Tài liệu sửa chữa xe SUZUKI SWIFT 2010

Tài liệu sửa chữa xe SUZUKI SWIFT 2010, sửa chữa động cơ, hệ thống điện động cơ, hệ thống treo, hệ thống lái, hệ thống truyền lực, hộp số, vi sai, bánh xe, hệ thống phanh, hệ thống điện thân xe, hệ thống điện điều khiển, lốp, nội thất, diều hoà

TABLE OF CONTENTS Volume PRECAUTIONS 00-i Precautions 00-1 GENERAL INFORMATION 0-i General Information 0A-1 Maintenance and Lubrication 0B-1 ENGINE 1-i Precautions 1-1 Engine General Information and Diagnosis 1A-1 Aux Emission Control Devices 1B-1 Engine Electrical Devices .1C-1 Engine Mechanical .1D-1 Engine Lubrication System 1E-1 Engine Cooling System 1F-1 Fuel System 1G-1 Ignition System .1H-1 Starting System 1I-1 Charging System 1J-1 Exhaust System 1K-1 SUSPENSION 2-i Precautions 2-1 Suspension General Diagnosis 2A-1 Front Suspension 2B-1 Rear Suspension 2C-1 Wheels and Tires 2D-1 00 Precautions 8-1 Seat Belts .8A-1 Air Bag System 8B-1 BODY, CAB AND ACCESSORIES 9-i Precautions 9-1 Wiring Systems 9A-1 Lighting Systems 9B-1 Instrumentation / Driver Info / Horn .9C-1 Wipers / Washers 9D-1 Glass / Windows / Mirrors 9E-1 Security and Locks 9F-1 Seats 9G-1 Interior Trim 9H-1 Hood / Fenders / Doors 9J-1 Body Structure .9K-1 Paint / Coatings 9L-1 CONTROL SYSTEMS 10-i Precautions 10-1 Body Electrical Control System 10B-1 Immobilizer Control System 10C-1 DRIVELINE / AXLE 3-i Drive Shaft / Axle 3A-1 BRAKES 4-i Precautions 4-1 Brake Control System and Diagnosis 4A-1 Front Brakes 4B-1 Rear Brakes 4C-1 Parking Brake .4D-1 ABS 4E-1 TRANSMISSION / TRANSAXLE 5-i Precautions 5-1 Automatic Transmission 5A-1 Manual Transmission 5B-1 Clutch .5C-1 STEERING 6-i Precautions 6-1 Steering General Diagnosis 6A-1 Steering Wheel and Column 6B-1 Power Assisted Steering System 6C-1 HVAC 7-i Precautions 7-1 Heater and Ventilation 7A-1 Air Conditioning System 7B-1 RESTRAINTS 8-i 10 11 Table of Contents 00- i Section 00 PRECAUTIONS CONTENTS Precautions .00-1 Precautions 00-1 Precautions for Vehicles Equipped with a Supplemental Restraint (Air Bag) System 00-1 General Precautions 00-3 Precautions for Catalytic Converter 00-6 Precautions for Installing Mobile Communication Equipment 00-6 Precaution for CAN Communication System 00-6 Precautions for Electrical Circuit Service 00-6 Air Bag Warning 00-8 Air Bag System Service Warning 00-8 Fastener Caution 00-8 Suspension Caution 00-9 Wheels and Tires Caution 00-9 Brake Caution 00-9 Repair Instructions 00-9 Electrical Circuit Inspection Procedure 00-9 Intermittent and Poor Connection Inspection 00-11 00 00-1 Precautions: Precautions Precautions Precautions for Vehicles Equipped with a Supplemental Restraint (Air Bag) System S4RS0A0000001, 01(01) WARNING: • The configuration of air bag system parts are as shown in the figure When it is necessary to service (remove, reinstall and inspect) these parts, be sure to follow procedures described in Air Bag System section Failure to follow proper procedures could result in possible air bag system activation, personal injury, damage to parts or air bag system being unable to activate when necessary • 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, dashboard, or any other air bag system components 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 beforehand to avoid component damage or unintended air bag system activation Diagnosis • When troubleshooting air bag system, be sure to follow “Diagnosis” in Air Bag System section Bypassing these procedures may result in extended diagnostic time, incorrect diagnosis, and incorrect parts replacement • Never use electrical test equipment other than that specified WARNING: Never attempt to measure the resistance of the air bag (inflator) modules (driver, passenger, side and curtain) and seat belt pretensioners (driver and passenger) It is very dangerous as the electric current from the tester may deploy the air bag or activate the pretensioner I4RS0A000002 Servicing and Handling 10 10 I4RS0A000001 Air bag wire harness (in floor, main and instrument panel harness) Driver air bag (inflator) module Passenger air bag (inflator) module Side air bag (inflator) module (if equipped) SDM Curtain air bag (inflator) module (if equipped) Seat belt pretensioner Contact coil Forward sensor 10 Side sensor (if equipped) WARNING: Many of service procedures require disconnection of “A/BAG” fuse and all air bag (inflator) module(s) from initiator circuit to avoid an accidental deployment Driver, Passenger, Side and Curtain Air Bag (Inflator) Modules Precautions: • For handling and storage of a live air bag (inflator) module, select a place where the ambient temperature below 65 °C (150 °F), without high humidity and away from electric noise • When carrying a live air bag (inflator) module, make sure the bag opening is pointed away from you In case of an accidental deployment, the bag will then deploy with minimal chance of injury Never carry the air bag (inflator) module by the wires or connector on the underside of the module When placing a live air bag (inflator) module on a bench or other surface, always face the bag up, away from the surface As the live passenger air bag (inflator) module must be placed with its bag (trim cover) facing up, place it on the workbench with a slit (1) or use the workbench vise (2) to hold it securely at its lower mounting bracket (3) It is also prohibited to place anything on top of the trim cover and stack air bag (inflator) modules This is necessary so that a free space is provided to allow the air bag to expand in the unlikely event of accidental deployment Otherwise, personal injury may result • Never dispose of live (undeployed) air bag (inflator) modules (driver, passenger, side and curtain) If disposal is necessary, be sure to deploy them according to deployment procedures described in “Air Bag (Inflator) Module and Seat Belt Pretensioner Disposal: in Section 8B” before disposal • The air bag (inflator) module immediately after deployment is very hot Wait for at least half an hour to cool it off before proceeding the work • After an air bag (inflator) module has been deployed, the surface of the air bag may contain a powdery residue This powder consists primarily of cornstarch (used to lubricate the bag as it inflates) and byproducts of the chemical reaction As with many service procedures, gloves and safety glasses should be worn 00-2 [A] [B] I4RS0A000003 [A]: Always carry air bag (inflator) module with trim cover (air bag opening) away from body [B]: Always place air bag (inflator) module on workbench with trim cover (air bag opening) up, away from loose objects WARNING: SDM • For handling and storage of a SDM, select a place where the ambient temperature below 65 °C (150 °F), without high humidity and away from electric noise • During service procedures, be very careful when handling a Sensing and Diagnostic Module (SDM) Never strike or jar the SDM • Never power up the air bag system when the SDM is not rigidly attached to the vehicle All SDM and mounting bracket fasteners must be carefully torqued and the arrow must be pointing toward the front of the vehicle to ensure proper operation of the air bag system 00-3 Precautions: The SDM could be activated when powered while not rigidly attached to the vehicle which could cause deployment and result in personal injury • WARNING: Driver and Passenger Seat Belt Pretensioners • For handling and storage of a live seat belt pretensioner, select a place where the ambient temperature below 65 °C (150 °F), without high humidity and away from electric noise • Never carry seat belt pretensioner by wire or connector of pretensioner When placing a live seat belt pretensioner on the workbench or some place like that, never put something on seat belt pretensioner Otherwise, personal injury may result • Never dispose of live (inactivated) seat belt pretensioners (drive and passenger) If disposal is necessary, be sure to activate them according to activation procedures described in “Air Bag (Inflator) Module and Seat Belt Pretensioner Disposal: in Section 8B” before disposal • The seat belt pretensioner immediately after activation is very hot Wait for at least half an hour to cool it off before proceeding the work • With many service procedures, gloves and safety glasses should be worn to prevent any possible irritation of the skin or eyes • Even when the accident was light enough not to cause air bags to activate, be sure to inspect system parts and other related parts according to instructions under “Repair and Inspection Required after Accident: in Section 8B” • When servicing parts other than air bag system, if shocks may be applied to air bag system component parts, remove those parts beforehand • When handling the air bag (inflator) modules (driver, passenger, side and curtain), seat belt pretensioners (driver and passenger), forward sensor, side sensors or SDM, be careful not to drop it or apply an impact to it If an excessive impact was applied, never attempt disassembly or repair but replace it with a new one • When grease, cleaning agent, oil, water, etc has got onto air bag (inflator) modules (driver, passenger, side and curtain) or seat belt pretensioners (drive and passenger), wipe off immediately with a dry cloth • Air bag wire harness is included in floor and instrument panel wire harnesses Air bag wire harness branched off from floor and instrument panel • • • • • • wire harnesses can be identified easily as it is covered with a yellow protection tube and it has yellow connectors Be very careful when handling it When an open in air bag wire harness, damaged wire harness, connector or terminal is found, replace wire harness, connectors and terminals as an assembly Do not apply power to the air bag system unless all components are connected or a diagnostic flow requests it, as this will set a DTC Never use air bag system component parts from another vehicle When using electric welding, be sure to disconnect all air bag (inflator) module connectors and pretensioner connectors from air bag wire harness respectively Never expose air bag system component parts directly to hot air (drying or baking the vehicle after painting) or flames WARNING / CAUTION labels are attached on each part of air bag system components Be sure to follow the instructions After vehicle is completely repaired, perform “Air Bag Diagnostic System Check: in Section 8B” General Precautions S4RS0A0000002, 01(01) The WARNING and CAUTION describe some general precautions that you should observe when servicing a vehicle These general precautions apply to many of the service procedures, 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 Section 0A” • When it is necessary to 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 automatic 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 refrigerant), make sure that the area you work in is wellventilated • To avoid getting burned, keep away from hot metal parts such as the radiator, exhaust manifold, tail pipe, muffler, etc Precautions: • 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 animals Brief contact with used oil may irritate skin To minimize your exposure to used engine oil, wear a longsleeve 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 • 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 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 – 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 00-4 • When performing service to electrical parts that does not require use of battery power, disconnect the negative cable of the battery • When disconnecting the negative cable from the battery, record displayed contents of the clock and/or audio system before disconnecting and reset it as before after connecting I2RH01010026 • 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 I2RH01010027 • 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 • 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 I2RH01010028 • Whenever you use oil seals, gaskets, packing, Orings, locking washers, split pins, self-locking nuts, and certain 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 I2RH01010025 00-5 Precautions: I2RH01010029 • 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 I2RH01010032 • After servicing fuel, oil, coolant, vacuum, exhaust or brake systems, check all lines related to the system for leaks “A”: Water tight sealant 99000–31250 I2RH01010033 I2RH01010030 • Be sure to use special tools when instructed Special tool (A): 09917-98221 (B): 09916-58210 I2RH01010031 • When disconnecting vacuum hoses, attach a tag describing the correct installation positions so that the hoses can be reinstalled correctly • For vehicles equipped with fuel injection systems, never disconnect the fuel line between the fuel pump and injector without first releasing the fuel pressure, or fuel can be sprayed out under pressure • 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 I2RH01010034 • Use care not to expose connectors and electrical parts to water which will be a cause of a trouble Precautions: 00-6 • Confirm that the antenna and feeder are correctly adjusted Precaution for CAN Communication System S4RS0A0000014, 01(01) • The loose (1) in the wire harnesses twist of the CAN lines except around the connector (3) should be within 100 mm (3.9 in.) Refer to the wiring diagram for the CAN lines discrimination Excessively-loosed lines may be influenced by the electric noise 3 I2RH01010035 • Always be careful not to handle electrical parts (computer, relay, etc.) in a rough manner or drop them 2 I4JA01000002 • Do not connect terminals of the CAN line using a bypass wire (1) Otherwise, the CAN line may be influenced by the electric noise I2RH01010036 Precautions for Catalytic Converter S4RS0A0000003, 01(01) For vehicles equipped with a catalytic converter, use only unleaded gasoline and be careful not to let a large amount of unburned gasoline enter the converter or it can be damaged • Conduct a spark jump test only when necessary, make it as short as possible, and not open the throttle • Conduct engine compression checks within the shortest possible time • Avoid situations which can result in engine misfire (e.g starting the engine when the fuel tank is nearly empty.) Precautions for Installing Mobile Communication Equipment I4JA01000003 Precautions for Electrical Circuit Service S4RS0A0000007, 01(01) • When replacing a fuse, make sure to use a fuse of the specified capacity Use of a fuse with a larger capacity will cause a damage to the electrical parts and a fire S4RS0A0000004, 01(01) When installing mobile communication equipment such as CB (Citizens-Band)-radio or cellular-telephone, be sure to observe the following precautions Failure to follow cautions may adversely affect electronic control system • Keep the antenna as far away as possible from the vehicle’s electronic control unit • Keep the antenna feeder more than 20 cm (7.9 in.) away from electronic control unit and its wire harnesses • Do not run the antenna feeder parallel with other wire harnesses I2RH01010038 • When disconnecting and connecting coupler, make sure to turn ignition switch OFF, or electronic parts may get damaged 00-7 Precautions: I2RH01010043 I2RH01010039 • To avoid damage to the harness, protect its part which may contact against a part forming a sharp angle by winding tape or the like around it • When disconnecting connectors, never pull the wiring harness Unlock the connector lock first and then pull them apart by holding connectors themselves I2RH01010044 • Be careful not to touch the electrical terminals of parts which use microcomputers (e.g electronic control unit like as ECM, PCM, P/S controller, etc.) The static electricity from your body can damage these parts I2RH01010040 • When connecting connectors, also hold connectors and put them together until they lock securely (a click is heard) I3RM0A000004 I2RH01010041 • When installing the wiring harness, fix it with clamps so that no slack is left I2RH01010042 • When installing vehicle parts, be careful so that the wiring harness is not interfered with or caught by any other part • Never connect any tester (voltmeter, ohmmeter, or whatever) to electronic control unit when its coupler is disconnected Attempt to it may cause damage to it • Never connect an ohmmeter to electronic control unit with its coupler connected to it Attempt to it may cause damage to electronic control unit and sensors • Be sure to use a specified voltmeter / ohmmeter Otherwise, accurate measurements may not be obtained or personal injury may result If not specified, use a voltmeter with high impedance (M Ω/V minimum) or a digital type voltmeter • When taking measurements at electrical connectors using a tester probe, be sure to insert the probe (2) from the wire harness side (backside) of the connector (1) 10C-1 Immobilizer Control System: Immobilizer Control System Precautions Precautions in Diagnosing Troubles S4RS0AA300001, 01(01) • Before confirming the diagnostic trouble code (DTC), not disconnect connector from ECM, battery cable from battery, ground wire harness, or main fuse Such disconnection will erase DTC stored in ECM • DTC stored in ECM memory can be checked as well as cleared by using SUZUKI scan tool Before using SUZUKI scan tool, read its operator's manual carefully to know how to use it and what functions are available • Be sure to read “Precautions for Electrical Circuit Service: in Section 00” before inspection • Communication of ECM, BCM, and combination meter is established by CAN (Computer Area Network) Therefore, handle CAN communication lines with care referring to “Precaution for CAN Communication System: in Section 00” Precaution in Replacing ECM I3RH0AA30002 • Do not leave ignition key in a place where temperature is high High temperature may cause damage to the transponder built in the ignition key S4RS0AA300003, 01(01) After ECM is replaced with new one, the transponder code in the transponder built in the ignition key has to be registered with ECM Or, the engine cannot be started up For the registration procedure, refer to “Procedure after ECM Replacement: ” Precautions in Handling Immobilizer Control System S4RS0AA300002, 01(01) • Do not turn ON ignition switch with ignition key in contact with another one or quite close to another one Or, the immobilizer control system may detect some abnormal condition and prevent the engine from starting I3RH0AA30003 • Do not turn ignition switch to ON position by bringing radio antenna close to coil antenna Or, the immobilizer control system may detect some abnormal condition and prevent the engine from starting I3RH0AA30001 • Do not turn ON ignition switch by using ignition key with any type of metal (1) wrapped its grip or in contact with it Or, the immobilizer control system may detect some abnormal condition and prevent the engine from starting I3RH0AA30004 Immobilizer Control System: 10C-2 General Description Immobilizer Control System Introduction reads the code by the coil antenna Then, if the code in transponder in the ignition key does not match with the one registered with ECM, ECM stops the operation of the fuel injection so as not to start up the engine and turns the immobilizer indicator lamp ON and OFF using CAN communication lines S4RS0AA301001, 03(01) The immobilizer control system is an anti-theft device that immobilizes the vehicle It stops the engine from working and prevents the vehicle from being stolen It mainly consists of the following components • Engine Control Module (ECM) • Immobilizer controller assembly with the built-in coil antenna • Ignition key with the built-in transponder A code called the transponder code is memorized in the transponder And, the code is registered with ECM Basically, when the ignition switch is turned ON, ECM NOTE: The authentication process mentioned above is only a part of the entire authentication process For security reasons, the detailed explanation is left out Immobilizer Control System Components Location S4RS0AA301004, 04(01) I4RS0AA30001 ECM Ignition key with keyless entry system Immobilizer indicator lamp Ignition key without keyless entry system Immobilizer controller assembly On-Board Diagnostic System Description (Selfdiagnosis Function) No trouble exists in the immobilizer control system (After starting up the engine, the lamp turns OFF.) ECM diagnoses if there is any trouble with the immobilizer control system The diagnostic information is stored as the diagnostic trouble code (DTC) in ECM To read the diagnostic information, use SUZUKI scan tool referring to “Diagnostic Trouble Code (DTC) Check: ” With the ignition switch turned ON (but the engine at stop) regardless of the condition of the engine and emission control system, ECM indicates whether there is any trouble with the immobilizer control system or not by either lighting ON or flashing ON and OFF the immobilizer indicator lamp Immobilizer indicator lamp flashes ON and OFF: There is some trouble with the immobilizer control system Its diagnostic information is stored in ECM S4RS0AA301002, 03(01) Immobilizer indicator lamp lights ON: 10C-3 Immobilizer Control System: I4RS0AA30002 Schematic and Routing Diagram Immobilizer Control System Wiring Circuit Diagram S4RS0AA302001, 10(03) NOTE: For more details about power supply and ground circuits for ECM, BCM, and combination meter, refer to “System Circuit Diagram: in Section 9A” Immobilizer Control System: 10 GRN WHT/BLU 10C-4 BLK/WHT G24-1 12V 12V 12V BLK/ORN G24-2 G24-4 WHT YEL/RED WHT/RED G24-3 YEL/BLK E23-13 E23-28 12V 15 BLK 12V 16 11 13 BLK/ORN G28-32 G28-31 E23-5 E23-3 E23-18 RED WHT PLL/WHT E46-9 PLL/WHT 12V 14 E46-2 E46-1 G37-5 G37-4 RED G28-10 G37-2 WHT G28-8 12 E46 17 18 14 13 12 11 10 19 G37 11 10 22 21 20 19 18 17 16 15 14 13 12 G24 G28 20 16 15 14 13 12 11 10 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 21 E23 15 14 30 29 C37 13 12 11 10 28 27 26 25 24 23 22 21 20 19 18 17 16 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 15 14 30 29 13 12 11 10 28 27 26 25 24 23 22 21 20 19 18 17 16 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 I4RS0AA30003 Battery “IG COIL” fuse (15 A) 13 Combination meter 19 Immobilizer controller assembly connector “G24” (harness side view) “MAIN” fuse (80 A) “DOME” fuse (15 A) 14 Immobilizer indicator lamp 20 Combination meter connector “G28” (harness side view) “LAMP” fuse (50 A) Data link connector (DLC) 15 From “DOME” fuse (15 A) 21 ECM connectors “E23” and “C37” (harness side view) “IGN” fuse (50 A) 10 Immobilizer controller assembly 16 From “METER” fuse (10 A) Ignition coil 11 ECM 17 BCM connector “E46” (harness side view) Junction block assembly 12 BCM 18 BCM connector “G37” (harness side view) 10C-5 Immobilizer Control System: Diagnostic Information and Procedures Immobilizer Control System Check Step S4RS0AA304001, 06(01) 1) Start the engine Is it possible to start the engine? Step YES Immobilizer control system is in good condition NO Go to Step 1) Check behavior of immobilizer indicator lamp (1) by turning the ignition switch to ON position I4RS0AA30004 Does it flash ON and OFF continuously? YES Check what diagnostic trouble code (DTC) is detected by ECM referring to “Diagnostic Trouble Code (DTC) Check: ” Then, perform the troubleshooting referring to the corresponding flowchart in this section NO Perform “Engine and Emission Control System Check: in Section 1A” Diagnostic Trouble Code (DTC) Check S4RS0AA304002, 06(01) NOTE: To know how to use SUZUKI scan tool in detail, refer to its operator’s manual 1) Turn the ignition switch to OFF position 2) Connect SUZUKI scan tool to data link connector (DLC) (1) located under instrument panel at driver’s seat side Special tool (A): SUZUKI scan tool 3) Turn the ignition switch to ON position 4) Check if any DTC is stored in ECM according to the instructions displayed on SUZUKI scan tool 5) After completing the check, turn ignition switch to OFF position, and then disconnect SUZUKI scan tool from DLC Diagnostic Trouble Code (DTC) Clearance S4RS0AA304027, 06(01) NOTE: To know how to use SUZUKI scan tool in detail, refer to its operator’s manual 1) Turn the ignition switch to OFF position, 2) Connect SUZUKI scan tool to data link connector (DLC) (1) located under instrument panel at driver’s seat side (A) Special tool (A): SUZUKI scan tool I4RS0AA30005 Immobilizer Control System: (A) 10C-6 2) Clear DTC(s) according to the instructions displayed on SUZUKI scan tool 3) After completing the clearance, turn the ignition switch to OFF position, and then disconnect SUZUKI scan tool from DLC I4RS0AA30005 1) Turn the ignition switch to ON position Diagnostic Trouble Code (DTC) Table S4RS0AA304003, 06(01) ECM DTC No Description Transponder response error P1614 Immobilizer communication line error P1621 P1622 P1623 P1625 EEPROM error Unregistered transponder Immobilizer antenna error Detecting Condition Transponder code in the transponder built in the ignition key cannot be read through immobilizer controller assembly Communication error between immobilizer controller assembly and ECM is detected by ECM EEPROM in ECM is corrupted Transponder code in the transponder built in the ignition key is invalid Immobilizer controller assembly is faulty NOTE: If any DTC other than the above DTCs is detected, refer to “DTC Table: in Section 1A” Scan Tool Data S4RS0AA304016, 06(01) The data listed below is the standard data obtained from the normal vehicle by using SUZUKI scan tool Those are output from ECM Use them as reference Scan Tool Data Vehicle Condition Normal Data NUMBER OF LEARNT KEY Ignition switch at ON position PCS INPUT YEAR Ignition switch at ON position 2004 INPUT MONTH Ignition switch at ON position NOTE: The normal data shown above is just an example Keep in mind that the data varies for each vehicle Scan Tool Data Definitions NUMBER OF LEARNT KEY - PCS: The number of the transponder code in the transponder built in the ignition key that is registered with ECM NOTE: A maximum of four transponder codes can be registered with ECM Therefore, the maximal value should be DTC P1614 Transponder Response Error INPUT YEAR 20**: The year in which the transponder code in the transponder built in the ignition key is registered with ECM INPUT MONTH – 12: The month in which the transponder code in the transponder built in the ignition key is registered with ECM S4RS0AA304028, 06(02) 10C-7 Immobilizer Control System: Possible Cause and Trouble Area Possible Cause • Temporary error • Use of the ignition key without the transponder • Corruption of the transponder in the ignition key • Immobilizer controller assembly faulty • ECM faulty • • • • • Trouble Area Communication among each component Ignition key Transponder Immobilizer controller assembly ECM Troubleshooting Step Diagnostic Trouble Code (DTC) confirmation: 1) Clear DTC(s) referring to “Diagnostic Trouble Code (DTC) Clearance: ” 2) Turn the ignition switch to OFF position 3) Check if any DTC is detected referring to “Diagnostic Trouble Code (DTC) Check: ” Is DTC P1614 still detected? Step YES Go to Step NO The troubleshooting is completed Diagnostic Trouble Code (DTC) check: 1) Check if any DTC other than P1614 is detected referring to “Diagnostic Trouble Code (DTC) Check: ” Is any DTC other than P1614 is detected? Step YES Perform troubleshooting referring to the corresponding flowchart in this section, and then go to Step NO Go to Step Registration of the new ignition key with ECM and Diagnostic Trouble Code (DTC) check: 1) The transponder in the ignition key is corrupted or the ignition key without the transponder is used Therefore, prepare the new ignition key 2) Register the transponder code in the transponder in the new ignition key with ECM referring to “Registration of the Ignition Key: ” 3) Make sure that DTC P1614 is not detected referring to “Diagnostic Trouble Code (DTC) Check: ” Is DTC P1614 still detected? Step YES Go to Step NO The troubleshooting is completed Check for fault of immobilizer controller assembly: 1) Check immobilizer controller assembly referring to “Inspection of Immobilizer Controller Assembly and Its Circuit: ” Is immobilizer controller assembly normal? YES Replace ECM with new one referring to “Engine Control Module (ECM) Removal and Installation: in Section 1C”, and then perform “Procedure after ECM Replacement: ” NO Replace immobilizer controller assembly with new one referring to “Immobilizer Controller Assembly Removal and Installation: ” DTC P1621 Immobilizer Communication Line Error S4RS0AA304029, 06(02) Immobilizer Control System: Possible Cause and Trouble Area Possible Cause • Temporary error • Related fuse(s) blown • Poor connection at immobilizer controller assembly connector • “BLK/WHT” wire open • “BLK/ORN” wire open • “YEL/BLK” wire open, short to ground circuit, short to power circuit, or shorted to “YEL/RED” wire • “YEL/RED” wire open, short to ground circuit, short to power circuit, or shorted to “YEL/BLK” wire • Immobilizer controller assembly faulty • ECM faulty • • • • • • • • 10C-8 Trouble Area Related fuse(s) Connection at immobilizer controller assembly “BLK/WHT” wire “BLK/ORN” wire “YEL/BLK” wire “YEL/RED” wire Immobilizer controller assembly ECM Troubleshooting Step Diagnostic Trouble Code (DTC) confirmation: 1) Clear DTC(s) referring to “Diagnostic Trouble Code (DTC) Clearance: ” 2) Turn the ignition switch to OFF position 3) Check if any DTC is detected referring to “Diagnostic Trouble Code (DTC) Check: ” Is DTC P1621 still detected? Step YES Go to Step NO The troubleshooting is completed Fuse check: 1) Check if any related fuse is blown Is any fuse blown? Step YES Replace blown fuse(s) with new one (s) NO Go to Step Check for poor connection at immobilizer controller assembly: 1) Disconnect immobilizer controller assembly connector “G24” referring to “Immobilizer Controller Assembly Removal and Installation: ” 2) Check if wire connections are normal at immobilizer assembly connector “G24” Is each wire connection normal? Step YES Go to Step NO Repair poor connection(s) Check for poor connection at ECM: 1) Disconnect ECM connector “E23” referring to “Engine Control Module (ECM) Removal and Installation: in Section 1C” 2) Check if wire connections at “E23-13” and “E23-28” wire terminals are normal Is each wire connection normal? YES Go to Step NO Repair poor connection(s) 10C-9 Immobilizer Control System: Step Check for open in “BLK/WHT” wire: 1) Connect immobilizer controller assembly connector “G24” referring to “Immobilizer Controller Assembly Removal and Installation: ” 2) With the ignition switch at ON position, check voltage between “G24-1” wire terminal at immobilizer controller assembly and body ground Is voltage about 12 V? Step YES Go to Step NO Repair open in “BLK/WHT” wire Check for open in “BLK/ORN” wire: 1) With the ignition switch at ON position, check voltage between “G24-2” wire terminal at immobilizer controller assembly and body ground Is voltage 0? Step YES Go to Step NO Repair open in “BLK/ORN” wire Check for open in “YEL/BLK” wire: 1) Disconnect immobilizer controller assembly connector “G24” referring to “Immobilizer Controller Assembly Removal and Installation: ” 2) Disconnect ECM connector “E23” referring to “Engine Control Module (ECM) Removal and Installation: in Section 1C” 3) Check resistance between “G24-3” wire terminal at immobilizer controller assembly connector and “E2328” wire terminal at ECM connector Is resistance infinite? Step YES Repair open in “YEL/BLK” wire NO Go to Step Check for short to ground circuit in “YEL/BLK” wire: 1) With immobilizer controller assembly connector “G24” and ECM connector “E23” disconnected, check resistance between “G24-3” wire terminal at immobilizer controller assembly connector and body ground Is resistance infinite? Step YES Go to Step NO Repair short to ground circuit in “YEL/BLK” wire Check for short to power circuit in “YEL/BLK” wire: 1) With immobilizer controller assembly connector “G24” and ECM connector “E23” disconnected, turn the ignition switch to ON position 2) Check voltage between “G24-3” wire terminal at immobilizer controller assembly connector and body ground Is voltage V? YES Go to Step 10 NO Repair short to power circuit in “YEL/BLK” wire Immobilizer Control System: 10C-10 Step 10 Check for open in “YEL/RED” wire: 1) With immobilizer controller assembly connector “G24” and ECM connector “E23” disconnected, check resistance between “G24-4” wire terminal at immobilizer controller assembly connector and “E23-13” wire terminal at ECM connector Is resistance infinite? YES Repair open in “YEL/RED” wire NO Go to Step 11 Step 11 Check for short to ground circuit in “YEL/RED” wire: 1) With immobilizer controller assembly connector “G24” and ECM connector “E23” disconnected, check resistance between “G24-4” wire terminal at immobilizer controller assembly connector and body ground Is resistance infinite? YES Go to Step 12 NO Repair short to ground circuit in “YEL/RED” wire Step 12 Check for short to power circuit in “YEL/RED” wire: 1) With immobilizer controller assembly connector “G24” and ECM connector “E23” disconnected, turn the ignition switch to ON position 2) Check voltage between “G24-4” wire terminal at immobilizer controller assembly connector and body ground Is voltage V? YES Go to Step 13 NO Repair short to power circuit in “YEL/RED” wire Step 13 Check for short of “YEL/BLK” and “YEL/RED” wires: 1) With immobilizer controller assembly connector “G24” and ECM connector “E23” disconnected, check resistance between “G24-3” wire terminal and “G24-4” wire terminal at immobilizer controller assembly connector Is resistance infinite? YES Go to Step 14 NO Repair short of “YEL/BLK” and “YEL/RED” wires Step 14 Check for fault of immobilizer controller assembly: 1) Check immobilizer controller assembly referring to “Inspection of Immobilizer Controller Assembly and Its Circuit: ” Is immobilizer controller assembly normal? YES Replace ECM with new one referring to “Engine Control Module (ECM) Removal and Installation: in Section 1C”, and then perform “Procedure after ECM Replacement: ” NO Replace immobilizer controller assembly with new one referring to “Immobilizer Controller Assembly Removal and Installation: ” DTC P1622 EEPROM Error S4RS0AA304030, 06(02) 10C-11 Immobilizer Control System: Possible Cause and Trouble Area Possible Cause • Temporary error • Internal failure (EEPROM corruption) of ECM Trouble Area ECM Troubleshooting 1) Clear DTC(s) referring to “Diagnostic Trouble Code (DTC) Clearance: ” 2) Turn the ignition switch to OFF position 3) Check if DTC P1622 is still detected referring to “Diagnostic Trouble Code (DTC) Check: ” If still detected, go to the next step If not, the troubleshooting is completed 4) Replace ECM with new one referring to “Engine Control Module (ECM) Removal and Installation: in Section 1C” 5) Perform “Procedure after ECM Replacement: ” DTC P1623 Unregistered Transponder Possible Cause and Trouble Area Possible Cause • Temporary error • Use of the unregistered ignition key • Immobilizer controller assembly faulty • ECM faulty S4RS0AA304031, 06(02) Trouble Area • Transponder in the ignition key • Immobilizer controller assembly • ECM Troubleshooting Step Diagnostic Trouble Code (DTC) confirmation: 1) Clear DTC(s) referring to “Diagnostic Trouble Code (DTC) Clearance: ” 2) Turn the ignition switch to OFF position 3) Check if any DTC is detected referring to “Diagnostic Trouble Code (DTC) Check: ” Is DTC P1623 still detected? Step YES Go to Step NO The troubleshooting is completed Diagnostic Trouble Code (DTC) check: 1) Check if any DTC other than P1623 is detected referring to “Diagnostic Trouble Code (DTC) Check: ” Is any DTC other than P1623 is detected? Step YES Perform troubleshooting referring to the corresponding flowchart in this section, and then go to Step NO Go to Step Registration of the unregistered ignition key with ECM and Diagnostic Trouble Code (DTC) check: 1) Register the transponder code in the transponder in the unregistered ignition key with ECM referring to “Registration of the Ignition Key: ” 2) Make sure that DTC P1623 is not detected referring to “Diagnostic Trouble Code (DTC) Check: ” Is DTC P1623 still detected? Step YES Go to Step NO The troubleshooting is completed Check for fault of immobilizer controller assembly: 1) Check immobilizer controller assembly referring to “Inspection of Immobilizer Controller Assembly and Its Circuit: ” Immobilizer Control System: 10C-12 Is immobilizer controller assembly normal? YES Replace ECM with new one referring to “Engine Control Module (ECM) Removal and Installation: in Section 1C”, and then perform “Procedure after ECM Replacement: ” NO Replace immobilizer controller assembly with new one referring to “Immobilizer Controller Assembly Removal and Installation: ” DTC P1625 Immobilizer Antenna Error Possible Cause and Trouble Area Possible Cause • Temporary error • Immobilizer controller assembly faulty • ECM faulty S4RS0AA304032, 06(02) Trouble Area • Immobilizer controller assembly • ECM Troubleshooting Step Diagnostic Trouble Code (DTC) confirmation: 1) Clear DTC(s) referring to “Diagnostic Trouble Code (DTC) Clearance: ” 2) Turn the ignition switch to OFF position 3) Check if any DTC is detected referring to “Diagnostic Trouble Code (DTC) Check: ” Is DTC P1625 still detected? Step YES Go to Step NO The troubleshooting is completed Immobilizer controller assembly replacement and Diagnostic Trouble Code (DTC) check: 1) Replace immobilizer controller assembly referring to “Immobilizer Controller Assembly Removal and Installation: ” 2) Check if DTC P1625 is still detected referring to “Diagnostic Trouble Code (DTC) Check: ” Is DTC P1625 still detected? YES Replace ECM with new one referring to “Engine Control Module (ECM) Removal and Installation: in Section 1C”, and then perform “Procedure after ECM Replacement: ” NO The troubleshooting is completed Inspection of Immobilizer Controller Assembly and Its Circuit S4RS0AA304015, 06(01) Reference: “Immobilizer Control System Wiring Circuit Diagram: ” Immobilizer controller assembly and its circuit can be checked at immobilizer controller assembly wiring connector by measuring voltage CAUTION: Immobilizer controller assembly cannot be checked by itself It is strictly prohibited to connect voltmeter or ohmmeter to immobilizer controller assembly with connector disconnected from it Voltage Check 1) Remove immobilizer controller assembly (1) from steering lock assembly referring to “Immobilizer Controller Assembly Removal and Installation: ” 2) Connect immobilizer controller assembly wiring connector (2) to immobilizer controller assembly 3) Check voltage at each terminal 10C-13 Immobilizer Control System: NOTE: As each terminal voltage is affected by the battery voltage, confirm that it is 11 V or more when the ignition switch is turned to ON position 2 G24 I4RS0AA30006 Connector G24 Terminal Circuit BLK/ Power supply WHT BLK/ Ground ORG YEL/ Serial communication line BLK YEL/ Clock line RED Normal Voltage About 12.0 V 0.0 V 0.0 V 0.0 V See the reference waveform 0.0 V See the reference waveform 0.0 V Condition Ignition switch at ON position Ignition switch at OFF position Ignition switch at ON position Ignition switch at OFF position — Ignition switch at OFF position — Ignition switch at OFF position Immobilizer Control System: Reference waveform 10C-14 NOTE: When ECM cannot read the transponder code at the first try, ECM tries to read the transponder code repeatedly up to times The second waveform is the example showing that ECM read the transponder code successfully at the second try Measurement terminals Oscilloscope settings Measurement condition CH1: G24-3 to G24-2 CH2: G24-4 to G24-2 CH1: V/DIV CH2: V/DIV TIME: 20 ms Right after the ignition switch is turned ON, the waveform can be read I4RS0AA30007- [A]: The transponder code read successfully at the first try [B]: The transponder code read successfully at the second try Serial communication line Clock line First try Second try Repair Instructions Immobilizer Controller Assembly Removal and Installation S4RS0AA306005, 08(01) Reference: “Inspection of Immobilizer Controller Assembly and Its Circuit: ” Removal 1) Disconnect negative (-) cable at battery 2) Disable air bag system referring to “Disabling Air Bag System: in Section 8B” 3) Remove driver air bag (inflator) module referring to “Driver Air Bag (Inflator) Module Removal and Installation: in Section 8B” 4) Remove steering wheel referring to “Steering Wheel Removal and Installation: in Section 6B” 5) Remove steering column lower and upper covers 6) Disconnect connector (1) from immobilizer controller assembly (2) 7) Remove a screw (3) from immobilizer controller assembly 10C-15 Immobilizer Control System: NOTE: • A maximum of four transponder codes can be registered with ECM • At an early part of the registration process, all transponder codes of the ignition keys in use already registered with ECM are cleared Therefore, before starting the registration, prepare all ignition keys in use in addition to the new ignition key(s) to be registered with ECM I4RS0AA30008 8) Remove immobilizer controller assembly from steering lock assembly Installation Reverse the removal procedure Registration of the Ignition Key S4RS0AA306002, 08(02) To finish the registration of the ignition key, the transponder code memorized in the transponder built in the ignition key has to be registered with ECM To register the transponder code with ECM, perform “Register Ig Key” mode of SUZUKI scan tool referring to “SUZUKI Tech Operator’s Manual” Procedure after ECM Replacement S4RS0AA306004, 08(03) After ECM is replaced with new one, the transponder code in the transponder built in the ignition key has to be registered with ECM To register transponder code in the ignition key with ECM, perform “Replace New ECM” mode of SUZUKI scan tool referring to “SUZUKI Tech Operator’s Manual” NOTE: A maximum of four transponder codes can be registered with ECM Special Tools and Equipment Special Tool SUZUKI scan tool — This kit includes following items Tech 2, PCMCIA card, DLC cable, SAE 16/19 adapter, Cigarette cable, DLC loopback adapter, Battery power cable, RS232 cable, RS232 adapter, 10 RS232 loop back connector, 11 Storage case, 12 Power supply (L10C001) / (L10C002) S4RS0AA308001, 11(01)