parameter at limit minimum Injection warning light (gravity 1
D2 Parameter at limit maximum fault) light up
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Troubleshooting

Switch off the ignition and wait 15 seconds.

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Check the connection and condition of the injector connector.

Repair if necessary.
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Check the connection and condition of the ECM “C47” connector.

Repair if necessary.
Using SUZUKI scan tool, carry out the “Cylinder 3 Injector” (in output test on scan tool).
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If injector 3 cannot be heard operating five times in a cycle, connect the wire of the injector of cylinder 4 to the
injector of cylinder 3 and carry out the “Cylinder 4 Injector” (in output test on scan tool).
Does this injector actuation cycle work?
Yes Injector 3 is not defective; the fault is in the injector 3 control circuit.
Check for continuity and absence of interference resistance of the connections:
• Between “C47-46” terminal of ECM connector and “C38-1” terminal of injector No.3 connector
• Between “C47-45” terminal of ECM connector and “C38-2” terminal of injector No.3 connector
Repair if necessary.
If DTC P0203 is still detected, replace the ECM.
No Injector 3 is faulty, replace the cylinder 3 injector.
 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE) 6-2-39

Troubleshooting for D1: At minimum stop, D2: At maximum stop

Check that the injector calibration codes are registered correctly in the ECM.
Check the connection and condition of the “C47-9” terminal of ECM connector.
Repair if necessary.
Check that the knock sensor is secured on the engine.
Repair if necessary.
After retightening the knock sensor, initialize the fuel pressure value by using “Initialize High Pressure Pump”
under “Miscellaneous test” (“MISC TEST”) of SUZUKI scan tool.
If DTC P0202 is still detected, replace the cylinder 2 injector.

After Repair
Deal with any faults detected by SUZUKI scan tool.
Clear the DTC.
Carry out a road test followed by another check with the SUZUKI scan tool.

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6-2-40 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE)

DTC P0204 Injector circuit malfunction – cylinder 4

NOTE:
• Cylinder number is counted from flywheel side.
• Fault finding procedure application conditions for stored DTC:
The DTC is detected when engine is running at idle speed.
• When DTC P0204 occurs, the idle speed is locked at 1000 rpm, there is engine noise, the engine
speed is unstable, and engine performance is reduced to 75%.

Wiring Diagram
For wiring circuit and connector number, refer to “A-4 Engine control system (DSL Type5):” in Section 8A.

Detecting Condition

NOTE:
Generic scan tool displays status with *mark only.

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Status displayed on Indicator/warning light
Detecting condition
SUZUKI scan tool operation
*CO Open circuit MIL and injection warning light

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*CC Short circuit (gravity 1 fault) light up
D1 Parameter at limit minimum Injection warning light (gravity 1
D2 Parameter at limit maximum fault) light up
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Troubleshooting for CO: Open circuit, CC: Short circuit

Switch off the ignition and wait 15 seconds.

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Check the connection and condition of the injector connector.

Repair if necessary.
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Check the connection and condition of the ECM “C47” connector.

Repair if necessary.
Using SUZUKI scan tool, carry out the “Cylinder 4 Injector” (in output test on scan tool).
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If injector 4 cannot be heard operating five times in a cycle, connect the wire of the injector of cylinder 3 to the
injector of cylinder 4 and carry out the “Cylinder 3 Injector” (in output test on scan tool).
Does this injector actuation cycle work?
Yes Injector 4 is not defective; the fault is in the injector 4 control circuit.
Check for continuity and absence of interference resistance of the connections:
• Between “C47-44” terminal of ECM connector and “C39-1” terminal of injector No.4 connector
• Between “C47-43” terminal of ECM connector and “C39-2” terminal of injector No.4 connector
Repair if necessary.
If DTC P0204 is still detected, replace the ECM.
No Injector 4 is faulty, replace the cylinder 4 injector.
 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE) 6-2-41

Troubleshooting for D1: At minimum stop, D2: At maximum stop

Check that the injector calibration codes are registered correctly in the ECM.
Check the connection and condition of the “C47-9” terminal of ECM connector.
Repair if necessary.
Check that the knock sensor is secured on the engine.
Repair if necessary.
After retightening the knock sensor, initialize the fuel pressure value by using “Initialize High Pressure Pump”
under “Miscellaneous test” (“MISC TEST”) of SUZUKI scan tool.
If DTC P0204 is still detected, replace the cylinder 4 injector.

After Repair
Deal with any faults detected by SUZUKI scan tool.
Clear the DTC.
Carry out a road test followed by another check with the SUZUKI scan tool.

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6-2-42 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE)

DTC P0225 Pedal position sensor 1 circuit

NOTE:
• Priority when dealing with a number of DTCs:
• If DTC P0225 and DTC P0641 are detected, deal with DTC P0641 Sensor Reference Voltage 1 first.
• If DTC P0225 is detected, engine speed maintained above 1000 rpm and engine performance
reduced to 75%.
• If DTC P0225 and DTC P2120 are detected, engine speed fixed at 1300 rpm.

Wiring Diagram
For wiring circuit and connector number, refer to “A-4 Engine control system (DSL Type5):” in Section 8A.

Detecting Condition

NOTE:
Generic scan tool displays status with *mark only.

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Status displayed on Indicator/warning light
Detecting condition
SUZUKI scan tool operation
*D1 Incoherence

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*D2 No signal
Injection warning light (gravity 1
D3 Component stuck
fault) light up
*CO0 Open circuit or short circuit to ground
*CC1
.
Short circuit to 12 V
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Troubleshooting for D1: Incoherence, D3: Component stuck
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Disconnect the ECM “E17” connector and the APP sensor connector.
Check for insulation between “E17-3” terminal and “E17-21” terminal of ECM connector
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Repair if necessary. If DTC P0225 is still detected, replace the APP sensor.
If DTC P0225 is still detected, replace the ECM.
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Troubleshooting for CO0: Open circuit or short circuit to ground, CC1: Short circuit to +12 V or D2:
No signal

Check the connection and condition of the APP sensor connector.

Repair if necessary.
Check the connection and condition of the ECM “E17” connector.
Repair if necessary.
Check APP sensor for resistance referring to “APP Sensor Inspection” in Section 6E2.
Replace the APP sensor necessary.
Check for 5 V on “E97-4” terminal of APP sensor connector.
Check for earth on “E97-5” terminal of APP sensor connector.
Repair if necessary.
Check for insulation, continuity and absence of interference resistance of the connections:
• Between “E97-3” terminal of APP sensor connector and “E17-4” terminal of ECM connector
• Between “E97-4” terminal of APP sensor connector and “E17-3” terminal of ECM connector
• Between “E97-5” terminal of APP sensor connector and “E17-5” terminal of ECM connector
Repair if necessary.
 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE) 6-2-43

Disconnect the ECM “E17” connector and the APP sensor connector.
Check for insulation between “E17-3” terminal and “E17-21” terminal of ECM connector
Repair if necessary.
If DTC P0225 is still detected, replace the APP sensor.
If DTC P0225 is still detected, replace the ECM.

After Repair
Deal with any faults detected by SUZUKI scan tool.
Clear the DTC.
Carry out a road test followed by another check with the SUZUKI scan tool.

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6-2-44 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE)

DTC P0231 Fuel pump secondary circuit low

NOTE:
If DTC P0231 is detected, the fuel flow actuator is fully opened (leading to engine rattling) and the
engine is stopped to prevent it from racing.

Wiring Diagram
For wiring circuit and connector number, refer to “A-4 Engine control system (DSL Type5):” in Section 8A.

Detecting Condition

NOTE:
Generic scan tool displays status with *mark only.

Status displayed on Indicator/warning light

Detecting condition
SUZUKI scan tool operation
CO0 Open circuit or short circuit to ground Red stop warning light (gravity 2

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CC1 Short circuit to 12 V fault) light up

Troubleshooting

Repair if necessary.
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Check the condition and connection of the flow actuator connector.

Check for the 12 V after ignition feed on “C40-1” terminal of the flow actuator connector.
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Check the connection and condition of the ECM “C47” connector.
Repair if necessary.
Check fuel flow actuator for resistance referring to “Fuel Flow Actuator Inspection” in Section 6E2.
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Replace fuel flow actuator if necessary.

Check for insulation, continuity and absence of interference resistance of the connection:
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• Between “C47-7” terminal of ECM connector and “C40-2” terminal of flow actuator connector
Repair if necessary.
If DTC P0231 is still detected, replace the ECM.
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After Repair
Deal with any faults detected by SUZUKI scan tool.
Clear the DTC.
Carry out a road test followed by another check with the SUZUKI scan tool.
 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE) 6-2-45

DTC P0235 Turbo pressure sensor circuit malfunction

NOTE:
• If DTC P0235 and DTC P0641 are detected, deal with DTC P0641 Sensor Reference Voltage 1 first.

Wiring Diagram
For wiring circuit and connector number, refer to “A-4 Engine control system (DSL Type5):” in Section 8A.

Detecting Condition

Status displayed on Indicator/warning light

Detecting condition
SUZUKI scan tool operation
D1 Parameter at limit minimum
Does not light
D2 Parameter at limit maximum
D3 Below minimum threshold
D4 Above maximum threshold
Injection warning light (gravity 1
D5 Trim minimum for high fuel

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fault) light up
D6 Trim maximum for high fuel
D7 Trim minimum for low fuel

minimum threshold and D4: Above maximum threshold

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Troubleshooting for D1: Parameter at limit minimum, D2: Parameter at limit maximum, D3: Below
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Check the connection and condition of the boost pressure sensor connector.
Repair if necessary.
Check the connection and condition of the ECM “C47” connector.
Repair if necessary.
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Check for the 5 V after ignition feed on “C47-16” terminal of boost pressure sensor connector.
Repair if necessary.
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Check for ground on “C47-36” terminal of the boost pressure sensor.

Check for insulation, continuity and absence of interference resistance of the connections:
• Between “C49-1” terminal of the boost pressure sensor connector and “C47-16 terminal of ECM connector
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• Between “C49-3” terminal of the boost pressure sensor connector and “C47-26 terminal of ECM connector
• Between “C49-2” terminal of the boost pressure sensor connector and “C47-36 terminal of ECM connector
Repair if necessary. If DTC P0235 is still detected, replace the boost pressure sensor.
If DTC P0235 is still detected, replace the ECM.
6-2-46 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE)

Troubleshooting for D5: Trim minimum for high fuel, D6: Trim maximum for high fuel and D7: Trim
minimum for low fuel

Visually check that the turbocharger circuit sealing.

Repair if necessary.
Remove the air supply ducts and check that they are not blocked.
Repair if necessary.
Check the condition of the boost pressure sensor connector and replace it if necessary.
With engine stationary, check the consistency between the barometric pressure and boost pressure.
With the engine stopped, the pressure should be approximately the same between the two sensors.
If the values are very different, replace the boost pressure sensor.
Check the turbocharger (wastegate pneumatic actuation circuit).
Repair if necessary.

After Repair
Deal with any faults detected by SUZUKI scan tool.
Clear the DTC.

m
Carry out a road test followed by another check with the SUZUKI scan tool.

. co
gn
ia
rd
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 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE) 6-2-47

DTC P0263 Cylinder 1 contribution/balance

NOTE:
• Cylinder number is counted from flywheel side.
• Fault finding procedure application conditions for stored DTC:
The DTC is detected when engine is running at idle speed.
• Priority when dealing with a number of DTCs:
– If DTC P0201 (CO: open circuit or CC: short circuit) and DTC P0263 are detected, deal with DTC
P0201 Injector Circuit Malfunction – Cylinder 1 first.
– If DTC P0089 (D1: Parameter at limit minimum, D2: Parameter at limit maximum or D7: Trim mini-
mum for low fuel) and DTC P0263 are detected, deal with DTC P0089 Fuel Pressure Regulator Per-
formance Problem first.
• If DTC P0263 is detected, engine performance reduced to 75% and injection warning light (gravity 1
fault) light up.

Troubleshooting

m
Check the engine compression.
Repair if necessary
Check the valve clearances and adjust them if necessary.

co
Check the air intake circuit and the EGR valve and clean them if necessary.
Replace the injector.
If DTC P0263 is still detected, replace the ECM.
.
gn
After Repair
Deal with any faults detected by SUZUKI scan tool.
Clear the DTC.
ia

Carry out a road test followed by another check with the SUZUKI scan tool.
rd
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6-2-48 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE)

DTC P0266 Cylinder 2 contribution/balance

NOTE:
• Cylinder number is counted from flywheel side.
• Fault finding procedure application conditions for stored DTC:
The TDC is detected when engine is running at idle speed.
• Priority when dealing with a number of DTCs:
– If DTC P0202 (CO: open circuit or CC: short circuit) and DTC P0266 are detected, deal with DTC
P0202 Injector Circuit Malfunction – Cylinder 2 first.
– If DTC P0089 (D1: Parameter at limit minimum, D2: Parameter at limit maximum or D7: Trim mini-
mum for low fuel) and DTC P0266 are detected, deal with DTC P0089 Fuel Pressure Regulator Per-
formance Problem first.
• If DTC P0266 is detected, engine performance reduced to 75% and injection warning light (gravity 1
fault) light up

Troubleshooting

m
Check the engine compression.
Repair if necessary
Check the valve clearances and adjust them if necessary.

co
Check the air intake circuit and the EGR valve and clean them if necessary.
Replace the injector.
If DTC P0266 is still detected, replace the ECM.
.
gn
After Repair
Deal with any faults detected by SUZUKI scan tool.
Clear the DTC.
ia

Carry out a road test followed by another check with the SUZUKI scan tool.
rd
ca
 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE) 6-2-49

DTC P0269 Cylinder 3 contribution/balance

NOTE:
• Cylinder number is counted from flywheel side.
• Fault finding procedure application conditions for stored DTC:
The DTC is detected when engine is running at idle speed.
• Priority when dealing with a number of DTCs:
– If DTC P0203 (CO: open circuit or CC: short circuit) and DTC P0269 are detected, deal with DTC
P0203 Injector Circuit Malfunction – Cylinder 3 first.
– If DTC P0089 (D1: Parameter at limit minimum, D2: Parameter at limit maximum or D7: Trim mini-
mum for low fuel) and DTC P0269 are detected, deal with DTC P0089 Fuel Pressure Regulator Per-
formance Problem first.
• If DTC P0269 is detected, engine performance reduced to 75% and injection warning light (gravity 1
fault) light up.

Troubleshooting

m
Check the engine compression.
Repair if necessary
Check the valve clearances and adjust them if necessary.

co
Check the air intake circuit and the EGR valve and clean them if necessary.
Replace the injector.
If DTC P0269 is still detected, replace the ECM.
.
gn
After Repair
Deal with any faults detected by SUZUKI scan tool.
Clear the DTC.
ia

Carry out a road test followed by another check with the SUZUKI scan tool.
rd
ca
6-2-50 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE)

DTC P0272 Cylinder 4 contribution/balance

NOTE:
• Cylinder number is counted from flywheel side.
• Fault finding procedure application conditions for stored DTC:
The DTC is detected when engine is running at idle speed.
• Priority when dealing with a number of DTCs:
– If DTC P0204 (CO: open circuit or CC: short circuit) and DTC P0272 are detected, deal with DTC
P0204 Injector Circuit Malfunction – Cylinder 4 first.
– If DTC P0089 (D1: Parameter at limit minimum, D2: Parameter at limit maximum or D7: Trim mini-
mum for low fuel) and DTC P0272 are detected, deal with DTC P0089 Fuel Pressure Regulator Per-
formance Problem first.
• If DTC P0272 is detected, engine performance reduced to 75% and injection warning light (gravity 1
fault) light up.

Troubleshooting

m
Check the engine compression.
Repair if necessary
Check the valve clearances and adjust them if necessary.

co
Check the air intake circuit and the EGR valve and clean them if necessary.
Replace the injector.
If DTC P0272 is still detected, replace the ECM.
.
gn
After Repair
Deal with any faults detected by SUZUKI scan tool.
Clear the DTC.
ia

Carry out a road test followed by another check with the SUZUKI scan tool.
rd
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 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE) 6-2-51

DTC P0325 Knock sensor circuit malfunction

NOTE:
• Fault finding procedure application conditions for stored DTC:
The DTC is detected when engine is running at idle speed.

Detecting Condition

Status displayed on Indicator/warning light

Detecting condition
SUZUKI scan tool operation
D2 No signal Injection warning light (gravity 1
fault) light up.

Troubleshooting

Check the connection and condition of the knock sensor connector.

Repair if necessary.

m
Check the connection and condition of the ECM “C47” connector and the sensor shielding on “C47-9”.
Repair if necessary.
Check for insulation, continuity and absence of interference resistance of the connections:

co
• Between “C12-1” wire of knock sensor connector and “C47-13” terminal of ECM connector
• Between “C12-2” wire of knock sensor connector and “C47-12” terminal of ECM connector
Repair if necessary.
.
Check that the fuel injector calibration codes are correctly entered on the ECM.
gn
Check that the knock sensor is secure on the engine.
Retightening the knock sensor.
Clear DTC.
ia

Carry out a road test followed by another check with the SUZUKI scan tool.
If the fault persists, replace the knock sensor.
rd

After Repair
Deal with any faults detected by SUZUKI scan tool.
ca

Clear the DTC.

Carry out a road test followed by another check with the SUZUKI scan tool.
6-2-52 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE)

DTC P0335 Crankshaft position sensor circuit malfunction

NOTE:
• Fault finding procedu application conditions for stored DTC:
The DTC is detected when engine is running at idle speed.
• This DTC indicated only with SUZUKI scan tool.
• If DTC P0335 (D1: incoherency D2: no signal, D3: too many extra teeth or D6: too many missing
teeth) is detected, the engine will stop.
• If DTC P0335 (D4: missing teeth or D5: extra teeth) 75% engine performance.

Wiring Diagram
For wiring circuit and connector number, refer to “A-4 Engine control system (DSL Type5):” in Section 8A.

Detecting Condition

Status displayed on Indicator/warning light

Detecting condition
SUZUKI scan tool operation

m
D1 Incoherency
Red stop warning light (gravity 2
D2 No signal
fault) light up

co
D3 Too many extra teeth
D4 Missing teeth Injection warning light (gravity 1
D5 Extra teeth fault) light up
D6 Too many missing teeth Red stop warning light (gravity 2
.
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fault) light up

Troubleshooting
ia

Check the connection and condition of the CKP sensor connector and repair if necessary.
Ensure the sensor is correctly fitted on the engine.
rd

Check the connection and condition of the ECM “C47” connector.

Repair if necessary.
Check CKP sensor for resistance referring to “Crankshaft Position (CKP) Sensor (Engine Speed Sensor)
ca

Inspection” in Section 6E2.

Replace CKP sensor if necessary.
Check the insulation, continuity and absence of interference resistance of the connections:
• Between “C30-2” terminal of CKP sensor connector and “C47-23” terminal of ECM connector
• Between “C30-1” terminal of CKP sensor connector and “C47-33” terminal of ECM connector
Repair if necessary.
Check that the flywheel ring gear is not faulty (missing teeth).
If DTC P0335 is still detected, replace the ECM.

After Repair
Deal with any faults detected by SUZUKI scan tool.
Clear the DTC.
Carry out a road test followed by another check with the SUZUKI scan tool.
 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE) 6-2-53

DTC P0340 Camshaft position sensor circuit malfunction

NOTE:
Fault finding procedure application conditions for stored DTC:
The DTC is detected when the starter motor is operating or the engine is running at idle speed.

Wiring Diagram
For wiring circuit and connector number, refer to “A-4 Engine control system (DSL Type5):” in Section 8A.

Detecting Condition

Status displayed on Indicator/warning light

Detecting condition
SUZUKI scan tool operation
D2 No signal Does not light

Troubleshooting

m
Check the connection and condition of the CMP sensor connector.
Repair if necessary.

co
Check the connection and condition of the ECM “C47” connector.
Repair if necessary.
Check for 12 V after ignition feed on “C90-1” terminal of the CMP sensor connector.
Check for earth on “C90-3” terminal of the CMP sensor connector.
Repair if necessary.
.
gn
Check the insulation, continuity and the absence of interference resistance on the following connections:
• Between “C90-2” terminal of CMP sensor connector and “C47-24” terminal of ECM connector
• Between “C90-3” terminal of CMP sensor connector and “C47-34” terminal of ECM connector
ia

Repair if necessary.
Check the valve timing referring to “Timing Belt Removal and Installation” in Section 6A2.
rd

Repair if necessary. If DTC P0340 is still detected, replace the CMP sensor.
If DTC P0340 is still detected, replace the ECM.
ca

After Repair
Deal with any faults detected by SUZUKI scan tool.
Clear the DTC.
Carry out a road test followed by another check with the SUZUKI scan tool.
6-2-54 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE)

DTC P0380 Glow plug/heater circuit malfunction

DTC P0670 Glow plug module control circuit

NOTE:
• DTC P0380 indicated only with SUZUKI scan tool.
• DTC P0670 indicated only with generic scan tool.
• This DTC only handles the fault finding with an open circuit.

Wiring Diagram
For wiring circuit and connector number, refer to “A-4 Engine control system (DSL Type5):” in Section 8A.

Detecting Condition

Status displayed on Indicator/warning light

Detecting condition
SUZUKI scan tool operation
CO Open circuit Does not light

m
Troubleshooting

co
Check the connection and condition of the pre-heating unit power supply fuse.
Replace the fuse if necessary.
Check the condition and connection of the pre-heating unit connector.
.
Repair if necessary.
gn
Check the condition and connection of the glow plug connectors.
Repair if necessary.
Check the condition and connection of the ECM “C48” connector.
Repair if necessary.
ia

Check glow plugs for resistance referring to “Glow Plug Inspection” in Section 6E2.
Replace the glow plug if necessary.
rd

Check for 12 V battery feed on “C83-7” terminal of the pre-heating unit connector.
Repair if necessary.
Check the continuity and insulation of the following connections:
ca

• Between “C48-10” terminal of ECM connector and “C83-3” terminal of pre-heating unit connector.
• Between “C48-18” terminal of ECM connector and “C83-1” terminal of pre-heating unit connector.
Repair if necessary. If DTC P0380 is still detected, replace the pre-heating unit.
If DTC P0380 is still detected, replace ECM.

After Repair
Deal with any faults detected by SUZUKI scan tool.
Clear the DTC.
Carry out a road test followed by another check with the SUZUKI scan tool.
 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE) 6-2-55

DTC P0382 Glow plug/heater circuit B malfunction

NOTE:
If DTC P0382 is detected, starting difficult (even impossible when cold).

Wiring Diagram
For wiring circuit and connector number, refer to “A-4 Engine control system (DSL Type5):” in Section 8A.

Detecting Condition

Status displayed on Indicator/warning light

Detecting condition
SUZUKI scan tool operation
CO0 Open circuit or short circuit to ground Does not light
CC1 Short circuit to 12 V

Troubleshooting

m
Check the condition and connection of the pre-heating unit connector.
Repair it if necessary.

co
Check the condition and condition of the ECM “C48” connector.
Repair if necessary.
Check the continuity and insulation of the following connections:
• “C83-7” terminal of pre-heating unit connector for power supply circuit.
.
• Between “C48-10” terminal of ECM connector and “C83-3” terminal of pre-heating unit connector.
gn
• Between “C48-18” terminal of ECM connector and “C83-1” terminal of pre-heating unit connector.
Repair if necessary. If DTC P0382 is still detected, replace the pre-heating unit.
If DTC P0382 is still detected, replace the ECM.
ia

After Repair
rd

Deal with any faults detected by SUZUKI scan tool.

Clear the DTC.
Carry out a road test followed by another check with the SUZUKI scan tool.
ca
6-2-56 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE)

DTC P0400 Exhaust gas recirculation flow

DTC P2413 Exhaust gas recirculation system performance

NOTE:
• DTC P2413 indicated only with generic scan tool.
• If DTC P0400 is detected, unstable idle speed and even stalling. Stating difficult or even impossible
when cold, smoke emissions and loss of performance possible.
• Conditions for applying fault finding procedures to stored DTC:
• The DTC is detected with the engine running.

Wiring diagram
For wiring circuit and connector number, refer to “A-4 Engine control system (DSL Type 5):” in Section 8A.

Detecting Condition

NOTE:

m
Generic scan tool displays status D5 of DTC P0400 as DTC P2413.

Status displayed on Indicator/warning light

Detecting condition

co
SUZUKI scan tool operation
D1 Parameter at limit minimum
D2 Parameter at limit maximum
Does not light
D3 Incoherence
.
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D4 Above maximum threshold
D5 Component stuck MIL and injection warning light
(gravity 1 fault) light up
ia

Troubleshooting
rd

Check the connection and condition of the EGR valve connector.

Repair if necessary.
Check the condition of the ECM “C47” connector.
ca

Repair if necessary.
Check for 5 V on “C46-5” terminal of the EGR valve connector.
Check EGR valve for operation referring to “EGR Valve Inspection” in Section 6E2.
Replace the EGR valve if necessary.
Check the continuity and insulation of the following connections:
• Between “C46-1” terminal of EGR valve connector and “C47-5” terminal of ECM connector.
• Between “C46-3” terminal of EGR valve connector and “C47-8” terminal of ECM connector.
Repair If necessary.
In addition, if D4 or D5 is indicated:
Remove the EGR valve. Check that there are no foreign bodies (scale, etc.) that could jam the valve.
Remove any foreign bodies and clean the EGR valve. Refit the EGR valve.
Clear the DTC. Carry out a road test and recheck DTC.
If DTC P0400 is still detected, replace the EGR valve.
If DTC P0400 is still detected, replace the ECM.

After Repair
Deal with any faults detected by SUZUKI scan tool.
Clear the DTC.
 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE) 6-2-57

Carry out a road test followed by another check with the SUZUKI scan tool.

m
. co
gn
ia
rd
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6-2-58 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE)

DTC P0403 Exhaust gas recirculation control circuit

NOTE:
• Fault finding procedure application conditions for stored fault:
The DTC is detected with the engine idling.

Wiring diagram
For wiring circuit and connector number, refer to “A-4 Engine control system (DSL Type 5):” in Section 8A.

Detecting Condition

Status displayed on Indicator/warning light

Detecting condition
SUZUKI scan tool operation
CO Open circuit
CC0 Short circuit to ground MIL light up
CC1 Incoherence
D2 Overheat Does not light

m
Troubleshooting

Repair if necessary.
co
Check the connection and condition of the EGR valve connector.

Check the connection and condition of the ECM “C47” connector.

.
gn
Repair if necessary.
Check EGR valve for operation referring to “EGR Valve Inspection” in Section 6E2.
Replace the EGR valve if necessary.
Check for 12 V on “C46-4” terminal of the EGR valve connector.
ia

Check the continuity and insulation of the following connections:

• Between “C46-1” terminal of EGR valve connector and “C47-5” terminal of ECM connector.
rd

• Between “C46-3” terminal of EGR valve connector and “C47-8” terminal of ECM connector.
Repair If necessary. If DTC P0403 is still detected, replace the EGR valve.
If DTC P0403 is still detected, replace the ECM.
ca

After Repair
Deal with any faults detected by SUZUKI scan tool.
Clear the DTC.
Carry out a road test followed by another check with the SUZUKI scan tool.
 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE) 6-2-59

DTC P0409 Exhaust gas recirculation sensor circuit

NOTE:
Priority when dealing with a number of DTCs:
If DTC P0409 and DTC P0641 are detected, deal with DTC P0641 Sensor Reference Voltage 1 Circuit/
Open first.

Wiring Diagram
For wiring circuit and connector number, refer to “A-4 Engine control system (DSL Type5):” in Section 8A.

Detecting Condition

Status displayed on Indicator/warning light

Detecting condition
SUZUKI scan tool operation
D1 Below minimum threshold
Does not light
D2 Above maximum threshold

m
Troubleshooting

co
Check the connection and condition of the EGR valve connector.
Repair if necessary.
Check the condition and connection of the ECM “C47” connector.
Repair if necessary.
.
gn
Check for 5 V on “C46-4” terminal of the EGR valve connector.
Check for earth on “C46-5” terminal of the EGR valve connector.
Repair if necessary.
Check the continuity and insulation of the following connections:
ia

• Between “C47-17” terminal of the ECM connector and “C46-4” terminal of the EGR valve connector.
• Between “C47-27” terminal of the ECM connector and “C46-6” terminal of the EGR valve connector.
rd

• Between “C47-37” terminal of the ECM connector and “C46-5” terminal of the EGR valve connector.
Repair if necessary. If DTC P0409 is still detected, replace the EGR valve.
If DTC P0409 is still detected, replace the ECM.
ca

After Repair
Deal with any faults detected by SUZUKI scan tool.
Clear the DTC.
Carry out a road test followed by another check with the SUZUKI scan tool.
6-2-60 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE)

DTC P0480 Radiator cooling fan low speed control system malfunction

NOTE:
This DTC indicated only with SUZUKI scan tool.

Wiring Diagram
For wiring circuit and connector number, refer to “A-4 Engine control system (DSL Type5):” in Section 8A.

Detecting Condition

Status displayed on Indicator/warning light

Detecting condition
SUZUKI scan tool operation
CO0 Open circuit or short circuit to ground
Does not light
CC1 Short circuit to 12 V

Troubleshooting

m
Check the condition and connection of the radiator fan relay No.2.
Repair if necessary.

co
Check the condition and connection of the ECM “E17” connector.
Repair if necessary.
Check the radiator cooling fan relay No. 2 referring to “Radiator Cooling Fan Relay Inspection” in Section 6B2.
Replace the relay if necessary.
.
gn
Check for insulation, continuity and absence of interference resistance of the connections:
• Between “E17-13” terminal of ECM connector and “C57-1” terminal of radiator fan relay No.2 socket
With the ignition on, check for the presence of 12 volts supply on “C57-2” and “C57-3” terminals of radiator fan
relay No.2 socket.
ia

Repair if necessary.
rd

After Repair
Deal with any faults detected by SUZUKI scan tool.
Clear the DTC.
ca

Carry out a road test followed by another check with the SUZUKI scan tool.
 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE) 6-2-61

DTC P0481 Radiator cooling fan high speed control system malfunction

NOTE:
This DTC indicated only with SUZUKI scan tool.

Wiring Diagram
For wiring circuit and connector number, refer to “A-4 Engine control system (DSL Type5):” in Section 8A.

Detecting Condition

Status displayed on Indicator/warning light

Detecting condition
SUZUKI scan tool operation
CO0 Open circuit or short circuit to ground
Does not light
CC1 Short circuit to 12 V

Troubleshooting

m
Check the condition and connection of the radiator fan relay No.1 and No.3.
Repair if necessary.

co
Check the condition and connection of the ECM “E17” connector.
Repair if necessary.
Check the radiator cooling fan relay No. 1 and No. 3 referring to “Radiator Cooling Fan Relay Inspection” in
Section 6B2.
Replace the relay if necessary.
.
gn
Check for insulation, continuity and absence of interference resistance of the connections:
• Between “E17-12” terminal of ECM connector and “C56-1” terminal of radiator fan relay No.1 socket
• Between “E17-12” terminal of ECM connector and “C53-1” terminal of radiator fan relay No.3 socket
ia

With the ignition on, check for 12 volts supply on “C56-2” and “C53-2” terminals of radiator fan relay No.1 and
No. 3 sockets.
rd

Repair if necessary.

After Repair
ca

Deal with any faults detected by SUZUKI scan tool.

Clear the DTC.
Carry out a road test followed by another check with the SUZUKI scan tool.
6-2-62 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE)

DTC P0487 Exhaust gas recirculation throttle position control circuit

NOTE:
Priority when dealing with a number of DTCs:
If DTC P0487 and DTC P0641 are detected, deal with DTC P0641 Sensor Reference Voltage 1 Circuit/
Open first.

Wiring Diagram
For wiring circuit and connector number, refer to “A-4 Engine control system (DSL Type5):” in Section 8A.

Detecting Condition

Status displayed on Indicator/warning light

Detecting condition
SUZUKI scan tool operation
CO0 Open circuit or short circuit to ground
MIL light up
CC1 Short circuit to 12 V

m
Troubleshooting

co
Check the connection and condition of the EGR valve connector.
Repair if necessary.
Check the condition and connection of the ECM “C47” connector.
Repair if necessary.
.
Check for 5 V on “C46-4” terminal of the EGR valve connector.
gn
Check for earth on “C46-5” terminal of the EGR valve connector.
Repair if necessary.
Check the continuity and insulation of the following connections:
ia

• Between “C47-17” terminal of the ECM connector and “C46-4” terminal of the EGR valve connector.
• Between “C47-27” terminal of the ECM connector and “C46-6” terminal of the EGR valve connector.
rd

• Between “C47-37” terminal of the ECM connector and “C46-5” terminal of the EGR valve connector.
Repair if necessary. If DTC P0487 is still detected, replace the EGR valve.
If DTC P0487 is still detected, replace the ECM.
ca

After Repair
Deal with any faults detected by SUZUKI scan tool.
Clear the DTC.
Carry out a road test followed by another check with the SUZUKI scan tool.
 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE) 6-2-63

DTC P0500 Vehicle speed sensor circuit malfunction

NOTE:
This DTC indicated only with SUZUKI scan tool.

Wiring Diagram
For wiring circuit and connector number, refer to “A-4 Engine control system (DSL Type5):” in Section 8A.

Detecting Condition

Status displayed on Indicator/warning light

Detecting condition
SUZUKI scan tool operation
D1 Below minimum threshold
D2 Incoherence
Does not light
D3 No signal
D4 Permanent low level

m
Troubleshooting

co
Check the condition and connection of the VSS connector.
Repair if necessary.
Check the connection and condition of the ECM “C48” connector.
Repair if necessary.
.
gn
Check the continuity and absence of interference resistance of the connections:
• “L46-1” terminal of the VSS for power supply circuit
• “L46-2” terminal of the VSS for ground circuit
Repair if necessary.
ia

Check for insulation form the +12 volt feed on the connection:
• Between “L46-3” terminal of VSS connector and “C48-23” terminal of ECM connector
rd

Repair if necessary. If DTC P0500 is still detected, replace the VSS.

If DTC P0500 is still detected, replace the ECM.
ca

After Repair
Deal with any faults detected by SUZUKI scan tool.
Clear the DTC.
Carry out a road test followed by another check with the SUZUKI scan tool.
6-2-64 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE)

DTC P0513 Incorrect immobilizer key

NOTE:
This DTC indicated only with SUZUKI scan tool.
If DTC P0513 is detected, the engine stops and impossible to restart.

Wiring Diagram
For wiring circuit and connector number, refer to “A-4 Engine control system (DSL Type5)” in Section 8A.

Troubleshooting

Check the connection and condition of the ECM “C48” connector.

Repair if necessary.
Check the connection and condition of the immobilizer control module connector.
Repair if necessary.
Check for insulation, continuity and absence of interference resistance of the connections:
• Between “C48-2” terminal of ECM connector and “G46-15” terminal of immobilizer control module connector

m
Repair if necessary. If DTC P0513 is still detected, replace the immobilizer control module.
If DTC P0513 is still detected, replace the ECM.

After Repair
Deal with any faults detected by SUZUKI scan tool.
Clear the DTC.
. co
gn
Carry out a road test followed by another check with the SUZUKI scan tool.
ia
rd
ca
 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE) 6-2-65

DTC P0530 A/C refrigerant pressure sensor circuit

NOTE:
• This DTC indicated only with SUZUKI scan tool.
• Priority when dealing with a number of DTCs:
If DTC P0530 and DTC P0641 are detected, deal with DTC P0641 Sensor Reference Voltage Circuit/
Open first.

Wiring Diagram
For wiring circuit and connector number, refer to “A-4 Engine control system (DSL Type5):” in Section 8A.

Detecting Condition

Status displayed on Indicator/warning light

Detecting condition
SUZUKI scan tool operation
CO1 Open circuit or short circuit to 12 V
Does not light
CC0 Short circuit to ground

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Troubleshooting

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Check the connection and condition of the A/C pressure sensor.
Repair if necessary.
Check the connection and condition of the ECM “C48” connector.
Repair if necessary.
.
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Check for 5 V on E100-1 of the A/C pressure sensor connector.
Check for earth on E100-2 of the A/C pressure sensor connector.
Repair if necessary.
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Check for insulation, continuity and absence of interference resistance of the connections:
• Between “E100-1” terminal of A/C pressure sensor connector and “C48-3” terminal of ECM connector
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• Between “E100-3” terminal of A/C pressure sensor connector and “C48-9” terminal of ECM connector
• Between “E100-2” terminal of A/C pressure sensor connector and “C48-27” terminal of ECM connector
Repair if necessary. If DTC P0530 is still detected, replace the A/C pressure sensor.
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If DTC P0530 is still detected, replace the ECM.

After Repair
Deal with any faults detected by SUZUKI scan tool.
Clear the DTC.
Carry out a road test followed by another check with the SUZUKI scan tool.
6-2-66 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE)

DTC P0560 System voltage

NOTE:
• This DTC indicated only with SUZUKI scan tool.
• This DTC is detected, engine shuts off and won’t start.

Wiring Diagram
For wiring circuit and connector number, refer to “A-4 Engine control system (DSL Type5):” in Section 8A.

Detecting Condition

Status displayed on Indicator/warning light

Detecting condition
SUZUKI scan tool operation
D1 Below minimum threshold Injection warning light (gravity 1
D2 Above maximum threshold fault) light up

Troubleshooting

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Measure the battery voltage when the ignition is switched on.

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If the battery voltage is less than 11 V recharge the battery.
Check the connection and condition of the battery terminals.
Repair if necessary.
Check the vehicle's charge circuit.
Repair if necessary.
.
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Check the connection and condition of the ECM “E17” connector.
Repair if necessary.
Check the insulation, continuity and absence of interference resistance of the connections:
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• ECM “E17-11” terminal for power supply circuit

• Between “E17-1” terminal of ECM connector and vehicle body ground
rd

• Between “E17-6” terminal of ECM connector and vehicle body ground

• Between “E17-7” terminal of ECM connector and vehicle body ground
• Between “E17-8” terminal of ECM connector and vehicle body ground
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Repair if necessary. If DTC P0560 is still detected, replace ECM.

After Repair
Deal with any faults detected by SUZUKI scan tool.
Clear the DTC.
Carry out a road test followed by another check with the SUZUKI scan tool.
 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE) 6-2-67

DTC P0571 Brake switch circuit

NOTE:
This DTC indicated only with SUZUKI scan tool.

Wiring Diagram
For wiring circuit and connector number, refer to “A-4 Engine control system (DSL Type5):” in Section 8A.

Detecting Condition

Status displayed on Indicator/warning light

Detecting condition
SUZUKI scan tool operation
CO0 Open circuit or short circuit to ground
Dose not light
D1 No signal

Troubleshooting

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Check the connection and condition of the stop (brake) lamp switch connector.
Repair if necessary.

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Check the connection and condition of the ECM “E17” connector.
Repair if necessary.
Check the stop (brake) lamp switch referring to “Stop (Brake) Lamp Switch” in Section 8.
Replace the stop (brake) lamp switch if necessary.
.
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Check for insulation, continuity and absence of interference resistance of the connections:
Between “E144-4” terminal of stop (brake) lamp switch connector and “E17-28” terminal of ECM connector
Repair If necessary. If DTC P0571 is still defected, replace the stop (brake) lamp switch.
If DTC P0571 is still detected, replace the ECM.
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After Repair
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Deal with any faults detected by SUZUKI scan tool.

Clear the DTC.
Carry out a road test followed by another check with the SUZUKI scan tool.
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6-2-68 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE)

DTC P0604 Control module internal fail

NOTE:
• This DTC indicated only with SUZUKI scan tool.
• Fault finding procedure application conditions for stored DTC:
The fault is declared present with the engine idling.
• If DTC P0604 is detected, engine stopped and restarting is impossible.

Detecting Condition

Status displayed on Indicator/warning light

Detecting condition
SUZUKI scan tool operation
D1 RAM integrity Red stop warning light (gravity 2
D2 Injector calibration code written failure fault) light up

Troubleshooting

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Check that the registered injector calibration code matched the injectors.
If not, write the injector calibration code referring to “ECM Registration (Programming)” in Section 6E2.
If injector calibration code corresponds correctly to the injectors, replace the ECM.

After Repair
Deal with any faults detected by SUZUKI scan tool.
Clear the DTC.
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Carry out a road test followed by another check with the SUZUKI scan tool.
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 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE) 6-2-69

DTC P0605 Control module program error

DTC P0606 Control module program error

NOTE:
• This DTC indicated only with SUZUKI scan tool.
• If DTC P0606 is detected, engine shuts off or engine runs noisily at 1300 rpm.

Detecting Condition

Status displayed on Indicator/warning light

Detecting condition
SUZUKI scan tool operation
D1 Analogue/ digital converter Red stop warning light (gravity 2
fault) light up
D4 Injector parameter fault Injection warning light (gravity 1
fault) light up
D5 Checksum code/calibration fault
Red stop warning light (gravity 2
D6 Watchdog fault

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fault) light up
D7 Noise in injector control line
D8 Watchdog stuck Injection warning light (gravity 1

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fault) light up

Troubleshooting for D1: Analogue/ digital converter, D5: Checksum code/calibration fault, D6:
.
Watchdog fault and D8: Watchdog stuck
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Check the connection and condition of the ECM “C47” connector.
Repair if necessary.
Rewrite program in the ECM again, refer to “ECM Registration (Programming)” in Section 6E2.
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If DTC P0606 is still detected, replace the ECM.

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Troubleshooting for D4: Injector parameter fault

Check that the registered injector calibration code matches the injectors.
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If not, rewrite the injector calibration codes in the ECM referring to “ECM Registration (Programming)” in Sec-
tion 6E2.
If injector calibration code corresponds correctly to the injectors, replace the ECM.

Troubleshooting for D7: Noise in injector control line

Check the ECM harness condition (pinched, cut, worn, damaged connector) between each fuel injector con-
nector and ECM connector.
Repair if necessary.
If DTC P0606 is still detected, replace the ECM.

After Repair
Deal with any faults detected by SUZUKI scan tool.
Clear the DTC.
Carry out a road test followed by another check with the SUZUKI scan tool.
6-2-70 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE)

DTC P062F Control module EEPROM failure

NOTE:
If DTC P062F is detected, engine speed forced 1300 rpm.

Detecting Condition

NOTE:
Generic scan tool displays status with * mark only.

Status displayed on Indicator/warning light

Detecting condition
SUZUKI scan tool operation
D1 Write EEPROM fault Injection warning light (gravity 1
fault) light up
*D2 Read EEPROM fault MIL and injection warning light
(gravity 1 fault) light up

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Troubleshooting

Check the connection and condition of the ECM connectors.

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Repair if necessary.
If DTC P062F is still detected, replace the ECM.
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After Repair
Deal with any faults detected by SUZUKI scan tool.
Clear the DTC.
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Carry out a road test followed by another check with the SUZUKI scan tool.
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 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE) 6-2-71

DTC P0641 Sensor reference voltage 1 circuit/open

NOTE:
• This DTC indicated only with SUZUKI scan tool.
• Priority when dealing with a number of DTCs:
If DTC P0641 and either one of DTC P0100, DTC P0190, DTC P0225, DTC P0235, DTC P0409, DTC
P0530 or DTC P2120 are detected, deal with DTC P0641 Sensor Reference Voltage 1 Circuit /Open
first.
• If DTC P0641 is detected, engine stopped and starting impossible.

Wiring Diagram
For wiring circuit and connector number, refer to “A-4 Engine control system (DSL Type5):” in Section 8A.

Detecting Condition

Status displayed on Indicator/warning light

Detecting condition
SUZUKI scan tool operation

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D1 Parameter at limit minimum Red stop warning light (gravity 2
D2 Parameter at limit maximum fault) light up

Troubleshooting

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Check the condition and connection of the connectors on all sensors with a 5 V feed.
• A/C pressure sensor
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• Boost pressure sensor
• Fuel pressure sensor
• APP sensor
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• EGR valve
• MAF and IAT sensor
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Repair if necessary.
Check the condition and connection of ECM connectors “E17”, “C47” and “C48”.
Repair if necessary.
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To locate any internal fault in one of the sensors with a 5 V supply (short circuit), disconnect earth of the sen-
sors on the list above.
Clear DTC and recheck DTC.
If the faulty sensor is located, check its connections and that it is in order.
If necessary replace the sensor.
Check the insulation, continuity and absence of interference resistance of the connections:
• Between “C48-3” terminal of ECM connector and “E100-3” terminal of A/C pressure sensor
• Between “C47-16” terminal of ECM connector and “C49-1” terminal of boost pressure sensor
• Between “C47-15” terminal of ECM connector and “C91-1” terminal of fuel pressure sensor
• Between “E17-4” terminal of ECM connector and “E97-3” terminal wire of APP sensor
• Between “C47-17” terminal of ECM connector and “C46-4”terminal wire of EGR valve
• Between “C47-18” terminal of ECM connector and “C98-5” terminal of MAF and IAT sensor
Repair if necessary.
If DTC P0641 is still detected, replace the ECM.
6-2-72 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE)

After Repair
Deal with any faults detected by SUZUKI scan tool.
Clear the DTC.
Carry out a road test followed by another check with the SUZUKI scan tool.

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 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE) 6-2-73

DTC P0645 A/C compressor relay control circuit

NOTE:
This DTC indicated only with SUZUKI scan tool.

Wiring Diagram
For wiring circuit and connector number, refer to “A-4 Engine control system (DSL Type5):” in Section 8A.

Detecting Condition

Status displayed on Indicator/warning light

Detecting condition
SUZUKI scan tool operation
CO0 Open circuit or short circuit to ground
Does not light
CC1 Short circuit to 12 V

Troubleshooting

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Check the connection and condition of the A/C relay.
Repair if necessary.

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Check the connection and condition of the ECM “C48” connector.
Repair if necessary.
Check for insulation, continuity and absence of interference resistance of the connections:
• Between “C55-1” terminal of A/C relay socket and “C48-21” terminal of ECM connector
.
Repair if necessary. If DTC P0645 is still detected, replace the A/C relay.
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After Repair
Deal with any faults detected by SUZUKI scan tool.
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Clear the DTC.

Carry out a road test followed by another check with the SUZUKI scan tool.
rd
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6-2-74 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE)

DTC P0651: Sensor reference voltage 2 circuit/open

Wiring Diagram
For wiring circuit and connector number, refer to “A-4 Engine control system (DSL Type5):” in Section 8A.

NOTE:
If DTC P0651 is detected, the idle speed is locked at 1000 rpm, engine performance is reduced to 75%.

Detecting Condition

Status displayed on Indicator/warning light

Detecting condition
SUZUKI scan tool operation
CC0 Short circuit to ground Injection warning light (gravity 1
CO0 Open circuit or short circuit to 12 V fault) light up

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 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE) 6-2-75

Troubleshooting for CC0: Short circuit to ground

Check the connection and condition of the APP sensor connector.

Repair if necessary.
Check the condition and connection of the ECM “E17” connector.
Repair if necessary.
Check APP sensor referring to “APP Sensor Inspection” in Section 6E2.
If the resistance is not, replace APP sensor.
Check for 5 V on “E97-2” terminal of the APP sensor connector.
Check for earth on “E97-6” terminal of the APP sensor connector.
Repair if necessary.
Check the insulation and continuity of the following connection:
Between “E17-15” terminal of the ECM connector and “E97-2” terminal of the APP sensor connector.
Repair if necessary.
Disconnect ECM “E17” connector and the APP sensor connector.
Check the earth insulation of the connection on “E17-15” terminal of the ECM connector.
Repair if necessary.

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If DTC P0651 is still detected, replace the ECM.

Troubleshooting for CO0: Open circuit or short circuit to 12 V

Repair if necessary. . co
Check the connection and condition of the APP sensor connector.

Check the condition and connection of the ECM “E17” connector.

gn
Repair if necessary.
Check APP sensor referring to “APP Sensor Inspection” in Section 6E2.
If the resistance is not, replace APP sensor.
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Check for 5 V on “E97-2” terminal of the APP sensor connector.

Check for earth on “E97-6” terminal of the APP sensor connector.
Repair if necessary.
rd

Disconnect ECM “E17” connector and the APP sensor connector.

• Check the insulation on ECM connector between “E17-15” and “E17-27” terminals.
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• Check the +12 V insulation of the connection on “E17-15” terminal of the ECM connector.
Repair if necessary.
Check the insulation and continuity of the following connection:
• Between “E17-15” terminal of the ECM connector and “E97-2” terminal of the APP sensor connector.
• Between “E17-27” terminal of the ECM connector and “E97-6” terminal of the APP sensor connector.
Repair if necessary.
If DTC P0651 is still detected, replace the ECM.

After repair
Deal with any faults detected by SUZUKI scan tool.
Clear the DTC.
Carry out a road test followed by another check with the SUZUKI scan tool.
6-2-76 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE)

DTC P0685 Main relay control circuit malfunction

Wiring Diagram
For wiring circuit and connector number, refer to “A-4 Engine control system (DSL Type5):” in Section 8A.

Detecting Condition

NOTE:
Generic scan tool displays status with *mark only.

Status displayed on Indicator/warning light

Detecting condition
SUZUKI scan tool operation
*D1 Relay stuck open
Does not light
D2 Relay stuck shut

Troubleshooting

Check the main relay supply fuse in main fuse box.

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Replace the fuse if necessary.
Check the connection and condition and connection of the main relay socket.
Repair if necessary.

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Check the condition and connection of the ECM connectors “E17” and “C48”.
Repair if necessary.
Check for insulation, continuity and absence of interference resistance of the connections:
.
• Between main fuse output and “C54-2 and 4” terminals of main relay socket terminal
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• Between “C54-1” terminal of main relay socket and “C48-24” terminal of ECM connector
• Between “C54-3” terminal of main relay socket and “E17-2” terminal of ECM connector
• Between “C54-3” terminal of main relay socket and “C48-30” terminal of ECM connector
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• Between “C54-3” terminal of main relay socket and “C48-29” terminal of ECM connector
• Between “E17-1” terminal of ECM connector and vehicle body ground
rd

• Between “E17-6” terminal of ECM connector and vehicle body ground

• Between “E17-7” terminal of ECM connector and vehicle body ground
• Between “E17-8” terminal of ECM connector and vehicle body ground
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Repair if necessary.
Check main relay for operation referring to “Main Relay and Radiator Fan Relay Inspection” in Section 6E2.
Replace the main relay if necessary.
If DTC P0685 is still detected, replace the ECM.

After Repair
Deal with any faults detected by SUZUKI scan tool.
Clear the DTC.
Carry out a road test followed by another check with the SUZUKI scan tool.
 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE) 6-2-77

DTC P1641 Additional heater relay circuit 1

NOTE:
This DTC indicated only with SUZUKI scan tool.

Wiring Diagram
For wiring circuit and connector number, refer to “A-4 Engine control system (DSL Type5):” in Section 8A.

Detecting Condition

Status displayed on Indicator/warning light

Detecting condition
SUZUKI scan tool operation
CO0 Open circuit or short circuit to ground
Dose not light
CC1 Short circuit to 12 V

Troubleshooting

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Check the condition and connection of the additional heater relay No.1 socket.
Repair if necessary.

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Check the condition of the ECM “C48” connector.
Repair if necessary.
Check the insulation, continuity and absence of interference resistance of the connections:
• Between “C48-15” terminal of ECM connector and “E93-10” terminal of additional heater relay No.1 socket
.
With the ignition on, check for the 12 V supply on “E93-6” terminal and “E93-9” terminal of additional heater
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relay No.1 socket.
Repair if necessary.
If DTC P1641 is still detected, replace the relay.
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After Repair
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Deal with any faults detected by SUZUKI scan tool.

Clear the DTC.
Carry out a road test followed by another check with the SUZUKI scan tool.
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6-2-78 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE)

DTC P1642 Additional heater relay circuit 2

NOTE:
This DTC indicated only with SUZUKI scan tool.

Wiring Diagram
For wiring circuit and connector number, refer to “A-4 Engine control system (DSL Type5):” in Section 8A.

Detecting Condition

Status displayed on Indicator/warning light

Detecting condition
SUZUKI scan tool operation
CO0 Open circuit or short circuit to ground
Does not light
CC1 Short circuit to 12 V

Troubleshooting

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Check the condition and connection of the additional heater relay No.2 and No.3 socket.
Repair if necessary.

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Check the condition of the ECM “C48” connector.
Repair if necessary.
Check the insulation, continuity and absence of interference resistance of the connections:
• Between “C48-16” terminal of ECM connector and “E93-5” terminal of additional heater relay No.2 socket
.
• Between “C48-16” terminal of ECM connector and “E173-4” terminal of additional heater relay No.3 socket
gn
With the ignition on, check for the 12 volts supply the following terminals:
• Between “E93-1” terminal of additional heater relay No.2 socket and vehicle body ground
• Between “E93-4” terminal of additional heater relay No.2 socket and vehicle body ground
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• Between “E173-3” terminal of additional heater relay No.3 socket and vehicle body ground
• Between “E173-2” terminal of additional heater relay No.3 socket and vehicle body ground.
rd

Repair if necessary.
If the fault persists, replace the relay.
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After Repair
Deal with any faults detected by SUZUKI scan tool.
Clear the DTC.
Carry out a road test followed by another check with the SUZUKI scan tool.
 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE) 6-2-79

DTC P2120 Pedal position sensor 2 circuit

NOTE:
• Priority when dealing with a number of DTCs:
If DTC P2120 and DTC P0651 are detected, deal with DTC P0651 Sensor Reference Voltage 2 Circuit/
Open first.
• If DTC P2120 is detected, engine speed maintained above 1000 rpm and engine performance
reduced to 75%.
• If DTC P2120 and DTC P0225 are detected, engine speed fixed at 1300 rpm.

Wiring Diagram
For wiring circuit and connector number, refer to “A-4 Engine control system (DSL Type5):” in Section 8A.

Detecting Condition

Status displayed on Indicator/warning light

Detecting condition
SUZUKI scan tool operation

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CO0 Open circuit or short circuit to ground Injection warning light (gravity 1
CC1 Short circuit to 12 V fault) light up

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Troubleshooting for CO0: Open circuit or short circuit to ground

Check the connection and condition of the pedal position sensor connector
Repair if necessary.
.
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Check the connection and condition of the ECM “E17” connector
Repair if necessary.
Check pedal position sensor for resistance referring to “PPS (Accelerator Pedal Position Sensor) Inspection” in
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Section 6E2.
Replace pedal position sensor if necessary.
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Check the following:

• Check for 5 V on “E97-2” terminal of the pedal position sensor connector
• Check for earth on “E97-6” terminal of the pedal position sensor connector
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Repair if necessary.
Disconnect the ECM “E17” connector and the pedal position sensor connector.
Check the insulation from earth on “E17-21” terminal of ECM connector.
Repair if necessary.
Check the continuity of the connection:
• Between “E97-1” terminal of pedal position sensor connector and “E17-21” terminal of ECM connector
Repair if necessary.
If DTC P2120 is still detected, replace the ECM.
6-2-80 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE)

Troubleshooting for CC1: Short circuit to + 12 volt

Check the connection and condition of the pedal position sensor connector
Repair if necessary.
Check the connection and condition of the ECM “E17” connector
Repair if necessary.
Check pedal position sensor for resistance referring to “PPS (Accelerator Pedal Position Sensor) Inspection” in
Section 6E2.
Replace pedal position sensor if necessary.
Disconnect the ECM “E17” connector and the pedal position sensor connector.
Check the insulation from the 12 V feed on “E17-15” terminal and “E17-21” terminal of ECM connector.
Repair if necessary.
Check the following:
• Check for 5 V on “E97-2” terminal of the pedal position sensor connector
• Check for earth on “E97-6” terminal of the pedal position sensor connector
Repair if necessary.
Check the continuity of the connections:

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• Between “E97-1” terminal of pedal position sensor connector and “E17-21” terminal of ECM connector
• Between “E97-2” terminal of pedal position sensor connector and “E17-15” terminal of ECM connector
• Between “E97-6” terminal of pedal position sensor connector and “E17-27” terminal of ECM connector

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Repair if necessary.
Disconnect “E17” connector from the ECM and the connector from the pedal position sensor.
Check for insulation between “E17-15” terminal and “E17-21” terminal of ECM connector.
.
Repair if necessary.
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If DTC P2120 is still detected, replace the ECM.

After Repair
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Deal with any faults detected by SUZUKI scan tool.

Clear the DTC.
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Carry out a road test followed by another check with the SUZUKI scan tool.
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 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE) 6-2-81

DTC P2226 Barometric pressure circuit malfunction

Detecting Condition

Status displayed on Indicator/warning light

Detecting condition
SUZUKI scan tool operation
CO0 Open circuit or short circuit to ground
Does not light
CC1 Short circuit to 12 V

Troubleshooting

Replace the ECM

After Repair
Deal with any faults detected by SUZUKI scan tool.
Clear the DTC.
Carry out a road test followed by another check with the SUZUKI scan tool.

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DTC P2263: Turbo charger boost system performance

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NOTE:
If DTC P2263 is detected, air flow regulation switched off, EGR valve closed, turbo charging regulation
switched off and reduced performance. .
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Wiring Diagram
For wiring circuit and connector number, refer to “A-4 Engine control system (DSL Type5):” in Section 8A.
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Detecting Condition

Status displayed on Indicator/warning light

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Detecting condition
SUZUKI scan tool operation
D1 At minimum limit Does not light
D2 At maximum limit Injection warning light (gravity 1
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fault) light up

Troubleshooting

Check that the turbo charger is operating correctly, check the air intake system (blocked, etc.), check the boost
pressure signal and check the gear number when changing gear.
Check the condition and connection of the boost pressure control solenoid valve connector.
Repair if necessary.
Check for the boost pressure control solenoid valve feed on “C97-2” terminal of the ECM connector.
Repair if necessary.
Check the condition and connection of “C47-3” terminal of the ECM connector.
Repair if necessary.
Check the boost pressure control solenoid valve for resistance referring to “Boost Pressure Control Solenoid
Valve Inspection” in Section 6E2.
Replace the boost pressure control solenoid valve if necessary.
6-2-82 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE)

Check the continuity and insulation of the following connections:

• Between “C47-3” terminal of the ECM connector and “C97-1” terminal of the boost pressure control solenoid
valve connector
• Between “C54-3” of the main relay connector and “C97-2” terminal of the boost pressure control solenoid
valve connector
Repair if necessary.
If DTC P2263 is still detected, replace the ECM.

After Repair
Deal with any faults detected by SUZUKI scan tool.
Clear the DTC.
Carry out a road test followed by another check with the SUZUKI scan tool.

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 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE) 6-2-83

Fault Finding – Customer Complaints

NOTE:
Only consult this customer complaint after a complete check using the scan tool.

Symptom Condition Referring Table

No communication with the ECM Not communication scan tool and ECM Refer to Table 1
The engine does not start Refer to Table 2
The engine starts with difficulty or starts then Refer to Table 3
Starting fault
stalls
Starting difficult with warm engine Refer to Table 4
Rough idle speed (pumping) Refer to Table 5
Idle speed fault
Idle speed too high or too low Refer to Table 6
Unexpected acceleration/deceleration and Refer to Table 7
engine stalling
Response fault Refer to Table 8
Engine stop (timing) Refer to Table 9

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Engine jerking Refer to Table 10
Behaviour while driving Lack of power Refer to Table 11

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Too much power Refer to Table 12
Excessive consumption Refer to Table 13
Overspeed when lifting off acceleration or chang- Refer to Table 14
ing gear
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Engine dies when pulling away Refer to Table 15
Engine rattling, noisy Refer to Table 16
Noise, odours or smoke Blue, white or black smoke Refer to Table 17
Smoke (blue, white or black) on acceleration Refer to Table 18
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6-2-84 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE)

Table 1 No dialogue with the ECM

Troubleshooting

Try the scan tool on another vehicle.

Check the ECM earth point.
Check:
• Check the connection between the scan tool and the data link connector
• Check the main and circuit fuses
Check the voltage (12 volts) between the following terminals (ignition switch turned ON):
• Between “G91-16” wire and “G91-4” wire of data link connector
• Between “G91-16” wire and “G91-5” wire of data link connector
Repair if necessary.
Check the insulation, continuity and absence of interference resistance of the connections:
• Between “E17-2” terminal of ECM connector and “C54-3” wire of main relay socket
• Between “C48-29” terminal of ECM connector and “C54-3” wire of main relay socket
• Between “C48-30” terminal of ECM connector and “C54-3” wire of main relay socket
• Between “E17-11” terminal of ECM connector and circuit fuse socket terminal

m
• Between “C48-24” terminal of ECM connector and “C54-1” wire of main relay socket (relay control)
• Between “E17-1” terminal of ECM connector and vehicle body ground
• Between “E17-6” terminal of ECM connector and vehicle body ground

co
• Between “E17-7” terminal of ECM connector and vehicle body ground
• Between “E17-8” terminal of ECM connector and vehicle body ground
• Between “E17-31” terminal of ECM connector and “G91-7” wire of data link connector (K-line)
Repair if necessary.
.
gn
ia
rd
ca
 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE) 6-2-85

Table 2 The engine does not start

Troubleshooting

Step Action Yes No

1 Check that the fuel tank is correctly filled and Go to Step 2. Refill the fuel tank cor-
that the fuel type is suitable. rectly.
Is the fuel type suitable and the tank correctly
filled?
2 Is the engine oil and coolant level correct? Go to Step 3. Top up the oil and coolant.
3 Is the starter motor working properly? Go to Step 4. Carry out the required
repairs.
4 Check the following: Go to Step 5. Carry out the required
• Check the low pressure circuit referring to repairs.
“Test 1: Low Pressure Circuit Check” in this
section
• Check for leaks in the high pressure circuit
• Check the electrical circuit referring to “Test

m
2: Electrical Circuit Check” in this section
• Check the engine parameters referring to
“Test 4: Parameter Check” in this section

co
• Check the air inlet circuit referring to “Test 5:
Air Inlet Circuit Check” in this section
Is it in good condition?
5
.
Check the “Fuel Rail Pressure” by using Go to Step 6. Apply the fault finding pro-
gn
SUZUKI scan tool. cedure for “DTC P0190
Is parameter indicated below 50 bar? Rail pressure sensor cir-
cuit”.
ia

6 Is the engine wiring harness cut off or jammed? Carry out the required Go to Step 7.
repairs.
rd

7 Check that the glow plugs are working properly. Replace the glow plugs. Go to Step 8.
Is the glow plug resistance above 1 Ω?
8 Are the compressions correct? Go to Step 9. Carry out the required
ca

repairs.
9 Check the injectors referring to “Test 3: Injector End of fault finding. Carry out the required
Check” in this section. repairs.
• Check the high pressure pump referring to
“Test 7: High Pressure System Check” in
this section
• Check the ECM referring to “Test 6: ECM
Check” in this section
Is it in good condition?
6-2-86 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE)

Table 3 The engine starts with difficulty or starts then stalls

Troubleshooting

Step Action Yes No

1 Check that the fuel tank is correctly filled and Go to Step 2. Refill the fuel tank cor-
that the fuel type is suitable. rectly.
Is the fuel type suitable and the tank correctly
filled?
2 Check the following: Go to Step 3. Carry out the required
• Check the low pressure circuit referring to repairs.
“Test 1: Low Pressure Circuit Check” in this
section
• Check for leaks in the high pressure circuit
• Check the electrical circuit referring to “Test
2: Electrical Circuit Check” in this section
• Check the engine parameters referring to
“Test 4: Parameter Check” in this section

m
• Check the air inlet circuit referring to “Test 5:
Air Inlet Circuit Check” in this section
Is it in good condition?

co
3 Check the valve timing referring to “Timing Belt Go to Step 4. Carry out the required
Removal and Installation” in Section 6A2. repairs.
Is it in good condition?
4 Is the engine oil and coolant level correct?
. Go to Step 5. Top up the oil and coolant.
gn
5 Is the catalytic converter sealed off or dam- Replace the catalytic con- Go to Step 6.
aged? verter.
6 Is the engine wiring harness cut off or jammed? Carry out the required Go to Step 7.
ia

repairs.
7 Check that the glow plugs are working properly. Replace the glow plug. Go to Step 8.
Is the glow plug resistance over 1 Ω?
rd

8 Are the compressions correct? Go to Step 9. Carry out the required

repairs.
ca

9 Check the following: End of fault finding. Carry out the required
• Check the high pressure system referring to repairs.
“Test 7: High pressure System check” in this
section
• Check the ECM referring to “Test 6: ECM
Check” in this section
Is it in good condition?
 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE) 6-2-87

Table 4 Starting difficult with warm engine

Troubleshooting

Step Action Yes No

1 Check that the fuel tank is correctly filled and Go to Step 2. Refill the fuel tank cor-
that the fuel type is suitable. rectly
Is the fuel type suitable and the tank correctly
filled?
2 Check the following: Go to Step 3. Carry out the required
• Check the low pressure circuit referring to repairs.
“Test 1: Low Pressure Circuit Check” in this
section
• Check the injectors referring to “Test 3:
Injector Check” in this section
• Check the engine parameters referring to
“Test 4: Parameter Check” in this section
• Check the air inlet circuit referring to “Test 5:

m
Air Inlet Circuit Check” in this section
Is it in good condition?
3 Is the catalytic converter sealed off or dam- Replace the catalytic con- Go to Step 4.

co
aged? verter.
4 Are the compressions correct? Go to Step 5. Carry out the required
repairs.
5
.
Is the engine wiring harness cut off or jammed? Carry out the required Go to Step 6.
gn
repairs.
6 Check the ECM referring to “Test 6: ECM End of fault finding. Carry out the required
Check” in this section repairs.
ia

Is it in good condition?
rd
ca
6-2-88 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE)

Table 5 Rough idle speed (pumping)

Troubleshooting

Step Action Yes No

1 Check that the fuel tank is correctly filled and Go to Step 2. Refill the fuel tank cor-
that the fuel type is suitable. rectly.
Is the fuel type suitable and the tank correctly
filled?
2 Check the following: Go to Step 3. Carry out the required
• Check the low pressure circuit referring to repairs.
“Test 1: Low Pressure Circuit Check” in this
section
• Check the engine parameters referring to
“Test 4: Parameter Check” in this section
Is it in good condition?
3 Is the engine wiring harness cut off or jammed? Carry out the required Go to Step 4.
repairs.

m
4 Check for leaks in the high pressure circuit. Go to Step 5. Carry out the required
Is it in good condition? repairs.
5 Check that the glow plugs are working properly. Replace the glow plug. Go to Step 6.

co
Is the glow plug resistance over 1 Ω?
6 Are the compressions correct? Go to Step 7. Carry out the required
repairs.
7 Check the following:
. End of fault finding. Carry out the required
gn
• Check the high pressure pump referring to repairs.
“Test 7: High Pressure System Check” in
this section
ia

Is it in good condition?
rd
ca
 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE) 6-2-89

Table 6 Idle speed too high/too low

Troubleshooting

Step Action Yes No

1 Check the following: Go to Step 2. Carry out the required
• Check the electrical circuit referring to “Test repairs.
2: Electrical Circuit Check” in this section
• Check the engine parameters referring to
“Test 4: Parameter Check” in this section
Is it in good condition?
2 Is the clutch linkage correct? Go to Step 3. Carry out the required
repairs.
3 Check the ECM referring to “Test 6: ECM End of fault finding. Carry out the required
Check” in this section repairs.
Is it in good condition?

m
. co
gn
ia
rd
ca
6-2-90 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE)

Table 7 Unexpected acceleration/deceleration and engine stalling

Troubleshooting

Step Action Yes No

1 Check the following: Go to Step 2. Carry out the required
• Check the engine parameters referring to repairs.
“Test 4: Parameter Check” in this section
• Check the air inlet circuit referring to “Test 5:
Air Inlet Circuit Check” in this section
Is it in good condition?
2 Is the engine wiring harness cut off or jammed? Carry out the required Go to Step 3.
repairs.
3 Check the injectors referring to “Test 3: Injector Go to Step 4. Carry out the required
Check” in this section repairs.
Is it in good condition?
4 Check that the engine has aspirated its oil Go to Step 5. Carry out the required
(engine racing). repairs.

m
Is it in good condition?
5 Check the ECM referring to “Test 6: ECM End of fault finding. Carry out the required
Check” in this section repairs.

co
Is it in good condition?
.
gn
ia
rd
ca
 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE) 6-2-91

Table 8 Response fault

Troubleshooting

Step Action Yes No

1 Check the following: Go to Step 2. Carry out the required
• Check the engine parameters referring to repairs.
“Test 4: Parameter Check” in this section
• Check the air inlet circuit referring to “Test 5:
Air Inlet Circuit Check” in this section
Is it in good condition?
2 Check that the turbocharger is working properly. Go to Step 3. Carry out the required
Is the turbocharger correct? repairs.
3 Check the low pressure circuit referring to “Test Go to Step 4. Carry out the required
1: Low Pressure Circuit Check” in this section repairs.
Is it in good condition?
4 Are the compressions correct? Go to Step 5. Carry out the required
repairs.

m
5 Check for leaks in the high pressure circuit. Go to Step 6. Carry out the required
Is it in good condition? repairs.
6 Check the following: End of fault finding. Carry out the required
• Check the injectors referring to “Test 3:
Injector Check” in this section
• Check the ECM referring to “Test 6: ECM
Check” in this section
. co repairs.
gn
Is it in good condition?
ia
rd
ca
6-2-92 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE)

Table 9 Engine stop/stalling

Troubleshooting

Step Action Yes No

1 Check that the fuel tank is correctly filled and Go to Step 2. Refill the fuel tank cor-
that the fuel type is suitable. rectly.
Is the fuel type suitable and the tank correctly
filled?
2 Check for leaks in the high pressure circuit. Go to Step 3. Carry out the required
Is it in good condition? repairs.
3 Check the following: Go to Step4. Carry out the required
• Check the low pressure circuit referring to repairs.
“Test 1: Low Pressure Circuit Check” in this
section
• Check for leaks in the high pressure circuit
• Check the electrical circuit referring to “Test
2: Electrical Circuit Check” in this section

m
• Check the engine parameters referring to
“Test 4: Parameter Check” in this section
• Check the air inlet circuit referring to “Test 5:

co
Air Inlet Circuit Check” in this section
Is it in good condition?
4 Is the engine oil and coolant level correctly? Go to Step 5. Top up the oil and coolant.
5
.
Is the engine wiring harness cut off or jammed? Carry out the required Go to Step 6.
gn
repairs.
6 Is the catalytic converter sealed off or dam- Replace the catalytic con- Go to Step 7.
aged? verter.
ia

7 Check that the engine has aspirated its oil Go to Step 8. Carry out the required
(engine racing). repairs.
rd

Is it in good condition?
8 Check the following: End of fault finding. Carry out the required
• Check the high pressure pump referring to repairs.
ca

“Test 7: High Pressure System Check” in

this section.
• Check the ECM referring to “Test 6: ECM
Check” in this section.
Is it in good condition?
 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE) 6-2-93

Table 10 Engine jerking

Troubleshooting

Step Action Yes No

1 Check that the fuel tank is correctly filled and Go to Step 2. Refill the fuel tank cor-
that the fuel type is suitable. rectly.
Is the fuel type suitable and the tank correctly
filled?
2 Check the following: Go to Step 3. Carry out the required
• Check the low pressure circuit referring to repairs.
“Test 1: Low Pressure Circuit Check” in this
section
• Check the engine parameters referring to
“Test 4: Parameter Check” in this section
Is it in good condition?
3 Is the engine wiring harness cut off or jammed? Carry out the required Go to Step 4.
repairs.

m
4 Check that the glow plugs are working properly. Replace the glow plug. Go to Step 5.
Is the glow plug resistance over 1 Ω?
5 Are the compressions correct? Go to Step 6. Carry out the required

co
repairs.
6 Is the valve clearance properly adjusted? Go to Step 7. Make the necessary
adjustments.
7 Check the following:
. Go to Step 8 Carry out the required
gn
• Check the high pressure pump referring to repairs.
“Test 7: High Pressure System Check” in
this section
ia

Is it in good condition?
8 Check the fuel filter. Go to Step 9. Replace the fuel filter.
rd

Is it in good condition?
9 • Check the ECM referring to “Test 6: ECM End of fault finding. Carry out the required
Check” in this section repairs.
ca

Is it in good condition?
6-2-94 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE)

Table 11 Lack of power

Troubleshooting

Step Action Yes No

1 Check the fuel filter. Go to Step 2. Replace the fuel filter.
Is it in good condition?
2 Check the following: Go to Step 3. Carry out the required
• Check the low pressure circuit referring to repairs.
“Test1: Low Pressure Circuit Check” in this
section
• Check the injectors referring to “Test 3:
Injector Check” in this section
Is it in good condition?
3 Is the engine oil level correct? Go to Step 4. Top up the oil.
4 Is the catalytic converter sealed off or dam- Replace the catalytic con- Go to Step 5.
aged? verter.
5 Check that the turbocharger is working properly. Go to Step 6. Carry out the required

m
Is the turbocharger correct? repairs.
6 Check the following: Go to step 7. Carry out the required
• Check the low pressure circuit referring to repairs.
“Test 1: Low Pressure Circuit Check” in this
section
• Check the injectors referring to “Test 3:
Injector Check” in this section
. co
gn
• Check the high pressure test referring to
“Test 7: high pressure System Check” in this
section
ia

Is it in good condition?
7 Are the compressions correct? Go to Step 8. Carry out the required
rd

repairs.
8 Is the valve clearance properly adjusted? End of fault finding. Make the necessary
adjustments.
ca
 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE) 6-2-95

Table 12 Too much power

Troubleshooting

Step Action Yes No

1 Check the following: Go to Step 2. Carry out the required
• Check the engine parameters referring to repairs.
“Test 4: Parameter Check” in this section
• Check the air inlet circuit referring to “Test 5:
Air Inlet Circuit Check” in this section
Is it in good condition?
2 Check that the engine has aspirated its oil Go to Step 3. Carry out the required
(engine racing). repairs.
Is it in good condition?
3 Check the following: End of fault finding. Carry out the required
• Check the injectors referring to “Test 3: repairs.
Injector Check” in this section
• Check the ECM referring to “Test 6: ECM

m
Check” in this section
Is it in good condition?

. co
gn
ia
rd
ca
6-2-96 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE)

Table 13 Excessive consumption

Troubleshooting

Step Action Yes No

1 Check that the fuel tank is correctly filled and Go to Step 2. Refill the fuel tank cor-
that the fuel type is suitable. rectly.
Is the fuel type suitable and the tank correctly
filled?
2 Check the low pressure circuit referring to “Test Go to Step 3. Carry out the required
1: Low Pressure Circuit Check” in this section repairs.
Is it in good condition?
3 Check for leak in the high pressure circuit. Go to Step 4. Carry out the required
Is it in good condition? repairs.
4 Check the following: Go to Step 5. Carry out the required
• Check the injectors referring to “Test 3: repairs.
Injector Check” in this section
• Check for leaks in the high pressure circuit

m
• Check the engine parameters referring to
“Test 4: Parameter Check” in this section
• Check the air inlet circuit referring to “Test 5:

co
Air Inlet Circuit Check” in this section
Is it in good condition?
5 Is the engine oil level correct? Go to Step 6. Top up the oil.
6
.
Is the catalytic converter clogged or damaged? Replace the catalytic con- Go to Step 7.
gn
verter.
7 Check that the turbocharger is working properly. Go to Step 8. Carry out the required
Is the turbocharger correct? repairs.
ia

8 Are the compressions correct? Go to Step 9. Carry out the required

repairs.
rd

9 Check the ECM referring to “Test 6: ECM End of fault finding. Carry out the required
Check” in this section. repairs.
Is it in good condition?
ca
 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE) 6-2-97

Table 14 Overspeed when lifting off accelerator or changing gear

Troubleshooting

Step Action Yes No

1 Check that there are no obstacls that might Go to Step 2. Carry out the required
impede the accelerator pedal travel (carpet, repairs.
hard point. etc.).
Is it in good condition?
2 Check the engine parameters referring to “Test Go to Step 3. Carry out the required
4: Parameter Check” in this section. repairs.
Is it in good condition?
3 Is the engine wiring harness cut or pinched? Carry out the required Go to Step 4.
repairs.
4 Is the clutch linkage properly adjusted? Go to Step 5. Carry out the required
repairs.
5 Check that the engine has not aspirated its oil Carry out the required Go to Step 6.
(engine racing). repairs.

m
6 Check that the turbocharger is working properly. Go to Step 7. Carry out the required
Is the turbocharger correct? repairs.

co
7 Check the following: End of fault finding. Carry out the required
• Check the injectors referring to “Test 3: repairs.
Injector Check” in this section
• Check the ECM referring to “Test 6: ECM
Check” in this section.
.
gn
Is it in good condition?
ia
rd
ca
6-2-98 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE)

Table 15 Engine dies on pulling away

Troubleshooting

Step Action Yes No

1 Check the following: Go to Step 2. Carry out the required
• Check the low pressure circuit referring to repairs.
“Test 1: Low Pressure Circuit Check” in this
section
• Check the engine parameters referring to
“Test 4: Parameter Check” in this section
• Check the air inlet circuit referring to “Test 5:
Air Inlet Circuit Check” in this section
Is it in good condition?
2 Is the catalytic converter clogged or damaged? Replace the catalytic con- Go to Step 3.
verter.
3 Is the clutch linkage properly adjusted? Go to Step 4. Carry out the required
repairs.

m
4 Is the engine wiring harness cut or pinched? Carry out the required Go to Step 5.
repairs.
5 Check the ECM referring to “Test 6: ECM End of fault finding. Carry out the required

co
Check” in this section repairs.
Is it in good condition? .
gn
ia
rd
ca
 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE) 6-2-99

Table 16 Engine rattling, noisy

Troubleshooting

Step Action Yes No

1 Check that the fuel tank is correctly filled and Go to Step 2. Refill the fuel tank cor-
that the fuel type is suitable. rectly.
Is the fuel type suitable and the tank correctly
filled?
2 Check the levels of engine oil and coolant. Go to Step 3. Top up the oil and coolant.
Is it in good condition?
3 Are the compressions correct? Go to Step 4. Carry out the required
repairs.
4 Check that the glow plugs are working properly. Replace the glow plug. Go to Step 5.
Is the glow plug resistance over 1 Ω?
5 Check the following: End of fault finding. Carry out the required
• Check the low pressure circuit referring to repairs.
“Test 1: Low Pressure Circuit Check” in this

m
section
• Check the injectors referring to “Test 3:
Injector Check” in this section

co
• Check the engine parameters referring to
“Test 4: Parameter Check” in this section
• Check the air inlet circuit referring to “Test 5:
.
Air Inlet Circuit Check” in this section
gn
Is it in good condition?
ia
rd
ca
6-2-100 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE)

Table 17 Blue, white or black smoke

Troubleshooting

Step Action Yes No

1 Check that the fuel tank is correctly filled and Go to Step 2. Refill the fuel tank cor-
that the fuel type is suitable. rectly.
Is the fuel type suitable and the tank correctly
filled?
2 Check the following: Go to Step 3. Carry out the required
• Check the engine parameters referring to repairs.
“Test 4: Parameter Check” in this section
• Check the air inlet circuit referring to “Test 5:
Air Inlet Circuit Check” in this section
Is it in good condition?
3 Is the engine oil level and coolant level correct? Go to Step 4. Top up the oil and coolant.
4 Check the low pressure circuit referring to “Test Go to Step 5. Carry out the required
1: Low Pressure Circuit Check” in this section repairs.

m
Is it in good condition?
5 Is the catalytic converter clogged or damaged? Replace the catalytic con- Go to Step 6.
verter.
6

7
Check that the engine has aspirated its oil
(engine racing).
Is it in good condition?
. co
Go to Step 7.

Check that the glow plugs are working properly. Replace the glow plugs.
Carry out the required
repairs.

Go to Step 8.
gn
Is the glow plug resistance above 1 Ω?
8 Are the compressions correct? Go to Step 9. Carry out the required
repairs.
ia

9 Check the injectors referring to “Test 3: Injector End of fault finding. Carry out the required
Check” in this section repairs.
rd

Is it in good condition?
ca
 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE) 6-2-101

Table 18 Blue, black or white smoke when accelerating

Troubleshooting

Step Action Yes No

1 Check that the fuel tank is correctly filled and Go to Step 2. Refill the fuel tank cor-
that the fuel type is suitable. rectly.
Is the fuel type suitable and the tank correctly
filled?
2 Check the following: Go to Step 3. Carry out the required
• Check the engine parameters referring to repairs.
“Test 4: Parameter Check” in this section
• Check the air inlet circuit referring to “Test 5:
Air Inlet Circuit Check” in this section
Is it in good condition?
3 Check the low pressure circuit referring to “Test Go to Step 4. Carry out the required
1: Low Pressure Circuit Check” in this section. repairs.
Is it in good condition?

m
4 Is the engine oil and coolant level correct? Go to Step 5. Top up the oil and coolant.
5 Check that the turbocharger is working properly. Go to Step 6. Carry out the required
Is the turbocharger correct? repairs.
6

7
Is the catalytic converter clogged or damaged?

Check that the engine has aspirated its oil

(engine racing).
. co Replace the catalytic con- Go to Step 7.
verter.
Go to Step 8. Carry out the required
repairs.
gn
Is it in good condition?
8 Check that the glow plugs are working properly. Replace the glow plugs. Go to Step 9.
Is the glow plug resistance above 1 Ω?
ia

9 Are the compressions correct? Go to Step 10. Carry out the required
repairs.
rd

10 Is the engine wiring harness cut or pinched? Carry out the required Go to Step 11.
repairs.
11 Check the following: End of fault finding. Carry out the required
ca

• Check the injectors referring to “Test 3: repairs.

Injector Check” in this section
• Check the ECM referring to “Test 6: ECM
Check” in this section
Is it in good condition?
6-2-102 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE)

Fault Finding – Tests

Some specific checks are grouped together into tests and are performed as required in the various fault finding
tables or when interpreting faults.

Test 1: Low pressure circuit check

Test 2: Electrical circuit check
Test 3: Injector check
Test 4: Parameter check
Test 5: Air inlet circuit check
Test 6: ECM check
Test 7: High pressure system check
Test 8: High pressure circuit sealing check
Test 9: Injector sealing check
Test 10: Injector return flow in starting phase

m
Test 11: Diesel filter check

. co
gn
ia
rd
ca
 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE) 6-2-103

Test 1: Low Pressure Circuit Check

Step Action Yes No

1 Check the conformity of the low pressure circuit Go to Step 2. Carry out the required
connections. repairs.
Are the low pressure circuit connections in
order?
2 Check the condition of the priming pump, and Carry out the required Go to Step 3.
that it is working properly. repairs.
Look for leaks on the unions.
Are there leaks in the hoses and unions?
3 Check for air bubbles in the diesel fuel. Bleed the low pressure Low pressure circuit cor-
Are there any air bubbles in the low pressure circuit. rect.
circuit? Place a container under
the filter:
• Disconnect the leak
return hose from the fil-

m
ter and cap the filter.
• Pump with the priming
pump until there is no

co
air left.
• Reconnect the return
. hose immediately.
gn
Test 2: Electrical Circuit Check
ia

Step Action Yes No

1 Check the battery charge and that the alterna- Go to Step 2. Carry out the required
tor is working properly. repairs.
rd

Is the charge circuit correct?

2 Check the fuses. Go to Step 3. Carry out the required
ca

Are the fuses correct? repairs.

3 Check that the main relay is working properly. Go to Step 4. Replace the relay.
Is the main relay working properly?
4 Check the engine earths. The electrical circuit is Carry out the required
Are the engine earths correct? correct. repairs.
6-2-104 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE)

Test 3: Injector Check

Step Action Yes No

1 Make a visual inspection around the injectors. Locate the source of leak Go to Step 2.
Is there diesel fuel around the injectors? and carry out the required
repairs.
2 Actuate the injectors using commands “Cylin- Go to Step 3. Carry out test 11.
der 1 Injector”, “Cylinder 2 Injector”, “Cylinder 3 If test 11 is in order,
Injector”, and “Cylinder 4 Injector” in output test replace the faulty injec-
on SUZUKI scan tool. tor(s).
Can you hear the operation sound of the injec-
tor?
3 Check the following: End of fault finding. Carry out the required
• Check the injector sealing referring to “Test repairs.
9 Injector Sealing Check” in this section
• Check the injector return flow in starting
phase referring to “Test 10 Injector Return

m
Flow in Starting Phase” in this section
Is it in good condition?

Test 4: Parameter Check

Step Action
. co Yes No
gn
1 Use the SUZUKI scan tool to check that injector Check that the “Data List” Use the SUZUKI scan tool
calibration code corresponds to the injectors. value (parameter) is con- to program injector cali-
Is injector calibration code correctly filled in? sistent. bration code into the
ia

memory, paying attention

to the cylinder numbers.
rd

Test 5: Air Inlet Circuit Check

ca

Step Action Yes No

1 Check for the presence of a leak/intake of air. Go to Step 2. Carry out the required
Is it in good condition? repairs.
2 Check the condition of the air filter. Go to Step 3. Replace the air filter.
Air filter correct?
3 Check that the intake manifold is not obstructed Clean the intake manifold. Air circuit correct.
(dirty).
Is the intake manifold blocked?

Test 6: ECM Check

Step Action Yes No

1 Check the condition of the ECM connections Lock the connectors cor- ECM correct.
(for bent pin, signs of oxidation, silicone, etc.). rectly.
Check that the ECM connectors are locked cor-
rectly.
Are the connectors poorly locked?
 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE) 6-2-105

Test 7 High Pressure System Check

NOTE:
It is useless and dangerous to engage the starter motor for more than 5 seconds.

Step Action Yes No

1 It is possible to check the high pressure pump Injection pump correct. Go to Step 2.
capacity by carrying out the following proce-
dure:
• Disconnect the fuel flow actuator connector
• Disconnect connector from the four injectors
• Connect the SUZUKI scan tool and check the
rail pressure parameter
• Run the starter motor for 5 seconds
• Read the maximum rail pressure value
Does the rail pressure greater than 1050 bar?

m
2 If the rail pressure below 900 bar, carry out Go to Step 3. Carry out the required
“Test 11 Diesel Fuel Check” in this section after repairs.
following procedure:

co
• Make sure that the ignition circuit is working
correctly (minimum engine speed 200 rpm at
engine cranking). .
• Turn ignition switch OFF, connect the all elec-
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trical connections disconnected in Step 1.
• Turn ignition switch ON, clear DTC by using
SUZUKI scan tool.
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Is it in good condition?
3 Carry out the following test: Replace the high pres- Replace the faulty injec-
• “Test 9 Injector Sealing Check” in this section sure pump. tor(s).
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• “Test 10 Injector Return Flow in Starting

Phase” in this section
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Are there no faults?

Test 8 High Pressure Circuit Sealing Test

NOTE:
• Certain faults make it impossible to carry out this test - deal with these first.
• This test does not identify a minor leak due to a union not being tightened to torque.
• Watch out for any objects (tool or others) on the sides of the engine room.

Procedure
• Engine is running.
• Tighten high pressure circuit specified torque.
• Engine coolant temperature above 60°C.
• Carry out “Leak detection test” by using SUZUKI scan tool and check for leaks in the high pressure circuit.
6-2-106 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE)

Test 9 Injector Sealing Check

NOTE:
• Certain faults make it impossible to carry out this test - deal with these first.
• Watch out for any objects (tool or others) on the sides of the engine room.
• It is useless and dangerous to engage the starter for more than 5 seconds.

Tooling required
Special Tool: 09912-96540 “Injector flow measuring kit” (Mot. 1711).

Procedure

Step Action Yes No

1 Check the injector return volume following pro- Replace faulty injector(s). Go to Step 2.
cedure:
• Ensure that the engine coolant temperature
is above 60°C.

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• Turn ignition switch OFF.
• Disconnect the return pipes from the four

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injectors.
• Cap the pump venturi tube to prevent the low
pressure circuit from contamination.
• Connect the four transparent tubes (09912-
96540) in place of the return pipes.
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• Put the other ends of the four pipes into four
graduated measuring cylinders (09912-
96540).
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• Having carried out these preparations, start

the engine and let it idle for 2 minutes.
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• Carry out “Leak detection test” by using

SUZUKI scan tool.
• Once the cycle is complete, carry out “Leak
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detection test” again to obtain a correct read-

ing of the return volume of each injector.
Is the return volume of one of the injectors
above 35 ml?
2 Carry out the following test to confirm the End of test. Carry out test 7.
repair:
• Disconnect the 4 transparent pipes and
reconnect the injector return circuit.
• With the ignition off, disconnect connector
from fuel flow actuator and connect the test
adapter in special tool (09912-96540).
• Disconnect the 4 electrical connectors from
all injectors.
• Connect SUZUKI scan tool and display “Data
list” on scan tool.
• Run the starter for 5 seconds, read the “Fuel
Rail Pressure” maximum value during the
test on the SUZUKI scan tool.
Is the rail pressure greater than 1050 bar?
 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE) 6-2-107

After Repair
• Turn ignition switch OFF, and reconnect the four injectors electrically.
• Disconnect the test adapter and reconnect the fuel flow actuator connector.
• Turn ignition switch ON, and clear the injection faults using SUZUKI scan tool.

Test 10 Injector Return Flow in Starting Phase

NOTE:
• Certain faults make it impossible to carry out this test - deal with these first.
• Watch out for any objects (tool or others) on the sides of the engine room.
• It is useless and dangerous to engage the starter for more than 5 seconds.

Tooling required
Special Tool: 09912 - 96540 “Injector flow measuring kit” (Mot. 1711).

Procedure

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Step Action Yes No

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1 Check the injector return volume following pro- Replace faulty injector(s). Go to Step 2.
cedure:
• Turn ignition switch OFF.
• Disconnect the return pipes from the four
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injectors.
• Cap the pump venturi tube to prevent the low
pressure circuit from contamination.
• Connect the four transparent pipes (09912-
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96540) in place of the return pipes.

• Disconnect connector from fuel flow actuator
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and connect a test adapter in special tool

(09912-96540).
• Disconnect connectors from all four injectors.
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• Switch on the ignition and run the starter for

5 seconds.
• Measure the amount of diesel fuel in each
pipe.
Is the leak return greater than 10 cm?
2 Carry out the following test to confirm the End of test. Carry out test 7.
repair:
• Disconnect the four transparent pipes and
reconnect the injector return circuit.
• Connect SUZUKI scan tool and display “Data
list” on scan tool.
• Run the starter for 5 seconds, read the rail
pressure maximum value “Fuel Rail Pres-
sure” during the test on the SUZUKI scan
tool.
Is the rail pressure greater than 1050 bar?
6-2-108 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE)

After Repair
• Turn ignition switch OFF, and reconnect the four injectors electrically.
• Disconnect the test adapter and reconnect the fuel flow actuator connector.
• Turn ignition switch ON, and clear the DTCs using SUZUKI scan tool.

Test 11: Diesel filter check

Step Action Yes No

1 Check the conformity of the fuel filter. Go to Step 2. Replace the fuel filter.
Is the fuel filter in order?
2 With ignition switch off, analyze the diesel fuel Go to Step 3. Fuel filter correct.
in the fuel filter.
• Disconnect the supply and return hoses from
the filter.
• Immediately block the filter inlets/outlets with
the appropriate caps.
• Remove the filter from its bracket and shake

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it well, keeping the caps in place and empty
the contents of the filter into glass container
by lifting up a protective cap and undoing the

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bleed screw.
Can you see at bottom of the container a
deposit of black particles?
3
.
Pass a magnet beneath the container to collect Repair or replace the Fuel filter correct.
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only all the metal particles. entire injection system.
Take the magnet away from the container.
Do the particles collected using the magnet
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cover a surface area greater than 1 cm2.

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 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE) 6-2-109

Special Tool

Tech 2 kit (SUZUKI scan tool)

(See NOTE)

NOTE:
This kit includes the following items.

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1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5. Cigarette cable,
6. DLC loopback adapter, 7. Battery power cable, 8. RS232 cable, 9. RS232 adapter,
10. RS232 loopback connector, 11. Storage case, 12. Power supply

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6-2-110 ENGINE GENERAL INFORMATION AND DIAGNOSIS (K9K ENGINE)

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 ENGINE MECHANICAL (K9K ENGINE) 6A2-1

SECTION 6A2

ENGINE MECHANICAL
(K9K ENGINE)
WARNING:
For vehicles equipped with a Supplemental Restraint (Air Bag) System:
• Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under
“General Description” in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGs and “Ser-
vice Precautions” under “On-Vehicle Service” in air bag system section before performing service
on or around the air bag system components or wiring. Failure to follow WARNINGs could result in

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unintentional activation of the system or could render the system inoperative. Either of these two
conditions may result in severe injury.
• Technical service work must be started at least 90 seconds after the ignition switch is turned to the

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“LOCK” position and the negative cable is disconnected from the battery. Otherwise, the system
may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).

CAUTION:
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Be sure to read “Precaution” in Section 6E2 before disconnecting fuel line or removing fuel system
part(s). Failure to follow “Precautions” could result unneeded fuel system repairs.
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6A2
CONTENTS
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Diagnosis Information and Procedure ........6A2-3 EGR Valve and Intake Pipe
Diagnosis Table ..........................................6A2-3 Removal and Installation........................... 6A2-17
Compression Check ....................................6A2-3 EGR Valve Disassembly and
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Oil Pressure Check .....................................6A2-4 Reassembly .............................................. 6A2-19

Valve Lash (Clearance)...............................6A2-6 EGR Valve and Intake Pipe Inspection..... 6A2-20
Measurement of valve lash (clearance) ..6A2-6 Turbocharger Components ....................... 6A2-21
Replacement of tappet ............................6A2-6 Turbocharger Removal and Installation .... 6A2-22
Repair Instructions .......................................6A2-8 Turbocharger Inspection ........................... 6A2-23
Exhaust Manifold Components ................. 6A2-23
Air Cleaner Filter Removal and
Exhaust Manifold Removal and
Installation ...................................................6A2-8
Installation................................................. 6A2-24
Air Cleaner Filter Inspection and
Oil Pan and Oil Pump Strainer
Cleaning ......................................................6A2-8
Components.............................................. 6A2-25
Air Cleaner Assembly Removal and
Oil Pan and Oil Pump Strainer
Installation ...................................................6A2-8
Removal and Installation........................... 6A2-26
Intercooler Components ..............................6A2-9
Engine Assembly Removal and
Intercooler Removal and Installation .........6A2-10
Installation................................................. 6A2-30
Cylinder Head Cover Components............6A2-11
Timing Belt and Belt Tensioner
Cylinder Head Cover Removal and
Components.............................................. 6A2-34
Installation .................................................6A2-11
Timing Belt and Belt Tensioner
Oil Pressure Switch Removal and
Removal and Installation........................... 6A2-35
Installation .................................................6A2-13
Timing Belt and Belt Tensioner
Heat Exchanger Removal and
Inspection.................................................. 6A2-43
Installation .................................................6A2-13
Oil Pump and Oil Pump Chain
EGR Valve and Intake Pipe
Components.............................................. 6A2-44
Components ..............................................6A2-16
6A2-2 ENGINE MECHANICAL (K9K ENGINE)

Oil Pump and Oil Pump Chain Pistons, Piston Rings, Connecting Rods and
Removal and Installation........................... 6A2-44 Cylinders Removal and Installation .......... 6A2-67
Oil Pump and Oil Pump Chain Pistons, Piston Rings, Connecting
Inspection.................................................. 6A2-47 Rods and Cylinders Disassembly and
Camshaft and Tappet Components .......... 6A2-48 Reassembly .............................................. 6A2-69
Camshaft and Tappet Removal and Pistons, Piston Rings, Connecting Rods
Installation................................................. 6A2-49 and Cylinders Inspection .......................... 6A2-71
Camshaft and Tappet Inspection .............. 6A2-53 Main Bearings, Crankshaft and Cylinder
Valves and Cylinder Head Components ... 6A2-57 Block Components.................................... 6A2-77
Valves and Cylinder Head Assembly Main Bearings, Crankshaft and Cylinder
Removal and Installation........................... 6A2-57 Block Removal and Installation................. 6A2-78
Valves and Cylinder Head Assembly Main Bearings, Crankshaft and Cylinder
Inspection.................................................. 6A2-60 Block Inspection........................................ 6A2-84
Valves and Cylinder Head Assembly Required Service Material.......................... 6A2-89
Disassembly and Reassembly.................. 6A2-60 Tightening Torque Specifications............. 6A2-89
Valves and Cylinder Head Components
Special Tool ................................................ 6A2-91
Inspection.................................................. 6A2-63
Pistons, Piston Rings, Connecting Rods and
Cylinders Components.............................. 6A2-66

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 ENGINE MECHANICAL (K9K ENGINE) 6A2-3

Diagnosis Information and Procedure

Diagnosis Table
Refer to “Fault Finding-Customer Complaints” in Section 6-2.

Compression Check
Check compression pressure on all 4 cylinders as follows:
1) Warm up engine.
2) Stop engine after warming up.

NOTE:
After warming up engine, place transmission gear shift
lever in “Neutral” and set parking brake and block drive
wheels.

3) Disconnect negative (–) cable at battery.

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4) Remove injector cover (1).
1
5) Remove all glow plugs referring to “Glow Plug Removal and

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Installation” in Section 6E2.
6) Disconnect ECM connectors.
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7) Install special tool (dummy heater plug) into glow plug hole.
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(B)
Special tool
(A): 09917-78120
(B): 09912-57821
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8) Connect negative (–) cable at battery.

(A)

9) Disengage clutch (1) (to lighten starting load on engine).

10) Crank engine with fully charged battery and read highest
pressure on compression gauge.
Compression pressure specification
Max. difference between any two cylinders:
300 kPa (3.0 kg/cm2, 42.6 psi)
11) Carry out steps 7) to 10) on each cylinder to obtain 4 read-
ings.
12) Disconnect negative (–) cable at battery.
13) After checking, install glow plugs referring to “Glow Plug
Removal and Installation” in Section 6E2.
6A2-4 ENGINE MECHANICAL (K9K ENGINE)

14) Install injector cover (1).

1
15) Connect ECM connectors.
16) Connect negative (–) cable at battery.

Oil Pressure Check

WARNING:
To avoid danger of being burned, do not touch exhaust
manifold when exhaust system is hot.

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1) Prior to checking oil pressure, check the following items.

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• Oil level in oil pan.
If oil level is low, add oil up to Full level mark (1) on oil level
.gauge (3).
• Oil quality.
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If oil is discolored, or deteriorated, change it.
For particular oil to be used, refer to “Engine Oil and Filter” in
Section 0B.
• Oil leaks.
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If leak is found, repair it.

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2. Low level mark

2) Detach degassing tank from its bracket.

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3) Disconnect oil pressure switch connector (1) and remove oil

pressure switch (2) from oil filter unit bracket.

1
2
 ENGINE MECHANICAL (K9K ENGINE) 6A2-5

4) Install special tools (Oil pressure gauge) to vacated threaded

hole.
(A)
CAUTION:
Be careful not to make special tool touch exhaust mani-
fold when installing because exhaust manifold becomes
very hot.

Special tool
(B) (A): 09915-77311
(C) (B): 09915-77420
(C): 09915-77430

5) Start engine and warm it up to normal operating tempera-

ture.

NOTE:
Be sure to place transmission gear shift lever in “Neu-

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tral” and set parking brake and block drive wheels.

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6) After warming up, measure oil pressure.
Oil pressure specification:
100 – 140 kPa (1.0 – 1.4 kg/cm2, 14.2 – 20.0 psi) at idle
. speed
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330 – 370 kPa (3.3 – 3.7 kg/cm2, 46.9 – 52.5 psi) at 3,000 r/
min
7) Stop engine and remove oil pressure gauge and attachment.
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8) Reinstall oil pressure switch (1), and tighten switch to speci-

fied torque.
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Tightening torque
Oil pressure switch (a): 35 N·m (3.5 kg-m, 25.5 lb-ft)
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9) Connect oil pressure switch coupler (2).

10) Install degassing tank to its bracket.
11) Start engine and check oil pressure switch for oil leakage.
2
1, (a) If oil leakage is found, repair it.
6A2-6 ENGINE MECHANICAL (K9K ENGINE)

Valve Lash (Clearance)

Measurement of valve lash (clearance)
1) Disconnect negative (–) cable at battery.
2) Remove cylinder head cover referring to “Cylinder Head
Cover Removal and Installation” in this section.
3) Turn crankshaft pulley clockwise until cam lobes become
perpendicular to tappet faces at valves “1” and “6” as shown
in figure.
4) Measure valve lashes with thickness gauge (1) according to
the following procedure.
a) Check valve lashes at valves “1” and “6”.
b) Turn camshaft by 90° (by turning crankshaft with wrench).
c) Make sure that cam lobes are perpendicular to tappet faces
at valves to be checked (in this case, “5” and “8”), if not,
adjust it by turning crankshaft. Check valve lashes.
d) In the same manner as b) – c), check valve lashes at valves

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1
“4” and “7”.
e) In the same manner as b) – c), check valve lashes at valves
"1" "2" "3" "4" "5" "6" "7" "8"
“2” and “3”.

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If valve lash (clearance) is out of specification, record valve lash
(clearance) and adjust it to specification by replacing tappet.
Refer to “Replacement of tappet” under “Valve Lash (Clearance)”
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in this section.
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Valve lash (clearance) specification

When cold
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Intake 0.125 – 0.250 mm (0.00493 – 0.00984 in.)

Exhaust 0.325 – 0.450 mm (0.01280 – 0.01771 in.)
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Replacement of tappet
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1) Measure valve lashes referring to “Measurement of Valve

Lash (Clearance)” under “Valve Lash (Clearance)” in this
section.
2) Remove tappet referring to “Camshaft and Tappet” in this
section.
3) Using micrometer, measure the thickness of the removed
tappet, and determine replacement tappet by calculating the
thickness of new tappet with the following formula and table.
Intake side
A = B + C – 0.1875 mm (0.007382 in.)
Exhaust side
A = B + C – 0.3875 mm (0.015256 in.)
A: Thickness of new tappet
B: Thickness of removed tappet
C: Measured valve lash (clearance)
 ENGINE MECHANICAL (K9K ENGINE) 6A2-7

Example of intake side:

When thickness of removed tappet is 7.8875 mm (0.310531 in.),
and measured valve lash (clearance) is 0.200 mm (0.00787 in.).
A = 7.8875 mm (0.310531 in.) + 0.200 mm (0.00787 in.) – 0.1875
mm (0.007382 in.) = 7.900 mm (0.31102 in.)
Calculated thickness of new tappet = 7.900 mm (0.31102 in.)

4) Select new tappet (1) with a thickness as close as possible

to calculated value.
Available new tappets

Thickness Thickness
mm (in.) mm (in.)
7.550 mm (0.29724 in.) 7.875 mm (0.31004 in.)
7.575 mm (0.29823 in.) 7.900 mm (0.31102 in.)
2 7.600 mm (0.29921 in.) 7.925 mm (0.31201 in.)
7.625 mm (0.30020 in.) 7.950 mm (0.31299 in.)

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1 7.650 mm (0.30118 in.) 7.975 mm (0.31398 in.)
7.675 mm (0.30217 in.) 8.000 mm (0.31496 in.)

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7.700 mm (0.30315 in.) 8.025 mm (0.31595 in.)
7.725 mm (0.30413 in.) 8.050 mm (0.31693 in.)
7.750 mm (0.30512 in.) 8.075 mm (0.31791 in.)
7.775 mm (0.30610 in.) 8.100 mm (0.31890 in.)
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7.800 mm (0.30709 in.) 8.125 mm (0.31988 in.)
7.825 mm (0.30807 in.) 8.150 mm (0.32087 in.)
7.850 mm (0.30906 in.)
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2. Tappet thickness
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5) Install new tappet and camshaft referring to “Camshaft and

Tappet Removal and Installation” in this section.
6) Measure valve lashes again referring to “Measurement of
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Valve Lash (Clearance)” under “Valve Lash (Clearance)” in

this section.
7) Install cylinder head cover referring to “Cylinder Head Cover
Removal and Installation” in this section.
6A2-8 ENGINE MECHANICAL (K9K ENGINE)

Repair Instructions
Air Cleaner Filter Removal and Installation
Removal

1) Open air cleaner case (2) unhooking its clamps (1).

2) Remove air cleaner filter from case.

2
Installation
Reverse removal procedure for installation.

Air Cleaner Filter Inspection and Cleaning

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Inspection
Check filter for dirt. Replace if excessively dirty filter.

Cleaning
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When cleaning filter, blow off dust by compressed air from air out-
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let side of filter. (i.e., the side facing up when installed in air
cleaner case.)
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Air Cleaner Assembly Removal and Installa-

tion
Removal
1) Disconnect negative (–) cable at battery.
2) Remove boost pressure control solenoid valve (4) from air
cleaner assembly.
3) Disconnect MAF and IAT sensor connector (1).
4 4) Disconnect air cleaner outlet hose (2) from air cleaner
assembly (3).
5) Remove air cleaner assembly from vehicle.
2

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 ENGINE MECHANICAL (K9K ENGINE) 6A2-9

Installation

Reverse removal procedure for installation noting the following.

• Tighten air cleaner outlet hose clamp (1) to specified torque.
Tightening torque
Air cleaner outlet hose clamp (a):
2.5 N·m (0.25 kg-m, 2.0 lb-ft)

1, (a)

Intercooler Components

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6

7
. 10 5 N·m (0.5 kg-m)
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8 25 N·m (2.5 kg-m)

5

11 28 N·m (2.8 kg-m)

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9 4 N·m (0.4 kg-m)

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3 9 4 N·m (0.4 kg-m)

8 25 N·m (2.5 kg-m)

1. Intercooler 8. Intercooler bracket bolt

2. Intercooler bracket 9. Intercooler hose clamp No.1
3. Intercooler hose clamp 10. Intercooler hose clamp No.2
4. Intercooler outlet hose No.1 11. Intercooler outlet pipe bolt
5. Intercooler inlet hose Tightening torque

6. Intercooler outlet pipe

7. Intercooler outlet hose No.2
6A2-10 ENGINE MECHANICAL (K9K ENGINE)

Intercooler Removal and Installation

Removal
1) Remove front bumper.
2) Remove intercooler inlet hose (1) and outlet hose (2) from
intercooler.
3
3) Remove intercooler (3) and its bracket (4).
2

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4

Installation
Reverse removal procedure for installation noting the following.

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• Install intercooler hose clamp (1) in specified direction as
shown in figure.

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[A]: Upper side

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• Tighten intercooler bracket bolts and intercooler hose

clamps (1) to specified torque.
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Tightening torque
1, (a)
Intercooler bracket bolt: 25 N·m (2.5 kg-m, 18.0 lb-ft)
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Intercooler hose clamp No.1 (a): 4 N·m (0.4 kg-m, 3.0 lb-ft)
• Install front bumper.
 ENGINE MECHANICAL (K9K ENGINE) 6A2-11

Cylinder Head Cover Components

518
4

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1. Cylinder head cover bolt
: Tighten 12 N·m (1.2 kg-m, 9.0 lb-ft) by
the specified procedure.
2. Cylinder head cover co
3. Cylinder head cover gasket

4. Cylinder head
.: Apply Loctite 518® referring to “Installation” under “Cylin-
der Head Cover Removal and Installation”.
Tightening torque

Do not reuse.
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Cylinder Head Cover Removal and Installa-

tion
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Removal
1) Disconnect negative (–) cable at battery.
2) Remove drive belt referring to “Generator Drive Belt
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Removal and Installation” in Section 6H2.

1
3) Remove injector cover (1), generator upper bracket (2), tim-
3 ing belt upper cover (3) and injector return hose cover .
4) Disconnect breather hose from cylinder head cover.

2
6A2-12 ENGINE MECHANICAL (K9K ENGINE)

“1” “5” “7” “3” 5) Loosen cylinder head cover bolts in such order (“1” to “8”) as
shown in the figure and remove them.
6) Remove cylinder head cover (1).
1

“2” “6” “8” “4”

Installation

“A” 1) Remove oil, old sealant and dust from sealing surfaces. After
cleaning, apply sealant “A” to cylinder head sealing surface
area as shown in the figure.
“A”: Loctite 518®

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“a”: 2 mm (0.08 in.)

“A” “a”
“A”
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2) Install cylinder head cover to cylinder head as follows.
“8”, (a) “4”, (a) “2”, (a) “6”, (a) a) Fit cylinder head cover to cylinder head with new gasket.
b) Tighten cylinder head cover bolts temporarily by hand.
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c) Tighten cylinder head cover bolts specified torque by

numerical order as shown in figure.
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Tightening torque
Cylinder head cover bolt (a):
Tighten 12 N·m (1.2 kg-m, 9.0 lb-ft) by the specified proce-
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“7”, (a) “3”, (a) “1”, (a) “5”, (a) dure

3) Connect breather hose to cylinder head cover.

3 4) Install injector return hose cover, timing belt upper cover (1),
1 generator upper bracket (2) and injector cover (3).
Tightening torque
Generator upper bracket bolt (a):
40 N·m (4.0 kg-m, 29.0 lb-ft)
2 5) Install drive belt referring to “Generator Drive Belt Removal
and Installation” in Section 6H2.
(a) 6) Connect negative (–) cable at battery.
 ENGINE MECHANICAL (K9K ENGINE) 6A2-13

Oil Pressure Switch Removal and Installation

Removal
1) Disconnect negative (–) cable at battery.
2) Detach degassing tank from its bracket.
3) Disconnect oil pressure switch connector (1).
4) Remove oil pressure switch (2).

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2

Installation

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1) Install oil pressure switch (1) with new gasket.
2) Tighten oil pressure switch (1) to specified torque.

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Tightening torque
Oil pressure switch (a): 35 N·m (3.5 kg-m, 25.5 lb-ft)
3) Connect oil pressure switch connector (2).
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4) Install degassing tank to its bracket.
5) Start engine and check for oil leakage.
2
1, (a)
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Heat Exchanger Removal and Installation

Removal
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1) Disconnect negative (–) cable at battery.

2) Drain engine coolant referring to “Coolant Replacement” in
Section 6B2.
3) Detach degassing tank from its bracket.
4) Disconnect oil pressure switch connector (1).
5) Remove generator referring to “Generator Dismounting and
Remounting” in Section 6H2.
6) Remove compressor referring to “Compressor” in Section
1B.
7) Remove radiator outlet hose.

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6A2-14 ENGINE MECHANICAL (K9K ENGINE)

8) Remove compressor bracket (1).

1

9) Install lifting device (1).

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4
10) Remove oil filter unit bracket (1).
3 11) Disconnect heat exchanger hose (4).
12) Remove engine left mounting bracket (2), and then remove
heat exchanger (3).
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Installation

3
1) Install heat exchanger (1) with new gasket.

1 Tightening torque
Heat exchanger bolt (a): 45 N·m (4.5 kg-m, 32.5 lb-ft)
2) Install engine left mounting bracket (2) referring to “Main
(a)
Bearings, Crankshaft and Cylinder Block Removal and
installation” in this section.
3) Connect heat exchanger hose (3).
2
 ENGINE MECHANICAL (K9K ENGINE) 6A2-15

4) Install oil filter unit bracket (1) as shown in figure.

NOTE:
Be sure to align lug (2) of oil filter unit bracket (1) with
(a)
hole (3) of heat exchanger (4).

Tightening torque
Oil filter unit bracket bolt (a): 45 N·m (4.5 kg-m, 32.5 lb-ft)
1

3
2

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5) Install generator and compressor bracket (1) referring to

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“Generator Drive Belt Tensioner Components” in section
6H2.
6) Install compressor referring to “Compressor” in Section 1B.
. 7) Install generator referring to “Generator Dismounting and
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Remounting” in Section 6H2.

1
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8) Connect oil pressure switch connector (1).

9) Install degassing tank to its bracket.
10) Refill engine coolant referring to “Coolant Replacement” in
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section 6B2.
11) Check engine oil level referring to “Engine Oil and Filter” in
Section 0B.
12) Check to make sure that there is no oil leakage and coolant
leakage at each connection.
1
6A2-16 ENGINE MECHANICAL (K9K ENGINE)

EGR Valve and Intake Pipe Components

14 12 N·m (1.2 kg-m)

7
19 11 N·m (1.1 kg-m)

18

10
17 21 N·m (2.1 kg-m)

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16 21 N·m (2.1 kg-m)
15 12 N·m (1.2 kg-m)
3

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6
20
10 5
12
.
12 N·m (1.2 kg-m)
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1

10 10
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2
11 12 N·m (1.2 kg-m)
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20
4

8 42 N·m
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(4.2 kg-m)

9 5 N·m (0.5 kg-m)

20

13 10N·m (1.0 kg-m)

1. EGR pipe 9. EGR pipe clamp 17. EGR valve body bolt
2. EGR cooler pipe 10. Gasket 18. Intake pipe No.1
3. EGR cooler 11. EGR cooler pipe bolt 19. Intake No.1 nut
4. Intake pipe No.2 12. EGR cooler bolt 20. O-ring
5. EGR valve body 13. Intake pipe No.2 bolt Tightening torque

6. EGR cooler water pipe 14. EGR valve bolt Do not reuse.

7. EGR valve 15. EGR cooler water pipe bolt

8. EGR pipe bolt 16. EGR cooler pipe bolt
 ENGINE MECHANICAL (K9K ENGINE) 6A2-17

EGR Valve and Intake Pipe Removal and

Installation
Removal
1) Disconnect negative (–) cable at battery.

3
2) Disconnect EGR valve connector (1) and boost pressure
2
1 sensor connector (2).
3) Disconnect hose (3) from oil vapor recirculation valve (4),
and then remove oil vapor recirculation valve.

4) Remove EGR valve (1) with gasket using special tool.

(A)

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Special tool
1
(A): 09916-48130

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gn
5) Remove intake pipe No.1 (1) and No.2 (2).
2
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1
rd
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6) Disconnect hoses (2) from EGR cooler water pipe (1), and
then remove EGR cooler water pipe.

2
1
6A2-18 ENGINE MECHANICAL (K9K ENGINE)

7) Remove EGR valve body (1) with EGR pipe (2).

1

1
2

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Installation

1 1) Install EGR valve body assembly (1) with new gasket and
.EGR pipe bolt.
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Tightening torque
EGR pipe bolt (a): 42 N·m (4.2 kg-m, 30.5 lb-ft)
(b)
EGR cooler pipe bolt (b): 21 N·m (2.1 kg-m, 15.5 lb-ft)
ia

EGR valve body bolt (c): 21 N·m (2.1 kg-m, 15.5 lb-ft)
rd

(a)

1
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(c)

2) Install EGR cooler water pipe assembly (1), and then con-
(a)
nect hoses (2) to EGR cooler water pipe assembly.
Tightening torque
EGR cooler water pipe assembly bolt (a):
1 12 N·m (1.2 kg-m, 9.0 lb-ft)

2
 ENGINE MECHANICAL (K9K ENGINE) 6A2-19

3) Install intake pipe No.1 with new gasket.

1 2
Tightening torque
Intake pipe No.1 nut: 11 N·m (1.1 kg-m, 8.0 lb-ft)
4) Apply engine oil to new O-ring, and install intake pipe No.2
(2) with new O-ring.

(a)
Tightening torque
Intake pipe No.2 bolt (a): 10 N·m (1.0 kg-m, 7.5 lb-ft)

2 5) Install EGR valve (1) with new gasket.

3

Tightening torque
4 EGR valve bolt (a): 12 N·m (1.2 kg-m, 9.0 lb-ft)
6) Install oil vapor recirculation valve (5), and then connect
5
hose (2) to oil vapor recirculation valve.
7) Connect EGR valve connector (3) and boost pressure sen-

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sor connector (4).
1 8) Connect negative (–) cable at battery.
(a)

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EGR Valve Disassembly and Reassembly
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Disassembly

1) Remove clamp (1) and EGR pipe (2) from exhaust gas
cooler pipe (3).
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2 3
1

3
2) Hold EGR valve body with soft jawed vise (1), and remove
exhaust gas cooler (2) with gasket.
1
3) Remove EGR cooler (3) with gasket.
2
6A2-20 ENGINE MECHANICAL (K9K ENGINE)

Reassembly

1) Hold EGR valve body with soft jawed vise (1), and install
(a)
EGR cooler (3) with new gasket.
3 2) Install EGR cooler pipe (2) with new gasket.
1
2 Tightening torque
EGR cooler bolt (a): 12 N·m (1.2 kg-m, 9.0 lb-ft)
EGR cooler pipe bolt (b): 12 N·m (1.2 kg-m, 9.0 lb-ft)
(b)

3) Install EGR pipe (1) to EGR cooler pipe (2), and then install
EGR pipe clamp (3).
Tightening torque
EGR pipe clamp (a): 5 N·m (0.5 kg-m, 4.0 lb-ft)

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1
3, (a) 2

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EGR Valve and Intake Pipe Inspection
EGR valve body
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Check inside (1) of EGR valve body (2) for wear or damaged.

2
EGR valve
rd

Refer to “EGR Valve Inspection” in Section 6E2.

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1
 ENGINE MECHANICAL (K9K ENGINE) 6A2-21

Turbocharger Components

WARNING:
To avoid danger of being burned, do not service exhaust system while it is still hot. Service should be
performed after system cools down.

6 23 N·m (2.3 kg-m)

10

7 12 N·m (1.2 kg-m)

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3 23 N·m (2.3 kg-m)

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4
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9 12 N·m
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(1.2 kg-m)
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5
11

1. Turbocharger oil return pipe 8. Turbocharger nut

2. Turbocharger 9. Turbocharger oil return bolt
Do not disassemble.
3. Lubrication pipe 10. Boost pressure control solenoid valve
: Apply thread lock LOCTITE FRENETANCH® to thread part.
4. Gasket 11. To vacuum pump
5. O-ring Tightening torque
: Apply engine oil.
6. Lubrication pipe union bolt Do not reuse.

7. Lubrication pipe clamp bolt

6A2-22 ENGINE MECHANICAL (K9K ENGINE)

Turbocharger Removal and Installation

Removal
1) Disconnect negative (–) cable at battery.
2) Remove air cleaner assembly referring to “Air Cleaner
Assembly Removal and Installation” in this section.
3) Remove EGR valve body referring to “EGR Valve and Intake
Pipe Removal and Installation” in this section.
4) Disconnect intercooler inlet hose (1).
5) Remove exhaust pipe No.1 referring to “Exhaust System
Components” in Section 6K2.

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6) Remove lubrication pipe (1).
1

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7) Disconnect turbocharger oil return pipe (2) from turbo-
charger.
4
8) Remove turbocharger assembly (3) from exhaust manifold
(4), and then remove turbocharger oil return pipe (2) from
.cylinder block.
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3

2
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Installation
1) Clean mating surfaces of turbocharger, exhaust pipe No.1
and exhaust manifold.
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2) Apply engine oil to new O-ring, and install turbocharger oil

return pipe with new O-ring to cylinder block.
3) Install turbocharger assembly (1) to exhaust manifold (2).
"A", (c)
3
4) Apply thread lock cement to thread part of lubrication pipe
(e)
2 (3), and then install it.
“A”: LOCTITLE FRENETANCH®
(d)
Tightening torque
Turbocharger nut (a): 25 N·m (2.5 kg-m, 18.0 lb-ft)
Turbocharger oil return pipe bolt (b):
1
12 N·m (1.2 kg-m, 9.0 lb-ft)
(a)
(b) Lubrication pipe (c): 23 N·m (2.3 kg-m, 17.0 lb-ft)
Lubrication pipe union bolt (d):
23 N·m (2.3 kg-m, 17.0 lb-ft)
Lubrication pipe clamp bolt (e): 12 N·m (1.2 kg-m, 9.0 lb-ft)

5) Install exhaust pipe No.1 referring to “Exhaust System Com-

ponents” in Section 6K2.
 ENGINE MECHANICAL (K9K ENGINE) 6A2-23

6) Connect intercooler inlet hose.

7) Install EGR valve body referring to “EGR Valve and Intake
Pipe Removal and Installation” in this section.
8) Install air cleaner assembly referring to “Air Cleaner Assem-
bly Removal and Installation” in this section.
9) Connect negative (–) cable to battery.
10) Using SUZUKI scan tool, cut fuel injection referring to “Oper-
ation Manual”.
11) Crank engine for 15 seconds in order to lubricate turbo-
charger.
12) Check to make sure that there is no oil leakage and exhaust
gas leakage at each connection.

Turbocharger Inspection
Rotate turbine shaft (1) by hand and verify that it turns smoothly
1

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without any abnormal noise and excessive runout.
If a malfunction is found, replace the turbocharger.

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Exhaust Manifold Components

rd

WARNING:
To avoid danger of being burned, do not service exhaust system while it is still hot. Service should be
performed after system cools down.
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3 2

1. Exhaust manifold 3. Exhaust manifold nut Do not reuse.

: Tighten 26 N·m (2.6 kg-m, 19.0 lb-ft) by the specified procedure.
2. Exhaust manifold gasket Tightening torque
6A2-24 ENGINE MECHANICAL (K9K ENGINE)

Exhaust Manifold Removal and Installation

WARNING:
To avoid danger of being burned, do not service exhaust
system while it is still hot. Service should be performed
after system cools down.

Removal
1) Disconnect negative (–) cable at battery.
2) Remove turbocharger assembly referring to “Turbocharger
Removal and Installation” in this section.

“5”
3) Loosen exhaust manifold nuts in numerical order (“1” to “8”)
“3” “7” “1”
evenly as indicated in the figure, and remove them.
4) Remove exhaust manifold (1) with gasket from cylinder
head (2).

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“4” “8” “6” “2”

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Installation

“6”, (a) “2”, (a) “4”, (a) “8”, (a) 1) Install exhaust manifold (1) to cylinder head (2) as follows.
a) Fit exhaust manifold to cylinder head with new gasket.
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b) Tighten exhaust manifold nuts temporarily by hand.

1
c) Tighten exhaust manifold nuts specified torque by numeri-
rd

cal order as shown in figure.

2 Tightening torque
Exhaust manifold nut (a):
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Tighten 26 N·m (2.6 kg-m, 19.0 lb-ft) by the specified pro-

“5”, (a) “1”, (a) “3”, (a) “7”, (a) cedure

2) Install turbocharger assembly referring to “Turbocharger

Removal and Installation” in this section.
3) Connect negative (–) cable at battery.
4) Check to make sure that there is no oil leakage and exhaust
gas leakage at each connection.
 ENGINE MECHANICAL (K9K ENGINE) 6A2-25

Oil Pan and Oil Pump Strainer Components

15 21 N·m (2.1 kg-m)

2 8 N·m (0.8 kg-m)

3 14

6
7 16

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8 12 N·m (1.2 kg-m)
5

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10
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12

11
rd

13 35 N·m (3.5 kg-m)

1. Upper oil pan gasket 7. Oil pump strainer 13. Engine oil drain plug
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2. Oil pan baffle plate bolt 8. Oil pump strainer bolt 14. Level gauge
3. Oil pan baffle plate 9. Lower oil pan gasket 15. Level gauge tube nut
4. Upper oil pan 10. Lower oil pan 16. Level gauge tube
: Apply RHODORSEAL 5661® referring to “Installation”
under “Oil Pan and Oil Pump Strainer Removal and Installa-
tion”.
5. Upper oil pan bolt 11. Lower oil pan bolt Tightening torque
: Tighten 6 N·m (0.6 kg-m, 4.5 lb-ft) and 16 N·m (1.6 kg-m, : Tighten 12 N·m (1.2 kg-m, 9.0 lb-ft)
12.0 lb-ft) by the specified procedure. by the specified procedure.
6. O-ring 12. Engine oil drain plug gasket Do not reuse.
: Apply engine oil.
6A2-26 ENGINE MECHANICAL (K9K ENGINE)

Oil Pan and Oil Pump Strainer Removal and

Installation
Removal
1) Disconnect negative (–) cable at battery.
2) Drain engine oil referring to “Engine Oil and Filter Change” in
Section 0B.
3) Remove engine hood after disconnecting windshield washer
hose.
4) Remove oil level gauge.
5) Remove clutch operating cylinder referring to “Transmission
Dismounting and Remounting” in Section 7A2.
6) To facilitate and ensure removal of oil pan, increase clear-
1 ance between engine and vehicle body according to the fol-
lowing procedures.
a) Install lifting device (1).
b) Remove engine mounting nuts (2).

m
c) Hoist engine 15 – 20 mm (0.6 – 0.8 in.).

CAUTION:

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Do not hoist engine more than instructed above. That
may cause trouble to engine or transmission.

4
.
d) Remove engine left mounting (3).
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7) Remove transmission to engine bolts (4).
2

4
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2 2
3

1
8) Remove engine mounting bracket bolts (1).
9) Remove accessory bracket bolt (2).

1 2
 ENGINE MECHANICAL (K9K ENGINE) 6A2-27

“19” “17” “15” “13” “11” “9” “7” “5” 10) Loosen lower oil pan bolts in numerical order (“1” to “22”) as
“3” shown in figure, and remove them.
“21”
“1” 11) Remove lower oil pan from upper oil pan.

“2”
“22”
“4”
“20”
“8” “6”
“18” “16” “14” “12” “10”

12) Remove oil pump strainer (1) from upper oil pan (2).

m
1

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2

“15” “5”
“13” “11” “9” “7” “3” “1” 13) Loosen upper oil pan bolts in numerical order (“1” to “20”) as
“17”
“19”
. shown in figure, and remove them.
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14) Remove upper oil pan from cylinder block.
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“20”
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“12”
“18” “16” “6” “2”
“14” “10” “8” “4”
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1 15) Remove oil pan baffle plate (1) from upper oil pan.
6A2-28 ENGINE MECHANICAL (K9K ENGINE)

Installation
1) Clean sealing surfaces on cylinder block, upper oil pan and
lower oil pan.
2) Clean Inside of oil pan and oil pump strainer screen (1).
1

1 3) Install oil pan baffle plate to upper oil pan.

(a) Tightening torque

Oil pan baffle plate bolt (a): 8 N·m (0.8 kg-m, 6.0 lb-ft)

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[A] 4) Apply sealant “A” to cylinder block and gasket holder sealing
surface area as shown in the figure.
“A”: RHODORSEAL 5661®
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[A]: Crankshaft pulley side

“A” [B]: Flywheel side
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“a”: 5 mm (0.20 in.)

“b”: 7 mm (0.27 in.)
“a”
“A” “b”
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“A”
“A”
[B]

“a”
“A”
“A”
 ENGINE MECHANICAL (K9K ENGINE) 6A2-29

5) Install upper oil pan to cylinder block as follows.

a) Fit upper oil pan to cylinder block with new gasket.
b) Tighten upper oil pan bolts temporarily by hand.
“8” “10” “12” “6” “14” “16” “18”
“20”
c) Tighten upper oil pan bolts (“1” to “8”) to 6 N·m (0.6 kg-m,
“4”
“2” 4.5 lb-ft) according to numerical order in figure.
d) Tighten upper oil pan bolts (“1” to “8”) to 16 N·m (1.6 kg-m,
12.0 lb-ft) by numerical order as shown in figure.
e) Tighten upper oil pan bolts (“9” to “20”) to 6 N·m (0.6 kg-m,
4.5 lb-ft) according to numerical order in figure.
f) Tighten upper oil pan bolts (“9” to “20”) to 16 N·m (1.6 kg-m,
“1”, (a) 12.0 lb-ft) by numerical order as shown in figure.
“3”
“7”
“9”
“11” “5” “13” “15” “17”
“19” Tightening torque
Upper oil pan bolt (a):
Tighten 6 N·m (0.6 kg-m, 4.5 lb-ft) and 16 N·m (1.6 kg-m,
12.0 lb-ft) by the specified procedure
(a)
6) Apply engine oil to O-ring, and install oil pump strainer (1) to

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upper oil pan (2) with new O-ring.
Tightening torque

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Oil pump strainer bolt (a): 12 N·m (1.2 kg-m, 9.0 lb-ft)

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2
1

“6” “8” “10” “12” “14” “16” “18”

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“4”
“20”
7) Install lower oil pan to upper oil pan as follows.
a) Fit lower oil pan (1) to upper oil pan.
“2” “22”
b) Tighten lower oil pan bolts temporarily by hand.
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c) Tighten lower oil pan bolts to specified torque by numerical

order as shown in figure.
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Tightening torque
“21”
“1”, (a) Lower oil pan bolt (a):
“19” Tighten12 N·m (1.2 kg-m, 9.0 lb-ft) by the specified proce-
“3” “17”
“5” “7” “9” “11” “13” “15” dure

1, (a) 8) Install engine mounting bracket bolts (1).

Tightening torque
Engine mounting bracket bolt (a):
40 N·m (4.0 kg-m, 29.0 lb-ft)
9) Install accessory bracket bolt (2).
Tightening torque
Accessory bracket bolt (b):
28 N·m (2.8 kg-m, 20.5 lb-ft)
1, (a) 2, (b)
6A2-30 ENGINE MECHANICAL (K9K ENGINE)

5, (c) 10) Install engine to vehicle as follows.

a) Install engine left mounting (1).
2, (a) b) Lower engine.
5, (c)
c) Tighten engine mounting nuts (2) to specified torque.
Tightening torque
Engine mounting nut (a):
55 N·m (5.5 kg-m, 40.0 lb-ft)
d) Remove lifting device (3).
11) Install drain plug (4) to oil pan with new gasket.
4, (b)
2, (a) 2, (a) Tightening torque
1
Engine oil drain plug (b): 35 N·m (3.5 kg-m, 25.5 lb-ft)
3
12) Install transmission to engine bolts (5).
Tightening torque
Transmission to engine bolt (c):
55 N·m (5.5 kg-m, 40.0 lb-ft)

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13) Apply engine oil to O-ring (1), and install oil level gauge with
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new O-ring.
Tightening torque
(a)
Level gauge tube nut (a): 21 N·m (2.1 kg-m, 15.5 lb-ft)
ia

14) Install clutch operating cylinder referring to “Clutch Operating

Cylinder Removal and Installation” in Section 7C2.
rd

15) Refill engine oil referring to “Engine Oil and Filter” in Section
0B.
1
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16) Connect negative (–) cable at battery.

17) Check to make sure that there is no oil leakage at each con-
nection.

Engine Assembly Removal and Installation

Removal
1) Disconnect positive (+) and negative (–) cables at battery.
2) Remove engine hood after disconnecting windshield washer
hose.
3) Remove air cleaner hose.
4) Remove boost pressure control solenoid valve referring to
“Boost Pressure Control Solenoid Valve Removal and Instal-
lation” in Section 6E2.
5) Remove radiator referring to “Radiator Removal and Installa-
tion” in Section 6B2.
6) Detach main fuse/relay box from its bracket.
7) Remove degassing tank.
 ENGINE MECHANICAL (K9K ENGINE) 6A2-31

8) Remove fuel filter referring to “Fuel Filter Removal and

Installation” in Section 6C2.
9) Disconnect discharge hose pipe from A/C compressor refer-
ring to “Major Components and Location” in section 1B.
10) Remove transmission referring to “Transmission Dismount-
ing and Remounting” in Section 7A2.
11) Remove starting motor referring to “Starting Motor Dis-
mounting and Remounting” in Section 6G2.
12) Disconnect the following electric wires, and then release wire
10 7 3 4
8
harnesses from clamps.
• ECM connectors (1)
• MAF and IAT sensor connector (2)
• Main fuse box connectors (3 and 4)
• Engine harness to main harness connector (5)
• Magnet clutch connector (6) of A/C compressor
• Supplementary fuse box connector (7)
12
• Battery to main harness connector (8)

m
• Pre-heating unit connector (9)
• Ground terminals (10 and 11)
13) Disconnect the following hoses.

2
13
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• Brake booster hose (12) and air lock hub hose (13) from vac-
uum pump
• Heater inlet hose No. 1 from thermo plunger
• Radiator inlet hose No.1 from thermostat assembly
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5 • Heater outlet hose from heater joint
9 14) With hose connected, detach power steering pump from its
bracket.
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15) Drain engine oil, if necessary.

6
rd

1
11
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6A2-32 ENGINE MECHANICAL (K9K ENGINE)

16) Install lifting device (1).

1
17) Remove engine mounting nuts (2).
18) Before lifting engine, check to ensure all hoses, electric wires
and cables are disconnected from engine.
19) Remove engine assembly from vehicle.

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2 2
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 ENGINE MECHANICAL (K9K ENGINE) 6A2-33

Installation

CAUTION:
Before installing intake air pressure sensor hose,
degrease connect part of hose and intercooler outlet
hose. Otherwise hose may become detached and cause
turbo system failure.

Reverse removal procedure for installation noting the following.

• Tighten engine mounting nuts (1) to specified torque.
Tightening torque
Engine mounting nut (a):
55 N·m (5.5 kg-m, 40.0 lb-ft)
• Install transmission assembly referring to “Transmission Dis-
mounting and Remounting” in Section 7A2.
• Check to ensure that all removed parts are back in place.

m
Reinstall any necessary parts which have not been rein-
stalled.
• Refill engine oil referring to “Engine Oil and Filter” in Section

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0B.
• Refill cooling system referring to “Coolant Replacement” in
Section 6B2.
1, (a) 1, (a)
.
• After connecting discharge hose pipe to A/C compressor,
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charge A/C system referring to “Charging Procedure” in Sec-
tion 1B.
• Check to make sure that there is no fuel leakage, oil leakage,
ia

coolant leakage, refrigerant and exhaust gas leakage at

each connection.
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6A2-34 ENGINE MECHANICAL (K9K ENGINE)

Timing Belt and Belt Tensioner Components

1 10

9
13 21 N·m (2.1 kg-m)

11

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8 27 N·m (2.7 kg-m)
12 9 N·m (0.9 kg-m)

3 14
15 8 N·m (0.8 kg-m)

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7
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4

1. Timing belt upper cover 7. Timing belt pulley 13. Generator upper bracket support
bolt
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2. Generator upper bracket support 8. Timing belt tensioner bolt 14. CMP sensor
3. Timing belt lower cover 9. Timing belt tensioner 15. CMP sensor bolt
4. Crankshaft pulley bolt 10. Timing belt Tightening torque
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: Tighten 120 N·m (12.0 kg-m, 87

lb-ft) and 95° by the specified pro-
cedure.
5. Washer 11. Timing belt inner cover
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6. Crankshaft pulley 12. Timing belt inner cover bolt

 ENGINE MECHANICAL (K9K ENGINE) 6A2-35

Timing Belt and Belt Tensioner Removal and

Installation
Removal
1) Remove engine assembly from vehicle referring to “Engine
Assembly Removal and Installation” in this section.

1
2) Remove injector cover (1) and generator upper bracket (2).

3) Remove timing belt upper cover (1) after unhooking its tabs

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(2).
4) Remove CMP sensor (3).

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5) Remove timing belt lower cover (1) after unhooking its tabs
(3) and removing its plastic bolt (2).
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6) Remove generator upper bracket support (1) from cylinder

head.
6A2-36 ENGINE MECHANICAL (K9K ENGINE)

7) Remove TDC pin cap (1).

8) Turn crankshaft pulley clockwise, and stop it just before

aligning slit (1) of camshaft pulley hub (2) matches with hole
(3) of cylinder head.

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9) Insert special tool (A) into TDC pin hole as shown in figure.
Special tool
.
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(A): 09919-58110
10) Turn crankshaft pulley clockwise until crankshaft touches
special tool (A).
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11) Check that special tool (B) inserts holes of camshaft pulley
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hub and cylinder head smoothly.

Special tool
(B): 09919-58120
 ENGINE MECHANICAL (K9K ENGINE) 6A2-37

12) Loosen crankshaft pulley bolt as follows.

a) Lock flywheel using special tool (C).
Special tool
(C): 09916-98110
b) Remove special tools (A) and (B).
c) Loosen crankshaft pulley bolt, and remove crank shaft pul-
ley.
d) Remove special tool (C).
e) Insert special tools (A) and (B) to removed positions at step
b).

13) Loosen timing belt tensioner bolt (2).

14) Remove timing belt (1).
15) Remove timing belt tensioner (5), timing belt pulley and tim-
ing belt inner cover (4), if necessary.

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Installation
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1) Clean mating surface of oil pump pulley, crankshaft timing
belt pulley and crankshaft accessory belt pulley.
2) Confirm that special tool (A) and (B) is installed to cylinder
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block and cylinder head. If special tool(s) is removed, install

special tool(s) referring to “Pistons, Piston Rings, Connecting
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Rods and Cylinders Removal and Installation” in this section

or “Camshaft and Tappet Removal and Installation” in this
section.
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Special tool
(A): 09919-58110
(B): 09919-58120
6A2-38 ENGINE MECHANICAL (K9K ENGINE)

3) Install timing belt inner cover (1), timing belt pulley (2) and
timing belt tensioner (3), if necessary.

CAUTION:
Install timing belt pulley so that boss side (6) may come
to the gasket holder plate side.

NOTE:
Be sure to position peg (5) of timing belt tensioner (3) to
groove (4) of cylinder block precisely.

[A]: Gasket holder plate side

4) Remove one camshaft pulley bolt (1), and loosen the other
two bolts (2) by one turn.

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5) Install timing belt (1) with aligning its matching lines (2) with
matching marks (3) of camshaft gear ring (4) and injection
pump pulley (5).
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NOTE:
• Match arrow mark on timing belt with rotating direction
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of camshaft.
• Timing belt has 18 teeth between its matching lines.
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6) Using hexagon wrench (3), align movable index (1) of timing

belt tensioner (2) to specified position as shown in figure by
turning timing belt tensioner counterclockwise. And then,
tighten timing belt tensioner bolt (4) to specified torque.
Tightening torque
Timing belt tensioner bolt (a): 27 N·m (2.7 kg-m, 19.5 lb-ft)
 ENGINE MECHANICAL (K9K ENGINE) 6A2-39

7) Check that camshaft pulley bolts (1) do not touch long slot-
ted end (2).
8) Install removed camshaft pulley bolt, and tighten all cam-
shaft pulley bolts to specified torque.
Tightening torque
Camshaft pulley bolt (a): 14 N·m (1.4 kg-m, 10.5 lb-ft)
9) Remove special tools (A) and (B).
10) Install crankshaft pulley bolt with washer temporarily.

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11) Turn crankshaft two revolutions clockwise, and stop it just

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before aligning slit (1) of camshaft pulley hub (2) matches
with hole (3) of cylinder head.
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12) Insert special tool (A) into TDC pin hole as shown in figure.
Special tool
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(A): 09919-58110
13) Turn crankshaft pulley clockwise until crankshaft touches
special tool (A).
6A2-40 ENGINE MECHANICAL (K9K ENGINE)

14) Check that special tool (B) inserts holes of camshaft belt pul-
ley hub and cylinder head smoothly.
If not, loosen camshaft pulley bolts (1) by one turn, and turn
camshaft pulley hub (2) to just aligning slit (3) of camshaft
pulley hub with hole (4) of cylinder head.

NOTE:
Do not tighten camshaft pulley bolts.

Special tool
(B): 09919-58120

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15) Check timing belt pulley key (1) is positioned vertical
upwards.

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16) Adjust timing belt tension as follows.

a) Loosen timing belt tensioner bolt (1) while holding timing
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belt tensioner by hexagon wrench, and then gradually bring

movable index (3) to center of timing window (2) turing tim-
ing belt tensioner.
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NOTE:
• If moving index position upper than timing window,
turn timing belt tensioner to counterclockwise.
• If moving index position is lower than timing window,
turn timing belt tensioner to clockwise.

b) Tighten timing belt tensioner bolt and camshaft pulley bolts

as specified torque.
Tightening torque
Timing belt tensioner bolt (a): 27 N·m (2.7 kg-m, 19.5 lb-ft)
Camshaft pulley bolt: 14 N·m (1.4 kg-m, 10.5 lb-ft)
17) Remove special tools (A) and (B).
 ENGINE MECHANICAL (K9K ENGINE) 6A2-41

18) Turn crankshaft two revolutions clockwise, and stop it just

before aligning slit (1) of camshaft pulley (2) with hole (3) of
cylinder head.

19) Insert special tool (A) into TDC pin hole as shown in figure.
Special tool
(A): 09919-58110
20) Turn crankshaft pulley clockwise until crankshaft touches
special tool (A).

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21) Check that special tool (B) inserts holes of timing belt pulley
and cylinder head smoothly.
If not, remove timing belt and return to step 4).
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Special tool
(B): 09919-58120
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22) Install crankshaft pulley as follows.

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a) Lock flywheel using special tool (C).

Tightening torque
(C): 09916-98110
b) Remove crankshaft pulley bolt.

(C)

c) Install crankshaft pulley (1) and washer, and tighten new

crankshaft pulley bolt (2) as follows.
i) Tighten crankshaft pulley (1) bolt to 120 N·m (12.0 kg-m,
87.0 lb-ft).
ii) Retighten crankshaft pulley bolt to 95°.
Tightening torque
Crankshaft pulley bolt (a): Tighten 120 N·m (12.0 kg-m,
87.0 lb-ft) and 95° by the specified procedure
6A2-42 ENGINE MECHANICAL (K9K ENGINE)

23) Apply sealant “A” to thread of TDC pin cap (1), and tighten
TDC pin cap as specified torque.
Tightening torque
TDC pin cap (a): 20 N·m (2.0 kg-m, 14.5 lb-ft)
“A”: RHODORSEAL 5661®

24) Install generator upper bracket support (1).

Tightening torque
Generator upper bracket support bolt (a):
21 N·m (2.1 kg-m, 15.5 lb-ft)

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25) Install timing belt lower cover (1) hooking its tabs (2), and
install its plastic bolt (3).
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NOTE:
When installing timing belt lower cover, position its tab
(4) into hole (5) of inner timing cover.
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26) Install timing belt upper cover (1) hooking its tabs (2).
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27) Install CMP sensor (3).

Tightening torque
CMP sensor bolt:
8 N·m (0.8 kg-m, 6.0 lb-ft)

28) Install generator upper bracket (1) and injector cover (2).
2

Tightening torque
Generator upper bracket bolt (a):
40 N·m (4.0 kg-m, 29.0 lb-ft)
29) Install engine assembly to vehicle referring to “Engine
Assembly Removal and Installation” in this section.
1
(a)
 ENGINE MECHANICAL (K9K ENGINE) 6A2-43

Timing Belt and Belt Tensioner Inspection

• Inspect timing belt for wear or crack.
Replace it as necessary.

• Inspect timing belt tensioner and roller for smooth rotation.

Replace it as necessary.

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6A2-44 ENGINE MECHANICAL (K9K ENGINE)

Oil Pump and Oil Pump Chain Components

CAUTION:
Never disassemble oil pump. Disassembly will spoil its original function. If faulty condition is found,
replace it with new one.

1
2

3 4

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6
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8 25 N·m (2.5 kg-m)

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1. Oil pump drive sprocket 5. Gasket holder plate oil seal Tightening Torque
: Apply engine oil to oil seal lip.

2. Oil pump chain 6. Gasket holder plate bolt Do not reuse.

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: Apply engine oil to sliding surface. : Tighten 11 N·m (1.1 kg-m, 8.0 lb-ft)
by the specified procedure.
3. Gasket 7. Oil pump assembly
: Never disassemble oil pump
assembly.
4. Gasket holder plate 8. Oil pump assembly bolt

Oil Pump and Oil Pump Chain Removal and

Installation
Removal
1) Remove engine assembly from vehicle referring to “Engine
Assembly Removal and Installation” in this section.
2) Remove upper oil pan referring to “Oil Pan and Oil Pump
Strainer Removal and Installation” in this section.
 ENGINE MECHANICAL (K9K ENGINE) 6A2-45

3) Remove oil pump (1) from cylinder block.

4) Remove timing belt referring to “Timing Belt and Belt Ten-
sioner Removal and Installation” in this section.

5) Remove gasket holder plate (1).

6) Remove gasket holder plate oil seal (2).

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7) Remove oil pump chain (1) and oil pump drive sprocket (2).
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Installation

1) Install oil pump (1), oil pump chain (2) and oil pump drive
sprocket all together.
Tighten oil pump bolts to specified torque.
Tightening torque
Oil pump bolt (a): 25 N·m (2.5 kg-m, 18.0 lb-ft)
6A2-46 ENGINE MECHANICAL (K9K ENGINE)

2) Install gasket holder plate (1) to cylinder block with new gas-
ket, and tighten gasket holder plate bolts as follows.
a) Tighten gasket holder plate bolts (“1” and “6”) to 11 N·m
(1.1 kg-m, 8.0 lb-ft).
b) Tighten gasket holder plate bolts (“2”, “3”, “4” and “5”) to 11
N·m (1.1 kg-m, 8.0 lb-ft).
Tightening torque
Gasket holder plate bolt (a):
Tighten 11 N·m (1.1 kg-m, 8.0 lb-ft) by the specified proce-
dure

3) Install upper oil pan and lower oil pan referring to “Oil Pan
and Oil Pump strainer Removal and Installation” in this sec-

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tion.

4) Install new gasket holder plate oil seal (1) to gasket holder

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1

plate using special tool as follows.

2
CAUTION:
.
(A)
3 Do not touch oil seal (1) so that it is extremely fragile. Be
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sure to install new oil seal using special tool (A), (B) and
protector (2) supplied with new oil seal. If it doesn’t fol-
low the above-mentioned service, it may cause oil leak
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(B)
from oil seal.
4

Special tool
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(A): 09911-98130
5
(B): 09911-98140
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3. Bolt
4. Spacer
5. Installer
6
6. Nut
7. Bolt (not necessary)
7
 ENGINE MECHANICAL (K9K ENGINE) 6A2-47

a) Install bolt (3) and spacer (4) of special tool to crankshaft.

b) Install protector (2) together with new oil seal (1) to spacer
(4).
c) Install oil seal installer (5) to bolt (3).
d) Tighten nut (6) of special tool until oil seal installer (5)
comes into contact with gasket holder plate (7).
e) Remove special tools and protector (2).
5) Install timing belt referring to “Timing Belt and Belt Tensioner
Removal and Installation” in this section.
6) Install engine assembly to vehicle referring to “Engine
Assembly Removal and Installation” in this section.

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Oil Pump and Oil Pump Chain Inspection
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• Check rotor and oil pump cases for excessive wear or dam-
age.
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If any malcondition is found, replace oil pump assembly.

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

If any malcondition is found, replace oil pump assembly.
6A2-48 ENGINE MECHANICAL (K9K ENGINE)

• Check oil pump chain for wear or damage.

If any malcondition is found, replace oil pump chain.

Camshaft and Tappet Components

12 16 N·m (1.6 kg-m)

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10

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8

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1. Camshaft housing bolt 6. Camshaft pulley 11. Vacuum pump oil hose
: Tighten 10 N·m (1.0 kg-m, 7.5 lb-ft)
by the specified procedure.
2. Camshaft housing 7. Camshaft pulley nut 12. Vacuum pump oil hose union bolt
: Apply engine oil to sliding surface : Tighten 30 N·m (3.0 kg-m, 22.0 lb-ft)
and 85° by the specified procedure.
3. Camshaft 8. Camshaft cover Tightening torque
: Apply engine oil to sliding surface

4. Tappet 9. Camshaft cover bolt Do not reuse.

: Apply engine oil around tappet. : Tighten 5 N·m (0.5 kg-m, 4.0 lb-ft)
and 12 N·m (1.2 kg-m, 9.0 lb-ft) by the
specified procedure.
5. Camshaft oil seal 10. Gasket
: Apply engine oil to oil seal lip.
 ENGINE MECHANICAL (K9K ENGINE) 6A2-49

Camshaft and Tappet Removal and Installa-

tion
Removal
1) Remove engine assembly from vehicle referring to “Engine
Assembly Removal and Installation” in this section.
2) Remove timing belt referring to “Timing Belt and Tensioner
Removal and Installation” in this section.

3) Remove special tool (A).

Special tool
(A): 09919-58120

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4) Remove camshaft pulley as follows.

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a) Fix camshaft pulley using special tool.
(A)
Special tool
(A): 09917-68221
.
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b) Loosen camshaft pulley nut, and remove camshaft pulley.
5) Remove cylinder head cover referring to “Cylinder Head
Cover Removal and Installation” in this section.
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6) Disconnect vacuum pump oil hose (1) from camshaft cover

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(2).
7) Remove camshaft cover (2).
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1 2

"10" "6" "2" "1" "5" "9" 8) Loosen camshaft housing bolts in numerical order (“1” to
“12”) as indicated in the figure, and remove them.
9) Remove camshaft housing and camshaft from cylinder head.

"11" "7" "3" "4" "8" "12"

6A2-50 ENGINE MECHANICAL (K9K ENGINE)

10) Remove tappet (1) from cylinder head.

CAUTION:
Note original position in which each tappet was installed
when valve lash (clearance) adjustment is not necessary.
If each tappet is not installed to original position, engine
1
will spoil its original performance.

Installation

1) Apply engine oil around tappet (1), and then install it to cylin-
der head.

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1

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2) Remove oil, old sealant and dust from sealing surfaces. After
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cleaning, apply sealant “A” to cylinder head (1) sealing sur-
face area as shown in figure.
“A”: Loctite 5181®
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“a”: 1 mm (0.04 in.)

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3) Install camshaft to cylinder head as follows.

a) Direct key groove (2) upward by turning crankshaft (1)
clockwise.

1
 ENGINE MECHANICAL (K9K ENGINE) 6A2-51

b) Install camshaft pulley (1) to camshaft with aligning key (3)

of camshaft pulley to key groove (4) of camshaft (2), and
2
then tighten camshaft pulley nut to temporary.
4 c) Apply engine oil to sliding surface of each camshaft and
camshaft journal.

d) Fit camshaft to cylinder head and install special tool into

holes of timing belt pulley (1) and cylinder head as shown in
figure.
Special tool
(A): 09919-58120

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"3", (a) "7", (a) "11", (a) "12", (a) "8", (a) "4", (a)
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4) Install camshaft housing to cylinder head as follows.
a) Fit camshaft housing to cylinder head in specified position
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as shown.
b) Tighten camshaft housing bolts temporarily by hand.
c) Tighten camshaft housing bolts in numerical order as indi-
cated in figure a little at a time till they are tightened to
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specified torque.
Tightening torque
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Camshaft housing bolt (a):

"2", (a) "6", (a) "10", (a) "9", (a) "5", (a) "1", (a) Tighten 10 N·m (1.0 kg-m, 7.5 lb-ft) by the specified proce-
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dure

5) Install camshaft cover (1) with new gasket.

(b) Tightening torque
Camshaft cover bolt (b):
Tighten 5 N·m (0.5 kg-m, 4.0 lb-ft) and 12 N·m (1.2 kg-m,
9.0 lb-ft) by the specified procedure
6) Connect vacuum pump oil hose (2) to rear camshaft (1)
cover with new gasket.
Tightening torque
Vacuum pump oil hose union bolt (c):
2 1
(c)
16 N·m (1.6 kg-m, 12.0 lb-ft)
7) Remove camshaft pulley and special tool.
6A2-52 ENGINE MECHANICAL (K9K ENGINE)

8) Install new oil seal (1) together with protector (2) using spe-
cial tool and plastic hammer until special tool comes into
contact with cylinder head.

CAUTION:
Do not touch oil seal (1) so that it is extremely fragile. Be
sure to install new oil seal using special tool (A) and pro-
tector (2) supplied with new oil seal. If it doesn’t follow
the above-mentioned service, it may cause oil leak from
oil seal.

Special tool
(A): 09911-98120
9) Install cylinder head cover referring to “Cylinder Head Cover
Removal and Installation” in this section.

10) Install camshaft pulley (1) to camshaft (2) as follows.

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a) Install camshaft pulley to camshaft with aligning key (3) of
camshaft pulley with key groove (4) of camshaft.
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b) Fix camshaft pulley using special tool.

(a) Special tool
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(A) (A): 09917-68221

c) Tighten new camshaft pulley nut to 30 N·m (3.0 kg-m, 22.0
lb-ft).
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d) Retighten camshaft pulley nut 85°.

Tightening torque
Camshaft pulley nut (a):
Tighten 30 N·m (3.0 kg-m, 22.0 lb-ft) and 85° by the speci-
fied procedure

11) Install special tool into timing belt pulley (1) and cylinder
head hole.
Special tool
(A): 09919-58120
12) Install timing belt referring to “Timing Belt and Tensioner
Removal and Installation” in this section.
13) Check valve lash (clearance) referring to “Valve Lash (Clear-
ance)” in this section.
14) Install engine assembly to vehicle referring to “Engine
Assembly Removal and Installation” in this section.
 ENGINE MECHANICAL (K9K ENGINE) 6A2-53

Camshaft and Tappet Inspection

Camshaft

• Check teeth of sprocket for wear or damage.

• Check journals and cam faces for wear or damage.
If any malcondition is found, replace camshaft.

• Using a micrometer, measure cam height “a”. If measured

height is out of specification, replace camshaft.
Cam height “a”

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In: 43.985 – 44.045 mm (1.73170 – 1.73405 in.)
Ex: 44.565 – 44.625 mm (1.75453 – 1.75688 in.)

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Camshaft Journal Wear

• Check camshaft journals and camshaft housings for pitting,

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scratches, wear or damage.

If any malcondition is found, replace camshaft or cylinder
head with housing. Never replace cylinder head without
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replacing housings.
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• Check clearance between camshaft and camshaft journal

using gauging plastic as follows.

NOTE:
Do not rotate camshaft while gauging plastic is installed.

a) Clean housings and camshaft journals.

b) Remove all tappets.
c) Install camshaft to cylinder head.
d) Place a piece of gauging plastic to full width of journal of
camshaft (parallel to camshaft).
6A2-54 ENGINE MECHANICAL (K9K ENGINE)

e) Install camshaft housing to cylinder head as follows.

"3", (a) "7", (a) "11", (a) "12", (a) "8", (a) "4", (a) i) Fit camshaft housing to cylinder head.
ii) Tighten camshaft housing bolts temporarily by hand.
iii) Tighten camshaft housing bolts in numerical order as indi-
cated in figure a little at a time till they are tightened to
specified torque.
Tightening torque
Camshaft housing bolt (a):
Tighten 10 N·m (1.0 kg-m, 7.5 lb-ft) by the specified proce-
dure
"2", (a) "6", (a) "10", (a) "9", (a) "5", (a) "1", (a)

f) Remove housing, and using scale (2) on gauging plastic (1)

envelop, measure gauging plastic width at its widest point.
Camshaft journal clearance:

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0.049 – 0.171 mm (0.00193 – 0.00673 in.)

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g) If measured camshaft journal clearance exceeds limit, mea-
sure journal (housing) bore and outside diameter of cam-
shaft journal. Replace camshaft or cylinder head assembly
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whichever the difference from specification is greater.

Camshaft journal outside diameter [A]
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No.6: 27.979 – 27.999 mm (1.10154 – 1.10232 in.)

Other: 24.979 – 24.999 mm (0.9835 – 0.98421 in.)
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Camshaft journal bore diameter [B]

No.6: 28.040 – 28.060 mm (1.10394 – 1.10472 in.)
Other: 25.040 – 25.060 mm (0.98583 – 0.98661 in.)
 ENGINE MECHANICAL (K9K ENGINE) 6A2-55

Camshaft Thrust Play

1) Clean housings and camshaft journals.
2) Remove all tappets.
3) Remove all valves referring to “Valves and Cylinder Head” in
this section.
4) Install camshaft to cylinder head.

"3", (a) "7", (a) "11", (a) "12", (a) "8", (a) "4", (a) 5) Install camshaft housing to cylinder head as follows.
a) Fit camshaft housing to cylinder head.
b) Tighten camshaft housing bolts temporarily by hand.
c) Tighten camshaft housing bolts in numerical order as indi-
cated in figure a little at a time till they are tightened to
specified torque.
Tightening torque
Camshaft housing bolt (a):
Tighten 10 N·m (1.0 kg-m, 7.5 lb-ft) by the specified proce-
"2", (a) "6", (a) "10", (a) "9", (a) "5", (a) "1", (a)
dure

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6) Measure camshaft thrust play using special tool, dial gauge
(1) and magnetic stand (2) as shown in figure.

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If measured thrust play is out of its specification, replace
camshaft or cylinder head.
Special tool
. (A): 09917-68110
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Camshaft thrust play:
0.080 – 0.178 mm (0.00315 – 0.00700 in.)
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Wear of Tappet

• Check tappet for pitting, scratches or damage.

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If any malcondition is found, replace.

6A2-56 ENGINE MECHANICAL (K9K ENGINE)

• Measure cylinder head bore and tappet outside diameter to

determine cylinder head-to-tappet clearance. If clearance
exceeds specification, replace tappet or cylinder head.
Cylinder head to tappet clearance:
0.015 – 0.075 mm (0.00059 – 0.00295 in.)
Tappet outside diameter [A]:
34.965 – 34.985 mm (1.37658 – 1.37736 in.)
Cylinder head tappet bore [B]:
35.000 – 35.040 mm (1.37796 – 1.37952 in.)

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 ENGINE MECHANICAL (K9K ENGINE) 6A2-57

Valves and Cylinder Head Components

3
9

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1. Valve cotter 6. Exhaust valve 11. Cylinder block

2. Valve spring retainer 7. Cylinder head bolt Tightening Torque
: Tighten 25 N·m (2.5 kg-m, 18.0 lb-ft) and 255° by
the specified procedure.
3. Valve spring 8. Cylinder head gasket Apply engine oil to sliding surface of each parts.

4. Valve stem seal 9. Cylinder head Do not reuse.

5. Intake valve 10. Knock pin

Valves and Cylinder Head Assembly Removal

and Installation
Removal
1) Remove engine assembly from vehicle referring to “Engine
Assembly Removal and Installation” in this section.
2) Remove exhaust manifold referring to “Exhaust Manifold
Removal and Installation” in this section.
3) Remove camshaft from cylinder head referring to “Camshaft
and Tappet Removal and Installation” in this section.
6A2-58 ENGINE MECHANICAL (K9K ENGINE)

4) Remove EGR valve body and intake pipe No.1 and No.2
referring to “EGR Body and Intake Pipe Removal and Instal-
lation” in this section.
5) Remove thermostat assembly referring to “Thermostat
Assembly Removal and Installation” in Section 6B2.
6) Remove injection pump referring to “Injection Pump Removal
and Installation” in Section 6E2.
7) Remove common rail referring to “Common rail (High Pres-
sure Fuel Injection Rail) Removal and Installation” in Section
6E2.
8) Remove fuel injector referring to “Fuel Injector Removal and
Installation” in Section 6E2.
9) Remove generator and generator upper bracket referring to
“Generator Dismounting and Remounting” in Section 6H2.
10) Remove grow plugs referring to “Grow Plug Removal and
Installation” in Section 6-2.
11) Loosen cylinder head bolts in numerical order as indicated in

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figure, and remove them.
12) Check all around cylinder head for any other parts required
to be removed or disconnected and remove or disconnect

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whatever necessary.
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Installation
1) Clean mating surface of cylinder head and cylinder block.
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Remove oil, old gasket and dust from mating surface.

2) Install knock pins (1) to cylinder block.
3) Install new cylinder head gasket (2) to cylinder block.
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1
 ENGINE MECHANICAL (K9K ENGINE) 6A2-59

4) Tighten new cylinder head bolts gradually as follows.

NOTE:
Do not oil cylinder head bolt.

a) Tighten all bolts to 25 N·m (2.5 kg-m, 18.0 lb-ft) according

to numerical order in figure.
b) Retighten all bolts 255° according to numerical order in fig-
ure.
Tightening torque
Cylinder head bolt (a):
Tighten 25 N·m (2.5 kg-m, 18.0 lb-ft) and 255° by the speci-
fied procedure

5) Install grow plugs referring to “Grow Plug Removal and

Installation” in Section 6-2.
6) Install generator and generator upper bracket referring to

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“Generator Dismounting and Remounting” in Section 6H2.
7) Install fuel injector referring to “Fuel Injector Removal and
Installation” in Section 6E2.

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8) Install common rail referring to “Common Rail (High Pres-
sure Fuel Injection Rail) Removal and Installation” in Section
6E2.
.
9) Install injection pump referring to “Injection Pump Removal
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and Installation” in Section 6E2.
10) Install thermostat referring to “Thermostat Assembly
Removal and Installation” in Section 6B2.
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11) Install EGR valve body and intake pipe referring to “EGR
Body and Intake Pipe Removal and Installation” in this sec-
tion.
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12) Install tappet and camshaft to cylinder head referring to

“Camshaft and Tappet Removal and Installation” in this sec-
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tion.
13) Install exhaust manifold referring to “Exhaust Manifold
Removal and Installation” in this section.
14) Install engine assembly to vehicle referring to “Engine
Assembly Removal and Installation” in this section.
6A2-60 ENGINE MECHANICAL (K9K ENGINE)

Valves and Cylinder Head Assembly Inspec-

tion
Valve Protrusion

1) Clean valve face and then measure protrusion of each valve

using special tool and dial gauge as shown in figure.
(A)
If average is out of specification, grind valve seat and then
lap valve on seat.
Special tool
(A): 09910-26510/OUT 0000005
2 Valve protrusion
Intake and exhaust valve protrusion
“a”: –0.07 to 0.07 mm (–0.0027 to 0.0027 in.)
3
2. Intake valve
3. Exhaust valve

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Valves and Cylinder Head Assembly Disas-

Disassembly
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sembly and Reassembly
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1) Using special tool (A) and (B), compress valve springs and
then remove valve cotters (1) using special tool (C) as shown
in figure.
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Special tool
(A): 09916-14510
(B): 09916-14521
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(C): 09916-84511
2) Release special tool, and remove spring retainer and valve
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spring.
3) Remove valve from combustion chamber side.

4) Measure stem seal height in order to install stem seal in

specified position as follows.
a) Fit pushrod (1) of special tool on valve stem seal.
b) Fit guide tube (2) of special tool over pushrod (1) until guide
tube comes into contact with cylinder head, and lock push-
rod with screw (3).
c) Remove special tool.
Special tool
(A): 09916-58130
 ENGINE MECHANICAL (K9K ENGINE) 6A2-61

(A) 5) Remove stem seal from valve stem using special tool.
Special tool
(A): 09916-48110

Reassembly

1) Apply engine oil to valve guide bore and valve stem, and
install valve to valve guide.

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2) Install special tool to valve stem in order to prevent stem seal
from damage, and install stem seal to valve stem.

NOTE:
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Be sure to remove special tool after installing stem seal.

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Special tool
(A): 09916-58130
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6A2-62 ENGINE MECHANICAL (K9K ENGINE)

3) Press into stem seal to valve stem in specified position as

follows.
a) Place special tool which is measured stem seal height in
removal procedure on valve stem seal.
Special tool
(A): 09916-58130
b) Press into stem seal tapping top of special tool by hand
until special tool touches cylinder head.

CAUTION:
Do not tap special tool by hammer.
It may result in misinstalling of stem seal and damage of
special tool.

NOTE:
Do not lubricate the valve stem seal before fitting then.

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4) Install valve spring and spring retainer.

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5) Using special tool (A) and (B), compress valve spring. And,
fit two valve cotters (1) into groove in valve stem using spe-
cial tool (C) as shown in figure.
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Special tool
(A): 09916-14510
(B): 09916-14521
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(C): 09916-84511
rd
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 ENGINE MECHANICAL (K9K ENGINE) 6A2-63

Valves and Cylinder Head Components

Inspection
Valve Guides

• Using a micrometer and bore gauge, take diameter readings

on valve stems and guides to check stem-to-guide clear-
ance. Be sure to take reading at more than one place along
the length of each stem and guide.
If clearance exceeds specification, replace valve and valve
guide.
Valve stem-to-guide clearance
In: 0.015 – 0.049 mm (0.00059 – 0.00192 in.)
Ex: 0.029 – 0.063 mm (0.00115 – 0.00248 in.)
Valve stem diameter [A]
In: 5.969 – 5.985 mm (0.23500 – 0.23562 in)
Ex: 5.955 – 5.971 mm (0.23445 – 0.23507 in.)

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Valve guide bore [B]
In and Ex: 6.000 – 6.018 mm (0.23622 – 0.23692 in.)

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Valves
• Remove all carbon from valves.
• Inspect each valve for wear, burn or distortion at its face and
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stem end, as necessary, replace it.

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• Measure length “a” of valve.

If measured length is out of specification, replace valve.
Valve length “a”
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In: 100.73 – 101.17 mm (3.9658 – 3.9830 in.)

Ex: 100.53 – 100.97 mm (3.9579 – 3.9751 in.)
"a"
• Measure diameter “b” of valve.
If measured diameter is out of specification, replace valve.
Valve head diameter “b”
In: 33.38 – 33.62 mm (1.3142 – 1.3236 in.)
Ex: 28.88 – 29.12 mm (1.1370 – 1.1464 in.)
"b"
6A2-64 ENGINE MECHANICAL (K9K ENGINE)

• Valve seat repair:

A valve seat not producing a uniform contact with its valve or
showing width of seating contact that is out of specified
range must be repaired by regrinding or by cutting and
regrinding and finished by lapping.
a) Valve Seat: Use valve seat cutters (1) to make a cut as
illustrated in figure.
Seat width
“a”: 1.8 mm (0.071 in.)
Seat angle
“b”: 89° 30’
b) Valve Lapping: Lap valve on seat in two steps, first with
coarse size lapping compound applied to face and the sec-
ond with fine-size compound, each time using valve lapper
according to usual lapping method.

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Cylinder Head

• Remove all carbon deposits from combustion chambers.

.
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NOTE:
Do not use any sharp-edged tool to scrape off carbon
deposits. Be careful not to scuff or nick metal surfaces
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when decarboning. The same applies to valves and valve

seats, too.
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• Check cylinder head for cracks on intake and exhaust ports,

combustion chambers, and head surface.
Using a straightedge and thickness gauge, check flatness of
gasketed surface at a total of 2 locations. If distortion limit,
given below, is exceeded, replace cylinder head.
Limit of distortion for surface of cylinder head piston side:
0.05 mm (0.00197 in.)
 ENGINE MECHANICAL (K9K ENGINE) 6A2-65

• Distortion of manifold seating faces:

Check seating faces of cylinder head for manifolds, using a
straightedge and thickness gauge, in order to determine
whether these faces should be corrected or cylinder head
replaced.
Limit of distortion for surface of cylinder head exhaust:
manifolds sides
0.2 mm (0.008 in.)

• Measure cylinder head height “a”.

If measured height is below its specification, replace cylinder
head.
Cylinder head height
“a”: 127 mm (5.00 in.)

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Valve Springs

• Referring to data given below, check to be sure that each

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spring is in sound condition, free of any evidence of break-
age or weakening. Remember, weakened valve springs can
cause chatter, not to mention possibility of reducing power
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output due to gas leakage caused by decreased seating

pressure.
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Valve spring free length (In and Ex) “a”:

43.31 mm (1.7051 in.)
Valve spring preload (In and Ex):
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23 N (2.3 kg) for 33.80 mm (5.0 lb/ 1.3307 in.)

50 N (5.0 kg) for 24.80 mm (11.0 lb/ 0.9764 in.)

Max. Valve Lift

1) Install valve, tappet and camshaft referring to “Install” under
“Valves and cylinder Head Removal and Installation” in this
section.
6A2-66 ENGINE MECHANICAL (K9K ENGINE)

2) Measure valve lift using dial gauge as shown in figure.

(A)
If measured valve lift is found to exceed its limit, adjust valve
lash (clearance) referring to “Valve Lash (Clearance)” in this
section.
Special tool
(A): 09910-26510/OUT 0000005
2

Max. valve lift

In: 8.015 mm (0.31555 In.)
3 Ex: 8.595 mm (0.33839 In.)

Pistons, Piston Rings, Connecting Rods and Cylinders Components

CAUTION:
Connecting rod and connecting rod bearing must be replaced as a set when either replacement

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becomes necessary.

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7

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1

2
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3
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8 4

10

1. Top ring 5. Piston pin 9. Connecting rod bearing cap Do not reuse.

2. 2nd ring 6. Piston pin circlip 10. Connecting rod bearing cap bolt
: Tighten 20 N·m (20 kg-m, 14.5 lb-ft) and 45°
by the specified procedure.
3. Oil ring 7. Connecting rod Tightening Torque

4. Piston 8. Connecting rod bearing Apply engine oil to sliding surface of each
parts.
 ENGINE MECHANICAL (K9K ENGINE) 6A2-67

Pistons, Piston Rings, Connecting Rods and

Cylinders Removal and Installation

CAUTION:
Connecting rod and connecting rod bearing must be
replaced as a set when either replacement becomes nec-
essary.

Removal
1) Remove engine assembly from vehicle referring to “Engine
Assembly Removal and Installation” in this section.
2) Remove cylinder head referring to “Valves and Cylinder
Head Removal and Installation” in this section.
3) Remove upper oil pan referring to “Oil Pan and Oil Pump
Strainer Removal and Installation” in this section.
4) Remove oil pump referring to “Oil Pump and Oil Pump Chain

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Removal and Installation” in this section.

5) Remove special tool (A).

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Special tool
(A): 09919-58110
.
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6) Mark cylinder number on all pistons, connecting rods (1) and

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rod bearing caps (2) using silver pencil or quick drying paint
(3) for installation.
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7) Remove connecting rod bearing caps.

8) Decarbon top of cylinder bore before removing piston from
cylinder.
9) Push piston and connecting rod assembly out through the
top of cylinder bore.

Installation

NOTE:
• All parts to be installed must be perfectly clean.
• Main bearings, main bearing caps, connecting rods,
connecting rod bearings, rod bearing caps, pistons
and piston rings are in combination sets. Do not dis-
turb such combination and make sure that each part
goes back to where it came from, when installing.
6A2-68 ENGINE MECHANICAL (K9K ENGINE)

1) Apply engine oil to pistons, rings, cylinder walls, connecting

rod bearings and crankpins.

NOTE:
Do not apply oil between connecting rod and bearing or
between bearing cap and bearing.

2) When installing piston and connecting rod assembly into cyl-

inder bore, point arrow mark (1) on piston head to flywheel
side (2).

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3) Install piston and connecting rod assembly into cylinder bore
matching cylinder number marked in removal. Use special

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

der number marked in removal.
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a) Tighten all cap bolts (2) to 20 N·m (2.0 kg-m, 14.5 lb-ft).
b) Retighten them by turning through 45°.
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Tightening torque
Connecting rod bearing cap bolt (a):
Tighten 20 N·m (2.0 kg-m, 14.5 lb-ft) and 45° by the speci-
fied procedure

5) Insert special tool into TDC pin hole as shown in figure.

And turn crankshaft clockwise until crankshaft touches spe-
cial tool.
Special tool
(A): 09919-58110
6) Install oil pump referring to “Oil Pump and Oil Pump Chain
Removal and Installation” in this section.

7) Install oil pan and oil level gauge referring to “Oil pan and Oil
Pump Strainer Removal and Installation” in this section.
 ENGINE MECHANICAL (K9K ENGINE) 6A2-69

8) Install cylinder head referring to “Valves and Cylinder Head

Removal and Installation” in this section.
9) Install engine assembly to vehicle referring to “Engine
Assembly Removal and Installation” in this section.

Pistons, Piston Rings, Connecting Rods and

Cylinders Disassembly and Reassembly
Disassembly
1) Using piston ring expander, remove top and 2nd compres-
sion rings and oil ring from piston.
2) Remove piston pin from connecting rod as follows.
a) Using flat head screw driver (2) or the like, remove piston
pin circlips (1) as shown.

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b) Remove piston pin (1) from piston (2).
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Reassembly

NOTE:
Whenever piston is replaced, select applicable piston
referring to “Selection of Piston” under “Pistons, Piston
Rings, Connecting Rods and Cylinder Inspection” in this
section.

1) Clean carbon from piston head and ring grooves using a

suitable tool.
6A2-70 ENGINE MECHANICAL (K9K ENGINE)

2) Install connecting rod bearings (3) to connecting rod (1) and

bearing cap (2) as follows.
a) Distinguish connecting rod bearing between connecting rod
side connecting rod bearing and bearing side connecting
rod bearing (4) measuring its width before installing.
Connecting rod side connecting rod bearing width “a”:
20.500 – 20.750 mm (0.80709 – 0.81692 in.)
Bearing cap side connecting rod bearing width “b”:
17.500 – 17.750 mm (0.68898 – 0.69881 in.)

b) Install special tool (B) to special tool (A).

NOTE:
Be sure to install special tool (B) to specified direction as
shown.

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Special tool
(A): 09913-98110
(B): 09913-88110

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1. Mark “B”

c) Install connecting rod (1) and connecting rod bearing to

. special tool (A and B) as shown.
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d) Install connecting rod bearing to connecting rod pushing
special tool (B) as shown.
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e) Install special tool (B) to special tool (A).

NOTE:
Be sure to install special tool (B) to specified direction as
shown.

Special tool
(A): 09913-98110
(B): 09913-88110
f) Install bearing cap (2) and connecting rod bearing to spe-
cial tool (A and B) as shown.
g) Install connecting rod bearing to bearing cap pushing spe-
cial tool (B) as shown.
1. Mark “A”
 ENGINE MECHANICAL (K9K ENGINE) 6A2-71

3) Install piston pin to piston and connecting rod as follows.

a) After applying engine oil to piston pin and piston pin holes
in piston and connecting rod, fit connecting rod to piston so
that flat part (2) of connecting rod bearing and arrow mark
(1) come on the same side, and insert piston pin to piston
and connecting rod.
b) Install piston pin circlips.
c) Position opening of piston pin circlip to opposite side of
removal and fitting channel (4).
5. Flywheel side

4) Install piston rings to piston noting the following.

NOTE:
• As indicated in figure, 1st and 2nd rings have “TOP”
mark respectively. When installing these piston rings
to piston, direct marked side of each ring toward top of

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piston.
• 1st ring (1) differs from 2nd ring (2) in thickness and

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shape.
Distinguish 1st ring from 2nd ring by referring to fig-
.ure.
• When installing oil ring, install spiral ring (3) first and
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then rail (4).
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Pistons, Piston Rings, Connecting Rods and

Cylinders Inspection
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Cylinders
• Inspect cylinder walls for scratches, roughness or ridges
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which indicate excessive wear. If cylinder bore is very rough,

deeply scratched or ridged, replace cylinder block.

Pistons
• Inspect piston for faults, cracks or other damaged.
Damaged or faulty piston should be replaced.
• Piston diameter:
As indicated in figure, piston diameter should be measured
at a position “a” from piston top in the direction perpendicular
to piston pin.
Piston diameter specification:
75.938 – 75.952 mm (2.98969 – 2.99023 in.)
“a”: 56.0 mm (2.205 in.)
6A2-72 ENGINE MECHANICAL (K9K ENGINE)

Piston Pin
• Check piston pin, connecting rod small end bore and piston
bore for wear or damage, paying particular attention to con-
dition of small end bore bush. If pin, connecting rod small
end bore or piston bore is badly worn or damaged, replace
pin, connecting rod and/or piston.
• Piston pin clearance:
Check piston pin clearance in small end and piston. Replace
connecting rod and/or piston if its small-end is badly worn or
damaged or if measured clearance out of specification.
Clearance between small-end and piston pin:
0.013 – 0.030 mm (0.00052 – 0.00118 in.)
Small-end bore for connecting rod:
26.013 – 26.025 mm (1.02414 – 1.02460 in.)
Piston pin outside diameter:

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25.995 – 26.000 mm (1.02343 – 1.02362 in.)

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Piston Rings
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• Piston ring end gap

To measure end gap, insert piston ring (1) into cylinder bore
rd

and then measure the gap by using thickness gauge (2).

If measured gap is out of specification, replace ring.
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NOTE:
Decarbonize and clean top of cylinder bore before insert-
ing piston ring.

Piston ring end gap

Top ring: 0.20 – 0.35 mm (0.0079 – 0.0137 in.)
2nd ring: 0.70 – 0.90 mm (0.0276 – 0.0354 in.)
Oil ring: 0.25 – 0.50 mm (0.0099 – 0.0196 in.)

• Piston ring thickness

Measure piston ring thickness. If measured thickness is out
of specification, replace piston ring.
Piston ring thickness
Top ring: 1.97 – 1.99 mm (0.0776 – 0.0783 in.)
2nd ring: 1.97 – 1.99 mm (0.0776 – 0.0783 in.)
Oil ring: 2.47 – 2.49 mm (0.0973 – 0.0980 in.)
 ENGINE MECHANICAL (K9K ENGINE) 6A2-73

• Ring groove clearance

Before checking, piston grooves must be clean, dry and free
of carbon.
Fit new piston ring (1) into piston groove, and measure clear-
ance between ring and ring land by using thickness gauge
(2).
If clearance is out of specification, replace piston.
Ring groove clearance
clearance
Top ring: 0.10 – 0.12 mm (0.0040 – 0.0047 in.)
2nd ring: 0.08 – 0.10 mm (0.0032 – 0.0039 in.)
Oil ring: 0.03 – 0.05 mm (0.0012 – 1.2700 in.)

Connecting Rod
• Connecting rod big end bore and length.

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a) Install bearing cap (2) to connecting rod (1).
b) Measure connecting rod big end bore and length.
If measured bore and length is out of specification, replace

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1
connecting rod.
“b”
Big end bore “a”:
.
47.610 – 47.628 mm (1.87441 – 1.87511 in.)
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Connecting rod length “b”:
2
“a” 170.56 – 170.57 mm (6.7150 – 6.7153 in.)
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• Connecting rod big end thrust play

a) Install connecting rod referring to “Installation” under “Pis-
rd

tons, Piston Rings, Connecting rods and Cylinders” in this

section.
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b) Check big-end of connecting rod for thrust play with rod

fitted and connected to its crank pin in the normal manner.
If measured thrust play is out of specification, replace
connecting rod.
Connecting rod big end thrust play:
0.205 – 0.467 mm (0.00807 – 0.01838 in.)
6A2-74 ENGINE MECHANICAL (K9K ENGINE)

Crank Pin and Connecting Rod Bearings

• Inspect crank pin for uneven wear or damage. Measure

crank pin for crank pin diameter using a micrometer. If crank
pin is damaged or crank pin diameter is out of specification,
replace crankshaft.
Crank pin diameter:
43.960 – 43.980 mm (1.73071 – 1.73150 in.)

• Rod bearing:
Inspect bearing shells for signs of fusion, pitting, burn or flak-
ing and observe contact pattern. Bearing shells found in
defective condition must be replaced.

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• Rod bearing clearance:
.
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NOTE:
Do not rotate crankshaft while gauging plastic is
installed.
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a) Before checking bearing clearance, clean bearing and

crank pin.
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b) Install bearing in connecting rod and bearing cap referring

to “Reassembly” under “Pistons, Piston Rings, Connecting
Rods and Cylinders Disassembly and Reassembly” in this
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section.
c) Place a piece of gauging plastic (1) to full width of crank pin
as contacted by bearing (parallel to crankshaft), avoiding oil
hole.
d) Install connecting rod and bearing cap referring to “Installa-
tion” under “Pistons, Piston Rings, Connecting rods and
Cylinders” in this section.
 ENGINE MECHANICAL (K9K ENGINE) 6A2-75

e) Using a scale (1) on gauging plastic (2) envelope, measure

gauging plastic width at the widest point (clearance) after
removing cap.
If clearance is out of specification, use a new bearing and
remeasure clearance.
Connecting rod bearing clearance:
0.010 – 0.064 mm (0.0004 – 0.0025 in.)

Piston Protrusion
1) Install piston and connecting rod referring to “Installation”
under “Pistons, Piston Rings, Connecting rods and Cylin-
ders” in this section.
2) Using special tool and dial gauge, measure piston protrusion

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at specified measurement position (2) as shown in figure
when piston (1) reaches top dead center. Repeat this proce-
dure with each piston.

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If piston protrusion is out of specification, proceed to next
1
step.
Piston protrusion “a”:
.
0.030 – 0.288 mm (0.00119 – 0.01133 in.)
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3) Check connecting rod length referring to “Connecting Rod”
2 under “Piston, Piston Rings, Connecting Rod and Cylinders
Inspection” in this section.
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If connecting rod is normal, proceed to next step.

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6A2-76 ENGINE MECHANICAL (K9K ENGINE)

4) Replace piston (1) as follows in order to adjust piston protru-

sion to specified value.
a) Remove piston, and measure the following specification.
• Piston pin diameter “b”
• Distance “c” between top of piston and top of piston pin hole
1 b) Obtain distance “d” between top of piston and center of pis-
ton pin hole by the following equation.
“d”= “b”/2 + “c”
c
d c) Using measured piston protrusion “a” at step 2), obtain
b adjusting distance “e’” by the following equation.
“e” = “d” + 0.159 mm (0.0063 in.) – “a”

Example:
When distance “d” of removed piston is 41.620 mm (1.63858 in.),
and measured piston protrusion “a” is 0.020 mm (0.0008 in.).
Calculated adjusting distance “e” = 41.620 mm (1.63965 in.) +

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0.159 mm (0.0307 in.) – 0.020 mm (0.0008 in.) = 41.759 mm
(1.64406 in.)

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d) Select new piston so that distance “e” is within range of dis-
tance “d” of new piston.
Piston class specification
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Piston class Distance “d”
(1)
J 41.605 – 41.645 mm (1.63800 – 1.64122 in.)
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K 41.674 – 41.687 mm (1.63965 – 1.64287 in.)

L 41.689 – 41.729 mm (1.64130 – 1.64287 in.)
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M 41.731 – 41.771 mm (1.64296 – 1.64452 in.)

N 41.773 – 41.813 mm (1.64461 – 1.64618 in.)
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NOTE:
• Piston class (1) is marked on piston top as shown in
figure.
• Supplied piston is only K, L and M classes.
If selected piston is J class, K class piston must be
installed as a replacement.
If selected piston is N class, M class piston must be
installed as a replacement.

e) Replace removed piston to selected piston.

f) Check piston protrusion, again.
 ENGINE MECHANICAL (K9K ENGINE) 6A2-77

Main Bearings, Crankshaft and Cylinder Block Components

3
4

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5

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8

2
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6
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1. Cylinder block 5. Main bearing Tightening Torque

: Apply RHODOSEAL 5661® referring to “Installation” under : Apply engine oil to bearing inside
“Main Bearings, Crankshaft and Cylinder Block Removal and surfaces.
Installation”.
2. Crankshaft 6. Main bearing cap Do not reuse.
: Apply engine oil to sliding surface.

3. Thrust bearing 7. Main bearing cap bolt

: Apply engine oil to sliding surface. : Tighten 25 N·m (2.5 kg-m, 18.0 lb-ft)
and 47° by the specified procedure.
4. Flywheel side crankshaft oil seal 8. Oil jet
: Apply engine oil to oil seal lip.
6A2-78 ENGINE MECHANICAL (K9K ENGINE)

Main Bearings, Crankshaft and Cylinder

Block Removal and Installation
Removal
1) Remove engine assembly from vehicle referring to “Engine
Assembly Removal and Installation” in this section.
2) Remove oil pan and oil pump strainer referring to “Oil Pan
and Oil Pump Strainer Removal and Installation” in this sec-
tion.
3) Remove exhaust manifold referring to “Exhaust Manifold
Removal and Installation” in this section.
4) Remove cylinder head cover referring to “Cylinder Head
Cover Removal and Installation” in this section.
5) Remove timing belt, belt tensioner, crankshaft pulley and tim-
ing belt cover referring to “Timing Belt and Belt Tensioner
Removal and Installation” in this section.
6) Remove heat exchanger referring to “Heat Exchanger
Removal and Installation” in this section.

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7) Remove oil pump, oil pump drive sprocket and gasket holder
plate referring to “Oil Pump Removal and Installation” in this

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section.
8) Remove power steering pump referring to “Power Steering
.(P/S) Pump” in Section 3B1.
9) Remove camshaft referring to “Camshaft and Tappet
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Removal and Installation” in this section.
10) Remove cylinder head assembly referring to “Valve and Cyl-
inder Head Removal and Installation” in this section.
11) Remove piston and connection rod referring to “Piston, Pis-
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ton Rings, Connecting Rods, Connecting Rods and Cylin-

ders Removal and Installation” in this section.
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12) Remove clutch cover, clutch disc and flywheel referring to

“Clutch Cover, Clutch Disc, Flywheel and Release Bearing
Removal and Installation” in Section 7C2.
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13) Loosen crankshaft bearing cap bolts in such order as indi-

cated in figure a little at a time, and remove bearing caps.
14) Remove crankshaft from cylinder block.
15) Remove flywheel side crankshaft oil seal from crankshaft.
 ENGINE MECHANICAL (K9K ENGINE) 6A2-79

1
16) Remove main bearings (1) and thrust bearings (2).

17) Remove oil jet as follows, if necessary.

a) Pack rag into cylinder to prevent swarf from entering.
b) Remove spring stop (1) and spring (2) using 7 mm (0.28
in.) diameter drill (4).

CAUTION:
Do not remove ball (3) to prevent swarf from entering

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cooling circuit.

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c) Desorb swarf from cylinder and oil jet.

d) Install special tool (A) to drilled hole of oil jet (1).

e) Remove oil jet from cylinder using special tools (A and B).
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Special tool
(A): 09916-48120
(B): 09916-58120
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Installation
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NOTE:
• Whenever crankshaft and cylinder block replaced,
select applicable piston referring to “Selection of Pis-
ton” under “Pistons, Piston Rings, Connecting Rods
and Cylinder Inspection” in this section.
• All parts to be installed must be perfectly clean.
• Be sure to apply oil to crankshaft journals, main bear-
ings and thrust bearings.
• Main bearings, main bearing caps, connecting rods,
connecting rod bearings, rod bearing caps, pistons
and piston rings are in combination sets. Do not dis-
turb such combination and make sure that each part
goes back to where it came from, when installing.
6A2-80 ENGINE MECHANICAL (K9K ENGINE)

1) Using special tool, install oil jet to cylinder block as follows, if

removed.
Special tool
(A): 09916-58110
1. Oil jet No.1
2. Oil jet No.2
3. Oil jet No.3
4. Oil jet No.4
5. Flywheel side
6. Push rod
7. Plate
8. Guide rod
9. Plate bolt

a) Install plate (1) to cylinder block tightening plate bolts (2) by

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hand.
b) Install guide rod (3) to plate aligning guide rod end with oil
jet hole.

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c) Tighten plate bolts, and remove guide rod.
[A]: Oil jet No.2 and 4
[B]: Oil jet No.1 and 3
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d) Insert oil jet (1) into push rod (2) facing oil jet with center of
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cylinder.
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e) Using hammer, tap push rod until push rod (1) comes into
contact with plate (2).
f) Remove special tool.
[A]: Oil jet No.2 and 4
[B]: Oil jet No.1 and 3
 ENGINE MECHANICAL (K9K ENGINE) 6A2-81

2) Using special tool, install main bearing to cylinder block and

bearing cap as follows.

NOTE:
One of two halves of main bearing has oil groove. Install
main bearing with oil grove to cylinder block, and the
other one without oil groove to bearing cap.

Special tool
(A): 09913-78110
a) Install special tool (A) to cylinder block.

b) Fit main bearing (1) in special tool (A) as shown, and then
press at “a” until main bearing is touched at “b”.

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c) Install special tool (A) to bearing cap (1).
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d) Fit main bearing (1) in special tool (A) as shown, and then
press at “a” until main bearing is touched at “b”.
6A2-82 ENGINE MECHANICAL (K9K ENGINE)

1
3) Install thrust bearings (1) to center of crankshaft journal fac-
ing its oil groove (2) to outside.
4) Install crankshaft to cylinder block.

5) Apply sealant to cylinder block as shown in figure.

“A”: RHODORSEAL 5661®
“a”: 4 mm (0.16 in.)

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6) Install main bearing caps in proper position matching cylin-
der number marked in removal.
7) Tighten main bearing cap bolts as follows.
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a) Tighten bolts to 25 N·m (2.5 kg-m, 18.0 lb-ft).
b) Retighten them by turning through 47°.
Tightening torque
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Main bearing cap bolt (a):

Tighten 25 N·m (2.5 kg-m, 18.0 lb-ft) and 47° by the speci-
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fied procedure

NOTE:
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After tightening cap bolts, check to be sure that crank-

shaft rotates smoothly.

(A) 3 8) Using special tool, install flywheel side oil seal as follows.
2

CAUTION:
Do not touch oil seal so that it is extremely fragile. When-
1
ever installing new oil seal, it must be installed using
special tool (A) and protector supplied with new oil seal.
If it doesn’t follow the above-mentioned service, it may
4 cause oil leak from oil seal.

Special tool
(A): 09911-98110
1. Fitting
2. Installer
3. Nut
4. Screw
 ENGINE MECHANICAL (K9K ENGINE) 6A2-83

a) Install fitting (1) and screw (2) to crankshaft.

b) Install protector (4) together with new oil seal (1) to fitting by
tightening nut (2) until installer (3) comes into contact with
cylinder block.
c) Remove special tool and protector.
9) Install piston and connecting rod referring to “Piston, Piston
Rings, Connecting Rods and Cylinders Removal and Instal-
lation” in this section.

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10) Install oil pump, oil pump drive sprocket and gasket holder
plate referring to “Oil Pump Removal and Installation” in this

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section.
11) Install oil pan and oil pump strainer referring to “Oil Pan and
Oil Pump Strainer Removal and Installation” in this section.
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12) Install cylinder head assembly referring to “Valve and Cylin-
der Head Removal and Installation” in this section.
13) Install camshaft referring to “Camshaft and Valve Tappet
Removal and Installation” in this section.
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14) Install timing belt, belt tensioner, crankshaft timing sprocket

and timing belt cover referring to “Timing Belt and Belt Ten-
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sioner Removal and Installation” in this section.

15) Install cylinder head cover referring to “Cylinder Head Cover
Removal and Installation” in this section.
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16) Install flywheel referring to “Clutch Cover, Clutch Disc, Fly-

wheel and Release Bearing Removal and Installation” in
Section 7C2.
17) Install exhaust manifold referring to “Exhaust Manifold
Removal and Installation” in this section.
18) Install turbocharger referring to Turbocharger Removal and
Installation” in this section.
19) Install clutch to flywheel referring to “Clutch Cover, Clutch
Disc, Flywheel and Release Bearing Removal and Installa-
tion” in Section 7C2.
6A2-84 ENGINE MECHANICAL (K9K ENGINE)

(a) 20) Install engine mounting brackets.

(c)

Tightening torque
Engine right mounting nut (a):
(c)
55 N·m (5.5 kg-m, 40.0 lb-ft)
Engine left mounting nut (b):
(b)
40 N·m (4.0 kg-m, 29.0 lb-ft)
Engine side mounting bracket bolt (c):
40 N·m (4.0 kg-m, 29.0 lb-ft)
21) Install engine assembly to vehicle referring to “Engine
Assembly” in this section.
(c)

Main Bearings, Crankshaft and Cylinder

Block Inspection

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Crankshaft Thrust Play

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1) Install main bearing, thrust bearing, crankshaft and main
bearing cap referring to “Main Bearings, Crankshaft and Cyl-
.inder Block Removal and Installation” in this section.
2) Use a dial gauge to read displacement in axial (thrust) direc-
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tion of crankshaft.
If measured value is out of specification, replace thrust bear-
ing.
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Crankshaft thrust play

New thrust bearing:
0.045 – 0.252 mm (0.00178 – 0.00992 in.)
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Reused thrust bearing:

0.045 – 0.852 mm (0.00178 – 0.03354 in.)
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Crankshaft
Crankshaft journal

• Inspect crankshaft journal for uneven wear or damage. Mea-

sure crankshaft journal diameter using a micrometer. If
crankshaft journal is damaged or diameter is out of specifica-
tion, replace crankshaft.
Crankshaft journal diameter:
47.990 – 48.010 (1.88937 – 1.89015 in.)
 ENGINE MECHANICAL (K9K ENGINE) 6A2-85

Crankshaft journal bore

• Inspect crankshaft journal bore for uneven wear or damage.

Measure crankshaft journal bore. If crankshaft journal bore is
damaged or diameter is out of specification, replace cylinder
block.
Crankshaft journal bore diameter “a”:
51.936 – 51.949 mm (2.04473 – 2.04523 in.)

Main Bearing

• Inspect bearing shells for signs of fusion, pitting, burn or flak-

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ing and observe contact pattern. Bearing shells found in
defective condition must be replaced.

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Main bearing thickness “a”:
1.943 – 1.959 mm (0.07650 – 0.07712 in.)
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Main bearing clearance

NOTE:
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Do not rotate crankshaft while gauging plastic is

installed.
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1) Before checking bearing clearance, clean bearing and crank-

shaft journal.
2) Install bearing to cylinder block and main bearing cap refer-
ring to “Main Bearings, Crankshaft and Cylinder Block
Removal and Installation” in this section.
3) Place a piece of gauging plastic (1) to full width of crankshaft
journal as contacted by bearing (parallel to crankshaft),
avoiding oil hole.
4) Install main bearing cap referring to “Main Bearings, Crank-
shaft and Cylinder Block Removal and Installation” in this
section.
6A2-86 ENGINE MECHANICAL (K9K ENGINE)

5) Remove cap and using a scale (1) on gauging plastic (2)

envelope, measure gauging plastic width at the widest point
(clearance).
If clearance is out of specification, use a new bearing and
remeasure clearance.
Crankshaft journal clearance:
0.027 – 0.054 mm (0.00107 – 0.00213 in.)

Selection of main bearings

If engine is under the following condition, select new bearing as
follows, and install it.
• Bearing is in malcondition.
• Bearing clearance is out of specification.
• Crankshaft or cylinder block is replaced.

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1) First, check journal diameter. As shown in figure, crank web
No.8 (1) or flywheel mating surface (2) has stamped journal

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diameter categories. Twelve kinds of alphabets (“A”, “B”, “C”,
“G”, “H”, “J”, “K”, “L”, “O”, “R”, “S” and “T”) represent the fol-
.lowing journal diameters.
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Journal diameter
Journal diameter category Journal diameter
“A”, “G”, “K”, “R” 47.990 – 47.997 mm
(1.88937 – 1.88964 in.)
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“B”, “H”, “L”, “S” 47.997 – 48.003 mm

(1.88965 – 1.88988 in.)
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“C”, “J”, “O”, “T” 48.003 – 48.010 mm

(1.88989 – 1.89015 in.)
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3. Crankshaft pulley side

4. Flywheel side

Journal bore diameter categories represent journal diameters

marked with an arrow in figure respectively. For example,
stamped alphabet “A” indicates that corresponding journal diame-
ter is 47.990 – 47.997 mm (1.88937 – 1.88964 in.).
 ENGINE MECHANICAL (K9K ENGINE) 6A2-87

2) Next, check journal bore diameter. Distance “a” between cyl-

inder head mating surface and drill hole (1) represents the
following journal bore diameters.

Journal bore diameter

Distance “a” between cylinder Journal bore diameter
head mating surface to drill
hole
33 mm (1.30 in.) 51.936 – 51.942 mm
(2.04473 – 2.04496 in.)
43 mm (1.69 in.) 51.942 – 51.949 mm
(2.0943 – 2.04523 in.)

For example, if distance “a” is 33 mm (1.30 in.), it means all jour-

nals bore diameter are 51.936 – 51.942 mm (2.04473 – 2.04496
in.).

3) There are 4 kinds of bearings differing in thickness. To distin-

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guish them, they are painted (1) in the following colors at the
position as indicated in figure. Each color indicates the fol-

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lowing thickness at the center of bearing.

Main bearing thickness

Color painted (1) Bearing thickness
. Black 1.943 – 1.949 mm
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(0.07650 – 0.07673 in.)
Blue 1.946 – 1.952 mm
(0.07662 – 0.07685 in.)
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Yellow 1.949 – 1.955 mm

(0.07674 – 0.07696 in.)
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RED 1.953 – 1.959 mm

(0.07689 – 0.07712 in.)
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4) From alphabets stamped on crank web No.8 or flywheel mating surface and cylinder head mating surface to
drill hole distance, determine new bearing to be installed to journal by referring to table shown.
For example, if alphabet stamped on crank web No.8 or flywheel mating surface is “A” and cylinder head
mating surface to drill hole distance is 33 mm (1.30 in.) on cylinder block, install new bearings painted in
“Yellow”.

Main bearing cross-reference table (new standard bearing)

Journal diameter category
“A”, “G”, “K”, “R” “B”, “H”, “L”, “S” “C”, “J”, “O”, “T”
Distance “a” between 33 mm Yellow Blue Black
cylinder head mating (1.30 in.)
surface and drill hole 43 mm Red Yellow Blue
(1.69 in.)

Visual inspection
Check bearings for pitting, scratches, wear or damage.
If any malcondition is found, replace both upper and lower halves.
Never replace one half without replacing the other half.
6A2-88 ENGINE MECHANICAL (K9K ENGINE)

Cylinder Block
Distortion of gasketed surface

• Using straightedge and thickness gauge, check gasketed

surface for distortion.
If flatness exceeds its limit, replace cylinder block.
Cylinder block flatness
Limit: 0.03 mm (0.0012 in.)

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 ENGINE MECHANICAL (K9K ENGINE) 6A2-89

Required Service Material

Recommended SUZUKI product or specification Use
Loctite 518® • To apply mating surface of cylinder head and cylin-
der head cover.
Loctite frentanch® • To apply mating surfaces of lubrication pipe union
bolt No.2 and cylinder block.
RHODORSEAL 5661® • To apply mating surfaces of cylinder block, gasket
holder plate and upper oil pan.
• To apply mating surface of cylinder block and main
bearing cap.
• To apply mating surfaces of TDC pin and pin hole.
Loctite 5181® • To apply mating surfaces of cylinder head and cam-
shaft housing.
Loctite 648® • To apply mating surface of lubrication pipe and cyl-
inder block.

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Tightening Torque Specifications
Tightening torque
Fastening part
. N•m kg-m lb-ft
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Oil pressure switch 35 3.5 25.5
Air cleaner outlet hose clamp 2.5 0.25 2.0
Boost pressure sensor bolt 8 0.8 6.0
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Intake pipe No.1 nut 11 1.1 8.0

Intercooler outlet pipe bolt 28 2.8 20.5
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Intercooler hose clamp No.1 4 0.4 3.0

Intercooler hose clamp No.2 5 0.5 4.0
Intercooler bracket bolt 25 2.5 18.0
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Cylinder hear cover bolt “Tighten 12 N·m (1.2 kg-m, 9.0 fb-ft) by the specified pro-
cedure”
Heat exchanger bolt 45 4.5 32.5
Oil filter unit bracket bolt 45 4.5 32.5
Generator upper bracket bolt 40 4.0 29.0
EGR cooler water pipe assembly bolt 12 1.2 9.0
EGR valve bolt 12 1.2 9.0
EGR valve body bolt 21 2.1 15.5
EGR pipe bolt 42 4.2 30.5
Exhaust gas cooler bolt 12 1.2 9.0
Intake pipe No.2 bolt 10 1.0 7.5
EGR cooler bolt 12 1.2 9.0
EGR cooler pipe bolt 21 2.1 15.5
EGR pipe clamp 5 0.5 4.0
Lubrication pipe 23 2.3 17
Lubrication pipe clamp bolt 12 1.2 9.0
Lubrication pipe union bolt 23 2.3 17
Turbocharger nut 25 2.5 18.0
6A2-90 ENGINE MECHANICAL (K9K ENGINE)

Tightening torque
Fastening part
N•m kg-m lb-ft
Turbocharger oil return bolt 12 1.2 9.0
Exhaust manifold nut “Tighten 26 N·m (2.6 kg-m, 19.0 lb-ft) by the specified pro-
cedure”
Level gauge tube nut 21 2.1 15.5
Oil pan baffle plate bolt 8 0.8 6.0
Upper oil pan bolt “Tighten 6 N·m (0.6 kg-m, 4.5 lb-ft) and 16 N·m (1.6 kg-m,
12.0 lb-ft) by the specified procedure”
Oil pump strainer bolt 12 1.2 9.0
Lower oil pan bolt “Tighten12 N·m (1.2 kg-m, 9.0 lb-ft) by the specified proce-
dure”
Engine oil drain plug 35 3.5 25.5
Engine mounting bracket bolt 40 4.0 29.0
Accessory bracket bolt 28 2.8 20.5
Engine mounting nut 55 5.5 40.0
Transmission to engine bolt 55 5.5 40.0

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Generator upper bracket support bolt 21 2.1 15.5
CMP sensor bolt 8 0.8 6.0

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Timing belt tensioner bolt 27 2.7 19.5
Camshaft pulley bolt 14 1.4 10.5
Crankshaft pulley bolt “Tighten 120 N·m (12.0 kg-m, 87.0 lb-ft) and 95° by the
. specified procedure”
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TDC pin cap 20 2.0 14.5
Gasket holder plate bolt “Tighten 11 N·m (1.1 kg-m, 8.0 lb-ft) and by the specified
procedure”
Oil pump bolt 25 2.5 18.0
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Vacuum pump oil hose union bolt 16 1.6 11.5

Camshaft cover bolt “Tighten 5 N·m (0.5 kg-m, 4.0 lb-ft) and 12 N·m (1.2 kg-m,
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9.0 lb-ft) by the specified procedure”

Camshaft housing bolt “Tighten 10 N·m (1.0 kg-m, 7.5 lb-ft) by the specified pro-
cedure”
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Camshaft pulley nut “Tighten 30 N·m (3.0 kg-m, 22.0 lb-ft) and 85° by the spec-
ified procedure”

Cylinder head bolt “Tighten 25 N·m (2.5 kg-m, 18.0 lb-ft) and 255° by the
specified procedure”

Connecting rod bearing cap bolt “Tighten 20 N·m (2.0 kg-m, 14.5 lb-ft) and 45° by the spec-
ified procedure”

Main bearing cap bolt “Tighten 25 N·m (2.5 kg-m, 18.0 lb-ft) and 47° by the spec-
ified procedure”
Engine right mounting nut 55 5.5 40.0
Engine left mounting nut 40 4.0 29.0
Engine side mounting bracket bolt 40 4.0 29.0
 ENGINE MECHANICAL (K9K ENGINE) 6A2-91

Special Tool

09917-78120 09915-77311 09915-77420 09915-77430

Dummy heater plug Oil pressure gauge Oil pressure gauge hose Oil pressure gauge attach-
ment

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09919-58110 (Mot. 1489) 09919-58120 (Mot. 1430) 09916-98110 (Mot. 582-01) 09911-98130 (Mot. 1714)
TDC setting pin Set of top dead center pins Flywheel locking tool Stud M14
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09911-98140 (Mot. 1586) 09917-68221 09917-68110 (Mot. 588) 09911-98120 (Mot. 1632)
Crankshaft oil seal fitting Camshaft lock holder Cylinder liner flange Camshaft oil seal fitting

09910-26510/OUT 0000005 09916-14510 09916-14521 09916-84511

Dial gauge support Valve lifter Valve lifter attachment Forceps
6A2-92 ENGINE MECHANICAL (K9K ENGINE)

09916-58130 (Mot. 1511-01) 09916-48110 (Mot. 1335) 09913-98110 (Mot. 1492) 09913-88110 (Mot. 1492-3)
Valve stem seal fitting Valve stem seal pliers Connecting rod bearing fitting Connecting rod bearing
adapter

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09916-77310
Piston ring compressor
09916-48120 (Mot. 1485-01)
Oil jet remover
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09916-58120 (Emb. 880)
Inertia extractor
09916-58110 (Mot. 1494)
Oil jet installer
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09913-78110 (Mot. 1493-01) 09911-98110 (Mot. 1585) 09912-57821 09916-48130 (Mot. 1729)
Main bearing fitting Crankshaft oil seal fitting Compression gauge EGR valve remover
 ENGINE COOLING (K9K ENGINE) 6B2-1

SECTION 6B2
6-3
6E3

ENGINE COOLING 6C3

(K9K ENGINE) 6E3

6G3
6H3
WARNING: 6K3
For vehicles equipped with a Supplemental Restraint (Air Bag) System:
• Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under
“General Description” in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser-
vice Precautions” under “On-Vehicle Service” in air bag system section before performing service
on or around the air bag system components or wiring. Failure to follow WARNINGS could result in

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unintentional activation of the system or could render the system inoperative. Either of these two
conditions may result in severe injury.
• Technical service work must be started at least 90 seconds after the ignition switch is turned to the

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“LOCK” position and the negative cable is disconnected from the battery. Otherwise, the system
may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).

NOTE:
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For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the Service Man-
ual mentioned in “FOREWORD” of this manual.
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CONTENTS
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General Description ......................................6B2-2 Engine Coolant Temperature Sensor 6B2

Cooling System Circulation .........................6B2-2 (ECT Sensor) Removal and Installation.......6B2-*
Engine Coolant Temperature Sensor
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Degassing Tank .......................................... 6B2-*

Water Pump ................................................ 6B2-* (ECT Sensor) Inspection..............................6B2-*
Thermostat .................................................. 6B2-* Radiator Cooling Fan Removal and
ECT sensor ................................................. 6B2-* Installation................................................... 6B2-5
Radiator Cooling Fan .................................. 6B2-* Radiator Cooling Fan motor On-Vehicle
Diagnosis ....................................................... 6B2-* Inspection.....................................................6B2-*
Radiator Cooling Fan Disassembly and
Maintenance ..................................................6B2-3
Reassembly .................................................6B2-*
Coolant........................................................6B2-3 Radiator Cooling Fan Relay Inspection .......6B2-*
Coolant Level Check ................................... 6B2-* Radiator Removal and Installation ...............6B2-*
Engine Cooling System Inspection and Radiator Inspection ......................................6B2-*
Service ........................................................ 6B2-* Water Pump Removal and Installation.........6B2-*
Coolant Replacement.................................. 6B2-* Water Pump Inspection................................6B2-*
On-Vehicle Service........................................6B2-4 Required Service Material ............................ 6B2-*
Cooling System Component .......................6B2-4 Tightening Torque Specification .................6B2-6
Cooling Water Pipes or Hoses Removal
and Installation ............................................ 6B2-*
Thermostat Assembly Removal and
Installation ................................................... 6B2-*
6B2-2 ENGINE COOLING (K9K ENGINE)

General Description
The cooling system consists of the degassing tank cap, radiator, degassing tank, hoses, water pump, radiator
cooling fan and thermostat assembly. The radiator is of tube-and-fin type.

Cooling System Circulation

[A] [B]

1 1

2 2
11 11

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3 3

5 5

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7 7
8 8
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9 9
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6 10 6 10
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[A]: When thermostat is close 3. Thermostat 7. Degassing tank cap 11. EGR cooler
[B]: When thermostat is open 4. Air bleed plug 8. Degassing tank
1. Heater 5. Cylinder block and cylinder head 9. Heat exchanger
2. Thermo plunger 6. Radiator 10. Water pump
 ENGINE COOLING (K9K ENGINE) 6B2-3

Maintenance
WARNING:
• Keep hands, tools and clothing away from radiator cooling fan to help prevent personal injury. This
fan is electric and can turn on whether engine is running or not. The fan can start automatically in
response to ECM with ignition switch turned on.
• To help avoid danger of being burned, do nut remove degassing tank cap while engine and radiator
are still hot.
Scalding fluid and steam can be blown out under pressure if cap is taken off too soon.

Coolant
When the system cools down, the coolant is drawn back into the radiator.
The cooling system has been filled at the factory with a quality coolant that is a 50/50 mixture of water and eth-
ylene glycol antifreeze.
This 50/50 mixture coolant solution provides freezing protection to –36 °C (–33 °F).

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• Maintain cooling system freeze protection at –36 °C (–33 °F) to ensure protection against corrosion and loss
of coolant from boiling.
This should be done even if freezing temperatures are not expected.

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• Add ethylene glycol base coolant when coolant has to be added because of coolant loss or to provide added
protection against freezing at temperature lower than –36 °C (–33 °F).

Anti-freeze proportioning chart

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°C –36
Freezing temperature
°F –33
Antifreeze/Anticorrosion coolant concentration % 50
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Itr. 3.65/3.65
Ratio of compound to cooling water US pt. 6.42/6.42
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Imp pt. 7.71/7.71

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Coolant capacity
: 7.3 liters (12.85/15.42 US/Imp pt.)

NOTE:
• Alcohol or methanol base coolant or plain water alone should not be used in cooling system at any
time as damage to cooling system could occur.
• Coolant must be mixed with demineraled water or distilled water.
6B2-4 ENGINE COOLING (K9K ENGINE)

On-Vehicle Service
CAUTION:
• Check to make sure that engine coolant temperature is cold before removing any part of cooling
system.
• Also be sure to disconnect negative (–) cable from battery terminal before removing any part.

Cooling System Component

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1. Radiator 10. Degassing tank cap 19. Ventilation hose (radiator to 3-way joint)
2. Hose clip 11. Degassing tank 20. 3-way joint
3. Radiator cooling fan assembly 12. Thermostat assembly 21. Ventilation hose (3-way joint to degassing tank)
4. Radiator inlet hose No.1 13. Heater inlet hose No.1 22. Degassing tank outlet hose
5. Radiator inlet pipe 14. Heater inlet hose No.2 23. EGR cooler water pipe
6. Radiator inlet hose No.2 15. Thermo plunger 24. EGR cooler outlet hose
7. Radiator outlet hose No.1 16. Heater inlet hose No.3 25. Heater outlet hose No.2
8. Radiator outlet pipe No.1 17. Heater outlet hose No.1 26. Heater inlet pipe
9. Radiator outlet hose No.2 18. Ventilation hose (engine to 3-way joint) 27. EGR cooler inlet
 ENGINE COOLING (K9K ENGINE) 6B2-5

Radiator Cooling Fan Removal and Installa-

tion

NOTE:
Do not disassemble radiator cooling fan.
If any repair is required on fan, replace it as assembly.

Removal
1) Disconnect negative (–) cable at battery.

2) Remove engine hanger (1) and accessory belt cover (2).

3) Recovery refrigerant from A/C system referring to “Recov-
1
ery” in Section 1B.
4) Remove A/C suction pipe and condenser outlet pipe refer-
ring to “Major Components and Location” in Section 1B.
5) Detach P/S reservoir from its bracket.

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6) Drain coolant from cooling system referring to “Coolant
Replacement” in this section.
2
7) Disconnect radiator inlet hose No.2 and ventilation hose from

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radiator.

2 8) Disconnect cooling fan motor connector (1).

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9) Remove radiator cooling fan (2).
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6B2-6 ENGINE COOLING (K9K ENGINE)

Installation

2 1) Install radiator cooling fan(2).

2) Connect cooling fan motor connector (1).
3) Connect radiator inlet hose No.2 and ventilation hose to radi-
ator.
4) Install P/S reservoir to its bracket.
5) Install A/C suction pipe and condenser outlet pipe referring
to “Major Components and Location” in Section 1B.
1

6) Install engine hanger (1) and accessory belt cover (2).

Tightening torque
1
Engine hanger bolt (a): 23 N·m (2.3 kg-m, 17.0 lb-ft)
7) Connect negative (–) cable at battery.

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8) Refill cooling system with coolant referring to “Coolant
Replacement” in this section.
9) Recharge A/C system with refrigerant referring to “Operation

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Procedure for Refrigerant Charging” in Section 1B.
2
10) Check to make sure that there is no coolant leakage and A/C
refrigerant leakage at each connection.
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Tightening Torque Specification

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Tightening torque
Fastening part
N•m kg-m lb-ft
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Thermostat assembly bolt 10 1.0 7.5

Engine hanger bolt 23 2.3 17.0
Radiator mounting bolt 11 1.1 8.0
Water pump bolt 11 1.1 8.0
Fan nut 6 0.6 4.5
Cooling fan motor bolt 4 0.4 3.0
 ENGINE FUEL (K9K ENGINE) 6C2-1

SECTION 6C2
6-3
6A3

ENGINE FUEL 6G3

(K9K ENGINE) 6E3

6G3
6H3
WARNING: 6K3
For vehicles equipped with a Supplemental Restraint (Air Bag) System:
• Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under
“General Description” in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser-
vice Precautions” under “On-Vehicle Service” in air bag system section before performing service
on or around the air bag system components or wiring. Failure to follow WARNINGS could result in

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unintentional activation of the system or could render the system inoperative. Either of these two
conditions may result in severe injury.
• Technical service work must be started at least 90 seconds after the ignition switch is turned to the

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“LOCK” position and the negative cable is disconnected from the battery. Otherwise, the system
may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).

NOTE:
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For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the Service Man-
ual mentioned in “FOREWORD” of this manual.
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CONTENTS
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General Description ..................................... 6C2-* Fuel Tank Inspection.................................. 6C2-*

On-Vehicle Service....................................... 6C2-2 Fuel Tank Purging Procedure .................... 6C2-*
Fuel System Components .......................... 6C2-2 Fuel Level Gauge Assembly Removal
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Precautions ................................................ 6C2-* and Installation........................................... 6C2-* 6C2

Water Draining of Fuel Filter ...................... 6C2-3 Fuel Pipe Removal and Installation ........... 6C2-*
Air Bleeding of Fuel System ....................... 6C2-3 Fuel Level Gauge Inspection ..................... 6C2-*
Fuel Line Inspection ................................... 6C2-* Fuel Filter Removal and Installation........... 6C2-3
Fuel Filler Cap Inspection .......................... 6C2-* Special Tool.................................................. 6C2-*
Fuel Tank Components .............................. 6C2-* Tightening Torque Specification ................ 6C2-*
Fuel Tank Removal and Installation ........... 6C2-*
6C2-2 ENGINE FUEL (K9K ENGINE)

On-Vehicle Service
CAUTION:
• Do not expose removed fuel parts to dust. Keep them always clean.
• Be sure to read “Precautions in Fuel Delivery System” in Section 6E2 before disconnecting fuel line
or removing fuel system part(s).
Failure to follow its instruction could result unneeded fuel system repairs.

Fuel System Components

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[A]: Type A 4. Fuel level gauge assembly bolt 9. Priming pump 14. Fuel feed hose No.2
[B]: TypeB 5. Fuel tank 10. Fuel feed hose No.1 Tightening torque
 ENGINE FUEL (K9K ENGINE) 6C2-3

1. Fuel level gauge 6. Fuel feed line 11. Fuel return hose No.1 Do not reuse.

2. Fuel level gauge plate gasket 7. Fuel return line 12. Fuel filter
3. Fuel level gauge plate 8. Fuel feed hose No.2 13. Fuel return hose No.2

Water Draining of Fuel Filter

1) Disconnect negative (–) cable at battery.
2) Place container under bleed screw (1), and loosen bleed
screw.
1
3) Pump priming pump several times until fuel flow out from
bleed screw in order to drain water from fuel filter.
4) Tighten bleed screw.
5) Connect negative (–) cable at battery.

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Air Bleeding of Fuel System
Air bleeding must be carried out when fuel system has been dis-
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assembled or when vehicle ran out of fuel.
Pump priming pump (1) 20 times or more, and then check engine
starts.
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Fuel Filter Removal and Installation

NOTE:
Fuel filter can not disassemble.
Replace fuel filter as an assembly, if necessary.
6C2-4 ENGINE FUEL (K9K ENGINE)

Removal
1) Disconnect negative (–) cable at battery.
1 2) Pull out fuel hoses (1) with pushing lock button (2).
2

2 3) Install plugs (special tool) to openings of fuel filter (3) and

3
fuel hose (1) in order to prevent its internal parts from dust.
For detail, refer to “Precaution in Fuel Delivery System” in
Section 6E2.
4) Remove fuel filter (3) from its bracket.

Installation
Reverse removal procedure for installation noting the following.
• Bleed air in system referring to “Air Bleeding Procedure” in
this section.

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• Start engine and check that there are no fuel leakage.

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 ENGINE AND EMISSION CONTROL SYSTEM (K9K ENGINE) 6E2-1

SECTION 6E2
6-3
6E2

ENGINE AND EMISSION CONTROL SYSTEM 6B3

6C3

(K9K ENGINE) 6H3

6G3
6H3
WARNING: 6K3
For vehicles equipped with a Supplemental Restraint (Air Bag) System:
• Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Refer to “System Components and Wiring Location View and Connec-
tors” under “General Description” in Section 10B in order to confirm whether you are performing
service on or near the air bag system components or wiring. Please observe all WARNINGS and
“Service Precautions” under “On-Vehicle Service” in Section 10B before performing service on or
around the air bag system components or wiring. Failure to follow WARNINGS could result in unin-

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tentional activation of the system or could render the system inoperative. Either of these two condi-
tions may result in severe injury.
• Technical service work must be started at least 90 seconds after the ignition switch is turned to the

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“LOCK” position and the negative cable is disconnected from the battery. Otherwise, the system
may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).

NOTE:
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For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the Service Man-
ual mentioned in “FOREWORD” of this manual.
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CONTENTS
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General Description ..................................... 6E2-3 Venturi removal and installation ........... 6E2-25
System Diagram......................................... 6E2-3 Electronic Control System........................ 6E2-26
Electronic Control System .......................... 6E2-5 Engine control module (ECM) removal
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System wiring diagram ........................... 6E2-5 and installation ..................................... 6E2-26

System location diagram ........................ 6E2-8 ECM registration (Programming) ......... 6E2-28
Air Intake System ....................................... 6E2-9 Glow plug removal and installation ......... 6E2-*
Fuel Delivery System ............................... 6E2-10 Glow plug inspection ............................... 6E2-*
On-Vehicle Service..................................... 6E2-11 APP sensor removal and
installation ............................................ 6E2-30
Idle Speed Inspection............................... 6E2-11
APP sensor inspection ......................... 6E2-31
Fuel Delivery System ............................... 6E2-12
Fuel temperature sensor removal and
Precautions in fuel delivery system ...... 6E2-12
installation ............................................ 6E2-32
Fuel delivery system components ........ 6E2-15
Fuel temperature sensor
Fuel pressure relief confirmation
inspection ................................................ 6E2-*
procedure ............................................... 6E2-*
Fuel flow actuator removal and
Fuel leakage check ................................ 6E2-*
installation ............................................ 6E2-33
High pressure pipes removal and
Fuel flow actuator inspection................... 6E2-*
installation ............................................ 6E2-16
Engine coolant temperature sensor
Fuel injector on-vehicle inspection ......... 6E2-*
(ECT sensor) removal and
Fuel injector removal and
installation ............................................ 6E2-34
installation ............................................ 6E2-21
Engine coolant temperature sensor
Common rail (High pressure fuel
(ECT sensor) inspection.......................... 6E2-*
injection rail) removal and
Camshaft position sensor
installation .............................................. 6E2-*
(CMP sensor) removal and
Injection pump removal and
installation ............................................... 6E2-*
installation ............................................ 6E2-23
6E2-2 ENGINE AND EMISSION CONTROL SYSTEM (K9K ENGINE)

Crankshaft position (CKP) sensor Radiator fan control system

(engine speed sensor) removal and inspection............................................. 6E2-40
installation ............................................ 6E2-35 Main relay and radiator fan relay
Crankshaft position (CKP) sensor inspection................................................ 6E2-*
(engine speed sensor) inspection ........ 6E2-36 Pre-heating unit removal and
MAF and IAT sensor removal and installation ............................................... 6E2-*
installation ............................................ 6E2-37 Knock sensor removal and
MAF and IAT sensor inspection ........... 6E2-37 installation ............................................... 6E2-*
Boost pressure sensor removal and EGR valve removal and
installation ............................................ 6E2-38 installation ............................................ 6E2-40
Boost pressure sensor inspection ........ 6E2-38 EGR valve inspection........................... 6E2-40
Boost pressure control solenoid valve Tightening Torque Specification.............. 6E2-42
removal and installation ....................... 6E2-39 Special Tool ............................................... 6E2-42
Boost pressure control solenoid valve
inspection ............................................. 6E2-39

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 3 31
1
24
2
System Diagram

32

33

25
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4 34

22 35
27
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23
15 29
36
11 8
22 12
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10 9
37
16

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7 6
18

13 14
. 38
17
General Description

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23
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20 28 41
42 40

21
ENGINE AND EMISSION CONTROL SYSTEM (K9K ENGINE) 6E2-3
6E2-4 ENGINE AND EMISSION CONTROL SYSTEM (K9K ENGINE)

1. Air cleaner 15. Fuel pressure sensor 29. ECM

2. MAF and IAT sensor 16. Fuel temperature sensor 30. Barometric pressure sensor
3. Turbocharger 17. Fuel flow actuator 31. A/C pressure sensor (if equipped with A/C)
4. Intercooler 18. Injection pump 32. A/C relay (if equipped with A/C)
5. Boost pressure sensor 19. Fuel filter 33. VSS
6. EGR valve 20. Priming pump 34. Radiator fan relays
7. ECT sensor 21. Fuel tank 35. A/C compressor relay (if equipped with A/C)
8. Boost pressure control solenoid valve 22. Fuel feed line 36. Additional heater relays
9. Pre-heating unit 23. Fuel return line 37. Combination meter
10. Glow plug 24. Waste gate actuator 38. Ignition switch
11. Fuel injector 25. Catalytic converter 39. Main relay
12. CMP sensor 26. Vacuum pump 40. Battery
13. CKP sensor 27. Common rail (high pressure fuel injection rail) 41. APP sensor
14. Knock sensor 28. EGR cooler 42. Stop (brake) lamp switch

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 ENGINE AND EMISSION CONTROL SYSTEM (K9K ENGINE) 6E2-5

Electronic Control System

System wiring diagram

17 18
GRN/RED C48-3 E17-28 GRN/WHT
1 LT GRN/RED C48-9 21 19
E17-19 BRN
GRN/YEL C48-27
22
C48-14 WHT/BLK
2 YEL/GRN C48-23
23
C48-20 WHT/RED
12
24
3 PNK C47-23 C48-25 PLL/YEL
BLU C47-33 20

ORN C47-15 25
4 RED/BLK C47-25 26
BLK C47-35

5 BLK/YEL C47-22
PNK C47-32

C47-9 27
WHT C47-12
6 C47-13
BLK 29

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C48-11 GRN/WHT IG1
ORN C47-16
7 GRY/RED C47-26 28
E17-11 BLK/WHT
LT GRN/RED C47-36 IG2
30

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C48-21 BRN
WHT C47-5 BRN
8-1 BLU C47-8 31
32
8 RED/WHT C47-17 E17-13 BLK/BLU
8-2 RED/YEL C47-27 GRN
LT GRN/RED C47-37
. L+ 33
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H+
BLU/RED C47-21 49
9 BLU/WHT C47-31

20 E17-12 BLK/YEL
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34
PPL WHT E17-32
C47-24 YEL
C47-34 35
BRN
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C47-7 GRN/BLK 36

PNK RED E17-26 C47-3 GRN/WHT 37

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PNK/GRN E17-31
C47-18 LT GRN
C47-28 LT GRN/BLK
11 YEL/BLK C48-2 38
C47-19 BLU/BLK
C47-38 LT GRN/RED
BLK/RED
39
BRN/WHT E17-4 C48-15 YEL/BLK
WHT/RED E17-3 42 BLK/BLU
RED E17-5
12 RED/WHT E17-15 40
RED/YEL E17-21 C48-16 YEL/RED
PNK/BLK E17-27 42 RED/WHT

41
BLK/YEL C47-48
13 BLU/YEL C47-47 42 RED
43
BLK/ORN C47-42
14 C47-41
BLU/ORN C48-24 BLU/BLK BLK/YEL
E17-2 BLK/RED
C48-29 BLK/RED
BLK/WHT C47-46 C48-30 BLK/RED
15
BLU/WHT C47-45 C48-10 BRN/WHT
C48-18 BLU
BLK/RED C47-44 WHT
16 44
BLU/RED C47-43 45 WHT/BLK
WHT/GRN 46
WHT/BLU
E17-1 BLK
E17-6 BLK
E17-7 BLK : 47
E17-8 BLK : 48
6E2-6 ENGINE AND EMISSION CONTROL SYSTEM (K9K ENGINE)

1. A/C pressure sensor (if equipped with 16. Fuel injector No.4 33. Radiator fan relay No.2
A/C)
2. VSS 17. ECM 34. Radiator fan relay No.3
3. CKP sensor 18. Stop (brake) lamp switch 35. CMP sensor
4. Fuel pressure sensor 19. Stop (brake) lamp 36. Fuel flow actuator
5. Fuel temperature sensor 20. Combination meter 37. Boost pressure control solenoid valve
6. Knock sensor 21. Tachometer 38. MAF and IAT sensor
7. Boost pressure sensor 22. Injection warning light (gravity 1 fault) 39. Additional heater relay No.1
8. EGR valve 23. Red stop warning light (gravity 2 fault) 40. Additional heater relay No.2
8-1. EGR valve motor 24. Malfunction indicator lamp (MIL) 41. Additional heater relay No.3
8-2. EGR valve position sensor 25. Heater blower motor 42. Additional heater plug
9. ECT sensor 26. Heater control lever assembly 43. Main relay
10. Data link connector 27. A/C evaporator temperature sensor (if equipped with A/C) 44. Pre-heating unit
11. Immobilizer control module 28. Ignition switch 45. Glow plug
12. APP sensor 29. A/C relay (if equipped with A/C) 46. Battery
13. Fuel injector No.1 30. A/C compressor relay (if equipped with A/C) 47. Body ground
14. Fuel injector No.2 31. A/C compressor (if equipped with A/C) 48. Engine ground
15. Fuel injector No.3 32. Radiator fan relay No.1 49. Radiator cooling fan motor

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 ENGINE AND EMISSION CONTROL SYSTEM (K9K ENGINE) 6E2-7

ECM Connector (Terminal Arrangement Viewed from Harness Side)

C48 C47 E17

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

TERMINAL CIRCUIT TERMINAL CIRCUIT TERMINAL CIRCUIT

1 – 6 – 45 Fuel injector No.3 output (low side)
2 Main power supply 7 Fuel flow actuator output 46 Fuel injector No.3 output (high side)
C47
3 APP sensor 1 signal 8 EGR valve output (–) 47 Fuel injector No.1 output (low side)
4 Power source for APP sensor 1 9 Ground of shield wire for knock sensor 48 Fuel injector No.1 output (high side)

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5 Ground for APP sensor 1 10 – 1 –
6 Ground for ECM 11 – 2 Immobilizer control module input
7 Ground for ECM 12 Knock sensor signal 3 Power source for A/C pressure sensor

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8 Ground for ECM 13 Ground for knock sensor 4 –
9 – 14 – 5 –
10 – 15 Power source for fuel pressure sensor 6 –
11 Ignition switch signal 16 Power source for boost pressure sensor 7 –
12 Radiator fan relay No.2 and No.3 output Power source for potentiometer in EGR 8 –
13 Radiator fan relay No.1 output
. 17 valve
9 A/C pressure sensor signal
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14 – 18 Power source for MAF sensor 10 Pre-heating unit diagnosis input
15 Power source for APP sensor 2 19 IAT sensor signal 11 A/C relay signal
16 – 20 – 12 –
17 – 21 ECT sensor signal 13 –
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18 – 22 Fuel temperature sensor signal 14 Injection warning light (gravity 1 fault)

Engine revolution signal for combination 23 CKP sensor signal 15 Additional heater relay No.1 output
19 meter
24 CMP sensor signal 16 Additional heater relay No.2 output
C47
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20 – 25 Fuel pressure sensor signal C48 17 –

21 APP sensor 2 signal 26 Boost pressure sensor signal 18 Pre-heating unit output
22 – 27 Signal for potentiometer in EGR valve 19 –
23 – 28 MAF sensor signal 20 Red stop warning light (gravity 2 fault)
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24 – 29 – 21 A/C compressor relay output

25 – 30 – 22 –
26 CAN line (high) 31 Ground for ECT sensor 23 VSS signal
27 Ground for APP sensor 2 32 Ground for fuel temperature sensor 24 Main relay output
28 Stop (brake) lamp switch 33 Ground for CKP sensor 25 Malfunction indicator lamp
29 – 34 Ground for CMP sensor 26 –
30 – 35 Ground for fuel pressure sensor 27 Ground for A/C pressure sensor
Serial communication line of data link 36 Ground for boost pressure sensor 28 –
31 connector 12 V
37 Ground for potentiometer in EGR valve 29 Main power supply
32 CAN line (low) 38 Ground for MAF and IAT sensor 30 Main power supply
1 – 39 – 31 –
2 – 40 – 32 –
Boost pressure control solenoid valve 41 Fuel injector No.2 output (low side)
C47 3 output
42 Fuel injector No.2 output (high side)
4 – 43 Fuel injector No.4 output (low side)
5 EGR valve output (+) 44 Fuel injector No.4 output (high side)
6E2-8 ENGINE AND EMISSION CONTROL SYSTEM (K9K ENGINE)

System location diagram

7 e

d
B f
9
c
p
14
j E
4 6
r 13
1 5
2 8

q
o
D

a
h
q b
s
g l

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11 m
12
n

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INFORMATION SENSORS CONTROLLED DEVICES OTHERS

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1. Boost pressure sensor a: Fuel injector A: ECM

2. Fuel pressure sensor b: Fuel flow actuator B: Data link connector
3. CMP sensor c: Malfunction indicator lamp C: Pre-heating unit
4. CKP sensor d: Injection warning light (gravity 1 fault) D: Main fuse box
5. ECT sensor e: Glow lamp E: Circuit fuse box
6. APP sensor f: Red stop warning light (gravity 2 fault)
7. VSS g: A/C relay (if equipped)
8. Knock sensor h: A/C compressor relay (if equipped)
9. Immobilizer control module i: Additional heater plug
10. A/C pressure sensor j: Additional heater relay No.1
11. MAF and IAT sensor k: Radiator fan relay No.1 (low)
12. Fuel temperature sensor l: Radiator fan relay No.2 (high)
13. Stop (brake) lamp switch m: Radiator fan relay No.3 (high)
14. A/C evaporator temperature sensor n: Main relay
o: EGR valve
p: Additional heater relay No.2
q: Glow plug
r: Additional heater relay No.3
s: Boost pressure control solenoid valve
 ENGINE AND EMISSION CONTROL SYSTEM (K9K ENGINE) 6E2-9

Air Intake System

3
1
11
2

4
12 5

10

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1. Air cleaner 4. Intercooler 7. Boost pressure control solenoid valve

2. MAF and IAT sensor 5. Boost pressure sensor 8. Vacuum pump
3. Turbocharger 6. EGR valve 9. Waste gate actuator
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3. Oil vapor recirculation valve 6. EGR cooler 9. Catalytic converter

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6E2-10 ENGINE AND EMISSION CONTROL SYSTEM (K9K ENGINE)

Fuel Delivery System

5
8

10
3

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: [A]
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: [B]
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1. Fuel tank 6. Common rail (High pressure fuel injection rail) [A]: Fuel feed line
2. Priming pump 7. Fuel injector [B]: Fuel return line
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3. Fuel filter 8. Fuel flow actuator

4. Fuel temperature sensor 9. Venturi
5. Injection pump (including high and low pressure pumps) 10. Fuel pressure sensor
 ENGINE AND EMISSION CONTROL SYSTEM (K9K ENGINE) 6E2-11

On-Vehicle Service
Idle Speed Inspection
1) Shift transmission into Neutral.
2) Start engine and warm it up to normal operating tempera-
ture.
3) Turn all electrical loads off.
4) Using SUZUKI scan tool, verify that idle speed is within
specification.
Engine speed: 730 – 880 rpm
5) If not, refer to “Table 5 Rough Idle Speed (Pumping)” or
“Table 6 Idle Speed Too High or Too Low” in Section 6-2.

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6E2-12 ENGINE AND EMISSION CONTROL SYSTEM (K9K ENGINE)

Fuel Delivery System

WARNING:
• Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel. Fuel line spills and leaks are dangerous. Fuel can ignite and
cause serious injuries or death and damage.
• Fuel can also irritate skin and eyes. To prevent this, always complete the following “Precautions”.
• Never disconnect fuel high-pressure line between injection pump and injectors under pressure, or
fuel can be sprayed out under pressure.
Be sure to confirm that fuel high-pressure line is not under pressure referring “Fuel pressure relief
confirmation procedure” in this section before disconnecting. If it is under pressure, wait till it is
not under pressure.

CAUTION:
Before servicing the fuel delivery system, read all contents described in “Precautions in Fuel Delivery
System”; otherwise not only the fuel delivery system but also the engine might be damaged.

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Precautions in fuel delivery system

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• The system is very sensitive to contamination. The risks caused by the introduction of contamination are:
– damage or destruction of the high pressure injection system and the engine.
– seizing or leaking of a component. .
• When servicing on the high pressure direct injection system, must be performed under very clean condi-
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tions. This means that no impurities (particles a few microns in side) get into the system during dismantling
or into the circuits via the fuel unions.
• The cleanliness principle must be applied from the filter to the injectors.
• Contamination is caused by:
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– metal or plastic chips,

– paint,
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– fibres: boxes, brushes, paper, clothing, cloths,

– foreign bodies such as hair,
– ambient air,
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– etc.
• It is not possible to clean the engine using a high pressure washer because of the risk of damaging connec-
tions. In addition, moisture may collect in the connectors and create electrical connection problems.
• The system can inject the diesel into the engine at a pressure up to 1600 bars. Before carrying out any work,
check that the injector rail is not under pressure and that the fuel temperature is not too high.
 ENGINE AND EMISSION CONTROL SYSTEM (K9K ENGINE) 6E2-13

Instructions to be Followed Before Any Work is Carried out on The Injection System
• Ensure that you have the plugs (1) for the unions to be opened. Plugs are to be used once only. After use,
they must be thrown away (once used they are soiled and cleaning is not sufficient to make them reusable).
Unused plugs must be thrown away.

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1. Plug (Cap set available as a spare part: parts number 15733-84A00)

Do not reuse.
6E2-14 ENGINE AND EMISSION CONTROL SYSTEM (K9K ENGINE)

• Ensure that you have hermetically resealable plastic bags for storing removed parts. Stored parts will there-
fore be less subject to the risk of impurities. The bags must be used only once, and after use they must be
thrown away.

• Make sure that lint-free towelettes. The use of a normal cloth or paper for cleaning purposes is forbidden.
These are not lint-free and may contaminate the fuel circuit of the system. Each lint-free cloth should only be
used once.

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Instructions to be Followed Before Opening The Fuel Circuit
• For each operation, use new thinner (used thinner contains impurities). Pour it into a clean receptacle.

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• For each operation, use a clean brush which is in good condition (the brush must not shed its bristles).
• Use a brush and thinners to clean the connections to be opened.
• Blow compressed air over the cleaned parts (tools, cleaned the same way as the parts, connections and
.
injection system zone). Check that no bristles remain adhered.
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• Wash your hands before and during the operation if necessary.
• When wearing leather protective gloves, cover these with latex gloves.
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Instructions to be Followed During The Operation

• As soon as the circuit is open, all openings must be plugged to prevent impurities from entering the system
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by using plug (available as a spare part). They must not, under any circumstances, be reused.
• Close the hermetically sealed bag, even if it has to be reopened shortly afterwards. Ambient air carries con-
tamination.
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• All components of the injection system that are removed must be stored in a hermetically sealed plastic bag
once the plugs have been inserted.
• The use of a brush, thinner, bellows, sponge or normal cloth is strictly forbidden once the circuit has been
opened.
These items are likely to allow impurities to enter the system.
• A new component replacing an old one must not be removed from its packaging until it is to be fitted to the
vehicle.
 ENGINE AND EMISSION CONTROL SYSTEM (K9K ENGINE) 6E2-15

Fuel delivery system components

6 (a)
6 (a)

1
7 17

10

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12 (d)
13 8 18

5 (b)
2

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19
9 (b)

15
3
16 (c)
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14 (c)
11 6 (a)
21 20
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1. Fuel return hose 8. Common rail 15. Venturi : 38 N·m (3.8 kg-m, 27.5 lb-ft)
: Apply oil (spare parts) to O-ring.

2. Fuel injector 9. Common rail nut 16. Venturi bolt : 28 N·m (2.8 kg-m, 20.5 lb-ft)

3. Sealing washer 10. Fuel pressure sensor 17. Fuel feed hose : 5.5 N·m (0.55 kg-m, 4.0 lb-ft)
: It is not possible to remove fuel
pressure sensor from common rail.
4. Fuel injector bracket 11. Injection pump 18. Fuel filter : 15 N·m (1.5 kg-m, 11.0 lb-ft)

5. Fuel injector bolt 12. Fuel temperature sensor 19. Priming pump : Do not reuse.
: Apply oil (spare parts) to O-ring.

6. High pressure pipe 13. Fuel flow actuator 20. To fuel feed pipe
: Apply oil (spare parts) to O-ring.

7. Clip 14. Fuel flow actuator bolt 21. To fuel return pipe
6E2-16 ENGINE AND EMISSION CONTROL SYSTEM (K9K ENGINE)

High pressure pipes removal and installation

Removal
1) Check that engine is cold and fuel pressure is not under
pressure referring to “Fuel Pressure Relief Confirmation Pro-
cedure” in this section.
2) Disconnect negative cable at battery.
3) Remove injector cover.

1 4) Remove oil level gauge guide (1) and injector cover bracket
(2).

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5) Loosen common rail nuts (1) a few turns.

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6) Remove clip (1) connecting high pressure pipes.

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 ENGINE AND EMISSION CONTROL SYSTEM (K9K ENGINE) 6E2-17

7) Remove high pressure pipes as follows.

(A) a) For fuel injector – common rail pipe

1
i) Loosen union nut of fuel injector side (1).
ii) Loosen union nut of common rail side (2).

CAUTION:
4 When loosing union nut of fuel injector side, hold fuel
injector with wrench (3) as shown.
3 2 Do not damage fuel return pipe (4) of fuel injector.

Special tool
(A): 09911-78110

(A)

m
iii) Move union nut (1) along pipe keeping flange part (2) in

co
contact with taper (3).
1 .
gn
2

3
ia

b) For injection pump – common rail pipe

rd

i) Loosen union nut of injection pump side (1).

(A) 1 ii) Loosen union nut of common rail side (2).
ca

Special tool
2 (A): 09911-78110
(A)

iii) Move union nut (1) along pipe keeping flange part (2) in
contact with taper (3).
1

3
6E2-18 ENGINE AND EMISSION CONTROL SYSTEM (K9K ENGINE)

8) Plug all joint part of disconnected fuel injection circuit with

cap available as a spare part to prevent them from entering
dust. (Refer to “Precautions in Fuel Delivery System” in this
section for parts number and handling).

Installation

CAUTION:
Do not reuse high pressure pipe because it has the pos-
sibility that fuel leaks out.

m
CAUTION:
In case of using extension special tool combined with

co
torque wrench, reading value of torque wrench is smaller
L1
than specified tightening torque. When using extension
special tool, reading value should be calculated accord-
. ing to below formula.
gn
L
Tightening torque formula
M = T x L/(L + L1)
ia

(A) M: Reading value using extension special tool

1 T: Specified tightening torque
L: Length of torque wrench
rd

L1: Length of special tool

ca

NOTE:
Fit injection pump – common rail pipe before common
rail - fuel injector pipes.

1) Remove high pressure pipes as follows.

a) For fuel injector – common rail pipe
i) Remove plugs (dust preventing cap) from common rail
outlet and fuel injector inlet.
ii) Insert high pressure pipe flange part (1) into taper (2) of
fuel injector inlet.
iii) Insert high pressure pipe flange part (1) into taper (2) of
common rail outlet.

2
 ENGINE AND EMISSION CONTROL SYSTEM (K9K ENGINE) 6E2-19

iv) Tighten fuel injector union nut (1) then common rail union
nut (2) by hand.
v) Install new clip (3) to high pressure pipes.
vi) Tighten fuel injector union nut then common rail union nut
to specified torque using special tool.
(A) 1, (a)
3 CAUTION:
• Do not touch pipes with wrench when tightening union
nuts.
• When tightening union nut of fuel injector side, hold
5 fuel injector with wrench (4) as shown.
• Do not damage fuel return pipe (5) of fuel injector.
4 2, (a)
Special tool
(A): 09911-78110

Tightening torque

m
High pressure pipe union nut
(a): 38 N·m (3.8 kg-m, 27.5 lb-ft) (See NOTE below.)

co
(A)
NOTE:
In case of using extension special tool combined with
. torque wrench, reading torque depends on the length of
the torque wrench.
gn
Therefore, calculate reading torque by using “Tightening
Torque Formula” described earlier in this installation pro-
cedure.
ia

b) For injection pump – common rail pipe

i) Remove plugs (dust prevent cap) from common rail outlet
rd

and fuel injector inlet.

ii) Insert high pressure pipe flange part (1) into taper (2) of
fuel injector inlet.
ca

iii) Insert high pressure pipe flange part (1) into taper (2) of
common rail outlet.

2
6E2-20 ENGINE AND EMISSION CONTROL SYSTEM (K9K ENGINE)

iv) Tighten common rail union nut (1) then injection pump
union nut (2) by hand.
v) Tighten common rail union nut then injection pump union
2, (a)
(A) nut to specified torque using special tool.

CAUTION:
Do not touch pipes with wrench when tightening union
nuts.

Special tool
(A): 09911-78110

Tightening torque
High pressure pipe union nut
1, (a) (a): 38 N·m (3.8 kg-m, 27.5 lb-ft) (See NOTE below.)
(A)
NOTE:

m
In case of using extension special tool combined with
torque wrench, reading torque depends on the length of
the torque wrench.

co
Therefore, calculate reading torque by using “Tightening
Torque Formula” described earlier in this installation pro-
cedure.
.
gn
2) Tighten common rail nuts to specified torque.
Tightening torque
ia

Common rail nut

(a): 28 N·m (2.8 kg-m, 20.5 lb-ft)
rd
ca

(a)

2 3) Install injector cover bracket (1) and oil level gauge guide (2).
Tighten oil level gauge guide nuts to specified torque.
Tightening torque
(b) Injector cover bracket nut
(a): 12 N·m (1.2 kg-m, 9.0 lb-ft)
Oil level gauge guide nut
1 (b): 21 N·m (2.1 kg-m, 15.5 lb-ft)

(a)
 ENGINE AND EMISSION CONTROL SYSTEM (K9K ENGINE) 6E2-21

4) Install injector cover.

5) Connect negative cable to battery.
6) Check fuel leakage referring to “Fuel Leakage Check” in this
section.

Fuel injector removal and installation

NOTE:
The calibration code (1) is the code that is given to each
fuel injector, and it represents the performance charac-
teristics of the fuel injector. It is registered in ECM, and
ECM controls fuel injection according to the performance
characteristics of the fuel injector. Therefore, after
removing fuel injectors, be sure to install them as they
were. In case that the fuel injectors were replaced with
new ones, be sure to register each calibration code in
ECM referring to “Fuel Injector Registration” under “ECM

m
Registration (Programming)” in this section. If it is not
registered correctly, DTC is stored in ECM and warning
light is turned ON. Also calibration codes registration in

co
ECM can be checked by SUZUKI scan tool.
.
gn
Removal
1) Check that engine is cold and fuel pressure is not under
pressure referring to “Fuel Pressure Relief Confirmation Pro-
cedure” in this section.
ia

2) Disconnect negative (–) cable at battery.

3) Remove injector cover.
rd

2 4) Disconnect fuel injector connector (1).

5) Disconnect return hose (2) from fuel injector.
ca

1
1

6) Plug fuel return pipe of fuel injector with cap available as a

spare part to prevent them from entering dust. (Refer to “Pre-
cautions in Fuel Delivery System” in this section for parts
number and handling.)
6E2-22 ENGINE AND EMISSION CONTROL SYSTEM (K9K ENGINE)

7) Remove high pressure pipe referring to “High Pressure

Pipes Removal and Installation” in this section.
8) Remove fuel injector (1) from cylinder head.
1 9) Remove searing washer from cylinder head hole.
10) Plug fuel injector nozzle with cap available as a spare part to
prevent them from entering dust. (Refer to “Precautions in
Fuel Delivery System” in this section for parts number and
handling.)

Installation
1) Clean fuel injector installing hole of cylinder head, fuel injec-
tor body and fuel injector bracket using a lint-free cloth
dipped in clean solvent.

m
2) Remove plug (dust preventing cap) (1) from fuel injector noz-
zle.

co
3) Install new searing washer to cylinder head.
4) Install fuel injector to cylinder head.
(a)
. Tighten fuel injector bracket bolt to specified torque.
Tightening torque
gn
Fuel injector bracket bolt
1
(a): 28 N·m (2.8 kg-m, 20.5 lb-ft)
ia

5) Install new high pressure pipe referring to “High Pressure

Pipes Removal and Installation” in this section.
rd

6) Remove plug (dust preventing cap) (1) from fuel return pipe
of fuel injector.
ca

2 7) Connect return hose (2) to fuel injector.

8) Connect fuel injector connector (1).
9) Install injector cover.

1
1
 ENGINE AND EMISSION CONTROL SYSTEM (K9K ENGINE) 6E2-23

10) Connect negative cable to battery.

11) Check fuel leakage referring to “Fuel Leakage Check” in this
section.

Injection pump removal and installation

NOTE:
After replacing injection pump, perform “High Pressure
Pump Data Initialization” using SUZUKI scan tool.

Removal
1) Check that engine is cold and fuel pressure is not under
pressure referring to “Fuel Pressure Relief Confirmation Pro-
cedure” in this section.
2) Disconnect negative cable at battery.
3) Remove timing belt referring to “Timing Belt and Belt Ten-

m
sioner Removal and Installation” in Section 6A2.
4
3
4) Disconnect connectors from fuel flow actuator (1) and fuel

co
2 temperature sensor (2).
1
5) Disconnect fuel feed hose (3) and fuel return hoses (4) from
injection pump.
6) Remove high pressure pipe (5) referring to “High Pressure
.
gn
Pipes Removal and Installation” in this section.
ia

1
rd

7) Remove injection pump pulley (1) as follows, if necessary.

a) Remove injection pump pulley nut.
b) Remove injection pump pulley using puller (2).
ca

CAUTION:
Be sure to apply claws of puller to the specified positions
on pulley indicated in figure. Applying to the other posi-
tions may break pulley.

2
6E2-24 ENGINE AND EMISSION CONTROL SYSTEM (K9K ENGINE)

8) Plug all joint part of disconnected fuel injection circuit with

cap available as a spare part to prevent them from entering
dust. (Refer to “Precautions in Fuel Delivery System” in this
section for parts number and handling.)
9) Remove injection pump (1) from cylinder head by removing
3 bolts (2).

Installation
Reverse removal procedure for installation noting the following.

m
(a) • Tighten injection pump bolts to specified torque.
Tightening torque

co
Injection pump bolt (a): 27 N·m (2.7 kg-m, 19.5 lb-ft)

.
gn
(a)
ia

• Install injection pump pulley (4) to injection pump (2) aligning

3
key (3) to groove (1).
rd

1
2

4
ca

(a) • Tighten injection pulley nut to specified torque.

Tightening torque
Injection pump pulley nut (a): 15 N·m (1.5 kg-m, 11.0 lb-ft)
and 60° by the specified procedure.
 ENGINE AND EMISSION CONTROL SYSTEM (K9K ENGINE) 6E2-25

• Install new high pressure pipe referring to “High Pressure

Pipes Removal and Installation” in this section.
• Install timing belt referring to “Timing Belt and Belt Tensioner
Removal and Installation” in Section 6A2.
• Check fuel leakage referring to “Fuel Leakage Check” in this
section.
• Perform “High Pressure Pump Data Initialization” under
“ECM Registration (Programming)” in this section.

Venturi removal and installation

Removal
1) Check that engine is cold and fuel pressure is not under
pressure referring to “Fuel Pressure Relief Confirmation Pro-
cedure” in this section.
2) Remove injector cover.
3) Disconnect return hoses (1) from venturi (2) on injection

m
pump.
4) Plug disconnected hose and venturi on injection pump with
cap available as a spare part to prevent them from entering

co
dust. (Refer to “Precautions in Fuel Delivery System” in this
section for parts number and handling.)
5) Remove venturi from injection pump.
.
gn
Installation
ia

Reverse removal procedure for installation noting the following.

• Apply oil (spare parts) to O-ring (1) of venturi.
rd

• Be careful not to damage O-ring when installing venturi.

1
ca

• Tighten venturi bolt to specified torque.

Tightening torque
Venturi bolt (a): 5.5 N·m (0.55 kg-m, 4.0 lb-ft)

(a)

• Check fuel leakage referring to “Fuel Leakage Check” in this

section.
6E2-26 ENGINE AND EMISSION CONTROL SYSTEM (K9K ENGINE)

Electronic Control System

Engine control module (ECM) removal and installa-
tion

CAUTION:
As ECM consists of precision parts, be careful not to
expose it to excessive shock.

NOTE:
• When ECM and immobilizer control module with a tran-
sponder code registered are connected and the igni-
tion switch is turned on, immobilizer control module
code is registered in ECM automatically. Note that
immobilizer control module code registered in ECM
cannot be erased or overwritten and that the ECM hav-
ing the registered immobilizer control module code
cannot be reused for another vehicle.

m
• When ECM is replaced with a new one, program new
ECM and register engine and vehicle information refer-

co
ring to “ECM Registration (Programming)” in this sec-
tion.

Removal
.
gn
1) Disconnect negative cable at battery.
2) Detach pre-heating unit (1), relay box (2) and harness con-
nectors (3) from ECM bracket.
ia

4 3) Disconnect ground wire harness (4) from vehicle body.

2
rd

3
ca

4) Disconnect connectors from ECM in order of “E17”, “C47”

“C48”
and “C48” as follows.
“C47”
“E17” a) Push lock (1) to release locking of lock lever (2).
b) Turn the lock lever to arrow direction until it stops.

2 2
1
 ENGINE AND EMISSION CONTROL SYSTEM (K9K ENGINE) 6E2-27

5) Remove ECM (1) from ECM bracket (2).

2

Installation
Reverse removal procedure for installation.

NOTE:
When installing new ECM, perform “Registration for ECM

m
Replacement” in this section.

. co
gn
ia
rd
ca
6E2-28 ENGINE AND EMISSION CONTROL SYSTEM (K9K ENGINE)

ECM registration (Programming)

NOTE:
New ECM itself has no program to control engine in it. After replacing ECM with a new one, be sure to
write engine control program in it first and then input engine and vehicle information.

The following information is registered and calibrated in ECM.

• Fuel injector calibration codes
• Vehicle variant (equipment such as additional heater plug, air conditioning and VSS)
• Injection correction data
• Air charge data
• Engine control data
• EGR valve data
• High pressure pump data

If any one of the following parts is replaced, register or initialize the necessary information in ECM as shown in
table below.

m
Replacement part Registered/Initialized data Reference
NOTE:

co
Before registering following data, make
sure that engine control program has
been written in ECM.
.
Engine and vehicle information: Go to “Registration for ECM
gn
ECM
• Fuel injector calibration codes Replacement”.
• Vehicle variant
• Injection correction data
ia

• Air charge data

• Engine control data
rd

Fuel injector(s) Fuel injector calibration code(s) Go to “Fuel Injector Registration”.

Go to “EGR Valve Data Initializa-
EGR valve EGR valve data
tion”.
ca

Go to “High Pressure Pump Data

High pressure pump High pressure pump data
Initialization”.
 ENGINE AND EMISSION CONTROL SYSTEM (K9K ENGINE) 6E2-29

Registration for ECM Replacement

NOTE:
• If engine and vehicle information cannot be downloaded from ECM due to ECM malfunction register
“Fuel injector calibration codes” and “Vehicle variant” in new ECM manually according to “Fuel
Injector Registration” and “Vehicle Variant Registration” and perform “High Pressure Pump Data
Initialization” instructed by SUZUKI scan tool.
• For details of SUZUKI scan tool, reprogramming tool or software referring to its operator’s manual.

1) Replace ECM with new one referring to “ECM Removal and Installation” in this section.
2) Using Suzuki Pass-Thru Reprogramming Software and Suzuki Pass-Thru Reprogramming Tool, program
new ECM by writing data (Calibration file) in it referring to “Suzuki Pass-Thru Reprogramming Tool Opera-
tor’s Manual”.
3) Register data (engine and vehicle information) saved in memory of previous ECM (ECM installed in vehicle
being repaired) in new ECM according to procedure described below.
a) Replace new ECM once installed to vehicle with previous ECM.
b) Upload “fuel injector calibration codes” registered in previous ECM into SUZUKI scan tool.

m
c) Replace previous ECM with new ECM programmed in step 2) and download “Fuel injector calibration
codes” in SUZUKI scan tool to new ECM.
4) Using same procedure of above steps a), b) and c), download following data into new ECM one by one.

co
– Injection correction data
– Air charge data
– Engine control data .
5) Register “Vehicle variant” in new ECM using SUZUKI scan tool.
gn
Fuel Injector Registration
In case of the following, register “Fuel injector calibration code” of each fuel injector manually in ECM, by read-
ia

ing fuel injector calibration code on each fuel injector using SUZUKI scan tool.
• After one or more fuel injector(s) is replaced
• If engine and vehicle information (“fuel injector calibration codes”) cannot be downloaded from ECM
rd

Vehicle Variant Registration

ca

In case of the followings, register vehicle variant (equipment such as additional heater plug, air conditioning and
VSS) by using SUZUKI scan tool.
• When ECM is replaced.
• When vehicle equipment is added or removed.

EGR Valve Data Initialization

After EGR valve is replaced with new one or used one, initialize valve position by using SUZUKI scan tool.

High Pressure Pump Data Initialization

After high pressure pump (Injection pump) is replaced, initialize fuel volume information in high pressure pump
by using SUZUKI scan tool.
6E2-30 ENGINE AND EMISSION CONTROL SYSTEM (K9K ENGINE)

APP sensor removal and installation

Removal
1) Disconnect negative cable at battery.
2) Disconnect connector (1) from APP sensor by pulling the
2
lock lever (2).
1
3) Remove accelerator pedal assembly from accelerator pedal
3
bracket.

Installation

m
Reverse removal procedure for installation noting the followings.
• Connect APP sensor connector securely.

co
• Tighten accelerator pedal assembly mounting bolts to speci-
fied torque.
(a) . Tightening torque
gn
Accelerator pedal mounting bolt
(a): 6 N·m (6.0 kg-m, 4.5 lb-ft)
ia
rd
ca
 ENGINE AND EMISSION CONTROL SYSTEM (K9K ENGINE) 6E2-31

APP sensor inspection

1) Disconnect negative cable at battery.
2) Remove accelerator pedal assembly referring to “APP Sen-
sor Removal and Installation” in this section.
3) Using ohmmeter, check resistance between terminals under
each condition given in table below.
If check result is not satisfactory, replace accelerator pedal
assembly.
1 2 3 4 5 6

APP sensor resistance

TERMINALS RESISTANCE
Between 3 and 5 0.67 – 1.69 kΩ
terminals
APP
1.134 – 1.018 kΩ, varying
sensor 1 Between 4 and 5
according to accelerator
[A] terminals
3 pedal depressing.

m
Between 2 and 6 1.17 – 2.48 kΩ
4
terminals
APP

co
5 1.100 – 1.796 kΩ, varying
sensor 2 Between 1 and 6
according to accelerator
[B] terminals
2 . pedal depressing.
[A]: APP sensor 1
1
gn
[B]: APP sensor 2
6 1. Output voltage terminal (APP sensor 2)
2. Reference voltage terminal (APP sensor 2)
3. Reference voltage terminal (APP sensor 1)
4. Output voltage terminal (APP sensor 1)
ia

5. Ground terminal (APP sensor 1)

6. Ground terminal (APP sensor 2)
rd

4) Connect pedal position sensor connector securely.

5) Connect negative cable to battery.
ca
6E2-32 ENGINE AND EMISSION CONTROL SYSTEM (K9K ENGINE)

Fuel temperature sensor removal and installation

Removal
1) Check that engine is cold and fuel pressure is not under
pressure referring to “Fuel Pressure Relief Confirmation Pro-
cedure” in this section.
2) Disconnect negative (–) cable at battery.
3) Remove injector cover.
2 4) Disconnect fuel temperature sensor connector (1).
1 5) Remove fuel temperature sensor (2) from injection pump.

m
Installation

. sor.
co
1) Apply oil (spare parts) to O-ring (1) of fuel temperature sen-
gn
1
ia
rd

2) Install fuel temperature sensor (2) to injection pump.

2, (a)
Tighten fuel temperature sensor to specified torque.
ca

1
CAUTION:
Be careful not to damage O-ring when installing fuel tem-
perature sensor.

Tightening torque
Fuel temperature sensor
(a): 15 N·m (1.5 kg-m, 11.0 lb-ft)
3) Connect fuel temperature sensor connector (1).
4) Install injector cover.
5) Connect negative cable to battery.
6) Check fuel leakage referring to “Fuel Leakage Check” in this
section.
 ENGINE AND EMISSION CONTROL SYSTEM (K9K ENGINE) 6E2-33

Fuel flow actuator removal and installation

Removal
1) Check that engine is cold and fuel pressure is not under
pressure referring to “Fuel Pressure Relief Confirmation Pro-
cedure” in this section.
2) Disconnect negative (–) cable at battery.
3) Remove injector cover.
4) Remove injector cover.
3
5) Disconnect fuel injector connectors (1) and glow plug con-
nectors (2) of No.3 and No.4 cylinders.
6) Remove high pressure pipe (3) of No.4 cylinder referring to
“High Pressure Pipes Removal and Installation” in this sec-
tion.

m
2

7) Disconnect return hose (1) from venturi (2) on injection

co
pump.
8) Plug disconnected hose and venturi of injection pump with
cap available as a spare part to prevent them from entering
. dust. (Refer to “Precautions in Fuel Delivery System” in this
gn
section for parts number and handling.)
ia
rd

1 9) Disconnect connectors from fuel temperature sensor (1) and

fuel flow actuator (2).
10) Remove fuel flow actuator screws (3).
ca

11) Pull out fuel flow actuator by hand using small successive
turns.

CAUTION:
3 3 Do not use fuel flow actuator connector as a lever arm
2
when turning fuel flow actuator.
6E2-34 ENGINE AND EMISSION CONTROL SYSTEM (K9K ENGINE)

Installation
For installation, reverse removal procedure noting the following.
• Do not apply to O-rings of fuel flow actuator with grease or
used diesel oil. Apply oil (spare parts) to O-ring of fuel flow
actuator.

• Tighten fuel flow actuator bolts to specified torque.

Tightening torque
Fuel flow actuator bolt

m
(a): 5.5 N·m (0.55 kg-m, 4.0 lb-ft)

(a) (a)
. co
gn
• Use new high pressure pipe of No.4 cylinder referring to
“High Pressure Pipes Removal and Installation” in this sec-
tion.
ia

• Check fuel leakage referring to “Fuel Leakage Check” in this

section.
rd

Engine coolant temperature sensor (ECT sensor)

removal and installation
ca

Removal
1) Disconnect negative (–) cable at battery.
2) Drain cooling system.
3) Remove EGR valve referring to “EGR Valve and Intake Pipe
Removal and Installation” in Section 6A2.
4) Disconnect ECT sensor connector (1) with unlocked connec-
tor lock.

1
 ENGINE AND EMISSION CONTROL SYSTEM (K9K ENGINE) 6E2-35

5) Remove ECT sensor (1) from thermostat assembly by

removing clip (2).

Installation
Reverse removal procedure for installation noting the following.
• Check ECT sensor O-ring for damage.
If malfunction is found, replace ECT sensor.
• Install EGR valve referring to “EGR Valve and Intake Pipe
Removal and Installation” in Section 6A2.”

m
• Refill cooling system referring to “Cooling System Refill” in
Section 6B2.

co
• Check cooling system leakage referring to “Cooling System
Service” in Section 6B2.

Crankshaft position (CKP) sensor (engine speed sen-

.
gn
sor) removal and installation
Removal
1) Disconnect negative (–) cable at battery.
ia

2) Remove exhaust pipe and exhaust pipe bracket referring to

“Exhaust System Components” in Section 6K2.
rd

3) Remove CKP sensor cover (1).

2
1
4) Disconnect CKP sensor connector (2).
5) Remove CKP sensor (3) from transmission case.
ca

3
6E2-36 ENGINE AND EMISSION CONTROL SYSTEM (K9K ENGINE)

Installation
Reverse removal procedure for installation noting the following.
• Clean CKP sensor and sensor rotor teeth before installation.
• Tighten CKP sensor bolts to specified torque.
Tightening torque
CKP sensor bolt (a): 12 N·m (1.2 kg-m, 9.0 lb-ft)

(a)

• Install exhaust pipe and exhaust pipe bracket referring to

“Exhaust System Components” in Section 6K2.

m
Crankshaft position (CKP) sensor (engine speed sen-
sor) inspection
1) Remove CKP sensor referring to “Crankshaft Position (CKP)

co
Sensor (Engine Speed Sensor) Removal and Installation” in
. this section.
2) Check that CKP sensor (1) and sensor rotor tooth (2) are
gn
free from any metal particles and damage.
ia
rd
ca

3) Check that resistance between terminals of CKP sensor is

within specification.
If resistance is not as specified, replace CKP sensor.
CKP sensor resistance
608 – 912 Ω at 20°C, 68°F
 ENGINE AND EMISSION CONTROL SYSTEM (K9K ENGINE) 6E2-37

MAF and IAT sensor removal and installation

Removal
1) Disconnect negative (–) cable at battery.
2) Disconnect MAF and IAT sensor connector (1).
3) Disconnect air cleaner outlet hose (2) from MAF and IAT
sensor (3).
4) Remove MAF and IAT sensor (3) from air cleaner case.

3
1 2

Installation
Reverse removal procedure for installation noting the following.

m
• Clean mating surfaces of MAF and IAT sensor and air
cleaner case.

co
• Tighten MAF and IAT sensor bolts to specified torque.
Tightening torque
MAF and IAT sensor bolt (a): 6 N·m (0.6 kg-m, 4.5 lb-ft)
.
gn
ia

(a)
rd

MAF and IAT sensor inspection

1) Disconnect negative cable at battery.
ca

2) Disconnect connector from MAF and IAT sensor (1).

3) Measure resistance between sensor terminals for IAT.
If resistance is out of specification, replace MAF and IAT
sensor.
1
IAT sensor resistance
20 °C (68 °F): 2353 – 2544 Ω
40 °C (104 °F): 1114 – 1186 Ω
60 °C (140 °F): 568.9 – 597.4 Ω
6E2-38 ENGINE AND EMISSION CONTROL SYSTEM (K9K ENGINE)

Boost pressure sensor removal and installation

Removal
1) Disconnect negative (–) cable at battery.
2) Disconnect boost pressure sensor connector (1).
3) Remove boost pressure sensor (2) from EGR body.
2

Installation
Reverse removal procedure for installation noting the following

m
• Tighten boost pressure sensor bolt to specified torque.
Tightening torque

co
Boost pressure sensor bolt: 8 N·m (0.8 kg-m, 6.0 lb-ft)

Boost pressure sensor inspection

.
1) Remove boost pressure sensor from turbocharger outlet air
gn
pipe referring to “Boost Pressure Sensor Removal and
Installation” in this section.
2) Check sensor for damage and sensor port (1) for clogging.
ia

If defective condition is found, replace boost pressure sen-

sor.
rd
ca

1
 ENGINE AND EMISSION CONTROL SYSTEM (K9K ENGINE) 6E2-39

Boost pressure control solenoid valve removal and

installation
Removal
1) Disconnect negative (–) cable at battery.
2) Disconnect boost pressure control solenoid valve connector
1
(1) with unlocked connector lock.
3) Disconnect vacuum hoses (2) from boost pressure control
solenoid valve.
4) Remove boost pressure control solenoid valve (3).

3
2

Installation

m
Reverse removal procedure for installation.

Boost pressure control solenoid valve inspection

. co
1) Remove boost pressure control solenoid valve referring to
“Boost pressure control solenoid valve removal and installa-
tion” in this section.
2) Check for resistance between boost pressure control sole-
gn
noid valve terminals.
If resistance is not as specified, replace boost pressure con-
trol solenoid valve.
ia

Boost pressure control solenoid valve resistance

18.9-23.1Ω at 23°C (73.4°F)
rd

3) Apply vacuum 80 kPa (0.8 kg/cm2 11.5 psi) to boost pres-

ca

sure control valve using special tool. If vacuum can be

applied, go to the next step. If not, replace boost pressure
control valve.
Special tool
B (A): 09917-47011
4) Connect 12 V battery to boost pressure control valve termi-
(B)
A nals. In this state, apply vacuum 70 kPa (0.7 kg/cm2 10.1
psi) to the outlet nozzle using a special tool. If vacuum can
not be applied, boost pressure control valve is in good condi-
(A) tion. If not, replace boost pressure control valve.
Special tool
(A): 09917-47011
(B): 09918-08210

[A]: Pipe to vacuum pump

[B]: Pipe to waste gate actuator
6E2-40 ENGINE AND EMISSION CONTROL SYSTEM (K9K ENGINE)

Radiator fan control system inspection

WARNING:
Keep hands, tools, and clothing away from engine cool-
ing fan to help prevent personal injury. This fan is electric
and can come on whether or not the engine is running.
The fan can start automatically in response to the ECT
sensor with the ignition switch in the “ON” position.

Check that radiator cooling fan operates at low and high speed
corresponding to the following coolant temperature.
If radiator cooling fan fails to operate properly, check radiator fan
relays, radiator cooling fan motor, electrical circuit and ECT sen-
sor.

Radiator cooling fan operating

Low speed ON 93 °C (199 °F) or higher

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OFF Below 90 °C (194 °F)
High speed ON 96 °C (205 °F) or higher

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OFF Below 93 °C (199 °F)

EGR valve removal and installation

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NOTE:
After replacing EGR valve with new one or used one, ini-
tialize new EGR valve position referring to “EGR Valve
Data Initialization” under “ECM Registration (Program-
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ming)” in this section.

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For removal and installation procedure of EGR valve, refer to

“EGR Valve and Intake Pipe Removal and Installation” in Section
6A2.
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EGR valve inspection

1) Remove EGR valve referring to “EGR Valve and Intake Pipe
Removal and Installation” in Section 6A2.
 ENGINE AND EMISSION CONTROL SYSTEM (K9K ENGINE) 6E2-41

2) Check resistance between terminals (“2” and “6”) of EGR

valve.
If resistance is out of specification, replace EGR valve.
EGR valve resistance
Approximately 23 Ω at 25 °C (77 °F)

“2” “6”

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6E2-42 ENGINE AND EMISSION CONTROL SYSTEM (K9K ENGINE)

Tightening Torque Specification

Tightening torque
Fastening part
N•m kg-m lb-ft
High pressure pipe union nut 38 3.8 27.5
Common rail nut 28 2.8 20.5
Injection cover bracket nut 12 1.2 9.0
Oil level gauge guide nut 21 2.1 15.5
Fuel injector bracket bolt 28 2.8 20.5
Injection pump bolt 27 2.7 19.5
Injection pump pulley nut Tighten 15 N·m (1.5 kg-m, 11.0 lb-ft) and 60° by the
specified procedure
Venturi bolt 5.5 0.55 4.0
Glow plug 15 1.5 11.0
Accelerator pedal mounting bolt 6 6.0 4.5
Fuel temperature sensor 15 1.5 11.0
Fuel flow actuator bolt 5.5 0.55 4.0

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CKP sensor bolt 12 1.2 9.0
MAF and IAT sensor bolt 6 0.6 4.5

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Boost pressure sensor bolt 8 0.8 6.0
Knock sensor 20 2.0 14.5
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Special Tool
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09911-78110 09917-47011 09918-08210

Tech 2 kit (SUZUKI scan tool) Crowfoot ratchet ends Vacuum pump gauge Vacuum gauge hose guide
(See NOTE)

NOTE:
This kit includes the following items.
1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5. Cigarette cable,
6. DLC loopback adapter, 7. Battery power cable, 8. RS232 cable, 9. RS232 adapter,
10. RS232 loopback connector, 11. Storage case, 12. Power supply
 CRANKING SYSTEM (K9K ENGINE) 6G2-1

SECTION 6G2
6-3
6A3

CRANKING SYSTEM 6B3

6C3
(K9K ENGINE) 6G2

WARNING: 6H3
6K3
For vehicles equipped with a Supplemental Restraint (Air Bag) System:
• Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Refer to “System Components and Wiring Location View and Connec-
tions” under “General Description” in Section 10B in order to confirm whether you are performing
service on or near the air bag system components or wiring. Please observe all WARNINGS and
“Service Precautions” under “On-Vehicle Service” in Section 10B before performing service on or
around the air bag system components or wiring. Failure to follow WARNINGS could result in unin-
tentional activation of the system or could render the system inoperative. Either of these two condi-

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tions may result in severe injury.
• Technical service work must be started at least 90 seconds after the ignition switch is turned to the

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“LOCK” position and the negative cable is disconnected from the battery. Otherwise, the system
may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).

NOTE:
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For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the Service Man-
ual mentioned in “FOREWORD” of this manual.
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CONTENTS
General Description ...................................... 6G2-* No-load performance test........................6G2-3
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Cranking System Circuit Diagram ............... 6G2-* ON-Vehicle Service .......................................6G2-4

Diagnosis ...................................................... 6G2-2 Starting Motor Dismounting and
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Cranking System Symptom Diagnosis ........ 6G2-* Remounting.................................................6G2-4

Cranking System Test ................................ 6G2-2 Dismounting ............................................6G2-4
Pull-in test............................................... 6G2-2 Remounting............................................. 6G2-*
Hold-in test ............................................. 6G2-2 Tightening Torque Specification ................. 6G2-*
Plunger and pinion return test ................ 6G2-2
6G2-2 CRANKING SYSTEM (K9K ENGINE)

Diagnosis
Cranking System Test

CAUTION:
Each test must be performed within 3 – 5 seconds to
avoid coil from burning.

Pull-in test

Connect battery to magnetic switch as shown.

1
Check that plunger and pinion move outward.
If plunger and pinion don’t move, replace starting motor.
3

NOTE:
Before testing, disconnect lead wire (3) from terminal
“M” (2).

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1. Terminal “S”

Hold-in test
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While connected as above with plunger out, disconnect negative
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lead from terminal “M”.
Check that plunger and pinion remain out.
If plunger and pinion return inward, replace starting motor.
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Plunger and pinion return test

Disconnect negative lead from starting motor body.
Check that plunger and pinion return inward.
If plunger and pinion don’t return, replace starting motor.
 CRANKING SYSTEM (K9K ENGINE) 6G2-3

No-load performance test

Connect lead wire (1) to terminal “M” (2).

Connect battery to starting motor as shown.
Check that starting motor rotates smoothly and steadily with pin-
2
ion moving out.
1 If check result is not satisfactory, replace starting motor.

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6G2-4 CRANKING SYSTEM (K9K ENGINE)

ON-Vehicle Service
Starting Motor Dismounting and Remounting

4 45 N·m (4.5 kg-m)

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2

1. Starting motor

2. Magnetic switch lead wire nut

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3. Battery cable nut

4. Starting motor mount bolt

Tightening torque
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Dismounting
1) Disconnect negative cable at battery.
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2) Remove fuel filter referring to “Fuel Filter Removal and Installation” in Section 6C.
3) Remove oil level gage tube.
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4) Disconnect magnetic switch lead wire and battery cable from starting motor terminals.
5) Remove starting motor mount bolt
6) Remove starting motor.
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 EXHAUST SYSTEM (K9K ENGINE) 6K2-1

SECTION 6K2
6-3
6A3

EXHAUST SYSTEM 6B3

6C3

(K9K ENGINE) 6E3

6G3

NOTE:
For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the Service Man- 6K2
ual mentioned in “FOREWORD” of this manual.

CONTENTS
General Description ...................................... 6K2-* Exhaust Manifold Inspection ........................6K2-*
Exhaust Pipe Removal and Installation ...... 6K2-3

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Maintenance .................................................. 6K2-*
On-Vehicle Service........................................6K2-2 Tightening Torque Specification .................6K2-4
Exhaust System Components .....................6K2-2

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Exhaust Manifold Removal and
Installation ................................................... 6K2-*
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6K2-2 EXHAUST SYSTEM (K9K ENGINE)

On-Vehicle Service
Exhaust System Components

WARNING:
To avoid the danger of being burned, do not touch the exhaust system when the system is hot. Any
service on the exhaust system should be performed when the system is cool.

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1. Seal ring 7. Center pipe 12. Gasket 18. Catalyst stiffener bolt
:Tighten 27N·m (2.7 kg-m, 19.5
lb-ft) by the specified procedure.
2. Exhaust pipe stud bolt 8. Mounting No.2 13. Catalyst stiffener No.1 19. Pressure plate block bolt
:Tighten 27N·m (2.7 kg-m, 19.5
lb-ft) by the specified procedure.
3. Exhaust pipe No.2 9-1. Mounting No.3 (Type A) 14. Pressure plate Tightening torque

4. Exhaust pipe nut 9-2. Mounting No.3 (Tyoe B) 15. Catalyst stiffener No.2 Do not reuse.
 EXHAUST SYSTEM (K9K ENGINE) 6K2-3

5. Mounting No.1 10. Muffler 16. Pressure plate block

6. Center pipe bolt 11. Muffler nut 17. Exhaust pipe No.1

Exhaust Pipe Removal and Installation

WARNING:
To avoid the danger of being burned, do not touch the
exhaust system when the system is hot. Any service on
the exhaust system should be performed when the system
is cool.

CAUTION:
Exhaust pipe No.1 has oxidation catalytic converter in it, it
should not be exposed to any impulse.
Be careful not to drop it or hit it against something.

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Removal
1) Disconnect negative (–) cable at battery.

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2) Remove gear shift control lever referring to “Gear Shift Con-
trol Lever Assembly Removal and Installation” in Section
7A2.
.
3) Remove propeller shaft No.1 and No.2 referring to “Propeller
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Shafts” in Section 4B.
4) Support transmission with transmission jack.
5) Remove rear mounting bracket (1) and gear shift control arm
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2
(2), and then slant transmission downward.
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6K2-4 EXHAUST SYSTEM (K9K ENGINE)

6) Remove pressure plate block bolts (1) and catalyst stiffener

bolts (2), and then remove catalyst stiffener No.1 (5), catalyst
stiffener No.2 (3) and pressure plate (4).
7) Remove exhaust pipe No.1 (6), No.2, center pipe and muffler
referring to “Exhaust System Components” in this section.

5
3
4

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 EXHAUST SYSTEM (K9K ENGINE) 6K2-5

Installation
Reverse removal procedure for installation noting the following.

1) Install exhaust pipe No.1 (1) as follows.

a) Install pressure plate (1) and catalyst stiffener No.1 (7) to
exhaust pipe No.1 (2).
b) Install exhaust pipe No.1 to turbocharger (3), and then
4, (a) tighten exhaust pipe nuts (4) to specified torque.
Tightening torque
7
Exhaust pipe nut (a): 27 N·m (2.7 kg-m, 19.5 lb-ft)

5, (b), “3” c) Tighten catalyst stiffener bolts (5) and pressure plate block
5, (b), “1”
bolts (6) temporarily.
2 3
Tightening torque
1 Catalyst stiffener bolt (b): Tighten 27 N·m (2.7 kg-m, 19.5
lb-ft) by the procedure.

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6, (c), “5” Pressure plate block bolt (c): Tighten 27 N·m (2.7 kg-m,
19.5 lb-ft) by the specified procedure.
6, (c), “6”
d) Tighten catalyst stiffener bolts and pressure plate block

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5, (b), “4”
bolts specified torque by numerical order as shown in fig-
5, (b), “2”
ure.
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2) Tighten each bolt and nut to specified torque referring to
“Exhaust System Components” in this section.
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3) After installation, start engine and check each joint of

exhaust system for leakage.
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Tightening Torque Specification

Tightening torque
Fastening part
N•m kg-m lb-ft
Exhaust pipe stud bolt 7 0.7 5.0
Exhaust pipe nut 27 2.7 19.5
Center pipe bolt 50 5.0 36.5
Muffler nut 50 5.0 36.5
Catalyst stiffener bolt “Tighten 27 N·m (2.7 kg-m, 19.5 lb-ft) by the specified proce-
dure.”
Pressure plate block bolt “Tighten 27 N·m (2.7 kg-m, 19.5 lb-ft) by the specified proce-
dure.”
6K2-6 EXHAUST SYSTEM (K9K ENGINE)

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 MANUAL TRANSMISSION (K9K ENGINE MODEL) 7A2-1

SECTION 7A2

MANUAL TRANSMISSION
(K9K ENGINE MODEL)
WARNING:
For vehicles equipped with a Supplemental Restraint (Air Bag) System:
• Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under
“General Description” in air bag system section in order to confirm whether you are performing ser-
7A2
vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser-
vice Precautions” under “On-Vehicle Service” in air bag system section before performing service
on or around the air bag system components or wiring. Failure to follow WARNINGS could result in

m
unintentional activation of the system or could render the system inoperative. Either of these two
conditions may result in severe injury.
• Technical service work must be started at least 90 seconds after the ignition switch is turned to the

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“LOCK” position and the negative cable is disconnected from the battery. Otherwise, the system
may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).

NOTE:
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For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the Service Man-
ual mentioned in “FOREWORD” of this manual.
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CONTENTS
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General Description ..................................... 7A2- * Back Up Lamp Switch Inspection ...............7A2- *

Transmission Components ........................ 7A2- * Manual Transmission Assembly
On-Vehicle Service........................................7A2-2 Components................................................ 7A2-6
Manual Transmission Assembly
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Manual Transmission Oil Change .............. 7A2- *

Disassembly and Reassembly.................... 7A2-7
Extension Case Oil Seal Replacement ...... 7A2- *
Locating Spring Inspection..........................7A2- *
Gear Shift Control Lever Assembly
Gear Shift Shaft and Fork Components......7A2- *
Components ................................................7A2-2
Gear Shift Fork Inspection ..........................7A2- *
Gear Shift Control Lever Assembly
Input Shaft, Countershaft and
Removal and Installation .............................7A2-3
Output Shaft Components ..........................7A2- *
Gear Shift Control Lever Assembly
Input Shaft Assembly Disassembly
Disassembly and Reassembly ................... 7A2- *
and Reassembly .........................................7A2- *
Gear Shift Control Lever Assembly
Input Shaft Assembly Inspection.................7A2- *
Inspection ................................................... 7A2- *
Countershaft Assembly Disassembly
Unit Repair Overhaul ....................................7A2-5 and Reassembly .........................................7A2- *
Manual Transmission Unit Components .....7A2-5 Countershaft Assembly Inspection .............7A2- *
Transmission Unit Dismounting and Output Shaft Assembly Disassembly
Remounting ................................................ 7A2- * and Reassembly .........................................7A2- *
Gear Shift Lever Case Assembly Output Shaft Assembly Inspection..............7A2- *
Components ............................................... 7A2- * Tightening Torque Specification ...............7A2-13
Gear Shift Lever Case Assembly
Required Service Material ........................... 7A2- *
Removal and Installation ............................ 7A2- *
Gear Shift Lever Case Assembly Special Tool.................................................. 7A2- *
Disassembly and Reassembly ................... 7A2- *
Back Up Lamp Switch Removal and
Installation .................................................. 7A2- *
7A2-2 MANUAL TRANSMISSION (K9K ENGINE MODEL)

On-Vehicle Service
Gear Shift Control Lever Assembly Components

6
3
15 23 N·m (2.3 kg-m)

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4

16 3.5 N·m (0.35 kg-m)

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7
9

17 23 N·m (2.3 kg-m) 8 A

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11

12
19 A
18
20 A
13 A
21 3.5 N·m (0.35 kg-m)

14 A

24
26

22 18 N·m (1.8 kg-m)

25 23
 MANUAL TRANSMISSION (K9K ENGINE MODEL) 7A2-3

1. Gear shift knob 10. Gear shift lever No.4 boot 19. Gear shift control shaft bush
: Apply grease 99000-25010 to bush.
2. Gear shift control lever 11. Gear shift stopper plate 20. Gear shift control joint washer
: Apply grease 99000-25010 to washer.
3. Gear shift control boot cover 12. Gear shift control joint bush 21. Gear shift control joint nut
4. Gear shift lever No. 1 boot 13. Gear shift control joint 22. Shift lever No.1 nut
: Apply grease 99000-25010 to con-
nected part.
5. Gear shift lever No. 3 boot 14. Gear shift control shaft 23. Shift lever No.1 washer
: Apply grease 99000-25010 to con-
nected part.
6. Gear shift lever No. 2 boot 15. Gear shift control boot cover bolt 24. Joint inner bush
7. Gear shift lever case cover 16. Gear shift control boot plate nut 25. Joint outer bush
8. Gear shift control arm 17. Shift lever No.2 bolt 26. Shift lever No.1 bolt
: Apply grease 99000-25010 to arm
inside.
9. Gear shift control boot plate 18. Gear shift control joint bolt Tightening torque

Gear Shift Control Lever Assembly Removal

and Installation

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Removal
1) Remove console box.

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2) Remove gear shift control boot cover (1) from floor panel and
gear shift lever No.1 boot (2).
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3) Remove gear shift control lever (2) while pushing and turning
2 gear shift lever case cover (1) counterclockwise.
1
4) Drain transmission oil referring to “Manual Transmission Oil
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Change” in this section.

5) Remove exhaust pipe referring to “Exhaust Pipe” in Section
6K2.
6) Remove propeller shaft No.1 and No.2 referring to “Propeller
Shafts” in Section 4B.

7) Remove gear shift control arm assembly (1).

2. Shift lever No.1 bolt
3. Shift lever No.2 bolts
7A2-4 MANUAL TRANSMISSION (K9K ENGINE MODEL)

Installation
Reverse removal procedure for installation noting the following.
• Tighten bolts and nut to specified torque as follows.
Tightening torque
Gear shift control boot cover bolt
(a): 23 N·m (2.3 kg-m, 17.0 lb-ft)
Shift lever No.1 nut
(b): 18 N·m (1.8 kg-m, 13.0 lb-ft)
Shift lever No.2 bolt
(c): 23 N·m (2.3 kg-m, 17.0 lb-ft)

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 MANUAL TRANSMISSION (K9K ENGINE MODEL) 7A2-5

Unit Repair Overhaul

Manual Transmission Unit Components

12
14 18 N·m (1.8 kg-m)

11 23 N·m (2.3 kg-m)

15 25 N·m (2.5 kg-m)
4 16 25 N·m (2.5 kg-m)

13

3 25 N·m (2.5 kg-m)

1 6

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10 23 N·m (2.3 kg-m)

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8 55 N·m (2.3 kg-m)
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7 50 N·m (5.0 kg-m)

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1. Transmission 7. Clutch operating cylinder bolt 13. Shift lever No.1 washer
2. Clutch operating cylinder 8. Transmission case bolt 14. Shift lever No.1 nut
3. Rear mounting bolt 9. Transmission hook 15. Rear mounting bracket bolt
4. Gear shift control lever assembly 10. Transmission hook bolt 16. Rear mounting bracket nut
5. Rear mounting bracket 11. Shift lever No.2 bolt Tightening torque

6. Rear mounting 12. Shift lever No.1 bolt

7A2-6 MANUAL TRANSMISSION (K9K ENGINE MODEL)

Manual Transmission Assembly Components

5 A
3

6 23 N·m (2.3 kg-m)

9 23 N·m (2.3 kg-m)

10
33

7
32
OIL

31
30 4 1217G 27
29

18

OIL
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8 1322 23 N·m
(2.3 kg-m) 11

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2 1217G

20
19

1217G
23 N·m
(2.3 kg-m)

23 N·m
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14 1322 23 N·m (2.3 kg-m)
(2.3 kg-m)
23 21 23 N·m (2.3 kg-m)
28
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15
22
13 A
25 24 1322 23 N·m
(2.3 kg-m)
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26

16 17
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1 1217G
 MANUAL TRANSMISSION (K9K ENGINE MODEL) 7A2-7

1. Transmission front case 13. Input shaft oil seal 25. Reverse gear shaft washer
: Apply sealant 99000-31260 to mating surface : Apply grease 99000-25010 to oil seal lip.
of front case and rear case.
2. Transmission rear case 14. 5th gear shift inverse lever bolt 26. Reverse idler gear
: Apply sealant 99000-31260 to mating surface : Apply thread lock 99000-32110 to all
of rear case and extension case. around thread part of bolt.
3. Extension case 15. Low gear shift inverse lever 27. Countershaft shim
4. Gear shift lever case assembly 16. Reverse gear shift lever 28. Input shaft & countershaft assembly
: Apply sealant 99000-31260 to mating surface
of rear case and gear shift lever case assembly.
5. Extension oil seal 17. Reverse shift locating 29. 5th speed synchronizer lever
: Apply grease 99000-25010 to oil seal lip.
6. Extension case bolt 18. O-ring 30. 5th speed synchronizer sleeve
7. Knock pin 19. Back up lamp switch 31. 5th speed synchronizer ring
8. Gear shift lever case bolt 20. Oil filler plug 32. Input shaft needle bearing
: Apply thread lock 99000-32110 to all around : Apply sealant 99000-31260 to all around
thread part of bolt. thread part of bolt.
9. Oil hole plug 21. Transmission case bolt 33. Output shaft assembly
10. Oil hole gasket 22. Reverse gear shaft Tightening torque

11. Oil gutter 23. Reverse shaft bolt washer Do not reuse.

12. Knock pin 24. Reverse shaft bolt Apply transmission oil.
: Apply thread lock 99000-32110 to all
around thread part of bolt.

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Manual Transmission Assembly Disassembly

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and Reassembly
Disassembly
1) Remove clutch release bearing and release fork referring to
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“Clutch Cover, Clutch Disc, Flywheel and Release Bearing
Removal and Installation” in Section 7C2.
2) Remove gear shift lever case assembly referring to “Gear
Shift Lever Case Assembly Removal and Installation” in this
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section.
3) Remove extension case.
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4) Remove output shaft assembly.

2 5) Remove reverse shaft bolt (1) and back up lamp switch (2).
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1 6) Remove gear shift locating bolts (1), then take out locating
2
springs and gear shift shaft balls.
7) Remove rear to front case bolts (2), then separate rear case
from front case tapping front case flange with plastic ham-
mer.
8) Remove oil gutter.

2 1
7A2-8 MANUAL TRANSMISSION (K9K ENGINE MODEL)

9) Remove reverse shaft assembly (1).

10) Remove 5th gear shift inverse lever (4).
3 11) Remove low speed gear shift shaft (2) and 5th & reverse
gear shift fork (3).
2 1
12) Remove input shaft needle bearing, 5th speed synchronizer
4 ring, 5th speed synchronizer levers and 5th speed synchro-
nizer sleeve.

13) Remove input shaft front bearing circlip (1) from case using
special tool.
Special tool
(A): 09900-06106
(A)

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1

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4 3
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14) Remove input shaft assembly (1), countershaft assembly (2),
high speed gear shift fork (3) and low speed gear shift fork
(4) as assembly from front case (5) tapping input shaft end
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by plastic hammer lightly.
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Reassembly
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1) Assemble input shaft assembly (1), countershaft assembly

4 3 (2), high speed gear shift fork (3) and low speed gear shift
1 fork (4), then install them all together into front case (5).

CAUTION:
Take care not to damage oil seal lip by input shaft, or oil
2 leakage may take place.

5
 MANUAL TRANSMISSION (K9K ENGINE MODEL) 7A2-9

2) Install input shaft front bearing circlip (1) using special tool.
Special tool
(A): 09900-06106

(A)

3) Install low speed gear shift shaft (1) and 5th gear shift
inverse lever (2) and tighten with bolt (3) to which thread lock
cement has been applied.
1
“A”: Thread lock cement 99000-32110
Tightening torque
5th gear shift inverse lever bolt

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(a): 23 N·m (2.3 kg-m, 17.0 lb-ft)

2
2 3, (a), “A”

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4) Fit 5th & reverse gear shift fork (1) to 5th speed synchronizer
sleeve (2), and install them into input shaft and front case in
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specified direction as shown in figure.
1
A: Chamfered side
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5) Set reverse idler gear (1), reverse gear shift lever (2) and
3
“B” reverse gear shaft washer (4), insert reverse gear shaft (3)
into case through idler gear and then align hole “B” in shaft
2 4 with protrusion “A” in case.
1
6) Install oil gutter

“A”
7A2-10 MANUAL TRANSMISSION (K9K ENGINE MODEL)

“A”
7) Install 5th speed synchronizer levers and 5th speed synchro-
nizer ring as follows.
a) Fit 5th speed synchronizer levers (1) to hub (2) aligning pro-
1 trusion “A” of 5th speed synchronizer levers with groove of
“A”

2 hub.

1 b) Install synchronizer ring (1) to hub (2) in specified direction

as shown in figure.

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8) Clean mating surfaces of both front and rear cases, and uni-
formly apply sealant to front case (3) as shown in figure.
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“A”: Sealant 99000-31260
9) Tighten case bolts (1) to specified torque.
Tightening torque
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Transmission case bolt (b): 23 N·m (2.3 kg-m, 17.0 lb-ft)

10) Apply thread lock cement to reverse shaft bolt (2), and
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“A” tighten it.

“B”: Thread lock cement 99000-32110
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Tightening torque
Reverse shaft bolt (a): 23 N·m (2.3 kg-m, 17.0 lb-ft)
11) Install back up lamp switch (4) referring to “Back Up Lamp
Switch Removal and Installation” in this section.

2, “B”, (a)
1, (b)

3, “B”, (a)
12) Apply grease to gear shift shaft balls (1) and locating springs
2, “A”
(2), then install them.
1, “A”
Apply thread lock cement to gear shift locating bolts (3), and
then tighten them.
“A”: Grease 99000-25010
“B”: Thread lock cement 99000-32110
2, “A”
1, “A” Tightening torque
3, “B”, (a)
Gear shift locating bolt (a): 23 N·m (2.3 kg-m, 17.0 lb-ft)
 MANUAL TRANSMISSION (K9K ENGINE MODEL) 7A2-11

13) Install output shaft into rear case.

14) Select a countershaft shim and output shaft shim as follows.
a) Measure depth “a” from mating surface of extension case
(1) to face processed for installation of countershaft rear
bearing (2) and measure depth “c” from mating surface of
extension case to face processed for installation of output
shaft rear bearing (4) using vernier caliper
b) Measure height “b” from mating surface of rear case (3) to
countershaft rear bearing (2) and measure height “d” from
mating surface of rear case (3) to output shaft rear bearing
(4) using vernier caliper.
c) Calculate “a” – “b” and “c” – “d”, and select a shim accord-
ing to the following table.
Countershaft shim selection table

Thickness of counter-
Clearance “a” – “b”
shaft shim

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1.15 – 1.24 mm (0.045 – 0.048 in.) 0.90 mm (0.035 in.)
1.25 – 1.34 mm (0.049 – 0.052 in.) 1.00 mm (0.039 in.)

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1.35 – 1.44 mm (0.053 – 0.056 in.) 1.10 mm (0.043 in.)
1.45 – 1.54 mm (0.057 – 0.060 in.) 1.20 mm (0.047 in.)
1.55 – 1.64 mm (0.061 – 0.064 in.) 1.30 mm (0.051 in.)
1.65 – 1.74 mm (0.065 – 0.068 in.) 1.40 mm (0.055 in.)
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1.75 – 1.84 mm (0.069 – 0.072 in.) 1.50 mm (0.059 in.)
1.85 – 1.94 mm (0.073 – 0.076 in.) 1.60 mm (0.063 in.)
1.95 – 2.04 mm (0.077 – 0.080 in.) 1.70 mm (0.067 in.)
2.05 – 2.14 mm (0.081 – 0.084 in.) 1.80 mm (0.071 in.)
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1.90 (0.90 + 1.00) mm

2.15 – 2.24 mm (0.085 – 0.088 in.)
(0.075 (0.035 + 0.039) in.)
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7A2-12 MANUAL TRANSMISSION (K9K ENGINE MODEL)

Output shaft shim selection table

Thickness of counter-
Clearance “c” – “d”
shaft shim
0 – 0.09 mm (0 – 0.004 in.) –
0.10 – 0.19 mm (0.004 – 0.007 in.) 0.10 mm (0.004 in.)
0.20 – 0.29 mm (0.008 – 0.011 in.) 0.20 mm (0.008 in.)
0.30 – 0.39 mm (0.012 – 0.015 in.) 0.30 mm (0.012 in.)
0.40 – 0.49 mm (0.016 – 0.019 in.) 0.40 mm (0.016 in.)
0.50 (0.20 + 0.30) mm
0.50 – 0.59 mm (0.020 – 0.023 in.)
(0.020 (0.008 + 0.012) in.)
0.60 (0.20 + 0.40) mm
0.60 – 0.69 mm (0.024 – 0.027 in.)
(0.024 (0.008 + 0.016) in.)
0.70 (0.30 + 0.40) mm
0.70 – 0.79 mm (0.028 – 0.031 in.)
(0.028 (0.012 + 0.016) in.)

15) Install selected countershaft shim and output shaft shim to

extension case.

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16) Clean mating surface of both rear case (1) and extension
case, and uniformly apply sealant to rear case as shown in

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figure.
“A”: Sealant 99000-31260
.
17) Tighten case bolts (2) to specified torque.
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Tightening torque
Extension case bolt (a): 23 N·m (2.3 kg-m, 17.0 lb-ft)
18) Install gear shift lever case assembly (3) referring to “Gear
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Shift Lever Case Assembly Removal and Installation” in this

section.
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19) Install clutch release bearing and release fork referring to

“Clutch Cover, Clutch Disc, Flywheel and Release Bearing
Removal and Installation” in Section 7C2.
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 MANUAL TRANSMISSION (K9K ENGINE MODEL) 7A2-13

Tightening Torque Specification

Tightening torque
Fastening part
N•m kg-m lb-ft
Transmission oil level / filler and drain plugs 23 2.3 17.0
Gear shift control boot cover bolt 23 2.3 17.0
Shift lever No.1 nut 18 1.8 13.0
Shift lever No.2 bolt 23 2.3 17.0
Back up lamp switch 23 2.3 17.0
Reverse shaft bolt 23 2.3 17.0
Gear shift locating bolt 23 2.3 17.0
Extension case bolt 23 2.3 17.0
Gear shift lever case bolt 23 2.3 17.0
5th gear shift inverse lever bolt 23 2.3 17.0
Input shaft 5th hub nut 210 21.0 152.0
Countershaft front bearing nut 210 21.0 152.0
Transmission to engine bolt 55 5.5 39.5

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Gear shift control joint nut 3.5 0.35 2.5
Gear shift control boot plate nut 3.5 0.35 2.5

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Gear shift stop bolt 23 2.3 17.0
Oil hole plug 23 2.3 17.0
Clutch operating cylinder bolt . 50 5.0 36.0
Transmission hook bolt 23 2.3 17.0
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CKP sensor bolt 8.5 0.85 6.0
Rear mounting bracket bolt 25 2.5 18.0
Rear mounting bracket nut 25 2.5 18.0
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Rear mounting bolt 25 2.5 18.0

Transmission case bolt 23 2.3 17.0
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7A2-14 MANUAL TRANSMISSION (K9K ENGINE MODEL)

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 CLUTCH (K9K ENGINE MODEL) 7C2-1

SECTION 7C2
6F1
6F2
CLUTCH 6G
6H
(K9K ENGINE MODEL) 6K

NOTE:
7A1
For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the Service Man- 7B1
ual mentioned in “FOREWORD” of this manual. 7C1
8B
8C
CONTENTS 8D
General Description ..................................... 7C2-2 Clutch Master Cylinder Inspection ............ 7C2- * 8B
Clutch Operating Cylinder Components ... 7C2- * 7C2

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Diagnosis ..................................................... 7C2- *
Diagnosis Table ........................................ 7C2- * Clutch Operating Cylinder Disassembly 8B
Clutch Pedal Inspection ............................ 7C2- * and Assembly ...........................................
7C2- * 8C
Clutch Operating Cylinder Inspection ....... 7C2- *

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Clutch Fluid Level Check .......................... 7C2- * 8D
Clutch Pedal and Clutch Pedal Bracket
On-Vehicle Service....................................... 7C2-3
7C2- * 8E
Components..............................................
Clutch Fluid Pipe and Hose Components .. 7C2-3 Clutch Cover, Clutch Disc, Flywheel and
Clutch Fluid Pipe and Hose Removal and
.
Installation .................................................. 7C2-4
Release Bearing Components ................... 7C2-7 9
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Clutch Cover, Clutch Disc, Flywheel and
Clutch Fluid Pipe and Hose Inspection ...... 7C2-5 Release Bearing Removal and
Clutch Master Cylinder Removal and 10
Installation.................................................. 7C2-8
Installation ................................................. 7C2- * Clutch Cover, Clutch Disc, Flywheel and 10
Clutch Operating Cylinder Removal and
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Release Bearing Inspection ...................... 7C2- * 10B

Installation .................................................. 7C2-6
Tightening Torque Specification .............. 7C2-10 7E
Unit Repair Overhaul ................................... 7C2-7
Required Service Material .......................... 7C2- *
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Clutch Master Cylinder Components......... 7C2- *

Special Tool................................................. 7C2- *
Clutch Master Cylinder Disassembly and
Assembly................................................... 7C2- *
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7C2-2 CLUTCH (K9K ENGINE MODEL)

General Description
The clutch is a diaphragm-spring clutch of a dry single disc type. The diaphragm spring is of a tapering finger
type, which is a solid ring in the outer diameter part, with a series of tapering fingers pointing inward. The disc,
carrying four torsional coil springs, is slidably mounted on the transmission input shaft with a serration fit.
The clutch cover is secured to the flywheel, and carries the diaphragm spring in such a way that the peripheral
edge of the spring pushes on the pressure plate against the flywheel with the disc in between, when the clutch
release bearing is held back: This is the engaged condition of the clutch.
Depressing the clutch pedal causes the release bearing to advance and push on the tips of the tapering fingers
of the diaphragm spring. When this happens, the diaphragm spring pulls the pressure plate away from the fly-
wheel, thereby interrupting the flow of drive from flywheel through clutch disc to transmission input shaft.

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1. Crankshaft 6. Diaphragm spring 11. Clutch release fork clip

2. Flywheel 7. Release bearing 12. Release fork
3. Clutch disc 8. Input shaft bearing 13. Clutch release fork support
4. Pressure plate 9. Input shaft
5. Clutch cover 10. Clutch operating cylinder
 CLUTCH (K9K ENGINE MODEL) 7C2-3

On-Vehicle Service
CAUTION:
• Do not allow fluid to get on painted surface.
• Do not use shock absorber fluid or any other fluid which contains mineral oil. Do not use a con-
tainer which has been used for mineral oil or a container which is wet from water. Mineral oil will
cause swelling and distortion of rubber parts in hydraulic brake system and water mixed into brake
fluid will lower fluid boiling point. Keep all fluid containers capped to prevent contamination.

Clutch Fluid Pipe and Hose Components

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6 16 N·m (1.6 kg-m)
2

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A 4

6 16 N·m (1.6 kg-m)

11 23 N·m (2.3 kg-m)
6
.
16 N·m (1.6 kg-m)
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2 6 16 N·m (1.6 kg-m)

2
11 23 N·m (2.3 kg-m)
8
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6 16 N·m (1.6 kg-m) 7

9
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10 10 N·m (1.0 kg-m) 5 23 N·m (2.3 kg-m) 3

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1. Clutch master cylinder 5. Union bolt 9. Clutch fluid throttle valve

2. Pipe 6. Clutch pipe flare nut 10. Clutch pipe joint nut
3. Hose 7. Clutch pipe joint bracket 11. Clutch pipe joint bracket bolt
4. Clutch operating cylinder 8. Clutch pipe joint Tightening torque
: Apply grease 99000-25010 to rod tip.
7C2-4 CLUTCH (K9K ENGINE MODEL)

Clutch Fluid Pipe and Hose Removal and

Installation
Removal
1) Remove dust and dirt from each joint of hose and pipe to be
disconnected and clean around reservoir cap.
2) Take out fluid with syringe or such from brake master cylin-
der reservoir.
3) Disconnect each fluid pipe and hose referring to “Clutch
Fluid Pipe and Hose Components” in this section.

NOTE:
To disconnect pipe (1) from hose (2), separate them by
using flare nut wrench (4) and spanner (3) so as not to
kink them.

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Installation

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Reverse removal procedure for installation, noting the following
instruction.

CAUTION:
.
Do not allow pipe and hose to contact hard against vehi-
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cle body or other parts.

• Install each clamp securely.

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• For installation angle of hose, refer to “Clutch Fluid Pipe and

Hose Components” in this section.
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• Install E-ring (1) securely as shown.

• Tighten each bolt and nut to specified torque referring to
“Clutch Fluid Pipe and Hose Components” in this section.
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NOTE:
To connect pipe to hose, connect them by using flare nut
wrench and spanner so as not to kink them.

• After installation, bleed air from system. (Refer to “Air Bleed-

ing of Brake System” in Section 5.)
• Check fluid leakage.
• Add fluid to MAX level of reservoir.
2. Hose
3. Pipe
 CLUTCH (K9K ENGINE MODEL) 7C2-5

Clutch Fluid Pipe and Hose Inspection

Check pipe (1) and hose (2) for dent, kink, crack, dirt and dust.
Replace if check result is not satisfactory.
2

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7C2-6 CLUTCH (K9K ENGINE MODEL)

Clutch Operating Cylinder Removal and

Installation
Removal
1) Clean around master cylinder reservoir cap and take out
fluid with syringe or such from brake master cylinder reser-
voir.
2) Remove pipe (2) from operating cylinder assembly (1) and
3 clutch fluid throttle valve (3).
3) Remove clutch operating cylinder assembly (1).

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Installation

1) Apply small amount of grease to rod tip.

NOTE:

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Do not allow any grease to be on boot.
.
“A”: Grease 99000-25010
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2) Install clutch operating cylinder assembly (1) and tighten

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clutch operating cylinder bolts (2) to specified torque.

Tightening torque
3, (b)
Clutch operating cylinder bolt
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(a): 50 N·m (5.0 kg-m, 36.5 lb-ft)

1 3) Install pipe and tighten clutch pipe flare nut (3) to specified
torque.
2, (a)
Tightening torque
Clutch pipe flare nut (b): 16 N·m (1.6 kg-m, 11.5 lb-ft)

4) Fill brake master cylinder reservoir with specified brake fluid

and check for fluid leakage.
5) For procedure of air bleeding, refer to “Air Bleeding of Brake
System” in Section 5.
6) Check clutch pedal free travel and clutch release margin.
(Refer to “Clutch Pedal Inspection” in this section.)
 CLUTCH (K9K ENGINE MODEL) 7C2-7

Unit Repair Overhaul

Clutch Cover, Clutch Disc, Flywheel and Release Bearing Components

7 A

2 23 N·m (2.3 kg-m)

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9 6 5 29 N·m (2.9 kg-m)

4 A
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8

11
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10 55 N·m (5.5 kg-m)

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1. Clutch cover 5. Clutch release fork support 9. Flywheel

2. Clutch cover bolt 6. Clutch release fork clip 10. Flywheel bolt
3. Clutch disc 7. Release bearing 11. Spacer
: Apply grease 99000-25010 to release
bearing inner surface.
4. Release fork 8. Clutch release fork boot Tightening torque
: Apply grease 99000-25010 to contact part with
clutch release bearing and contact part with clutch
release fork support.
7C2-8 CLUTCH (K9K ENGINE MODEL)

Clutch Cover, Clutch Disc, Flywheel and

Release Bearing Removal and Installation
Removal
1) Dismount transmission assembly referring to “Transmission
Unit Dismounting and Remounting” in Section 7A2.
2) Hold flywheel with special tool and remove clutch cover bolts
(1) and take off clutch cover (2) and disc.
Special tool
1 (A): 09916-98110

2
(A)

3) Hold flywheel (1) with special tool and remove flywheel bolts

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3 (2) and take off flywheel with spacer (3).
Special tool

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1 (A): 09916-98110
4) Remove input shaft bearing from crankshaft by hand, if nec-
essary.
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2
(A)
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5) Remove release bearing (1) and clutch release fork (2).

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2
 CLUTCH (K9K ENGINE MODEL) 7C2-9

Installation

NOTE:
Before assembling, make sure that flywheel surface and
pressure plate surface have been cleaned and dried thor-
oughly.

1) Apply grease to release bearing (1) inner surface and

release fork (2).
“A”: Grease 99000-25010

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2) Install input shaft bearing to crankshaft.
3) Install flywheel (1) with spacer (3) to crankshaft as shown in

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figure and tighten bolts (2) to specified torque.
Special tool
1
. (A): 09916-98110
Tightening torque
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2, (a)
Flywheel bolt
(a): 55 N·m (5.5 kg-m, 40.0 lb-ft)
(A)
3
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[A]: Flywheel side

[A]
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4) Using special tool, install clutch disc and clutch cover (1).
Tighten clutch cover bolts (2) to specification using special
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tool.

NOTE:
1
• While tightening clutch cover bolts, compress clutch
disc with special tool (A) by hand so that disc cen-
tered.
2, (a)
• Tighten cover bolts little by little evenly in diagonal
order.

Special tool
(A) (A): 09923-36320
(B)
(B): 09916-98110
Tightening torque
Clutch cover bolt
(a): 23 N·m (2.3 kg-m, 17.0 lb-ft)
7C2-10 CLUTCH (K9K ENGINE MODEL)

5) Install release bearing (1) and clutch release fork (2).

1 “A”
6) Slightly apply grease to input shaft. Then join transmission
with engine. Refer to “Transmission Unit Dismounting and
Remounting” in Section 7A2.
2 “A”: Grease 99000-25210

Tightening Torque Specification

Tightening torque
Fastening part
N•m kg-m lb-ft

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Flywheel bolt 55 5.5 40.0
Clutch cover bolt 23 2.3 17.0

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Clutch pipe flare nut 16 1.6 11.5
Union bolt 23 2.3 17.0
Clutch master cylinder nut and bolt . 13 1.3 9.5
Clutch operating cylinder bolt 50 5.0 36.5
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Clutch pedal shaft arm nut 17 1.7 12.5
Bracket nut 23 2.3 17.0
Clutch pedal free height nut 5.5 0.55 4.0
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 BODY ELECTRICAL SYSTEM 8-1

SECTION 8
6F1
6F2
BODY ELECTRICAL SYSTEM 6G
6H
6K
WARNING:
For vehicles equipped with a Supplement Restraint (Air Bag) System 7A
• Service on and around the air bag system components or wiring must be performed only by an 7A1
authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under 7B1
“General Description” in air bag system section in order to confirm whether you are performing ser- 7C1
vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser-
7D
vice Precautions” under “On-Vehicle Service” in air bag system section before performing service
7E
on or around the air bag system components or wiring. Failure to follow WARNINGS could result in
7F
unintentional activation of the system or could render the system inoperative. Either of these two
conditions may result in severe injury.
8A

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• Technical service work must be started at least 90 seconds after the ignition switch is turned to the
“LOCK” position and the negative cable is disconnected from the battery. Otherwise, the system
9
may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).

NOTE:

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For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the Service Man-
ual mentioned in “FOREWORD” of this manual.
. 8E
8
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CONTENTS 10A
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10B
Diagnosis ........................................................... 8-3 Front Seat Heater (If Equipped)....................... 8-*
Headlight ..........................................................8-* Cigarette Lighter .............................................. 8-*
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Headlights with Leveling System Interior Lights ................................................... 8-*

(If Equipped).....................................................8-* On-Vehicle Service ........................................... 8-5
Rear Fog Light (If Equipped) ............................8-* Headlight.......................................................... 8-*
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Turn Signal and Hazard Warning Lights ..........8-* Headlight switch ........................................... 8-*
Clearance, Tail and License Plate Lights .........8-* Headlight ...................................................... 8-*
Back-up Light ...................................................8-* Bulb replacement ......................................... 8-* 8D
Brake Lights .....................................................8-* Headlight aiming adjustment with
Tachometer and ECM ......................................8-* screen .......................................................... 8-*
Speedometer and VSS ....................................8-* Headlights with Leveling System
Fuel Meter and Fuel Gauge Unit ......................8-* (If Equipped) .................................................... 8-*
Engine Coolant Temp. (ECT) Meter and ECT Leveling switch............................................. 8-*
Sensor ..............................................................8-* Leveling actuator.......................................... 8-*
Oil Pressure Light.............................................8-* Turn Signal and Hazard Warning Lights
Brake and Parking Brake Warning Light ..........8-* System ............................................................. 8-*
Seat Belt Warning Light ...................................8-* Turn signal and hazard warning lights
Rear Window Defogger (If Equipped) ..............8-* system circuit inspection .............................. 8-*
Front Wiper and Washer ..................................8-* Turn signal light switch................................. 8-*
Rear wiper and washer (If equipped) ...............8-* Hazard switch............................................... 8-*
Power Window Control System Stop (Brake) Lamp........................................... 8-*
(If Equipped).....................................................8-* Stop (brake) lamp switch.............................. 8-*
Power Door Lock System (If Equipped) .......... 8-3 Rear Fog Light (If Equipped)............................ 8-*
Power Door Lock System with Keyless Entry Rear fog light switch..................................... 8-*
System (If Equipped)....................................... 8-3 Ignition Switch.................................................. 8-*
Power Door Mirror Control System ................. 8-4 Combination Meter.......................................... 8-5
Door Mirror Heater (If Equipped)..................... 8-4 Fuel Meter/Fuel Gauge Unit............................. 8-*
8-2 BODY ELECTRICAL SYSTEM

Fuel level meter............................................ 8-* Power door lock system operation

Fuel sender gauge ....................................... 8-* inspection..................................................... 8-*
Engine Coolant Temperature Meter and Power door lock system circuit
Sensor Unit ...................................................... 8-* inspection.....................................................8-8
Engine coolant temperature meter............... 8-* Driver side key cylinder switch..................... 8-*
Engine coolant temperature sensor ............. 8-* Power door lock actuator ............................. 8-*
Oil Pressure Warning Light .............................. 8-* Power Door Lock System with Keyless
Oil pressure switch....................................... 8-* Entry System (If Equipped)............................8-10
Brake and Parking Brake Warning Light.......... 8-* Power door lock system with keyless
Brake fluid level switch................................. 8-* entry system component location ..............8-10
Parking brake switch .................................... 8-* System description.....................................8-11
Brake vacuum switch ................................... 8-* Change of signal mode ..............................8-11
Seat Belt Warning Light (If Equipped).............. 8-* Keyless entry system operation
Seat belt switch ............................................ 8-* inspection...................................................8-11
Rear Window Defogger.................................... 8-* Keyless entry system circuit inspection .....8-12
Defogger switch ........................................... 8-* Transmitter.................................................8-15
Defogger wire............................................... 8-* Driver side key cylinder switch..................... 8-*
Defogger relay.............................................. 8-* Power door lock actuator ............................. 8-*
Wiper and Washer ........................................... 8-* Door switch .................................................. 8-*
Front wiper/washer switch............................ 8-* Power Door Mirror Control System

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Wiper motor.................................................. 8-* (If Equipped) ..................................................8-17
Washer pump............................................... 8-* Mirror switch................................................. 8-*
Rear Wiper and Washer .................................. 8-* Door mirror actuator...................................8-17

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Wiper and washer switch ............................. 8-* Door Mirror Heater (If Equipped) ...................8-18
Rear wiper motor.......................................... 8-* Mirror heater switch ..................................... 8-*
Rear wiper intermittent relay ........................ 8-* Mirror heater (if equipped) .........................8-18
Power Window Control System Front Seat Heater (If Equipped)....................... 8-*
.
(If Equipped) .................................................... 8-* Seat heater switch (driver and
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Breaker......................................................... 8-* passenger side) ........................................... 8-*
Power window main switch .......................... 8-* Seat heater wire........................................... 8-*
Power Door Lock System (If Equipped).......... 8-8
Power door lock system component
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location......................................................... 8-*
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 BODY ELECTRICAL SYSTEM 8-3

Diagnosis
Power Door Lock System (If Equipped)
Condition Possible Cause Correction
All are not locked/ Circuit fuse blown After checking short circuit, replace
unlocked by only fuse.
driver side key cylin- Driver side key cylinder switch faulty Check system referring to “Power
der switch Power door lock controller faulty Door Lock System” in this section.
Wiring or ground faulty
Only one door is not Power door lock actuator faulty Check system referring to “Power
locked/unlocked Wiring or grounding faulty Door Lock System” in this section.

Power Door Lock System with Keyless Entry System (If Equipped)
Condition Possible Cause Correction
All are not locked/ Circuit fuse blown After checking short circuit, replace

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unlocked by only fuse.
driver side key cylin- Driver side key cylinder switch faulty Check system referring to “Power
der switch Power door lock controller faulty Door Lock System” in this section.

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Wiring or ground faulty
Only one door is not Power door lock actuator faulty Check system referring to “Power
locked/unlocked Wiring or grounding faulty Door Lock System” in this section.
All doors are not
.
Transmitter battery dead Replace battery.
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locked/unlocked by Transmitter faulty Replace transmitter.
only keyless entry Code registration error Perform code registration.
transmitter Door switch faulty Check system referring to “Power
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Key remainder switch (in ignition switch) faulty Door Lock System” in this section.
Power door lock controller faulty
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Wiring or grounding faulty

Turn signal lights are Keyless entry system is in interior light signal Change signal mode referring to
not flashed when mode (M13 engine model) “Change of Signal Mode” in this sec-
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doors are locked/ tion, if necessary.

unlocked by transmit- Turn signal and hazard warning system faulty Check system referring to “Turn Sig-
ter nal and Hazard Warning Light Sys-
tem” in this section.
Power door lock controller faulty Check system referring “Power Door
Wiring or grounding faulty Lock System With Keyless Entry
System” in this section.
Interior light does not Power door lock controller faulty Check system referring to “Power
turn ON when interior Wiring or grounding faulty Door Lock System With Keyless
light switch is at Entry System” in this section.
DOOR position and
doors are unlocked by
transmitter
8-4 BODY ELECTRICAL SYSTEM

Power Door Mirror Control System

Condition Possible Cause Correction
All power mirrors do Circuit fuse blown After checking short circuit, replace
not operate fuse.
Power door mirror switch faulty Check switch.
Wiring or grounding faulty Repair as necessary.
One power mirror Power door mirror switch faulty Check switch.
does not operate Actuator (power door mirror motor) faulty Check actuator.
Wiring or grounding faulty Repair as necessary.

Door Mirror Heater (If Equipped)

Condition Possible Cause Correction
All door mirrors mist Circuit fuse blown After checking short circuit, replace
when rear defogger fuse.
switch is ON Rear defogger switch faulty Check switch.

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Door mirror heater relay faulty Check relay
Wiring or grounding faulty Repair circuit.

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One door mirror mists Mirror heater faulty Check actuator.
when rear defogger Wiring or grounding faulty Repair circuit.
switch is ON .
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 BODY ELECTRICAL SYSTEM 8-5

On-Vehicle Service
Combination Meter
Combination Meter Circuit Diagram
M13 Engine Model

1 2 3 3 3

G93-22 G92-15 G93-20

G93-21 G92-2

9
4

L 2 3 D N R P
5

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10
6

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7

LCD
8 .
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G93-2 G92-1 G92-13 G92-11 G92-17 G92-18 G93-13 G93-16 G93-10 G93-5 G93-3
G93-18 G92-10 G92-14 G92-16 G92-3 G93-14 G93-15 G93-12 G93-8 G93-11 G93-4

17 18 19 20 23 25 26 17 22 24 21 21 17 17 3
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*1

11
12 13 14 15 16
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1 Main fuse 10. CPU 19. DLC

2. METER fuse 11. Fuel level gauge 20. ABS control module (if equipped)
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3. Combination switch 12. Brake fluid level switch 21. 4WD control module
4. Speedometer 13. Parking brake switch 22. Key remainder switch
5. Tachometer 14. Oil pressure switch 23. SDM (if equipped)
6. ECT meter 15. Door switch (except driver side) 24. Generator
7. Fuel level meter 16. Door switch (driver side) 25. Seat belt switch (if equipped)
8. Odometer (tripmeter) 17. ECM 26. TCM (A/T vehicle)
9. Back light 18. VSS *1. Serial communication line
8-6 BODY ELECTRICAL SYSTEM

K9K Engine Model

1 2 3 3 3

G93-22 G92-15 G93-20

G93-21 G92-2

9
4

5
10 STOP

LCD

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G93-2 G92-1 G92-13 G92-17 G92-18 G93-14 G93-15 G93-12 G93-7 G93-11 G93-4
G93-18 G92-10 G92-16 G92-3 G93-13 G93-16 G93-8 G93-6 G93-5 G93-3

17 18 19 20 23 25 22 . 24 21 21 17 17 17 3

11
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26 12 13 14 15 16

1 Main fuse 10. CPU 19. DLC

2. METER fuse 11. Fuel level gauge 20. ABS control module
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3. Combination switch 12. Brake fluid level switch 21. 4WD control module
4. Speedometer 13. Parking brake switch 22. Key remainder switch
5. Tachometer 14. Oil pressure switch 23. SDM
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6. ECT meter 15. Door switch (except driver side) 24. Generator
7. Fuel level meter 16. Door switch (driver side) 25. ECT sensor
8. Odometer (tripmeter) 17. ECM 26. Brake vacuum switch
9. Back light 18. VSS
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 BODY ELECTRICAL SYSTEM 8-7

Terminal Arrangement of Coupler Viewed From Harness Side

G92 G93

10 9 2 1
8 7 6 5 4 3 10 9 8 7 6 5 4 3 2 1
20 19 12 11
18 17 16 15 14 13 22 21 20 19 18 17 16 15 14 13 12 11

Connector Terminal Circuit Connector Terminal Circuit

1 To DLC 3 To door switch (except driver side)
2 To combination switch (turn R) 4 To door switch (driver side)
3 To engine ground 5 To oil pressure switch
4 – To ECM (glow plug indicator light/injection warning light/
6 water in fuel warning light control signal, K9K engine)
5 –
6 – To ECM (red stop warning light control signal, K9K

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7 engine)
7 –
8 – 8 To ECM (MIL control signal)
9 – 9 –

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To ABS control module (ABS indicator control signal, if 10 To ECM (immobilizer indicator control signal, if equipped)
10 equipped)
11 To combination switch (dimmer switch)
G92
11 To TCM (A/T vehicle) G93 12 To 4WD control module (4WD indicator control signal)
12 – 13 To parking brake switch
13 To SDM (if equipped)
. 14
To brake fluid level switch and brake vacuum switch (K9K
engine)
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14 To seat belt switch (if equipped)
15 To combination switch (headlight switch) 15 To generator
To ECM (ECT meter signal, M13 engine) 16 To 4WD control module (4L indicator control signal)
16
To ECT sensor (K9K engine) 17 –
17 To fuel level gauge 18 To VSS
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18 To key remainder switch 19 –

19 – 20 To combination switch (turn L)
20 – 21 To ignition switch
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1 – 22 To main fuse
G93
2 To ECM (tachometer signal)
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8-8 BODY ELECTRICAL SYSTEM

Removal
1) Disconnect negative cable at battery.
1 2) Remove meter cluster panel (1).
3) Disconnect couplers from combination meter (2).
4) Remove combination meter (2).

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Installation

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Reverse removal procedure for installation.

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Power Door Lock System (If Equipped)
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Power door lock system circuit inspection
1) Disconnect negative cable from battery.
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2) Disconnect door lock controller coupler (1).

3) Confirm that all doors are unlocked. Connect battery positive
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(+) and negative (–) terminals to door lock controller coupler

[A] terminals and check power door lock operation as follows.
1 If it does not operate as specified, repair applicable circuit or
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5 4 3 2 1
check actuator. If it operates as specified, go to next step.
12 11 10 9 8 7 6 Power door lock operation for vehicle:

TERMINAL [A]
[B] 1
10 11
Step OPERATION
8 7 6 5 4 3 2 1 TERMINAL [B]
18 17 16 15 14 13 12 11 10 9 3 10
1 UNLOCK LOCK
2 LOCK UNLOCK

[A]: For M13 engine model and K9K engine model without keyless entry system
[B]: For K9K engine model with keyless entry system
1. Power door lock controller coupler viewed from harness side

4) Connect negative (–) cable to battery.

 BODY ELECTRICAL SYSTEM 8-9

[A] 5) Check that the voltage and continuity between the following
1
5 4 3 2 1 terminals and body ground are specifications under each
12 11 10 9 8 7 6
conditions.
If check result is not as specified, repair circuit.
If check result is OK, recheck power door lock system as fol-
[B] 1 lows.
a) Substitute a known-good door lock controller.
8 7 6 5 4 3 2 1
b) Recheck power door lock system circuit.
18 17 16 15 14 13 12 11 10 9
[A]: For M13 engine model and K9K engine model without keyless entry system
[B]: For K9K engine model with keyless entry system
1. Power door lock controller coupler viewed from harness side

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Power Door Lock System Circuit Check
For M13 Engine Model and K9K Engine Model Without Keyless Entry System

Terminal
7
Circuit
Main power supply
Driver side door knob switch
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Specification
10 – 14 V
.
Continuity
–
Condition

Driver side door knob switch is lock position.

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lock signal circuit No continuity Driver side door knob switch is unlock position.
Driver side door knob switch Continuity Driver side door knob switch is unlock position.
9
unlock signal circuit No continuity Driver side door knob switch is lock position.
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12 Ground 0–1V –
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For K9K Engine Model With Keyless Entry System

Terminal Circuit Specification Condition

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Driver side door knob switch Continuity Driver side door knob switch is lock position.
5
lock signal circuit No continuity Driver side door knob switch is unlock position.
9 Main power supply 10 – 14 V –
10 – 14 V Ignition switch is ACC position.
11 ACC switch circuit
0–1V Ignition switch is OFF position.
10 – 14 V Ignition switch is ON position.
12 Ignition switch circuit
0–1V Ignition switch is OFF position.
Driver side door knob switch Continuity Driver side door knob switch is unlock position.
16
unlock signal circuit No continuity Driver side door knob switch is lock position.
17 Ground 0–1V –
8-10 BODY ELECTRICAL SYSTEM

Power Door Lock System with Keyless Entry System (If Equipped)
Power door lock system with keyless entry system component location

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[A]: M13 engine model 3. LOCK position 7. Transmitter

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[B]: K9K engine model 4. UNLOCK position 8. Door switch

1. Power door lock controller 5. Front door actuator
2. Driver side door knob switch 6. Back door actuator
 BODY ELECTRICAL SYSTEM 8-11

System description
Only for M13 Engine Model
The keyless entry system has the following signal modes in order to feed back the signal when the controller
received LOCK and UNLOCK signals from transmitter.

Received signal
LOCK signal UNLOCK signal
Signal mode
Hazard warning light signal The hazard warning lights flash once. The hazard warning lights flash twice and
mode the interior light turns on about 15 seconds.
The interior light flashes twice. The interior light turns on about 15 seconds.
Interior light signal mode

NOTE:
• These signal modes are able to change referring to “Change of Signal Mode” in this section.
• The initial condition is the hazard warning light signal mode.

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Change of signal mode

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Only for M13 Engine Model
1) Confirm that all doors are closed and ignition key is out of
ignition switch.
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2) Perform the following procedures within 15 seconds.
a) Insert ignition key to ignition switch and pull out ignition key
from ignition switch.
b) Repeat step a) two times.
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c) Insert ignition key to ignition switch, and then push “LOCK”

button on transmitter more than five times.
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3) Confirm that hazard warning light or interior light flash once.

With this, change of signal mode is completed.
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Keyless entry system operation inspection

NOTE:
For M13 engine model, if keyless entry system is in inte-
rior light signal mode, change to hazard warning light
signal mode referring to “Change of Signal Mode” in this
section.
1) Confirm that power door lock system is good condition refer-
ring to “Power Door Lock System Operation Inspection” in
this section.
2) Confirm that turn signal and hazard warning light system is
good condition referring to “Turn Signal and Hazard Warning
Light System” in this section.
3) Check transmitter battery for dead. If battery is dead, replace
battery referring to “Replacement of Transmitter Battery”
under “Transmitter” in this section.
4) Confirm that all doors are closed and unlocked.
8-12 BODY ELECTRICAL SYSTEM

5) Check the following operation:

a) When pushing “LOCK” button (1) on transmitter (2), check
all doors lock and hazard warning lights flash once.
2
[A] b) When pushing “UNLOCK” button (3) on transmitter (2),
check all doors unlock and hazard warning lights flash twice
and interior light turn on about 15 seconds with the interior
light switch in the middle position.
3
1 [A]: M13 engine model
[B]: K9K engine model
[B] 1
2 If check result is not satisfied, go to “Keyless Entry System Circuit
Inspection” in this section.
3

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Keyless entry system circuit inspection

NOTE:

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For M13 engine model, if keyless entry system is in inte-
.
rior light signal mode, change to hazard warning light
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signal mode referring to “Change of Signal Mode” in this
section.

Check that the voltage and continuity between the following termi-
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[A]
1 nals and body ground are specifications under each conditions.
5 4 3 2 1 If check result is not as specified, check applicable circuit.
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12 11 10 9 8 7 6 If circuit is normal, recheck keyless entry system circuit as follows.

1) Substitute a known-good door lock controller.
2) Register key code referring to “Code Registration Procedure”
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[B] 1
under “Transmitter” in this section.
8 7 6 5 4 3 2 1 3) Recheck keyless entry system circuit.
18 17 16 15 14 13 12 11 10 9
[A]: M13 engine model
[B]: K9K engine model
1. Door lock controller

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 BODY ELECTRICAL SYSTEM 8-13

Keyless Entry System Circuit Check

M13 Engine Model

Terminal Circuit Specification Condition

10 – 14 V Ignition key is in ignition switch.
2 Key remainder circuit
0–1V Ignition key is not in ignition switch.
0–1V Driver side, passenger side or back door is open.
10 – 14 V All doors are close.
Fulfill the following conditions.
Door switch & interior light
4 • All door is close.
circuit
Figure “A” • Interior light switch is middle position.
• 15 seconds after pushing “UNLOCK” button
on transmitter.
Figure “B” Push “LOCK” button on transmitter.
5 Hazard warning signal circuit
Figure “C” Push “UNLOCK” button on transmitter.

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[A] [B] [C]

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12V 12V 12V

0V
. 0V 0V
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2ms/div 0.5 s/div 0.5 s/div
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[A]: Figure “A”

[B]: Figure “B”
[C]: Figure “C”
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8-14 BODY ELECTRICAL SYSTEM

K9K Engine Model

Terminal Circuit Specification Condition

Hazard waning signal circuit Figure “A” Push “LOCK” button on transmitter once.
7
(right side) Figure “B” Push “UNLOCK” button on transmitter once.
Hazard waning signal circuit Figure “A” Push “LOCK” button on transmitter once.
8
(left side) Figure “B” Push “UNLOCK” button on transmitter once.
0–1V Driver side, passenger side or back door is open.
10 – 14 V All doors are close.
Fulfill the following conditions.
Door switch & interior light
15 • All door is close.
circuit
Figure “C” • Interior light switch is middle position.
• 20 seconds after pushing
“UNLOCK” button on transmitter once

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[A] [B] [C]

12V 12V 12V

0V

1s/div
.0V
co1s/div
0V

2ms/div
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[A]: Figure “A”
[B]: Figure “B”
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[C]: Figure “C”

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 BODY ELECTRICAL SYSTEM 8-15

Transmitter
Replacement of Transmitter Battery

CAUTION:
Use care not to allow grease or dirt to be attached on the
printed circuit board and the battery.

NOTE:
• To prevent theft, be sure to break the transmitter
before discarding it.
• Dispose of the used battery properly according to
applicable rules or regulations. Do not dispose of lith-
ium batteries with ordinary household trash.

If transmitter becomes unreliable, replace transmitter battery as

follows.

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M13 Engine Model
1 1) Remove screw (1) and transmitter cover (2).

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2) Remove transmitter (3) from transmitter holder (4).
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3) Put edge of coin or flat blade screwdriver in slot of transmit-
. ter (3) and by pry it open.
3 4) Replace the battery (lithium disc-type CR1616 or equivalent
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battery) so its + terminal faces “+” mark on transmitter.
4
5) Fit together transmitter (3) and install it into transmitter
holder (4).
6) Install transmitter cover (2) and screw (1).
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7) Make sure the door locks can be operated with transmitter.

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K9K Engine Model

1) Put the edge of a coin (1) or a flat blade screwdriver in the

2 slot (2) of transmitter (3) and pry it open.
2) Replace battery (lithium disc-type CR 2032 or equivalent
battery) (4) so its + terminal faces the “+” mark of the trans-
mitter (3).
3 3) Close the transmitter (3) firmly.
4
3 4) Make sure the door locks can be operated with transmitter
1 (3).
8-16 BODY ELECTRICAL SYSTEM

Code Registration Procedure

If transmitter or door lock controller is replaced with new one or
additional transmitter(s) is necessary, register key code(s) as fol-
lows.

M13 Engine Model

1) Confirm that the vehicle is the following conditions.

• All doors are closed.
• Ignition key is out of ignition switch.
• Driver side door is unlocked and its window is opened.
2) Disconnect negative (–) cable from battery.
3) After 30 seconds, perform the following procedure within 60
seconds.
a) Connect negative (–) cable to battery.
b) Operate driver side door knob switch from lock to unlock
twice.
c) Push “LOCK” button on transmitter and confirm that all

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doors are operated from lock to unlock.
d) Push driver side door knob switch to lock position.

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e) Push “LOCK” button on transmitter twice and confirm that
all doors are operated from unlock to lock. With this, code
. registration is completed.
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NOTE:
• Two transmitter codes can be registered.
• When a new transmitter code is registered, the oldest
one will be cleared.
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K9K Engine Model

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1) Make sure that all doors are closed and ignition key is out of
ignition key cylinder.
2) Open driver side door.
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3) Turn ignition switch to ON position, and then remove ignition

key from ignition key cylinder within 10 seconds after that.
4) Push and release driver side door switch (1) at 3 times by
hand within 20 seconds after removing ignition key from igni-
tion key cylinder.
5) Turn ignition switch to ON position, and then remove ignition
key from ignition key cylinder within 10 seconds after that.
2 6) Push “UNLOCK” button (2) on transmitter (3) and confirm
that all doors are operated from lock to unlock.
With this, code registration is completed.

3 1 NOTE:
• Three transmitter codes can be registered.
• When a new transmitter code is registered, the oldest
one will be cleared.
 BODY ELECTRICAL SYSTEM 8-17

Power Door Mirror Control System (If

Equipped)
Door mirror actuator
Inspection
1) Remove front door inner garnish from front door.
2) Disconnect door mirror coupler.
3) Check that door mirror operates properly when battery volt-
age is applied to coupler terminals.
Connect battery positive and negative terminal to the door
mirror terminal shown below.
If it does not follow the table’s operation, replace door mirror
assembly.

Terminal
COM M1 M2
Operation
Up

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Down
Left

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Right

NOTE:
.
When installing door mirror to door, be careful not to
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pinch harness between door and door mirror.

[A]: Door mirror coupler

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8-18 BODY ELECTRICAL SYSTEM

Door Mirror Heater (If Equipped)

Mirror heater (if equipped)
Inspection

1) Remove door inner garnish from front door.

2) Disconnect door mirror coupler (1).
3) Check for continuity between terminals “a” and “b”.
if not continuity, replace outside mirror.

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 m
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Prepared by
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1st Ed. January, 2006
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