Eeco CNG

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
This service manual is intended for authorized MARUTI 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.
Improper repair may result in injury to the technician and may render the vehicle unsafe for the driver
and passengers.
! WARNING
For vehicles equipped with a Supplemental Restraint (Air Bag) System:
• Service on and around the air bag system components or wiring must be performed only by an
authorized MARUTI dealer. Refer to “Air Bag System Components and Wiring Location View” under
“General Description” in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser-
vice Precautions” under “On-Vehicle Service” in air bag system section before performing service
on or around the air bag system components or wiring. Failure to follow WARNINGS could result in
unintentional activation of the system or could render the system inoperative. Either of these two
conditions may result in severe injury.
• If the air bag system and another vehicle system both need repair, MARUTI 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 EECO (MGA412) SERVICE MANUAL.
It has been prepared exclusively for the following applicable model.
Applicable model:
EECO CNG (MGA412C)
This supplementary service manual describes only different service information of the above applicable model
as compared with related manuals which is tabulated below. Therefore, whenever servicing the above applicable
models, consult this supplement first. And for any section, item or description not found in this supplement, refer
to the related manual below.
When replacing parts or servicing by disassembling, it is recommended to use MARUTI genuine parts, tools and
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
standard specifications among others.
Therefore, note that illustrations may differ from the vehicle being actually serviced.
The right is reserved to make changes at any time without notice.
Related Manuals:
Manual Name Manual No.

MGA413 SERVICE MANUAL 99500M76A00-74E
MGA413 SUPPLEMENTARY SERVICE MANUAL 99510M76A51-74E
MGA412 SUPPLEMENTARY SERVICE MANUAL 99510M78L00-74E
MGA413 WIRING DIAGRAM MANUAL 99512M76A00-74E
MARUTI SUZUKI INDIA LIMITED

Service Division
© 2010 COPYRIGHT MARUTI SUZUKI INDIA LIMITED All righst reserved.

No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechan-
ical, for any purpose, without the express written permission of Maruti Suzuki India Limited.
RECOMMENDATON OF MARUTI GENUINE PARTS AND ACCESSORIES USE
MARUTI SUZUKI strongly recommends the use of genuine parts and accessories. Genuine parts and accesso-
ries 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 MARUTI 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 MARUTI parts and accessories is not covered under warranty.
TABLE OF CONTENTS
GENERAL INFORMATION ENGINE
General Information 0A Engine 6 0A 6
Maintenance and Lubrication 0B Engine Mechanical 6A 0B 6A
Engine Cooling 6B 6B
HEATING AND AIR CONDITIONING
Engine Fuel 6C1 1A 6C1
Heater and Ventilation 1A
Engine and Emission 6E1 6E1
Air Conditioning 1B 1B
Control System
STEERING, SUSPENSION, WHEELS Ignition System 6F 6F

AND TIRES
Cranking System 6G 6G
Steering, Suspension, 3 3
Wheels and Tires Charging System 6H 6H
Exhaust System 6K 3A 6K
Front End Alignment 3A
TRANSMISSION, CLUTCH AND 3B
Manual Rack and Pinion 3B
DIFFERENTIAL
Electrical Power Steering 3B1 Manual Transmission 7A 3B1 7A
(P/S) System
Clutch 7C 7C
Steering Wheel and Column 3C 3C
Differential 7F 7F
Front Suspension 3D 3D
ELECTRICAL SYSTEM
Rear Suspension 3E 3E
Electrical System 8 8
Wheel and Tires 3F 3F
Wiring Diagram 8A 8A
PROPELLER SHAFT 4B 4B
BODY SERVICE 9 9
BRAKE SYSTEM 5 5
RESTRAINT SYSTEM 10 10
NOTE:
For the screen toned sections in the “TABLE OF CONTENTS” above, refer to the same
sections of the Service Manual mentioned in the FOREWORD of this manual.
GENERAL INFORMATION 0A-1
Section 0A
GENERAL INFORMATION
CONTENTS
NOTE:
For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the Service
Manual mentioned in the “FOREWORD” of this manual.
HOW TO USE THIS MANUAL ............................... 0A-2 CNG COMPONENT LOCATION ..........................0A-13
PRECAUTION ........................................................ 0A-3 CNG Labels .................................................... 0A-13
General precautions.......................................... 0A-3 WARNING, CAUTION AND
Precautions for Vehicles Equipped with INFROMATION LABELS ................................ 0A-14
CNG System ..................................................... 0A-5 VEHICLE LIFTING POINTS ................................... 0A-*

Precautions for Catalytic Converter .................. 0A-6 Wire colour symbols in this manual ...................0A-*
Precaution for Electrical Circuit Service ........... 0A-7 Abbreviations may be used
Electrical Circuit Inspection Procedure ............. 0A-8 in this manual .................................................. 0A-15
Intermittent and Poor Connection ................... 0A-11 FASTENER INFROMATION ................................0A-17
Precaution for Installing Mobile Metric Fastener .............................................. 0A-17
Communication Equipment............................. 0A-12 Fastener Strength Identification ...................... 0A-17
IDENTIFICATION INFORMATION ....................... 0A-12 Standard Tightening Torque ........................... 0A-17
Body Number .................................................. 0A-12 TIGHTENING TORQUE CHART ..........................0A-18
Engine Identification Number.......................... 0A-12
0A-2 GENERAL INFORMATION
HOW TO USE THIS MANUAL

1) There is a TABLE OF CONTENTS FOR THE WHOLE MANUAL
on the third page of this manual, whereby you can easily find the
section that offers the information you need. Also, there is a
CONTENTS on the first page of EACH SECTION, where the
main items in that section are listed.
2) Each section of this manual has its own pagination. It is
indicated at the top of each page along with the Section name.
3) The SPECIAL TOOL usage and TORQUE SPECIFICATION are
given as shown in figure below
6) Install oil pump. Refer to OIL PUMP.

7) Install flywheel (for M/T vehicle) or drive plate (for A/T
vehicle).
Using special tool. lock flywheel or drive plate, and
tighten flywheel or drive plat bolts to specified torque.
Special Tool
(A): 09924M17810
Tightening Torque
1. Flywheel bolts or drive plate bolts for A/T
vehicle (c): 78 N.m (7.8 kg-m, 56.0 lb-ft)
4) A number of abbrevations are used in the text.

For their full explanation, refer to ABBREVIATION MAY BE
USED IN THIS MANUAL of this section.
5) The SI, metric and foot-pound system are used as units in this
manual.
6) DIAGNOSIS are included in each section as necessary.
7) At the end of each section, there are description of SPECIAL
TOOLS, REQUIRED SERVICE MATERIALS and TIGHTENING
TORQUE SPECIFICATION that should be used for the servicing
work that described in that section.
PRECAUTIONS
GENERAL PRECAUTIONS
The WARNING and CAUTION below escribe some general precaution that you should observe when servicing a
vehicle. The general precaution apply to many of the service rocedures described in this manual, and they will not
necessarily be repeated with each procedure to which they apply.
WARNING:
• Whenever raising a vehicle for service, be sure to follow the instructions under VEHICLE LIFTING
POINTS on SECTION 0A.
• When it is necessary to do service work with the engine running, make sure that the parking brake is
set fully and the transmission is in Neutral (for manual transmission vehicles) or Park (for 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 well-ventilated.
• To avoid getting burned, keep away from hot metal parts such as the radiator, exhaust manifold,
tailpipe, muffler, etc.
• New and used engine oil can be hazardous. Children and pets may be harmed by swallowing new or
used oil. Keep new and used oil and used engine oil filters away from children and pets. Continuous
contact with used engine oil has been found to cause [skin] cancer in laboratory animals. Brief
contact with used oil may irritate skin. To minimize your exposure to used engine oil, wear a long-
sleeve shirt and moisture-proof gloves (such as dish washing gloves) when chang ing engine oil. If
engine oil contacts your skin, wash thoroughly with soap and water. Launder any clothing or rags if
wet with oil, recycle or properly dispose of used oil and filters.
• Make sure the bonnet (front hood) 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.
CAUTION:
• 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.
• When performing service to electrical parts that does not

require use of battery power, disconnect the negative cable
of the battery.
1. – terminal
2. + terminal
• When removing the battery, be sure to disconnect the

negative terminal 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.
1. -VE terminal
2. +VE terminal
3. Terminal cover
• When removing parts that are to be reused, be sure to keep

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

locking washers, split pins, self-locking nuts, and 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.
• 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 99000M31150
• Be sure to use special tools when instructed.
Special Tool
(A): 09917M98221
(B): 09916M58210
• When disconnecting vacuum hoses, attach a tag describing

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

systems, check all lines related to the system for leaks.
• Never disconnect the fuel line between the fuel pump and
injector without first releasing the fuel pressure, or fuel can
be sprayed out under pressure.
Precautions for Vehicles Equipped with

CNG System
Safety Precautions (Do’s)
• If any service or body repair is to be carried out, turn the manual
shut-off valve on CNG cylinder valve to close position prior to
commencement of the repair work.
• Get the CNG cylinder checked every five (5) years from the date of
last testing / retesting of cylinder by government authorized CNG
cylinder testing agency.
• If the vehicle does not changeover to CNG in Auto mode, then have
your vehicle checked by Maruti Suzuki authorized workshop at the
earliest.
• Switch “OFF” engine while fuel filling (CNG/Petrol).
• After refueling CNG, ensure that the CNG fuel filler cover is closed.
(Other-wise vehicle cannot be started)
• In AUTO MODE, It is programmed to start the vehicle in petrol and

automatically shift to CNG, based on Engine temperature etc. Do
not press the accelerator pedal to change from petrol to CNG.
Safety Precautions (Don’ts)

• Do not change/modify the configuration, settings or the
components from CNG system.
• The CNG cylinder should not be repaired under any
circumstances, in case of any problem, consult with Maruti Suzuki
authorized dealer.
• Do not adjust setting of CNG system.
• Never install LPG or any other gas cylinder in place of CNG
cylinder.
• Avoid carrying inflammable material near the CNG cylinder.
• Do not fill any other type of gas other than CNG.
• Do not press the accelerator pedal to change from petrol to CNG
mode.
PRECAUTIONS FOR CATALYTIC

CONVERTER
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 test only when necessary, make it as
short as possible, and do 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 ELECTRICAL

CIRCUIT SERVICE
• When disconnecting and connecting coupler, make sure to
turn ignition switch to OFF position, or electronic parts may
get damaged.
• 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.
• Never connect any tester (voltmeter, ohmmeter, or whatever)

to electronic control unit when its coupler is disconnected.
• Attempt to do it may cause damage to it.
• Never connect an ohmmeter to electronic control unit with its
coupler connected to it. Attempt to do 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.
• When taking measurements at electrical connectors using a

tester probe, be sure to insert the probe from the wire
harness side (backside) of the connector.
1. Coupler
2. Probe
• When connecting meter probe from terminal side of coupler

because it can’t be connected from harness side, use extra
care not to bend male terminal of coupler or force its female
terminal open for connection.
In case of such coupler as shown connect probe as shown to
avoid opening female terminal.
Never connect probe where male terminal is supposed to fit.
1. Coupler
2. Probe
3. Where male terminal fits
• When checking connection of terminals, check its male half

for bend and female half for excessive opening and both for
locking (looseness), corrosion, dust, etc.
• Before measuring voltage to check for electrical system,

check to make sure that battery voltage is 11V or higher.
Such terminal voltage check at low battery voltage will lead
to erroneous diagnosis.
ELECTRICAL CIRCUIT INSPECTION

PROCEDURE
While there are various electrical circuit inspection methods,
described here is a general method to check its open and short circuit
by using an ohmmeter and a voltmeter.
OPEN CIRCUIT CHECK

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

such as ECM etc., it is important to perform careful check, starting
with items which are easier to check.
1) Disconnect negative cable at battery.
2) Check each connector at both ends of the circuit being checked
for loose connection. Also check lock condition of connector if
equipped with connector lock.
1. Check for loose connection
2. Sensor
3. ECM
3) Using a test male terminal, check both terminals of the circuit

being checked for contact tension of its female terminal. Check
each terminal visually for poor contact (possibly caused by dirt,
corrosion, rust entry of foreign object, etc.). At the same time,
check to make sure that each terminal is locked in the
connector fully.
4) Using continuity check or voltage check procedure described in

the following page, check the wire harness for open circuit and
poor connection with its terminals. Locate abnormality, if any.
1. Looseness of crimping
2. Open
3. Thin wire (single strand of wire)
Continuity check
1) Measure resistance between connector terminals at both ends
of the circuit being checked (between A-1 and C-1 in the figure).
If no continuity is indicated (infinity or over limit), that means that
the circuit is open between terminals A-1 and C-1.
2) Disconnect the connector included in the circuit (connector-B in

the figure) and measure resistance between terminals A-1 and
B-1.
If no continuity is indicated, that means that the circuit is open
between terminals A-1 and B-1. If continuity is indicated, there
is an open circuit between terminals B-1 and C-1 or an
abnormality in connector-B.
Voltage check
If voltage is supplied to the circuit being checked, voltage check can
be used as circuit check.
1) With all connectors connected and voltage applied to the circuit
being checked, measure voltage between each terminal and
body ground.
If measurements were taken as shown in the figure and results were

as listed below, it means that the circuit is open between terminals
B-1 and A-1.
Voltage Between:
C-1 and body ground: Approx. 5V
B-1 and body ground: Approx. 5V
A-1 and body ground: 0V
Also, if measured values were as listed below, it means that there is a
resistance (abnormality) of such level that corresponds to the voltage
drop in the circuit between terminals A-1 and B-1.
Voltage Between:
C-1 and body ground: Approx. 5V
B-1 and body ground: Approx. 5V ————— 2V voltage drop
A-1 and body ground: Approx. 3V ———
Short circuit check (wire harness to ground)

2) Disconnect connectors at both ends of the circuit to be checked.
NOTE:
If the circuit to be checked is connected to other parts,
disconnect all connectors of those parts.
Otherwise, diagnosis will be misled.
3) Measure resistance between terminal at one end of circuit (A-1

terminal in figure) and body ground. If continuity is indicated, it
means that there is a short to ground between terminals A-1
and C-1 of the circuit.
4) Disconnect the connector included in circuit (connector B) and

measure resistance between A-1 and body ground. If continuity
is indicated, it means that the circuit is shorted to the ground
between terminals A-1 and B-1.
INTERMITTENT AND POOR CONNECTION

Most intermittent are caused by faulty electrical connections or wiring,
although a sticking relay or solenoid can occasionally be at fault.
When checking it for proper connection, perform careful check of
suspect circuits for:
• Poor mating of connector halves, or terminals not fully seated in the

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

Check each connector terminal in problem circuits carefully to
ensure good contact tension by using the corresponding mating
terminal.
If contact tension is not enough, reform it to increase contact
tension or replace.
1. Check contact tension by inserting and

removing just for once.
2. Check each terminal for bend and proper
alignment.
• Poor terminal-to-wire connection.

Check each wire harness in problem circuits for poor connection by
shaking it by hand lightly. If any abnormal condition is found, repair
or replace.
• Wire insulation which is rubbed through, causing an intermittent

short as the bare area touches other wiring or parts of the vehicle.
• Wiring broken inside the insulation. This condition could cause
continuity check to show a good circuit, but if only 1 or 2 strands of
a multi-strand-type wire are intact, resistance could be far too high.
If any abnormality is found, repair or replace.
PRECAUTIONS FOR INSTALLING MOBILE

COMMUNICATION EQUIPMENT
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.
• Confirm that the antenna and feeder are correctly adjusted.
IDENTIFICATION INFORMATION
BODY NUMBER
The vehicle body number is punched on the upper surface of the
engine room right side panel located under the driver seat.
1. Driver seat
2. Engine compartment
3. Engine room right side panel
ENGINE IDENTIFICATION NUMBER

The number is punched on the cylinder block.
CNG COMPONENT LOCATION

Layout of the CNG system
1 Changeover switch 7 Vent hose 13 Water hose

2 High pressure pipe 8 CNG controller 14 High pressure sensor
3 Receptacle 9 CNG injectors 15 High pressure gauge
4 Fuel lid switch 10 Low pressure & temperature sensor 16 Low pressure hose
5 CNG cylinder valve 11 Engine 17 CNG filter
6 CNG cylinder 12 Pressure regulator
The figure above shows main components for CNG fuel system. When servicing and handling parts, refer to
WARNING/CAUTION instructions printed on labels.
WARNING, CAUTION AND INFORMATION LABELS

CNG Labels
NOTE:
These labels are attached on vehicle equipped with CNG system only.
The figure below shows main labels among others that are related to vehicle component parts.
When servicing and handling parts, refer to WARNING / CAUTION / NOTE instructions printed on labels.
If any WARNING / CAUTION / NOTE label is found stained or damaged, clean or replace it as necessary.
Front Driver door Label Rear Slide Door Label (Right Side)
CNG Label on dashboard CNG Cylinder Warning Labels
(a) (b) (c)
(a) Manual Shut off valve label

(b) CNG cylinder warning label
(c) CNG label on cylinder
ABBREVIATIONS MAY USED IN THIS MANUAL
A ECT Sensor : Engine Coolant Temperature

ABS : Anti-lock Brake System Sensor (Water Temp. Sensor,
WTS)
ATDC : After Top Dead Center
EGR : Exhaust Gas Recirculation
API : American Petroleum Institute
EGRT Sensor : EGR Temperature Sensor
ATF : Automatic Transmission Fluid (Recirculated Exhaust Gas Temp.
ALR : Automatic Locking Retractor Sensor, REGTS)
AC : Alternating Current EFE Heater : Early Fuel Evaporation Heater
A/T : Automatic Transmission (Positive Temperature Coefficient,
PTC Heater)
A/C : Air Conditioning
ELR : Emergency Locking Retractor
ABDC : After Bottom Dead Center
EPS : Electrical Power Steering
A/F : Air Fuel Mixture Ratio
EVAP : Evaporative Emission
A-ELR : Automatic-Emergency Locking
Retractor EVAP Canister : Evaporative Emission Canister
B (Charcoal Canister)
F
B+ : Battery Positive Voltage
4WD : 4 Wheel Drive
BTDC : Before Top Dead Center G
BBDC : Before Bottom Dead Center GEN : Generator
C GND : Ground
CKT : Circuit H
CMP Sensor : Camshaft Position Sensor (Crank HC : Hydrocarbons
Angle Sensor, CAS)
HO2S : Heated Oxygen Sensor
CO : Carbon Monoxide
IAC Valve : Idle Air Control Valve (Idle Speed
CPP Switch : Clutch Pedal Position Switch Control Solenoid Valve, ISC
(Clutch Switch, Clutch Start Solenoid Valve)
Switch)
IAT Sensor : Intake Air Temperature Sensor (Air
CPU : Central Processing Unit temperature Sensor, ATS)
CRS : Child Restraint System ICM : Immobilizer Control Module
D IG : Ignition
DC : Direct Current ISC Actuator : Idle Speed Control Actuator
DLC : Data Link Connector (Assembly (Motor)
Line Diag. Link, ALDL, Serial Data L
Link, SDL) LH : Left Hand
DOHC : Double Over Head Cam shaf
LSPV : Load Sensing Proportioning Valve
DOJ : Double Offset Joint
M
DRL : Daytime Running Light MAF Sensor : Mass Air Flow Sensor (Air Flow
DTC : Diagnostic Trouble Code Sensor, AFS, Air Flow Meter, AFM)
(Diagnostic Code) MAP Sensor : Manifold Absolute Pressure
E Sensor (Pressure Sensor, PS)
EBCM : Electronic Brake Control Module, Max : Maximum
ABS Control Module MFI : Multiport Fuel Injection
ECM : Engine Control Module (Multipoint Fuel Injection)
Min : Minimum
T
MIL : Malfunction Indicator Lamp TBI : Throttle Body Fuel Injection
(“CHECK ENGINE” Light) (Single-Point Fuel Injection, SPI)
M/T : Manual Transmission TCC : Torque Converter Clutch
N TCM : Transmission Control Module
NOx : Nitrogen Oxides (A/ T Controller, A/T Control
Module)
O
TP Sensor : Throttle Position Sensor
OBD : On-Board Diagnostic System
TVV : Thermal Vacuum Valve (Thermal
(Self-Diagnosis Function)
Vacuum Switching Valve, TVSV,
O/D : Overdrive Bimetal Vacuum Switching Valve,
OHC : Over Head Camshaft BVSV)
P TWC : Three Way Catalytic Converter
(Three Way Catalyst)
PNP : Park/ Neutral Position
2WD : 2 Wheel Drive
P/S : Power Steering
V
PSP Switch : Power Steering Pressure Switch
(P/ S Pressure Switch ) VIN : Vehicle Identification Number
PCM : Powertrain Control Module VSS : Vehicle Speed Sensor
PCV : Positive Crankcase Ventilation W
R WU-OC : Warm Up Oxidation Catalytic
RH : Right Hand Converter
WU-TWC : Warm Up Three Way Catalytic
S
Converter
SAE : Society of Automotive Engineers
SDM : Sensing and Diagnostic Module
(Air bag controller, Air bag control
module)
SFI : Sequential Multiport Fuel Injection
SOHC : Single Over Head Camshaft
FASTENER INFORMATION
METRIC FASTENERS
Most of the fasteners used for this vehicle are metric. When replacing any fasteners, it is most important that
replacement fasteners be the correct diameter, thread pitch and strength.
FASTENER STRENGTH IDENTIFICATION

Most commonly used metric fastener strength property classes are 4T, 6.8, 7T, 8.8 and radial line with the class
identification embossed on the head of each bolt. Some metric nuts will be marked with punch, 6 or 8 mark strength
identification on the nut face. Figure shows the different strength markings.
When replacing metric fasteners, be careful to use bolts and nuts of the same strength or greater than the original
fasteners (the same number marking or higher). It is likewise important to select replacement fasteners of the correct
size. Correct replacement bolts and nuts are available through the parts division.
Metric bolts: Identification class numbers or marks correspond to bolt strength (increasing numbers represent
increasing strength).
1. Nut strength identification
STANDARD TIGHTENING TORQUE

Each fastener should be tightened to the torque specified in each section of this manual. If no description or
specification is provided, refer to the following tightening torque chart for the applicable torque for each fastener. When
a fastener of greater strength than the original one is used, however, use the torque specified for the original fastener.
NOTE:
• For the flanged bolt and nut, add 10% to the tightening torque given in the chart below.
• The chart below is applicable only where the fastened parts are made of steel light alloy.
Tightening Torque Chart
Thread Diameter (Nominal Diameter) (mm)
4 5 6 8 10 12 14 16 18
A equivalent of 4T strength faster
N.m 1.5 3.0 5.5 13 29 45 65 105 160
Kg.m 0.15 0.30 0.55 1.3 2.9 4.5 6.5 10.5 16
lb-ft 1.0 2.5 4.0 9.5 21 32.5 47 76 116
A equivalent of 6.8 strenght

fastner without flange N.m 2.4 4.7 8.4 20 42 80 125 193 280
Kg.m 0.24 0.47 0.84 2.0 4.2 8.0 12.5 19.3 28
lb-ft 2.0 3.5 6.0 14.5 30.5 58 90.5 139.5 202.5
A equivalent of 6.8 strength fast-

ener with flange * Self lock nut N.m 2.4 4.9 8.8 21 44 84 133 203 298
Kg.m 0.24 0.49 0.88 2.1 4.4 8.4 13.3 20.3 29.8
lb-ft 2.0 3.5 6.5 15.5 32 61 96.5 147 215.5

Strength
A equivalent of 7T strength
fastener N.m 2.3 4.5 10 23 50 85 135 210 240
Kg.m 0.23 0.45 1.0 2.3 5.0 8.5 13.5 21 24
lb-ft 2.0 3.5 7.5 17 36.5 61.5 98.0 152 174
A equivalent of 8.8 strength

fastener without flange N.m 3.1 6.3 11 27 56 105 168 258 373
Kg.m 0.31 0.63 1.1 2.7 5.6 10.5 16.8 25.8 37.3
lb-ft 2.5 4.5 8.0 19.5 40.5 76.0 121.5 187 270
A equivalent of 8.8 strength

fastener with flange N.m 3.2 6.5 12 29 59 113 175 270 395
Kg.m 0.32 0.65 1.2 2.9 5.9 11.3 17.5 27 39.5
lb-ft 2.5 5.0 9.0 21.0 43.0 82.0 126.5 195.5 286.0
MAINTENANCE AND LUBRICATION 0B-1
Section 0B
MAINTENANCE AND LUBRICATION

CONTENTS
NOTE:
For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the Service
Manual mentioned in the “FOREWORD” of this manual.
MAINTENANCE SCHEDULE................................ 0B-2 Emission control system ....................................0B-*

Maintenance schedule (CNG) .......................... 0B-2 Chassis and body ..............................................0B-*
MAINTENANCE SERVICE..................................... 0B-3 Final inspection ................................................. 0B-3
Engine................................................................0B-* RECOMMENDED FLUIDS
Ignition system .................................................. 0B-* AND LUBRICANTS ................................................ 0B-4
Fuel system .......................................................0B-*

0B-2 MAINTENANCE AND LUBRICATION
PERIODIC MAINTENANCE SCHEDULE

Maintenance Schedule (CNG)
NOTE
• This interval should be judged by odometer reading or months, whichever comes first.
• This table includes service as scheduled up to 1,00,000 kms. Beyond 1,00,000 kms, carry out the
same services at the same intervals respectively.
Km (x 1,000) 1 5 10 20 30 40 50 60 70 80 90 100
Interval
Months 1 6 12 24 36 48 60 72 84 96 108 120
CNG Related Components
All Joints (Gas Leakage) (I: Refer to “Fuel
I I I I I I I I I I I I
Leakage Check Procedure” in Section 6)
Coolant Hoses (Leakage, damage) (I:) I I I I I I I I I I I I
All Fasteners torque values (T: Refer to
T T T T T T T T T T T T
“Tightening Torque Specifications” in Section 6C1)
CNG Reducer Filter Cartridge With O-Ring
— — — — — R — — — R — —
(R: Refer to "Fuel Filter" in Section 6C1)
CNG Low Pressure Filter Cartridge With O-Ring
(R: Refer to "CNG Pressure Regulator Removal" — — — R — R — R — R — R
in Section 6E1)
NOTE
• “R”: Replace or change
• “I”: Inspect and correct, replace or lubricate if necessary
• “C”: Clean
• “T”: Tighten to specified torque
MAINTENANCE AND LUBRICATION 0B-3
Final Inspection
ITEM 1-1
Fuel Lines and Connections
Inspection
1) For CNG model refer “fuel lines and connection inspection in
section 6C1”.
ITEM 1-2
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 CNG filter with new one. (Refer to “FUEL FILTER” in

SECTION 6C1.)
All CNG Joints Inspection

Inspect all CNG related pipe joints. (Refer to “Fuel Leakage Check
Procedure” in sec 6.)
All CNG Joints Tightening Torque Inspection

Tighten all CNG joints to the specified torque. (Refer to “Tightening
Torque Specifications” in section 6C1.)
CNG Reducer Filter Cartridge With O-Ring

Replacement
Replace CNG reducer filter cartridge with O-Ring. (Refer to "Fuel
Filter" in Section 6C1.)
CNG Low Pressure Filter Cartridge With O-Ring

Replacement
Replace CNG low pressure filter cartridge with O-Ring. (Refer to
"CNG Pressure Regulator Removal" in Section 6E1.)
0B-4 MAINTENANCE AND LUBRICATION
RECOMMENDED FLUIDS AND LUBRICANTS

5W-30, SG+, SH, SJ or SL
Engine oil
(Refer section 0B of related manual mentioned in FOREWORD of this manual.)
Antifreeze/Anticorrosion coolant
Engine coolant (Ethylene glycol
(Refer to ITEM 1-5 of MAINTENANCE SERVICE in related manual mentioned
base coolant)
in FOREWORD of this manual for detail.)
Brake fluid An equivalent of DOT 3 or SAE J1703 or more
API GL-4
Manual transmission oil (Refer to MAINTENANCE SERVICE in SECTION 7A in related manual
mentioned in FOREWORD of this manual for detail)
Hypoid gear oil API GL-5
Differential oil (Refer to OIL CHANGE in SECTION 7F in related manual mentioned in
FOREWORD of this manual for detail.)
Water resistance chassis grease
Clutch linkage pivot points
(SUZUKI SUPER GREASE A 99000M25010)
Door hinges
Engine oil or water resistance chassis grease
Hood latch assembly
Key lock cylinder Spray lubricant
ENGINE 6-1
SECTION 6
ENGINE
NOTE:
For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of Service Manual
mentioned in the FOREWORD of this manual.
CONTENTS
PRECAUTIONS .................................................. 6-2 SYSTEM ......................................................... 6-6
PRECAUTIONS ON FUEL SYSTEM GENERAL INFORMATION ................................ 6-7
SERVICE ........................................................ 6-2 STATEMENT ON CLEANLINESS AND
PRECAUTIONS FOR ENGINE SERVICE ...... 6-2 CARE .............................................................. 6- *
PRECAUTIONS FOR DIAGNOSING GENERAL INFORMATION ON ENGINE
TROUBLE ....................................................... 6-2 SERVICE ........................................................ 6- *
PRECAUTION FOR CNG CONTROL MODULE FUEL PRESSURE RELIEF PROCEDURE .... 6-7
CIRCUIT INSPECTION FUEL LEAKAGE CHECK PROCEDURE ....... 6-8
(BI-FUEL CNG MODEL) ................................. 6-3 ENGINE DIAGNOSIS ....................................... 6-11
PRECAUTIONS FOR DTC
ON-BOARD DIAGNOSTIC SYSTEM
TROUBLESHOOTING .................................... 6-4
DESCRIPTION ............................................... 6- *
PRECAUTION OF TROUBLESHOOTING FOR
ENGINE DIAGNOSTIC FLOW TABLE ......... 6-11
CAN................................................................. 6-4
ENGINE DIAGNOSIS TABLE....................... 6-18
PRECAUTION FOR CAN COMMUNICATION
6-2 ENGINE
PRECAUTIONS
PRECAUTIONS ON FUEL SYSTEM SERVICE
WARNING:
Before servicing on fuel system, the following points should be always observed in order to reduce
the risk of fire and personal injury.
• Disconnect negative (–) cable at battery.
• Do not smoke, and place NO SMOKING signs near working area.
• Be sure to have CO2 fire extinguisher handy.
• Be sure to perform work in a well-ventilated area and away from any open flames such as gas
heater.
For bi-fuel CNG model, provide detecting instrument such as a gas leak alarm in the working area
and do not perform any actions that will spark, in preparation for gas leak.
• Wear safety glasses.
• To relieve fuel vapor pressure in fuel tank, remove fuel filler cap from fuel filler neck and then rein-
stall it.
• As fuel feed line is still under high fuel pressure even after stopping engine, loosening or discon-
necting fuel feed line directly may cause dangerous spout of fuel. Before loosening or disconnect-
ing fuel feed line, make sure to relieve fuel pressure. Refer to FUEL PRESSURE RELIEF
PROCEDURE.
• A small amount of fuel may be released when the fuel line is disconnected. In order to reduce the
risk of personal injury, cover the fitting to be disconnected with shop cloth. Be sure to put that cloth
in an approved container after disconnecting.
• Never perform service work when engine and exhaust system are hot.
PRECAUTIONS FOR ENGINE SERVICE
CAUTION:
Carefully observe the following information on engine service in order to prevent damage and to con-
tribute to reliable engine performance.
• When raising or supporting the engine for any reason, do not apply a jack under oil pan. Otherwise,
oil pan may be damaged.
• 12-volt electrical system is capable of damaging circuits. When performing any work where electri-
cal terminals could possibly be grounded, disconnect negative cable at battery.
• Any time the air cleaner, throttle body or intake manifold is removed, be careful not to admit foreign
materials (like dust and metallic particle) to engine, throttle body and throttle valve. Otherwise,
engine could be damaged or throttle body assembly would break down due to stuck throttle valve.
PRECAUTIONS FOR DIAGNOSING TROUBLE

ECM
• Don’t disconnect ECM connectors from ECM, battery cable from battery, ECM ground wire harness from
engine, main fuse or “RADIO-DOME” fuse before confirming diagnostic information (DTC, freeze frame
data, etc.) stored in ECM memory. Such disconnection erases memorized information in ECM memory.
• Check ECM for DTC when MIL lights on.
• Diagnostic information stored in ECM memory can be cleared as well as checked by using SUZUKI scan
tool or CAN communication OBD generic scan tool. Before using scan tool, read its Operator’s (Instruction)
Manual to know what functions are available and how to use it.
ENGINE 6-3
• Be sure to read PRECAUTION FOR CAN COMMUNICATION SYSTEM before inspection and observe what
is written there.
• ECM Replacement
When ECM is replaced with new one or substituted one, check for the following conditions. Neglecting this
check may cause damage to ECM.
– Resistance value of all relays and actuators are as specified respectively.
– MAP sensor and TP sensor are in good condition and none of power circuits of these sensors is shorted
to ground.
• Communication of ECM, CNG control module (bi-fuel CNG model) and combination meter is established by
CAN (Controller Area Network). For more detail of CAN communication for ECM, refer to CAN COMMUNI-
CATION SYSTEM DESCRIPTION in Section 6E (petrol model) or Section 6E1 (bi-fuel CNG model).
• Handle CAN communication line with care referring to PRECAUTION FOR CAN COMMUNICATION SYS-
TEM in this section.
CNG Control Module (Bi-Fuel CNG Model)

• Check CNG control module for DTC by using SUZUKI scan tool when CNG warning light lights on.
• Diagnostic information stored in CNG control module memory can be cleared as well as checked by using
SUZUKI scan tool. Before using scan tool, read its Operator's (Instruction) Manual to know what functions
are available and how to use it.
• Be sure to read PRECAUTION FOR CAN COMMUNICATION SYSTEM before inspection and observe what
is written there.
• CNG control module replacement
When CNG control module is replaced with new one or substituted one, check for the following conditions.
Neglecting this check may cause damage to CNG control module.
– Resistance value of all relays and actuators are as specified respectively.
– CNG pressure-and-temperature sensor and CNG cylinder pressure sensor are in good condition and
none of power circuits of these sensors is shorted to ground.
• Communication of CNG control module, ECM and combination meter is established by CAN (Controller
Area Network). For more detail of CAN communication for CNG control module, refer to CAN COMMUNI-
CATION SYSTEM DESCRIPTION in Section 6E1.
Therefore, handle CAN communication line with care referring to PRECAUTION FOR CAN COMMUNICA-
TION SYSTEM in this section.
PRECAUTION FOR CNG CONTROL MODULE CIRCUIT INSPECTION (BI-FUEL

CNG MODEL)
CNG control module connectors are waterproofed. Each terminal of CNG control module connectors is sealed
with grommet.
Therefore, do not insert the tester probe into sealed terminal from harness side. When measuring circuit voltage
and/or pulse signal at CNG control module connector, be sure to connect service wires (5) to each sensor (1)
and sensor connector (2). Otherwise, CNG control module and its circuits may be damaged by water ingress.
6-4 ENGINE
3. Voltmeter 4. Oscilloscope
PRECAUTIONS FOR DTC TROUBLESHOOTING

Upon completion of inspection and repair work, perform “DTC CONFIRMATION PROCEDURE” and confirm
that no DTC is detected.
PRECAUTION OF TROUBLESHOOTING FOR CAN

CAN Schematic and Routing Diagram
1 3
4
[A] 2
[B]
[A]: Bi-fuel CNG model [B]: CAN communication line
No. Part Name Communication with scan tool Monitor of CAN-DTC

1. ECM CAN Available
2. CNG control module (bi-fuel CNG CAN Available
model)
3. Combination meter Not available Not available
4. DLC – –
ENGINE 6-5
Outline of Troubleshooting
When there is a trouble with CAN, perform the following troubleshooting.
• Petrol model: TROUBLESHOOTING FOR COMMUNICATION ERROR WITH SCAN TOOL in Section 6E
and/or TROUBLESHOOTING FOR CAN-DTC in Section 6E.
• Bi-fuel CNG model: TROUBLESHOOTING FOR COMMUNICATION ERROR WITH SCAN TOOL in Sec-
tion 6E1 and/or TROUBLESHOOTING FOR CAN-DTC in Section 6E1.
Not using this procedure or performing troubleshooting in any other way may skip some check points resulting
in misdiagnosis or take a longer time than necessary.
1) Checking connector related to CAN
2) Checking CAN line
3) Checking each control module using “DTC check” or “Bus Check”
4) Checking power and ground connection of each control module
CAN-DTC
Even when DTC related to CAN (= CAN-DTC) as described below is detected, it is not possible to point out the
specific trouble point by CAN-DTC itself. Be sure to troubleshoot according to TROUBLESHOOTING FOR CAN-
DTC in Section 6E (petrol model) or Section 6E1 (bi-fuel CNG model).
CAN-DTC Table
DTC No. Detecting item Detecting condition
ECM
U0073 Control Module Communication Bus Off Transmitting and receiving error of ECM for
specified time continuously.
U0108 Lost Communication With Alternative Fuel Receiving error of ECM from CNG control
Control Module module for specified time continuously.
U0155 Lost Communication With Instrument Panel Receiving error of ECM from combination
Cluster (IPC) Control Module meter for specified time continuously.
CNG control module (bi-fuel CNG model)
U0073 Control Module Communication Bus Off Transmitting and receiving error of CNG con-
trol module for specified time continuously.
U0100 Lost Communication With ECM Receiving error of CNG control module from
ECM for specified time continuously.
Communication with Scan Tool

• CAN line is used for communication between each control module and scan tool.
Refer to “CAN Schematic and Routing Diagram” to determine which line is used for communication between
each control module and scan tool.
• ECM and CNG control module (bi-fuel CNG model) uses CAN line for communication with scan tool. Even if
CAN has a trouble other than between DLC and combination meter, communication may also fail between
scan tool and these control module, or between scan tool and combination meter. In such case, perform
troubleshooting according to TROUBLESHOOTING FOR COMMUNICATION ERROR WITH SCAN TOOL
in Section 6E (petrol model) or Section 6E1 (bi-fuel CNG model).
Bus Check with SUZUKI Scan Tool

SUZUKI scan tool (SUZUKI-SDT) efficiently diagnoses a CAN bus malfunction by “Communication Bus Check”
and “Communication Malfunction DTC” under “Bus check”.
“Communication Bus Check” can display all control modules name communicated by CAN.
6-6 ENGINE
PRECAUTION FOR CAN COMMUNICATION SYSTEM

• The loose (1) in the wire harnesses twist of the CAN lines except around the connector (2) should be within
100 mm (3.94 in.). Refer to the wiring diagram for the CAN lines discrimination.
Excessively-loosed lines may be influenced by the electric noise.
2 2
• Do not connect terminals of the CAN line using a bypass wire (1). Otherwise, the CAN line may be influ-
enced by the electric noise.
1
ENGINE 6-7
GENERAL INFORMATION
FUEL PRESSURE RELIEF PROCEDURE
CAUTION:
Never perform this work when engine is hot.
Doing so may cause adverse effect to catalyst.
NOTE:
If ECM detects DTC(s) after servicing, clear DTC(s) refer-
ring to DTC CLEARANCE in Section 6E (petrol model) or
Section 6E1 (bi-fuel CNG model).
Petrol System
2 1) Make sure that engine is cold.

2) Place gear shift lever in “Neutral” and apply parking brake
and block drive wheels.
3) Disconnect fuel pump relay (1) from relay box (2).
4) Remove fuel filler cap in order to release fuel vapor pressure
1
in fuel tank, and then reinstall it.
5) Start engine and run it until engine stops for lack of fuel.
Repeat cranking engine 2 – 3 times for about 3 seconds
each time to dissipate fuel pressure in lines. Fuel connec-
tions are now safe for servicing.
6) After servicing, connect fuel pump relay (1) to relay box (2)
and install relay box cover.
CNG System
1) Make sure that engine is cold.

2) Place gear shift lever in “Neutral” and apply parking brake
[A] [B]
and block drive wheels.
3) Turn manual CNG cylinder valve (1) to close position.
4) Turn ignition switch to ON position and select “AUTO MODE”
or “FORCED CNG MODE” with fuel selector switch.
1
1
5) Make sure that CNG pressure in pressure gauge becomes
“0”.
6) Start engine and run it until engine stops for lack of CNG.
Repeat cranking engine 2 – 3 times for about 3 seconds
each time to dissipate CNG fuel pressure in lines. CNG fuel
feed line connections are now safe for servicing.
[A]: 5-seater model [B]: 2-seater model

6-8 ENGINE
FUEL LEAKAGE CHECK PROCEDURE

Petrol System
After performing any service on fuel system, check that there is no fuel leakage as follows.
1) Apply fuel pressure to fuel feed line according to the following procedure.
a) Turn ignition switch to ON position to operate fuel pump.
b) After 2 sec., turn it OFF.
c) Repeat Step a) and b) three or four times.
d) Make sure that fuel pressure is applied to fuel line by placing hand on fuel feed hose and feel fuel pressure.
2) Check that there is no fuel leakage from any part of fuel system.
CNG System
CAUTION:
• Clean inspection points indicated in figure with mild detergent if they are particularly dirty.
• Any parts that have been deformed should be replaced with new one, even if CNG fuel leak check
fails to find any CNG fuel leaks.
After performing any service on CNG system, check that there is no CNG fuel leakage as follows.
1) Clean inspection points.
2) Visually inspect CNG fuel pipes, joints, and operating parts for damage, corrosion, and wear.
3) Turn ignition switch to ON position and select “Forced CNG MODE” with fuel selector switch.
4) Check that CNG cylinder pressure gauge reading is more than 12 MPa (120 kgf/cm2, 1740 psi) or above. If
CNG cylinder pressure is less than 12 MPa (120 kgf/cm2,1740 psi), recharge CNG.
5) Check the inspection points on CNG feed line, which are pointed by arrows in figure, for CNG fuel leakage
using gas leak detection liquid or gas detector under the following each condition.
• For inspection points of low pressure CNG fuel feed line
a) Start engine and keep idling until fuel is switched to CNG.
b) Check the inspection points for CNG fuel leakage.
• For Inspection points of high pressure CNG fuel feed line
a) Start engine and keep idling until fuel is switched to CNG.
b) Check the inspection points for CNG fuel leakage.
ENGINE 6-9
[A] [B]
[A]
[B]
[B]
[A]
:1 :2
[A]: 5 seater model 1. Inspection point of low pressure CNG fuel feed line
[B]: 2 seater model 2. Inspection point of high pressure CNG fuel feed line
6) If CNG fuel leak has been detected, relieve CNG fuel pressure and then replace the faulty parts or retighten
CNG fuel pipe nuts. Recheck for CNG fuel leakage after replacing the faulty parts or retightening CNG fuel
pipe nuts.
6-10 ENGINE
When Using Gas Leak Detection Liquid
1) Apply gas leak detection liquid (1) to inspection points.
1 2) Visually inspect inspection points applied gas leak detection

liquid. The gas leak detection liquid will bubble (1) if there is
CNG fuel leak.
3) Wipe off the gas leak detection liquid.
When Using Gas Detector
1) Check the inspection points for CNG fuel leakage using gas
detector (1).
1
NOTE:
• Use gas detector capable of detecting methane gas
concentrations of less than 0.01%.
• Use duct to suck away any vehicle exhaust gas, as gas
detectors will react to it.
• Let gas detector absorb gas for at least 10 seconds in
each location.
ENGINE 6-11
ENGINE DIAGNOSIS
This vehicle is equipped with an engine and emission control system, which controls the A/F mixture, ignition
timing, emission, etc. suitably to engine conditions by ECM / CNG control module (bi-fuel CNG model). ECM /
CNG control module (bi-fuel CNG model) has an On-Board Diagnostic system which detects a malfunction in
this system.
When diagnosing a trouble in the engine including this system, be sure to have understanding of the outline of
ON-BOARD DIAGNOSTIC SYSTEM DESCRIPTION and each item in PRECAUTIONS FOR DIAGNOSING
TROUBLE and follow ENGINE DIAGNOSTIC FLOW TABLE given below to obtain correct result smoothly.
ENGINE DIAGNOSTIC FLOW TABLE

Refer to the following pages for the details of each step.
STEP ACTION YES NO

1 Customer Complaint Analysis Go to Step 2. Perform customer
1) Perform customer complaint analysis. complaint analysis.
Was customer complaint analysis performed?
2 DTC / freeze frame data Check, Record and Clear- 1) Print DTC and Go to Step 4.
ance freeze frame data
1) Check for DTC. or write them
Is there any malfunction DTC(s)? down and clear
them. Refer to
DTC CLEAR-
ANCE in Section
6E (petrol model)
or Section 6E1
(bi-fuel CNG
model).
2) Go to Step 3.
3 Visual Inspection 1) Repair or replace Go to Step 5.
1) Perform visual inspection. malfunction part.
Is there any faulty condition? 2) Go to Step 11.
4 Visual Inspection 1) Repair or replace Go to Step 8.

1) Perform visual inspection. malfunction part.
Is there any faulty condition? 2) Go to Step 11.
5 Trouble Symptom Confirmation Go to Step 6. Go to Step 7.
1) Confirm trouble symptom.
Is trouble symptom identified?
6 Rechecking and Record of DTC / freeze frame data Go to Step 9. Go to Step 8.

1) Recheck for DTC.
Is there any DTC(s)?
7 Rechecking and Record of DTC / freeze frame data Go to Step 9. Go to Step 10.
1) Recheck for DTC.
Is there any malfunction DTC(s)?
6-12 ENGINE
8 Engine Basic Inspection and Engine Diagnosis Table Go to Step 11. 1) Check and repair
1) Check and repair according to ENGINE BASIC malfunction
INSPECTION FLOW TABLE and ENGINE DIAG- part(s).
NOSIS TABLE. 2) Go to Step 11.
Are check and repair complete?
9 Troubleshooting for DTC Go to Step 11. 1) Check and repair
1) Check and repair according to applicable DTC malfunction
diagnosis flow table in Section 6E (petrol model) or part(s).
6E1 (bi-fuel CNG model). 2) Go to Step 11.
Are check and repair complete?
10 Check for Intermittent Problems 1) Repair or replace Go to Step 11.
1) Check for intermittent problems. malfunction
Is there any faulty condition? part(s).
2) Go to Step 11.
11 Final Confirmation Test Go to Step 6. End.
1) Clear DTC if any.
2) Perform final confirmation test.
Is there any problem symptom, malfunction DTC or
abnormal condition?
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.
ENGINE 6-13
CUSTOMER PROBLEM INSPECTION FORM (EXAMPLE)
User name: Model: VIN:
Date of issue: Date of Reg.: Date of problem: Mileage:
PROBLEM SYMPTOMS
Difficult Starting Poor Driveability
No cranking Hesitation on acceleration
No initial combustion Back fire/ After fire
No combustion Lack of power
Poor starting at Surging
( cold warm always) Abnormal knocking
Other__________ Other__________
Poor idling Engine Stall when

Poor fast idle Immediately after start
Abnormal idling speed Accel. pedal is depressed
( High Low) ( r /min.) Accel. pedal is released
Unstable Load is applied
Hunting ( r /min. to r /min.) A/C Electric load P/S
Other__________ Other__________
Other__________
OTHERS:
VEHICLE/ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS

Environmental Condition
Weather Fair Cloudy Rain Snow Always Other
O O
Temperature Hot Warm Cool Cold ( F/ C) Always
Frequency Always Sometimes ( times/ day, month) Only once Under certain condition
Road Urban Suburb Highway Mountainous ( Uphill Downhill) Tarmacadam
Gravel Other
Vehicle Condition
Engine Cold Warming up phase Warmed up Always Other at starting
Condition Immediately after start Racing without load Engine speed ( r/min)
Vehicle During driving: Constant speed Accelerating Decelerating
condition Right hand corner left hand corner When shifting (Lever position ) At stop
Vehicle speed when problem occurs ( km/ h, Mile/ h) Other
MIL / CNG warning Always ON Sometimes ON Always OFF Good condition

light condition
Diagnostic trouble First check: No code Normal code Malfunction code ( )
code Second check: No code Normal code Malfunction code ( )
6-14 ENGINE
2.DTC / Freeze Frame Data Check, Record and Clearance

First, check DTC (current and pending DTC). Refer to DTC CHECK in Section 6E (petrol model) or Section 6E1
(bi-fuel CNG model). If DTC is indicated, print it and freeze frame data or write them down and then clear them.
Refer to DTC CLEARANCE in Section 6E (petrol model) or Section 6E1 (bi-fuel CNG model). DTC indicates
malfunction that occurred in the system but does not indicate whether it exists now or it occurred in the past and
the normal condition has been restored now. To check which case applies, check the symptom in question
according to Step 5 and recheck DTC according to Step 6 or 7.
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.
3.AND 4. VISUAL INSPECTION

Be sure to perform visual check of the following items that support proper function of the engine.
ENGINE 6-15
5.TROUBLE SYMPTOM CONFIRMATION

Based on information obtained in Step 1 customer complaint analysis and Step 2 DTC / freeze frame data
check, confirm trouble symptoms. Also, reconfirm DTC according to “DTC CONFIRMATION PROCEDURE” in
Section 6E (petrol model) or Section 6E1 (bi-fuel CNG model).
6.AND 7. RECHECKING AND RECORD OF DTC / FREEZE FRAME DATA

Refer to DTC CHECK in Section 6E (petrol model) or Section 6E1 (bi-fuel CNG model) for checking procedure.
8.ENGINE BASIC INSPECTION AND ENGINE DIAGNOSIS TABLE

Perform basic engine check according to the “ENGINE BASIC INSPECTION FLOW TABLE” first. When the end
of the flow table has been reached, check the parts of the system suspected as a possible cause. Refer to
ENGINE DIAGNOSIS TABLE 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.
ENGINE BASIC INSPECTION FLOW TABLE FOR PETROL MODEL
Step Action Yes No
1 Was ENGINE DIAGNOSTIC FLOW TABLE performed? Go to Step 2. Go to ENGINE DIAG-
NOSTIC FLOW
TABLE.
2 Check battery voltage. Go to Step 3 Go to DIAGNOSIS in
Is it 11 V or more? Section 6H.
3 Is engine cranked? Go to Step 4. Go to DIAGNOSIS in
Section 6G.
4 Does engine start? Go to Step 5. Go to Step 7.
5 Check engine idle speed/IAC duty. Refer to IDLE SPEED Go to Step 6. Go to ENGINE DIAG-
AND IAC (IDLE AIR CONTROL) DUTY INSPECTION in NOSIS TABLE.
Section 6E.
Is check result as specified?
6 Check ignition timing. Refer to IGNITION TIMING in Sec- Go to Step 7. Go to DIAGNOSIS in
tion 6F. Section 6F.
7 Check fuel supply as follows: Go to Step 9. Go to Step 8.
1) Check that fuel remains in fuel tank enough.
2) Turn the ignition switch ON position for 3 seconds
and then turn it OFF position. Repeat this a few
times.
Is fuel return pressure (returning sounds) felt from fuel
return hose when the ignition switch is turned ON posi-
tion?
8 Check fuel pump for operating. Go to FUEL PRES- Go to FUEL PUMP
1) Was fuel pump operating sound heard from fuel filler SURE CHECK in CIRCUIT CHECK in
for about 2 seconds after turning the ignition switch Section 6E. Section 6E.
ON position and stop?
9 Check spark plug and ignition spark. Refer to SPARK Go to Step 10. Go to DIAGNOSIS in
PLUG in Section 6F and IGNITION SPARK TEST in Sec- Section 6F.
tion 6F.
Is it in good condition?
6-16 ENGINE
10 Check fuel injector. Refer to FUEL INJECTOR in Section Go to ENGINE Go to FUEL INJEC-
6E. DIAGNOSIS TABLE. TOR CIRCUIT
Is it in good condition? CHECK in Section
6E.
ENGINE BASIC INSPECTION FLOW TABLE FOR BI-FUEL CNG MODEL
Step Action Yes No
1 Was ENGINE DIAGNOSTIC FLOW TABLE performed? Go to Step 2. Go to ENGINE DIAG-
NOSTIC FLOW
TABLE in this section.
2 Check battery voltage. Go to Step 3. Go to DIAGNOSIS in
Is it 11 V or more? Section 6H.
3 Is engine cranked? Go to Step 4. Go to DIAGNOSIS in
Section 6G.
4 Check each “Petrol MODE”, “AUTO MODE” and “Forced Go to Step 5. Go to ENGINE DIAG-
CNG MODE” can be selected. Refer to BI-FUEL SELEC- NOSTIC TABLE in
TOR SWITCH EQUIPPED WITH INDICATOR (BI-FUEL this section.
CNG MODEL) in Section 8.
5 Crank engine with “Petrol MODE” and “Forced CNG Go to Step 7. Go to Step 6.
MODE” respectively.
Does engine start on both petrol and CNG?
6 Does engine start on petrol or on CNG? Engine starts only on Go to Step 10.
petrol: Go to Step 15.
Engine start only on
CNG: Go to Step 11.
7 Check “AUTO MODE” operation as follows: Go to Step 8. Go to ENGINE DIAG-
1) Select “AUTO MODE”. NOSTIC TABLE in
2) Start engine. this section.
3) Check that fuel is switched from petrol to CNG auto-
matically.
Is it good condition?
8 Check engine idle speed / IAC duty, when engine run- Go to Step 9. Go to ENGINE DIAG-
ning on each of petrol and CNG. Refer to IDLE SPEED NOSTIC TABLE in
AND IAC DUTY INSPECTION in Section 6E1. this section.
9 Check ignition timing. Refer to IGNITION TIMING in Sec- Go to ENGINE Check ignition con-
tion 6F. DIAGNOSTIC trol related parts
Is check result as specified? TABLE in this sec- referring to IGNI-
tion. TION TIMING in Sec-
tion 6F.
10 Check CNG receptacle switch as follows: Go to Step 11. CNG receptacle
1) Check that CNG receptacle cap is closed. switch malfunction.
2) Check CNG receptacle switch. Refer to CNG
RECEPTACLE in Section 6E1.
Are they in good condition?
ENGINE 6-17
11 Check petrol fuel supply as follows: Go to Step 13. Go to Step 12.

1) Check that fuel remains in fuel tank enough.
2) Turn ON ignition switch for 2 sec. and then OFF.
3) Repeat Step 2 for 3 times.
Is fuel return pressure (returning sounds) felt from fuel
return hose when ignition switch is turned ON?
12 Check fuel pump for operating. Go to FUEL PRES- Go to FUEL PUMP
Was fuel pump operating sound heard from fuel filler for SURE CHECK in CIRCUIT CHECK in
about 2 seconds after ignition switch ON position and Section 6E1. Section 6E1.
stop?
13 Check spark plug and ignition spark. Refer to SPARK Go to Step 14. Go to DIAGNOSIS in
PLUG in Section 6F and IGNITION SPARK TEST in Sec- Section 6F.
tion 6F.
14 Check petrol fuel injector. Refer to FUEL INJECTOR in Go to ENGINE Go to FUEL INJEC-
Section 6E1. DIAGNOSTIC TOR CIRCUIT
Is it in good condition? TABLE in this sec- CHECK in Section
tion. 6E1.
15 Check CNG fuel supply as follows: Go to Step 16. Recharge CNG.
1) Check that manual valve is open.
2) Check to make sure that remaining CNG fuel is
enough. Refer to BI-FUEL SELECTOR SWITCH
EQUIPPED WITH INDICATOR (BI-FUEL CNG
MODEL) in Section 8.
16 Check shut-off valve for operation as follows: Go to Step 17. CNG shutoff valve
• Shut-off valve of CNG pressure regulator. Refer to malfunction.
CNG PRESSURE REGULATOR in Section 6E1
• Shut-off valve of CNG cylinder. Refer to CNG CYLIN-
DER WITH VALVE in Section 6C1
17 Check CNG fuel injector for operation. Refer to FUEL Go to ENGINE Go to FUEL INJEC-
INJECTOR in Section 6E1. DIAGNOSTIC TOR CIRCUIT
Is it in good condition? TABLE in this sec- CHECK in Section
tion. 6E1.
9.TROUBLESHOOTING FOR DTC

Based on the DTC indicated in Step 6 or 7, locate the cause of the trouble, namely in a sensor, switch, wire har-
ness, connector, actuator, ECM or other part and repair or replace faulty parts. Refer to the applicable DTC diag.
flow table in Section 6E (petrol model) or Section 6E1 (bi-fuel CNG model).
10.CHECK FOR INTERMITTENT PROBLEM

Check parts where an intermittent trouble is easy to occur (e.g., wire harness, connector, etc.). Refer to INTER-
MITTENT AND POOR CONNECTION in Section 0A and related circuit of DTC recorded in Step 2.
11.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, perform DTC confirmation procedure in Section 6E
(petrol model) or Section 6E1 (bi-fuel CNG model) and confirm that no malfunction DTC (a normal code) is indi-
cated.
6-18 ENGINE
ENGINE DIAGNOSIS TABLE

Perform troubleshooting referring to the following table when ECM / CNG control module has detected no DTC
and no abnormality has been found in “3.AND 4. VISUAL INSPECTION” and “8.ENGINE BASIC INSPECTION
AND ENGINE DIAGNOSIS TABLE” under “ENGINE DIAGNOSTIC FLOW TABLE” in this section.
Condition Possible Cause Reference Item

Hard starting Engine and emission control system out of
(Engine cranks order.
OK) • Faulty CMP sensing rotor CMP SENSING ROTOR (INSPECTION)
in Section 6E (petrol model) or Section
6E1 (bi-fuel CNG model).
• Faulty idle air control system IDLE AIR CONTROL SYSTEM CIRCUIT
CHECK in Section 6E (petrol model) or
• Faulty ECT sensor, TP sensor, CKP sen- ECT SENSOR, TP SENSOR, CKP SEN-
sor, CMP sensor or MAP sensor SOR, CMP SENSOR or MAP SENSOR in
Section 6E (petrol model) or Section 6E1
(bi-fuel CNG model).
• Fuel pressure out of specification FUEL PRESSURE CHECK in Section 6E
(petrol model) or Section 6E1 (bi-fuel
CNG model).
• Faulty fuel injector FUEL INJECTOR in Section 6E (petrol
model) or Section 6E1 (bi-fuel CNG
model).
• Faulty CNG receptacle switch CNG RECEPTACLE in Section 6C1.
• Faulty ECM ECM AND ITS CIRCUIT VOLTAGE
TABLE in Section 6E (petrol model) or
• Faulty CNG control module (bi-fuel CNG CNG CONTROL MODULE AND ITS CIR-
model) CUIT VOLTAGE TABLE in Section 6E1.
• Malfunctioning PCV system PCV SYSTEM in Section 6E (petrol
model).
Low compression. COMPRESSION CHECK in Section 6A.
• Improper valve lash VALVE LASH in Section 6A.
• Improper valve timing TIMING BELT AND BELT TENSIONER in
Section 6A.
• Compression leak from valve seat VALVES AND CYLINDER HEAD in Sec-
tion 6A.
• Sticky valve stem VALVES AND CYLINDER HEAD in Sec-
tion 6A.
• Weak or damaged valve springs VALVES AND CYLINDER HEAD in Sec-
tion 6A.
• Compression leak at cylinder head gasket VALVES AND CYLINDER HEAD or MAIN
BEARINGS, CRANKSHAFT AND CYLIN-
DER BLOCK in Section 6A.
• Sticking or damaged piston ring PISTON, PISTON RINGS, CONNECTING
RODS AND CYLINDERS in Section 6A.
• Worn piston, piston ring or cylinder PISTON, PISTON RINGS, CONNECTING
ENGINE 6-19

Hard starting Ignition system out of order.
(Engine cranks • Faulty ignition coil, high-tension cord or IGNITION COIL ASSEMBLY (INCLUD-
OK) spark plug ING IGNITOR), HIGH-TENSION CORD,
SPARK PLUG in Section 6F.
Engine has no Engine overheating. Refer to “Overheating” of this table.
power Ignition system out of order.
• Faulty ignition coil, high-tension cord or IGNITION COIL ASSEMBLY (INCLUD-
spark plug ING IGNITOR), HIGH-TENSION CORD,
Engine and emission control system out of
order.
CNG model).
• Faulty injector FUEL INJECTOR in Section 6E (petrol
model).
• Faulty TP sensor, ECT sensor or MAP TP SENSOR, ECT SENSOR or MAP
sensor SENSOR in Section 6E (petrol model) or
• Faulty CNG pressure-and-temperature CNG PRESSURE-AND-TEMPERATURE
sensor (bi-fuel CNG model) SENSOR in this section.
• Faulty EGR system EGR SYSTEM in Section 6E.
Low compression. Previously outlined.
Others.
• Dragging brakes BRAKE DIAGNOSIS TABLE in Section 5.
• Slipping clutch DIAGNOSIS in Section 7C.
6-20 ENGINE

Improper engine Ignition system out of order.
idling or engine • Faulty ignition coil, high-tension cord or IGNITION COIL ASSEMBLY (INCLUD-
fails to idle spark plug ING IGNITOR), HIGH-TENSION CORD,
Engine overheating. Refer to “Overheating” of this table.
order.
CNG model).
• Faulty idle air control system IDLE AIR CONTROL SYSTEM CIRCUIT
CHECK in Section 6E (petrol model) or
• Faulty evaporative emission control system EVAPORATIVE EMISSION CONTROL
SYSTEM CHECK in Section 6E.
model).
• Faulty ECT sensor, TP sensor or MAP ECT SENSOR, TP SENSOR or MAP
• Malfunctioning PCV system PCV SYSTEM in Section 6E.
• Faulty A/C signal circuit A/C CONTROL SIGNAL CHECK (IF
EQUIPPED) in Section 6E (petrol model)
or Section 6E1 (bi-fuel CNG model).
Others.
ENGINE 6-21

Engine hesitates Ignition system out of order.
(Momentary lack • Faulty ignition coil, high-tension cords or IGNITION COIL ASSEMBLY (INCLUD-
of response as the spark plug ING IGNITOR), HIGH-TENSION CORD,
accelerator is SPARK PLUG in Section 6F.
depressed. Can Engine overheating. Refer to “Overheating” of this table.
occur at all vehicle Engine and emission control system out of
speeds. Usually order.
most severe when • Fuel pressure out of specification FUEL PRESSURE CHECK in Section 6E
first trying to (petrol model) or Section 6E1 (bi-fuel
make the vehicle CNG model).
move, as from a • Faulty injector FUEL INJECTOR in Section 6E (petrol
stop sign.) model) or Section 6E1 (bi-fuel CNG
model).
6-22 ENGINE

Surges Ignition system out of order.
(Engine power • Faulty ignition coil, high-tension cord or IGNITION COIL ASSEMBLY (INCLUD-
variation under spark plug ING IGNITOR), HIGH-TENSION CORD,
steady throttle or SPARK PLUG in Section 6F.
cruise. Feels like Engine and emission control system out of
the vehicle speeds order.
up and down with • Variable fuel pressure FUEL PRESSURE CHECK in Section 6E
no change in the (petrol model) or Section 6E1 (bi-fuel
accelerator pedal.) CNG model).
• Kinky or damaged petrol and/or CNG fuel FUEL LINES in Section 6C (petrol model)
lines or Section 6C1 (bi-fuel CNG model)
• Faulty fuel pump (clogged fuel filter) FUEL PUMP CIRCUIT CHECK in Section
6E.
• Faulty MAP sensor MAP SENSOR in Section 6E.
model).
ENGINE 6-23

Excessive detona- Engine overheating. Refer to “Overheating” of this table.
tion Ignition system out of order.
(The engine • Improper ignition timing IGNITION TIMING in Section 6F.
makes sharp Engine and emission control system out of
metallic knocks order.
that change with • Clogged fuel filter and fuel lines FUEL PRESSURE CHECK in Section 6E
throttle opening. (petrol model) or Section 6E1 (bi-fuel
Sounds like pop- CNG model).
corn popping.) • Faulty knock sensor, ECT sensor or MAP KNOCK SENSOR, ECT SENSOR or
sensor MAP SENSOR in Section 6E (petrol
model).
model).
Others.
• Excessive combustion chamber deposits Piston and cylinder head cleaning in Sec-
tion 6A.
Overheating • Inoperative thermostat Thermostat in Section 6B.
• Faulty radiator fan motor or its circuit RADIATOR FAN CONTROL SYSTEM
CIRCUIT CHECK in Section 6E.
• Loose or slip water pump belt WATER PUMP BELT in Section 6B.
• Poor water pump performance WATER PUMP in Section 6B.
• Clogged or leaky radiator RADIATOR in Section 6B.
• Improper engine oil grade Engine Oil and Filter Change in Section
0B.
• Clogged oil filter or oil strainer OIL PRESSURE CHECK in Section 6A.
• Poor oil pump performance OIL PRESSURE CHECK in Section 6A.
• Blown cylinder head gasket VALVES AND CYLINDER HEAD in Sec-
tion 6A.
6-24 ENGINE

Poor fuel mileage Ignition system out of order.
• Faulty ignition coil, high-tension cord or IGNITION COIL ASSEMBLY (INCLUD-
spark plug ING IGNITOR), HIGH-TENSION CORD,
order.
CNG model).
model).
Others.
• Poor valve seating VALVES AND CYLINDER HEAD in Sec-
tion 6A.
• Thermostat out of order THERMOSTAT in Section 6B.
• Improper tire pressure
Excessive engine Oil entering combustion chamber.
oil consumption • Sticky piston ring PISTON, PISTON RINGS, CONNECTING
• Worn piston and cylinder PISTON, PISTON RINGS, CONNECTING
• Worn piston ring groove and ring PISTON, PISTON RINGS, CONNECTING
• Improper location of piston ring gap PISTON, PISTON RINGS, CONNECTING
• Worn or damaged valve stem seal VALVES AND CYLINDER HEAD in Sec-
tion 6A.
• Worn valve stem VALVES AND CYLINDER HEAD in Sec-
tion 6A.
ENGINE 6-25

Low oil pressure • Improper oil viscosity Engine Oil and Filter Change in Section
0B.
• Malfunctioning oil pressure switch ENGINE OIL PRESSURE WARNING
LIGHT in Section 8.
• Clogged oil strainer OIL PAN AND OIL PUMP STRAINER in
Section 6A.
• Functional deterioration of oil pump OIL PUMP in Section 6A.
• Worn oil pump relief valve OIL PUMP in Section 6A.
• Excessive clearance in various sliding
parts
Engine noise Valve noise.
Note: Before • Improper valve lash VALVE LASH in Section 6A.
checking the • Worn valve stem and guide VALVES AND CYLINDER HEAD in Sec-
mechanical noise, tion 6A.
make sure that: • Weak or broken valve spring VALVES AND CYLINDER HEAD in Sec-
• Ignition timing is tion 6A.
properly • Warped or bent valve VALVES AND CYLINDER HEAD in Sec-
adjusted. tion 6A.
• Specified spark • Loose camshaft housing bolts ROCKER ARMS, ROCKER ARM SHAFT
plug is used. AND CAMSHAFT in Section 6A.
• Specified fuel is Piston, ring and cylinder noise.
used. • Worn piston, ring and cylinder bore PISTON, PISTON RINGS, CONNECTING
Connecting rod noise.
• Worn crankpin bearing PISTON, PISTON RINGS, CONNECTING
• Worn crankpin PISTON, PISTON RINGS, CONNECTING
• Loose connecting rod nuts PISTON, PISTON RINGS, CONNECTING
• Low oil pressure Previously outlined.
Crankshaft noise.
• Low oil pressure Previously outlined.
• Worn crankshaft journal bearing MAIN BEARINGS, CRANKSHAFT AND
CYLINDER BLOCK in Section 6A.
• Worn crankshaft journal MAIN BEARINGS, CRANKSHAFT AND
• Loose lower crankcase (bearing cap) bolts MAIN BEARINGS, CRANKSHAFT AND
• Excessive crankshaft thrust play MAIN BEARINGS, CRANKSHAFT AND
6-26 ENGINE

Excessive hydro- Ignition system out of order.
carbon (HC) emis- • Faulty ignition coil, high-tension cord or IGNITION COIL ASSEMBLY (INCLUD-
sion or Excessive spark plug ING IGNITOR), HIGH-TENSION CORD,
carbon monoxide SPARK PLUG in Section 6F.
(CO) emission Engine and Emission control system out of
order.
CNG model).
• Lead contamination of three way catalytic Check for absence of filler neck restrictor.
converter
• Malfunctioning PCV system PCV SYSTEM in Section 6E.
• Faulty EVAP control system EVAPORATIVE EMISSION CONTROL
SYSTEM CHECK in Section 6E (petrol
model).
• Closed loop system (A/F feed back com- Check heated oxygen sensor output volt-
pensation) fails age.
– Faulty TP sensor Refer to DTC P0130 in Section 6E (petrol
– Faulty ECT sensor or MAP sensor model) or Section 6E1 (bi-fuel CNG
– Faulty heated oxygen sensor model).
model).
ENGINE 6-27

Excessive nitro- Engine and emission control system.
gen oxides (NOx) • Fuel pressure out of specification FUEL PRESSURE CHECK in Section 6E
emission (petrol model) or Section 6E1 (bi-fuel
CNG model).
• Lead contamination of three way catalytic Check for absence of filler neck restrictor.
converter
• Closed loop system (A/F feed back com- Check heated oxygen sensor output volt-
pensation) fails age.
– Faulty TP sensor Refer to DTC P0130 in Section 6E (petrol
– Faulty ECT sensor or MAP sensor model) or Section 6E1 (bi-fuel CNG
– Faulty heated oxygen sensor model).
model).
Unusable CNG • Faulty IAT, ECT, TP or HEATED OXYGEN IAT, ECT, TP or HEATED OXYGEN SEN-
(“AUTO MODE” or sensor SOR in Section 6E1.
“Forced CNG • Faulty shut off valve of CNG cylinder CNG CYLINDER WITH VALVE in Section
MODE” can not be 6C1.
selected) • Faulty shut off valve of CNG pressure reg- CNG PRESSURE REGULATOR in Sec-
ulator tion 6E1.
• Faulty fuel selector switch BI-FUEL SELECTOR SWITCH
EQUIPPED WITH INDICATOR (BI-FUEL
CNG MODEL) in Section 8.
• Faulty CNG valve control relay Check CNG valve control relay.
• Faulty CNG receptacle switch CNG RECEPTACLE in Section 6C1.
CHECK in Section 6E1.
• Faulty CNG control module CNG CONTROL MODULE AND ITS CIR-
CUIT VOLTAGE CHECK in Section 6E1.
Unusable CNG • Faulty IAT, ECT, TP or HEATED OXYGEN IAT, ECT, TP or HEATED OXYGEN SEN-
(Fuel can not sensor SOR in Section 6E1.
change over to • Faulty CNG receptacle switch CNG RECEPTACLE in Section 6C1.
CNG in “AUTO • Faulty ECM ECM AND ITS CIRCUIT VOLTAGE
MODE”) CHECK in Section 6E1.
• Faulty CNG control module CNG CONTROL MODULE AND ITS CIR-
CUIT VOLTAGE CHECK in Section 6E1.
ENGINE MECHANICAL 6A-1
SECTION 6A
ENGINE MECHANICAL
CONTENTS
GENERAL DESCRIPTION ...............................6A-2 OIL PUMP................................................... 6A-24
ENGINE ........................................................6A-2 ROCKER ARMS, ROCKER ARM SHAFT
ENGINE LUBRICATION ...............................6A-3 AND CAMSHAFT........................................ 6A-29
ON-VEHICLE SERVICE ...................................6A-4 VALVES AND CYLINDER HEAD ............... 6A-37
PISTON, PISTON RINGS, CONNECTING
COMPRESSION CHECK..............................6A-4
RODS AND CYLINDERS ........................... 6A-48
ENGINE VACUUM CHECK ..........................6A-5
OIL PRESSURE CHECK ..............................6A-6 UNIT REPAIR OVERHAUL............................6A-57
VALVE LASH (CLEARANCE) .......................6A-7 ENGINE ASSEMBLY.................................. 6A-57
AIR CLEANER ELEMENT ............................6A-9 MAIN BEARINGS, CRANKSHAFT AND
CYLINDER HEAD COVER ...........................6A-9 CYLINDER BLOCK..................................... 6A-62
THROTTLE BODY AND INTAKE TIGHTENING TORQUE SPECIFICATIONS ..6A-74
MANIFOLD..................................................6A-11 SPECIAL TOOLS ...........................................6A-75
EXHAUST MANIFOLD................................6A-14 REQUIRED SERVICE MATERIALS ..............6A-76
TIMING BELT AND BELT TENSIONER .....6A-15
OIL PAN AND OIL PUMP STRAINER ........6A-21
NOTE:
For what each abbreviation stands for (i.e., full term), refer to SECTION 0A.
6A-2 ENGINE MECHANICAL
GENERAL DESCRIPTION
ENGINE
The engine is a water-cooled, in line 4 cylinders, 4 stroke cycle gasoline unit equipped with its S.O.H.C. (Single
Overhead Camshaft) valve mechanism arranged for “V”-type valve configuration and 16 valves (IN 2 and EX 2/
one cylinder).
The single overhead camshaft is mounted over the cylinder head, it is driven from crankshaft through timing belt
and opens and closes its valves via the rocker arms.
ENGINE LUBRICATION
The oil pump is of a trochoid type, and mounted on crankshaft at crankshaft pulley side. Oil is drawn up through
oil pump strainer and passed through pump to oil filter.
The filtered oil flows into two paths in cylinder block. In one path, oil reaches crankshaft journal bearings. Oil
from crankshaft journal bearings is supplied to connecting rod bearings by means of intersecting passages
drilled in crankshaft, and then injected from a small hole provided on big end of connecting rod to lubricate pis-
ton, rings, and cylinder wall.
In another path, oil goes up to cylinder head and lubricates camshaft journals, rocker arms, camshaft, etc.,
passing through oil gallery in rocker arm shaft.
An oil relief valve is provided on oil pump. This valve starts relieving oil pressure when the pressure comes over
about 400 kPa (4.0 kgf/cm2, 56.9 psi). Relieved oil drains back to oil pan.
ON-VEHICLE SERVICE
COMPRESSION CHECK
Check compression pressure on all four 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 all fuel injector wire harness connectors.
4) Remove all ignition coil assemblies and all spark plugs refer-
ring to section 6F.
5) Install special tools (Compression gauge) into spark plug
hole.
Special tool
(A): 09915M64510-001
(B): 09915M64510-002
(C): 09915M64530
(D): 09915M67010
6) Disengage clutch (to lighten starting load on engine), and

depress accelerator pedal all the way to make throttle valve
full-open.
7) Crank engine with fully charged battery, and read the highest
pressure on compression gauge.
NOTE:
For measuring compression pressure, crank engine at
least 250 r/min. by using fully charged battery.
Compression pressure
1400 kPa
Standard
(14.0 kg/cm2, 199.0 psi)
1200 kPa
Limit
(12.0 kg/cm2, 170.0 psi)
Max. difference between 100 kPa
any two cylinders (1.0 kg/cm2, 14.2 psi)
8) Carry out steps 5) through 7) on each cylinder to obtain four

readings.
9) After checking, install spark plugs and ignition coil assem-
blies and connect injector wire harness connector securely.
ENGINE VACUUM CHECK

The engine vacuum that develops in the intake line is a good indi-
cator of the condition of the engine. The vacuum checking proce-
dure is as follows:
1) Warm up engine to normal operating temperature.
NOTE:
After warming up engine, place transmission gear shift
lever in “Neutral” and set parking brake and block drive
wheels.
2) With engine stopped, disconnect vacuum hose from fuel

pressure regulator and connect 3-way joint, hoses and spe-
cial tool (vacuum gauge and joint) between fuel pressure
regulator and vacuum hose disconnected.
Special tool
(A): 09915M67311
(B): 09918M08210
SUZUKI GENUINE PARTS
(C): Hose 09355M35754-6010
(D): 3-way joint 09367M04002
3) Run engine at specified idle speed, and read vacuum gauge.
Vacuum should be within following specification.
Vacuum specification (at sea level):
58.7 – 74.7 kPa (44 – 56 cmHg, 17.3 – 22.0 in.Hg) at speci-
fied idling speed
4) After checking, connect vacuum hose to intake manifold.
OIL PRESSURE CHECK
NOTE:
Prior to checking oil pressure, check following items.
• Oil level in oil pan.
If oil level is low, add oil up to Full level mark on oil
level gauge.
• Oil quality.
If oil is discolored, or deteriorated, change it.
For particular oil to be used, refer to the table in MAIN-
TENANCE SERVICE in Section 0B.
• Oil leaks.
If leak is found, repair it.
1. Low level mark

2. Full level mark
1) Remove oil pressure switch from cylinder block.

2) Install special tools (Oil pressure gauge) to vacated threaded
hole.
Special tool
(A): 09915M77311
(B): 09915M78211
3) Set engine tachometer.
4) Start engine and warm it up to normal operating tempera-
ture.
NOTE:
Check oil level in oil pan. If oil level is low, add oil up to
Full level hole on oil level gauge.
5) After warming up, raise engine speed to 4,000 r/min and
measure oil pressure.
Oil pressure specifications:
330 – 430 kPa (3.3 – 4.3 kgf/cm2, 46.9 – 61.1 psi)
at 4,000 r/min (rpm)
6) After checking oil pressure, stop engine and remove oil pres-
sure gauge.
7) Before reinstalling oil pressure switch, be sure to wrap its

screw threads with a sealing tape and tighten switch to spec-
ified torque.
NOTE:
If sealing tape edge is bulged out from screw threads of
switch, cut it off.
Tightening torque
(a): 14 N·m (1.4 kgf-m, 10.5 lbf-ft)
8) Start engine and check oil pressure switch for oil leakage.
9) Stop engine and connect terminal to pressure switch termi-
nal and cover pressure switch by boot with certainty.
1. Sealing tape
2. Oil filter
VALVE LASH (CLEARANCE)

2) Remove cylinder head cover referring to item CYLINDER
HEAD COVER.
3) Remove service lid, then remove ignition timing inspection
plug from clutch housing of transmission case.
4) Turn crankshaft clockwise (viewing from crankshaft pulley
1. Match mark
2. “T” (TDC) mark side) to the extent that line below “T” mark punched on fly-
3. Floor wheel is aligned with match mark on transmission case as
4. Ignition timing
inspection hole shown, i.e. No. 1 cylinder piston reaches TDC position.
5) Check if the rocker arms of No.1 cylinder are off the respec-
tive cam lobes (of camshaft); if so, valves (1), (2), (5) and (7)
in left figure are ready for clearance checking and adjust-
ment.
Check valve lashes at valves (1), (2), (5) and (7).
If the rocker arms of No.4 cylinder are off the respective cam
lobes, check valve lashes at valves (3), (4), (6) and (8).
NOTE:
When checking valve clearance, insert thickness gauge
between camshaft and cam-riding face of rocker arm.
6) If valve lash is out of specification, adjust it to specification by

turning adjusting screw after loosening lock nut. After adjust-
ment, tighten lock nut to specified torque while holding
adjusting screw stationary, and then make sure again that
valve lash is within specification.
When cold When hot

(Coolant tempera- (Coolant tempera-
Valve
ture is 15 – 25 °C ture is 60 – 68 °C
clear-
or 59 – 77 °F) or 140 – 154 °F)
ance
0.13 – 0.17 mm 0.17 – 0.21 mm
specifi- Intake
(0.005 – 0.007 in.) (0.007 – 0.008 in.)
cation
0.23 – 0.27 mm 0.27 – 0.31 mm
Exhaust
(0.009 – 0.011 in.) (0.011 – 0.012 in.)
Special tool
(A): 09917M18211
1. Thickness gauge
Tightening torque
2. Lock nut (a): 12 N·m (1.2 kgf-m, 9.0 lbf-ft)
7) After checking and adjusting valve lashes at valves (1), (2),

(5) and (7), (or (3), (4), (6) and (8)) rotate crankshaft exactly
one full turn (360°) and check the same at valves (3), (4), (6)
and (8) (or (1), (2), (5) and (7)). Adjust them as necessary.
8) After checking and adjusting all valves, reverse removal pro-
cedure for installation.
AIR CLEANER ELEMENT

REMOVAL AND INSTALLATION
1) Remove air cleaner case clamps.
2) Remove air cleaner element from case.
3) Check air cleaner element for dirt.
4) If necessary, blow off dust by compressed air from air outlet
side of element.
If excessively dirty, replace element.
5) Reverse removal procedure for installation.
1. Air cleaner case

2. Clamp
CYLINDER HEAD COVER

REMOVAL
1) Disconnect negative (–) and positive (+) battery cables at
battery terminal and remove battery.
2) For bi-fuel CNG model, relieve CNG fuel pressure in CNG
fuel feed line. Refer to FUEL PRESSURE RELIEF PROCE-
DURE in Section 6.
3) For bi-fuel CNG model, remove CNG fuel injector assembly,
referring to FUEL INJECTOR in Section 6E1.
4) Remove ignition coil assemblies with high-tension cord.
1. Cylinder head
cover 5) Disconnect PCV valve and breather hose from head cover.
2. Cylinder head 6) Remove cylinder head cover with cylinder head cover gasket
cover gasket
3. O-rings and O-rings.
INSTALLATION
1) Install O-rings and cylinder head cover gasket to cylinder
head cover.
NOTE:
Be sure to check each of these parts for deterioration or
1. Cylinder head
cover gasket any damage before installation and replace if found
2. O-rings defective.
3. Cylinder head
cover
2) Install cylinder head cover to cylinder head and tighten cover

bolts to specified torque.
Tightening torque
(a): 11 N·m (1.1 kgf-m, 8.0 lbf-ft)
NOTE:
When installing cylinder head cover, use care so that cyl-
inder head cover gasket or O-rings will not get out of
place or fall off.
3) Install ignition coil assemblies with high-tension cord.

4) For bi-fuel CNG model, install CNG fuel injector assembly,
referring to FUEL INJECTOR in Section 6E1.
5) Connect PCV valve and breather hose to head cover.
6) Install battery, connect positive (+) and negative (–) cable at
battery.
7) For bi-fuel CNG model, check for CNG fuel leaks. Refer to
FUEL LEAKAGE CHECK PROCEDURE in Section 6.
THROTTLE BODY AND INTAKE MANIFOLD
1. Intake manifold
6
2. Gasket
3. Intake manifold stiffener
3 4. Engine hook
2
5. Throttle body
6. Throttle body gasket
REMOVAL
WARNING:
To help avoid danger of being burned, do not remove
drain plug and radiator cap while engine and radiator are
still hot. Scalding fluid and steam can be blown out under
pressure if plug and cap are taken off too soon.
1) Relieve fuel pressure according to FUEL PRESSURE

RELIEF PROCEDURE described in Section 6.
2) Disconnect negative cable at battery and remove engine
room center member with shift control and parking brake
lever.
3) Remove generator adjusting arm reinforcement.
2
1 4) Drain engine coolant by disconnecting radiator outlet hose
1 from radiator.
1. Center member bolt 5) Remove air intake hose and air cleaner case.
2. Gear shift control lever bolt
(front side) 6) For bi-fuel CNG model, remove console box.
7) For bi-fuel CNG model, remove center member bolts and
gear shift control lever front side 2 bolts.
NOTE:
In order to make workspace, lift center member to upper
level and hold it by inserting wooden block etc.
8) For bi-fuel CNG model, remove CNG fuel injector assembly.
Refer to FUEL INJECTOR in Section 6E1.
9) Disconnect following electric lead wires:

• Ground wires from intake manifold
• Engine coolant temperature sensor
• Injectors lead wires at the coupler
• EVAP canister purge valve
• Throttle position sensor
• Idle air control valve
• MAP sensor
• EGR valve
10) Disconnect accelerator cable from throttle body.
11) Disconnect following hoses:

• Brake booster hose from intake manifold
• Canister purge hose from EVAP canister purge valve
• Heater inlet hose from throttle body (if equipped)
• Radiator inlet hose and reservoir hose from thermostat cap
• PCV hoses from intake manifold
• Fuel feed hose and return hose from each pipe
• Vacuum hose from intake manifold (bi-fuel CNG model)
• CNG fuel injector hoses from intake manifold (bi-fuel CNG
model)
NOTE:
ALPHABET in the figure shows where each hose is con-
nected.
2
1. Vacuum hose
2. CNG fuel injector hose
12) Remove throttle body from intake manifold.

13) Remove intake manifold stiffener.
14) Remove intake manifold from cylinder head, and then its
gasket.
1. Intake manifold
2. Throttle body
3. Intake manifold stiffener
INSPECTION
• Using a straight edge and thickness gauge, check surface at
a total of 6 locations. If distortion limit, given below, is
exceeded, correct gasket contact surface or replace intake
manifold.
Limit of distortion: 0.07 mm (0.003 in.)
INSTALLATION
Reverse removal procedure for installation noting the followings.
• Use new intake manifold gasket and new throttle body gas-
ket.
• Tighten bolts and nuts to specified torque.
Tightening torque
(a): 25 N·m (2.5 kgf-m, 18.5 lbf-ft)
(b): 55 N·m (5.6 kgf-m, 40.5 lbf-ft)
• Connect gear shift cables to gear shift control lever, refer to

GEAR SHIFT CONTROL INSTALLATION in Section 7A.
• Connect parking brake cable to parking brake lever and per-
form parking brake adjustment by referring PARKING
BRAKE INSPECTION AND ADJUSTMENT in Section 5.
• Adjust accelerator cable play, referring to ACCELERATOR
CABLE AND PEDAL ADJUSTMENT in Section 6E.
• Check to ensure that all removed parts are back in place.
Reinstall any necessary parts which have not been rein-
stalled.
• Install engine room center member.
• Refill cooling system and bleed air from system, referring to
COOLING SYSTEM FLUSH AND REFILL in Section 6B.
• Check for fuel leaks. Refer to FUEL PRESSURE RELIEF
PROCEDURE described in Section 6.
• Finally, start engine and check for engine coolant leaks.
EXHAUST MANIFOLD
WARNING:
To avoid danger of being burned, do not service exhaust
system while it is still hot. Service should be performed
after system cools down.
REMOVAL
2) Remove under cover and its stay.
3) Disconnect oxygen sensor coupler.
4) Remove exhaust manifold lower cover of exhaust manifold.
5) Disconnect ground wire from exhaust manifold.
6) Remove or disconnect exhaust pipe from exhaust manifold.
1. Exhaust manifold 7) Remove exhaust manifold and its gasket from cylinder head.
2. Exhaust manifold lower cover
3. Exhaust pipe
INSTALLATION
1) Install new gasket to cylinder head.
2) Install exhaust manifold.
Tighten nuts to specified torque.
Tightening torque
(a): 23 N·m (2.3 kgf-m, 17.0 lbf-ft)
3) Install pipe gasket and install exhaust pipe to exhaust mani-
fold.
Before installing pipe gasket, check it for deterioration or
damage, and replace as necessary.
Tighten pipe fasteners to specified torque.
Tightening torque
(b): 50 N·m (5.0 kgf-m, 36.5 lbf-ft)
4) Install lower cover to exhaust manifold.
5) Connect oxygen sensor connector.
6) Connect negative cable at battery.
1. Gasket 7) Check exhaust system for exhaust gas leakage.
2. Pipe gasket
3. Oxygen sensor
TIMING BELT AND BELT TENSIONER
1. Timing belt
2. Tensioner
3. Tensioner plate
4. Tensioner spring
5. Camshaft timing pulley
6. Tensioner bolt
7. Pulley bolt
8. Seal
9. Inside cover seal
10. Inside cover
11. Outside cover seal
12. Outside cover
13. Tensioner stud
14. Water hose bracket
REMOVAL
2) For bi-fuel CNG model, relieve CNG fuel pressure in fuel
feed line. Refer to FUEL PRESSURE RELIEF PROCEDURE
in Section 6.
1. Drive belt
2. Crankshaft pulley 4) Remove brake booster hose from intake manifold.
3. A/C compressor 5) Drain engine coolant and remove water hoses from intake
manifold, thermostat cap and water floor pipe, referring to
COOLING WATER PIPES OR HOSES in Section 6B.
1 6) For bi-fuel CNG model, remove CNG fuel pipe No.2 and
CNG pressure regulator pipe.
1. CNG fuel pipe No.2

2. CNG pressure regulator pipe
7) For bi-fuel CNG model, remove oil pan guard member bolts.
NOTE:
In order to make workspace, push oil pan guard member
for stabilizer with CNG pressure regulator mounted on it
and hold the position pulling with appropriate cords.
1
8) Remove generator belt and A/C compressor belt, if
1 equipped.
1. Oil pan guard member bolt
9) Remove water pump pulley.

10) Remove crankshaft pulley by removing 5 pulley bolts.
1. Pulley bolt
11) Remove water hose bracket with clamp and then timing belt
outside cover.
12) For removal of timing belt, align 4 timing marks as shown in

figure by turning crankshaft.
1. “V” mark on cylinder head

cover
2. Timing mark on camshaft
timing belt pulley
3. Arrow mark on oil pump
case
4. Punch mark on crankshaft
timing belt pulley
13) Remove timing belt tensioner, tensioner plate, tensioner

spring and timing belt.
1. Timing belt
2. Tensioner plate 4. Tensioner stud
3. Tensioner bolt 5. Spring
CAUTION:
• After timing belt is removed, never turn camshaft and
crankshaft independently more than such an extent as
shown in figure. If turned, interference may occur
among piston and valves, and parts related to piston
and valves may be damaged.
• Never bend timing belt.
1. Camshaft allowable turning range - - - By

timing mark, within 90O from “V” mark on head
cover on both right and left.
2. Crankshaft allowable turning range - - - By
punch mark, within 90O from arrow mark on oil
pump case on both right and left.
INSPECTION
• Inspect timing belt for wear or crack.
Replace it as necessary.
• Inspect tensioner for smooth rotation.

INSTALLATION
1) Install tensioner plate to tensioner.
Insert lug of tensioner plate into hole in tensioner.
1. Lug
2. Hole
2) Install tensioner and tensioner plate:

Tighten tensioner bolt by hand.
Make sure that tensioner moves in the same direction as
tensioner plate, when tensioner plate is moved in direction of
the arrow as shown in figure.
If tensioner movement is not synchronized to tensioner plate
movement, remove tensioner and tensioner plate, and then
reinsert tensioner plate lug into tensioner hole properly.
1. Tensioner bolt 3. Tensioner plate
2. Tensioner
3) Check that timing mark on camshaft timing belt pulley is

aligned with “V” mark on cylinder head cover. If not, align two
marks by turning camshaft.
CAUTION:
Be careful not to turn it more than its allowable turning
range which is described on previous page.
1. “V” mark
2. Timing mark
4) Check that punch mark on crankshaft timing belt pulley is

aligned with arrow mark on oil pump case. If not, align two
marks by turning crankshaft.
CAUTION:
Be careful not to turn it more than its allowable turning
range which is described on previous page.
1. Arrow mark
2. Punch mark
5) Install timing belt and tensioner spring.

With two sets of marks aligned and tensioner plate pushed
up, install timing belt on two pulleys in such a way that drive
side of belt is free from any slack.
And then install tensioner spring as shown in figure, and
hand tighten tensioner stud.
NOTE:
• When installing timing belt, match arrow mark (o) on
timing belt with rotating direction of crankshaft.
• In this state, No. 4 piston is at top dead center of com-
pression stroke.
1. Drive side of belt

2. Tensioner spring
3. Tensioner stud
4. Damper
6) To take up slack of timing belt, turn crankshaft two rotations

clockwise after installing it. After making sure that belt is free
from slack, tighten tensioner stud first and then tensioner
bolt to each specified torque.
Then confirm again that two sets of marks are aligned
respectively.
Tightening torque
(a): 11 N·m (1.1 kgf-m, 8.0 lbf-ft)
(b): 27 N·m (2.8 kgf-m, 20.0 lbf-ft)
7) Install timing belt outside cover and water hose bracket.

Before installing, make sure that seal is between water pump
and oil pump case.
Tightening torque
(a): 11 N·m (1.1 kgf-m, 8.0 lbf-ft)
8) Install crankshaft pulley.

Fit hole of pulley to pin on crankshaft timing belt pulley, and
tighten pulley bolts to specified torque.
Tightening torque
(a): 16 N·m (1.6 kgf-m, 11.5 lbf-ft)
1. Pin
2. Crankshaft pulley
3. Pulley bolt
9) Install water pump pulley and drive belt.

Adjust generator drive belt tension, referring to BELT TEN-
SION INSPECTION in Section 6H.
Tightening torque
(a): 11 N·m (1.1 kgf-m, 8.0 lbf-ft)
1. Drive belt
2. Crankshaft pulley
3. A/C compressor
4. Water pump pulley
10) For bi-fuel CNG model, install oil pan guard member.
1. Oil pan guard member
11) For bi-fuel CNG model, install CNG fuel pipe No.2 and CNG
1
pressure regulator pipe.
12) Install A/C compressor belt, if equipped.
Adjust its belt tension, referring to A/C COMPRESSOR
DRIVE BELT INSPECTION in Section 1B.

13) Connect brake booster hose and water hoses to intake man-
ifold, thermostat cap and water floor pipe, clamp them
securely.
14) Refill cooling system and bleed air from system, referring to
15) Connect negative cable to battery.
16) Verify that there is no coolant leakage at hose connection.
17) Install under cover and its stay.
OIL PAN AND OIL PUMP STRAINER
1. Baffle plate
2. Oil pump strainer
3. O-ring
4. Upper oil pan
5. Lower oil pan
REMOVAL

2) Drain engine oil by removing drain plug.
3) Remove lower oil pan.
1. Lower oil pan

2. Drain plug
3. Upper oil pan
4) Remove engine and transmission stiffener.

5) Remove CKP sensor, referring to CKP SENSOR in Section
6E.
1. Stiffener
2. Upper oil pan 3. Clutch cable
6) Remove baffle plate and upper oil pan and then oil pump
strainer.
CLEANING
• Clean mating surfaces of oil pan and cylinder block.
Remove oil, old sealant, and dusts from mating surfaces and
oil pan inside.
• Clean oil pump strainer screen.

INSTALLATION
1) Install oil pump strainer.
Install new seal in such position as shown in figure.
Tighten strainer bolt first and then bracket bolt to specified
torque.
Tightening torque
1. Seal (a): 11 N·m (1.1 kgf-m, 8.0 lbf-ft)
2. Strainer
3. Bracket
2) Clean mating surfaces of upper and lower oil pan and cylin-
der block. Remove oil, old sealant, and dusts from mating
surfaces.
3) Apply sealant to upper oil pan mating surface continuously

as shown in figure.
“A”: Sealant 99000-31250
1. Upper oil pan
4) Install upper oil pan to cylinder block, and then Install baffle
plate to upper oil pan.
Tightening torque
(a): 11 N·m (1.1 kgf-m, 8.0 lbf-ft)
5) Apply sealant to lower oil pan mating surface continuously as

shown in figure.
“A”: Sealant 99000-31250
1. Lower oil pan
6) Install lower oil pan to cylinder block.

Tightening torque
(a): 11 N·m (1.1 kgf-m, 8.0 lbf-ft)
7) Install CKP sensor, referring to CKP SENSOR in Section 6E.
8) Install new gasket and drain plug to oil pan.
Tightening torque
(b): 50 N·m (5.0 kgf-m, 36.5 lbf-ft)
9) Refill engine with engine oil, referring to ITEM 1_4 Engine Oil
and Filter Change in Section 0B.
OIL PUMP
1. Rotor plate 6. Pin

2. Inner rotor 7. Relief valve
3. Outer rotor 8. Spring
4. Gasket 9. Retainer
5. Pin 10. Retainer ring
REMOVAL
2) Remove timing belt as previously outlined.
3) Remove crankshaft timing belt pulley according to the follow-
ing procedure.
a) Lock crankshaft by inserting flat-head rod or the like into fly-
wheel gear through hole of transmission case as shown in
3
figure.
5 b) With crankshaft locked, loosen crankshaft timing belt pulley
bolt, and remove crankshaft timing belt pulley.
3
4
1. Crankshaft timing belt pulley bolt

2. Crankshaft timing belt pulley
3. Flat-head rod
4. Transaxle case
5. Fly wheel
4) Remove CKP sensor, oil pan and oil pump strainer as previ-
ously outlined.
5) Remove oil pump assembly after removing bolts.
1. Oil pump
2. Bolt
DISASSEMBLY
Remove rotor plate.
1. Rotor plate
INSPECTION
• Check oil seal lip for fault or other damage. Replace as nec-
essary. Apply engine oil to oil seal lip before installing.
NOTE:
When installing oil seal, press-fit it till its end face is
flush with oil pump case end face.
1. Oil seal
2. Oil pump case
• Check outer and inner rotors, rotor plate, and oil pump case
for excessive wear or damage.
1. Outer rotor
2. Inner rotor
1. Outer rotor MEASUREMENT

2. Inner rotor
• Radial clearance
Check radial clearance between outer rotor and case, using
thickness gauge.
If clearance exceeds its limit, replace outer rotor or case.
Limit on radial clearance between outer rotor and case:
0.310 mm (0.0122 in.)
• Side clearance
Using straight edge and thickness gauge, measure side
clearance.
Limit on side clearance: 0.15 mm (0.0059 in.)
ASSEMBLY
1) Wash, clean and then dry all disassembled parts.
2) Apply thin coat of engine oil to inner and outer rotors, oil seal
lip portion, and inside surfaces of oil pump case and plate.
3) Install outer and inner rotors to pump case.
4) Install rotor plate. Tighten 5 screw securely.
After installing plate, check to be sure that gears turn
smoothly by hand.
Tightening torque
(a): 11 N·m (1.1 kgf-m, 8.0 lbf-ft)
INSTALLATION
1) Install two oil pump pins and oil pump gasket to cylinder
block. Use a new gasket.
2) To prevent oil seal lip from being damaged or upturned when
installing oil pump to crankshaft, fit special tool (Oil seal
guide) to crankshaft, and apply engine oil to special tool.
Special tool
(A): 09926M18210
1. No. 1 bolts (short) 3) Install oil pump to cylinder block.

2. No. 2 bolts (long) As there are 2 types of oil pump bolts, refer to figure for their
correct use and tighten them to specified torque.
Tightening torque
(a): 11 N·m (1.1 kgf-m, 8.0 lbf-ft)
4) Install rubber seal between oil pump and water pump.

5) Install crankshaft timing belt pulley according to the following

procedure.
a) Install timing pulley key and crankshaft timing belt pulley.
Refer to figure for proper installation of these parts.
b) Lock crankshaft by inserting flat-head rod or the like into fly-
wheel gear through hole of transmission case as shown in
figure.
c) With crankshaft locked, tighten crankshaft timing belt pulley
bolt to specified torque.
Tightening torque
(a): 130 N·m (13.0 kgf-m, 94.0 lbf-ft)
5
6
1. Key
2. Crankshaft timing belt pulley
3. Crankshaft timing belt pulley bolt
4. Dowel pin (crankshaft pulley pin)
5. Flat-head rod
6. Transaxle case
7. Fly wheel
6) Install timing belt, tensioner, oil pump strainer, oil pan, CKP
sensor and other parts as previously outlined.
7) Check to ensure that all removed parts are back in place.
stalled.
8) Adjust generator drive belt (water pump drive belt) tension,
referring to BELT TENSION INSPECTION in Section 6H.
9) Adjust A/C compressor belt tension, if equipped. Refer to
A/C COMPRESSOR DRIVE BELT INSPECTION in Section
1B.
and Filter Change. in Section 0B.
11) Refill cooling system and bleed air from system, referring to
13) Verify that there is no coolant leakage and each oil leakage
at each connection.
14) After completing installation, check oil pressure by running
engine.
ROCKER ARMS, ROCKER ARM SHAFT AND CAMSHAFT
1. Camshaft
2. Camshaft oil seal
3. Rocker arm shaft
4. O-ring
5. Rocker shaft bolt
6. Rocker arm (IN)
7. Rocker arm No. 1 (EX)
8. Rocker arm No. 2 (EX)
9. Valve adjusting screw
11. Clamp
12. Lock nut (without flange)
12-1. Lock nut (with flange)
13. Rocker arm spring
14. Intake valve
15. Exhaust valve
16. Valve spring
17. Valve spring retainer
18. Valve cotter
19. Valve spring seat
20. Valve stem seal
REMOVAL
1) Disconnect negative (–) and positive (+) cable at battery and
remove battery.
2) Drain engine coolant by disconnecting radiator outlet hose
from radiator.
3) Remove water hoses and timing belt as previously outlined.
4) Remove camshaft timing belt pulley by using special tool.
Special tool
(A): 09917-68221
1. CMP sensor 5) Remove cylinder head cover as previously outlined.

2. CMP sensor case
6) Disconnect CMP sensor connector and remove CMP sensor
case from cylinder head.
Place a container or rag under CMP sensor case, for a small
amount of oil flows out during removal of case.
7) After loosening all valve adjusting screw lock nuts, turn

adjusting screws back all the way to allow all rocker arms to
move freely.

2. Lock nut
3. Rocker arm
8) Remove camshaft housing and camshaft.
NOTE:
To remove camshaft housing bolts, loosen them in such
order as indicated in figure, a little at a time.
1. Oil plug 9) Remove oil plug and timing belt inside cover.
2. Timing belt
inside cover
10) Remove intake rocker arm with clamp from rocker arm shaft.
NOTE:
Do not bend clamp when removing intake rocker arm.
1. Rocker arm (IN)

2. Clamp
3. Rocker arm shaft
11) Remove rocker arm shaft bolts.
1. Rocker arm shaft bolt

2. Rocker arm shaft
1. Rocker arm shaft 12) Push off rocker arm shaft end to CMP sensor case side and
2. O-ring remove O-ring from shaft.
13) Remove exhaust rocker arms and rocker arm spring by pull-
ing rocker arm shaft to CMP sensor side.
1. Rocker arm (EX)

2. Rocker arm spring
INSPECTION
EX IN
Adjusting Screw and Rocker Arm
If tip of adjusting screw is badly worn, replace it.
Rocker arm must be replaced if its cam-riding face is badly worn.
1. Adjusting screw
2. Rocker arm
3. Cam-riding face
Rocker Arm Shaft Runout

Using “V” blocks and dial gauge, check runout. If runout exceeds
its limit, replace rocker arm shaft.
Runout limit: 0.20 mm (0.008 in.)
Rocker Arm-to-Rocker Arm Shaft Clearance

Using a micrometer and a bore gauge, measure rocker shaft dia.
and rocker arm l.D.
Difference between two readings is arm-to-shaft clearance on
which a limit is specified.
If limit is exceeded, replace shaft or arm, or both.
Item Standard Limit

15.985 – 16.005 mm
Rocker arm I.D. —
(0.629 – 0.630 in.)
Rocker arm 15.969 – 15.984 mm
—
shaft dia. (0.6287 – 0.6293 in.)
Arm-to-shaft 0.001 – 0.036 mm 0.09 mm
clearance (0.0001 – 0.0014 in.) (0.0035 in.)
Cam Wear
Using a micrometer, measured height of cam. If measured height
is below limit, replace camshaft.
Cam height Standard Limit

36.184 – 36.344 mm 36.084 mm
Intake cam
(1.4246 – 1.4308 in.) (1.4206 in.)
35.900 – 36.060 mm 35.800 mm
Exhaust cam
(1.4134 – 1.4197 in.) (1.4094 in.)
Camshaft Runout
Hold camshaft between two “V” blocks, and measure runout by
using a dial gauge.
If runout exceeds the limit, replace camshaft.
Runout limit: 0.10 mm (0.0039 in.)
Camshaft Journal Wear

Check camshaft journals and camshaft housings for pitting,
scratches, wear or damage.
If any malcondition is found, replace camshaft or cylinder head
with housing. Never replace cylinder head without replacing hous-
ing.
1. Camshaft housing
Check clearance by using gaging plastic.

The procedure is as follows.
1) Clean housing and camshaft journals.
2) Install camshaft to cylinder head.
3) Place a piece of gaging plastic the full width of journal of
camshaft (parallel to camshaft).
4) Install camshaft housing, referring to page 6A-35.
5) Tighten camshaft housing bolts in such order as indicated in
figure a little at a time till they are tightened to specified
torque.
Tightening torque
(a): 11 N·m (1.1 kgf-m, 8.0 lbf-ft)
NOTE:
Do not rotate camshaft while gaging plastic is installed.
1. Gaging plastic 6) Remove housing and using scale on gaging plastic enve-
2. Scale
lope, measure gaging plastic width at its widest point.
Standard Limit
Journal 0.040 – 0.082 mm 0.12 mm
clearance (0.0016 – 0.0032 in.) (0.0047 in.)
If measured camshaft journal clearance exceeds limit, measure
journal (housing) bore and outside diameter of camshaft journal.
Replace camshaft or cylinder head assembly whichever the differ-
ence from specification is greater.
Item Standard
28.000 – 28.021 mm
Camshaft Journal bore dia.
(1.1024 – 1.1031 in.)
27.939 – 27.960 mm
Camshaft journal O.D.
(1.1000 – 1.1008 in.)
INSTALLATION
1) Apply engine oil to rocker arm shaft and rocker arms.
2) Install rocker arm shaft, rocker arm (exhaust side) and rocker
1. Rocker arm spring arm spring.
2. Rocker arm (EX) No.1
3. Rocker arm (EX) No.2
3) Install oil plug and timing belt inside cover.

Then tighten oil plug to specified torque.
Tightening torque
(a): 33 N·m (3.3 kgf-m, 24.0 lbf-ft)
1. Rocker arm shaft 4) With O-ring groove in rocker arm shaft exposed to transmis-
2. O-ring
sion side once, install new O-ring to rocker arm shaft.
1. Parallel 5) Set rocker arm shaft so that its cut part becomes in parallel
2. Cut part with head cover mating surface.
3. Cylinder block
Face rocker arm shaft pivot holding part (for intake rocker
arm) up.
Dimension “a”: 5 mm (0.20 in.)
6) Install rocker arm shaft bolts and tighten them to specified

torque.
Tightening torque
(a): 11 N·m (1.1 kgf-m, 8.0 lbf-ft)
7) Fill small amount of engine oil into arm pivot holding part of
rocker arm shaft. Install rocker arm (intake side) with clamps
to rocker arm shaft.
1. Rocker arm (IN)

2. Clamp
3. Rocker arm shaft
8) Apply engine oil to cams and journals on camshaft and put

camshaft on cylinder head. Install camshaft housing to cam-
shaft and cylinder head.
• Apply engine oil to sliding surface of each housing against
camshaft journal.
• Apply sealant to mating surface of No.6 housing which will
mate with cylinder head.
1. Timing belt side
2. Flywheel side “A” Sealant: 99000-31110
• Embossed marks are provided on each camshaft housing,

indicating position and direction for installation. Install hous-
ing as indicated by these marks.
• As camshaft housing No. 1 retains camshaft in proper posi-
tion as to thrust direction, make sure to first fit No. 1 housing
to No. 1 journal of camshaft securely.
• After applying engine oil to housing bolts, tighten them tem-

porarily first. Then tighten them by following sequence as
indicated in figure.
Tighten a little at a time and evenly among bolts and repeat
tightening sequence three to four times before they are tight-
ened to specified torque.
Tightening torque
(a): 11 N·m (1.1 kgf-m, 8.0 lbf-ft)
9) Install new camshaft oil seal.

After applying engine oil to oil seal lip, press-fit camshaft oil
seal till oil seal surface becomes flush with housing surface.
1. Camshaft oil seal
10) Install camshaft timing belt pulley to camshaft while fitting pin
on camshaft into slot.
1. Camshaft timing belt pulley 2. Dwell pin
11) Using special tool, tighten pulley bolt to specified torque.

Tightening torque
(a): 60 N·m (6.0 kgf-m, 43.5 lbf-ft)
Special tool
(A): 09917M68221
12) Install belt tensioner, timing belt, outside cover, crankshaft
pulley and generator belt as previously outlined.
13) After applying sealant to part “A” as shown in figure at the

left, install CMP sensor case to cylinder head and tighten its
fixing bolts to specified torque.
“A” Sealant: 99000–31110
Tightening torque
(a): 11 N·m (1.1 kgf-m, 8.0 lbf-ft)
14) Connect CMP sensor connector.
1. O-ring
15) Adjust valve clearance as previously outlined.

16) Install cylinder head cover.
17) Refill cooling system and bleed air from system referring to
18) Adjust generator belt tension, referring to BELT TENSION
INSPECTION in Section 6H.
20) Upon completion of installation, verify that there is no coolant
leakage at each connection.
22) Confirm that ignition timing is within specification referring to

IGNITION TIMING in Section 6F.
VALVES AND CYLINDER HEAD
1. Valve cotters
3. Valve spring
4. Valve stem seal
6. Exhaust valve
7. Intake valve
REMOVAL
2) Disconnect cables at battery and remove battery.
3) Release front seat lock handle and raise front seats, then
remove engine room center member with shift control and
parking brake lever.
4) Drain engine coolant by disconnecting radiator outlet hose
from radiator.
5) Remove air intake hose and air cleaner case.

6) Disconnect following electric wires:
• Ground wires from intake manifold
• CMP sensor
• Engine coolant temp. sensor
• Fuel injector wires at the connector
• CNG fuel injector connectors (bi-fuel CNG model)
• Generator
• Ground cable from cylinder block
• Heated oxygen sensor
• MAP sensor
• EGR valve
and then release wire harnesses from clamps.

• Radiator inlet hose and reservoir hose from thermostat cap
• Heater inlet hose from pipe
• Coolant hoses and brake booster hose from floor pipe
NOTE:
nected.
8) Disconnect accelerator cable from throttle body and each

clamp.
9) Remove intake manifold as previously outlined.
10) Remove cylinder head cover as previously outlined. Loosen

all valve lash adjusting screws fully.
11) Remove timing belt and camshaft as previously outlined.
12) Remove exhaust manifold as previously outlined.
13) Loosen cylinder head bolts in such order as indicated in fig-

ure and remove them.
14) Check all around cylinder head for any other parts required
to be removed or disconnected and remove or disconnect
whatever necessary.
“1”: Camshaft pulley side

“2”: CMP sensor case side
15) Remove cylinder head.

DISASSEMBLY
1) Remove intake rocker arm with clamp from rocker arm shaft,
remove rocker arm shaft bolts and remove exhaust rocker
arms and springs by pulling its shaft out to transmission side.
2) Using special tool (Valve lifter), compress valve springs and
then remove valve cotters by using special tool (Forceps) as
shown.
Special tool
(A): 09916M14510
(B): 09916M14910
(C): 09916M84511
3) Release special tool, and remove spring retainer and valve
spring.
4) Remove valve from combustion chamber side.
1. Valve cotters
5) Remove valve stem oil seal from valve guide, and then valve
spring seat.
NOTE:
Do not reuse oil seal once disassembled. Be sure to use
new oil seal when assembling.
1. Valve stem oil seal

6) Using special tool (Valve guide remover), drive valve guide

out from combustion chamber side to valve spring side.
Special tool
(A): 09916M44910
NOTE:
Do not reuse valve guide once disassembled. Be sure to
use new valve guide (Oversize) when assembling.
7) Place disassembled parts except valve stem seal and valve

guide in order, so that they can be installed in their original
position.
INSPECTION
Valve Guides
Using a micrometer and bore gauge, take diameter readings on
valve stems and guides to check stem-to-guide clearance.
Be sure to take reading at more than one place along the length
of each stem and guide.
If clearance exceeds limit, replace valve and valve guide.
Item Standard Limit

5.465 – 5.480 mm
In —
Valve stem (0.2152 – 0.2157 in.)
diameter 5.440 – 5.455 mm
Ex —
(0.2142 – 0.2148 in.)
In 5.500 – 5.512 mm
Valve guide I.D. —
Ex (0.2166 – 0.2170 in.)
0.020 – 0.047 mm 0.07 mm
In
Stem-to-guide (0.0008 – 0.0018 in.) (0.0027 in.)
clearance 0.045 – 0.072 mm 0.09 mm
Ex
(0.0018 – 0.0028 in.) (0.0035 in.)
If bore gauge is not available, check end deflection of valve stem

with a dial gauge instead.
Move stem end in directions (1) and (2) to measure end deflec-
tion.
If deflection exceeds its limit, replace valve stem and valve guide.
Valve stem end deflection In 0.14 mm (0.005 in.)

limit Ex 0.18 mm (0.007 in.)
Valves
• Remove all carbon deposits from valves.
• Inspect each valve for wear, burn or distortion at its face and
stem and, as necessary, replace it.
• Measure thickness of valve head. If measured thickness
exceeds limit, replace valve.
Valve head thickness

Standard Limit
IN 0.8 – 1.2 mm 0.6 mm (0.024 in.)
EX (0.03 – 0.047 in.) 0.7 mm (0.027 in.)
1. Valve head thickness

2. 45 O
• Inspect valve stem end face for pitting and wear. If pitting or
wear is found there, valve stem end may be resurfaced, but
not so much as to grind off its chamfer. When it is worn so
much that its chamfer is gone, replace valve.
• Seating contact width:

Create contact pattern on each valve in the usual manner,
i.e., by giving uniform coat of marking compound to valve
seat and by rotatingly tapping seat with valve head. Valve
lapper (tool used in valve lapping) must be used.
Pattern produced on seating face of valve must be a continu-
ous ring without any break, and the width of pattern must be
within specified range.
Standard seating width In

1.1 – 1.3 mm
revealed by contact pattern
Ex (0.0433 – 0.0512 in.)
on valve face
• 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.
1) EXHAUST VALVE SEAT: Use valve seat cutters to make two
cuts as illustrated in figure. Two cutters must be used: the
first for making 15° angle, and the second for making 45°
angle.
The second cut must be made to produce desired seat
width.
Seat width for exhaust valve seat:
1.1 – 1.3 mm (0.0433 – 0.0512 in.)
1. Valve seat cutter
2) INTAKE VALVE SEAT: Cutting sequence is the same as for

exhaust valve seats.
Seat width for intake valve seat:
1.1 – 1.3 mm (0.0433 – 0.0512 in.)
3) 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
1. Valve seat according to usual lapping method.
Cylinder Head
• Remove all carbon deposits from combustion chambers.
NOTE:
Do not use any sharp-edged tool to scrape off carbon
deposits. Be careful not to scuff or nick metal surfaces
when removing carbon deposits. The same applies to
valves and valve seats, too.
• Check cylinder head for cracks in intake and exhaust ports,

combustion chambers, and head surface.
• Flatness of gasket contact surface:

Using a straightedge and thickness gauge, check surface at
a total of 6 locations. If distortion limit, given below, is
exceeded, correct gasket contact surface with a surface
plate and abrasive paper of about #400 (Waterproof silicon
carbide abrasive paper): place paper on and over surface
plate, and rub gasket contact surface against paper to grind
off high spots. Should this fail to reduce thickness gauge
readings to within limit, replace cylinder head. Leakage of
combustion gases from this gasket contact joint is often due
to warped gasket contact surface: such leakage results in
reduced power output.
• 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.
Valve Springs
• Referring to data given below, check to be sure that each
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
output due to gas leakage caused by decreased seating
pressure.
Item Standard Limit

Valve spring free 36.83 mm 35.67 mm
length (1.4500 in.) (1.4043 in.)
Valve spring preload 106 – 122 N
91 N
when compressed to (10.8 – 12.4 kgf,
(9.3 kgf, 20.5 lbf)
31.5 mm (1.24 in.) 23.8 – 27.4 lbf)
• Spring squareness:
Use a square and surface plate to check each spring for
squareness in terms of clearance between end of valve
spring and square. Valve springs found to exhibit a larger
clearance than limit given below must be replaced.
Valve spring squareness limit: 2.0 mm (0.079 in.)
ASSEMBLY
1) Before installing valve guide into cylinder head, ream guide
hole with special tool (11 mm reamer) so remove burrs and
make it truly round.
Special tool
(A): 09916M34542
(B): 09916M38210
2) Install valve guide to cylinder head.
Heat cylinder head uniformly at a temperature of 80 °C to
100 °C (176 °F to 212 °F) so that head will not be distorted,
and drive new valve guide into hole with special tools. Drive
in new valve guide until special tool (Valve guide installer)
contacts cylinder head.
After installing, make sure that valve guide protrudes by 11.5
mm (0.45 in.) from cylinder head.
Special tool
(C): 09916M56011
(D): 09916M58210
NOTE:
• Do not reuse valve guide once disassembled.
Install new valve guide (Oversize).
1. 11.5 mm (0.45 in.)
• Intake and exhaust valve guides are identical.
Valve guide oversize: 0.03 mm (0.0012 in.)
Valve guide protrusion (In and Ex): 11.5 mm (0.45 in.)
3) Ream valve guide bore with special tool (5.5 mm reamer).

After reaming, clean bore.
Special tool
(A): 09916M34542
(B): 09916M34550
4) Install valve spring seat to cylinder head.

5) Install new valve stem seal to valve guide.

After applying engine oil to seal and spindle of special tool
(Valve guide installer handle), fit oil seal to spindle, and then
install seal to valve guide pushing special tool by hand. After
installing, check that seal is properly fixed to valve guide.
Special tool
(A): 09917M98221
(B): 09916M58210
NOTE:
• Do not reuse seal once disassembled. Be sure to
install new seal.
• When installing, never tap or hit special tool with a
hammer or else. Install seal to guide only pushing spe-
1. Valve stem seal cial tool by hand. Tapping or hitting special tool may
cause damage to seal.
6) Install valve to valve guide.

Before installing valve to valve guide, apply engine oil to
stem seal, valve guide bore, and valve stem.
1. Large-pitch 7) Install valve spring and spring retainer.

2. Small-pitch
Each valve spring has top end (large-pitch end) and bottom
side end (small-pitch end). Be sure to position spring in place with
side its bottom end (small-pitch end) facing the bottom (valve
spring seat side).
8) Using special tool (Valve lifter), compress valve spring and fit
two valve cotters into groove in valve stem.
Special tool
(A): 09916M14510
(B): 09916M14910
(C): 09916M84511
1. Valve cotters
9) Install rocker arms, springs and rocker arm shaft as previ-

ously outlined.
INSTALLATION
1) Remove old cylinder head gasket and oil on mating surfaces
and install new cylinder head gasket as shown in figure, that
is, “TOP” mark provided on gasket comes to crankshaft pul-
ley side, facing up (toward cylinder head side).
1. Cylinder head gasket 3. Flywheel side

2. Crankshaft pulley side 4. Dowel pin
2) Make sure that oil jet (venturi plug) is no clogging and install
venturi plug to specified torque.
Tightening torque
(a): 3.5 N·m (0.35 kgf-m, 2.5 lbf-ft)
3) Apply engine oil to cylinder head bolts and tighten them

gradually as follows.
a) Tighten all bolts to 33 N·m (3.4 kgf-m, 24.5 lbf-ft) according
to numerical order in figure.
b) In the same manner as in Step a), tighten them to 53 N·m
(5.4 kgf-m, 39.0 lbf-ft).
c) Loosen all bolts until tightening torque is reduced to 0 in
reverse order of tightening.
d) In the same manner as in Step a), tighten them to 33 N·m
(3.4 kgf-m, 24.5 lbf-ft).
e) In the same manner as in Step a) again, tighten them to 66
N·m (6.7 kgf-m, 49.0 lbf-ft).
Tightening torque
“1”: Camshaft pulley side
(a): 33 N·m o 53 N·m o 0 N·m o 33 N·m o 66 N·m (3.4 kgf-
m o 5.4 kgf-m o 0 kgf-m o 3.4 kgf-m o 6.7 kgf-m, 24.5
lbf-ft o 39.0 lbf-ft o 0 lbf-ft o 24.5 lbf-ft o 49.0 lbf-ft)
4) Install belt tensioner, timing belt, outside cover, crankshaft

pulley and generator belt as previously outlined.
5) Install cylinder head cover.
6) Adjust generator drive belt tension, referring to BELT TEN-
7) Adjust A/C compressor belt tension, if equipped. Refer to A/
C COMPRESSOR DRIVE BELT INSPECTION in Section
1B.
8) Adjust intake and exhaust valve lashes as previously out-
lined.
9) Adjust accelerator cable play. Refer to ACCELERATOR
stalled.
12) Install battery and connect cables at battery.
13) Verify that there is no fuel leakage, coolant leakage and
exhaust gas leakage at each connection.
15) Confirm that ignition timing is within specification referring to
16) Connect shift control cables to gear shift control lever, refer
to GEAR SHIFT CONTROL INSTALLATION in Section 7A.
17) Perform parking brake adjustment, refer to PARKING
BRAKE INSPECTION AND ADJUSTMENT in Section 5.
18) Install engine room center member and hook front seat lock
handle securely.
PISTON, PISTON RINGS, CONNECTING

RODS AND CYLINDERS
1. Top ring 6. Connecting rod bearing

2. 2nd ring cap
3. Oil ring 7. Connecting rod bearing
4. Piston 8. Piston pin
5. Connecting rod 9. Piston pin circlip
REMOVAL
1) Remove cylinder head from cylinder block as previously out-
lined.
2) Drain engine oil.
3) Remove oil pans and oil pump strainer as previously out-
lined.
4) Mark cylinder number on all pistons, connecting rods and
rod bearing caps, using silver pencil or quick drying paint.
5) Remove rod bearing caps.

6) Install guide hose over threads of rod bolts. This is to prevent
damage to bearing journal and rod bolt threads when remov-
ing connecting rod.
7) Remove carbon deposits from tops of cylinder bore before
removing piston from cylinder.
8) Push piston and connecting rod assembly out through the
top of cylinder bore.
1. Guide hoses
DISASSEMBLY
1) Using piston ring expander, remove two compression rings
(Top and 2nd) and oil ring from piston.
2) Remove piston pin from connecting rod.
• Ease out piston pin circlips, as shown.
1. Piston pin circlip
• Force piston pin out.
CLEANING
Clean carbon from piston head and ring grooves, using a suitable
tool.
INSPECTION
Cylinders
• Inspect cylinder walls for scratches, roughness, or ridges
which indicate excessive wear. If cylinder bore is very rough
or deeply scratched, or ridged, rebore cylinder and use over-
size piston.
• Using a cylinder gauge, measure cylinder bore in thrust and

axial directions at two positions as shown in figure.
If any of following conditions is noted, rebore cylinder.
1) Cylinder bore dia. exceeds limit.
2) Difference of measurements at two positions exceeds taper
limit.
3) Difference between thrust and axial measurements exceeds
out-of-round limit.
1. 50 mm (1.96 in.)
2. 95 mm (3.74 in.) Cylinder bore dia. limit: 71.15 mm (2.8012 in.)
Taper and out-of-round limit: 0.10 mm (0.0039 in.)
NOTE:
If any one of four cylinders has to be rebored, rebore all
four to the same next oversize. This is necessary for the
sake of uniformity and balance.
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 10 mm (0.39 in.) from piston skirt end in the
direction perpendicular to piston pin.
1. 10 mm (0.39 in.)
70.970 – 70.990 mm
Standard
(2.7941 – 2.7948 in.)
0.50 mm 71.470 – 71.490 mm
Piston diameter
(0.0196 in.) (2.8138 – 2.8145 in.)
• Piston clearance:
Measure cylinder bore diameter and piston diameter to find
their difference which is piston clearance. Piston clearance
should be within specification as given below. If it is out of
specification, rebore cylinder and use oversize piston.
Piston clearance: 0.02 – 0.04 mm (0.0008 – 0.0015 in.)
NOTE:
Cylinder bore diameters used here are measured in
thrust direction at two positions.
1. 10 mm (0.39 in.)
• Ring groove clearance:

Before checking, piston grooves must be clean, dry and free
of carbon.
Fit new piston ring into piston groove, and measure clear-
ance between ring and ring land by using thickness gauge.
If clearance is out of specification, replace piston.
Ring groove clearance:
1. Piston ring Top: 0.03 – 0.07 mm (0.0012 – 0.0027 in.)
2. Thickness gauge
2nd: 0.02 – 0.06 mm (0.0008 – 0.0023 in.)
Piston Pin
Check piston pin, connecting rod small end bore and piston bore
for wear or damage, paying particular attention to condition of
small end bore bush. If pin, connecting rod small end bore or pis-
ton bore is badly worn or damaged, replace pin, connecting rod or
piston.
• Piston pin clearance:
Check piston pin clearance in small end. Replace connecting
rod if its small end is badly worn or damaged or if measured
clearance exceeds limit.
Item Standard Limit

Piston clearance 0.003 – 0.018 mm 0.05 mm
in small end (0.0001 – 0.0007 in.) (0.0020 in.)
Small-end bore:
19.003 – 19.013 mm (0.7482 – 0.7485 in.)
Piston pin dia.:
18.995 – 19.000 mm (0.7479 – 0.7480 in.)
Piston Rings
To measure end gap, insert piston ring into cylinder bore and then
measure the gap by using thickness gauge.
If measured gap is out of specification, replace ring.
NOTE:
Remove carbon deposits from top of cylinder bore before
inserting piston ring.
Item Standard Limit

0.15 – 0.30 mm 0.7 mm
Top ring
(0.0059 – 0.0118 in.) (0.0275 in.)
Piston ring 0.20 – 0.35 mm 0.7 mm
2nd ring
1. Cylinder block end gap (0.0079 – 0.0137 in.) (0.0275 in.)
2. Feeler gauge
3. Piston ring
0.20 – 0.70 mm 1.5 mm
Oil ring
4. 120 mm (4.72 in.) (0.0079 – 0.0275 in.) (0.0591 in.)
Connecting Rod
• Big-end side clearance:
Check big-end of connecting rod for side clearance, with rod
fitted and connected to its crank pin in the normal manner. If
measured clearance is found to exceed its limit, replace con-
necting rod.
Item Standard Limit

Big-end side 0.10 – 0.20 mm 0.35 mm
clearance (0.0039 – 0.0079 in.) (0.0137 in.)
• Connecting rod alignment:

Mount connecting rod on aligner to check it for bow and twist
and, if limit is exceeded, replace it.
Limit on bow: 0.05 mm (0.0020 in.)
Limit on twist: 0.10 mm (0.0039 in.)
Crank Pin and Connecting Rod Bearings

• Inspect crank pin for uneven wear or damage. Measure
crank pin for out-of-round or taper with a micrometer. If crank
pin is damaged, or out-of-round or taper is out of limit,
replace crankshaft or regrind crank pin referring to following
step 6).
Connecting rod bearing size Crank pin diameter

41.982 – 42.000 mm
Standard
(1.6528 – 1.6535 in.)
41.732 – 41.750 mm
0.25 mm (0.0098 in.) undersize
(1.6430 – 1.6437 in.)
Out-of-round and taper limit: 0.01 mm (0.0004 in.)
• Rod bearing:
Inspect bearing shells for signs of fusion, pitting, burn or flak-
ing and observe contact pattern. Bearing shells found in
defective condition must be replaced.
Two kinds of rod bearing are available; standard size bearing
and 0.25 mm undersize bearing. To distinguish them, 0. 25
mm undersize bearing has the stamped number (US025) on
its backside as indicated in figure, but standard size one has
no number.
• Rod bearing clearance:

1) Before checking bearing clearance, clean bearing and crank
pin.
2) Install bearing in connecting rod and bearing cap.
3) Place a piece of gaging plastic to full width of crankpin as
contacted by bearing (parallel to crankshaft), avoiding oil
hole.
1. Gaging plastic
4) Install rod bearing cap to connecting rod.

When installing cap, be sure to point arrow mark on cap to
crankshaft pulley side, as shown in figure. After applying
engine oil to rod bolts, tighten cap nuts to specified torque.
Do not turn crankshaft with gaging plastic installed.
Tightening torque
(a): 35 N·m (3.5 kgf-m, 25.5 lbf-ft)
1. Rod bearing cap
2. Arrow mark
3. Crankshaft pulley side
5) Remove cap and using a scale on gaging plastic envelope,

measure gaging plastic width at the widest point (clearance).
If clearance exceeds its limit, use a new standard size bear-
ing and recheck clearance.
Item Standard Limit

Bearing 0.020 – 0.050 mm 0.080 mm
clearance (0.0008 – 0.0019 in.) (0.0031 in.)
6) If clearance can not be brought to within its limit even by

using a new standard size bearing, replace crankshaft or
regrind crankpin to undersize as follows.
– Install 0.25 mm undersize bearing to connecting rod big
end.
– Measure bore diameter of connecting rod big end.
– Regrind crankpin to following finished diameter.
1. Gaging plastic
Finished Measured big end bore
0.035 mm
2. Scale crankpin = dia. (including undersize –
(0.0014 in.)
dia. bearing)
– Confirm that bearing clearance is within above standard
value.
ASSEMBLY
NOTE:
Two sizes of piston are available as standard size spare
part so as to ensure proper piston-to-cylinder clearance.
When installing a standard size piston, make sure to
match piston with cylinder as follows.
a) Each piston has stamped number (1 or 2) or painted color

(red or blue) as shown. It represents outer diameter of pis-
ton.
b) There are also stamped numbers (1 and 2) or painted color
(red and blue) on the cylinder block as shown. The first
number represents inner diameter of No.1 cylinder, the sec-
ond number of No.2 cylinder, the third number of No.3 cylin-
der and the fourth number of No.4 cylinder.
c) Stamped number or painted color on piston and that on cyl-

inder block should correspond. That is, install number 2
stamped or blue painted piston to cylinder which is identi-
fied with number 2 and a number 1 or red piston to cylinder
with number 1 or red.
Piston Cylinder
Number at
Number Piston-to-cylinder
or color
Outer diameter or color Bore diameter clearance
the top
(mark)
(mark)
70.98 – 70.99 mm 71.01 – 71.02 mm 0.02 – 0.04 mm
1 or Red 1 or Red
(2.7945 – 2.7948 in.) (2.7957 – 2.7960 in.) (0.0008 – 0.0015 in.)
1. Painted color 70.97 – 70.98 mm 71.00 – 71.01 mm 0.02 – 0.04 mm
2 or Blue 2 or Blue
(2.7941 – 2.7945 in.) (2.7953 – 2.7957 in.) (0.0008 – 0.0015 in.)
1) Install piston pin to piston and connecting rod:

After applying engine oil to piston pin and piston pin holes in
piston and connecting rod, fit connecting rod to piston as
shown in figure and insert piston pin to piston and connect-
ing rod, and install piston pin circlips.
1. Piston
2. Match mark (O or )
3. Circlip
4. Connecting rod NOTE:
5. Oil hole
The oil hole should
Install so that circlip end gap comes within the range
come on intake side indicated by arrow as shown in figure.
2) Install piston rings to piston:

• As indicated in figure at the left, 1st and 2nd rings have
“GTP” mark respectively. When installing these piston rings
to piston, direct marked side of each ring toward top of pis-
ton.
• 1st ring differs from 2nd ring in shape and color of surface
1. 1st ring
contacting cylinder wall.
2. 2nd ring Distinguish 1st ring from 2nd ring by referring to figure.
3. Oil ring
• When installing oil ring, install spacer first and then two rails.
3) After installing three rings (1st, 2nd and oil rings), distribute
1. Match mark their end gaps as shown in figure.
(O or )
2. 1st ring end gap
3. 2nd ring end gap
and oil ring spacer
gap
4. Oil ring upper rail
gap
5. Oil ring lower rail
gap
6. Intake side
7. Exhaust side
INSTALLATION OR CONNECTION
1) Apply engine oil to pistons, rings, cylinder walls, connecting
rod bearings and crankpins.
NOTE:
Do not apply oil between connecting rod and bearing or
between bearing cap and bearing.
2) Install guide hoses over connecting rod bolts.

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

inder bore, point match mark (O or m) on piston head to
crankshaft pulley side.

2. Flywheel side
4) Install piston and connecting rod assembly into cylinder

bore. Use special tool (Piston ring compressor) to compress
rings. Guide connecting rod into place on crankshaft.
Using a hammer handle, tap piston head to install piston into
bore. Hold ring compressor firmly against cylinder block until
all piston rings have entered cylinder bore.
Special tool
(A): 09916M77310
5) Install bearing cap:

Point arrow mark on cap to crankshaft pulley side.
Tighten cap nuts to specification.
Tightening torque
(a): 35 N·m (3.5 kgf-m, 25.5 lbf-ft)
1. Rod bearing cap

2. Arrow mark
6) Reverse removal procedure for installation, as previously

outlined.
8) Adjust A/C compressor belt tension, if equipped. Refer to
A/C COMPRESSOR DRIVE BELT INSPECTION in Section
1B.
9) Adjust intake and exhaust valve lashes as previously out-
lined.
stalled.
12) Refill engine with engine oil, referring to item ITEM 1_4
Engine Oil and Filter Change in Section 0B.
14) Install battery, connect cables at battery.
15) Verify that there is no fuel leakage, coolant leakage, oil leak-
age and exhaust gas leakage at each connection.
16) Verify that ignition timing is within specification referring to

UNIT REPAIR OVERHAUL

ENGINE ASSEMBLY
REMOVAL

2) Remove front seats, then remove engine room center mem-
ber with shift control and parking brake lever.
3) Remove battery and its tray.
4) Drain transmission oil.
5) Drain engine coolant by disconnecting radiator outlet hose or
CNG pressure regulator water inlet hose.
6) Remove air intake hose.
7) Disconnect following electric wires:
• Ground wires from intake manifold, exhaust manifold and
transmission
• Camshaft position sensor
• Engine coolant temp. sensor
• Fuel injector wire at the connector
• Generator
• Ground cable from cylinder block
• Heated oxygen sensor
• Engine oil pressure switch
• Ignition coil
• MAP sensor
• CNG fuel injector connectors (bi-fuel CNG model)
• Starter motor
• Vehicle speed sensor
• Back up light switch
• EGR valve
and then release wire harnesses from clamps.
1. CNG fuel injector connector


• Radiator outlet hose from water floor pipe
• Heater inlet hose from water floor pipe
• Radiator inlet hose, brake booster hose and reservoir hose
from water floor pipe
• Vacuum hose from CNG fuel injector (bi-fuel CNG model)
• CNG fuel hose from CNG fuel injector (bi-fuel CNG model)
NOTE:
nected.
10) Disconnect accelerator cable from throttle body and each

clamp.
2
1. Vacuum hose
2. CNG fuel hose
11) Remove generator.

12) With hose connected, detach A/C compressor and bracket
from cylinder block if equipped.
NOTE:
Suspended removed compressor at a place where no
damage will be caused during removal and installation of
engine assembly.
13) Hoist vehicle.

14) Drain engine oil if necessary.
15) Remove exhaust pipe bolts.
16) Disconnect clutch cable from clutch release arm and trans-
mission case (engine and transmission stiffener).
17) Remove propeller shaft.
18) Disconnect shift and select cable from transmission case.
1. Stiffener
2. Upper oil pan 3. Clutch cable
1 19) For bi-fuel CNG model, remove CNG fuel pipe No.2 and
CNG pressure regulator pipe.

20) For bi-fuel CNG model, remove oil pan guard member bolts.
NOTE:
In order to make workspace, push oil pan guard member
for stabilizer with CNG pressure regulator mounted on it
and hold the position pulling with appropriate cords.
1
21) Place transmission jack under engine with transmission.
1 When applying the jack to the engine, make sure that its flat
face will support the entire oil pan evenly. Engine with trans-
1. Oil pan guard member bolt mission should be held horizontally even when rear mount-
ing bracket bolts are removed.
22) Remove engine mounting bracket bolts.
23) Before lowering engine with transmission, recheck to make
sure all hoses, electric wires and cables are disconnected
from engine and transmission.
24) Remove engine with transmission from body.
25) Remove transmission stiffener and separate engine from
transmission.
26) Remove engine brackets and replace mount bushing, if nec-
essary.
INSTALLATION
1) Combine engine with transmission.
2) Tighten engine mounting bracket bolts (R & L) and rear
mounting nut as shown in the figure above.
3) Reverse removal procedure for installation.
• Install generator bracket, A/C compressor and generator
referring to Section 1B and 6H.
• Tighten bolts of exhaust pipes to specified torque.
Tightening torque
(a): 50 N·m (5.0 kgf-m, 36.5 lbf-ft)

5) Adjust A/C compressor belt tension, if equipped. Refer to A/
C COMPRESSOR DRIVE BELT INSPECTION in Section
1B.
6) Connect gear shift cables to gear shift control lever, refer to
GEAR SHIFT CONTROL INSTALLATION in Section 7A.
7) Connect parking brake cable to parking brake lever. Perform
parking brake adjustment, refer to PARKING BRAKE
INSPECTION AND ADJUSTMENT in Section 5.
8) Adjust clutch free travel, referring to CLUTCH PEDAL FREE
TRAVEL in Section 7C.
stalled.
and Filter Change in Section 0B.
13) Verify that there is no fuel (gasoline and/or CNG) leakage,
coolant leakage and exhaust gas leakage at each connec-
tion.
MAIN BEARINGS, CRANKSHAFT AND CYLINDER BLOCK
1. Cylinder block 7. Crankshaft 12. Oil seal housing

2. Front oil seal 8. Thrust bearing 13. Housing bolt
3. Main bearing 9. Rear oil seal 14. Input shaft bearing
4. Bearing cap 10. Pin 15. Flywheel
5. Cap bolt 11. Oil seal housing gasket 16. Flywheel bolt
6. Timing pulley key
REMOVAL
1) Remove engine assembly from body as previously outlined.
2) Separate transmission from engine, then remove clutch
cover, clutch disc and flywheel.
Special tool
(A): 09924M17811
1. Flywheel bolt
3) Remove crankshaft pulley, timing belt and crankshaft timing

pulley.
4) Remove cylinder head assembly.
5) Remove CKP sensor, upper oil pan with lower oil pan and oil
pump strainer.
6) Remove oil pump.
1. Oil pump
2. Bolt
7) Remove oil seal housing.

8) Remove connecting rod bearing caps.
9) Loosen crankshaft bearing cap bolts in such order as indi-

cated in figure a little at a time and remove bearing caps.
10) Remove crankshaft from cylinder block.
INSPECTION
Crankshaft
Crankshaft runout
Using a dial gauge, measure runout at center journal. Rotate
crankshaft slowly. If runout exceeds its limit, replace crankshaft.
Limit on runout: 0.06 mm (0.0023 in.)
Crankshaft thrust play

Measure this play with crankshaft set in cylinder block in the nor-
mal manner, that is, with thrust bearing and journal bearing caps
installed.
1. Thrust bearing
Use a dial gauge to read displacement in axial (thrust) direction of

crankshaft.
If its limit is exceeded, replace thrust bearing with new standard
one or oversize one to obtain standard thrust play.
Item Standard Limit

Crankshaft 0.11 – 0.31 mm 0.35 mm
thrust play (0.0044 – 0.0122 in.) (0.0137 in.)
2.500 mm
Thickness of Standard
(0.0984 in.)
crankshaft
0.125 mm 2.563 mm
thrust bearing Oversize:
(0.0049 in.) (0.1009 in.)
Out-of-round and taper (uneven wear) of journals

An unevenly worn crankshaft journal shows up as a difference in
diameter at a cross section or along its length (or both). This dif-
ference, if any, is determined by taking micrometer readings.
If any one of journals is badly damaged or if amount of uneven
wear in the sense explained above exceeds its limit, regrind or
replace crankshaft.
Limit on out-of-round and taper: 0.01 mm (0.0004 in.)
Main Bearings
General information
• Service main bearings are available in standard size and
0.25 mm (0.0098 in.) undersize, and each of them has 5
kinds of bearings differing in tolerance.
• Upper half of bearing has oil groove as shown in figure.
1. Cylinder block
Install this half with oil groove to cylinder block.
2. Upper half of bearing
3. Oil groove
• On each main bearing cap, arrow mark and number are

embossed as shown in figure.
When installing each bearing cap to cylinder block, point
arrow mark toward crankshaft pulley side and install each
cap from that side to flywheel side in ascending order of
numbers “1”, “2”, “3”, “4” and “5”. Tighten cap bolts to speci-
fied torque.
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.
Main bearing clearance

Check clearance by using gaging plastic according to following
procedure.
1) Remove bearing caps.
2) Clean bearings and main journals.
3) Place a piece of gaging plastic to full width of bearing (paral-
lel to crankshaft) on journal, avoiding oil hole.
1. Gaging plastic
4) Install bearing cap as previously outlined and evenly torque

cap bolts to specified torque.
Bearing cap MUST be torqued to specification in order to
assure proper reading of clearance.
Tightening torque
(a): 53 N·m (5.3 kgf-m, 38.5 lbf-ft)
NOTE:
Do not rotate crankshaft while gaging plastic is installed.
5) Remove cap and using scale on gaging plastic envelope,

measure gaging plastic width at its widest point. If clearance
exceeds its limit, replace bearing. Always replace both upper
and lower inserts as a unit.
A new standard bearing may produce proper clearance. If
not, it will be necessary to regrind crankshaft journal for use
of 0.25 mm undersize bearing.
After selecting new bearing, recheck clearance.
Standard Limit
Bearing clear-
0.020 – 0.040 mm 0.060 mm
ance
(0.0008 – 0.0016 in.) (0.0023 in.)
1. Gaging plastic
2. Scale
Selection of main bearings

STANDARD BEARING:
If bearing is in malcondition, or bearing clearance is out of specifi-
cation, select a new standard bearing according to following pro-
cedure and install it.
1) First check journal diameter by using following procedure.
As shown in figure, crank webs of No.1 cylinders have five
stamped numbers.
Three kinds of numbers (“1”, “2” and “3”) represent following
journal diameters.
Stamped number Journal diameter

44.994 – 45.000 mm
1
(1.7714 – 1.7716 in.)
44.988 – 44.994 mm
2
(1.7712 – 1.7714 in.)
44.982 – 44.988 mm
3
(1.7709 – 1.7712 in.)
The first, second, third, fourth and fifth (top to bottom) stamped
numbers represent journal diameters at bearing caps “1”, “2”, “3”,
“4” and “5” respectively.
1. Crank web of No.1 cylinder For example, in figure, the first (top) numbers “3” indicates that
journal dia. at bearing cap “1” is within 44.982 – 44.988 mm, and
second one “1” indicate that journal dia. at cap “2” is within 44.994
– 45.000 mm.
2) Next, check bearing cap bore diameter without bearing. On

mating surface of cylinder block, four alphabets are stamped
as shown in figure.
Three kinds of alphabets (“A”, “B” and “C”) represent follow-
ing cap bore diameters.
Bearing cap bore diameter

Stamped alphabet
(without bearing)
49.000 – 49.006 mm
A
(1.9291 – 1.9294 in.)
49.006 – 49.012 mm
B
(1.9294 – 1.9296 in.)
49.012 – 49.018 mm
C
(1.9296 – 1.9298 in.)
The first, second, third, fourth and fifth (left to right) stamped
alphabets represent cap bore diameters of bearing caps “1”, “2”,
“3”, “4” and “5”, respectively.
For example, in figure, the first (leftmost) alphabet “B” indicates
that cap bore dia. of bearing cap “1” is within 49.006 – 49.012
mm, and the fifth (rightmost) alphabet “A” indicates that cap bore
dia. of cap “5” is within 49.000 – 49.006 mm.
3) There are five kinds of standard bearings differing in thick-

ness.
To distinguish them, they are painted in following colors at
the position as indicated in figure.
Each color indicates following thickness at the center of
bearing.
Color painted Bearing thickness

1.996 – 2.000 mm
Green
(0.0786 – 0.0788 in.)
1.999 – 2.003 mm
Black
(0.0787 – 0.0789 in.)
2.002 – 2.006 mm
Colorless (no paint)
(0.0788 – 0.0790 in.)
2.005 – 2.009 mm
1. Paint Yellow
(0.0789 – 0.0791 in.)
2.008 – 2.012 mm
Blue
(0.0790 – 0.0792 in.)
4) From numbers stamped on crank webs of No.2 and No.3 cyl-

inders and the alphabets stamped on mating surface of cyl-
inder block, determine new standard bearing to be installed
to journal, by referring to table given below.
For example, if number stamped on crank web is “1” and
alphabet stamped on mating surface is “B”, install a new
standard bearing painted in “Black” to its journal.
Number stamped on crank web

(Journal diameter)
1 2 3
Alphabet stamped on A Green Black Colorless
1. Crank web of No.1 cylinder mating surface (Bear- B Black Colorless Yellow
ing cap bore dia.) C Colorless Yellow Blue
New standard bearing to be
installed.
5) Using gaging plastic, check bearing clearance with newly

selected standard bearing.
If clearance still exceeds its limit, use next thicker bearing
and recheck clearance.
6) When replacing crankshaft or cylinder block due to any rea-
son, select new standard bearings to be installed by referring
to numerals stamped on new crankshaft or alphabets
1. Gaging plastic
stamped on mating surface of new cylinder block.
2. Scale
UNDERSIZE BEARING (0.25 mm):

• 0.25 mm undersize bearing is available, in five kinds varying
in thickness.
To distinguish them, each bearing is painted in following col-
ors at such position as indicated in figure.
Each color represents following thickness at the center of
bearing.
Color painted Bearing thickness

2.121 – 2.125 mm
Green & Red
(0.0836 – 0.0838 in.)
2.124 – 2.138 mm
Black & Red
(0.0836 – 0.0838 in.)
2.127 – 2.131 mm
Red only
(0.0837 – 0.0839 in.)
2.130 – 2.134 mm
1. Paint Yellow & Red
(0.0839 – 0.0840 in.)
2.133 – 2.137 mm
Blue & Red
(0.0840 – 0.0841 in.)
• If necessary, regrind crankshaft journal and select under-

size bearing to use with it as follows.
1) Regrind journal to following finished diameter.
Finished diameter: 44.732 – 44.750 mm
(1.7611 – 1.7618 in.)
2) Using micrometer, measure reground journal diameter.

Measurement should be taken in two directions perpendicu-
lar to each other in order to check for out-of-round.
3) Using journal diameter measured above and alphabets
stamped on mating surface of cylinder block, select an
undersize bearing by referring to table given below.
Check bearing clearance with newly selected undersize
bearing.
Measured journal diameter

44.744 – 44.750 mm 44.738 – 44.744 mm 44.732 – 44.738 mm
(2.0371 – 2.0373 in.) (2.0369 – 2.0371 in.) (2.0367 – 2.0369 in.)
Alphabet stamped on A Green & Red Black & Red Red only
mating surface of B Black & Red Red only Yellow & Red
cylinder block C Red only Yellow & Red Blue & Red
Undersize bearing to be installed
Rear Oil Seal

Carefully inspect oil seal for wear or damage. If its lip is worn or
damaged, replace it.
1. Rear oil seal
For oil seal installation, press-fit rear oil seal so that oil seal hous-
ing end face is flush with oil seal end face.
1 Oil seal
2. Oil seal housing
Flywheel
• If ring gear is damaged, cracked or worn, replace flywheel.
• If the surface contacting clutch disc is damaged, or exces-
sively worn, replace flywheel.
• Check flywheel for face runout with dial gauge.
If runout exceeds its limit, replace flywheel.
Limit on runout: 0.2 mm (0.0078 in.)
Cylinder Block
Distortion of gasket contact surface
Using straightedge and thickness gauge, check gasket contact
surface for distortion and, if flatness exceeds its limit, correct it.
Item Standard Limit

0.03 mm 0.06 mm
Flatness
(0.0012 in.) (0.0024 in.)
Honing or reboring cylinders

1) When any cylinder needs reboring, all other cylinders must
also be rebored at the same time.
2) Select oversized piston according to amount of cylinder
wear.
Size Piston diameter

71.470 – 71.490 mm
O/S 0.50
(2.8138 – 2.8145 in.)
3) Using micrometer, measure piston diameter.
1. 10 mm (0.39 in.)
4) Calculate cylinder bore diameter to be rebored.

D=A+B–C
D: Cylinder bore diameter to be rebored.
A: Piston diameter as measured.
B: Piston clearance = 0.02 – 0.04 mm
(0.0008 – 0.0015 in.)
C: Allowance for honing = 0.02 mm (0.0008 in.)
5) Rebore and hone cylinder to calculated dimension.
NOTE:
Before reboring, install all main bearing caps in place
and tighten to specification to avoid distortion of bearing
bores.
6) Measure piston clearance after honing.
INSTALLATION
NOTE:
• All parts to be installed must be perfectly clean.
• Be sure to oil crankshaft journals, journal bearings,
thrust bearings, crankpins, connecting rod bearings,
pistons, piston rings and cylinder bores.
• Journal bearings, bearing caps, connecting rods, rod
bearings, rod bearing caps, pistons and piston rings
are in combination sets. Do not disturb such combina-
tion and make sure that each part goes back to where
it came from, when installing.
1) Install main bearings to cylinder block.

Upper half of main bearing, has an oil groove. Install it to cyl-
inder block, and the other half without oil groove to bearing
cap.
Make sure that two halves are painted in the same color.
1. Cylinder block
2. Upper half of bearing
3. Oil groove
1. Thrust bearing 2) Install thrust bearings to cylinder block between No.2 and
2. Oil groove
No.3 cylinders. Face oil groove sides to crank webs.
3) Install crankshaft to cylinder block.

4) Install bearing cap to cylinder block, making sure to point
arrow mark (on each cap) to crankshaft pulley side. Fit them
sequentially in ascending order, 1, 2, 3, 4 and 5, starting
from pulley side.
After installing bearing cap stiffeners, tighten bearing cap
bolts in such order as shown in figure a little at a time and
repeat it till they are tightened to specified torque.
Tightening torque
(a): 53 N·m (5.3 kgf-m, 38.5 lbf-ft)
NOTE:
After tightening cap bolts, check to be sure that crank-
shaft rotates smoothly when turning it by 8.0 N·m (0.8
kgf-m, 5.8 lbf-ft) torque or below.
5) Install new gasket and oil seal housing.

Do not reuse gasket removed in disassembly. Apply engine
oil to oil seal lip before installation. Tighten housing bolts to
specification.
Tightening torque
(a): 11 N·m (1.1 kgf-m, 8.0 lbf-ft)
NOTE:
As there are 2 types of housing bolts, refer to figure for
installation.
After installing oil seal housing, gasket edges might bulge
out; if so, cut them off to make them flush with cylinder block
and oil seal housing.
1. Short bolts
2. Long bolts 6) Install oil pump.
Refer to item OIL PUMP for installation of oil pump.
7) Install flywheel.
Using special tool, lock flywheel or drive plate, and torque its
bolts to specification.
Special tool
(A): 09924-17811
Tightening torque
(a): 76 N·m (7.7 kgf-m, 56.0 lbf-ft)
8) Install pistons and connecting rods as previously outlined.

9) Install CKP sensor, oil pump strainer and oil pan as previ-
ously outlined.
10) Install cylinder head assembly to cylinder block as previously
outlined.
11) Install camshaft, crankshaft timing belt pulley, timing belt,
crankshaft pulley, water pump pulley, etc., as previously out-
lined.
12) Install clutch to flywheel. For clutch installation, refer to
CLUTCH COVER, CLUTCH DISC AND FLYWHEEL in Sec-
tion 7C.
13) Combine engine with transmission referring to REMOUNT-
ING in Section 7A.
14) Install engine and transmission assembly to vehicle as previ-
ously outlined.
TIGHTENING TORQUE SPECIFICATIONS

Tightening torque
Fastening part
N•m kgf-m lbf-ft
Oil pressure switch 14 1.4 10.5
Valve adjusting screw lock nuts 12 1.2 9.0
Cylinder head cover bolts 11 1.1 8.0
Intake manifold nuts and bolts 25 2.5 18.5
Intake manifold stiffener bolt 55 5.6 40.5
Exhaust manifold nuts 23 2.3 17.0
Exhaust pipe bolts 50 5.0 36.5
Timing belt tensioner stud 11 1.1 8.0
Timing belt tensioner bolt 27 2.8 20.0
Timing belt cover bolts and nut 11 1.1 8.0
Crankshaft pulley bolt 16 1.6 11.5
Water pump pulley bolts 11 1.1 8.0
Oil pump strainer bolt and stay bolt
11 1.1 8.0
Oil pan bolts and nuts
Oil pan drain plug 50 5.0 36.5
Oil pump rotor plate screws
11 1.1 8.0
Oil pump case bolts
Crankshaft timing belt pulley bolt 130 13.0 94.0
Camshaft housing bolts 11 1.1 8.0
Rocker arm shaft bolts 11 1.1 80
Oil gallery plug 33 3.3 24.0
Camshaft timing belt pulley bolt 60 6.0 43.5
CMP sensor case bolts 11 1.1 8.0
Cylinder head venturi plug 3.5 0.35 2.5
33 N·m o 53 N·m o 0 N·m o 33 N·m o 66
N·m (3.4 kgf-m o 5.4 kgf-m o 0 kgf-m o
Cylinder head bolts
3.4 kgf-m o 6.7 kgf-m, 24.5 lbf-ft o 39.0 lbf-
ft o 0 lbf-ft o 24.5 lbf-ft o 49.0 lbf-ft)
Connecting rod bearing cap nuts 35 3.5 25.5
Bolt and nuts fastening T/M and cylinder block 50 5.0 36.5
Crankshaft main bearing cap bolts 53 5.3 38.5
Flywheel bolts 76 7.7 56.0
Engine mounting & bracket bolts and nuts Refer to 6A-60.
Oil level gauge guide bolt and nut 11 1.1 8.0
Oil seal housing bolts 11 1.1 8.0
SPECIAL TOOLS
1. 09915M64510-001
Compression gauge
2. 09915M64510-002
Connector
3. 09915M64530
Hose 09915M78211
4. 09915M67010 09915M67311 09915M77311 Oil pressure gauge
Attachment Vacuum gauge Oil pressure gauge attachment
1. 09916M14510
Valve lifter
2. 09916M14910 09916M34542 09916M34550 09916M38210
Valve lifter attachment Reamer handle Reamer (5.5 mm) Reamer (11 mm)
09916M56011 09916M58210
09916M44910 Valve guide installer Valve guide installer 09916M77310
Valve guide remover attachment handle Piston ring compressor
09916M84511 09917M18211 09917M68221 09917M98221

Forceps Tappet adjuster wrench Camshaft pulley holder Valve stem seal installer
09926M18210
09918M08210 09924M17811 Oil seal guide
Vacuum gauge hose joint Flywheel holder (Vinyl resin)
REQUIRED SERVICE MATERIALS
RECOMMENDED
MATERIALS USE
SUZUKI PRODUCT
SUZUKI BOND NO. 1207F
Sealant • Mating surfaces of cylinder block and oil pan.
(99000-31250)
• Mating surfaces of camshaft housings (No.6).
SUZUKI BOND NO. 1215
Sealant • Mating surfaces of camshaft position sensor case
(99000-31110)
and cylinder head.
ENGINE COOLING 6B-1
SECTION 6B
ENGINE COOLING
NOTE:
CONTENTS
GENERAL DESCRIPTION ...............................6B-2 ON-VEHICLE SERVICE ...................................6B-7
COOLING SYSTEM CIRCULATION.............6B-2 COOLING SYSTEM DRAINING ................... 6B-7
DIAGNOSIS ......................................................6B-4 COOLING WATER PIPES OR HOSES ........ 6B-8
MAINTENANCE................................................6B-5 THERMOSTAT ............................................. 6B-9
WATER PUMP BELT.................................. 6B-10
COOLANT .....................................................6B-5
RADIATOR ................................................. 6B-10
COOLING SYSTEM FLUSH AND REFILL ...6B-6
WATER PUMP BELT TENSION ...................6B-7 TIGHTENING TORQUE SPECIFICATIONS ..6B-11
6B-2 ENGINE COOLING
GENERAL DESCRIPTION
WARNING:
• Be sure to check coolant level only on reservoir tank (a translucent container) and add coolant only
into the reservoir tank when replenishment is needed. Never remove radiator cap to check coolant
level or add coolant, as doing so is very dangerous for the following reasons:
– Coolant in cooling system may be extremely high in temperature, even exceeding the boiling
point as it is under pressure. If radiator cap is removed in this condition, high-temperature and
high-pressure coolant will instantaneously boil up and gush out; you could then be seriously
scalded by hot coolant and steam. Furthermore, as coolant contains flammable anti-freeze mate-
rial, coolant splashing over engine and fenders can start fire.
• Be sure to check that engine coolant is cold before removing any part of cooling system.
• Be sure to disconnect negative (–) cable from battery before removing any part of cooling system.
The cooling system consists of the radiator cap, radiator, reservoir tank, hoses, water pump, cooling fan, ther-
mostat. The radiator is of tube-and-fin type.
COOLING SYSTEM CIRCULATION

1) While the engine is warmed up (thermostat closed), coolant circulates as follows.
ENGINE COOLING 6B-3
2) When coolant is warmed up to normal temperature and the thermostat opens, coolant passes through the
radiator core to be cooled as follows.
6B-4 ENGINE COOLING
DIAGNOSIS
Condition Possible Cause Correction
Engine overheats • Loose or broken water pump belt Adjust or replace.
• Not enough coolant Check coolant level and add as
necessary.
• Faulty thermostat Replace.
• Faulty water pump Replace.
• Dirty or bent radiator fins Clean or remedy.
• Coolant leakage on cooling system Repair.
• Defective cooling fan motor or ETC sensor Check and replace as necessary.
• Plugged radiator Check and replace radiator as nec-
essary.
• Faulty radiator cap Replace.
• Dragging brakes Adjust or brake.
• Slipping clutch Adjust or replace.
• Poor charged battery Check and replace battery as nec-
essary.
• Poor electricity generated by generator Check and replace generator as
necessary.
• Faulty ECM Check and replace ECM as neces-
sary.
• Faulty wiring or grounding Repair wiring.
• Equipped with too many additional electrical Dismount them.
part(s)
• Fuse blown Check and replace fuse as neces-
sary.
• Radiator cooling fan relay faulty Check and replace radiator cooling
fan relay as necessary.
ENGINE COOLING 6B-5
MAINTENANCE
COOLANT
The coolant recovery system is a standard system, which allows part of coolant to flow from the radiator into the
coolant reservoir when it is expanded by heat. When the cooling system cools down, the coolant in the coolant
reservoir is drawn back into the radiator.
The cooling system has been filled with a quality coolant that is a 70/30 mixture of water and ethylene glycol
antifreeze.
This 70/30 mixture coolant solution provides freezing protection to a temperature as low as –15 °C (5 °F).
• Freeze protection down to –15 °C (5 °F) is also important to ensure protection against corrosion and loss of
coolant from boiling. This level of protection should be maintained even if freezing temperatures are not
expected.
• Add ethylene glycol base coolant when coolant has to be added because of coolant loss or to provide added
protection against freezing at temperatures lower than –15 °C (5 °F).
NOTE:
• Ethanol or methanol base coolant or plain water alone should not be used in cooling system at any
time as damage to cooling system could occur.
• Coolant must be mixed with demineralized water or distilled water.
ANTI-FREEZE PROPORTIONING CHART

T
O
C -15
ANTI-FREEZE PROPORTIONING
Freezing temperature
O
F 5
Anti-freeze/Anti-corrosion coolant concentration % 30

CHART
ltr. 1.59 / 3.71

Ratio of compound to cooling water
(ethylene glycol antifreeze / water) US pt. 3.36 / 7.84
lmp pt. 2.80 / 6.53
Engine radiator and heater 2.7 liters

(5.71 / 4.75 US/lmp. pt.)
COOLANT CAPACITY
0.5 liters
Reservoir tank
(1.06 / 0.88 US/lmp. pt.)
2.1 liters
Other
(4.44 / 3.70 US/lmp. pt.)
Total 5.3 liters

(11.20 / 9.33 US/lmp. pt.)
6B-6 ENGINE COOLING
COOLING SYSTEM FLUSH AND REFILL
WARNING:
The cap of thermostat cap must not be removed.
1) Remove radiator cap when engine is cool.
WARNING:
To help avoid danger of being burned, do not remove
radiator cap while engine and radiator are still hot. Scald-
ing fluid and steam can be blown out under pressure if
cap is taken off too soon.
2) Drain coolant by disconnecting radiator outlet hose from

radiator or by disconnecting CNG pressure regulator water
inlet hose (bi-fuel CNG model).
NOTE:
While draining coolant, connect appropriate hose to the
pipe where the water inlet hose is disconnected and pre-
1
vent spreading of coolant.
1. CNG pressure regulator water inlet hose

3) Connect disconnected hose as it was. Fill system with water
and run engine until radiator inlet hose becomes hot with
radiator cap removed.
4) Stop engine and wait until engine comes cooled down, and
then drain coolant by disconnecting radiator outlet hose or
CNG pressure regulator water inlet hose.
WARNING:
To help avoid danger of being burned, do not disconnect
radiator outlet hose while the hose is hot.
5) Repeat Steps 3) and 4) several times until drained liquid is
nearly colorless.
6) Connect disconnected hose as it was.
7) Remove reservoir tank and remove cap from reservoir tank
and pour out any fluid, scrub and clean inside of tank with
soap and water.
Flush it well with clean water and drain. Reinstall tank.
ENGINE COOLING 6B-7
8) Add 70/30 mixture of good quality ethylene glycol antifreeze

and water to radiator and tank. Bleed air from cooling system
by disconnecting heater breather hose and loosening ther-
mostat cap bleeder bolt, and add coolant to radiator until
coolant comes out from thermostat cap bleeder hole. Then
tighten thermostat cap bleeder bolt.
Tightening torque
(a): 3.0 N·m (0.3 kgf-m, 2.2 Ibf-ft)
9) Fill radiator to the bottom of radiator filler neck and reservoir
tank to “FULL” level mark. Reinstall reservoir tank cap.
10) Connect heater breather hose.
11) Run engine with radiator cap removed, until radiator upper
hose is hot. Add coolant to radiator until level reaches the
bottom of filler neck.
12) Stop engine and install radiator cap. Add coolant to reservoir
tank when engine cold.
1. Thermostat cap 3. Heater breather
13) Repeat step 8) to 12) accordingly when air is still in cooling
bleeder bolt hose system.
2. Thermostat cap 4. Vehicle jack
WATER PUMP BELT TENSION

For water pump belt tension inspection, refer to GENERATOR
(WATER PUMP) BELT in Section 6H.
ON-VEHICLE SERVICE
WARNING:
• Check to make sure that engine coolant temperature is
cold before removing any part of cooling system.
• Also be sure to disconnect negative cable from battery
before removing any part.
COOLING SYSTEM DRAINING

1) Remove radiator cap.
2) Drain coolant by disconnecting radiator outlet hose or CNG
pressure regulator water inlet hose.
3) After draining coolant, be sure to connect disconnected hose
securely.
4) Fill cooling system. (Refer to COOLING SYSTEM FLUSH
AND REFILL.)
6B-8 ENGINE COOLING
COOLING WATER PIPES OR HOSES
REMOVAL
2) To remove these pipes or hoses, loosen clamp on each hose
and pull hose end off.
INSTALLATION
Install removed parts in reverse order of removal procedure, not-
ing the following.
• Set each clamp as it was.
• Refill cooling system with proper coolant, referring to COOL-
ING SYSTEM FLUSH AND REFILL.
• Use new O-ring when installing water pipe to water pump.
ENGINE COOLING 6B-9
THERMOSTAT
CAUTION:
Do not remove cap part of thermostat cap.
REMOVAL
2) Remove engine room center member bolts and lift engine
room center member with gear shift control lever and parking
brake lever.
3) Remove generator adjusting arm reinforcement and then
1. Generator adjusting arm reinforcement
remove thermostat cap from intake manifold.
2. Thermostat cap 4) Remove thermostat.
3. Thermostat cap bolt
INSPECTION
1) Make sure that air bleed valve of thermostat is clean.
2) Check to make sure that valve seat is free from foreign mat-
ters which would prevent valve from seating tight.
3) Check thermostat seal for breakage, deterioration or any
other damage.
1. Air bleed valve

2. Thermostat seal
4) Check thermostatic movement of wax pellet as follows:

a) Immerse thermostat in water, and heat water gradually.
b) Check that valve starts to open at specific temperature.
c) If valve starts to open at a temperature substantially below
or above specific temperature, thermostat unit should be
replaced with a new one. Such a unit, if reused, will bring
about overcooling or overheating tendency.
Thermostat functional spec. ±1.5 °C (2.7 °F)

Temp. at which valve
82 °C (179 °F)
begins to open
Temp. at which valve
95 °C (203 °F)
becomes fully open
1. Thermostat
2. Thermometer
3. Heater
6B-10 ENGINE COOLING
INSTALLATION
1) Install thermostat.
NOTE:
When installing thermostat on intake manifold, be sure to
position it so that air bleed valve is positioned on the
right side of vehicle as shown in left figure.
1. Thermostat
2. Air bleed valve 2) Install thermostat cap to intake manifold.
3. Intake manifold
F: Vehicle forward 3) Install generator adjusting arm reinforcement.
R: Vehicle rigtward
4) Install engine room center member.
5) Fill cooling system, referring to COOLING SYSTEM FLUSH

AND REFILL.
6) After installation, check each part for leakage.
WATER PUMP BELT

For removal, installation, inspection or adjustment, refer to GEN-
ERATOR (WATER PUMP) BELT in Section 6H.
RADIATOR
REMOVAL
3) Disconnect coupler of cooling fan motor.
4) Disconnect radiator inlet and outlet hoses and reservoir tank
hose from radiator.
5) Remove radiator upper bracket bolts.
6) Remove radiator with cooling fan motor.
1. Bolt
2. Radiator upper bracket
ENGINE COOLING 6B-11
INSPECTION
Check radiator for leakage or damage. Straighten bent fins, if any.
CLEANING
Clean frontal area of radiator cores.
INSTALLATION
Reverse removal procedures.
NOTE:
• Refill cooling system with proper coolant referring to
COOLANT item of MAINTENANCE.
• After installation, check each joint for leakage.
TIGHTENING TORQUE SPECIFICATIONS

Tightening torque
Fastening part
N•m kgf-m lbf-ft
Thermostat cap bleeder bolt 3.0 0.3 2.2
ENGINE FUEL (BI-FUEL USING CNG) 6C1-1
SECTION 6C1
ENGINE FUEL
(BI-FUEL USING CNG)
NOTE:
CONTENTS
GENERAL DESCRIPTION .............................6C1-2 FUEL FILTER .............................................6C1-6
FUEL SYSTEM ...........................................6C1-2 FUEL PIPE..................................................6C1-8
FUEL TANK ................................................. 6C- * FUEL FILLER CAP ...................................... 6C- *
CNG RECEPTACLE ...................................6C1-2 FUEL TANK ..............................................6C1-12
CNG CYLINDER .........................................6C1-2 FUEL PUMP ASSEMBLY (WITH FUEL LEVEL
FUEL PUMP ASSEMBLY (WITH LEVEL GAUGE, FUEL CUT VALVE AND TANK
GAUGE, FUEL CUT VALVE AND TANK PRESSURE CONTROL VALVE) ..............6C1-16
PRESSURE CONTROL VALVE) ................. 6C- * CNG CYLINDER WITH VALVE ................6C1-18
FUEL FILLER CAP ...................................... 6C- * CNG RECEPTACLE .................................6C1-24
CNG CYLINDER VALVE ............................6C1-3 CNG RECEPTACLE O-RING ...................6C1-28
CNG FUEL FILTER.....................................6C1-4 TIGHTENING TORQUE SPECIFICATION...6C1-29
ON-VEHICLE SERVICE .................................6C1-5 SPECIAL TOOL ...........................................6C1-29
FUEL LINES................................................6C1-6
6C1-2 ENGINE FUEL (BI-FUEL USING CNG)
GENERAL DESCRIPTION
FUEL SYSTEM
This model employs a bi-fuel system capable of utilizing two types of fuel, petrol and CNG appropriately.
This system operates in three fuel modes: “AUTO MODE”, “Petrol MODE” and “Forced CNG MODE”, each of
which can be selected with the fuel selector switch.
PETROL SYSTEM
Refer to “FUEL SYSTEM” in section 6C.
CNG SYSTEM
Main components of CNG fuel system are CNG receptacle, CNG cylinder, CNG cylinder valve, CNG pressure
regulator, CNG fuel filter and CNG fuel feed line.
For the details of fuel flow, refer to “ENGINE AND EMISSION CONTROL SYSTEM” in section 6E1.
CNG RECEPTACLE
The vehicle is refueled with gas through the CNG receptacle. When refueling, a refueling nozzle is connected to
the CNG receptacle. As the pressure increases on the nozzle side, the one-way valve inside the CNG recepta-
cle opens to admit gas to the CNG cylinder.
CNG CYLINDER
The CNG cylinder is made of chrome molybdenum steel. The vehicle is equipped with one CNG cylinder with a
capacity of 65 liters (137.37/114.38 US/Imp pt.) in the luggage compartment.
The CNG cylinder valve located on the outlet port is equipped with a safety mechanism.
SPECIFICATIONS
Volume 65 liters (137.37/114.38 US/Imp pt.)
Maximum fueling pressure 20 MPa (203.9 kg/cm2, 2900 psi)
Vessel weight Approximately 64 kg (141 lb)
Material Chrome molybdenum steel
CNG CYLINDER VALVE

The CNG cylinder valve, which is attached on the outlet port of the CNG cylinder, is equipped with a manual
CNG cylinder valve, a shut-off valve of CNG cylinder, and an excess flow valve. Additionally, a fusible plug and
pressure relief device are fitted as safety devices.
1. Excess flow valve area 3. Shut-off valve of CNG cylinder area 5. Pressure relief device
2. Manual CNG cylinder valve area 4. Fusible plug 6. CNG cylinder
MANUAL CNG CYLINDER VALVE

Rotating the handle clockwise shuts off the main path within the CNG cylinder valve, and halts the discharge of
gas.
This valve has to be open when driving the vehicle normally or when refueling the CNG cylinder, and it has to be
shut in unusual circumstances, such as when an accident has occurred or when the vehicle will not be used for
an extended period of time.
EXCESS FLOW VALVE

The excess flow valve is a safety valve that operates automatically on the difference between the internal pres-
sure of the CNG cylinder and the pressure at the outlet, when gas flow becomes abnormal due to damaged
CNG fuel pipe, etc.
When the difference between the internal pressure of the CNG cylinder and the pressure at the outlet is within
normal range, the valve plate of the excess flow valve is held by a spring. Thus the excess flow valve opens
under normal circumstances.
When pressure at the outlet lowers due to such occurrences as a damaged CNG fuel pipe, the pressure inside
the CNG cylinder becomes bigger than the spring force. As a result, the valve plate is pushed against the spring
and the gas path is closed.
When the excess flow valve operates, its state is maintained. The excess flow valve can be returned to its nor-
mal state by closing the manual CNG cylinder valve to its full extent for a period of time and fully opening the
manual CNG cylinder valve again.
SHUT-OFF VALVE OF CNG CYLINDER

The shut-off valve of CNG cylinder is an electromagnetic isolation valve in the fuel path that opens and shuts in
response to a signal from the CNG control module.
When electric current is supplied to the coil based on a signal from the CNG control module, the plunger lifts,
placing the shut-off valve of CNG cylinder in an open state.
This area is also equipped with a one-way valve mechanism, so that even when the engine is stopped for refuel-
ing (with the valve shut, with no current passing through it), increased gas pressure on the refueling nozzle side
will open the valve, admitting gas to the CNG cylinder.
FUSIBLE PLUG
To prevent the CNG cylinder from burst, when the gas or the atmosphere temperature exceeds a specified tem-
perature (approximately 100 – 120 °C (212 – 248 °F)), the fuse metal melts and the fuel gas in the cylinder is
released into the atmosphere.
PRESSURE RELIEF DEVICE

To prevent the CNG cylinder from burst, when the gas pressure inside the CNG cylinder exceeds a specified
value (approximately 30 MPa (305.9 kgf/cm2, 4351 psi)), the valve opens to relieve the gas into atmosphere.
CNG FUEL FILTER

The CNG fuel filter is located downstream from the CNG pressure regulator to remove any impurities (mostly oil)
from the fuel gas.
ON-VEHICLE SERVICE
With short pipe, fit hose as it reaches pipe joint as shown.
WARNING:
Before attempting service of any type on fuel system, fol-
lowing cautions should be always observed.
• Disconnect negative cable at battery.
• Do not smoke, and place “NO SMOKING” signs near
work area.
With the following type pipe, fir hose as far as its peripheral projec- • Be sure to perform work in a well-ventilated area and
tion as shown.
away from any open flames (such as gas hot heater).
• To relieve fuel vapor pressure in fuel tank, remove fuel
filler cap from fuel filler neck and then reinstall it.
• As fuel feed line is still under high fuel pressure even
after engine was stopped, loosening or disconnecting
With bent pipe, fit hose as far as its bent part as shown or till pipe
fuel feed line directly may cause dangerous spout of
is about 20 to 30 mm (0.79 - 1.18 in.) into the hose.
fuel to occur where loosened or disconnected.
Before loosening or disconnecting fuel feed line, make
sure to relieve fuel pressure according to procedure
described in “ENGINE” section.
• A small amount of fuel may be released after the fuel
line is disconnected. In order to reduce the chance of
personal injury, cover the fitting to be disconnected
with a shop cloth. Be sure to put that cloth in an
approved container when disconnection is completed.
• Note that fuel hose connection varies with each type of
With straight pipe, fit hose pipe is about 20 to 25 mm (0.79 - 0.98 in.)
in the hose. pipe. Be sure to connect and clamp each hose cor-
rectly referring to the left figure.
With red mark pipe, fit hose till hose end reached red mark on pipe.
1. Pipe
2. Hose
3. Clamp
1. Clamp securely at a position 3 to 7 mm
(0.12 – 0.28 in.) from hose end.
FUEL LINES
Due to the fact that fuel line is under high pressure, use special
care when servicing it.
INSPECTION
PETROL SYSTEM
Refer to “FUEL LINES” in section 6C.
CNG SYSTEM
Inspect CNG fuel lines for CNG fuel leaks referring to “FUEL
LEAKAGE CHECK PROCEDURE” in section 6.
FUEL FILTER
PETROL SYSTEM
Refer to “FUEL FILLER” in section 6C.
CNG SYSTEM
REMOVAL
1) Relieve CNG fuel pressure in CNG fuel feed line referring to
“FUEL PRESSURE RELIEF PROCEDURE” in section 6.
2) Disconnect negative (–) cable at battery.
3) Remove engine undercover.
4) Disconnect CNG fuel hoses (1) from CNG fuel filter assem-
bly (2).
1
5) Remove CNG fuel filter assembly from CNG fuel filter
bracket (3).
3
1 6) Remove CNG fuel filter lower case (2) from CNG fuel filter
upper case (1), and then remove CNG fuel filter (3) from
CNG fuel filter lower case.
3 2
INSTALLATION
Reverse removal procedure noting the following.
• Check CNG fuel filter element (3) for evidence of dirt and
contamination.
If the filter is found faulty, replace CNG fuel filter.
• Use new O-rings (1).
• Wipe off the accumulated oil in CNG fuel filter lower case
completely.
• Tighten CNG fuel filter lower case (2) to specified torque.
Tightening torque
CNG fuel filter lower case (a): 8.0 N·m (0.82 kgf-m, 6.0 lbf-
ft)
1 1
3 2, (a)
1
• Make sure that arrow mark (1) on the CNG fuel filter (2) is
pointed toward CNG delivery pipe.
• Check CNG fuel hoses for CNG fuel leaks referring to “FUEL
FUEL PIPE
PETROL SYSTEM
Refer to “FUEL PIPE” in section 6C.
CNG SYSTEM
REMOVAL
CNG FUEL PIPE NO.1 (CNG CYLINDER TO PIPE JOINT
NO.1)
3) Disconnect CNG fuel pipe No.1 (1) from CNG fuel pipe joint
No.1 (2) located at left side of underbody.
[B]
[A]
[A]
4
3 2
1 [a]
[B]
1
3
2 [a]
[a]: Vehicle forward 3. CNG fuel pipe No.2

[A]: 5-seater model 4. CNG receptacle pipe
[B]: 2-seater model
[A] [B] 4) Disconnect vent hoses (1), CNG receptacle pipe (5) (2-
seater model) and CNG fuel pipe No.1 (2) from CNG cylinder
1
1 valve (3).
5) Disconnect vent hoses and vent hose duct (4) from vehicle
5 body and then remove CNG fuel pipe No.1, vent hoses and
3
3 vent hose duct.
2 2
1
1
CNG FUEL PIPE NO.2 (PIPE JOINT NO.1 TO PIPE JOINT

NO.2 FOR 5-SEATER MODEL, OR CNG PRESSURE REGU-
LATOR FOR 2-SEATER MODEL)
1) Relieve fuel pressure in petrol fuel feed line and CNG fuel
feed line referring to “FUEL PRESSURE RELIEF PROCE-
DURE” in section 6.
2) Disconnect negative (–) cable at battery
3) Remove engine undercover.
4) Disconnect fuel pipe No.2 (3) from CNG fuel pipe joint No.1
(2).
[B]
[A]
[A]
4
3 2
1 [a]
[B]
1
3
2 [a]
[a]: Vehicle forward 1. CNG fuel pipe No.1

[A]: 5-seater model 4. CNG receptacle pipe
[B]: 2-seater model
5) Disconnect fuel pipe No.2 (1) from CNG fuel pipe joint No.2
1
(2) and then remove fuel pipe No.2.
INSTALLATION
CNG FUEL PIPE NO.1 (CNG CYLINDER TO PIPE JOINT
NO.1)
• Tighten CNG fuel pipe nuts to specified torque.
Tightening torque
2 CNG fuel pipe nut: 17 N·m (1.7 kgf-m, 12.5 lbf-ft)
• Install vent hose duct (1) so that the mark (2) points toward
vehicle front.
• Tighten vent hose clamps to specified torque.
1
Tightening torque
Vent hose clamp: 1.7 N·m (0.17 kgf-m, 1.5 lbf-ft)
• Check fuel pipe joints for CNG fuel leaks referring to “FUEL
CNG FUEL PIPE NO.2 (PIPE JOINT NO.1 TO PIPE JOINT

NO.2 FOR 5-SEATER MODEL, OR CNG PRESSURE REGU-
LATOR FOR 2-SEATER MODEL)
Reverse removal procedure for installation noting the following.
• Tighten CNG fuel pipe nuts to specified torque.
Tightening torque
CNG fuel pipe nut: 17 N·m (1.7 kgf-m, 12.5 lbf-ft)
• Check fuel pipe joints for CNG fuel leaks referring to “FUEL
FUEL TANK
REMOVAL
WARNING:
• Refer to the WARNING at the beginning of ON-VEHI-
CLE SERVICE in this section.
• Store drained fuel in an airtight container to reduce the
risk of fire and personal injury.
1) Relieve fuel pressure in fuel feed line referring to SECTION
6.
3) Due to absence of fuel tank drain plug, drain fuel tank by
pumping fuel out at fuel tank filler.
Use hand operated pump device to drain fuel in space “A” in
the figure.
CAUTION:
Do not force hand operated pump hose into fuel tank. It
1. Fuel filler hose may damage inlet valve.
2. Fuel tank inlet (check) valve
4) Hoist vehicle.
5) Disconnect fuel pump wire coupler.
1. Fuel pump wire coupler 2. Fuel tank
1. Fuel filler hose 6) Disconnect fuel filler hose from filler neck, breather hose
2. Breather hose
3. Fuel filler neck
from tank.
4. Fuel tank
7) Disconnect fuel feed hose and fuel return hose as previously

outlined in “FUEL PIPE”.
Special tool
(A): 09919M47020
Disconnect fuel vapor hose from pipe.
WARNING:
A small amount of fuel may be released after fuel hose is
disconnected. In order to reduce the chance of personal
injury, cover hose and pipe to be disconnected with a
shop cloth. Be sure to put that cloth in an approved con-
tainer when disconnection is completed.
1. Quick joint
2. Pipe
3. Breather hose
4. Fuel vapor hose
: Before disconnecting, blow off dust, etc.
of this portion with compressed air.
8) Support fuel tank with jack and remove 4 bolts.

9) Remove fuel tank from vehicle.
1. Fuel tank
2. Jack
10) Disconnect fuel tank filler hose from fuel tank, and drain fuel
from fuel tank as follows.
(1) Remove fuel tank inlet (check) valve from fuel tank.
(2) Insert hose of a hand operated pump into fuel tank inlet and
drain remaining fuel with hand operated pump till fuel stops.
(3) Cover fuel tank inlet with moisture proof cloth adhesive tape
or the like so as not to let fuel come out from it when remov-
ing fuel tank.
WARNING:
Be sure to cover fuel tank inlet. Fuel may remain in space
“B” in fuel tank even after fuel drainage procedure. Work-
ing on tank without covering its inlet may cause personal
injury or fire.
1. Fuel tank inlet valve

2. Cover inlet
11) Disconnect fuel feed hose, fuel vapor hose and fuel return
hose from fuel pump assembly.
When disconnecting joint of fuel feed line or return line from
pipe, unlock joint by inserting special tool between pipe and
joint lock first.
Special tool
(A): 09919M47020
Disconnect joint from pipe.
WARNING:
A small amount of fuel may be released after the fuel
hose is disconnected. In order to reduce the chance of
personal injury, cover the hose and pipe to be discon-
nected with a shop cloth. Be sure to put that cloth in an
1. Joint approved container when disconnection is completed.
2. Fuel return hose
3. Fuel feed hose
4. Fuel vapor hose
1: Before disconnecting, blow off dust, etc.
of this portion with compressed air.
INSPECTION
After removing fuel tank, check hoses and pipes connected to fuel
tank for leaks, loose connections, deterioration or damage. Also
check fuel pump assembly gaskets for leaks, visually inspect fuel
tank for leaks and damage.
If any damage or abnormality is found, replace damaged or
abnormal parts.
Fuel Tank Purging Procedure
WARNING:
This purging procedure will not remove all fuel vapor. Do
not attempt any repair on tank using heat or flame as an
explosion resulting in personal injury could occur.
CAUTION:
Never leave water in fuel tank after washing, or fuel tank
inside will get corrosion.
Following procedure is used for purging fuel tank.

1) After removing fuel tank, remove all hoses, pipes, fuel pump
assembly from fuel tank.
2) Drain all remaining fuel from tank.
3) Move tank to flushing area.
4) Fill tank with warm water or tap water, and agitate vigorously
and drain. Repeat this washing until inside of tank is clean.
Replace tank if its inside is rusty.
5) Completely flush out remaining water after washing.
6) Be sure to dry fuel tank assembly thoroughly out of direct
sunlight after washing.
INSTALLATION
1) If parts have been removed from fuel tank, install them
before installing fuel tank to vehicle.
2) Connect fuel vapor hose and pipe joints to fuel pump assem-
bly, and clamp vapor hose securely.
CAUTION:
When connecting joint, clean outside surfaces of pipe
where joint is to be inserted, push joint into pipe till joint
lock clicks and check to ensure that pipes are connected
securely, or fuel leak may occur.
3) Install fuel tank to vehicle. Tighten fuel tank bolts to specified
torque in numerical order (“1” – “4”) shown in figure.
Tightening torque
(a): 40 N·m (4.1 kgf-m, 29.5 lbf-ft)
“1” “3”
“4”
“2”
1. Joint
2. Fuel return hose
3. Fuel feed hose
4. Fuel vapor hose
5. Fuel tank
6. Bolt
4) Connect fuel filler hose to filler neck and breather hose to

fuel tank and clamp hoses securely.
Tightening torque
(b): 1.5 N·m (0.15 kgf-m, 1.0 lbf-ft)
5) Connect fuel hoses to each pipe and fuel vapor hose to fuel
tank. Refer to “ON-VEHICLE SERVICE” for proper connec-
tion.
1. Fuel filler hose

2. Breather hose
3. Fuel filler neck
4. Fuel tank
6) Connect fuel pump wire coupler.
1. Fuel pump wire coupler

With engine “OFF” and ignition switch “ON”, check for fuel
leaks.
FUEL PUMP ASSEMBLY (WITH FUEL LEVEL

GAUGE, FUEL CUT VALVE AND TANK PRES-
SURE CONTROL VALVE)
WARNING:
Refer to the WARNING at the beginning of ON-VEHICLE
SERVICE in this section.
REMOVAL
1) Remove fuel tank from vehicle. Refer to FUEL TANK
REMOVAL in this section.
2) Remove fuel pump assembly from fuel tank.
1. Fuel pump
assembly
INSPECTION
Check fuel pump assembly for damage.
Check fuel suction filter for evidence of dirt and contamination. If
present, replace or clean and check for presence of dirt in fuel
tank. For inspection of fuel level gauge, refer to “BODY ELECTRI-
CAL” section of this manual.
1. Fuel pump
assembly
DISASSEMBLY
1. Bracket sub assembly

2. Fuel level gauge
(Fuel sender gauge)
3. Fuel pump
1) Disconnect gauge lead wire connector from bracket sub

assembly.
2) While pressing snap-fit part, remove fuel level gauge (sender
gauge) by sliding it in the arrow direction.
1
CAUTION:
While removing fuel level gauge, do not contact resistor
2 plate or deform arm. It may cause fuel level gauge to fail.
1. Snap-fit part
2. Fuel level gauge
REASSEMBLY
1) Install fuel level gauge to housing. Fit groove of fuel level
3
gauge in protrusion of housing and slide fuel level gauge
down until snap-fit locks.
2) Connect fuel level gauge connector to bracket sub assembly.
1. Protrusion 1
2. Groove 2
3. Snap-fit part
INSTALLATION
1) Clean mating surfaces of fuel pump assembly and fuel tank.
2) Install new gasket and plate to fuel pump assembly then
install fuel pump assembly to fuel tank.
Tightening torque
(a): 10 N·m (1.0 kgf-m, 7.5 lbf-ft)
1. Fuel pump
assembly
2. Gasket
3. Plate
3) Connect wire harness coupler and fuel vapor hose to fuel

pump assembly.
1. Fuel pump
assembly
2. Coupler
3. Fuel vapor hose
4) Install fuel tank to vehicle. Refer to FUEL TANK INSTALLA-

TION in this section.
CNG CYLINDER WITH VALVE

ON-VEHICLE INSPECTION
1) Check CNG cylinder and CNG cylinder valve for cracks,
deformation or damage. If any faulty condition is found,
replace CNG cylinder with valve.
2) Check CNG cylinder and CNG cylinder valve for CNG fuel
leakage referring to “FUEL LEAKAGE CHECK PROCE-
DURE” in section 6. If leakage is found, replace CNG cylin-
der with valve.
3) Check the shut-off valve of CNG cylinder for resistance and
operating sound as follows.
a) Disconnect negative (–) cable at battery.
b) Disconnect shut-off valve of CNG cylinder connector.
c) Using ohmmeter, check resistance between terminals of
shut-off valve of CNG cylinder connector (1).
If check result is not satisfactory, replace CNG cylinder with
valve.
1
Reference resistance of shut-off valve of CNG cylinder
10 – 12 : at 20 °C (68 °F)
1
d) Check that shut-off valve of CNG cylinder clicks when con-

necting 12-V battery to terminals of shut-off valve of CNG
cylinder connector (1). If operating sound is not heard,
replace CNG cylinder with valve.
1
REMOVAL
WARNING:
CNG cylinder should be installed or removed by 2 or more
persons. Otherwise CNG cylinder can drop and it cause per-
sonal injury, because CNG cylinder is very heavy.

3) For 5-seater model, remove CNG cylinder partition (1) from
1
vehicle body and side frame.
4) For 2-seater model, remove luggage floor member (1) from

side frame (2).
1
2
2
5) Put matchmarks (1) on CNG cylinder (2), CNG cylinder
holder No.2 (3) and main frame (4) as shown in figure.
3 3 4
1 3
[A] [B] 6) Disconnect vent hoses (1) from CNG cylinder valve (2).
1 1
7) Disconnect shut-off valve of CNG cylinder connector (4) and
then remove CNG fuel pipe No.1 (3) and CNG receptacle
4
pipe (5) (2-seater model) referring to “FUEL PIPE” in this
5
section.
2
2 3
3
1
1
1 8) For 5-seater model, remove rear seat and then remove side
frame (1).
2 9) Loosen CNG cylinder holder lock nuts (1), and then loosen
3
CNG cylinder holder adjusting bolts (2).
10) Remove CNG cylinder holder No.1 (3) and CNG cylinder
1 holder No.2 (4) from main frame (5).
11) Remove CNG cylinder (6) with valve.
4 6
5
12) Remove main frame (1) if necessary.

[A]
[B]
INSTALLATION
[A]
1) Install main frame (1) and tighten main frame bolts (2) to
2, (a)
specified torque if removed.
Tightening torque
Main frame bolt (a): 38 N·m (3.9 kgf-m, 28.0 lbf-ft)
[B] 2, (a)

2 2) Place CNG cylinder (2) on the main frame so that the match-
1
marks (1) on CNG cylinder, CNG cylinder holder No.2 (3)
and main frame (4) aligns.
3, (c)
3) Tighten cylinder holder No.1 bolts (1) and then No.2 bolts (2)
to specified torque.
1, (a)
4, (d)
Tightening torque
2, (a) Cylinder holder No.1 bolt (a): 60 N·m (6.1 kgf-m, 44.5 lbf-ft)
Cylinder holder No.2 bolt (a): 60 N·m (6.1 kgf-m, 44.5 lbf-ft)
4) Tighten cylinder holder adjusting bolts (3) to specified

torque.
Tightening torque
Cylinder holder adjusting bolt (c): 35 N·m (3.6 kgf-m, 26.0
lbf-ft)
5) Tighten cylinder holder lock nuts (4) to specified torque.
5 Tightening torque
Cylinder holder lock nut (d): 35 N·m (3.6 kgf-m, 26.0 lbf-ft)
6) As proof that the bolts and nuts are tightened to the specified
torque, put red paint mark on the cylinder holder adjusting
bolts and cylinder locking nuts.
7) Install side frame and tighten side frame bolt (1) temporary
by hand.
1
[A] [B] 8) Install CNG fuel pipe No.1 (1) and CNG receptacle pipe (6)
3 3
(2-seater model) referring to “FUEL PIPE” in this section.
4 9) Connect shut-off valve of CNG cylinder connector (2) and
4
2
vent hoses (3) to CNG cylinder valve (5) and then tighten
6 vent hose clamps (4) to specified torque.
5
5 1
1 Tightening torque
2
4
Vent hose clamp (a) 1.7 N·m (0.17 kgf-m, 1.5 lbf-ft)
4 3
3 10) For 5-seater model, install rear seat.
3, (a)
11) For 2-seater model, install luggage floor member (1) to side
frame (2) and tighten luggage floor member bolts (3) to spec-
ified torque.
1
3, (a) Tightening torque
2
Luggage floor member bolt (a): 8 N·m (0.82 kgf-m, 6.0 lbf-
ft)
12) For 5-seater model, install CNG cylinder partition (1) and
2, (a)
2, (a) tighten CNG cylinder partition bolts (2) to specified torque.
1
Tightening torque
CNG cylinder partition bolt (a): 8 N·m (0.82 kgf-m, 6.0 lbf-
ft)
13) Tighten side frame bolts to specified torque.
Tightening torque
2, (a) Side frame bolt: 38 N·m (3.9 kgf-m, 28.0 lbf-ft)
14) Connect negative (–) cable to battery.

15) Check fuel pipe joints for CNG fuel leaks referring to “FUEL
CNG RECEPTACLE
• Check CNG receptacle for cracks, deformation or damage.
If any faulty condition is found, replace CNG receptacle.
• Check O-ring for cracks, deformation or damage.
If any faulty condition is found, replace O-ring.
• Check CNG receptacle for CNG fuel leakage referring to
“FUEL LEAKAGE CHECK PROCEDURE” in section 6. If
leakage is found, replace CNG receptacle.
REMOVAL
2) Remove vent hose cover (1) from vehicle body.
3) Disconnect vent hose (1) from vent hose duct (3) and then
disconnect CNG receptacle pipe (2).
1
2
4) Remove battery referring to “BATTERY” in section 6H.

5) Disconnect CNG receptacle switch connector (1).
1 6) Remove CNG receptacle screws (2) and CNG receptacle

cap screw (4). Then remove CNG receptacle assembly (1)
4 and CNG receptacle cap (3) from vehicle.
2
7) Remove vent hose (1) from CNG receptacle assembly (2).
1
8) Turning protection tube (1) counterclockwise remove it from

CNG receptacle holder nut (2).
9) Remove CNG receptacle pipe (3) from CNG receptacle.
5
10) Remove CNG receptacle switch (5) from CNG receptacle
holder (6).
11) Remove O-ring (4) from CNG receptacle holder nut (2).
2
3
12) Remove CNG receptacle holder (3) from CNG receptacle (1)
1 2 by removing CNG receptacle holder nut (2).
INSTALLATION
1) Install CNG receptacle holder (1) to CNG receptacle (2) and
tighten CNG receptacle holder nut (3) to specified torque.
Tightening torque
CNG receptacle holder nut (a): 20 N·m (2.0 kgf-m, 15.0 lbf-
ft)
2) Install new O-ring (4) to CNG receptacle holder nut (3).

1
2 3, (a)
4
3) Install CNG receptacle pipe (1) to CNG receptacle referring

to “FUEL PIPE” in this section.
2
4) Install CNG receptacle switch (2) to CNG receptacle holder
(3).
5) Install protection tube (4) to CNG receptacle holder nut (5)
and tighten protection tube to specified torque.
5
1 Tightening torque
Protection tube (a): 40 N·m (4.1 kgf-m, 29.5 lbf-ft)
4, (a)
6) Install vent hose (1) to CNG receptacle assembly (2) and

tighten vent hose clamp (3) to specified torque.
Tightening torque
2
Vent hose clamp (a): 1.7 N·m (0.17 kgf-m, 1.5 lbf-ft)
3, (a)
7) Install CNG receptacle assembly (1) and CNG receptacle

1
cap (3) to vehicle and tighten CNG receptacle screws (2) to
specified torque.
2, (a)
Tightening torque
CNG receptacle screw (a): 3.0 N·m (0.31 kgf-m, 2.5 lbf-ft)
2, (a)
3
8) Connect CNG receptacle pipe (1) and tighten CNG fuel pipe
nut (3) referring to “FUEL PIPE” in this section.
9) Connect vent hose (5) to vent hose duct (2) and tighten vent
4, (a)
hose clamp (4) to specified torque.
5 2
Tightening torque
Vent hose clamp (a): 1.7 N·m (0.17 kgf-m, 1.5 lbf-ft)
3
1
10) Install vent hose cover (1) to vehicle.

11) Open manual CNG cylinder valve.
12) Check CNG receptacle pipe for CNG fuel leaks referring to
“FUEL LEAKAGE CHECK PROCEDURE” in section 6.
1
CNG RECEPTACLE O-RING

REMOVAL
1) Close manual CNG cylinder valve.
2) Remove CNG receptacle O-ring (1) using flat-head rod or
the like (2).
1
INSTALLATION
• Use new O-ring.
TIGHTENING TORQUE SPECIFICATION

Tightening torque
Fastening part
N•m kgf-m lbf-ft
Fuel pump assembly bolt 10 1.0 7.5
Fuel tank bolt 40 4.1 29.5
Fuel filter bolt 25 2.5 18.5
Fuel tank hose clamp 1.5 0.15 1.0
CNG fuel filter lower case 8.0 0.82 6.0
CNG fuel hose clamp 1.7 0.17 1.5
Vent hose clamp 1.7 0.17 1.5
CNG fuel pipe nut 17 1.7 12.5
Main frame bolt 38 3.9 28.0
Cylinder holder No.1 bolt 60 6.1 44.5
Cylinder holder No.2 bolt 60 6.1 44.5
Cylinder holder adjusting bolt 35 3.6 26.0
Cylinder holder lock nut 55 5.6 40.5
Luggage floor member bolt 8 0.82 6.0
Side frame bolt 38 3.9 28.0
CNG cylinder partition bolt 8 0.82 6.0
CNG receptacle holder nut 20 2.0 15.0
Protection tube 40 4.1 29.5
CNG receptacle screw 3.0 0.31 2.5
SPECIAL TOOL
09919M47020
Quick joint remover
ENGINE AND EMISSION CONTROL SYSTEM (BI-FUEL USING CNG) 6E1-1
SECTION 6E1
ENGINE AND EMISSION CONTROL SYSTEM

(BI-FUEL USING CNG)
CONTENTS
PRECAUTIONS ..............................................6E1-3 TROUBLESHOOTING FOR COMMUNICATION
PRECAUTIONS ON FUEL SYSTEM ERROR WITH SCAN TOOL ..................... 6E1-25
SERVICE ....................................................6E1-3 DTC TABLE .............................................. 6E1-25
GENERAL DESCRIPTION .............................6E1-4 FAIL-SAFE TABLE ................................... 6E1-28
SCAN TOOL DATA................................... 6E1-30
ENGINE DIAGNOSIS GENERAL
MIL DOES NOT COME ON WITH IGNITION
DESCRIPTION............................................6E1-4
SWITCH IN ON POSITION AND ENGINE
ON-BOARD DIAGNOSTIC (OBD) SYSTEM
STOPPED (BUT ENGINE CAN BE
DESCRIPTION............................................6E1-4
STARTED) ................................................ 6E1-38
DLC (DATA LINK CONNECTOR)
MIL REMAINS ON AFTER ENGINE
DESCRIPTION............................................6E1-5
STARTS.................................................... 6E1-38
ENGINE AND EMISSION CONTROL SYSTEM
CNG WARNING LIGHT DOES NOT COME ON
DESCRIPTION............................................6E1-6
WITH IGNITION SWITCH IN ON POSITION AND
BI-FUEL CNG SYSTEM DESCRIPTION ....6E1-6
ENGINE STOPPED (BUT ENGINE CAN BE
BI-FUEL CNG SYSTEM
STARTED) ................................................ 6E1-38
CONSTRUCTION .......................................6E1-7
CNG WARNING LIGHT REMAINS ON AFTER
BI-FUEL CNG SYSTEM COMPONENTS
ENGINE STARTS ..................................... 6E1-39
DESCRIPTION............................................6E1-7
DTC P0031 / P0032.................................. 6E1-40
CAN COMMUNICATION SYSTEM
DTC P0107 / P0108.................................. 6E1-40
DESCRIPTION............................................6E1-8
DTC P0112 / P0113.................................. 6E1-42
AIR INTAKE SYSTEM DESCRIPTION .......6E1-9
DTC P0117 / P0118.................................. 6E1-43
FUEL SYSTEM DESCRIPTION..................6E1-9
DTC P0122 / P0123.................................. 6E1-44
FUEL DELIVERY SYSTEM
DTC P0130 ............................................... 6E1-46
DESCRIPTION............................................6E1-9
DTC P0327 / P0328.................................. 6E1-46
ELECTRONIC CONTROL SYSTEM
DTC P0335 ............................................... 6E1-48
DESCRIPTION............................................6E1-9
DTC P0340 ............................................... 6E1-48
ENGINE AND EMISSION CONTROL INPUT /
DTC P0403 ............................................... 6E1-50
OUTPUT TABLE .......................................6E1-10
DTC P0443 ............................................... 6E1-52
SCHEMATIC AND ROUTING DIAGRAM ....6E1-14 DTC P0480 ............................................... 6E1-54
ENGINE AND EMISSION CONTROL SYSTEM DTC P0482 ............................................... 6E1-56
DIAGRAM .................................................6E1-14 DTC P0500 ............................................... 6E1-57
ENGINE AND EMISSION CONTROL SYSTEM DTC P0505 ............................................... 6E1-57
FLOW DIAGRAM ......................................6E1-16 DTC P0560 ............................................... 6E1-58
ENGINE CONTROL SYSTEM CIRCUIT DTC P0601 (ECM).................................... 6E1-59
DIAGRAM .................................................6E1-16 DTC P0602 (ECM).................................... 6E1-59
COMPONENT LOCATION ...........................6E1-22 DTC P0616 / P0617.................................. 6E1-59
ELECTRONIC CONTROL SYSTEM DTC U0073 (ECM).................................... 6E1-59
COMPONENT LOCATION........................6E1-22 DTC U0108 ............................................... 6E1-59
DIAGNOSTIC INFORMATION AND DTC U0155 ............................................... 6E1-59
PROCEDURES.............................................6E1-23 DTC P0005 / P0007.................................. 6E1-60
DTC P0182 / P0183.................................. 6E1-63
MALFUNCTION INDICATOR LAMP (MIL)
DTC P0192 / P0193.................................. 6E1-64
CHECK......................................................6E1-23
DTC P0201 / P0202 / P0203 / P0204 ....... 6E1-66
CNG WARNING LIGHT CHECK...............6E1-23
WIRING DIAGRAM................................... 6E1-67
DTC CHECK .............................................6E1-23
DTC P0601 / P0602 (CNG CONTROL MODULE) /
DTC CLEARANCE ....................................6E1-24
P062F ....................................................... 6E1-68
6E1-2 ENGINE AND EMISSION CONTROL SYSTEM (BI-FUEL USING CNG)
DTC P0607 ............................................... 6E1-69 CKP SENSOR ........................................ 6E1-110

DTC P0612 ............................................... 6E1-70 KNOCK SENSOR................................... 6E1-110
DTC P1432 / P1433.................................. 6E1-71 FUEL PRESSURE INSPECTION........... 6E1-110
DTC P1601 ............................................... 6E1-73 FUEL PUMP (ON-VEHICLE INSPECTION
DTC P2408 ............................................... 6E1-74 AND REMOVAL / INSPECTION /
DTC P2665 / P2667.................................. 6E1-75 INSTALLATION) ......................................... 6E1- *
DTC P2668 ............................................... 6E1-77 CNG PRESSURE REGULATOR............ 6E1-111
TROUBLESHOOTING FOR CAN-DTC .... 6E1-79 FUEL PRESSURE REGULATOR
ECM AND ITS CIRCUIT VOLTAGE (ON-VEHICLE INSPECTION, REMOVAL
TABLE....................................................... 6E1-87 AND INSTALLATION) ................................ 6E1- *
CNG CONTROL MODULE AND ITS CIRCUIT FUEL INJECTOR.................................... 6E1-113
VOLTAGE TABLE..................................... 6E1-97 ENGINE CONTROL MODULE (ECM).... 6E1-114
ECM POWER AND GROUND CIRCUIT CNG CONTROL MODULE..................... 6E1-114
CHECK ................................................... 6E1-103 MAP SENSOR........................................ 6E1-114
CNG CONTROL MODULE POWER AND ECT SENSOR ........................................ 6E1-114
GROUND CIRCUIT CHECK................... 6E1-103 TP SENSOR ........................................... 6E1-114
FUEL PUMP CIRCUIT CHECK .............. 6E1-105 HEATED OXYGEN SENSOR................. 6E1-115
FUEL INJECTOR CIRCUIT CHECK....... 6E1-105 IAT SENSOR (REMOVAL/INSTALLATION
FUEL PRESSURE CHECK .................... 6E1-107 AND INSPECTION) .................................... 6E1- *
IDLE AIR CONTROL SYSTEM CIRCUIT FUEL CUT OPERATION (INSPECTION)... 6E1- *
CHECK ................................................... 6E1-108 A/C SIGNAL, A/C ON SIGNAL CONTROL
EVAPORATIVE EMISSION CONTROL SYSTEM (IF A/C EQUIPPED)
SYSTEM CHECK.................................... 6E1-108 (INSPECTION) ........................................... 6E1- *
A/C CONTROL SIGNAL CHECK RADIATOR FAN CONTROL SYSTEM
(IF EQUIPPED)....................................... 6E1-108 (SYSTEM INSPECTION)............................ 6E1- *
RADIATOR FAN CONTROL SYSTEM CIRCUIT EVAP EMISSION CONTROL SYSTEM
CHECK ................................................... 6E1-108 (INSPECTION) ........................................... 6E1- *
FUEL CUT OPERATION CHECK........... 6E1-108 EVAP CANISTER PURGE VALVE
EGR CHECK........................................... 6E1-108 (ON-VEHICLE INSPECTION) .................... 6E1- *
EVAP CANISTER PURGE SYSTEM TANK PRESSURE CONTROL VALVE
INSPECTION .......................................... 6E1-108 (INSPECTION) ........................................... 6E1- *
IAC (IDLE AIR CONTROL) VALVE OPERATION PCV SYSTEM (INSPECTION) ................... 6E1- *
INSPECTION .......................................... 6E1-108 EGR SYSTEM ............................................ 6E1- *
POWER BALANCE TEST ...................... 6E1-108 CNG PRESSURE-AND-TEMPERATURE
REPAIR INSTRUCTIONS .......................... 6E1-110 SENSOR................................................. 6E1-115
ACCELERATOR CABLE AND PEDAL CNG RECEPTACLE SWITCH................ 6E1-116
ADJUSTMENT............................................6E1- * MAIN RELAY/FUEL PUMP RELAY/RADIATOR
IDLE SPEED AND IAC (IDLE AIR CONTROL) FAN RELAY / CNG VALVE CONTROL
DUTY INSPECTION ............................... 6E1-110 RELAY .................................................... 6E1-116
IAC VALVE (REMOVAL, INSPECTION FUEL CUT OPERATION ........................ 6E1-117
AND INSTALLATION).................................6E1- * EVAP CANISTER ................................... 6E1-117
THROTTLE BODY.................................. 6E1-110 TIGHTENING TORQUE
VEHICLE SPEED SENSOR (VSS)......... 6E1-110 SPECIFICATION ........................................ 6E1-118
CMP SENSOR........................................ 6E1-110 SPECIAL TOOLS AND EQUIPMENT........ 6E1-118
CMP SENSING ROTOR......................... 6E1-110
Engine
PRECAUTIONS
PRECAUTIONS ON FUEL SYSTEM SERVICE

! WARNING
Before servicing on fuel system, the following points should be always observed in order to reduce the
risk of fire and personal injury.
• Disconnect negative cable at battery.
• Do not smoke, and place no smoking signs near working area.
• Be sure to perform work in a well-ventilated area. If necessary, install equipment such as a gas leak
alarm in the working area.
• Do not perform any actions that will spark, if gas leak is detected.
• Be sure to perform work away from any open flames such as gas heater.
• To relieve fuel vapor pressure in fuel tank, remove fuel filler cap from fuel filler neck and then
reinstall it.
• As fuel feed line is still under high fuel pressure even after stopping engine, loosening or
disconnecting fuel feed line directly may cause dangerous spout of fuel. Before loosening or
disconnecting fuel feed line, make sure to relieve fuel pressure. Refer to FUEL PRESSURE RELIEF
PROCEDURE.
• A small amount of fuel may be released when the fuel line is disconnected. In order to reduce the
risk of personal injury, cover the fitting to be disconnected with shop cloth. Be sure to put that cloth
in an approved container after disconnecting.
• Never perform service work when engine and exhaust system and hot.
GENERAL DESCRIPTION
ENGINE DIAGNOSIS GENERAL DESCRIPTION • For some malfunctions, CNG control module adopts
the 2 D/C detecting logic to prevent erroneous
The engine and emission control systems in this vehicle
detection. With this logic, CNG warning light is turned
are controlled by ECM / CNG control module. ECM /
on when the malfunction is detected in 2 consecutive
CNG control module, has an On-Board Diagnostic
driving cycles.
(OBD) system which detects a malfunction in this system
and abnormality of those parts that influence the engine • When a malfunction is detected, engine and driving
exhaust emission. When diagnosing engine troubles, be conditions at that moment are stored in CNG control
sure to have full understanding of the outline of ON- module memory as freeze frame data.
BOARD DIAGNOSTIC (OBD) SYSTEM DESCRIPTION For details, refer to description on FREEZE FRAME
in this section and each item in PRECAUTIONS FOR DATA in this section.
DIAGNOSING TROUBLE and execute diagnosis • SUZUKI scan tool (2) or CAN communication OBD
according to ENGINE DIAGNOSTIC FLOW TABLE in generic scan tool can communicate with CNG control
Section 6. module via DLC (3).
There is a close relationship between the emission
system, engine mechanical, engine cooling system, 1
ignition system, exhaust system, etc. in their structure

and operation. In case of an engine trouble, even when
the malfunction indicator lamp (MIL) and/or CNG
warning light doesn’t turn on, it should be diagnosed
according to ENGINE DIAGNOSTIC FLOW TABLE in
Section 6.
ON-BOARD DIAGNOSTIC (OBD) SYSTEM

DESCRIPTION 3
ECM
Refer to ON-BOARD DIAGNOSTIC (OBD) SYSTEM
DESCRIPTION in Section 6E. 2
NOTE
For bi-fuel CNG, three freeze frame data,
which can be read from ECM, are added.
Warm-up Cycle
They are “Type of Fuel”, “CNG Temperature”
Warm-up cycle means that the coolant temperature has
and “CNG Pressure”.
risen by at least 22 °C (40 °F) from engine starting and
reaches a minimum temperature of at least 71 °C (160
CNG CONTROL MODULE °F).
General Description Driving Cycle (D/C)

CNG control module in this vehicle has the following Driving cycle means a period which starts of engine
functions. starting and ends at engine shutoff.
• When the ignition switch is turned to ON position with
the engine stopped, CNG warning light (1) turns on in 2 Driving Cycle Detection Logic
order to check the CNG warning light (1) and its The malfunction detected in the first driving cycle is
circuit. stored in CNG control module memory (in the form of
• When CNG control module detects a malfunction in pending DTC and freeze frame data) but the CNG
CNG control system for more than specified driving warning light does not turn on at this time. It turns on at
cycles, it turns on CNG warning light in the the second detection of the same malfunction in the next
combination meter and stores the diagnostic trouble driving cycle.
code (DTC) in its memory.
(If it detects normal condition for continuously 3 Pending DTC
driving cycles after detecting a malfunction, it turns off Pending DTC means a DTC detected and stored
CNG warning light although DTC is stored in its temporarily at the first driving cycle of the 2 driving cycle
memory as a history DTC.) detection logic.
Freeze Frame Data Freeze frame data (for example)

CNG control module stores the engine and driving
conditions (in the form of data as shown) at the moment Function View System Bar Help
of the detection of a malfunction in its memory. This data CNG / Freeze Frame Data
is called “Freeze frame data”. P2408 Fuel Cap Sensor / Switch Circuit
It is possible to know engine and driving conditions (e.g.,
Parameter Value Unit
whether the fuel was petrol or CNG, whether the engine
DTC P2408
was warm or not, whether the vehicle was running or
ECT 25 C
stopped) when a malfunction was detected by checking
Short Term Fuel Trim 0.00 %
the freeze frame data. Also, CNG control module has a Long Term Fuel Trim 0.00 %
function to store each freeze frame data for three MAP 102 kPa
different malfunctions in the order of their detection. Engine Speed 0 rpm
Utilizing this function, it is possible to know the order of Vehicle Speed 0 km/h
detection of these malfunctions. This is helpful when Intake Air Temperature 26 C
Absolute TP 1 0.00 %
rechecking or diagnosing a trouble.
For details of freeze frame data that can be read from Exit
CNG control module, refer to table below.
Data Active
DTC DTC
List
View
Test
Utility
ECT
Short Term Fuel Trim
Long Term Fuel Trim Freeze frame data clearance
MAP The freeze frame data is cleared at the same time as
Engine Speed clearance of DTC.
Vehicle Speed
Intake Air Temperature DLC (DATA LINK CONNECTOR) DESCRIPTION
Absolute TP 1
Fuel Pressure Refer to DLC (DATA LINK CONNECTOR)
Fuel Temperature DESCRIPTION in Section 6E.
CNG Pressure
Fuel Select Mode
Fuel Running Status
Inj Pulse Width #1
Inj Pulse Width #2
Inj Pulse Width #3
Inj Pulse Width #4
CNG Inj Pulse Width #1
Ignition Switch
Fuel Select Switch
Fuel Lid SW 1
Fuel Lid SW 2
Fuel Change Relay1
Fuel Change Relay2
Fuel Change Relay3
Fuel Change Relay4
Power Supply Relay
Power Supply Relay (Mon)
Shut Off V Tank
Shut Off V Tank (Mon)
Shut Off V Reg
Shut Off V Reg (Mon)
Battery Voltage
ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION

The engine and emission control system is divided into 4 major sub-systems: air intake system, fuel delivery system,
electronic control system and emission control system.
The air intake system includes air cleaner, MAP sensor, throttle body, IAC valve and intake manifold.
The fuel delivery system includes fuel pump, CNG cylinder valve, petrol fuel delivery pipe / CNG fuel delivery pipe,
petrol fuel pressure regulator / CNG pressure regulator, petrol fuel injector / CNG fuel injectors, etc.
The electronic control system includes ECM / CNG control module, various sensors and controlled devices.
The emission control system includes EGR, EVAP and PCV systems.
When hoses are disconnected and system components are removed for service, be sure to reinstall components
properly and route and connect hoses after service.
BI-FUEL CNG SYSTEM DESCRIPTION

Bi-fuel CNG system consists of two kinds of fuel system (petrol and CNG).
CNG system, which consists of CNG fuel supply system and CNG fuel injection system, is added to conventional
petrol system. Vehicle runs using either petrol or CNG. For detail about fuel system, refer to FUEL SYSTEM
DESCRIPTION in this section.
Bi-fuel CNG system is equipped with fuel selector switch and operating mode can be selected from three modes by
fuel selector switch as follows.
When ignition switch is turned to ON position, CNG control module selects “Petrol MODE” or “AUTO MODE”
automatically.
PETROL MODE
During “Petrol MODE”, engine runs on petrol only. Operating mode can be switched between “Petrol MODE” and
“AUTO MODE” at every push of fuel selector switch when ignition switch is ON.
AUTO MODE
During “AUTO MODE”, engine starts in petrol system and then the system automatically switches to CNG system,
depending on the condition of engine warming up.
Operating mode can be switched between “AUTO MODE” and “Petrol MODE” at every push of fuel selector switch
when ignition switch is ON with engine stopped, or when engine is running.
FORCED CNG MODE

During “Forced CNG MODE”, engine runs on CNG only. “Forced CNG MODE” can be selected by pushing and
holding fuel selector switch for more than 3 seconds when ignition switch is ON.
If ignition switch is turned to OFF position and then turned to ON position again under “Forced CNG MODE”, operating
mode is switched to “AUTO MODE”.
PETROL / CNG INDICATOR

Petrol / CNG indicator is on fuel selector switch. Petrol / CNG indicator lights up or blinks depending on selected
operating mode. For detail, refer to FUEL SELECTOR SWITCH (BI-FUEL CNG MODEL) in Section 8.
BI-FUEL CNG SYSTEM CONSTRUCTION
21
22
2
C1 4 A1
B1
C2 5 A2
B2 23
3
C3 6 A3 1
B3
C4 7 A4
B4
28
26
8 9 10 11 24
31
16
27
25
30
12 13 14 15 17
18
19
20 29
A1: Fuel injector No.1 control signal from ECM 4. Fuel control relay No.1 19. Shut off valve of CNG pressure regulator
A2: Fuel injector No.2 control signal from ECM 5. Fuel control relay No.2 20. CNG receptacle switch
A3: Fuel injector No.3 control signal from ECM 6. Fuel control relay No.3 21. Fuel selector switch
A4: Fuel injector No.4 control signal from ECM 7. Fuel control relay No.4 22. Fuel tank
B1: Petrol fuel injector No.1 control signal 8. Petrol fuel injector No.1 23. CNG cylinder
B2: Petrol fuel injector No.2 control signal 9. Petrol fuel injector No.2 24. CNG cylinder valve
B3: Petrol fuel injector No.3 control signal 10. Petrol fuel injector No.3 25. Shut off valve of CNG cylinder
B4: Petrol fuel injector No.4 control signal 11. Petrol fuel injector No.4 26. Manual CNG cylinder valve
C1: CNG fuel injector No.1 control signal 12. CNG fuel injector No.1 27. CNG fuel delivery pipe
C2: CNG fuel injector No.2 control signal 13. CNG fuel injector No.2 28. Petrol fuel delivery pipe
C3: CNG fuel injector No.3 control signal 14. CNG fuel injector No.3 29. CNG receptacle
C4: CNG fuel injector No.4 control signal 15. CNG fuel injector No.4 30. CNG fuel filter
1. ECM 16. CNG pressure-and-temperature sensor 31. CNG valve control relay
2. CNG control module 17. CNG pressure regulator
3. CPU 18. CNG cylinder pressure sensor
BI-FUEL CNG SYSTEM COMPONENTS CNG Shut Off Valve Power Supply Control
DESCRIPTION CNG control module drives CNG valve control relay for
Bi-fuel CNG system consists of the following power supply to shut off valve of CNG cylinder and shut
components. off valve of CNG pressure regulator.
CNG CONTROL MODULE CNG Shut Off Valve Control

CNG control module controls the fuel system as follows, During “Forced CNG MODE” or CNG control in “AUTO
based on the signals from ECM and sensors related to MODE”, CNG control module opens shut off valve of
CNG system. CNG cylinder and shut off valve of CNG pressure
regulator to supply CNG fuel, and closes them when
Fuel Injection Control “Petrol MODE” or petrol control in “AUTO MODE”
ECM and CNG control module judge the fuel system operating.
depending on the signal from fuel selector switch.
Therefore, CNG control module switches built-in four Starting Control
fuel control relays and controls petrol fuel injector or When CNG receptacle cap is open, CNG control module
CNG fuel injector. restrict fuel injection at engine cranking, and stop engine
idling at vehicle stopped. CNG warning lights blinks
under this control.
Indicator Control CNG CYLINDER PRESSURE SENSOR

• CNG control module calculates remaining CNG CNG cylinder pressure sensor installed in CNG pressure
amount in CNG cylinder based on CNG cylinder regulator senses CNG pressure in CNG cylinder. CNG
pressure sensor signal, and then indicates the control module detects remaining amount of CNG in the
remaining CNG amount by CNG pressure indicator on cylinder by monitoring the signal from this sensor.
fuel selector switch.
CNG RECEPTACLE SWITCH
• CNG control module determines fuel system based on
CNG receptacle switch detects open / close state of
signal from fuel selector switch and ECM, and then
CNG receptacle cap.
indicates selected fuel system by petrol / CNG
indicator on fuel selector switch.
SHUT OFF VALVE OF CNG CYLINDER
• CNG warning light lights up or blinks, when CNG Shut off valve is installed in CNG cylinder valve, and
control module detects malfunction in bi-fuel CNG opens and closes solenoid valve based on signals from
system. CNG control module to supply or to shut off CNG to
CNG fuel lines. For detail, refer to CNG CYLINDER
Fail Safe Control WITH VALVE in Section 6C1.
If CNG system cannot maintain the control, “Petrol
MODE” is only selected. CNG warning lights blinks FUEL SELECTOR SWITCH
under this control. Fuel selector switch, which is installed on instrument
panel, outputs on / off signal to CNG control module to
CNG PRESSURE-AND-TEMPERATURE SENSOR select operating mode among three modes. Selected
CNG pressure-and-temperature sensor detects CNG operating mode and remaining amount of CNG are
pressure and CNG temperature of CNG fuel delivery indicated by the indicator built in this switch. For detail,
pipe. refer to BI-FUEL SELECTOR SWITCH AND
INDICATOR (BI-FUEL CNG MODEL) in Section 8.
SHUT OFF VALVE OF CNG PRESSURE REGULATOR
Shut off valve is installed in CNG pressure regulator, and
opens and closes solenoid valve based on signals from
CNG control module to supply or to shut off CNG fuel to
CNG fuel delivery pipe. For detail, refer to CNG
PRESSURE REGULATOR in Section 6C1.
CAN COMMUNICATION SYSTEM DESCRIPTION

ECM (1), CNG control module (2) and combination meter (3) of this vehicle communicate control data between each
control module.
Communication of each control module is established by CAN (Controller Area Network) communication system.
1 3
4
2
[A]
[A]: CAN communication line 4. DLC
CAN communication system uses the serial communication in which data is transmitted at a high speed. It uses a
twisted pair of two communication lines for the high-speed data transmission. As one of its characteristics, multiple
control modules can communicate simultaneously. In addition, it has a function to detect a communication error
automatically. Each module reads necessary data from the received data and transmits data.
CAN COMMUNICATION SYSTEM TRANSMITTING AND RECEIVING DATA TABLE

ECM Combination meter CNG control module
Engine speed signal T R —
ECM Combination meter CNG control module

MIL control signal T R —
Vehicle speed signal T R R
Engine coolant temperature signal T R R
Electric load signal R T —
CNG warning light control signal — R T
NOTE
• T (Transmitting): When two or more control modules start transmission at the same time, control
module transmitting the highest priority information gets transmission right and all other control
modules enter reception mode.
• R (Receiving): All control modules connected with CAN communication lines receive all information
on CAN communication line. Each control module selects only what is necessary and use it for its
control function.
AIR INTAKE SYSTEM DESCRIPTION

Refer to AIR INTAKE SYSTEM DESCRIPTION in Section 6E.
FUEL SYSTEM DESCRIPTION

This model employs a bi-fuel system capable of utilizing two kinds of fuel, petrol and CNG appropriately.
This system operates in three fuel modes: “Petrol MODE”, “Forced CNG MODE” and “AUTO MODE”, each of which
can be selected with the fuel selector switch.
For more information on the system control, refer to BI-FUEL CNG SYSTEM DESCRIPTION in this section.
Petrol and CNG fuel systems contain the following principle components respectively.
• Petrol fuel system
Fuel tank, fuel pump assembly (with built-in petrol fuel pressure regulator), petrol fuel filter, petrol fuel delivery pipe,
petrol fuel injectors, petrol fuel feed line, fuel return line and fuel vapor line.
• CNG fuel system
CNG receptacle, CNG cylinder, CNG cylinder valve, CNG cylinder pressure gauge, CNG pressure regulator, CNG
fuel filter, CNG fuel injector assembly and CNG fuel feed line.
FUEL DELIVERY SYSTEM DESCRIPTION

PETROL DELIVERY SYSTEM
Refer to FUEL DELIVERY SYSTEM in related manual.
CNG DELIVERY SYSTEM

Gas contained in the CNG cylinder passes through the CNG fuel pipe to the CNG pressure regulator when the shut-off
valve of the CNG cylinder valve is opened.
High pressure gas is decompressed to a suitable pressure for CNG fuel injection by the CNG pressure regulator. The
decompressed gas passes through the CNG fuel filter in order to remove oil, etc. The gas is then injected from CNG
fuel injector.
ELECTRONIC CONTROL SYSTEM DESCRIPTION

The electronic control system consists of various sensors, switches, ECUs which detect the state of engine and driving
conditions, ECM / CNG control module which controls various electric control devices according to the signals from
various sensors and various electric control devices.
Functionally, it is divided into the following subsystems:
ECM
• Fuel injection control system
• Ignition control system
• Fuel pump control system
• Radiator cooling fan control system
• Evaporative emission control system
• HO2S heater control system
• A/C control system
• EGR system
• Controller (computer) communication
CNG CONTROL MODULE

• Fuel select control
• Petrol injection control
• CNG injection control
• Starting control
• CNG shut off valve control
• Controller (computer) communication
Especially, ECM, CNG control module and combination meter intercommunicate by means of CAN communication.
Refer to ENGINE AND EMISSION CONTROL SYSTEM FLOW DIAGRAM and ENGINE CONTROL SYSTEM
CIRCUIT DIAGRAM in this section.
ENGINE AND EMISSION CONTROL INPUT / OUTPUT TABLE

ECM
Function Output Input

• Ignition switch
• Starter switch
• ECT sensor
• CKP sensor
• CMP sensor
• TP sensor
Injection control CNG control module • MAP sensor
• IAT sensor
• HO2S
• Battery voltage
• VSS
• CNG control module

• Ignition switch
• Starter switch
• ECT sensor
• CKP sensor
• CMP sensor
• TP sensor
Ignition control Ignition coil assembly
• MAP sensor
• IAT sensor
• Knock sensor
• Battery voltage
• VSS
• Ignition switch
• Starter switch
• ECT sensor
• CKP sensor
• TP sensor
• MAP sensor
Idle air control IAC valve
• IAT sensor
• Generator
• Battery voltage
• VSS
• Ignition switch
• Starter switch
• ECT sensor
HO2S heater control HO2S • CKP sensor
• MAP sensor
• IAT sensor
• Battery voltage
• Ignition switch
• ECT sensor
• CKP sensor
EVAP canister purge • TP sensor
EVAP purge control
valve • MAP sensor
• IAT sensor
• HO2S
• VSS
• Ignition switch
• IAT sensor
• ECT sensor
• CKP sensor
EGR control EGR valve
• TP sensor
• MAP sensor
• VSS
• Battery voltage

• Ignition switch
• Starter switch
• ECT sensor
• MAP sensor
A/C compressor control A/C compressor relay • CKP sensor
• TP sensor
• A/C switch
• A/C evaporator outlet air temperature sensor
• VSS
• Ignition switch
A/C condenser fan control A/C condenser fan relay • A/C switch
• ECT sensor
• Ignition switch
Radiator cooling fan • ECT sensor
Radiator cooling fan control
relay • CKP sensor
• VSS
• Ignition switch
• Starter switch
Fuel pump control Fuel pump relay
• CKP sensor
Starting motor control relay Starting motor control
control relay • Ignition switch
Main relay control Main relay
CNG CONTROL MODULE

• Ignition switch
• ECT sensor
• CKP sensor
• CMP sensor
• IAT sensor
Fuel select control ECM
• TP sensor
• HO2S
• CNG pressure-and-temperature sensor
• Fuel selector switch
• Battery voltage
• Ignition switch
Petrol injection control Petrol fuel injector
• CNG receptacle switch
• ECM
• Ignition switch
• ECT sensor
• MAP sensor
CNG injection control CNG fuel injector • CNG pressure-and-temperature sensor
• CNG receptacle switch
• ECM
Petrol fuel injector / CNG • Ignition switch
Starting control
fuel injector • CNG receptacle switch

Shut off valve of CNG • Ignition switch
CNG shut off valve control pressure regulator / • Fuel selector switch
CNG cylinder valve • CNG valve control relay
SCHEMATIC AND ROUTING DIAGRAM

ENGINE AND EMISSION CONTROL SYSTEM DIAGRAM
30
28
32
35
27
31
23
21
22
24
25
33
29
26
34
20
38
40
41
42
36
43
39
45
6
18
17
44
37
12
11
13
46
9
14
10
5
3
15
47
19
1
48
16
2
7
1. Air cleaner 17. Ignition coil assembly 33. Ignition switch

2. IAT sensor 18. VSS 34. Main relay
3. IAC valve 19. EGR valve 35. Starting magnetic switch
4. Throttle body 20. ECM 36. CNG control module
5. TP sensor 21. Electric load 37. CNG fuel injector
6. MAP sensor 22. A/C evaporator outlet air temp. sensor 38. Fuel selector switch
7. EVAP canister 23. A/C switch 39. CNG valve control relay
8. EVAP canister purge valve 24. A/C compressor relay 40. CNG pressure-and-temperature sensor
9. PCV valve 25. A/C condenser fan relay 41. CNG pressure regulator
10. CMP sensor 26. Combination meter 42. CNG cylinder pressure sensor
11. Petrol fuel injector 27. Battery 43. Shut off valve of CNG pressure regulator
12. ECT sensor 28. DLC 44. CNG cylinder valve
13. Knock sensor 29. Radiator cooling fan 45. Shut off valve of CNG cylinder
14. CKP sensor 30. Brake light 46. CNG cylinder
15. HO2S 31. Starting motor control relay 47. CNG receptacle switch
16. Fuel pump 32. Brake light switch 48. CNG receptacle
NOTE
Electric signal Air Vapor
CAN signal Exhaust gas Fuel (Petrol)

Fuel (CNG)
MAP EGR
sensor valve Exhaust Three way Exhaust
IAC Engine manifold catalyst pipe
valve
Intake manifold
Throttle HO2S
body assembly CMP CKP Knock Ignition coil
TP Petrol fuel CNG fuel sensor sensor sensor with igniter
sensor injector injector ECT sensor
Air cleaner EVAP EVAP

canister canister
IAT purge Fuel
sensor valve pump CNG fuel delivery pipe CNG pressure regulator
CNG pressure-and- CNG cylinder pressure sensor
Fuel tank temperature sensor
ENGINE CONTROL SYSTEM CIRCUIT DIAGRAM

Shut off valve
Shut off valve

ECM
CNG cylinder valve
CNG Cylinder
ENGINE AND EMISSION CONTROL SYSTEM FLOW DIAGRAM
A/C compressor CNG valve Fuel CNG

VSS relay selector receptacle
control relay switch switch
Combination meter
· MIL A/C condenser
A/C switch
· CNG warning light fan relay
· Coolant temperature
· Speedometer Brake light CNG control module
· Odometer switch Radiator cooling
fan relay
Starting motor
DLC
A/C evaporator
outlet air temp sensor
For identification of each cylinder, refer to STATEMENT ON CLEANLINESS AND CARE in Section 6.
ECM
1
+B
2 L69-5 Br/B a
L69-4 Br b
G/R L70-34
B
L69-3 Br/W c
3 10
Br L70-35 L69-2 Br/Y d
+B
Y L70-27
24
B L70-26 L69-14 G/Y
4
Lg/B L70-14 25
L69-8 Or IG1
Lg/R L70-6
5
Gr/Bl L70-15 26
L69-13 P/Bl
6 Lg/R L70-20 P
Gr/R L70-12
7 27
Lg L70-13
B
Bl/Y L70-31 28
L69-12 R/G
+BB Bl/R
B/W 10 G L70-30 29
8 IG2
R L70-16 B
Bl L70-7
B L70-19 [A] 30
L69-11 P/Bl
Lg
9 10 31
Bl L70-8 32
B/W L70-9 L69-22 W
B L70-10 R/Bl
+BB
33
IG2
B
11 P/B L71-16
34
13 14
12 L69-29 W/B
35
IG1 [A]
L69-30 V
15
36
Or L71-3 L69-16 R/W
16 L69-17 R
17
W/B L71-7 L69-33 R/Bl
L69-34 R/Y
Bl/Y L71-33
+B
+BB
18 Y L70-32
L70-33 B/W
40
L71-6 W
+BB 37
19 20 41 IG2 42
L69-10 B/Or
IG1
G/W L71-1 L70-2 B/R ST
R L70-1 B/R 38 43
+BB
21
L71-5 B/Y
W
22
39
W/B L71-34 23
23
R/B L71-35 L70-4 B +
44
L69-7 B/Bl
e B/Y L70-29 L69-6 B/Bl
f Or L70-28
: 45 : 46 : 5V : 12V
[A]: A/C model 12. Blower motor 30. A/C compressor relay
a: To CNG control module “L76-12” 13. Blower motor resistor 31. A/C compressor magnet clutch
b: To CNG control module “L76-3” 14. Blower speed selector 32. A/C condenser fan relay
c: To CNG control module “L76-11” 15. A/C switch 33. A/C condenser fan motor
d: To CNG control module “L76-2” 16. Pressure switch 34. Ignition coil assembly No.1
e: To CNG control module “L77-25” 17. A/C evaporator outlet air temp. sensor 35. Ignition coil assembly No.2
f: To CNG control module “L77-33” 18. VSS 36. EGR valve
1. ECM 19. Brake light 37. Main relay
2. CMP sensor 20. Brake light switch 38. Starting motor control relay
3. CKP sensor 21. DLC 39. Starting motor
4. IAT sensor 22. Combination meter 40. “RADIO DOME” fuse
5. TP sensor 23. CAN driver 41. “IG METER” fuse
6. MAP sensor 24. EVAP canister purge valve 42. Ignition switch
7. ECT sensor 25. IAC valve 43. “ST SIG” fuse
8. HO2S 26. Fuel pump relay 44. Battery
9. Knock sensor 27. Fuel pump 45. Engine ground
10. Shield wire 28. Radiator cooling fan relay 46. Body ground
11. Blower motor relay 29. Radiator cooling fan motor
Terminal arrangement of ECM connector
[A]
L69 L70 L71
7 6 5 4 3 2 1 7 6 5 4 3 2 1 6 5 4 3 2 1
17 16 15 14 13 12 11 10 9 8 19 18 17 16 15 14 13 12 11 10 9 8 16 15 14 13 12 11 10 9 8 7
27 26 25 24 23 22 21 20 19 18 27 26 25 24 23 22 21 20 27 26 25 24 23 22 21 20 19 18 17 [a]
34 33 32 31 30 29 28 35 34 33 32 31 30 29 28 35 34 33 32 31 30 29 28
[A]: ECM connector (View: [a])
CONNECTOR L69 Terminal Circuit

Terminal Circuit L69-31 —
L69-1 — L69-32 —
L69-2 Fuel injector No.4 control circuit L69-33 EGR valve drive circuit 4
L69-3 Fuel injector No.3 control circuit L69-34 EGR valve drive circuit 3
L69-4 Fuel injector No.2 control circuit
L69-5 Fuel injector No.1 control circuit CONNECTOR L70
L69-6 ECM ground circuit Terminal Circuit
L69-7 ECM ground circuit L70-1 Main power supply circuit 2
L69-8 IAC valve control circuit L70-2 Main power supply circuit 1
L69-9 — L70-3 —
L69-10 Main relay drive circuit L70-4 ECM ground circuit
L69-11 A/C compressor relay drive circuit L70-5 —
L69-12 Radiator cooling fan relay drive circuit L70-6 TP sensor power supply circuit
L69-13 Fuel pump relay drive circuit L70-7 HO2S heater control circuit
L69-14 EVAP canister purge valve control circuit L70-8 Knock sensor signal circuit
L69-15 — L70-9 Knock sensor ground circuit
L69-16 EGR valve drive circuit 1 L70-10 Knock sensor shield ground circuit
L69-17 EGR valve drive circuit 2 L70-11 —
L69-18 — L70-12 MAP sensor signal circuit
L69-19 — L70-13 ECT sensor signal circuit
L69-20 — L70-14 IAT sensor signal circuit
L69-21 — L70-15 TP sensor signal circuit
L69-22 A/C condenser fan relay drive circuit L70-16 HO2S signal circuit
L69-23 — L70-17 —
L69-24 — L70-18 —
L69-25 — L70-19 HO2S shield ground circuit
L69-26 — L70-20 MAP sensor power supply circuit
L69-27 — L70-21 —
L69-28 — L70-22 —
L69-29 Ignition coil assembly No.1 control circuit L70-23 —
L69-30 Ignition coil assembly No.2 control circuit L70-24 —
Terminal Circuit
L70-25 —
L70-26 CKP sensor shield ground circuit
L70-27 CKP sensor ground circuit
L70-28 CAN (low) communication circuit to CNG
control module
L70-29 CAN (high) communication circuit to CNG
control module
L70-30 HO2S ground circuit
L70-31 Sensor ground circuit
L70-32 VSS signal circuit
L70-33 Ignition switch signal circuit
L70-34 CMP sensor signal circuit
L70-35 CKP sensor signal circuit
CONNECTOR L71
Terminal Circuit
L71-1 Brake light switch signal circuit
L71-2 —
L71-3 A/C switch input signal circuit
L71-4 —
L71-5 Starting motor control relay signal circuit
L71-6 Back-up power supply circuit
L71-7 A/C evaporator outlet air temp. sensor signal
circuit
L71-8 —
L71-9 —
L71-10 —
L71-11 —
L71-12 —
L71-13 —
L71-14 —
L71-15 —
L71-16 Blower motor signal circuit
L71-17 —
L71-18 —
L71-19 —
L71-20 —
L71-21 —
L71-22 —
L71-23 —
L71-24 —
L71-25 —
L71-26 —
L71-27 —
L71-28 —
L71-29 —
L71-30 —
L71-31 —
L71-32 —
L71-33 A/C evaporator outlet air temp. sensor
ground circuit
L71-34 CAN (high) communication circuit to
combination meter
L71-35 CAN (low) communication circuit to
combination meter
CNG CONTROL MODULE
+B
B/R
1
5 9
L77-6 Br/B
10 R/B
L77-1 Bl
a Br/B L76-12
6
L77-14 Br
11
L77-10 R/Bl
b Br L76-3
7
L77-5 Br/W
12
L77-18 G
c Br/W L76-11
8
L77-13 Br/Y
13
L77-27 Y
d Br/Y L76-2
12V 5V
3
B/G L76-5 L76-1 R/B
Bl/B L76-14 2
IG1
L76-10 R/B
Or L76-13
20
V L76-24
L76-21 B/W
4 14
G L76-6
L76-31 P
Lbl L76-15 B +BB2
L76-30 G
B/R L76-23
15 W/R
e L76-29 R B/W
B/Y L77-25 16
f Or L77-33
L76-22 Lg B
17
L76-4 Bl
18
L76-34 Bl/W
B/Bl L77-9
B/Bl L77-17 19
L76-26 P/B
B/Bl L77-26
: 21 : 22 : 5V : 12V
a: To ECM “L69-5” 2. CPU 9. “CNG” fuse 16. “CNG VLV” fuse

b: To ECM “L69-4” 3. CNG pressure-and-temperature 10. CNG fuel injector No.1 17. CNG valve control relay
sensor
c: To ECM “L69-3” 4. CNG cylinder pressure sensor 11. CNG fuel injector No.2 18. Shut off valve of CNG cylinder
d: To ECM “L69-2” 5. Petrol fuel injector No.1 12. CNG fuel injector No.3 19. Shut off valve of CNG pressure regulator
e: To ECM “L70-29” 6. Petrol fuel injector No.2 13. CNG fuel injector No.4 20. “IG METER” fuse
f: To ECM “L70-28” 7. Petrol fuel injector No.3 14. CNG receptacle switch 21. Engine ground
1. CNG control module 8. Petrol fuel injector No.4 15. Fuel selector switch 22. Body ground
Terminal Arrangement of CNG Control Module Connector
[A]
L76 L77
9 8 7 6 5 4 3 2 1 9 8 7 6
5 4 3 2 1
A
17 16 15 14 13 12 11 10 17 16 15 14 13 12 11 10
26 25 24 23 22 21 20 19 18 26 25 24 23 22 21 20 19 18
34 33 32 31 30 29 28 27 34 33 32 31 30 29 28 27
[A]: CNG control module connector (View: [a])
CONNECTOR L76 CONNECTOR L77

L76-1 Main power supply circuit 1 L77-1 CNG fuel injector No.1 control circuit
L76-2 Fuel injector No.4 control signal from ECM L77-2 —
circuit L77-3 —
circuit L77-5 Petrol fuel injector No.3 control circuit
L76-4 CNG valve control relay drive circuit L77-6 Petrol fuel injector No.1 control circuit
L76-5 CNG pressure-and-temperature sensor L77-7 —
power supply circuit L77-8 —
L76-6 CNG cylinder pressure sensor power supply L77-9 CNG control module ground circuit
circuit L77-10 CNG fuel injector No.2 control circuit
L76-7 — L77-11 —
L76-8 — L77-12 —
L76-9 — L77-13 Petrol fuel injector No.4 control circuit
L76-10 Main power supply circuit 2 L77-14 Petrol fuel injector No.2 control circuit
circuit L77-16 —
L76-12 Fuel injector No.1 control signal from ECM L77-17 CNG control module ground circuit
circuit L77-18 CNG fuel injector No.3 control circuit
L76-13 CNG temperature sensor signal circuit L77-19 —
L76-14 CNG pressure sensor signal circuit L77-20 —
L76-15 CNG cylinder pressure sensor signal circuit L77-21 —
L76-16 — L77-22 —
L76-17 — L77-23 —
L76-18 — L77-24 —
L76-19 — L77-25 CAN (high) communication circuit to ECM
L76-20 — L77-26 CNG control module ground circuit
L76-21 Ignition switch signal circuit L77-27 CNG fuel injector No.4 control circuit
L76-22 Fuel selector switch signal circuit L77-28 —
L76-23 CNG cylinder pressure sensor ground circuit L77-29 —
L76-24 CNG pressure-and-temperature sensor L77-30 —
ground circuit L77-31 —
L76-25 — L77-32 —
L76-26 Shut off valve of CNG pressure regulator L77-33 CAN (low) communication circuit to ECM
control circuit L77-34
L76-27 —
L76-28 —
L76-29 Fuel selector switch indicator signal circuit
L76-30 CNG receptacle switch No.2 signal circuit
L76-31 CNG receptacle switch No.1 signal circuit
L76-32 —
L76-33 —
L76-34 Shut off valve of CNG cylinder control circuit
COMPONENT LOCATION
ELECTRONIC CONTROL SYSTEM COMPONENT LOCATION
[3]
[q] [r]
13
[1]
[4]
5
[t]
[s]
[b] [c]
[d]
9
[2] [e]
[k] [g]
[f] [o]
[h] 10
[l]
[u]
[a]
[m] [i] 3
8
[j]
[n] [x]
12
[p]
2
7 [5]
11
[v]
14, [w]
Information sensors / switches Control device Others

1. Knock sensor [a]: EVAP canister purge valve [1]: ECM
2. CMP sensor [b]: Radiator cooling fan relay [2]: Relay box
3. IAT sensor [c]: Starting motor control relay [3]: Combination meter
4. Fuel pump [d]: Main relay [4]: DLC
5. Brake light switch [e]: Fuel pump relay [5]: CNG control module
6. ECT sensor [f]: CNG valve control relay
7. HO2S [g]: Petrol fuel injector No.1
8. MAP sensor [h]: Petrol fuel injector No.2
9. CKP sensor [i]: Petrol fuel injector No.3
10. Throttle body assembly (with TP sensor) [j]: Petrol fuel injector No.4
11. VSS [k]: CNG fuel injector No.1
12. CNG pressure-and-temperature sensor [l]: CNG fuel injector No.2
13. Fuel selector switch [m]: CNG fuel injector No.3
14. CNG cylinder pressure sensor (included in [n]: CNG fuel injector No.4
CNG pressure regulator)
[o]: Ignition coil assembly No.1
[p]: Ignition coil assembly No.2
[q]: MIL
[r]: CNG warning light
[s]: A/C compressor relay (if equipped)
[t]: A/C condenser fan relay (if equipped)
[u]: IAC valve
[v]: Shut off valve of CNG cylinder
(installed in CNG cylinder valve)
[w]: Shut off valve of CNG pressure
regulator (installed in CNG pressure
regulator)
[x]: EGR valve
DIAGNOSTIC INFORMATION AND PROCEDURES
MALFUNCTION INDICATOR LAMP (MIL) CHECK

Refer to MALFUNCTION INDICATOR LAMP (MIL) 1
CHECK in Section 6E.
CNG WARNING LIGHT CHECK

1) Turn ignition switch to ON position (with engine
stopped) and check that CNG warning light (1) lights
for approx. 2 sec. and then turns OFF.
If CNG warning light does not light up (or CNG
warning light dims), go to CNG WARNING LIGHT
DOES NOT COME ON WITH IGNITION SWITCH IN
ON POSITION AND ENGINE STOPPED model for
troubleshooting.
2) Start engine and check that CNG warning light turns
OFF. DTC CHECK
If CNG warning light remains ON and no DTC is ECM
stored in CNG control module, go to CNG Refer to DTC CHECK in Section 6E.
WARNING LIGHT REMAINS ON AFTER ENGINE
STARTS for troubleshooting.
CNG CONTROL MODULE operator’s manual for details.

If communication between scan tool and CNG
NOTE
control module is not possible, go to
In case that CNG warning light lights while TROUBLESHOOTING FOR COMMUNICATION
engine is running, the malfunction(s) is ERROR WITH SCAN TOOL in this section.
detected by CNG control module and it 4) After completing the clearance, turn off ignition
stores the trouble information (DTC, freeze switch and disconnect scan tool from DLC.
frame data, etc.) in its memory.
NOTE
1) Prepare CAN communication OBD generic scan tool
DTC and freeze frame data stored in CNG
or SUZUKI scan tool.
control module memory are also cleared in
Special tool the following cases. Be careful not to clear
(A): SUZUKI scan tool (SUZUKI-SDT) them before recording them.
2) With ignition switch turned OFF, connect CAN • When power to CNG control module is cut
communication OBD generic scan tool or SUZUKI off (by disconnecting battery cable,
scan tool to DLC (1) located on underside of removing fuse or disconnecting CNG
instrument panel at driver’s seat side. control module (connectors)).
• When the same malfunction (DTC) is not
detected again during 40 engine warm-up
cycles (refer to WARM-UP CYCLE of ON-
BOARD DIAGNOSTIC (OBD) SYSTEM
DESCRIPTION in this section).
(A)
3) Turn ignition switch to ON position and confirm that

CNG warning light lights.
4) Read DTC and freeze frame data according to
instructions displayed on scan tool and print them or
write them down. Refer to scan tool operator’s
manual for details.
If communication between scan tool and ECM is not
possible, go to TROUBLESHOOTING FOR CAN-
DTC.
5) After completing the check, turn off ignition switch
and disconnect scan tool from DLC.
DTC CLEARANCE
ECM
Refer to DTC CLEARANCE in section 6E.
CNG CONTROL MODULE
1) With ignition switch turned off, connect CAN

communication OBD generic scan tool or SUZUKI
scan tool to DLC.
2) Turn ignition switch to ON position.
3) Erase DTC and pending DTC according to
instructions displayed on scan tool. Freeze frame
data is cleared together with DTC. Refer to scan tool
TROUBLESHOOTING FOR COMMUNICATION ERROR WITH SCAN TOOL

Refer to TROUBLESHOOTING FOR CAN-DTC in this section.
DTC TABLE
ECM
DTC
DTC DTC name DTC detecting condition detection MIL
logic
Voltage of HO2S heater circuit is lower than
HO2S Heater Control Circuit specification for more than 5 sec. even though
P0031 2 D/C Applicable
Low control duty of HO2S heater is lower than 75% with
engine running.
Voltage of HO2S heater circuit is higher than
HO2S Heater Control Circuit specification for more than 5 sec. even though
High control duty of HO2S heater is higher than 25%
with engine running.
Manifold Absolute Pressure /
Voltage of MAP sensor signal circuit is lower than
P0107 Barometric Pressure Circuit 2 D/C Applicable
0.2 V for 5 sec.
Low
Manifold Absolute Pressure /
Voltage of MAP sensor signal circuit is higher than
P0108 Barometric Pressure Circuit 2 D/C Applicable
4.7 V for 5 sec.
High
Intake Air Temperature Sensor Voltage of IAT sensor signal circuit is lower than
1 Circuit Low 0.15 V for 5 sec.
Intake Air Temperature Sensor Voltage of IAT sensor signal circuit is higher than
1 Circuit High 4.85 V for 5 sec.
Engine Coolant Temperature Voltage of ECT sensor signal circuit is lower than
Sensor 1 Circuit Low 0.15 V for 5 sec.
Engine Coolant Temperature Voltage of ECT sensor signal circuit is higher than
Sensor 1 Circuit High 4.85 V for 5 sec.
Throttle / Pedal Position Voltage of TP sensor signal circuit is lower than 0.1
Sensor / Switch “A” Circuit Low V for 5 sec.
Throttle / Pedal Position
Voltage of TP sensor signal circuit is higher than
P0123 Sensor / Switch “A” Circuit 2 D/C Applicable
4.7 V for 5 sec.
High
This DTC is detected if any one of the following
conditions is met.
• Circuit voltage of HO2S is lower than 0.3 V for
more than specified time continuously with
P0130 O2 Sensor Circuit 2 D/C Applicable
engine running.
• Circuit voltage of HO2S is higher than 0.6 V for
more than specified time continuously with
engine running.
Voltage of knock sensor signal circuit is lower than
P0327 Knock Sensor 1 Circuit Low 2 D/C Applicable
1.23 V for 5 sec.
Voltage of knock sensor signal circuit is higher than
P0328 Knock Sensor 1 Circuit High 2 D/C Applicable
3.91 V for 5 sec.
Crankshaft Position Sensor “A” Output signal of CKP sensor is not input for 2 sec.
Circuit even if starter switch ON signal is input.
DTC
DTC DTC name DTC detecting condition detection MIL
logic
conditions is met.
• CMP sensor generates less than 3 pulses per 6
revolutions of crankshaft from engine start.
Camshaft Position Sensor “A”
P0340 • CMP sensor generates no pulse per 6 2 D/C Applicable
Circuit
revolutions of crankshaft.
• CMP sensor generates no pulse between BTDC
75° and BTDC 5° within crankshaft 6 revolutions
from engine start.
Exhaust Gas Recirculation “A” Any one of monitor signals of EGR valve is low
Control Circuit level (ON) for 1 sec. when command signal is OFF.
Duty pulse monitor signal of EVAP canister purge
Evaporative Emission System
P0443 valve control circuit is different from its command 2 D/C Applicable
Purge Control Valve Circuit
duty signal for 5 sec. (circuit open or short)
Monitor voltage of radiator cooling fan relay output Not
P0480 Fan 1 Control Circuit 2 D/C
is different from its command signal for 5 sec. applicable
Monitor voltage of A/C condenser fan relay output Not
P0482 Fan 3 Control Circuit 2 D/C
is different from its command signal for 5 sec. applicable
Vehicle speed signal is not input although fuel is
P0500 Vehicle Speed Sensor “A” kept cut for 4 sec. or more at deceleration in lower 2 D/C Applicable
than 3,600 rpm.
IAC control duty pulse is not detected as its
P0505 Idle Air Control System 2 D/C Applicable
monitor signal.
Voltage of backup power supply circuit is lower
P0560 System Voltage 2 D/C Applicable
than specification for 5 sec.
Internal Control Module
P0601 Data writing error or check sum error. 2 D/C Applicable
Memory Check Sum Error
Control Module Programming Not
P0602 Data programming error. 1 D/C
Error applicable
Starter switch ON signal is not input even when
P0616 Starter Relay Circuit Low 2 D/C Applicable
cranking engine.
Starter switch ON signal is input for more than 180
P0617 Starter Relay Circuit High 2 D/C Applicable
sec. after engine has started.
Control Module Transmitting or receiving error of ECM for specified Not
U0073 1 D/C
Communication Bus “A” Off time continuously. applicable
Lost Communication With
Receiving error of ECM from CNG control module
U0108 Alternative Fuel Control 1 D/C Applicable
for specified time continuously.
Module
Lost Communication With
Not
U0155 Instrument Panel Cluster (IPC) ECM lost communication with combination meter. 1 D/C
applicable
Control Module
CNG CONTROL MODULE
NOTE
When DTC with asterisk (*) No. in the following table is detected, CNG warning light blinks.
DTC CNG
DTC DTC name DTC detecting condition detection warning
logic light
Monitor voltage of shut off valve of CNG pressure
Fuel Shutoff Valve “A” Control regulator is lower than specified voltage for 5 sec.
P0005* 1 D/C Applicable
Circuit / Open only if its command signal is not output and CNG
valve control relay is ON.
DTC CNG
logic light
Monitor voltage of shut off valve of CNG pressure
Fuel Shutoff Valve “A” Control regulator is higher than specified voltage for 5 sec.
Circuit High only if its command signal is output and CNG valve
control relay is ON.
Fuel Temperature Sensor “A” Voltage of CNG temperature sensor signal circuit is
Circuit Low lower than 0.1 V for 5 sec.
Fuel Temperature Sensor “A” Voltage of CNG temperature sensor signal circuit is
Circuit High higher than 4.9 V for 5 sec.
Fuel Rail Pressure Sensor “A” Voltage of CNG pressure sensor signal circuit is
Circuit Low lower than 0.15 V for 5 sec.
Fuel Rail Pressure Sensor “A” Voltage of CNG pressure sensor signal circuit is
Circuit High higher than 4.9 V for 5 sec.
Monitor voltage of CNG fuel injector No.1 is lower
Injector Circuit / Open -
P0201 than specified voltage for 5 sec. even if its 2 D/C Applicable
Cylinder 1
command signal is not output.
Cylinder 2
Cylinder 3
Cylinder 4
Internal Control Module CNG control module internal failure related to
Memory Check Sum Error check sum.
Control Module Programming CNG control module internal failure. (data Not
P0602 1 D/C
Error programming error) applicable
conditions is met.
• Monitor voltage of CNG valve control relay is
lower than specified voltage for 3 sec. even if its
P0607* Control Module Performance 1 D/C Applicable
command signal is output.
• Monitor voltage of CNG valve control relay is
higher than specified voltage for 3 sec. even if its
conditions is met.
• Monitor signal of either of fuel control relays is in
Fuel Injector Control Module “Petrol” side for 5 sec. with engine running on
Relay Control CNG.
• Monitor signal of either of fuel control relays is in
“CNG” side for 5 sec. with engine running on
petrol.
Internal Control Module CNG control module internal failure. (EEPROM Not
P062F 2 D/C
EEPROM Error error) applicable
Remaining CNG Pressure Voltage of CNG cylinder pressure sensor signal
Sensor Low Voltage circuit is lower than 0.1 V for 5 sec.
Remaining CNG Pressure Voltage of CNG cylinder pressure sensor signal
Sensor High Voltage circuit is higher than 4.9 V for 5 sec.
DTC CNG
logic light
conditions is met.
• The state of changing over “Petrol” to “CNG” is
P1601* Monitor Circuit Fault 1 D/C Applicable
detected continuously for 5 sec.
• The state of changing over “CNG” to “Petrol” is
detected continuously for 5 sec.
conditions is met.
Fuel Cap Sensor / Switch • Both CNG receptacle switch No.1 and No.2 ON
Circuit signals are input simultaneously for 5 sec.
• Both CNG receptacle switch No.1 and No.2 OFF
signals are input simultaneously for 5 sec.
Monitor voltage of shut off valve of CNG cylinder is
Fuel Shutoff Valve “B” Control lower than specified voltage for 5 sec. only if its
Circuit / Open command signal is not output and CNG valve
control relay is ON.
Monitor voltage of shut off valve of CNG cylinder is
Fuel Shutoff Valve “B” Control higher than specified voltage for 5 sec. only if its
Circuit High command signal is output and CNG valve control
relay is ON.
Fuel Mode Indicator Lamp Fuel selector switch ON signal is input
Control Circuit continuously for more than 120 sec.
Control Module Transmitting and receiving error of ECM for
U0073* 1 D/C Applicable
Communication Bus “A” Off specified time continuously
Receiving error of CNG control module from ECM
U0100* Lost Communication with ECM 1 D/C Applicable
for specified time continuously.
FAIL-SAFE TABLE
ECM
When any of the following DTCs is detected, ECM enters fail-safe mode as long as malfunction continues to exist but
that mode is canceled when ECM detects normal condition.
DTC DTC name Fail-safe operation
P0031 HO2S Heater Control Circuit Low
—
P0032 HO2S Heater Control Circuit High
Manifold Absolute Pressure / Barometric • ECM presumes MAP by engine speed and throttle
P0107
Pressure Circuit Low position.
• ECM controls actuators assuming that barometric
Manifold Absolute Pressure / Barometric
P0108 Pressure is 101 kPa.
Pressure Circuit High
• ECM stops controls related to MAP sensor.
P0112 Intake Air Temperature Sensor 1 Circuit Low ECM controls actuators assuming that intake air
temperature is 20 qC (68 qF).
P0113 Intake Air Temperature Sensor 1 Circuit High
• ECM stops controls related to IAT sensor.
Engine Coolant Temperature Sensor 1 Circuit • ECM controls actuators assuming that engine coolant
P0117
Low temperature is 80 qC (176 qF).
Engine Coolant Temperature Sensor 1 Circuit • ECM operates radiator cooling fan.
P0118
High • ECM stops controls related to ECT sensor.
Throttle / Pedal Position Sensor / Switch “A” • ECM controls actuators assuming that throttle
P0122
Circuit Low opening is about 20q.
Throttle / Pedal Position Sensor / Switch “A”
P0123 • ECM stops controls related to TP sensor.
Circuit High
P0130 O2 Sensor Circuit • ECM stops controls related to HO2S.
P0327 Knock Sensor 1 Circuit Low
• ECM stops controls related to knock sensor.
P0328 Knock Sensor 1 Circuit High

P0335 Crankshaft Position Sensor “A” Circuit • ECM controls fuel cut at specified engine speed.
• ECM controls fuel cut at specified engine speed.
P0340 Camshaft Position Sensor “A” Circuit
• ECM stops controls related to knock sensor.
P0403 Exhaust Gas Recirculation “A” Control Circuit • ECM stops controls related to EGR valve control.
Evaporative Emission System Purge Control
P0443
Valve Circuit
—
P0480 Fan 1 Control Circuit
P0482 Fan 3 Control Circuit
• ECM stops controls related to VSS.
P0500 Vehicle Speed Sensor “A” • ECM controls actuators assuming that vehicle speed
is 0 km/h (0 mile/h).
P0505 Idle Air Control System
P0560 System Voltage
Internal Control Module Memory Check Sum
P0601
Error
P0602 Control Module Programming Error
P0616 Starter Relay Circuit Low
—
P0617 Starter Relay Circuit High
U0073 Control Module Communication Bus “A” Off
Lost Communication With Alternative Fuel
U0108
Control Module
Lost Communication With Instrument Panel
U0155
Cluster (IPC) Control Module
CNG CONTROL MODULE

When any of the following DTCs is detected, CNG control module enters fail-safe mode as long as malfunction
continues to exist but that mode is canceled when CNG control module detects normal condition.
NOTE
When CNG control is stopped by fail-safe control, CNG warning light blinks.

P0005 Fuel Shutoff Valve “A” Control Circuit / Open • CNG control module closes shut off valve of CNG
cylinder.
P0007 Fuel Shutoff Valve “A” Control Circuit High • CNG control module stops CNG control and then
shifts to “Petrol MODE”.
P0182 Fuel Temperature Sensor “A” Circuit Low CNG control module controls engine assuming that
P0183 Fuel Temperature Sensor “A” Circuit High CNG temperature is 50 qC (122 qF).
P0192 Fuel Rail Pressure Sensor “A” Circuit Low CNG control module controls engine assuming that
CNG pressure is MAP (Manifold Absolute Pressure) +
P0193 Fuel Rail Pressure Sensor “A” Circuit High
190 kPa.
P0201 Injector Circuit / Open - Cylinder 1 —
Internal Control Module Memory Check Sum
P0601 —
Error
P0602 Control Module Programming Error —
CNG control module stops CNG control and then shifts
P0607 Control Module Performance
to “Petrol MODE”.
P0612 Fuel Injector Control Module Relay Control —
P062F Internal Control Module EEPROM Error —
P1432 Remaining CNG Pressure Sensor Low Voltage
CNG control module stops CNG residual quantity
Remaining CNG Pressure Sensor High
P1433 indication.
Voltage
CNG control module stops CNG control and then shifts
P1601 Monitor Circuit Fault
to “Petrol MODE”.

P2408 Fuel Cap Sensor / Switch Circuit —
P2665 Fuel Shutoff Valve “B” Control Circuit / Open • CNG control module closes shut off valve of CNG
pressure regulator.
P2667 Fuel Shutoff Valve “B” Control Circuit High • CNG control module stops CNG control and then
shifts to “Petrol MODE”.
P2668 Fuel Mode Indicator Lamp Control Circuit —
U0073 Control Module Communication Bus Off CNG control module stops CNG control and then shifts
U0100 Lost Communication with ECM to “Petrol MODE”.
SCAN TOOL DATA
ECM
As the data values are standard values estimated on the basis of values obtained from the normally operating vehicles
by using a scan tool, use them as reference values. Even when the vehicle is in good condition, there may be cases
where the checked value does not fall within each specified data range. Therefore, judgment as abnormal should not
be made by checking with these data alone.
Also, conditions that can be checked by the scan tool are those detected by ECM and output from ECM as commands
and there may be cases where the engine or actuator is not operating (in the condition) as indicated by the scan tool.
Be sure to use the timing light to check the ignition timing.
NOTE
• When checking the data with the engine running at idle or racing, be sure to place gear shift lever in
“Neutral” and pull the parking brake fully. Also, if nothing or “no load” is indicated, turn OFF A/C, all
electric loads, all the other switches.
• For the detail of items, refer to SCAN TOOL DATA DEFINITIONS.
Normal condition /
Scan tool data Vehicle condition
reference value
–5 qC(–9 qF) +
• Engine condition: Idle speed after warm-up environmental temperature
CNG Temperature
• Fuel select mode: Forced CNG MODE to 40 qC (72 qF) +
environmental temperature
• Engine condition: Idle speed after warm-up
CNG Pressure Approx. 200 to 265 kPa
• Fuel select mode: Forced CNG MODE
Engine condition: ETC > 20 qC, No DTC, while engine
OL (open loop)
warming up
Open-loop due to driving conditions (Power enrichment,
OL-Drive (open loop)
Fuel System etc.)
Open-loop due to system fault detection OL-Fault (open loop)
Closed-loop using HO2S as feedback for fuel control CL (closed loop)
When engine stops with ignition switch ON —
Short Term Fuel Trim Specified idle speed for 2 min. after warming up Approx. –10 – 10%
Long Term Fuel Trim Specified idle speed for 2 min. after warming up Approx. –10 – 10%
Total Fuel Trim Specified idle speed for 2 min. after warming up Approx. –20 – 20%
Inj Pulse Width Specified idle speed with no load after warming up Approx. 1.5 – 4.0 msec
Specified idle speed with no load after warming up 10 r 6q BTDC
Ignition Advance Ignition timing: Fix (using “Fixed Spark Control” of “Engine /
5q BTDC
Active Test” mode on scan tool)
Calculated Load Specified idle speed with no load after warming up Approx. 15 – 25%
• Radiator cooling fan: Stopping
Engine Speed • All electrical parts: OFF Approx. 750 – 850 rpm
• Shift lever: Neutral position
• Engine condition: Specified idle speed after warming up
• Radiator cooling fan: Stopping
Desired Idle Approx. 800 rpm
• All electrical parts: OFF
• Shift lever: Neutral position
Normal condition /
reference value
Value as the same as
Vehicle Speed Vehicle running
speedometer
MAP Specified idle speed with no load after warming up Approx. 25 – 40 kPa
Approx. 80 – 100 qC (176 –
ECT Specified idle speed after warming up
212 qF)
–5 qC (23 qF) +
Intake Air Temperature Specified idle speed after warming up
to 40 qC (104 qF) +
Barometric pressure is
Barometric Pres —
displayed.
EVAP Canist Prg Duty Engine condition: 2,000 rpm after warming up Approx. 10 – 30%
EGR Valve Opening Engine racing after warming up Approx. 10 – 30%
IAC Flow Duty Specified idle speed with no load after warming up Approx. 5 – 20%
• Engine condition: Stopped
0.6 – 1.0 V
• Accelerator pedal: Released
TP Sensor 1 Volt
3.7 – 4.2 V
• Accelerator pedal: Depressed fully
Approx. 0%
Throttle Position
88 – 100%
O2S B1 S1 2,000 rpm for 3 min. or more after warming up Approx. 0.1 – 0.9 V
Battery Voltage Specified idle speed Approx. 12 – 15 V
Fuel Tank Level Ignition switch: ON 0 – 100%
Engine condition: running on petrol Petrol
Type of Fuel
Engine condition: running on CNG CNG
• Engine condition: Specified idle speed with no load after
warm-up 0 msec
• Fuel select mode: Petrol MODE
Inj Pulse Width (CNG)
warm-up Approx. 3.5 – 5.5 msec
Fuel select mode: AUTO MODE Auto
Fuel Select Mode Fuel select mode: Petrol MODE Petrol
Fuel select mode: Forced CNG MODE CNG
Radiator cooling fan: ON ON
Radiator Fan
Radiator cooling fan: OFF OFF
A/C condenser fan: ON ON
A/C Cond Fan
A/C condenser fan: OFF OFF
• A/C switch: ON
ON
A/C Comp Relay • Blower fan switch: 1st speed position or more
A/C switch: OFF OFF
Engine running ON
Fuel Pump
Other than above condition OFF
Ignition switch: ST position (engine cranking) ON
Starter SW
• A/C switch: ON
ON
A/C Switch • Blower fan switch: 1st speed position or more
A/C switch: OFF OFF
Blower fan switch: 2nd or 3rd speed position ON
Blower Fan
Brake pedal: Depressed fully ON
Brake Switch
Brake pedal: Released OFF
Position light: ON ON
Electric Load 1
Position light: OFF OFF
Normal condition /
reference value
Position light: ON ON
Electric Load 2
Position light: OFF OFF
Specified idle speed after warming up OFF
Fuel Cut • Accelerator pedal: Released
ON
• Engine condition: 2,000 rpm or more after warming up
ON
Closed Throttle Pos
OFF
O2S B1 S1 Act Specified idle speed after warming up Active
SCAN TOOL DATA DEFINITIONS Inj Pulse Width (Fuel Injection Pulse Width, msec)
This parameter indicates injector drive pulse (valve
CNG Temperature (qC, qF) opening time) of No.1 (cylinder) petrol fuel injector
This parameter indicates the calculated CNG controlled by ECM.
temperature based on CNG temperature sensor signal.
Ignition Advance (Ignition Timing Advance for NO.1
CNG Pressure (kPa) Cylinder, q BTDC)
This parameter indicates the calculated CNG pressure in This parameter indicates the ignition timing of No.1
CNG fuel delivery pipe based on CNG pressure sensor cylinder commanded by ECM. The actual ignition timing
signal. should be checked using the timing light.
Fuel System (Fuel System Status) Calculated Load (Calculated Load Value, %)
This parameter indicates A/F ratio feedback loop status This parameter indicates the percentage of engine load
displayed as one of the following. calculated based on input signal to ECM from various
OL: Refers to Open-loop, namely, initial setting engine engine sensors.
running that has not yet satisfied engine conditions (ECT
> 20 qC, IAT, TP sensor / system = OK) to go feedback Engine Speed (rpm)
control This parameter indicates the calculated engine speed
CL: Closed-loop using HO2S as feedback for fuel control based on reference pulses from the camshaft position
OL-DRIVE: Open-loop due to driving conditions (Power sensor.
enrichment, etc.)
OL-FAULT: Open-loop due to detected system fault Desired Idle (Desired Idle Speed, rpm)
This parameter indicates the ECM internal parameter
Short Term Fuel Trim (%) which indicates the ECM requested idle. If the engine is
This parameter indicates the short term corrections of not running, this number is not valid.
the air / fuel mixture computation.
0%: No correction Vehicle Speed (km/h, MPH)
Above 0%: Enrichment correction This parameter indicates the calculated vehicle speed
Below 0%: Lean mixture correction based on VSS signal.
Long Term Fuel Trim (%) MAP (Manifold Absolute Pressure, kPa, inHg, inH2O,
This parameter indicates the long term corrections of the mmHg, psi)
air / fuel mixture computation. This parameter indicates the calculated manifold
0%: No correction pressure based on MAP sensor signal.
Above 0%: Enrichment correction
Below 0%: Lean mixture correction ECT (Engine Coolant Temperature, qC, qF)
This parameter indicates the calculated engine coolant
Total Fuel Trim (%) temperature based on ECT sensor signal.
This parameter indicates the calculated total fuel trim
value based on values of short term fuel trim and long Intake Air Temperature (qC, qF)
term fuel trim. This parameter indicates the calculated intake air
0%: No correction temperature based on IAT sensor signal.
Above 0%: Enrichment correction
Below 0%: Lean mixture correction
Barometric Pres (Barometric Pressure, kPa, inHg, Fuel Select Mode (Auto / Petrol / CNG)
inH2O, mmHg, psi) This parameter indicates the selected mode.
This parameter indicates the calculated barometric air Auto: AUTO MODE is selected.
pressure based on MAP sensor signal. Petrol: Petrol MODE is selected.
CNG: Forced CNG MODE is selected.
EVAP Canist Prg Duty (EVAP Canister Purge Flow
Duty, %) Radiator Fan (Radiator Cooling Fan Relay, ON / OFF)
This parameter indicates the calculated opening rate of This parameter indicates the state of radiator cooling fan
EVAP canister purge valve based on control signal of relay.
EVAP canister purge valve. ON: ON command being output to radiator cooling fan
0%: EVAP canister purge valve is fully closed relay
100%: EVAP canister purge valve is fully opened OFF: No command being output
EGR Valve Opening (%) A/C Cond Fan (A/C Condenser Fan Relay, ON / OFF)
This parameter indicates opening rate of EGR valve This parameter indicates the state of A/C condenser fan
which controls the amount of EGR flow. relay.
ON: ON command being output to A/C condenser fan
IAC Flow Duty (Idle Air Control Flow Duty, %) relay
This parameter indicates current flow time rate within a OFF: No command being output
certain set cycle of IAC valve (valve opening rate) which
controls the amount of bypass air (idle speed). A/C Comp Relay (A/C Compressor Relay, ON / OFF)
0%: Minimum idle air flow This parameter indicates the state of A/C compressor
100%: Maximum idle air flow relay.
ON: ON command being output to A/C compressor relay
TP Sensor 1 Volt (TP Sensor Output Voltage, V) OFF: No command being output
This parameter indicates the signal voltage of throttle
position sensor. Fuel Pump (Fuel Pump Relay, ON / OFF)
This parameter indicates the state of fuel pump relay.
Throttle Position (Absolute Throttle Position, %) ON: ON command being output to fuel pump relay
This parameter indicates the calculated opening OFF: No command being output
percentage of throttle valve based on signal voltage of
throttle position sensor. Starter SW (Starter Switch, ON / OFF)
0 – 5%: Throttle valve is fully closed This parameter indicates the state of starting motor relay.
90 – 100%: Throttle valve is fully opened ON: Starting motor control relay is ON
OFF: Starting motor control relay is OFF
O2S B1 S1 (HO2S, V)
This parameter indicates the output voltage of HO2S A/C Switch (ON / OFF)
installed on exhaust manifold (pre-TWC). This parameter indicates the state of A/C switch.
ON: A/C switch is ON
Battery Voltage (V) OFF: A/C switch is OFF
This parameter indicates the battery positive voltage
inputted from main relay to ECM. Blower Fan (ON / OFF)
This parameter indicates the state of the blower fan
Fuel Tank Level (%) motor switch.
This parameter indicates approximate fuel level in fuel
tank. As detectable range of fuel level sensor is set as 0 Brake Switch (ON / OFF)
to 100%. This parameter indicates the state of the brake switch.
ON: Brake pedal is depressed position
Type of Fuel (Petrol / CNG) OFF: Brake pedal is released position
This parameter indicates the state of fuel.
Petrol: Engine is running on petrol. Electric Load 1 (ON / OFF)
CNG: Engine is running on CNG. This parameter indicates the state of electrical load.
ON: Position light ON signal input
Inj Pulse Width (CNG) OFF: Above electric load turned OFF
This parameter indicates injector drive pulse (valve
opening time) of No.1 (cylinder) CNG fuel injector Electric Load 2 (ON / OFF)
controlled by CNG control module. This parameter indicates the state of electrical load.
ON: Position light ON signal input
OFF: Above electric load turned OFF
Fuel Cut (ON / OFF) ON: Throttle valve is at idle position (fully closed)
This parameter indicates state of fuel cut control. OFF: Throttle valve opens wider than the idle position
ON: Fuel being cut (output signal to petrol fuel injector is
stopped) O2S B1 S1 ACT (HO2S, Active / Inactive)
OFF: Fuel not being cut This parameter indicates the activation condition of
HO2S.
Closed Throttle Pos (Closed Throttle Position, ON /
OFF)
This parameter indicates the state of throttle valve
position.
CNG CONTROL MODULE

As the data values are standard values estimated on the basis of values obtained from the normally operating vehicles
by using a scan tool, use them as reference values. Even when the vehicle is in good condition, there may be cases
where the checked value does not fall within each specified data range. Therefore, judgment as abnormal should not
be made by checking with these data alone.
NOTE
When checking the data with the engine running at idle or racing, be sure to place gear shift lever in
“Neutral” and pull the parking brake fully.
Normal condition /
reference value
Inj Pulse Width #1
Inj Pulse Width #2
Inj Pulse Width #3
Inj Pulse Width #4
warm-up 0 msec
Normal condition /
reference value
warm-up 0 msec
warm-up 0 msec
warm-up 0 msec
Calculated Load Specified idle speed with no load after warm-up Approx. 20 to 40%
Engine condition: Specified idle speed after warm-up
Engine Speed All electrical parts: OFF Approx. 830 to 930 rpm
Shift lever: Neutral position
Vehicle Speed Vehicle running Vehicle speed is displayed.
MAP Specified idle speed with no load after warm-up Approx. 20 – 45 KPa
Approx. 80 – 100 qC (176 –
ECT Specified idle speed after warm-up
212 qF)
–5 qC (–9 qF) +
Intake Air Temperature Specified idle speed after warm-up
to 40 qC (72 qF) +
Approx. 0%
Throttle Position
90 – 100%
Fuel select mode: AUTO MODE Auto
Fuel Select Mode Fuel select mode: Petrol MODE Petrol
Fuel select mode: Forced CNG MODE CNG
Engine condition: Running on petrol Petrol
Fuel Running Status
Engine condition: Running on CNG CNG
–5 qC (–9 qF) +
• Engine condition: Idle speed after warm-up environmental temperature
CNG Temperature
• Fuel select mode: Forced CNG MODE to 40 qC (72 qF) +
CNG Pressure Approx. 200 to 265 KPa
CNG Injection Pressure Approx. 160 to 225 KPa
CNG pressure in CNG
CNG Cylinder Pressure Fuel select mode: Forced CNG MODE
cylinder is displayed.
Battery Voltage Engine condition: Idle speed Approx. 12 to 15 V
Ignition Switch Ignition switch: ON ON
Fuel selector switch: Pushed ON
Fuel Select Switch
Fuel selector switch: Not pushed OFF
CNG receptacle cap: Close ON
Fuel Filler Lid SW 1
CNG receptacle cap: Open OFF
Normal condition /
reference value
CNG receptacle cap: Close OFF
Fuel Filler Lid SW 2
CNG receptacle cap: Open ON
Fuel select mode: Petrol MODE OFF
Shut Off V Tank
Fuel select mode: Forced CNG MODE ON
Fuel select mode: Petrol MODE OFF
Shut Off V Reg
Fuel select mode: Forced CNG MODE ON
OFF
Power Supply Relay • Fuel select mode: Petrol MODE
Engine condition: Running ON
SCAN TOOL DATA DEFINITIONS Calculated Load (Calculated Load Value, %)

This parameter indicates the percentage of engine load
Inj Pulse Width #1 (Fuel Injection Pulse Width No.1, calculated based on input signal to ECM from various
msec.) engine sensors.
This parameter indicates time of the injector drive (valve
opening) pulse which is output from ECM. Engine Speed (rpm)
This parameter indicates the calculated engine speed
Inj Pulse Width #2 (Fuel Injection Pulse Width No.2, based on reference pulses from the camshaft position
msec.) sensor.
This parameter indicates time of the injector drive (valve
opening) pulse which is output from ECM. Vehicle Speed (km/h, MPH)
This parameter indicates the calculated vehicle speed
Inj Pulse Width #3 (Fuel Injection Pulse Width No.3, based on vehicle speed sensor signal.
msec.)
This parameter indicates time of the injector drive (valve MAP (Manifold Absolute Pressure, kPa, inHg, inH2O,
opening) pulse which is output from ECM. mmHg, psi)
This parameter indicates the calculated manifold
Inj Pulse Width #4 (Fuel Injection Pulse Width No.4, pressure based on MAP sensor signal.
msec.)
This parameter indicates time of the injector drive (valve ECT (Engine Coolant Temperature, qC, qF)
opening) pulse which is output from ECM. This parameter indicates the calculated engine coolant
temperature based on ECT sensor signal.
CNG Inj Pulse Width #1 (CNG Injection Pulse Width
No.1, msec.) Intake Air Temperature (qC, qF)
This parameter indicates time of CNG fuel injector drive This parameter indicates the calculated intake air
(valve opening) pulse which is output from CNG control temperature based on IAT sensor signal.
module.
Throttle Position (Absolute Throttle Position, %)
CNG Inj Pulse Width #2 (CNG Injection Pulse Width This parameter indicates the calculated opening
No.2, msec.) percentage of throttle valve based on signal voltage of
This parameter indicates time of CNG fuel injector drive throttle position sensor.
(valve opening) pulse which is output from CNG control 0 – 5%: Throttle valve is fully closed.
module. 90 – 100%: Throttle valve is fully opened.
CNG Inj Pulse Width #3 (CNG Injection Pulse Width Fuel Select Mode (Auto / Petrol / CNG)
No.3, msec.) This parameter indicates the state of fuel select mode.
This parameter indicates time of CNG fuel injector drive Auto: AUTO MODE is selected.
(valve opening) pulse which is output from CNG control Petrol: Petrol MODE is selected.
module. CNG: Forced CNG MODE is selected.
CNG Inj Pulse Width #4 (CNG Injection Pulse Width Fuel Running Status (Petrol / CNG)
No.4, msec.) This parameter indicates the state of fuel.
This parameter indicates time of CNG fuel injector drive Petrol: Engine is running on petrol.
(valve opening) pulse which is output from CNG control CNG: Engine is running on CNG.
module.
CNG Temperature (qC, qF)
This parameter indicates the calculated CNG
temperature based on CNG temperature sensor signal.
CNG Pressure (kPa)

This parameter indicates the calculated CNG pressure in
CNG fuel delivery pipe based on CNG pressure sensor
signal.
CNG Injection Pressure (kPa)

This parameter indicates the calculated CNG fuel
injector pressure based on CNG pressure-and-
temperature sensor signal and MAP sensor signal.
CNG Cylinder Pressure (kPa)

This parameter indicates the calculated CNG pressure in
CNG cylinder based on CNG cylinder pressure sensor
signal.
Battery Voltage (V)

This parameter indicates the battery positive voltage
inputted from main relay to ECM.
Ignition Switch (ON / OFF)

This parameter indicates the state of ignition switch.
Fuel Select Switch (ON / OFF)

This parameter indicates the state of fuel selector switch.
ON: Fuel selector switch is ON.
OFF: Fuel selector switch is OFF.
Fuel Filler Lid SW 1 (CNG Receptacle Switch 1 (ON /

OFF))
This parameter indicates the state of CNG receptacle
switch No.1.
ON: CNG receptacle cap is closed.
OFF: CNG receptacle cap is opened.
Fuel Filler Lid SW 2 (CNG Receptacle Switch 2, ON /

OFF))
This parameter indicates the state of CNG receptacle
switch No.2.
ON: CNG receptacle cap is opened.
OFF: CNG receptacle cap is closed.
Shut Off V Tank (Shut Off Valve Tank, ON / OFF)

This parameter indicates the state of shut off valve of
CNG cylinder.
ON: Shut off valve of CNG cylinder is opened.
OFF: Shut off valve of CNG cylinder is closed.
Shut Off V Reg (Shut Off Valve Regulator, ON / OFF)

This parameter indicates the state of shut off valve of
CNG pressure regulator.
ON: Shut off valve of CNG pressure regulator is opened.
OFF: Shut off valve of CNG pressure regulator is closed.
Power Supply Relay (CNG Valve Control Relay) (ON /

OFF)
This parameter indicates the state of CNG valve control
relay.
ON: CNG valve control relay is ON.
OFF: CNG valve control relay is OFF.
MIL DOES NOT COME ON WITH IGNITION SWITCH IN ON POSITION AND ENGINE STOPPED (BUT
ENGINE CAN BE STARTED)
Refer to MIL DOES NOT COME ON WITH IGNITION SWITCH IN ON POSITION AND ENGINE STOPPED (BUT
ENGINE CAN BE STARTED) in Section 6E.
MIL REMAINS ON AFTER ENGINE STARTS

Refer to MIL REMAINS ON AFTER ENGINE STARTS in Section 6E.
CNG WARNING LIGHT DOES NOT COME ON WITH IGNITION SWITCH IN ON POSITION AND
ENGINE STOPPED (BUT ENGINE CAN BE STARTED)
WIRING DIAGRAM
13 9 IG1
12 A1
10 7
L71-34 W/B G20-6 G20-1 R/B
L71-35 R/B G20-8
11
B1
G20-4 B
12 15
L70-29 B/Y L77-25 B/W
L76-21
L70-28 Or L77-33
5V 12V L77-9 B/Bl
L77-17 B/Bl 8
R/B L76-1 L77-26 B/Bl
12V R/B L76-10 5
14
3
L70-33 B/W
6
4
L69-10 B/Or
L70-1 B/R W
12V
5V L70-2 B/R
2
+
L69-6 B/BL 1
L69-7 B/Bl
L70-4 B
[A]
L76 L77
9 8 7 6 5 4 3 2 1 9 8 7 6
5 4 3 2 1
17 16 15 14 13 12 11 10 17 16 15 14 13 12 11 10
26 25 24 23 22 21 20 19 18 26 25 24 23 22 21 20 19 18 A
34 33 32 31 30 29 28 27 34 33 32 31 30 29 28 27
[B]
L69 L70 L71
7 6 5 4 3 2 1 7 6 5 4 3 2 1 6 5 4 3 2 1
17 16 15 14 13 12 11 10 9 8 19 18 17 16 15 14 13 12 11 10 9 8 16 15 14 13 12 11 10 9 8 7
27 26 25 24 23 22 21 20 19 18 27 26 25 24 23 22 21 20 27 26 25 24 23 22 21 20 19 18 17
34 33 32 31 30 29 28 35 34 33 32 31 30 29 28 35 34 33 32 31 30 29 28
[A]: CNG control module connector (View: A) 2. Main fuse box 7. “MTR” fuse 12. CAN communication line
[B]: ECM connector (View: A) 3. “IGN” fuse 8. “IG METER” fuse 13. ECM
A1: Combination meter power supply circuit 4. “FI” fuse 9. Combination meter 14. “CNG” fuse
B1: Combination meter ground circuit 5. Ignition switch 10. MIL 15. CNG control module
1. Battery 6. Main relay 11. CNG warning light
CIRCUIT DESCRIPTION
Operation (ON/OFF) of CNG warning light is controlled by CNG control module. If the CNG system is in good
condition, CNG control module turns CNG warning light on at the ignition switch on, keeps it on for approx. 2 sec. and
then turns it off. If an abnormality in the system is detected, CNG warning light remains on or blinks.
TROUBLESHOOTING
Step Action Yes No

1 CNG warning light power supply check Go to Step 2. Go to Step 4.
Do other warning lights come ON?

2 DTC check in ECM and CNG control module for CAN- Go to troubleshooting Go to Step 3.
DTC for applicable DTC.
1) Turn ignition switch to OFF position and then connect
scan tool to DLC.
2) Turn ignition switch to ON position and check DTC in
ECM and CNG control module.
Is there any CAN-DTC(s) detected?

3 CAN communication circuit check Go to Step 5. Repair or replace
1) Check CAN communication circuit between control defective wire harness.
modules for open, short, high resistance and
connections referring to Step 1 of TROUBLESHOOTING
under TROUBLESHOOTING FOR COMMUNICATION
BUS OFF in this Section.
Is circuit in good condition?

4 “MTR” fuse check Go to Step 5. Replace “MTR” fuse
1) Turn ignition switch to OFF position. and check for short.
2) Check if “MTR” fuse in junction block is blown.
Is “MTR” fuse in good condition?

5 Combination meter power supply circuit check Go to Step 6. Repair or replace
1) Remove combination meter. defective wire harness.
2) Check for proper connection to combination meter
connector at combination meter power supply circuit and
combination meter ground circuit.
3) If OK, then turn ignition switch to ON position and
measure voltage between combination meter power
supply circuit (A1) and vehicle body ground.
Is it 10 – 14 V?
6 Combination meter ground circuit check Substitute a known- Repair or replace
1) Turn ignition switch to OFF position. good combination meter defective wire harness.
and recheck. If CNG
2) Measure resistance between combination meter ground
warning light still
circuit (B1) and vehicle body ground.
remains OFF, substitute
Is resistance 1 : or less? a known-good CNG
control module and
recheck.
CNG WARNING LIGHT REMAINS ON AFTER ENGINE STARTS

WIRING DIAGRAM
Refer to CNG WARNING LIGHT DOES NOT COME ON WITH IGNITION SWITCH IN ON POSITION AND ENGINE
STOPPED in this section.
CIRCUIT DESCRIPTION
Refer to CNG WARNING LIGHT DOES NOT COME ON WITH IGNITION SWITCH IN ON POSITION AND ENGINE
STOPPED in this section.
TROUBLESHOOTING
Step Action Yes No
1 DTC check Go to troubleshooting Substitute a known-
1) Start engine and recheck CNG control module for DTC for applicable DTC. good combination meter
while engine running. and recheck. If CNG
warning light still
Is there any DTC(s)? remains ON, substitute
a known-good CNG
control module and
recheck.
DTC P0031 / P0032

Refer to DTC P0031 / P0032 in Section 6E.
DTC P0107 / P0108

DTC DETECTING CONDITION AND TROUBLE AREA
DTC detecting condition Trouble area
P0107: Manifold Absolute Pressure / Barometric Pressure Circuit Low • MAP sensor and/or its circuit
Voltage of MAP sensor signal circuit is lower than 0.2 V for 5 sec. • ECM
(2 D/C detection logic)
P0108: Manifold Absolute Pressure / Barometric Pressure Circuit High
Voltage of MAP sensor signal circuit is higher than 4.7 V for 5 sec.
WIRING DIAGRAM
2
5V
A1 5V
Lg/R L70-20
A2
1
Gr/R L70-12
A3
Bl/Y L70-31
[A]
L69 L70 L71
7 6 5 4 3 2 1 7 6 5 4 3 2 1 6 5 4 3 2 1
17 16 15 14 13 12 11 10 9 8 19 18 17 16 15 14 1312 11 10 9 8 16 15 14 13 12 11 10 9 8 7
27 26 25 24 23 22 21 20 19 18 27 26 25 24 23 22 21 20 27 26 25 24 23 22 21 20 19 18 17 [a]
34 33 32 31 30 29 28 35 34 33 32 31 30 29 28 35 34 33 32 31 30 29 28
[A]: ECM connector (View: [a]) A2: MAP sensor signal circuit 1. MAP sensor
A1: MAP sensor power supply circuit A3: MAP sensor ground circuit 2. ECM
DTC CONFIRMATION PROCEDURE

1) Run engine at idle speed for 1 min.
DTC TROUBLESHOOTING
Step Action Yes No
1 Was ENGINE DIAGNOSTIC FLOW TABLE performed? Go to Step 2. Go to ENGINE
DIAGNOSTIC FLOW
TABLE in Section 6.
Step Action Yes No

2 MAP sensor power supply circuit check Go to Step 5. Go to Step 3.
1) Turn OFF ignition switch and disconnect connector from
MAP sensor.
2) Check for proper terminal connection to MAP sensor
connector.
3) If connection is OK, turn ignition switch to ON position.
4) Check that voltage between MAP sensor power supply
circuit (A1) and ground circuit (A3) is 5 V at MAP sensor
connector.
3 MAP sensor power supply circuit check Repair or replace MAP Go to Step 4.
1) Check that voltage between MAP sensor power supply sensor ground circuit
circuit (A1) and vehicle body ground is 5 V at MAP (A3).
sensor connector. If this DTC is detected
again, substitute a
It is in good condition? known-good ECM and
recheck.
4 MAP sensor power supply circuit check Substitute a known- Repair or replace MAP
1) With ignition switch OFF, disconnect connectors from good ECM and recheck. sensor power supply
ECM. circuit.
2) Check for proper terminal connection to ECM
connectors.
3) If connections are OK, check that MAP sensor power
supply circuit (A1) is as follows.
• Wiring harness resistance of MAP sensor power
supply circuit between MAP sensor and ECM
connectors is less than 1 :.
• Insulation resistance of MAP sensor power supply
circuit is infinity between MAP sensor and vehicle
body ground.
• Insulation resistance of wire harness is infinity
between MAP sensor power supply circuit terminal
and each other terminal at MAP sensor connector.

5 MAP sensor signal circuit check Go to Step 6. Repair or replace MAP
1) With ignition switch OFF, disconnect connectors from sensor signal circuit.
ECM.
connectors.
3) If connections are OK, check that MAP sensor signal
circuit (A2) is as follows.
• Wiring harness resistance of MAP sensor signal
circuit between MAP sensor and ECM connectors is
less than 1 :.
• Insulation resistance of MAP sensor signal circuit is
infinity between MAP sensor connector and vehicle
body ground.
between MAP sensor signal terminal and each other
terminal at MAP sensor connector.
Step Action Yes No

6 MAP sensor check Substitute a known- Replace MAP sensor.
1) Check MAP sensor. Refer to MAP SENSOR in this good ECM and recheck.
section.
DTC P0112 / P0113

P0112: Intake Air Temperature Sensor 1 Circuit Low • IAT sensor and/or its circuit
Voltage of IAT sensor signal circuit is lower than 0.15 V for 5 sec. • ECM
P0113: Intake Air Temperature Sensor 1 Circuit High
Voltage of IAT sensor signal circuit is higher than 4.85 V for 5 sec.
WIRING DIAGRAM
2
5V
1 A1
Lg/B L70-14
A2
Bl/Y L70-31
[A]
L69 L70 L71
7 6 5 4 3 2 1 7 6 5 4 3 2 1 6 5 4 3 2 1
17 16 15 14 13 12 11 10 9 8 19 18 17 16 15 14 1312 11 10 9 8 16 15 14 13 12 11 10 9 8 7
[a]
27 26 25 24 23 22 21 20 19 18 27 26 25 24 23 22 21 20 27 26 25 24 23 22 21 20 19 18 17
34 33 32 31 30 29 28 35 34 33 32 31 30 29 28 35 34 33 32 31 30 29 28
[A]: ECM connector (View: [a]) A2: IAT sensor ground circuit 2. ECM
A1: IAT sensor signal circuit 1. IAT sensor

1) Turn ignition switch to ON position for 10 sec.
DTC TROUBLESHOOTING
Step Action Yes No
DIAGNOSTIC FLOW
TABLE in Section 6.
Step Action Yes No

2 IAT sensor signal circuit and ground circuit check Go to Step 3. Repair or replace
1) Turn OFF ignition switch and disconnect connectors defective wire harness.
from IAT sensor and ECM.
2) Check for proper terminal connection to IAT sensor and
ECM connectors.
3) If connections are OK, check that IAT sensor signal
circuit (A1) and IAT sensor ground circuit (A2) are as
follows.
• Wiring harness resistance of each IAT sensor signal
circuit and ground circuit between IAT sensor and
ECM connectors is less than 1 :.
• Insulation resistance of IAT sensor signal circuit is
infinity between IAT sensor connector and vehicle
body ground.
between IAT sensor signal circuit terminal and ground
circuit terminal at IAT sensor connector.

3 IAT sensor check Substitute a known- Replace IAT sensor.
1) Check IAT sensor. Refer to IAT SENSOR in related good ECM and recheck.
manual.
DTC P0117 / P0118

P0117: Engine Coolant Temperature Sensor 1 Circuit Low • ECT sensor and/or its circuit
Voltage of ECT sensor signal circuit is lower than 0.15 V for 5 sec. • ECM
P0118: Engine Coolant Temperature Sensor 1 Circuit High
Voltage of ECT sensor signal circuit is higher than 4.85 V for 5 sec.
WIRING DIAGRAM
2
5V
1 A1
Lg L70-13
A2
Bl/Y L70-31
[A]
L69 L70 L71
7 6 5 4 3 2 1 7 6 5 4 3 2 1 6 5 4 3 2 1
17 16 15 14 13 12 11 10 9 8 19 18 17 16 15 14 1312 11 10 9 8 16 15 14 13 12 11 10 9 8 7
[a]
27 26 25 24 23 22 21 20 19 18 27 26 25 24 23 22 21 20 27 26 25 24 23 22 21 20 19 18 17
34 33 32 31 30 29 28 35 34 33 32 31 30 29 28 35 34 33 32 31 30 29 28
[A]: ECM connector (View: [a]) A2: ECT sensor ground circuit 2. ECM
A1: ECT sensor signal circuit 1. ECT sensor

DTC TROUBLESHOOTING
Step Action Yes No
DIAGNOSTIC FLOW
TABLE in Section 6.
2 ECT sensor signal circuit and ground circuit check Go to Step 3. Repair or replace
from ECT sensor and ECM.
2) Check for proper terminal connection to ECT sensor and
ECM connectors.
3) If connections are OK, check that ECT sensor signal
circuit (A1) and ground circuit (A2) are as follows.
• Wiring harness resistance of each ECT sensor signal
circuit and ground circuit between ECT sensor and
• Insulation resistance of ECT sensor signal circuit is
infinity between ECT sensor connector and vehicle
body ground.
between ECT sensor signal circuit terminal and
ground circuit terminal at ECT sensor connector.

3 ECT sensor circuit voltage check Go to Step 4. Substitute a known-
1) Connect connectors to ECM. good ECM and recheck.
3) Check that voltage between ECT sensor signal circuit
terminal and vehicle body ground is 5 V at ECT sensor
connector.
4 ECT sensor check Substitute a known- Replace ECT sensor.
1) Check ECT sensor. Refer to ECT SENSOR in this good ECM and recheck.
section.
DTC P0122 / P0123

P0122: Throttle / Pedal Position Sensor / Switch “A” Circuit Low • TP sensor and/or its circuit
Voltage of TP sensor signal circuit is lower than 0.1 V for 5 sec. • ECM
P0123: Throttle / Pedal Position Sensor / Switch “A” Circuit High
Voltage of TP sensor signal circuit is higher than 4.7 V for 5 sec.
WIRING DIAGRAM
1
5V
A1 2
Lg/R L70-6
5V
A2
Gr/Bl L70-15
A3
Bl/Y L70-31
[A]
L69 L70 L71
7 6 5 4 3 2 1 7 6 5 4 3 2 1 6 5 4 3 2 1
17 16 15 14 13 12 11 10 9 8 19 18 17 16 15 14 1312 11 10 9 8 16 15 14 13 12 11 10 9 8 7
[a]
27 26 25 24 23 22 21 20 19 18 27 26 25 24 23 22 21 20 27 26 25 24 23 22 21 20 19 18 17
34 33 32 31 30 29 28 35 34 33 32 31 30 29 28 35 34 33 32 31 30 29 28
[A]: ECM connector (View: [a]) A2: TP sensor signal circuit 1. TP sensor
A1: TP sensor power supply circuit A3: TP sensor ground circuit 2. ECM

1) Turn ignition switch to ON position and leave it for 10 sec.
2) Depress accelerator pedal fully, and release it.
3) Repeat the above Step 2) three times.
DTC TROUBLESHOOTING
Step Action Yes No
DIAGNOSTIC FLOW
TABLE in Section 6.
2 TP sensor power supply circuit check Go to Step 5. Go to Step 3.
1) Turn OFF ignition switch and disconnect connector from
TP sensor.
2) Check for proper terminal connection to TP sensor
connector.
3) If connection is OK, turn ignition switch to ON position.
4) Check that voltage between TP sensor power supply
circuit (A1) and ground circuit (A3) is about 5 V at TP
sensor connector.
3 TP sensor power supply circuit check Repair or replace TP Go to Step 4.
1) Check that voltage between TP sensor power supply sensor ground circuit
circuit (A1) and vehicle body ground is 5 V at TP sensor (A3).
connector. If this DTC is detected
again, substitute a
It is in good condition? known-good ECM and
recheck.
Step Action Yes No

4 TP sensor power supply circuit check Substitute a known- Repair or replace TP
1) With ignition switch OFF, disconnect connectors from good ECM and recheck. sensor power supply
ECM. circuit.
connectors.
3) If connections are OK, check that TP sensor power
supply circuit (A1) is as follows.
• Wiring harness resistance of TP sensor power supply
circuit between TP sensor and ECM connectors is
less than 1 :.
• Insulation resistance of TP sensor power supply
circuit is infinity between TP sensor and vehicle body
ground.
between TP sensor power supply circuit terminal and
each other terminal at TP sensor connector.

5 TP sensor signal circuit check Go to Step 6. Repair or replace TP
1) With ignition switch OFF, disconnect connectors from sensor signal circuit.
ECM.
connectors.
3) If connections are OK, check that TP sensor signal
circuit (A2) is as follows.
• Wiring harness resistance of TP sensor signal circuit
between TP sensor and ECM connectors is less than
1 :.
• Insulation resistance of TP sensor signal circuit is
infinity between TP sensor and vehicle body ground.
between TP sensor signal terminal and each other
terminal at TP sensor connector.

6 TP sensor check Substitute a known- Replace throttle body.
1) Check TP sensor. Refer to TP SENSOR in this section. good ECM and recheck.
DTC P0130
Refer to DTC P0130 in Section 6E.
DTC P0327 / P0328

P0327: Knock Sensor 1 Circuit Low • Knock sensor and/or its circuit
Voltage of knock sensor signal circuit is lower than 1.23 V for 5 sec. • ECM
P0328: Knock Sensor 1 Circuit High
Voltage of knock sensor signal circuit is higher than 3.91 V for 5 sec.
WIRING DIAGRAM
3
5V
A1
1 2
Bl L70-8
B/W L70-9
A2
B L70-10
[A]
L69 L70 L71
7 6 5 4 3 2 1 7 6 5 4 3 2 1 6 5 4 3 2 1
17 16 15 14 13 12 11 10 9 8 19 18 17 16 15 14 1312 11 10 9 8 16 15 14 13 12 11 10 9 8 7
[a]
27 26 25 24 23 22 21 20 19 18 27 26 25 24 23 22 21 20 27 26 25 24 23 22 21 20 19 18 17
34 33 32 31 30 29 28 35 34 33 32 31 30 29 28 35 34 33 32 31 30 29 28
[A]: ECM connector (View: [a]) A2: Knock sensor ground circuit 2. Shield wire
A1: Knock sensor signal circuit 1. Knock sensor 3. ECM

DTC TROUBLESHOOTING
Step Action Yes No
DIAGNOSTIC FLOW
TABLE in Section 6.
2 Knock sensor signal circuit and ground circuit check Go to Step 3. Repair or replace
from knock sensor and ECM.
2) Check for proper terminal connection to knock sensor
and ECM connectors.
3) If connections are OK, check that knock sensor signal
• Wiring harness resistance of each knock sensor
signal circuit and ground circuit between knock sensor
and ECM connectors is less than 1 :.
• Insulation resistance of knock sensor signal circuit is
infinity between knock sensor connector and vehicle
body ground.
between knock sensor signal circuit terminal and the
other terminal at knock sensor connector.

3 Knock sensor reference voltage check Go to Step 4. Substitute a known-
1) Connect connectors to ECM. good ECM and recheck.
3) Check that knock sensor signal circuit voltage is 5 V
between knock sensor connector and vehicle body
ground.
Step Action Yes No

4 Knock sensor check Substitute a known- Replace knock sensor.
1) Check knock sensor. Refer to KNOCK SENSOR in this good ECM and recheck.
section.
DTC P0335
DTC P0340
P0340: Camshaft Position Sensor “A” Circuit • CMP sensor and/or its circuit
This DTC is detected if any one of the following conditions is met. • Signal rotor
• CMP sensor generates less than 3 pulses per 6 revolutions of crankshaft • ECM
from engine start.
• CMP sensor generates no pulse per 6 revolutions of crankshaft.
• CMP sensor generates no pulse between BTDC 75° and BTDC 5° within
crankshaft 6 revolutions from engine start.
WIRING DIAGRAM
3
5 12V
B/Y B/W L70-33
6 4
B/Y B/Y B/Or L69-10
B/Y B/R L70-2

W
8 7 B/R L70-1
1
A1 A2
Gr/R L70-34 L70-4 B
B L69-7 B/Bl
2 A3
L69-6 B/Bl
[A]
L69 L70 L71
7 6 5 4 3 2 1 7 6 5 4 3 2 1 6 5 4 3 2 1
17 16 15 14 13 12 11 10 9 8 19 18 17 16 15 14 13 12 11 10 9 8 16 15 14 13 12 11 10 9 8 7
27 26 25 24 23 22 21 20 19 18 [a]
27 26 25 24 23 22 21 20 27 26 25 24 23 22 21 20 19 18 17
34 33 32 31 30 29 28 35 34 33 32 31 30 29 28 35 34 33 32 31 30 29 28
[A]: ECM connector (View: [a]) 1. CMP sensor 5. “IG METER” fuse
A1: CMP sensor power supply circuit 2. Signal rotor 6. Ignition switch
A2: CMP sensor signal circuit 3. ECM 7. “FI” fuse
A3: CMP sensor ground circuit 4. Main relay 8. “IGN” fuse
SYSTEM DESCRIPTION
The CMP sensor located on the cylinder head consists of the signal generator (magnetic sensor) and signal rotor
(fixed to intake camshaft).
The signal generator generates reference signal through slits in the signal rotor which turns together with the
camshaft.
REFERENCE SIGNAL
The CMP sensor generates 2 pulses of signals each of which has a different waveform length while the camshaft
makes one full rotation. Refer to ECM AND ITS CIRCUIT VOLTAGE TABLE.
Based on CMP sensor signal and CKP sensor signal, ECM judges which cylinder piston is in the compression stroke.
NOTE
Check to make sure that following condition is satisfied when using this “DTC CONFIRMATION
PROCEDURE”.
• The following DTC is not detected:
– CKP sensor (P0335)
1) Battery voltage is 12 V or higher.

DTC TROUBLESHOOTING
Step Action Yes No
DIAGNOSTIC FLOW
TABLE in Section 6.
2 DTC check Go to applicable Go to Step 3.
1) Check DTC. DTC(s).
Is there DTC(s) other than P0340?

3 CMP sensor power supply circuit check Go to Step 4. Repair or replace
1) Turn OFF ignition switch and disconnect connector from defective wire harness.
CMP sensor.
2) Check for proper terminal connection to CMP sensor
connector.
3) If connections are OK, turn ignition switch to ON
position.
4) Check that battery voltage is applied to power supply
circuit (A1) of CMP sensor at CMP sensor connector.
4 CMP sensor signal circuit and ground circuit check Go to Step 5. Repair or replace
from ECM.
connectors.
3) If connections are OK, check that CMP sensor signal
• Wiring harness resistance of each CMP sensor signal
circuit and ground circuit between CMP sensor and
between CMP sensor signal circuit and vehicle body
ground.
between CMP sensor signal circuit terminal and each
terminal at CMP sensor connector.
between CMP sensor ground circuit terminal and
each terminal at CMP sensor connector.

Step Action Yes No

5 CMP sensor signal circuit voltage check Go to Step 6. Substitute a known-
1) Check that CMP sensor signal circuit voltage is 5 V good ECM and recheck.
between CMP sensor connector and vehicle body
ground.
6 CMP sensor and signal rotor check Substitute a known- Replace CMP sensor.
1) Check CMP sensor and signal rotor. Refer to CMP good ECM and recheck.
SENSOR in this section.
DTC P0403
P0403: Exhaust Gas Recirculation “A” Control Circuit • EGR valve and/or its circuit
Any one of monitor signals of EGR valve is low level (ON) for 1 sec. when • ECM
command signal is OFF.
WIRING DIAGRAM
7
4 12V
B/Y B/W L70-33
3 5
B/Y B/Y B/Or L69-10
Y B/R L70-2
W
1 2 B/R L70-1
6
B1 A1
R/W L69-16
A2
R L69-17
B2 A3
R/Bl L69-33
A4
R/Y L69-34
L70-4 B
L69-7 B/Bl
L69-6 B/Bl
[A]
L69 L70 L71
7 6 5 4 3 2 1 7 6 5 4 3 2 1 6 5 4 3 2 1
17 16 15 14 13 12 11 10 9 8 19 18 17 16 15 14 13 12 11 10 9 8 16 15 14 13 12 11 10 9 8 7
27 26 25 24 23 22 21 20 19 18 [a]
27 26 25 24 23 22 21 20 27 26 25 24 23 22 21 20 19 18 17
34 33 32 31 30 29 28 35 34 33 32 31 30 29 28 35 34 33 32 31 30 29 28
[A]: ECM connector (View: [a]) B1: EGR valve power supply circuit 1 4. “IG METER” fuse
A1: EGR valve drive circuit 1 B2: EGR valve power supply circuit 2 5. Main relay
A2: EGR valve drive circuit 2 1. “IGN” fuse 6. EGR valve
A3: EGR valve drive circuit 3 2. “FI” fuse 7. ECM
A4: EGR valve drive circuit 4 3. Ignition switch

DTC TROUBLESHOOTING
Step Action Yes No
DIAGNOSTIC FLOW
TABLE in Section 6.
2 EGR valve power supply circuit check Go to Step 3. Repair or replace EGR
1) With ignition switch OFF, disconnect connector from valve power supply
EGR valve. circuit (B1, B2).
2) Check for proper terminal connection to EGR valve.
position.
4) Check that voltage between EGR valve power supply
circuit (B1, B2) and vehicle body ground is battery
voltage.
3 EGR valve drive circuit check Go to Step 4. Repair or replace
1) With ignition switch OFF, disconnect connectors from defective wire harness.
ECM.
2) Check that EGR valve control circuit is as follows.
• Wiring harness resistance of each EGR valve drive
circuit (A1 – A4) is less than 1 :.
• Insulation resistance of each EGR valve drive circuits
are infinity between EGR valve connector and vehicle
body ground.
between each EGR valve drive circuit terminal and
each other terminal at EGR valve connector.
• Circuit voltage of each EGR valve drive circuits are 0
– 1 V with ignition switch turned ON.
4 EGR valve check Substitute a known- Replace EGR valve.
1) Check EGR valve. Refer to EGR SYSTEM in related good ECM and recheck.
manual.
DTC P0443
P0443: Evaporative Emission System Purge Control Valve Circuit • EVAP canister purge valve and/or its
Duty pulse monitor signal of EVAP canister purge valve control circuit is circuit
different from its command duty for 5 sec. (Circuit open or short) • ECM
WIRING DIAGRAM
7
4 12V
B/Y B/W L70-33
3 5
B/Y B/Y B/Or L69-10
B/Y B/R L70-2

W
B/R L70-1
1 2
A1 6
L70-4 B
Or L69-14
L69-7 B/Bl
L69-6 B/Bl
B1
[A]
L69 L70 L71
7 6 5 4 3 2 1 7 6 5 4 3 2 1 6 5 4 3 2 1
17 16 15 14 13 12 11 10 9 8 19 18 17 16 15 14 13 12 11 10 9 8 16 15 14 13 12 11 10 9 8 7
27 26 25 24 23 22 21 20 19 18 [a]
27 26 25 24 23 22 21 20 27 26 25 24 23 22 21 20 19 18 17
34 33 32 31 30 29 28 35 34 33 32 31 30 29 28 35 34 33 32 31 30 29 28
[A]: ECM connector (View: [a]) 2. “FI” fuse 6. EVAP canister purge valve
A1: EVAP canister purge valve power supply circuit 3. Ignition switch 7. ECM
B1: EVAP canister purge valve control circuit 4. “IG METER” fuse
1. “IGN” fuse 5. Main relay

1) Run engine at 2,000 rpm after warming up.
DTC TROUBLESHOOTING
Step Action Yes No
DIAGNOSTIC FLOW
TABLE in Section 6.
Step Action Yes No

2 EVAP canister purge valve power supply circuit check Go to Step 3. Repair or replace
1) Turn OFF ignition switch and disconnect connector from defective wire harness.
EVAP canister purge valve.
2) Check for proper terminal connection to EVAP canister
purge valve connector.
position.
4) Check that voltage between EVAP canister purge valve
power supply circuit (A1) and vehicle body ground is
battery voltage at EVAP canister purge valve connector.
3 EVAP canister purge valve control circuit check Go to Step 4. Repair or replace
from ECM.
2) Check that EVAP canister purge valve control circuit
(B1) is as follows.
• Wiring harness resistance of EVAP canister purge
valve control circuit between EVAP canister purge
valve and ECM connectors is less than 1 :.
• Insulation resistance of EVAP canister purge valve
control circuit is infinity between EVAP canister purge
valve connector and vehicle body ground.
between EVAP canister purge valve control circuit
terminal and power supply circuit terminal at EVAP
canister purge valve connector.

4 EVAP canister purge valve check Substitute a known- Replace EVAP canister
1) Check EVAP canister purge valve. Refer to EVAP good ECM and recheck. purge valve.
CANISTER in this section.
DTC P0480
P0480: Fan 1 Control Circuit • Radiator cooling fan relay (coil side) and/or its
Monitor voltage of radiator cooling fan relay output is different from circuit
its command signal for 5 sec. • ECM
(2 D/C detection logic but MIL does not light up)
WIRING DIAGRAM
+B
1 B1 A1
4
L69-12 Bl
3
Bl/R
12V B +BB
11
8
L70-33 B/W W
7
L71-6 W
5
L69-10 B/Or
L70-2 B/R
L70-1 B/R
5V
2
L70-13 Lg
9 10 14 6
L70-31 Bl/Y
L70-4 B 12
L69-7 B/Bl
L69-6 B/Bl +
13
[A]
L69 L70 L71
7 6 5 4 3 2 1 7 6 5 4 3 2 1 6 5 4 3 2 1
17 16 15 14 13 12 11 10 9 8 19 18 17 16 15 14 13 12 11 10 9 8 16 15 14 13 12 11 10 9 8 7
[a]
27 26 25 24 23 22 21 20 19 18 27 26 25 24 23 22 21 20 27 26 25 24 23 22 21 20 19 18 17
34 33 32 31 30 29 28 35 34 33 32 31 30 29 28 35 34 33 32 31 30 29 28
[A]: ECM connector (View: [a]) 4. Radiator cooling fan relay 10. “IGN” fuse
A1: Radiator cooling fan relay power supply circuit (coil side) 5. Main relay 11. Ignition switch
B1: Radiator cooling fan relay drive circuit 6. “CPRSR” fuse 12. Main fuse box
1. ECM 7. “RADIO DOME” fuse 13. Battery
2. ECT sensor 8. “IG METER” fuse 14. “BTRY” fuse
3. Radiator cooling fan motor 9. “FI” fuse

1) Start engine and warm up to normal operating temperature.
2) Keep engine at idle speed until engine coolant temperature reaches 90 qC (194 qF) or more.
DTC TROUBLESHOOTING
Step Action Yes No
DIAGNOSTIC FLOW
TABLE in Section 6.
Step Action Yes No

2 Radiator cooling fan relay power supply circuit (coil Go to Step 3. Repair or replace
side) check defective wire harness.
1) Turn OFF ignition switch and remove radiator cooling fan
relay.
2) Check for proper terminal connection to cooling fan relay
connector.
position.
4) Check that voltage between radiator cooling fan relay
power supply circuit (coil side) (A1) and vehicle body
ground is battery voltage at radiator cooling fan relay
connector.
3 Radiator cooling fan relay check Go to Step 4. Replace radiator cooling
1) Check radiator cooling fan relay. Refer to MAIN RELAY/ fan relay.
FUEL PUMP RELAY/RADIATOR FAN RELAY in related
manual.
4 Radiator cooling fan relay drive circuit check Substitute a known- Repair or replace
1) Turn OFF ignition switch and disconnect connectors good ECM and recheck. defective wire harness.
from ECM.
2) Check that radiator cooling fan relay drive circuit (B1) is
as follows.
• Wiring harness resistance of radiator cooling fan relay
drive circuit between radiator cooling fan relay and
between radiator cooling fan relay drive circuit and
vehicle body ground.
between radiator cooling fan relay drive circuit
terminal and each terminal at radiator cooling fan
relay connector.

DTC P0482
P0482: Fan 3 Control Circuit • A/C condenser fan relay (coil side) and/or its
Monitor voltage of A/C condenser fan relay output is different from circuit
its command signal for 5 sec. • ECM
WIRING DIAGRAM
IG2
1 B1 A1
4
L69-22 W
3
R/Bl
5
12V B +BB
8
L70-33 B/W W
7
L71-6 W
2
L69-10 B/Or
L70-2 B/R
L70-1 B/R
9 10 11 6
L70-4 B 12
L69-7 B/Bl
L69-6 B/Bl +
13
[A]
L69 L70 L71
7 6 5 4 3 2 1 7 6 5 4 3 2 1 6 5 4 3 2 1
17 16 15 14 13 12 11 10 9 8 19 18 17 16 15 14 13 12 11 10 9 8 16 15 14 13 12 11 10 9 8 7
[a]
27 26 25 24 23 22 21 20 19 18 27 26 25 24 23 22 21 20 27 26 25 24 23 22 21 20 19 18 17
34 33 32 31 30 29 28 35 34 33 32 31 30 29 28 35 34 33 32 31 30 29 28
[A]: ECM connector (View: [a]) 4. A/C condenser fan relay 10. “IGN” fuse
A1: A/C condenser fan relay power supply circuit (coil side) 5. Ignition switch 11. “BTRY” fuse
B1: A/C condenser fan relay drive circuit 6. “RDTR” fuse 12. Main fuse box
1. ECM 7. “RADIO DOME” fuse 13. Battery
2. Main relay 8. “IG METER” fuse
3. A/C condenser fan motor 9. “FI” fuse

2) Turn ON A/C switch, and set blower fan switch at 2nd or 3rd speed position.
DTC TROUBLESHOOTING
Step Action Yes No

DIAGNOSTIC FLOW
TABLE in Section 6.
2 A/C condenser fan relay power supply circuit (coil side) Go to Step 3. Repair or replace
check defective wire harness.
1) Turn OFF ignition switch and remove A/C condenser fan
relay.
2) Check for proper terminal connection to A/C condenser
fan relay connector.
position.
4) Check that voltage between A/C condenser fan relay
power supply circuit (coil side) (A1) and vehicle body
ground is battery voltage at A/C condenser fan relay
connector.
3 A/C condenser fan relay check Go to Step 4. Replace A/C condenser
1) Check A/C condenser fan relay. Refer to A/C fan relay.
COMPRESSOR RELAY CONDENSER FAN RELAY in
Section 1B.
4 A/C condenser fan relay drive circuit check Substitute a known- Repair or replace
1) Turn OFF ignition switch and disconnect connectors good ECM and recheck. defective wire harness.
from ECM.
2) Check that A/C condenser fan relay drive circuit (B1) is
as follows.
• Wiring harness resistance of A/C condenser fan relay
drive circuit between A/C condenser fan relay and
between A/C condenser fan relay drive circuit and
vehicle body ground.
between A/C condenser fan relay drive circuit terminal
and each terminal at A/C condenser fan relay
connector.
DTC P0500
DTC P0505
Refer to DTC P 0505 in Section 6E.
DTC P0560
P0560: System Voltage • Backup power supply circuit
Voltage of backup power supply circuit is lower than specification for 5 sec. • Charging system
• ECM
WIRING DIAGRAM
A1
2
W W L71-6
[A]
L69 L70 L71
7 6 5 4 3 2 1 7 6 5 4 3 2 1 6 5 4 3 2 1
17 16 15 14 13 12 11 10 9 8 19 18 17 16 15 14 13 12 11 10 9 8 16 15 14 13 12 11 10 9 8 7 [a]
27 26 25 24 23 22 21 20 19 18 27 26 25 24 23 22 21 20 27 26 25 24 23 22 21 20 19 18 17
34 33 32 31 30 29 28 35 34 33 32 31 30 29 28 35 34 33 32 31 30 29 28
[A]: ECM connector (View: [a]) 1. Main fuse box 3. ECM

A1: Backup power supply circuit 2. “RADIO DOME” fuse

CIRCUIT DESCRIPTION
Battery voltage is supplied so that DTC memory, values for engine control learned by ECM, etc. are kept in ECM even
when the ignition switch is turned OFF.
DTC TROUBLESHOOTING
Step Action Yes No
DIAGNOSTIC FLOW
TABLE in Section 6.
2 Backup power supply circuit check Check for intermittent “RADIO DOME” fuse
1) Turn OFF ignition switch and disconnect connectors trouble. Refer to blown, ECM backup
from ECM. INTERMITTENT AND power supply circuit is
POOR CONNECTION open or short to ground
in Section 0A. circuit, or charging
connectors.
If OK, substitute a system faulty.
known-good ECM and
position.
recheck.
4) Check that voltage between backup power supply circuit
(A1) and vehicle body ground is battery voltage at ECM
connector.
DTC P0601 (ECM)

NOTE
After reprogramming ECM, if the DTC P0601 is indicated, it is possible that the reprogramming of ECM
is not completed correctly.

P0601: Internal Control Module Memory Check Sum Error • ECM power supply circuit and/or ground circuit
Data writing error or check sum error. • ECM
SYSTEM DESCRIPTION
Internal control module is installed in ECM.

DTC TROUBLESHOOTING
Step Action Yes No
1 DTC recheck Go to Step 2. Check for intermittent
1) Clear DTC. Refer to DTC CLEARANCE. trouble. Refer to
INTERMITTENT AND
2) Turn OFF ignition switch.
POOR CONNECTION
3) Perform DTC confirmation procedure, and check DTC. in Section 0A.
Is DTC P0601 still detected?
2 ECM power and ground circuit check Substitute a known- Repair or replace
1) Check ECM power supply circuit and ECM ground circuit good ECM and recheck. defective wire harness.
is in good condition. Refer to ECM POWER AND
GROUND CIRCUIT CHECK.
DTC P0602 (ECM)

Refer to DTC P 0602 in Section 6E.
DTC P0616 / P0617

Refer to DTC P0616 / P0617 in section 6E.
DTC U0073 (ECM)

DTC U0108
DTC U0155
DTC P0005 / P0007

P0005: Fuel Shutoff Valve “A” Control Circuit / Open • Shut off valve of CNG pressure regulator
Monitor voltage of shut off valve of CNG pressure regulator is lower than and/or its circuit
specified voltage for 5 sec. only if its command signal is not output and • CNG valve control relay and/or its circuit
CNG valve control relay is ON.
P0007: Fuel Shutoff Valve “A” Control Circuit High
Monitor voltage of shut off valve of CNG pressure regulator is higher
than specified voltage for 5 sec. only if its command signal is output and
CNG valve control relay is ON.
Wiring Diagram
+B
B/R
1
5
12V 5V
R/B
L76-1 R/B
L76-10 R/B
IG1 +BB2
L76-21 B/W
W/R
12V B1 C1
4
L76-4 Bl B 6
B2 2 A2
L76-34 Bl/W Br Br/B
B/Bl L77-9
B/Bl L77-17 A1
B3 A3
B/Bl L77-26 3
L76-26 P/B
[A]
L76 L77
9 8 7 6 5 4 3 2 1 9 8 7
5 4 3 26 1
17 16 15 14 13 12 11 10 17 16 15 14 13 12 11 10 A
26 25 24 23 22 21 20 19 18 26 25 24 23 22 21 20 19 18
34 33 32 31 30 29 28 27 34 33 32 31 30 29 28 27
[A]: CNG control module connector (View: A) C1: CNG valve control relay ground circuit (coil side)
A1: CNG valve control relay power supply circuit (switch side) 1. CNG control module
A2: Shut off valve of CNG cylinder power supply circuit 2. Shut off valve of CNG cylinder
A3: Shut off valve of CNG pressure regulator power supply circuit 3. Shut off valve of CNG pressure regulator
B1: CNG valve control relay drive circuit 4. CNG valve control relay
B2: Shut off valve of CNG cylinder control circuit 5. “CNG” fuse
B3: Shut off valve of CNG pressure regulator control circuit 6. “CNG VLV” fuse
NOTE
Check to make sure that following conditions are satisfied when using this “DTC CONFIRMATION
PROCEDURE”.
• DTC P0607 is not detected.

2) Select “Forced CNG MODE” with fuel selector switch.
3) Keep it for 10 sec.
4) Select “Petrol MODE” with fuel selector switch.
5) Start engine and run it for 1 min.
DTC TROUBLESHOOTING
Step DIAGNOSTIC Yes No
DIAGNOSIS FLOW
TABLE in Section 6.
2 DTC check Go to Step 3. Go to Step 7.
Is there DTC P2665 and/or P2667?

3 CNG valve control relay power supply circuit (switch Go to Step 5. Go to Step 4.
side) check
1) Turn ignition switch to OFF position and then remove
CNG valve control relay.
2) Check for proper terminal connection to CNG valve
control relay connector.
3) If connections are OK, turn ignition switch to ON position
and then check that voltage between CNG valve control
relay power supply circuit (switch side) (A1) and vehicle
body ground is battery voltage.
4 “CNG VLV” fuse check Repair or replace Check that CNG valve
1) Turn OFF ignition switch. defective wire harness. control relay power
supply circuit (switch
2) Check if “CNG VLV” fuse in relay block is blown.
side) is shorted to
Is “CNG VLV” fuse in good condition? ground. If OK, replace
“CNG VLV” fuse.
5 CNG valve control relay check Go to Step 6. Replace CNG valve
1) Check CNG valve control relay. Refer to MAIN RELAY / control relay.
FUEL PUMP RELAY / RADIATOR FAN RELAY / CNG
VALVE CONTROL RELAY (INSPECTION) in this
section.
6 Shut off valve power supply circuit check Go to Step 7. Shut off valve of CNG
1) Turn ignition switch to OFF position and then disconnect pressure regulator
connectors from shut off valve of CNG pressure power supply circuit
regulator and shut off valve of CNG cylinder. and/or shut off valve of
CNG cylinder power
2) Check for proper terminal connection to shut off valve of
supply circuit are
CNG pressure regulator and shut off valve of CNG
shorted to ground.
cylinder connectors.
3) If connections are OK, measure resistance between shut
off valve of CNG pressure regulator power supply circuit
(A3) and vehicle body ground.
Is resistance infinity?
Step DIAGNOSTIC Yes No

7 Power supply circuit check for shut off valve on CNG Go to Step 8. Repair or replace power
pressure regulator supply circuit of shut off
1) Turn ignition switch to OFF position and then disconnect valve on CNG pressure
connector from shut off valve of CNG pressure regulator. regulator.
2) Remove CNG valve control relay.
control relay and shut off valve of CNG pressure
regulator connectors.
4) If connections are OK, measure wiring harness
resistance of shut off valve of CNG pressure regulator
power supply circuit (A3).
Is resistance 1 : or less?
8 Shut off valve of CNG pressure regulator control circuit Go to Step 9. Repair or replace
check defective wire harness.
1) Disconnect connectors from CNG control module.
2) Check for proper terminal connection to CNG control
module connectors.
3) If connections are OK, check that shut off valve of CNG
pressure regulator control circuit (B3) is as follows.
• Wiring harness resistance of shut off valve of CNG
pressure regulator control circuit is less than 1 :.
• Insulation resistance of shut off valve of CNG
pressure regulator control circuit between shut off
valve of CNG pressure regulator connector and
vehicle body ground is infinity.
between shut off valve of CNG pressure regulator
control circuit terminal and each terminal at shut off
valve of CNG pressure regulator connector.
• Voltage of shut off valve of CNG pressure regulator
control circuit is 0 – 1 V with ignition switch in ON
position.

9 Shut off valve of CNG pressure regulator check Substitute a known- Replace CNG pressure
1) Check shut off valve of CNG pressure regulator. Refer to good CNG control regulator.
Inspection of Shut-Off Valve under CNG PRESSURE module and recheck.
REGULATOR in this section.
DTC P0182 / P0183

P0182: Fuel Temperature Sensor “A” Circuit Low • CNG pressure-and-temperature
Voltage of CNG temperature sensor signal circuit is lower than 0.1 V for 5 sec. sensor and/or its circuit
(2 D/C detection logic) • CNG control module
P0183: Fuel Temperature Sensor “A” Circuit High
Voltage of CNG temperature sensor signal circuit is higher than 4.9 V for 5 sec.
WIRING DIAGRAM
2 5V
A1
B/G L76-5 12V
Bl/B L76-14
B1 5V
B2
Or L76-13
V L76-24
C1
[A]
L76 L77
9 8 7 6 5 4 3 2 1 9 8 7 6 5 4 3 2 1
17 16 15 14 13 12 11 10 17 16 15 14 13 12 11 10 A
26 25 24 23 22 21 20 19 18 26 25 24 23 22 21 20 19 18
34 33 32 31 30 29 28 27 34 33 32 31 30 29 28 27
[A]: CNG control module connector (View: A) B2: CNG temperature sensor signal circuit 2. CNG pressure-and-temperature sensor
A1: CNG pressure-and-temperature sensor power C1: CNG pressure-and-temperature sensor ground
supply circuit circuit
B1: CNG pressure sensor signal circuit 1. CNG control module

1) Turn ignition switch to ON position and keep it for 10 sec.
DTC TROUBLESHOOTING
Step Action Yes No
DIAGNOSIS FLOW
TABLE in Section 6.
Step Action Yes No

2 CNG temperature sensor signal circuit and ground Go to Step 3. Repair or replace
circuit check defective wire harness.
1) Turn ignition switch to OFF position and then disconnect
connectors from CNG pressure-and-temperature sensor
and CNG control module.
2) Check for proper terminal connection to CNG pressure-
and-temperature sensor and CNG control module
connectors.
3) If connections are OK, check that CNG temperature
sensor signal circuit (B2) and CNG pressure-and-
temperature sensor ground circuit (C1) are as follows.
• Wiring harness resistance of each CNG temperature
sensor signal circuit and CNG pressure-and-
temperature sensor ground circuit is less than 1 :.
• Insulation resistance CNG temperature sensor signal
circuit between CNG pressure-and-temperature
sensor connector and vehicle body ground is infinity.
between CNG temperature sensor signal circuit
terminal and each terminal at CNG pressure-and-
temperature sensor connector.
• Voltage of each CNG temperature sensor signal
circuit and CNG pressure-and-temperature sensor
ground circuit is 0 – 1 V with ignition switch in ON
position.

3 CNG temperature sensor signal circuit voltage check Go to Step 4. Substitute a known-
1) Connect connectors to CNG control module. good CNG control
module and recheck.
3) Check that voltage between CNG temperature sensor
signal circuit terminal and body ground is approx. 5 V at
CNG pressure-and-temperature sensor connector.
4 CNG pressure-and-temperature sensor check Substitute a known- Replace CNG pressure-
1) Check CNG pressure-and-temperature sensor. Refer to good CNG control and-temperature
CNG PRESSURE-AND-TEMPERATURE SENSOR in module and recheck. sensor.
this section.
DTC P0192 / P0193

P0192: Fuel Rail Pressure Sensor “A” Circuit Low • CNG pressure-and-temperature
Voltage of CNG pressure sensor signal circuit is lower than 0.15 V for 5 sensor and/or its circuit
sec. • CNG control module
P0193: Fuel Rail Pressure Sensor “A” Circuit High
Voltage of CNG pressure sensor signal circuit is higher than 4.9 V for 5 sec.
WIRING DIAGRAM
Refer to DTC P0182 / P0183 in this section.

DTC TROUBLESHOOTING
Step Action Yes No

DIAGNOSIS FLOW
TABLE in Section 6.
2 CNG pressure-and-temperature sensor power supply Go to Step 4. Go to Step 3.
circuit check
connector from CNG pressure-and-temperature sensor.
2) Check for proper terminal connection to CNG pressure-
and-temperature sensor.
position.
4) Check that voltage between CNG pressure-and-
temperature sensor power supply circuit (A1) and
vehicle body ground is approx. 5 V.
3 CNG pressure-and-temperature sensor power supply Substitute a known- Repair or replace power
circuit check good CNG control supply circuit of CNG
1) Turn ignition switch to OFF position and then disconnect module and recheck. pressure-and-
connectors from CNG control module. temperature sensor.
module connectors.
3) If connections are OK, check that CNG pressure-and-
temperature sensor power supply circuit (A1) is as
follows.
• Wiring harness resistance of CNG pressure-and-
temperature sensor power supply circuit is less than 1
:.
• Insulation resistance CNG pressure-and-temperature
sensor power supply circuit between CNG pressure-
and-temperature sensor connector and vehicle body
ground is infinity.
between CNG pressure-and-temperature sensor
power supply circuit terminal and each terminal at
CNG pressure-and-temperature sensor connector.
• Voltage of CNG pressure-and-temperature sensor
power supply circuit is 0 – 1 V with ignition switch in
ON position.
4 CNG pressure-and-temperature sensor ground circuit Go to Step 5. Repair or replace
check ground circuit of CNG
1) Measure resistance between CNG pressure-and- pressure-and-
temperature sensor ground circuit (C1) and vehicle body temperature sensor.
ground.
Step Action Yes No

5 CNG pressure sensor signal circuit check Go to Step 6. Repair or replace
1) Turn ignition switch to OFF position and then disconnect defective wire harness.
connectors from CNG control module.
module connectors.
3) If connections are OK, check that CNG pressure-and-
temperature sensor signal circuit (B1) is as follows.
• Wiring harness resistance of CNG pressure sensor
signal circuit is less than 1 :.
• Insulation resistance CNG pressure sensor signal
circuit between CNG pressure-and-temperature
between CNG pressure sensor signal circuit terminal
and each terminal at CNG pressure-and-temperature
sensor connector.
• Voltage of CNG pressure sensor signal circuit is 0 – 1
V with ignition switch in ON position.
6 CNG pressure-and-temperature sensor check Substitute a known- Replace CNG pressure-
1) Check CNG pressure-and-temperature sensor. Refer to good CNG control and-temperature
CNG PRESSURE-AND-TEMPERATURE SENSOR in module and recheck. sensor.
this section.
DTC P0201 / P0202 / P0203 / P0204

S

P0201: Injector Circuit / Open - Cylinder 1 • CNG fuel injector and/or its circuit
Monitor voltage of CNG fuel injector No.1 is lower than specified • CNG control module
voltage for 5 sec. even if its command signal is not output.
P0202: Injector Circuit / Open - Cylinder 2
Monitor voltage of CNG fuel injector No.2 is lower than specified
WIRING DIAGRAM
+B
B/R
1 2
C1 A1
5 4
L77-6 Br/B
E1 F1
9 R/B
L77-1 Bl
L69-5 Br/B L76-12
D1 B1
C2 A2
6
L77-14 Br
E2 F2
10
L77-10 R/Bl
L69-4 Br L76-3
D2 B2
3 C3 A3
7
L77-5 Br/W
E3 F3
11
L77-18 G
L69-3 Br/W L76-11
D3 B3
C4 A4
8
L77-13 Br/Y
E4 F4
12
L77-27 Y
L69-2 Br/Y L76-2
D4 B4
G1 12V 5V
L70-29 B/Y L77-25 L76-1 R/B

L70-28 Or L77-33
L76-10 R/B
[A]
L76 L77
9 8 7 6 5 4 3 2 1 9 8 7 6 5 4 3 2 1
17 16 15 14 13 12 11 10 17 16 15 14 13 12 11 10
26 25 24 23 22 21 20 19 18 26 25 24 23 22 21 20 19 18
34 33 32 31 30 29 28 27 34 33 32 31 30 29 28 27
A
[B]
L69 L70 L71
7 6 5 4 3 2 1 7 6 5 4 3 2 1 6 5 4 3 2 1
17 16 15 14 13 12 11 10 9 8 19 18 17 16 15 14 13 12 11 10 9 8 16 15 14 13 12 11 10 9 8 7
27 26 25 24 23 22 21 20 19 18 27 26 25 24 23 22 21 20 27 26 25 24 23 22 21 20 19 18 17
34 33 32 31 30 29 28 35 34 33 32 31 30 29 28 35 34 33 32 31 30 29 28
[A]: CNG control module connector (View: A) C4: Petrol fuel injector No.4 control circuit G1: CAN communication line circuit
[B]: ECM connector (View: A) D1: CNG fuel injector No.1 control circuit 1. ECM
A1: Petrol fuel injector No.1 power supply circuit D2: CNG fuel injector No.2 control circuit 2. CNG control module
A2: Petrol fuel injector No.2 power supply circuit D3: CNG fuel injector No.3 control circuit 3. CPU
A3: Petrol fuel injector No.3 power supply circuit D4: CNG fuel injector No.4 control circuit 4. “CNG” fuse
A4: Petrol fuel injector No.4 power supply circuit E1: Fuel injector No.1 control signal from ECM circuit 5. Petrol fuel injector No.1
B1: CNG fuel injector No.1 power supply circuit E2: Fuel injector No.2 control signal from ECM circuit 6. Petrol fuel injector No.2
B4: CNG fuel injector No.4 power supply circuit F1: Fuel control relay No.1 9. CNG fuel injector No.1
C1: Petrol fuel injector No.1 control circuit F2: Fuel control relay No.2 10. CNG fuel injector No.2

Step Action Yes No
DIAGNOSIS FLOW
TABLE in Section 6.
2 CNG fuel injector power supply circuit check Go to Step 3. Repair or replace
connectors from CNG fuel injectors.
2) Check for proper terminal connection to CNG fuel
injector connectors.
position.
4) Check that voltage between CNG fuel injector power
supply circuits (B1, B2, B3 or B4) and vehicle body
ground is battery voltage.
3 CNG fuel injector control circuit check Go to Step 4. Repair or replace
module connectors.
3) If connections are OK, check that CNG fuel injector
control circuits (D1, D2, D3 and D4) are as follows.
• Wiring harness resistance of each CNG fuel injector
control circuit is less than 1 :.
• Insulation resistance of each CNG fuel injector control
circuit between CNG fuel injector connector and
between each CNG fuel injector control circuit
terminal and each terminal at CNG fuel injector
connector.
• Voltage of each CNG fuel injector control circuit is 0 –
1 V with ignition switch in ON position.
4 CNG fuel injector check Substitute a known- Replace CNG fuel
1) Check CNG fuel injector. Refer to CNG System under good CNG control injector.
FUEL INJECTOR in this section. module and recheck.
DTC P0601 / P0602 (CNG CONTROL MODULE) / P062F
DTC Detecting Condition and Trouble Area

P0601: Internal Control Module Memory Check Sum Error • CNG control module power supply circuit and/
CNG control module internal failure related to check sum. or ground circuit
(2 D/C detection logic) • CNG control module
P0602: Control Module Programming Error
CNG control module internal failure. (data programming error)
(1 D/C detection logic but CNG warning light does not light up)
P062F: Internal Control Module EEPROM Error
CNG control module internal failure. (EEPROM error)
(2 D/C detection logic but CNG warning light does not light up)

2) Start engine if possible.
DTC TROUBLESHOOTING
Step Action Yes No
1 DTC recheck Go to Step 2. Check for intermittent
1) Clear DTC. Refer to DTC CLEARANCE in this section. trouble. Refer to
INTERMITTENT AND
2) Turn ignition switch to OFF position.
POOR CONNECTION
3) Perform DTC confirmation procedure, and check DTC. in Section 0A.
Is DTC P0601, P0602 or P062F still detected?
2 CNG control module power and ground circuit check Substitute a known- Repair or replace
1) Check CNG control module power supply circuit and good CNG control defective wire harness.
CNG control module ground circuit is in good condition. module and recheck.
Refer to CNG CONTROL MODULE POWER AND
GROUND CIRCUIT CHECK in this section.
DTC P0607

P0607: Control Module Performance • CNG valve control relay (coil side) and/or its
This DTC is detected if any one of the following conditions is met. circuit
• Monitor voltage of CNG valve control relay is lower than • CNG control module
specified voltage for 3 sec. even if its command signal is output.
• Monitor voltage of CNG valve control relay is higher than
specified voltage for 3 sec. even if its command signal is not
output.
WIRING DIAGRAM

DTC TROUBLESHOOTING
Step Action Yes No
DIAGNOSIS FLOW
TABLE in Section 6.
2 CNG valve control relay ground circuit check Go to Step 3. Repair or replace
1) Turn ignition switch to OFF position and then remove ground circuit of CNG
CNG valve control relay. valve control relay.
control relay connector.
3) If connections are OK, measure resistance between
CNG valve control relay ground circuit (C1) and vehicle
body ground.
Step Action Yes No

3 CNG valve control relay drive circuit check Go to Step 4. Repair or replace
1) Disconnect connectors from CNG control module. defective wire harness.
module connectors.
3) If connections are OK, check that CNG valve control
relay drive circuit (B1) is as follows.
• Wiring harness resistance of CNG valve control relay
drive circuit is less than 1 :.
• Insulation resistance of CNG valve control relay drive
circuit between CNG valve control relay connector
and vehicle body ground is infinity.
between CNG valve control relay drive circuit terminal
and each terminal at CNG valve control relay
connector.
• Voltage of CNG valve control relay drive circuit is 0 – 1
V with ignition switch in ON position.
4 CNG valve control relay check Substitute a known- Replace CNG valve
1) Check CNG valve control relay. Refer to MAIN RELAY / good CNG control control relay.
FUEL PUMP RELAY / RADIATOR FAN RELAY / CNG module and recheck.
VALVE CONTROL RELAY (INSPECTION) in this
section.
DTC P0612

P0612: Fuel Injector Control Module Relay Control • Fuel injector control circuit between
This DTC is detected if any one of the following conditions is met. ECM and CNG control module
• Monitor signal of either of fuel control relays is in “Petrol” side for 5 sec. • CNG control module
while engine running on CNG. • ECM
• Monitor signal of either of fuel control relays is in “CNG” side for 5 sec.
while engine running on petrol.
WIRING DIAGRAM
Refer to DTC P0201 / P0202 / P0203 / P0204 in this section.

2) Operate fuel selector switch and select “Forced CNG MODE”.
3) Run engine at idle speed for 10 sec.
4) Select “Petrol MODE”.
5) Run engine at idle speed for 10 sec.
DTC TROUBLESHOOTING
Step Action Yes No
DIAGNOSIS FLOW
TABLE in Section 6.
Step Action Yes No

2 DTC recheck Substitute a known- End.
1) Substitute a known-good CNG control module. good ECM and recheck.
2) Perform DTC confirmation procedure and check DTC.
Is DTC P0612 is still detect?
DTC P1432 / P1433

P1432: Remaining Fuel Sensor Low Voltage • CNG cylinder pressure sensor and/or its
Voltage of CNG cylinder pressure sensor signal circuit is lower than 0.1 circuit
V for 5 sec. • CNG control module
• ECM
P1433: Remaining Fuel Sensor High Voltage
Voltage of CNG cylinder pressure sensor signal circuit is higher than
4.9 V for 5 sec.
WIRING DIAGRAM
2 A1 5V
G L76-6
Lbl L76-15
B1
B/R L76-23
C1
[A]
L76 L77
9 8 7 6 5 4 3 2 1 9 8 7 65 4 3 2 1
17 16 15 14 13 12 11 10 17 16 15 14 13 12 11 10 A
26 25 24 23 22 21 20 19 18 26 25 24 23 22 21 20 19 18
34 33 32 31 30 29 28 27 34 33 32 31 30 29 28 27
[A]: CNG control module connector (View: A) B1: CNG cylinder pressure sensor signal circuit 1. CNG control module
A1: CNG cylinder pressure sensor power supply circuit C1: CNG cylinder pressure sensor ground circuit 2. CNG cylinder pressure sensor

DTC TROUBLESHOOTING
Step Action Yes No
DIAGNOSIS FLOW
TABLE in Section 6.
Step Action Yes No

2 CNG cylinder pressure sensor power supply circuit Go to Step 4. Go to Step 3.
check
connector from CNG cylinder pressure sensor.
2) Check for proper terminal connection to CNG cylinder
pressure sensor.
position.
4) Check that voltage between CNG cylinder pressure
sensor power supply circuit (A1) and vehicle body
ground is approx. 5 V.
3 CNG cylinder pressure sensor power supply circuit Substitute a known- Repair or replace
check good CNG control defective wire harness.
1) Turn ignition switch to OFF position and then disconnect module and recheck.
module connectors.
3) If connections are OK, check that CNG cylinder pressure
sensor power supply circuit (A1) is as follows.
• Wiring harness resistance of CNG cylinder pressure
sensor power supply circuit is less than 1 :.
• Insulation resistance CNG cylinder pressure sensor
power supply circuit between CNG cylinder pressure
between CNG cylinder pressure sensor power supply
circuit terminal and each terminal at CNG cylinder
pressure sensor connector.
• Voltage of CNG cylinder pressure sensor power
supply circuit is 0 – 1 V with ignition switch in ON
position.
4 CNG cylinder pressure sensor ground circuit check Go to Step 5. Repair or replace
1) Measure resistance between CNG cylinder pressure ground circuit of CNG
sensor ground circuit (C1) and vehicle body ground. pressure sensor.
Step Action Yes No

5 CNG cylinder pressure sensor signal circuit check Go to Step 6. Repair or replace
module connectors.
3) If connections are OK, check that CNG cylinder pressure
sensor signal circuit (B1) is as follows.
• Wiring harness resistance of CNG cylinder pressure
sensor signal circuit is less than 1 :.
• Insulation resistance CNG cylinder pressure sensor
signal circuit between CNG cylinder pressure sensor
connector and vehicle body ground is infinity.
between CNG cylinder pressure sensor signal circuit
terminal and each terminal at CNG cylinder pressure
sensor connector.
• Voltage of CNG cylinder pressure sensor signal circuit
is 0 – 1 V with ignition switch in ON position.
6 CNG cylinder pressure sensor check Substitute a known- Replace CNG pressure
1) Check CNG cylinder pressure sensor. Refer to On- good CNG control regulator.
Vehicle Inspection under CNG PRESSURE module and recheck.
REGULATOR in this section.
DTC P1601

P1601: Monitor Circuit Fault • CAN communication line
This DTC is detected if any one of the following conditions is met. • CNG control module
• The state of changing over “Petrol” to “CNG” is detected continuously • ECM
for 5 sec.
• The state of changing over “CNG” to “Petrol” is detected continuously
for 5 sec.
WIRING DIAGRAM
Refer to DTC P0201 / P0202 / P0203 /P0204 in this section.

2) Select “Forced CNG MODE” with fuel selector switch and keep it for 10 sec.
3) Change over from “Forced CNG MODE” to “Petrol MODE” and keep “Petrol MODE” for 10 sec.
DTC TROUBLESHOOTING
Step Action Yes No

DIAGNOSIS FLOW
TABLE in Section 6.
Step Action Yes No

1) Check CAN communication circuit. Refer to defective wire harness.
TROUBLESHOOTING FOR CAN-DTC in this section.
3 DTC recheck Substitute a known- End.
1) Substitute a known-good CNG control module. good ECM and recheck.
2) Perform DTC confirmation procedure and check DTC.
Is DTC P1601 is still detect?
DTC P2408

P2408: Fuel Cap Sensor / Switch Circuit • CNG receptacle switch and/or its circuit
This DTC is detected if any one of the following conditions is met. • CNG control module
• Both CNG receptacle switch No.1 and No.2 ON signals are input
simultaneously for 5 sec.
• Both CNG receptacle switch No.1 and No.2 OFF signals are input
simultaneously for 5 sec.
WIRING DIAGRAM
A1 2
12V B1
L76-31 P
12V B
L76-30 G
A2
[A]
L76 L77
9 8 7 6 5 4 3 2 1 9 8 7 6
5 4 3 2 1
17 16 15 14 13 12 11 10 17 16 15 14 13 12 11 10 A
26 25 24 23 22 21 20 19 18 26 25 24 23 22 21 20 19 18
34 33 32 31 30 29 28 27 34 33 32 31 30 29 28 27
[A]: CNG control module connector (View: A) A2: CNG receptacle switch No.2 signal circuit 1. CNG control module
A1: CNG receptacle switch No.1 signal circuit B1: CNG receptacle switch ground circuit 2. CNG receptacle switch

1) Turn ignition switch to ON position with CNG receptacle cap is set.
3) Detach CNG receptacle cap and keep it for 10 sec.
DTC TROUBLESHOOTING
Step Action Yes No
DIAGNOSIS FLOW
TABLE in Section 6.
Step Action Yes No

2 CNG receptacle switch ground circuit check Go to Step 3. Repair or replace
1) Turn ignition switch to OFF position and then disconnect ground circuit of CNG
connector from CNG receptacle switch. receptacle switch.
2) Check for proper terminal connection to CNG receptacle
switch connector.
3) If connections are OK, measure resistance between
CNG receptacle switch ground circuit (B1) and vehicle
body ground.
3 CNG receptacle switch signal circuit check Go to Step 4. Repair or replace
1) Disconnect connectors from CNG control module. defective wire harness.
module connectors.
3) If connections are OK, check that CNG receptacle switch
signal circuits (A1 and A2) are as follows.
• Wiring harness resistance of each CNG receptacle
switch signal circuit is less than 1 :.
• Insulation resistance of each CNG receptacle switch
signal circuit between CNG receptacle switch
between each CNG receptacle switch signal circuit
terminal and each terminal at CNG receptacle switch
connector.
• Voltage of each CNG receptacle switch signal circuit

4 CNG receptacle switch Check Substitute a known Replace CNG
1) Check CNG receptacle switch. Refer to CNG good CNG control receptacle switch.
RECEPTACLE SWITCH in Section 6C1. module and recheck.
DTC P2665 / P2667

P2665: Fuel Shutoff Valve “B” Control Circuit / Open • Shut off valve of CNG cylinder
Monitor voltage of shut off valve of CNG cylinder is lower than specified voltage and/or its circuit
for 5 sec. only if its command signal is not output and CNG valve control relay is • CNG valve control relay and/or its
ON. circuit
P2667: Fuel Shutoff Valve “B” Control Circuit High
Monitor voltage of shut off valve of CNG cylinder is higher than specified
voltage for 5 sec. only if its command signal is output and CNG valve control
relay is ON.
WIRING DIAGRAM
NOTE
Check to make sure that following condition is satisfied when using this “DTC Confirmation
Procedure”.
• DTC P0607 is not detected.

2) Operate fuel selector switch and select “Forced CNG MODE”.
4) Select “Petrol MODE”.
DTC TROUBLESHOOTING
Step Action Yes No
DIAGNOSIS FLOW
TABLE in Section 6.
2 DTC check Go to Step 3. Go to Step 5.
Is there DTC P0005 and/or P0007?

3 CNG valve control relay and its circuit check Go to Step 4. Repair or replace
1) Check CNG valve control relay and its circuit according defective part.
to step 3 through 5 of DTC P0005 / P0007 in this
section.
4 Shut off valve power supply circuit check Go to Step 5. Repair or replace
1) Check power supply circuits of shut off valves on CNG defective wire harness.
fuel pressure regulator and on CNG cylinder respectively
according to step 6 of DTC P0005 / P0007 in this
section.
5 Power supply circuit check for shut off valve on CNG Go to Step 6. Repair or replace power
cylinder supply circuit of shut off
1) Turn ignition switch to OFF position and then disconnect valve on CNG cylinder.
connector from shut off valve of CNG cylinder.
2) Remove CNG valve control relay.
control relay and shut off valve of CNG cylinder
connector.
4) If connections are OK, measure wiring harness
resistance of shut off valve of CNG cylinder power
supply circuit (A2).
Step Action Yes No

6 Control circuit check for shut off valve on CNG cylinder Go to Step 7. Repair or replace
module connectors.
3) If connection are OK, check that shut off valve of CNG
cylinder control circuit (B2) is as follows.
• Wiring harness resistance of shut off valve of CNG
cylinder control circuit is less than 1 :.
• Insulation resistance of shut off valve of CNG cylinder
control circuit between shut off valve of CNG cylinder
between shut off valve of CNG cylinder control circuit
terminal and each terminal at shut off valve of CNG
cylinder connector.
• Voltage of shut off valve of CNG cylinder control
circuit is 0 – 1 V with ignition switch in ON position.
7 Check of shut off valve on CNG cylinder Substitute a known- Replace CNG cylinder.
1) Check shut off valve of CNG Cylinder Refer to CNG good CNG control
CYLINDER WITH VALVE in Section 6C1. module and recheck.
DTC P2668

P2668: Fuel Mode Indicator Lamp Control Circuit • Fuel selector switch and/or its circuit
Fuel selector switch ON signal is input continuously for more than 120 • CNG control module
sec.
WIRING DIAGRAM
IG1
1
12V 2 3
L76-29 R B/W
12V A1 B1
L76-22 Lg B
[A]
L76 L77
9 8 7 6 5 4 3 2 1 9 8 7 6 5 4 3 2 1
17 16 15 14 13 12 11 10 17 16 15 14 13 12 11 10 A
26 25 24 23 22 21 20 19 18 26 25 24 23 22 21 20 19 18
34 33 32 31 30 29 28 27 34 33 32 31 30 29 28 27
[A]: CNG control module connector (View: A) B1: Fuel selector switch ground circuit 2. Fuel selector switch
A1: Fuel selector switch signal circuit 1. CNG control module 3. “IG METER” fuse

Turn ignition switch to ON position and keep it for 3 min.
DTC TROUBLESHOOTING
Step Action Yes No

DIAGNOSIS FLOW
TABLE in Section 6.
2 Fuel selector switch ground circuit check Go to Step 3. Repair or replace
1) Turn ignition switch to OFF position and then disconnect ground circuit of fuel
connector from fuel selector switch. selector switch.
2) Check for proper terminal connection to fuel selector
switch connector.
3) If connection is OK, measure resistance between fuel
selector switch ground circuit (B1) and vehicle body
ground.
3 Fuel selector switch signal circuit check Go to Step 4. Repair or replace
connector from CNG control module.
module connectors.
3) If connections are OK, check that fuel selector switch
signal circuit (A1) is as follows.
• Wiring harness resistance of fuel selector switch
signal circuit is less than 1 :.
• Insulation resistance of fuel selector switch signal
circuit between fuel selector switch connector and
between fuel selector switch signal circuit terminal
and each terminal at fuel selector switch connector.
• Voltage of fuel selector switch signal circuit is 0 – 1 V
with ignition switch in ON position.
4 Fuel selector switch check Substitute a known- Replace fuel selector
1) Check fuel selector switch. Refer to FUEL SELECTOR good CNG control switch.
SWITCH (BI-FUEL CNG MODEL) in Section 8. module and recheck.
TROUBLESHOOTING FOR CAN-DTC
CAN COMMUNICATION SYSTEM CIRCUIT DIAGRAM

1 3
[a]
L71-35 R/B G20-7
5 5
L71-34 W/B G20-9
2
[b] [c]
L70-29 B/Y L77-25 G20-6 R 4
5
L70-28 Or L77-33 G20-8 W
[A] [C] G20
L76 L77 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
9 8 7 6 5 4 3 2 1 9 8 7 6 5 4 3 2 1 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
17 16 15 14 13 12 11 10 17 16 15 14 13 12 11 10
26 25 24 23 22 21 20 19 18 26 25 24 23 22 21 20 19 18
34 33 32 31 30 29 28 27 34 33 32 31 30 29 28 27 [D] E47
16 15 14 13 12 11 10 9
8 7 6 5 4 3 2 1
[B]
L69 L70 L71
7 6 5 4 3 2 1 7 6 5 4 3 2 1 6 5 4 3 2 1 A
17 16 15 14 13 12 11 10 9 8 19 18 17 16 15 14 13 12 11 10 9 8 16 15 14 13 12 11 10 9 8 7
27 26 25 24 23 22 21 20 19 18 27 26 25 24 23 22 21 20 27 26 25 24 23 22 21 20 19 18 17 B
34 33 32 31 30 29 28 35 34 33 32 31 30 29 28 35 34 33 32 31 30 29 28
[A]: CNG control module connector (View: A) [a] to [c]: CAN communication line (link with diagnosis 4. DLC
flows A to C of DIAGNOSIS FLOW SELECTION
TABLE in this section.
[B]: ECM connector (View: A) 1. ECM 5. CAN driver
[C]: Combination meter connector (View: A) 2. CNG control module
[D]: DLC (View: B) 3. Combination meter
CAN COMMUNICATION CHECK

Using SUZUKI scan tool, execute “Communication Malfunction DTC” under “Bus check” and check all control modules
connected through CAN communication bus for DTC.
Condition Action
Only history DTC was detected in either of systems Recheck DTC after clear DTC and performing the driving
test. If check results is OK, it is intermittent trouble.
“Control Module Bus Off” was detected in either of system Perform TROUBLESHOOTING FOR COMMUNICATION
(current DTC) BUS OFF in this section.
Only “Lost Communication” was detected in either of Perform TROUBLESHOOTING FOR LOST
system (current DTC) COMMUNICATION in this section.
No display on SUZUKI scan tool (It is not possible to Check if SUZUKI scan tool is communicable by
communicate with all systems.) connecting to another vehicle.
Perform TROUBLESHOOTING FOR LOST
COMMUNICATION in this section.
CAN DTC (LOST COMMUNICATION AND COMMUNICATION BUS OFF) TABLE

DTC DTC name Detecting condition
ECM
U0073 Control Module Communication Transmitting and receiving error of ECM for specified time
Bus “A” Off continuously.
U0108 Lost Communication With Receiving error of ECM from CNG control module for
Alternative Fuel Control Module specified time continuously.
U0155 Lost Communication with Receiving error of ECM from combination meter for
Instrument Panel Cluster (IPC) specified time continuously.
Control Module
CNG control module
U0073 Control Module Communication Transmitting and receiving error of CNG control module
Bus Off for specified time continuously.
U0100 Lost Communication with ECM Receiving error of CNG control module from ECM for
specified time continuously.
TROUBLESHOOTING FOR LOST COMMUNICATION
Wiring Diagram
Refer to CAN COMMUNICATION SYSTEM CIRCUIT DIAGRAM in this section.
Diagnosis Procedure
NOTE
Be sure to perform CAN COMMUNICATION CHECK before following this flow.
When “Lost Communication” is detected in any control modules, perform inspection using the following procedure.
1) Connect SUZUKI scan tool to DLC, and then turn ignition switch to ON position.
2) Using “Communication Bus Check” under “Bus Check” of SUZUKI scan tool, diagnose control module disabled to
communicate (no display on screen).
3) Based on above check results, select applicable diagnosis flow (A to C) from DIAGNOSIS FLOW SELECTION
TABLE.
4) Perform troubleshooting according to selected diagnosis flow.
Diagnosis Flow Selection Table

! CAUTION
• If control module or sensor alone fails to communicate, check if power circuit or grounding circuit
of applicable control module or sensor is in good condition, referring to system circuit diagram, etc.
before diagnosing trouble according to flow chart.
• If it is not possible to select suitable diagnosis flow from DIAGNOSIS FLOW SELECTION TABLE or
two or more diagnosis flows are selectable, perform TROUBLESHOOTING FOR COMMUNICATION
BUS OFF in this section.
NOTE
Diagnosis flows A to C link with CAN communication lines [a] to [c] of CAN COMMUNICATION
SYSTEM CIRCUIT DIAGRAM in this section.
Communication disabled control module / sensor Diagnosis flow

ECM and CNG control module A
CNG control module B
All control module communicated by CAN C
Troubleshooting
Diagnosis flow: A
Step Action Yes No
1) Disconnect negative cable from battery. defective wire harness.
2) Disconnect “L71” connector from ECM and “G20”
connector from combination meter.
3) Check for proper terminal connection at ECM and
combination meter connectors.
4) If OK, check CAN communication circuit [a] between
ECM connector and combination meter connector for
breaking.
2 ECM terminating resistance check Substitute a known- Substitute a known-
1) Connect “L71” connector to ECM. good combination meter good ECM and recheck.
and recheck.
2) Measure resistance between “G20-7” and “G20-9”
terminal of combination meter connector.
Is resistance 114 – 134 :?
Diagnosis flow: B
Step Action Yes No
2) Disconnect “L70” connector from ECM and “L77”
connector from CNG control module.
3) Check for proper terminal connection at ECM and CNG
control module connectors.
4) If OK, check CAN communication circuit [b] between
ECM connector and CNG control module connector for
breaking.
2 ECM terminating resistance check Substitute a known- Substitute a known-
1) Connect “L70” connector to ECM. good CNG control good ECM and recheck.
module and recheck.
2) Disconnect “L71” connector from ECM.
3) Measure resistance between “L77-25” and “L77-33”
terminal of CNG control module connector.
Diagnosis flow: C
Step Action Yes No
2) Disconnect “G20” connector from combination meter.
3) Check for proper terminal connection combination meter
connector and DLC.
4) If OK, check CAN communication circuit [c] between
combination meter connector and DLC for breaking.
Step Action Yes No

2 Combination meter terminating resistance check Go to “Troubleshooting Substitute a known-
1) Connect “G20” connector to combination meter. for Communication Bus good combination meter
Off”. and recheck.
2) Disconnect “L71” connector from ECM.
terminal of DLC.
TROUBLESHOOTING FOR COMMUNICATION BUS OFF

NOTE
Be sure to perform CAN COMMUNICATION CHECK before performing this flow.
Wiring Diagram
Refer to CAN COMMUNICATION SYSTEM CIRCUIT DIAGRAM in this section.
Diagnosis Procedure
When “CAN Communication Bus Off” is detected in any control modules, or when it is not possible to communicate
with ECM, CNG control module and/or combination meter by using SUZUKI scan tool, perform inspection using the
following procedure.
1) Using oscilloscope or oscilloscope function of SUZUKI scan tool, observe waveform at DLC on the following
condition when ignition switch is at ON position.
Channel Probe Terminal No.
+ E47-6 (Refer to CAN Communication System Circuit
1 Diagram in this section)
– Vehicle body ground
+ E47-14 (Refer to CAN Communication System Circuit
2 Diagram in this section.)
– Vehicle body ground
2) Compare waveform displayed on oscilloscope with waveforms given as REFERENCE WAVEFORM and identify
the system in trouble and trouble cause by finding the most similar waveform.
3) Perform troubleshooting according to Troubleshooting in TROUBLESHOOTING FOR COMMUNICATION BUS
OFF in this section.
Reference Waveform
NOTE
• Shown below are waveforms observed with oscilloscope function of SUZUKI scan tool as examples
for reference.
• Waveforms in “Examples of abnormal waveforms” are picked up as samples among CAN
communication waveforms during occurrence of abnormality. However, the same waveform cannot
necessarily be observed. Therefore, to identify the content of abnormality, select a waveform which
is the most similar to the observed waveform from “Examples of abnormal waveforms”.
Normal Waveform
Normal waveform Description
Reference voltages both of CAN High
signal and CAN Low signal is 2.5 V.
Waveform of CAN High signal is 2.5 –
3.5 V and that of CAN Low signal is
2.5 – 1.5 V.
[A]: Ground level of each channel [D]: Waveform of channel 1

[B]: Volt/div of each channel [E]: Waveform of channel 2
[C]: Time/div of each channel
Examples of abnormal waveforms

Characteristic waveform
Possible cause Description
CAN High signal CAN Low signal
Shorted to ground In case of CAN High
signal wire is shorted to
ground circuit
Both of CAN High signal
and CAN Low signal are
fixed to GND level (0 V)
In case of CAN Low signal
wire is shorted to ground
circuit
Reference level both of
CAN High signal and CAN
Low signal is GND level (0
V) and CAN High signal
waveform oscillates
irregularly.
• CAN High signal:
Between 0 V and 3 V
• CAN Low signal: Fixed to
0V
Open In case of CAN High
signal wire is open
Reference voltage both of
Low signal is 2.5 V and
these waveform oscillates
irregularly.
Between 3.5 V and 1.0 V
• CAN Low signal:
wire is open
irregularly.
• CAN Low signal:
Characteristic waveform
Possible cause Description
CAN High signal CAN Low signal
Shorted to power In case of CAN High
supply circuit (12 V) signal wire is shorted to
power supply circuit (12
V)
CAN High signal is fixed to
12 V and CAN Low signal
oscillate irregularly between
12 V and 2 V.
wire is shorted to power
supply circuit (12 V)
Both of CAN High signal
and CAN Low signal are
fixed to 12 V.
Shorted to power In case of CAN High

supply circuit (5 V) signal wire is shorted to
power supply circuit (5 V)
irregularly.
• CAN Low signal:
wire is shorted to power
supply circuit (5 V)
Low signal is 5.0 V with
phase and these waveform
oscillates irregularly
between 5.0 V and 2.5 V.
CAN High signal Both of CAN High signal
and CAN Low and CAN Low signal are
signal wire are fixed to near 2.5 V.
shorted each other
Troubleshooting
NOTE
• Before diagnosing a trouble, be sure to check equipment of vehicle being serviced as well as
control module connected to CAN communication line.
• Before using SUZUKI scan tool, read its operator’s manual to know how to use it and what functions
are available.
• When performing “Communication Bus Check” by using SUZUKI scan tool in this troubleshooting,
refer to JUDGMENT OF COMMUNICATION BUS CHECK in this section.
Step Action Yes No

1 CAN communication line check Go to Step 2. Repair or replace
2) Disconnect connector from all the following control
modules communicated by CAN. Refer to CAN
COMMUNICATION SYSTEM CIRCUIT DIAGRAM in
this section.
3) Check for proper terminal connection to each CAN
communication circuit at all control module
(communicated by CAN) connectors and DLC.
4) If OK, check each CAN communication circuit for
breaking, shorting to power circuit, shorting to ground
circuit, shorting to each other CAN communication wire
or high resistance, based on results obtained through
measurement and identification of trouble nature in
Steps 2) of DIAGNOSIS PROCEDURE in
TROUBLESHOOTING FOR COMMUNICATION BUS
OFF in this section.
2 ECM CAN terminating resistance check Go to Step 3. Substitute a known-
1) Connect L71 connector to ECM. good ECM and recheck.
terminal at Combination meter connector.

3 Combination meter CAN terminating resistance check Go to Step 4. Substitute a known-
1) Disconnect “L71” connector from ECM. good combination meter
and recheck.
2) Connect “G20” connector to combination meter.
3) Measure resistance between “L71-35” and “L71-34”
terminal of ECM connector.

4 ECM and combination meter communication check Perform Go to Step 5.
1) Connect “L71” connector to ECM. COMMUNICATION
CHECK in
2) Connect negative cable to battery and turn ignition
TROUBLESHOOTING
switch to ON position.
FOR
3) Turn ignition switch to ON position and select COMMUNICATION
“Communication Bus Check” under “Bus check” menu in BUS OFF in this
SUZUKI scan tool, and check that CAN communication section.
is normal condition for ECM and combination meter.
Is communication normal?
Step Action Yes No

5 Combination meter check Replace faulty Substitute a known-
1) Turn ignition switch to OFF position. combination meter good ECM and recheck.
(combination meter was
2) Substitute a known-good combination meter.
faulty condition).
3) Turn ignition switch to ON position and select
“Communication Bus Check” under “Bus check” menu in
SUZUKI scan tool, and check that CAN communication
is normal condition for ECM and combination meter.
Is communication normal?
Communication check
CNG control module

1) Turn ignition switch to OFF position.
2) Connect “L77” connector to CNG control module.
3) Turn ignition switch to ON position and select “Communication Bus Check” under “Bus check” menu in SUZUKI
scan tool, and check that CAN communication is normal condition for ECM, combination meter and CNG control
module. Refer to JUDGMENT OF COMMUNICATION BUS CHECK in TROUBLESHOOTING FOR
COMMUNICATION BUS OFF in this section.
4) If any malfunction is found, substitute a known-good CNG control module and recheck.
Judgment of communication bus check

When performing “Communication Bus Check” by using SUZUKI scan tool, refer to the following table for judgment.
Judgment Display of Communication Bus Check
Normal • All connected control modules / sensors (communicated by CAN) are displayed and its back
ground color is “White”.
• Above state remains unchanged while monitoring for longer than 1 minute.
Abnormal • Even one of connected control modules / sensors (communicated by CAN) is not displayed.
• Background color of control modules / sensors (communicated by CAN) is displayed in “Gray” or
“Light blue”.
• Background color of control modules / sensors (communicated by CAN) is changed to “Gray”
(the numbers of control modules / sensors are decreased) or “Light blue” (the numbers of control
modules / sensors are increase).
• “Communication Bus Check” cannot be executed.
ECM AND ITS CIRCUIT VOLTAGE TABLE

VOLTAGE CHECK
1) Remove ECM from vehicle body with ignition switch OFF referring to ENGINE CONTROL MODULE (ECM) in this
section.
2) Connect ECM connectors to ECM.
3) Check voltage at each terminal of connectors connected.
NOTE
• As each terminal voltage is affected by battery voltage, confirm that it is 11 V or more when ignition
switch is turned to ON position.
• Terminal No. with asterisk (*) cannot be measured with voltmeter because it is pulse signal. Use
oscilloscope for its check if necessary. Reference waveforms are described after the table.
[A]
L69 L70 L71
7 6 5 4 3 2 1 7 6 5 4 3 2 1 6 5 4 3 2 1
17 16 15 14 13 12 11 10 9 8 19 18 17 16 15 14 13 12 11 10 9 8 16 15 14 13 12 11 10 9 8 7
27 26 25 24 23 22 21 20 19 18 27 26 25 24 23 22 21 20 27 26 25 24 23 22 21 20 19 18 17 [a]
34 33 32 31 30 29 28 35 34 33 32 31 30 29 28 35 34 33 32 31 30 29 28
[A]: ECM connector (View: [a])
Terminal No. Wire color Circuit Normal voltage Condition

L69-1 — — — —
10 – 14 V Ignition switch: ON
Fuel injector No.4 con- 0–1V
L69-2* Br/Y Engine: Idle speed after
trol circuit np
warming up
10 – 14 V
L69-3* Br/W Engine: Idle speed after
trol circuit np
warming up
10 – 14 V
L69-4* Br Engine: Idle speed after
trol circuit np
warming up
10 – 14 V
L69-5* Br/B Engine: Idle speed after
trol circuit np
warming up
10 – 14 V
L69-6 B/Bl ECM ground circuit Below 0.3 V Ignition switch: ON
L69-7 B/Bl ECM ground circuit Below 0.3 V Ignition switch: ON
0–1V
IAC valve control cir- Engine: Idle speed after
L69-8* Or np
cuit warming up
10 – 14 V
L69-9 — — — —
10 – 14 V Ignition switch: OFF
L69-10 B/Or Main relay drive circuit
0–1V Ignition switch: ON
A/C compressor: Not oper-
A/C compressor relay 10 – 14 V
L69-11 P/Bl ated
drive circuit
0–1V A/C compressor: Operated
Ignition switch: ON
10 – 14 V ECT < 85 °C (185 °F)
Radiator cooling fan A/C switch: OFF
L69-12 R/G
relay drive circuit Ignition switch: ON
0–1V ECT > 90 °C (194 °F)
A/C switch: OFF
0–1V
Ignition switch:
Fuel pump relay drive np
L69-13* P/Bl OFFoONoSTART
circuit 10 – 14 V
0–1V Engine: Running on petrol

0–1V EVAP canister purge valve:
EVAP canister purge
L69-14* G/Y np 10% open (using active test
valve control circuit
10 – 14 V of SUZUKI scan tool)
L69-15 — — — —
EGR valve drive circuit 0–1V
L69-16* R/W Engine: Immediately after
1 np
engine start-up
10 – 14 V
L69-17* R Engine: Immediately after
2 np
engine start-up
10 – 14 V
L69-18 — — — —
L69-19 — — — —
L69-20 — — — —
L69-21 — — — —
A/C condenser fan: Not
10 – 14 V
A/C condenser fan operated
L69-22 W
relay drive circuit A/C condenser fan: Oper-
0–1V
ated
L69-23 — — — —
L69-24 — — — —
L69-25 — — — —
L69-26 — — — —
L69-27 — — — —
L69-28 — — — —
Ignition coil assembly 0–1V
L69-29* W/B Engine: Idle speed after
No.1 control circuit np
warming up
4–6V
Ignition coil assembly 0–1V
L69-30* V Engine: Idle speed after
warming up
4–6V
L69-31 — — — —
L69-32 — — — —
L69-33* R/Bl Engine: Immediately after
4 np
engine start-up
10 – 14 V
L69-34* R/Y Engine: Immediately after
3 np
engine start-up
10 – 14 V
Main power supply cir- 10 – 14 V Ignition switch: ON
L70-1 B/R
cuit 2 0–1V Ignition switch: OFF
Main power supply cir- 10 – 14 V Ignition switch: ON
L70-2 B/R
cuit 1 0–1V Ignition switch: OFF
L70-3 — — — —
L70-4 B ECM ground circuit Below 0.3 V Ignition switch: ON
L70-5 — — — —
TP sensor power sup-
L70-6 Lg/R 4.5 – 5.5 V Ignition switch: ON
ply circuit
HO2S heater control 0–1V
L70-7* Bl Engine: Idle speed after
circuit np
warming up
10 – 14 V
Knock sensor signal Engine: Running at 4,000
L70-8* Bl 2–3V
circuit rpm after warming up

Knock sensor ground
L70-9 B/W Below 0.3 V Ignition switch: ON
circuit
Knock sensor shield
L70-10 B Below 0.3 V Ignition switch: ON
ground circuit
L70-11 — — — —
Ignition switch: ON
3.70 – 4.52 V Barometric pressure: 100
kPa, 760 mmHg
MAP sensor signal cir-
L70-12 Gr/R Engine: Idle speed after
cuit
warming up
1.13 – 1.39 V
Barometric pressure: 100
kPa, 760 mmHg
Ignition switch: ON
3.48 – 4.26 V
ECT: 0 °C (32 °F)
ECT sensor signal cir- Ignition switch: ON
L70-13 Lg 1.41 – 1.73 V
cuit ECT: 50 °C (122 °F)
Ignition switch: ON
0.42 – 0.52 V
ECT: 100 °C (212 °F)
Ignition switch: ON
3.85 – 4.71 V
IAT: –20 °C (–4 °F)
IAT sensor signal cir- Ignition switch: ON
L70-14 Lg/B 2.14 – 2.62 V
cuit IAT: 20 °C (68 °F)
Ignition switch: ON
0.79 – 0.97 V
IAT: 60 °C (140 °F)
Ignition switch: ON
0.6 – 1.0 V
Accelerator pedal: Released
TP sensor signal cir-
L70-15 Gr/Bl Ignition switch: ON
cuit
3.7 – 4.2 V Accelerator pedal:
Depressed fully
Engine: Idle speed after
L70-16* R HO2S signal circuit 0.1 – 0.9 V
warming up
L70-17 — — — —
L70-18 — — — —
HO2S shield ground
L70-19 B Below 0.3 V Ignition switch: ON
circuit
MAP sensor power
L70-20 Lg/R 4.5 – 5.5 V Ignition switch: ON
supply circuit
L70-21 — — — —
L70-22 — — — —
L70-23 — — — —
L70-24 — — — —
L70-25 — — — —
CKP sensor shield
L70-26 B Below 0.3 V —
ground circuit
CKP sensor ground
L70-27 Y Below 0.3 V —
circuit
CAN (low)
communication circuit
L70-28 Or 1.5 – 2.5 V Ignition switch: ON
to CNG control
module
CAN (high)
communication circuit
L70-29 B/Y 2.5 – 3.5 V Ignition switch: ON
to CNG control
module
L70-30 G HO2S ground circuit Below 0.3 V Ignition switch: ON
L70-31 Bl/Y Sensor ground circuit Below 0.3 V Ignition switch: ON

0–1V
or Ignition switch: ON
4–5V
L70-32* Y VSS signal circuit
0–1V
np Vehicle running
4–6V
Ignition switch signal 0–1V Ignition switch: OFF
L70-33 B/W
circuit 10 – 14 V Ignition switch: ON
0–1V
or Ignition switch: ON
CMP sensor signal cir- 4–5V
L70-34* G/R
cuit 0–1V
np
warming up
4–6V
1 – 1.5 V
CKP sensor signal cir- Engine: Idle speed after
L70-35* Br np
cuit warming up
–1 – –1.5 V
Ignition switch: ON
0–1V
Brake pedal: Released
Brake light switch sig-
L71-1 G/W Ignition switch: ON
nal circuit
10 – 14 V Brake pedal: Depressed
fully
L71-2 — — — —
Ignition switch: ON
10 – 14 V A/C switch: OFF
A/C switch input signal Blower fan switch: OFF
L71-3 Or
circuit Ignition switch: ON
0–1V A/C switch: ON
Blower fan switch: ON
L71-4 — — — —
Starting motor control 0–1V Ignition switch: ON
L71-5 B/Y
relay signal circuit 6 – 12 V Ignition switch: START
Back-up power supply
L71-6 W 10 – 14 V Ignition switch: All positions
circuit
Ignition switch: ON
3.20 – 3.91 V A/C evaporator outlet tem-
A/C evaporator outlet
perature: 0 °C (32 °F)
L71-7 W/B air temp. sensor signal
Ignition switch: ON
circuit
1.92 – 2.34 V A/C evaporator outlet tem-
perature: 25 °C (77 °F)
L71-8 — — — —
L71-9 — — — —
L71-10 — — — —
L71-11 — — — —
L71-12 — — — —
L71-13 — — — —
L71-14 — — — —
L71-15 — — — —
Blower motor signal
L71-16 P/B Blower fan switch: 1st speed
circuit 0–1V
position or more
L71-17 — — — —
L71-18 — — — —
L71-19 — — — —
L71-20 — — — —
L71-21 — — — —
L71-22 — — — —
L71-23 — — — —
L71-24 — — — —

L71-25 — — — —
L71-26 — — — —
L71-27 — — — —
L71-28 — — — —
L71-29 — — — —
L71-30 — — — —
L71-31 — — — —
L71-32 — — — —
A/C evaporator outlet
L71-33 Bl/Y air temp. sensor Below 0.3 V Ignition switch: ON
ground circuit
CAN (high) communi-
L71-34* W/B cation circuit to combi- 2.5 – 3.5 V Ignition switch: ON
nation meter
CAN (low) communi-
L71-35* R/B cation circuit to combi- 1.5 – 2.5 V Ignition switch: ON
nation meter
Reference Waveform
NOTE
• Waveform analysis is as follows.
1. Fuel injector control signal
Fuel injector No.1 control signal and ignition coil

No.1 signal
Fuel injector No.1 control signal (1):
[A]: Waveform of channel 1 [C]: VOLT/DIV of each channel
+ L69-5
[B]: Ground level of each channel [D]: TIME/DIV 1
– L69-6
• Waveform might change for measurement
Ignition coil No.1 signal (2):
condition and vehicle spec.
+ L69-29
Fuel injector control signal 2
– L69-6
L69-5 (No.1) CKP sensor signal (3):
L69-4 (No.2) Channel Probe Terminal No.
+
1 L69-3 (No.3) + L70-35
L69-2 (No.4) 3
– L69-6
– L69-6
CMP sensor signal (4):
Measurement Condition Channel Probe Terminal No.
• Engine: Idle speed after warming up + L70-34
4
– L69-6

1
– L69-6
1
2 Channel Probe Terminal No.
+ L69-30
2
5 – L69-6
3
CKP sensor signal (3):
6
+ L70-35
3
4 – L69-6

5. Crankshaft 720q angle 6. Camshaft 360q angle Channel Probe Terminal No.
+ L70-34
Fuel injector No.2 control signal and ignition coil 4
– L69-6
No.2 signal
Fuel injector No.2 control signal (1): Measurement Condition
Channel Probe Terminal No. • Engine: Idle Speed After Warming Up
+ L69-4
1
– L69-6 1

2
+ L69-30 5
2 3
– L69-6
6
+ L70-35 4
3
– L69-6
CMP sensor signal (4): 5. Crankshaft 720q angle 6. Camshaft 360q angle

+ L70-34 Fuel injector No.4 control signal and ignition coil
4 No.1 signal
– L69-6
1
– L69-6
1
2
+ L69-29
2
5 – L69-6
3
6
+ L70-35
3
4 – L69-6

5. Crankshaft 720q angle 6. Camshaft 360q angle Channel Probe Terminal No.
+ L70-34
4
Fuel injector No.3 control signal and ignition coil – L69-6
No.2 signal
Measurement Condition Ignition coil signal

• Engine: Idle speed after warming up Channel Probe Terminal No.
L69-29 (No.1)
+
1
1 L69-30 (No.2)
– L69-6
2
Measurement Condition
5 • Engine: Idle speed after warming up
3
5. Crankshaft 720q angle 6. Camshaft 360q angle
HO2S signal and HO2S heater signal

HO2S signal (1):
+ L70-16 1. Ignition coil signal
1
– L69-6
IAC valve signal
HO2S heater signal (2): Channel Probe Terminal No.
Channel Probe Terminal No. + L69-8
+ L70-7 1
2 – L69-6
– L69-6
Measurement Condition • Engine: Idle speed after warming up
• Engine: Idle speed after warming up
1. IAC valve signal
Measurement Condition EVAP canister purge valve signal

• Engine: Racing after warming up Channel Probe Terminal No.
+ L69-14
1
– L69-6
• EVAP canister purge valve: 10% open (using “Active
Test” of SUZUKI scan tool)
3. Engine: Racing 4. Engine: Idle speed

1. EVAP canister purge valve signal

1. Vehicle speed signal
EGR valve signal CKP sensor signal and CMP sensor signal
EGR valve drive signal (1): CKP sensor signal (1):
Channel Probe Terminal No. Channel Probe Terminal No.
+ L69-16 + L70-35
1 1
– L69-6 – L69-6
EGR valve drive signal (2): CMP sensor signal (2):
+ L69-17 + L70-34
2 2
– L69-6 – L69-6
EGR valve drive signal (3): Measurement Condition
Channel Probe Terminal No. • Engine: Idle speed after warming up
+ L69-33
3
– L69-6 1
EGR valve drive signal (4):

+ L69-34
4
– L69-6
Measurement Condition 2
• Engine: Immediately after engine started
Knock sensor signal

3 Channel Probe Terminal No.
+ L70-8
1
– L70-9
4
• Engine: Running at 4,000 rpm after warming up
VSS signal
+ L70-32
1
– L69-6
• Engine: Drive vehicle at 30 km/h (19 mph) after
warming up
• Ignition switch: ON
1. Knock sensor signal
Fuel pump relay signal

+ L69-13
1
– L69-6
• Ignition switch: OFF o ON o START
2 3 4
1. Fuel pump relay signal 3. Ignition switch: ON

2. Ignition switch: OFF 4. Ignition switch: ON o START
CAN communication signal

CAN communication signal (High) (1):
L71-34 (to
combination
meter)
+
1 L70-29 (to
CNG control
module)
– L69-6
CAN communication signal (Low) (2):

L71-35 (to
combination
meter)
+
2 L70-28 (to
CNG control
module)
– L69-6
• Engine: Stop
CNG CONTROL MODULE AND ITS CIRCUIT VOLTAGE TABLE
VOLTAGE CHECK
NOTE
• As each terminal voltage is affected by battery voltage, confirm that it is 11 V or more when ignition
switch is turned to ON position.
• Terminal No. with asterisk (*) cannot be measured with voltmeter because it is pulse signal. Use
oscilloscope for its check if necessary.
• Before performing this check, be sure to read PRECAUTION FOR CNG CONTROL MODULE CIRCUIT
INSPECTION in Section 6.
[A]
L76 L77
9 8 7 6 5 4 3 2 1 9 8 7 6 5 4 3 2 1
A
17 16 15 14 13 12 11 10 17 16 15 14 13 12 11 10
26 25 24 23 22 21 20 19 18 26 25 24 23 22 21 20 19 18
34 33 32 31 30 29 28 27 34 33 32 31 30 29 28 27
[A]: CNG control module connector (View: A)

Main power supply 10 – 14 V Ignition switch: ON
L76-1 R/B
circuit 1 0–1V Ignition switch: OFF
Fuel injector No.4
0–1V
L76-2 Br/Y control signal from Engine: Idle speed after
np
ECM circuit warming up
10 – 14 V
Fuel injector No.2 10 – 14 V Ignition switch: ON
control signal from 0–1V
L76-3 Br Engine: Idle speed after
ECM circuit np
warming up
10 – 14 V
CNG valve control 0–1V Ignition switch: OFF
L76-4 Bl
relay drive circuit 10 – 14 V Engine: Running
CNG pressure-and- 4.5 – 5.5 V Ignition switch: ON
L76-5 B/G temperature sensor
0–1V Ignition switch: OFF
power supply circuit
CNG cylinder 4.5 – 5.5 V Ignition switch: ON
L76-6 G pressure sensor
power supply circuit
L76-7 — — — —
L76-8 — — — —
L76-9 — — — —
Main power supply 10 – 14 V Ignition switch: ON
L76-10 R/B
circuit 2 0–1V Ignition switch: OFF
Fuel injector No.3
0–1V
L76-11 Br/W control signal from Engine: Idle speed after
np
10 – 14 V
Fuel injector No.1
0–1V
L76-12 Br/B control signal from Engine: Idle speed after
np
10 – 14 V

Ignition switch: ON
3.21 – 3.93 V CNG temperature: 20 qC (68
qF)
Ignition switch: ON
CNG temperature
L76-13 Or 2.43 – 2.97 V CNG temperature: 40 qC
sensor signal circuit
(104 qF)
Ignition switch: ON
1.67 – 2.05 V CNG temperature: 60 qC
(140 qF)
Ignition switch: ON
0.78 – 0.96 V
CNG pressure: 100 KPa
CNG pressure sensor Ignition switch: ON
L76-14 Bl/B 1.43 – 1.75 V
signal circuit CNG pressure: 200 KPa
Ignition switch: ON
2.08 – 2.55 V
CNG pressure: 300 KPa
Ignition switch: ON
Fuel select mode: Forced
0.73 – 0.89 V CNG MODE
CNG cylinder pressure: 2
MPa
Ignition switch: ON
CNG cylinder Fuel select mode: Forced
L76-15 Lbl pressure sensor 1.15 – 1.41 V CNG MODE
signal circuit CNG cylinder pressure: 5
MPa
Ignition switch: ON
Fuel select mode: Forced
1.86 – 2.27 V CNG MODE
CNG cylinder pressure: 10
MPa
L76-16 — — — —
L76-17 — — — —
L76-18 — — — —
L76-19 — — — —
L76-20 — — — —
Ignition switch signal 10 – 14 V Ignition switch: ON
L76-21 B/W
circuit 0–1V Ignition switch: OFF
Ignition switch: ON
0–1V Fuel selector switch:
Fuel selector switch Pushed
L76-22 Lg
signal circuit Ignition switch: ON
8 – 13 V Fuel selector switch: Not
pushed
CNG cylinder
L76-23 B/R pressure sensor Below 0.3 V Ignition switch: ON
ground circuit
CNG pressure-and-
L76-24 V temperature sensor Below 0.3 V Ignition switch: ON
ground circuit
L76-25 — — — —
Engine: Running
Shut off valve of CNG 10 – 14 V Fuel select mode: Petrol
L76-26 P/B pressure regulator MODE
control circuit Engine: Running
0–1V Fuel select mode: Forced
CNG MODE
L76-27 — — — —
L76-28 — — — —

0–1V
Fuel selector switch
L76-29 R np Ignition switch: ON
indicator signal circuit
10 – 14 V
CNG receptacle Ignition switch: ON
0–1V
L76-30 P switch No.2 signal CNG receptacle cap: Open
8 – 13 V
CNG receptacle cap: Close
CNG receptacle Ignition switch: ON
8 – 13 V
L76-31 G switch No.1 signal CNG receptacle cap: Open
0–1V
CNG receptacle cap: Close
L76-32 — — — —
L76-33 — — — —
Engine: Running
10 – 14 V Fuel select mode: Petrol
Shut off valve of CNG
L76-34 Bl/W MODE
cylinder control circuit
Engine: Running
0–1V Fuel select mode: Forced
CNG MODE

CNG fuel injector No.1 0–1V warming up
L77-1 Bl
control circuit np Fuel select mode: Forced
10 – 14 V CNG MODE switched by
AUTO MODE
L77-2 — — — —
L77-3 — — — —
L77-4 — — — —
Petrol fuel injector 0–1V
L77-5 Br/W warming up
Fuel select mode: Petrol
10 – 14 V
MODE
L77-6 Br/B warming up
10 – 14 V
MODE
L77-7 — — — —
L77-8 — — — —
CNG control module
L77-9 B/Bl Below 0.3 V Ignition switch: ON
ground circuit
L77-10 R/Bl
AUTO MODE
L77-11 — — — —
L77-12 — — — —

L77-13 Br/Y warming up
10 – 14 V
MODE
L77-14 Br warming up
10 – 14 V
MODE
L77-15 — — — —
L77-16 — — — —
CNG control module
ground circuit
L77-18 G
AUTO MODE
L77-19 — — — —
L77-20 — — — —
L77-21 — — — —
L77-22 — — — —
L77-23 — — — —
L77-24 — — — —
CAN (high)
L77-25 B/Y communication circuit 2.5 – 3.5 V Ignition switch: ON
to ECM
CNG control module
ground circuit
L77-27 Y
AUTO MODE
L77-28 — — — —
L77-29 — — — —
L77-30 — — — —
L77-31 — — — —
L77-32 — — — —
CAN (low)
L77-33 Or communication circuit 1.5 – 2.5 V Ignition switch: ON
to ECM
L77-34 — — — —
Reference Waveform CNG fuel injector control signal (2):

NOTE L77-1 (No.1)
• Waveform analysis is as follows. L77-10 (No.2)
+
2 L77-18 (No.3)
L77-27 (No.4)
– L77-9
• Engine: Idle speed after warm-up
[A]: Waveform of channel 1 [C]: VOLT/DIV of each channel

[B]: Ground level of each channel [D]: TIME/DIV
• Waveform might change for measurement

condition and vehicle spec.
Petrol fuel injector signal and CNG fuel injector

Petrol fuel injector signal signal
Petrol fuel injector control signal (1): Fuel injector control signal from ECM (1):
L77-6 (No.1) L76-12 (No.1)
L77-14 (No.2) L76-3 (No.2)
+ +
1 L77-5 (No.3) 1 L76-11 (No.3)
L77-13 (No.4) L76-2 (No.4)
– L77-9 – L77-9
Measurement Condition CNG fuel injector control signal (2):
• Engine: Idle speed after warm-up Channel Probe Terminal No.
• Fuel select mode: Petrol MODE L77-1 (No.1)
L77-10 (No.2)
+
2 L77-18 (No.3)
L77-27 (No.4)
– L77-9
Petrol fuel injector control signal (3):

L77-6 (No.1)
L77-14 (No.2)
+
3 L77-5 (No.3)
L77-13 (No.4)
– L77-9
CNG fuel injector signal Measurement Condition

Fuel injector control signal from ECM (1): • Engine: Idle speed after warm-up
L76-12 (No.1)
L76-3 (No.2)
+
1 L76-11 (No.3)
L76-2 (No.4)
– L77-9
CAN communication signal (Low) (2):

+ L77-33
2
– L77-9
• Engine: Stop
• Engine: Idle speed after warm-up

Fuel selector switch indicator signal

Fuel selector switch indicator signal (1):
+ L76-29
1
– L77-9
• Fuel select mode: Petrol control in “AUTO MODE”
• Remaining CNG: Low
CAN communication signal

CAN communication signal (High) (1):
+ L77-25
1
– L77-9
ECM POWER AND GROUND CIRCUIT CHECK

Refer to ECM POWER AND GROUND CIRCUIT CHECK in Section 6E.
CNG CONTROL MODULE POWER AND GROUND CIRCUIT CHECK
WIRING DIAGRAM
1
C1 IG1
B /G L76-5
Bl/B L76-14
2
Or L76-13 A1
V L76-24
D1 L76-21 B/W
G L76-6
3 Lbl L76-15 E1
B/R L76-23 L77-9 B/Bl
5 5V 12V E2
B1 L77-17 B/Bl 8
12V IG1 E3
R/B L76-1 L77-26 B/Bl
R/B L76-10 7
L70-33 B/W B2
4 10 6
9
L69-10 B/Or
12V
L70-1 B/R 11
5V L70-2 B/R
+
L69-6 B/BL 12
L69-7 B/Bl
L70-4 B
[A]
L76 L77
9 8 7 6 5 4 3 2 1 9 8 7 6 5 4 3 2 1
A
17 16 15 14 13 12 11 10 17 16 15 14 13 12 11 10
26 25 24 23 22 21 20 19 18 26 25 24 23 22 21 20 19 18
34 33 32 31 30 29 28 27 34 33 32 31 30 29 28 27
[A]: CNG control module connector (View: A) E2: CNG control module ground circuit 2 6. “IGN” fuse
A1: Ignition switch signal circuit E3: CNG control module ground circuit 3 7. Ignition switch
B1: Main power supply circuit 1 1. CNG control module 8. “IG METER” fuse
B2: Main power supply circuit 2 2. CNG pressure-and-temperature sensor 9. “FI” fuse
C1: CNG pressure-and-temperature sensor power supply circuit 3. CNG cylinder pressure sensor 10. Main relay
D1: CNG cylinder pressure sensor power supply circuit 4. “CNG” fuse 11. Main fuse box
E1: CNG control module ground circuit 1 5. ECM 12. Battery
CIRCUIT DESCRIPTION
When the ignition switch is turned to ON position, the main relay turns ON (the contact point closes) and the main
power is supplied to ECM and CNG control module. And then CNG control module supplies 5 V power to each sensor
(CNG pressure-and-temperature sensor and CNG cylinder pressure sensor).
TROUBLESHOOTING
NOTE
Before troubleshooting, perform following items.
• Confirm that fuses related to power circuit of CNG control module do not blow out.
If fuse blows out, replace fuse(s) and check circuits connected to blown fuse(s) for short circuit to
ground.
• Confirm that battery voltage is 11 V or more.
Step Action Yes No

1 Ignition signal check Go to Step 2. Ignition switch signal
1) Turn ignition switch to OFF position and then disconnect circuit between battery
connectors from CNG control module. and CNG control
module is open and/or
short circuit.
3) Measure voltage between “L76-21” terminal of CNG
control module connector and body ground.
Is voltage 10 – 14 V?
2 CNG control module ground circuit check Go to Step 3. Repair or replace
1) Measure resistance of the following circuits between defective wire harness.
CNG control module connectors and vehicle body
ground.
• CNG control module ground circuit 1 (E1)
Are resistance 1 : or less?

3 Main relay and its circuit check Go to Step 4. Repair or replace
1) Check main relay and its circuit referring to ECM defective wire harness
POWER AND GROUND CIRCUIT CHECK in Section and/or main relay.
6E.
4 Check of power supply circuit for CNG control module Go to Step 5. Repair or replace
1) Turn ignition switch to OFF position and then remove defective wire harness.
main relay from relay box.
2) Measure resistance of the following circuits between
main relay and CNG control module connector.
• Main power supply circuit 1 (B1)
• Main power supply circuit 2 (B2)

5 Sensor power source circuit check Check internal short Repair or replace
1) Disconnect connectors from CNG pressure-and- circuit of CNG pressure- defective wire harness.
temperature sensor and CNG cylinder pressure sensor. and-temperature sensor
and/or CNG cylinder
2) Measure resistance of the following circuits between
pressure sensor.
each sensor and CNG control module connectors.
• CNG pressure-and-temperature sensor power supply
circuit (C1)
• CNG cylinder pressure sensor power supply circuit
(D1)

FUEL PUMP CIRCUIT CHECK

Refer to “FUEL PUMP CIRCUIT CHECK” in section 6E.
FUEL INJECTOR CIRCUIT CHECK

NOTE
• Before troubleshooting, be sure to read PRECAUTIONS ON FUEL SYSTEM SERVICE in this section.
• Function of fuel injector can be inspected using “Fuel Injector” output control in “Active Test” mode
of SUZUKI scan tool.
PETROL SYSTEM
Circuit Diagram
Troubleshooting
Step Action Yes No
1 Petrol fuel injector check for operating sound Petrol fuel injector Go to Step 2.
1) Using sound scope, check each petrol fuel injector for circuit is in good
operating sound with engine cranking on “Petrol MODE”. condition.
Do all petrol fuel injectors make operating sound?

2 Petrol fuel injector resistance check Go to Step 3. Replace petrol fuel
1) Turn OFF ignition switch and disconnect connectors injector.
from petrol fuel injectors.
2) Check for proper connection to petrol fuel injector at
each terminals.
3) If OK, check all petrol fuel injectors for resistance. Refer
to ON-VEHICLE INSPECTION under FUEL INJECTOR
in the section.
Are all petrol fuel injectors in good condition?

3 Petrol fuel injector insulation resistance check Go to Step 4. Replace petrol fuel
1) Check that insulation resistance is infinity between each injector.
petrol fuel injector terminal and engine ground.
4 Petrol fuel injector power supply circuit check Go to Step 5. Repair or replace petrol
1) Check that voltage between each petrol fuel injector fuel injector power
power supply circuit (A1, A2, A3, A4) and engine ground supply circuit.
is battery voltage with ignition switch in ON position.
5 Petrol fuel injector drive circuit check Go to Step 6. Repair or replace petrol
1) Turn OFF ignition switch and disconnect connectors fuel injector drive circuit.
from CNG control module.
2) Check that petrol fuel injector drive circuits (C1, C2, C3,
C4) are as follows.
• Wiring harness resistance of each petrol fuel injector
drive circuit is less than 1 :.
• Insulation resistance between each petrol fuel injector
drive circuit and vehicle body ground is infinity.
• Circuit voltage of each petrol fuel injector drive circuit

Step Action Yes No

6 Fuel injector control circuit check Go to Step 7. Repair or replace fuel
1) Turn OFF ignition switch and disconnect connectors injector control circuit.
from ECM and CNG control module.
2) Check for proper terminal connection to ECM connector
and CNG control module connector.
3) Check that fuel injector control circuits (E1, E2, E3, E4)
are as follows.
• Wiring harness resistance of each fuel injector control
circuit is less than 1 :.
• Insulation resistance between each fuel injector
control circuit and vehicle body ground is infinity.
• Circuit voltage of each fuel injector control circuit is 0
– 1 V with ignition switch in ON position.

7 Petrol fuel injector check Substitute a known- Replace petrol fuel
1) Check petrol fuel injector. Refer to INJECTION VOLUME good CNG control injector.
INSPECTION in this section. module and recheck. If
malfunction continues,
Is it in good condition? substitute a known-
good ECM and recheck.
CNG SYSTEM
Circuit Diagram
Troubleshooting
Step Action Yes No
1 DTC check in CNG control module Go to applicable DTC Go to Step 2.
1) Check DTC. Refer to DTC CHECK in this section. troubleshooting and
recheck.
Is there DTC(s)?
2 CNG fuel injector check for operating sound 1 CNG fuel injector circuit Go to Step 3.
1) Using sound scope, check each CNG fuel injector for is in good condition.
operating sound with engine cranking on “Forced CNG
MODE”.
Do all CNG fuel injectors make operating sound?

3 Fuel injector control circuit check Go to Step 4. Repair or replace fuel
1) Turn OFF ignition switch and disconnect connectors injector control circuit.
from ECM and CNG control module.
2) Check for proper terminal connection to ECM connector
and CNG control module connector.
3) Check that fuel injector control circuits (E1, E2, E3, E4)
are as follows.
• Wiring harness resistance of each fuel injector control
circuit is less than 1 :.
• Insulation resistance between each fuel injector
control circuit and vehicle body ground is infinity.
• Circuit voltage of each fuel injector control circuit is 0
– 1 V with ignition switch in ON position.

Step Action Yes No

4 CNG fuel injector check for operating sound 2 END. Substitute a known-
1) Substitute a known-good CNG fuel injector assembly. good CNG control
module and recheck. If
2) Check CNG fuel injector for operating sound with engine
malfunction continues,
cranking on “Forced CNG MODE”.
substitute a known-
Do CNG fuel injectors make operating sound? good ECM and recheck.
FUEL PRESSURE CHECK
PETROL SYSTEM
Refer to FUEL PRESSURE CHECK in Section 6E.
CNG SYSTEM
! CAUTION
Do not use special tools that had been used for a petrol fuel line. If petrol mixes in the CNG fuel line, it
could damage the CNG fuel injector.
System Diagram
Special tool
(A): 09800M00051
5 4
(A)
10 9 8 7
3
6
12
1
11
1. CNG cylinder 4. Manual CNG cylinder valve 7. Shut-off valve of CNG pressure regulator 10. CNG fuel delivery pipe
2. CNG receptacle 5. Shut-off valve of CNG cylinder 8. CNG cylinder pressure sensor 11. CNG fuel injector
3. CNG cylinder valve 6. CNG cylinder pressure gauge 9. CNG pressure regulator 12. CNG pressure-and-temperature sensor
Troubleshooting
NOTE
Before using the following flow, check the manual CNG cylinder valve of the cylinder valve is open.
Step Action Yes No

1 DTC check Go to applicable DTC Go to Step 2.
1) Check DTC. Refer to DTC CHECK in this section. troubleshooting and
recheck.
Is there DTC(s)?
Step Action Yes No

2 CNG fuel feed line check 1 Go to Step 3. Repair or replace
1) Check CNG fuel pipe, CNG fuel hose and joint for defective part.
damage or deformation.

3 Shut-off valve operation sound check Go to Step 4. Replace CNG cylinder
1) Select “Forced CNG MODE” and check shut-off valves with valve or CNG
on CNG cylinder and on CNG fuel pressure regulator for pressure regulator.
operating sound.
Do all shut-off valves make operating sound?

4 CNG fuel feed line check 2 Go to Step 5. Repair or replace
1) Check CNG fuel pipe, CNG fuel hose and joint for CNG defective part.
fuel leakage. Refer to FUEL LEAKAGE CHECK
PROCEDURE in Section 6.

5 CNG cylinder pressure check Go to Step 6. Replace CNG pressure
1) Check CNG cylinder pressure. Refer to FUEL regulator.
PRESSURE INSPECTION in this section.
Is check result satisfactory?

6 CNG fuel filter check CNG system is in good Replace CNG fuel filter.
1) Check CNG fuel filter for evidence of dirt and condition.
contamination. Refer to INSPECTION under CNG
PRESSURE REGULATOR in this section.
IDLE AIR CONTROL SYSTEM CIRCUIT CHECK

Refer to “IDLE AIR CONTROL SYSTEM CIRCUIT CHECK” in section 6E.
EVAPORATIVE EMISSION CONTROL SYSTEM CHECK

Refer to “EVAPORATIVE EMISSION CONTROL SYSTEM CHECK” in section 6E.
A/C CONTROL SIGNAL CHECK (IF EQUIPPED)

Refer to “A/C CONTROL SIGNAL CHECK (IF EQUIPPED)” in section 6E.
RADIATOR FAN CONTROL SYSTEM CIRCUIT CHECK

Refer to “RADIATOR FAN CONTROL SYSTEM CIRCUIT CHECK” in section 6E.
FUEL CUT OPERATION CHECK

Refer to FUEL CUT OPERATION CHECK in Section 6E.
EGR CHECK
Refer to “EGR CHECK” in section 6E.
EVAP CANISTER PURGE SYSTEM INSPECTION POWER BALANCE TEST

Refer to EVAP CANISTER PURGE SYSTEM ! CAUTION
INSPECTION in Section 6E.
Never increase engine speed higher than the
specified idling speed during power balance
IAC (IDLE AIR CONTROL) VALVE OPERATION test. Increasing of engine speed in power
INSPECTION balance test can damage engine.
Refer to IAC (IDLE AIR CONTROL) VALVE
OPERATION INSPECTION in Section 6E.
USING SUZUKI SCAN TOOL 5) For petrol system, disconnect petrol fuel injector
1) Place gear shift lever in “Neutral” and apply parking connector (1) for cylinder No.1.
brake. For CNG system, disconnect CNG fuel injector
connector (2) for cylinder No.1.
2) Connect scan tool to DLC (1) with ignition switch
turned OFF.
2
Special tool
(A): SUZUKI scan tool (SUZUKI-SDT)
1
(A)
6) Check that engine speed decreases from specified
idle speed.
3) Clear DTC. Refer to DTC CLEARANCE in this 7) Repeat Steps 5) and 6) for all cylinders, compare
section. decreasing rates of engine speed.
4) For petrol system, select “Petrol MODE” with fuel 8) If decreasing rates of engine speed are not in scale,
selector switch. check the following items.
For CNG system, select “Forced CNG MODE” with • Fuel injector circuit
fuel selector switch.
• Petrol fuel injector
5) Start engine and warm up to normal operating
• CNG fuel injector
temperature.
• Spark plug
6) Select “Fuel Injector” in “Active Test” on scan tool
and turn off each fuel injector. • Ignition coil circuit
7) With each fuel injector turned off, confirm that engine • Ignition coil
speed decreases. • Engine compression
8) If decreasing rates of engine speed are not in scale, 9) Clear DTC. Refer to DTC CLEARANCE in this
check following items. section.
• Fuel injector circuit
• Petrol fuel injector
• CNG fuel injector
• Spark plug
• Ignition coil circuit
• Ignition coil
• Engine compression
NOT USING SUZUKI SCAN TOOL

1) Place gear shift lever in “Neutral” and apply parking
brake.
2) Start engine and warm up to normal operating
temperature.
3) Remove air cleaner assembly.
4) For checking petrol system, select “Petrol MODE”
with fuel selector switch.
For checking CNG system, select “Forced CNG
MODE” with fuel selector switch.
REPAIR INSTRUCTIONS
IDLE SPEED AND IAC (IDLE AIR CONTROL) 4) Check that specified engine idle speed is obtained
DUTY INSPECTION with A/C turned ON if vehicle is equipped with A/C.
If not, check A/C system.
Before idle speed / IAC duty check, make sure of the
following.
THROTTLE BODY
• Lead wires and hoses of electronic fuel injection and Refer to THROTTLE BODY in Section 6E.
engine and emission control systems are connected
securely.
VEHICLE SPEED SENSOR (VSS)
• Accelerator cable has some play, that is, it is not tight. Refer to VEHICLE SPEED SENSOR (VSS) in Section
• Valve clearance has been checked according to 6E.
maintenance schedule.
• Ignition timing is within specification. CMP SENSOR
• All electrical systems (wipers, heater, lights, A/C, etc.) Refer to CMP SENSOR in Section 6E.
are out of service.
• Air cleaner has been properly installed and is in good CMP SENSING ROTOR
condition. Refer to CMP SENSING ROTOR in Section 6E.
• Air intake system has no abnormal air inhaling.
• PCV valve and PCV hoses have no obstruction. CKP SENSOR
Refer to CKP SENSOR in Section 6E.
• ECM stores no DTC.
• CNG control module stores no DTC.
KNOCK SENSOR
After confirming all items, check idle speed and IAC duty
Refer to KNOCK SENSOR in Section 6E.
as follows.
NOTE
FUEL PRESSURE INSPECTION
Before starting engine, place gear shift lever
in “Neutral” and set parking brake and block PETROL SYSTEM
drive wheels. Refer to FUEL PRESSURE INSPECTION in Section 6E.
1) Turn OFF ignition switch and connect SUZUKI scan CNG SYSTEM
tool to DLC (1).
Special tool
! CAUTION
(A): SUZUKI scan tool (SUZUKI-SDT) Do not use special tools that had been used
for a petrol fuel line. If petrol mixes in the
CNG fuel line, it could damage the CNG fuel
injector.
1) Check that CNG cylinder pressure is more than 1

MPa (10.2 kgf/cm2, 145 psi) or above using SUZUKI
scan tool. If CNG cylinder pressure is less than 1
1 MPa (10.2 kgf/cm2, 145psi), recharge CNG.
2) Relieve CNG cylinder pressure in CNG fuel feed
line. Refer to FUEL PRESSURE RELIEF
PROCEDURE in Section 6.
(A) 3) Remove engine under cover.
4) Disconnect CNG fuel hoses (1) from CNG fuel filter
assembly (2).
3) Check engine idle speed and IAC duty referring to
“IAC Flow Duty” using “Data List” mode on scan tool.
Engine idle speed
A/C OFF: 750 – 850 rpm (IAC duty: 5 – 20%)
A/C ON: 800 – 900 rpm (IAC duty: 10 – 55%)
11) For 2 seater model, tighten CNG fuel hose clamp to

1
specified torque. Refer to CNG FUEL FILTER in this
Section 6C1.
12) Check CNG fuel leakage. Refer to FUEL LEAKAGE
CHECK PROCEDURE in Section 6.
CNG PRESSURE REGULATOR
1) Check CNG pressure regulator for coolant leak,
2
deformation and damage. If any faulty condition is
found, replace CNG pressure regulator.
5) Connect special tools between CNG fuel hoses (1)
2) Check CNG pressure regulator for CNG fuel
as shown in figure, and clamp hoses securely to
leakage. If faulty condition is found, replace CNG
ensure that no leaks occur during checking.
pressure regulator. Refer to FUEL LEAKAGE
Special tool CHECK PROCEDURE in Section 6.
(A): 09800M00051 3) Check shut-off valve for operation sound as follows.
a) Turn ignition switch to ON position.
1 (A) b) Select “Forced CNG MODE” with fuel selector
1 switch and check operation sound of shut-off
valve. If operating sound of shut-off valve is not
heard, replace CNG pressure regulator.
4) Inspect the CNG pressure sensor as follows.
a) Turn ignition switch to OFF position and then
connect SUZUKI scan tool to DLC (1).
Special tool
(A): SUZUKI scan tool (SUZUKI-SDT)
6) Open manual cylinder valve and then turn ignition

switch to ON position and select “Forced CNG
MODE” with fuel selector switch.
7) Start engine and warm up to within operating
temperature, and measure fuel pressure at idling on
1
CNG mode.
• If measured pressure is within specification, check
CNG fuel filter for evidence of dirt and
contamination. Refer to FUEL FILTER in Section
(A)
6C1.
• If measured pressure is out of specification, there
is possibility of the following cause.
b) Turn ignition switch to ON position and select
– CNG fuel leakage “Forced CNG MODE” with fuel selector switch.
– Vacuum hose fault c) Select “CNG Cylinder Pressure” under “Data
– CNG pressure regulator fault List” mode on scan tool. Check CNG pressure
displayed on scan tool.
CNG fuel pressure specification
At specified idle speed: 110 – 160 kPa (1.1 – 1.6 kg/ d) Check that CNG pressure on CNG cylinder
cm2, 16.0 – 23.2 psi) pressure gauge and “CNG Cylinder Pressure” on
SUZUKI scan tool is similarly decreased, when
8) Relieve CNG cylinder pressure. Refer to FUEL CNG pressure is relieved. If check result not
PRESSURE RELIEF PROCEDURE in Section 6. satisfactory, replace CNG pressure regulator.
9) Remove special tools from CNG fuel hose and CNG
fuel filter assembly. REMOVAL
10) Connect CNG fuel hose to CNG fuel filter assembly 1) Relieve CNG pressure in CNG fuel feed line. Refer
and clamp it securely. to FUEL PRESSURE RELIEF PROCEDURE in
Section 6.
2) Drain coolant. Refer to COOLING SYSTEM

DRAINING in Section 6B.
3) Remove battery.
4) Remove engine under cover.
5) Remove CNG fuel pipe (1).
6) Disconnect CNG cylinder pressure sensor connect
(2) and shut-off valve connector (3).
Operation check
Check that shut-off valve (1) operates with clicking
sound when 12-V battery is connected.
If valve does not operate or click, replace CNG fuel
pressure regulator.
7) Disconnect coolant hoses (1), CNG fuel hose (2) and
vacuum hose (3) from CNG pressure regulator.
8) Remove CNG pressure regulator (4).
2
1 3
1
4
INSPECTION
Shut-off Valve
Filter
Resistance check
Measure resistance between terminals of shut-off valve Removal
(1). If resistance is out of reference value greatly, replace 1) Relieve CNG pressure in CNG fuel feed line. Refer
CNG pressure regulator. to FUEL PRESSURE RELIEF PROCEDURE in
Section 6.
Reference resistance of shut-off valve
8.0 – 10.0 : at 20 qC (68 qF) 2) Remove CNG pressure regulator. Refer to
REMOVAL under CNG PRESSURE REGULATOR
in this section.
3) Remove fitting plug (1).
4) Remove CNG pressure regulator filter (2) with spring
(3).
5) Detach spring (3) from CNG pressure regulator filter
(2).
FUEL INJECTOR
PETROL SYSTEM
Refer to FUEL INJECTOR in Section 6E.
CNG SYSTEM
1
On-vehicle Inspection
Operating sound check
3 1) Turn ignition switch to ON position and select
2 “Forced CNG MODE” with fuel selector switch.
2) Using sound scope (1) or the like, check operating
Inspection sound of CNG fuel injector (2) when engine is
Check CNG pressure regulator filter for evidence of dirt running or cranking. Cycle of operating sound should
and contamination. If filter is clogged, replace CNG vary according to engine speed.
pressure regulator filter. If no sound or unusual sound is heard, check CNG
fuel injector circuit or CNG fuel injector.
Installation
Reverse removal procedure noting the following points.
• Use new O-ring (1), new CNG pressure regulator filter
(2) and new spring (3).
• Tighten fitting plug (4) to specified torque.
2
Tightening torque
Fitting plug (a): 60 N·m (6.1 kgf-m, 44.5 lbf-ft)
4, (a) 2 Resistance check

Connect ohmmeter between terminals of CNG fuel
injector and check resistance.
3 If resistance is out of reference value greatly, replace
1 CNG fuel injector assembly.
• Refill cooling system. Refer to COOLING SYSTEM Reference resistance of CNG fuel injector
FLUSH AND REFILL in Section 6B. 1.19 – 1.31 : at 20 qC (68 qF)
• Check for coolant leaks. Refer to COOLING SYSTEM
SERVICE in Section 6B.
• Check for CNG fuel leaks. Refer to FUEL LEAKAGE
Installation
• Tighten CNG pressure regulator bolts to specified
torque.
Tightening torque Removal
CNG pressure regulator bolt: 23 N·m (2.3 kgf-m,
17.0 lbf-ft) 1) Relieve CNG pressure in CNG fuel feed line. Refer
to FUEL PRESSURE RELIEF PROCEDURE in
• Refill cooling system. Refer to COOLING SYSTEM Section 6.
FLUSH AND REFILL in Section 6B. 2) Remove battery.
• Check for coolant leaks. Refer to COOLING SYSTEM 3) Disconnect CNG fuel injector hoses (1) from CNG
SERVICE in Section 6B. fuel injectors.
• Check for CNG fuel leaks. Refer to FUEL LEAKAGE
4) Disconnect vacuum hoses (2) from CNG fuel • Check for CNG fuel leaks. Refer to FUEL LEAKAGE
injector. CHECK PROCEDURE in Section 6.
5) Disconnect CNG fuel hose (3) from CNG fuel
delivery pipe. ENGINE CONTROL MODULE (ECM)
6) Remove CNG fuel injector assembly bolts (4). Refer to ENGINE CONTROL MODULE (ECM) in
Section 6E.
7) Disconnect CNG fuel injector connectors (5) from
CNG fuel injectors.
CNG CONTROL MODULE
8) Remove CNG fuel injector harness clamp (6).
! CAUTION
1 2 As CNG control module consists of precision
parts, be careful not to expose it to excessive
shock.
1
REMOVAL
1) Disconnect negative (–) cable from battery.
2) Remove air cleaner.
3) Disconnect connectors (1) from CNG control
2 module.
4) Remove CNG control module with its bracket (2).
3
2
6
5 5) Remove CNG control module from its bracket.
9) Remove CNG fuel injector assembly. INSTALLATION

Installation • Tighten CNG control module nuts to specified torque.
Tightening torque
• Tighten CNG fuel injector hose clamps (1) to specified
CNG control module nut 5.5 N·m (0.56 kgf-m, 4.0
torque.
lbf-ft)
Tightening torque • Tighten CNG control module bracket nut to specified
CNG fuel injector hose clamp (a): 1.4 N·m (0.14 torque.
kgf-m, 1.0 lbf-ft)
1, (a) Tightening torque
CNG control module bracket nut: 5.5 N·m (0.56
kgf-m, 4.0 lbf-ft)
MAP SENSOR
Refer to MAP SENSOR in Section 6E.
ECT SENSOR
Refer to ECT SENSOR in Section 6E.
TP SENSOR
Refer to TP SENSOR in Section 6E.
HEATED OXYGEN SENSOR

Refer to HEATED OXYGEN SENSOR in Section 6E. 1
CNG PRESSURE-AND-TEMPERATURE 2
SENSOR
3
CNG Pressure Sensor
1) Relieve fuel pressure in CNG fuel line. Refer to
FUEL PRESSURE RELIEF PROCEDURE in
Section 6.
2) Disconnect CNG fuel hose between CNG fuel CNG TEMPERATURE SENSOR INSPECTION
delivery pipe and CNG pressure regulator. 1) Remove CNG pressure-and-temperature sensor.
3) Install pressure gauge between CNG pressure 2) Check O-ring (1) for damage and deterioration. If
regulator and CNG fuel delivery pipe, referring to faulty condition is found, replace CNG pressure-and-
FUEL PRESSURE INSPECTION in this section. temperature sensor.
4) Connect SUZUKI scan tool to DLC (1). 3) Measure resistance between sensor terminals “1”
Special tool and “2” while blowing hot air to temperature sensing
(A): SUZUKI scan tool (SUZUKI-SDT) part (2) of CNG pressure-and-temperature sensor
(3) using hot air drier (4). If measured resistance is
out of specified value, replace CNG pressure-and-
temperature sensor.
! CAUTION
Do not heat up CNG pressure-and-
temperature sensor more than 100 qC (212
1 qF). Otherwise, CNG pressure-and-
temperature sensor will be damaged.
CNG temperature sensor resistance

(A)
0 qC (32 qF): 5.30 – 6.48 k:
20 qC (68 qF): 2.24 – 2.75 k:
40 qC (104 qF): 1.05 – 1.29 k:
5) Turn ignition switch to ON position and select “CNG 60 qC (140 qF): 0.535 – 0.655 k:
Pressure” under “Data List” mode on scan tool.
Check CNG pressure displayed on scan tool.
6) Check that fuel pressure on pressure gauge and
“CNG Pressure” on SUZUKI scan tool are similarly
decreased, when fuel pressure is relieved. If check
result not satisfactory, replace CNG pressure-and-
temperature sensor.
REMOVAL
1) Relieve fuel pressure in CNG fuel line. Refer to
FUEL PRESSURE RELIEF PROCEDURE in
Section 6.
2) Disconnect negative (–) cable from battery.
3) Disconnect CNG pressure-and-temperature sensor
connector (1).
4) Remove CNG pressure-and-temperature sensor (2)
from CNG fuel delivery pipe (3).
“1” “2”
"1"
"2"
5
“3”
1
4 [A] “1” “2” “3”

[B]
2
[C]
[D]
[A]: Terminal [C]: Switch shaft is free

[B]: Switch condition [D]: Switch shaft is pushed
[A]
INSTALLATION
Reverse removal procedure.
MAIN RELAY/FUEL PUMP RELAY/RADIATOR

FAN RELAY / CNG VALVE CONTROL RELAY
INSPECTION
2.24 - 2.75
Main Relay / Fuel Pump Relay / Radiator Fan Relay
1.05 - 1.29 1) Disconnect negative cable at battery.
0.535 - 0.655 2) Remove each relay from main fuse.
0 20 40 60 80 [B]
32 68 104 140 176 F
[A]: Resistance 5. Temperature gauge

[B]: Temperature
INSTALLATION
Reverse removal procedure noting the following point.
• Clean mating surface of CNG pressure-and-
1. Main fuse box 3. Main relay
temperature sensor and CNG fuel delivery pipe.
2. Fuel pump relay 4. Radiator fan relay
CNG RECEPTACLE SWITCH 3) Check resistance between each two terminals as in

REMOVAL table below.
TERMINALS RESISTANCE
1) Disconnect negative (–) cable from battery. Between 1 and 2 f (Infinity)
2) Detach CNG receptacle cap. Between 3 and 4 56 – 146 : at 20 qC, 68 qF
3) Remove CNG receptacle switch with CNG
receptacle. Refer to CNG RECEPTACLE in Section If check results are as specified, proceed to next
6C1. operation check. If not, replace.
2
3
INSPECTION
Check CNG receptacle switch for continuity between
terminals at each switch condition. If check result is not
as specified, replace CNG receptacle switch.
4) Check that there is continuity between terminals “1”

and “2” when battery is connected to terminals “3”
and “4”. If malfunction is found, replace.
5) Check that there is continuity between terminals “1”

“3” “2”
and “2” when battery is connected to terminals “3”
and “4”. If malfunction is found, replace.
“4” “3” “1”

“1”
“4” “2”
CNG Valve Control Relay

1) Remove battery.
2) Remove CNG valve control relay (1) from vehicle
body.
3) Disconnect CNG valve control relay connector. FUEL CUT OPERATION
INSPECTION
NOTE
Before inspection, check to make sure that
1 gear shift lever is in Neutral position and that
parking brake lever is pulled all the way up.

2) While listening to sound of injector by using sound
scope or such, increase engine speed to higher than
3,000 r/min.
3) Check to make sure that sound to indicate operation
4) Check resistance between each two terminals as in of injector stops when throttle valve is closed
table below. instantly and it is heard again when engine speed is
TERMINALS RESISTANCE reduced to less than about 2,000 r/min.
Between 1 and 2 f (Infinity) If not, go to FUEL CUT OPERATION CHECK in
Between 3 and 4 56 – 146 : at 20 qC, 68 qF related manual.
4) If injector sound is not heard, perform FUEL
If check results are as specified, proceed to next
INJECTOR CIRCUIT CHECK in this section.
operation check. If not, replace.
3 1
2
4
EVAP CANISTER
Refer to EVAP CANISTER in Section 6E.
TIGHTENING TORQUE SPECIFICATION
Tightening torque
Fastening part
N•m kgf-m lbf-ft
Fitting plug 60 6.1 44.5
CNG pressure regulator bolt 23 2.3 17.0
CNG fuel injector hose clamp 1.4 0.14 1.0
CNG control module nut 5.5 0.56 4.0
CNG control module bracket nut 5.5 0.56 4.0
SPECIAL TOOLS AND EQUIPMENT
SUZUKI scan tool (SUZUKI-SDT)

09800M00051
CNG Pressure gauge
This kit includes following items
1. Suzuki SDT 6
2. DLC3 cable
3. USB cable 1 2
4. AC/DC power supply
4
5. Voltage meter probe 3
6. Storage case
5
09912M58432
Fuel pressure gauge hose
this tool is included in fuel
pressure gauge set
(09912M58413).
BODY ELECTRICAL SYSTEM 8-1
SECTION 8
BODY ELECTRICAL SYSTEM

NOTE:
• For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of Service Man-
ual mentioned in the FOREWORD of this manual.
• For circuit diagram and unit parts location that is not described in this section, refer to WIRING DIA-
GRAM MANUAL in FOREWORD of this manual.
CONTENTS
GENERAL DESCRIPTION .................................8- * SCHEMATIC AND ROUTING DIAGRAM .......... 8-5
HEADLIGHT....................................................8- * BI-FUEL SELECTOR SWITCH EQUIPPED WITH
COMBINATION METER ................................. 8-2 INDICATOR CIRCUIT DIAGRAM (BI-FUEL CNG
BI-FUEL SELECTOR SWITCH EQUIPPED WITH MODEL) .......................................................... 8-5
INDICATOR (BI-FUEL CNG MODEL)............. 8-3 DIAGNOSIS........................................................ 8- *
WINDSHIELD WIPER AND WASHER............8- * ON-VEHICLE SERVICE ..................................... 8- *
REAR WIPER AND WASHER
BI-FUEL SELECTOR SWITCH EQUIPPED WITH
(IF EQUIPPED) ...............................................8- *
INDICATOR (BI-FUEL CNG MODEL) ............ 8-5
POWER WINDOW SYSTEM
(IF EQUIPPED) ...............................................8- *
POWER DOOR LOCK SYSTEM
(IF EQUIPPED) ...............................................8- *
8-2 BODY ELECTRICAL SYSTEM
COMBINATION METER
4 5
1
8
3 7 6
9 2
11 10
1. Speedometer 7. MIL (malfunction indicator lamp)

2. Petrol fuel meter 8. Oil pressure warning light
3. High engine coolant temperature warning indicator 9. Charge warning light
4. Turn signal indicator light (L) 10. Brake fluid level warning light (parking brake indicator and brake warning light)
5. Turn signal indicator light (R) 11. CNG warning light (bi-fuel CNG model)
6. High beam indicator
NOTE:
Terminal arrangement of coupler viewed from harness side.
E39 (View A)
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
A
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
Wire Wire
Circuit Circuit
Color Color
1. Power supply BLK/WHT 17. — —
2. Backup power source WHT 18. — —
3. Illumination signal input RED/YEL 19. — —
4. Ground BLK 20. — —
5. Fuel level sensor signal YEL/RED 21. Fuel level sensor ground BLK/YEL
6. CAN communication line (low) to RED 22. — —
DLC
7. CAN communication line (low) to RED/BLK 23. — —
ECM
8. CAN communication line (high) to WHT 24. — —
DLC
9. CAN communication line (high) to WHT/BLK 25. — —
ECM
10. Turn signal and hazard warning GRN/RED 26. — —
relay (turn L)
11. Turn signal and hazard warning GRN/YEL 27. — —
relay (turn R)
12. — — 28. Parking brake indicator control sig- RED/BLK
nal (to parking brake switch)
Wire Wire
Circuit Circuit
Color Color
13. — — 29. Brake warning light control signal BLU
(to brake fluid level switch)
14. — — 30. — —
15. — — 31. Charge warning light control signal WHT/RED
(to generator)
16. Lighting switch (high beam switch) RED 32. Oil pressure warning light signal (to YEL/BLK
oil pressure switch)
BI-FUEL SELECTOR SWITCH EQUIPPED WITH INDICATOR (BI-FUEL CNG

MODEL)
Bi-fuel selector switch equipped with indicator (1) consists of fuel selector switch (3), petrol indicator (4), CNG
indicator (2) and CNG pressure indicator (green (5) and red (6)).
3 5
6
4
FUEL MODE SELECTION

• Fuel mode can be switched between “Petrol MODE” and “AUTO MODE” at every push of fuel selector switch
when ignition switch is turned to “ON” position with engine stopped, or when engine is running.
• “Forced CNG MODE” can be selected by pushing and holding fuel selector switch for more than 8 sec. when
ignition switch is ON with engine stopped.
• If ignition switch is turned to OFF position and then turned to ON position again under “Forced CNG MODE”,
fuel mode is switched to “AUTO MODE”.
SELECTOR SWITCH INDICATIONS

PETROL MODE
Petrol indicator lights up, and also CNG pressure indicator (green or red) lights up corresponding to the amount
of remaining CNG.
FORCED CNG MODE

• CNG indicator lights up.
• When CNG cylinder is charged fully with CNG, i.e. CNG pressure gauge reading is approx. 15,048 kPa
(153.4 kgf/cm2, 2,182.5 psi, 150.5 bar), all CNG pressure indicators (green) light up.
• When amount of remaining CNG is less than specification, i.e. CNG pressure gauge reading is less than
approx. 5,835 kPa (59.5 kgf/cm2, 846.3 psi, 58.4 bar), CNG pressure indicator (red) lights up.
NOTE:
The number of CNG pressure indicators that light up changes corresponding to the amount of remain-
ing CNG when switching to “Forced CNG MODE”.
AUTO MODE
• Petrol indicator and CNG pressure indicator light up in petrol system. At the same time CNG indicator blinks.
• Indication in CNG system is the same as “Forced CNG MODE”.
ABNORMAL CONDITION
Petrol indicator and CNG indicator blink alternately when communication error occurs between bi-fuel selector
switch equipped with indicator and CNG control module.
[A] [B]
[a]
[c] [c]
[a] [d] [d]
[C] [D] [E]

[c] [a]
[b] [c]
[b]
[a] [d] [d]
[A]: Petrol MODE [a]: Lighting up

[B]: Forced CNG MODE [b]: Blinking
[C]: AUTO MODE (in petrol system) [c]: Lighting up depending on the remaining amount of CNG
[D]: AUTO MODE (in CNG system) [d]: Lighting up when amount of CNG, pressure in CNG cylinder,
is less than approx. 5,835 kPa (59.5 kgf/cm2, 846.3 psi, 58.4
bar)
[E]: Abnormal condition
SCHEMATIC AND ROUTING DIAGRAM

BI-FUEL SELECTOR SWITCH EQUIPPED WITH INDICATOR CIRCUIT DIA-
GRAM (BI-FUEL CNG MODEL)
1 2
4
3
L76-29 R E76-2 E76-4 B/W
12V
L76-22 Lg E76-1 E76-5 B
[A] [B]
L76 L77 E76

9 8 7 6 5 4 3 2 1 9 8 7 6 5 4 3 2 1
17 16 15 14 13 12 11 10 17 16 15 14 13 12 11 10 2 1 A
26 25 24 23 22 21 20 19 18 26 25 24 23 22 21 20 19 18
6 5 4 3
34 33 32 31 30 29 28 27 34 33 32 31 30 29 28 27
[A]: CNG control module connector (View: A) 1. CNG control module 3. “IG METER” fuse
[B]: Bi-fuel selector switch equipped with indicator connector (View: A) 2. Bi-fuel selector switch equipped with indicator 4. Ignition switch
BI-FUEL SELECTOR SWITCH EQUIPPED WITH INDICATOR (BI-FUEL CNG

MODEL)
REMOVAL
1) Release clips (1) and then remove bi-fuel selector switch equipped with indicator (2) from instrument panel
(3).
2) Remove connector from bi-fuel selector switch equipped with indicator.
1 2
INSTALLATION
Reverse removal procedure.
INSPECTION
1) Remove bi-fuel selector switch equipped with indicator.
2) Check for continuity between terminals. If check result is not as specified, replace bi-fuel selector switch
equipped with indicator.
2 1
6 5 4 3
[A]
1 5
[B]
ON
OFF
[A]: Terminal [B]: Switch position
3) Connect battery to the terminals of bi-fuel selector switch equipped with indicator as indicated in the figure.
4) Check that all indicators light up for approx. 2 seconds, and then start to blink.
If indicator does not operate or any abnormality is found, replace abnormal bi-fuel selector switch equipped
with indicator.
2 1
6 5 4 3
1. Lighting up 2. Blinking
Foreword
Foreword
This manual contains SECTION XX “Wiring Diagram” which is a part of the ELECTRICAL SYSTEM section of
the service manual.
Applicable model:
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All information, illustrations and specifications contained in this literature are based on the latest product infor-
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base model specifications. Therefore, please note that the actual vehicle being serviced may differ from the
ha
manual. SUZUKI MOTOR CORPORATION reserves the right to make changes at any time without notice.
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Please note that this manual contains references to equipment that may not be marketed in all countries.
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For inspection and service work, refer to the service manual(s) listed below.
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NOTE:
This manual shows the circuits for all the possible variations in production specifications. However,
depending on the specifications of the vehicle you are handling, its wiring harness may not include
some of the circuits or wiring shown in this manual.
Related Manual
Manual Name Part Number
© COPYRIGHT SUZUKI MOTOR CORPORATION 2010

Foreword
Table of Contents
Table of Contents
Precautions................................................... 8A-0-1 Circuit Fuse Box........................................8A-5-3
General Information ..................................... 8A-1-1 System Circuit Diagram ...............................8A-6-1 8A-0
How to Read Connector Layout Diagram....8A-1-1 A-1 Cranking System ................................8A-6-1
How to Read Connector Codes and Terminal A-2 Charging System ................................8A-6-2
Nos. .............................................................8A-1-2 A-3 Ignition System ...................................8A-6-3 8A-1
A-4 Cooling System ..................................8A-6-4
How to Read Ground (Earth) Point .............8A-1-4
A-5 Engine & A/C Control System
How to Read Power Supply Diagram..........8A-1-5 (Petrol Model) ...........................................8A-6-6
How to Read System Circuit Diagram.........8A-1-6 A-5 Engine & A/C Control System 8A-3
Symbols and Marks.....................................8A-1-8 (Bi-Fuel CNG Model) ..............................8A-6-10
Abbreviations ............................................8A-1-10 B-1 Windshield Wiper and Washer .........8A-6-14
Wire / Connector Color Symbols ...............8A-1-11 B-7 Horn / Optional Security System ......8A-6-16 8A-4
C-1 Combination Meter
Connector Layout Diagram ......................... 8A-3-1
(Meter and Gauge)..................................8A-6-17
Front ............................................................8A-3-1 C-2 Combination Meter
B: Joint Harness ........................................8A-3-1 8A-5
(Indicator Lamp) ......................................8A-6-18
E: Main Harness........................................8A-3-2 C-3 Combination Meter
Engine Compartment ..................................8A-3-3 (Warning Lamp) ......................................8A-6-19
A: Battery Cable / C: Engine Harness D-1 Headlight System .............................8A-6-20 8A-6
(Petrol Model) / L: Floor Harness ..............8A-3-3 D-2 Position, Tail and License Plate
A: Battery Cable / C: Engine Harness Light ........................................................8A-6-21
(Bi-Fuel CNG Model) / L: Floor Harness ...8A-3-4 D-4 Illumination Light ..............................8A-6-22 8A-7
Instrument Panel .........................................8A-3-6 D-5 Interior Light .....................................8A-6-24
D-6 Turn Signal and Hazard Warning
E: Main Harness, Heater Blower Joint
Light ........................................................8A-6-25
Wire ...........................................................8A-3-6
D-7 Brake Light .......................................8A-6-26
Roof.............................................................8A-3-8 D-8 Back-up Light ...................................8A-6-27
K: Roof Wire ..............................................8A-3-8 D-9 Headlight Beam Leveling System ....8A-6-28
L: Floor Harness, Fuel Pump Wire, CNG E-1 Heater and Air Conditioner ...............8A-6-30
Tank Wire ..................................................8A-3-9 F-1 Warning Buzzer ................................8A-6-32
Rear ..........................................................8A-3-11 G-1 Radio / Cigar Lighter Circuit
O: Rear Door Wire...................................8A-3-11 Diagram ..................................................8A-6-33
Ground (Earth) Point.................................... 8A-4-1 List of Connectors ........................................8A-7-1
Body & Engine Compartment....................8A-4-1 B Connector ..............................................8A-7-1
Instrument Panel .......................................8A-4-2 C Connector ..............................................8A-7-1
Power Supply Diagram ................................ 8A-5-1 E Connector ..............................................8A-7-2
Power Supply Diagram..............................8A-5-1 K Connector ..............................................8A-7-4
Fuses and The Protected Parts.................8A-5-3 L Connector ..............................................8A-7-5
Main Fuse Box ..........................................8A-5-3 O Connector..............................................8A-7-7
Table of Contents
8A-0-1
Precautions
EXAMPLE 8A-0
Air bag/seat belt pretensioner Warnings
CD
Service manual
WARNING:
(For the vehicles with the Supplemental Restraint System (Air Bags) and/or the Seat Belt Pretensioner
System)
Service on or around the air bag system / Seat belt pretensioner system components or their wiring
must be performed only by an authorized SUZUKI dealer. Observe all the warnings in the service man-
ual and disable the systems before servicing on or around the components and the wiring of the sys-
tems. The service manual(s) is (are) mentioned in the FOREWORD of this manual. Failure to follow the
Warnings could result in unintended activation of the systems or could render the systems inopera-
tive. Either of these two conditions may result in severe injury.
CAUTION:
To prevent damage to the electrical/ electronic parts (especially computers or semi-conductors) or to
prevent fire:
• When disconnecting the battery terminals, be sure to (1) turn off the ignition switch and all other switches,(2)
disconnect the negative (-) terminal wire and then (3) disconnect the positive (+) terminal wire.Connect the
wires in the reverse order of disconnecting.
• When disconnecting the connectors, be sure to unlock the connector lock (if equipped) and then pull the
connector shells to detach them. Do not pull the wires.
• Connect the connectors by holding the connector shells. Make sure they are securely locked.
• Install the wiring harness securely without any slack.
• When installing parts, make sure the wiring harness is not interfered with or pinched by them.
• Avoid routing the wiring harness near or around a sharp corner or edge of the vehicle body or parts as much
as possible. If necessary, protect the wiring harness by winding tape or the like around on it.
• When replacing a fuse, make sure to use the specified capacity fuse. Using a fuse with a larger capacity can
cause damage to the electrical parts or a fire.
• Do not handle electrical/ electronic parts (computer, relay, etc.) roughly or drop them.
• Do not expose electrical/ electronic parts to high temperature (Approximately 80°C(176°F) or higher) or
water.
• For open back connectors, be sure to insert the tester probe into the back side (wiring harness side) of the
connector for inspection. For sealed back connectors, apply the tester probe to the terminal as gently as
possible not to damage or deform the terminal.
8A-0-2
Memo
8A-1-1
General Information
How to Read Connector Layout Diagram
[B]
L33 L36
L20 L25 L24 L26 (TO O01) R02
L28 11 L09 Connector code
L10 8A-1
L11 L 36
L12
L14
[A-1] [A-2]
{ L15
R01
L42 R04
[B]
L16
R05 L05 L13
L01 (TO G01)
L02 (TO E04) L32 12 L07 (TO K02)
L03 (TO E05) L19
[A-1] Harness classification

A Battery harness
B A/C harness
C Engine harness
D Injector harness
E Main harness, Oil pressure switch wire, Console wire
G Instrument panel harness
[A-1] J Side door wire (Power window)
K Interior light harness, Rear speaker wire, Roof wire
L Floor harness, G sensor wire (Fuel pump harness)
M Rear bumper harness
O Rear end door harness
Q Air bag / Pretensioner harness
R (Fuel pump wire)
[A-2] Connector Number
[B] Ground (earth) point No.
8A-1-2
How to Read Connector Codes and Terminal Nos.

Connector Code / Terminal No. / Terminal Layout
View Z
Connector code.
Male terminal
A40
4 3 2 1
8 7 6 5
(View Z) A40
5
D18
Female terminal
D18
1 2 3 4
5 6 7 8
(View Z)
Terminal No.
Section 8A-7 ("CONNECTOR LIST")
Connector Type
8A-1-3
Terminals in One Connector (Broken Line) (B15) / Terminals in Different Con-

nectors (B14,B16)
B15
B14 B16
B15 5 7 B14 5 B16 7
Connector Location, Shape and Terminal No.
Section 8A-6
("SYSTEM CIRCUIT DIAGRAM")
-Connector code and terminal No.
Section 8A-3 Section 8A-7
("CONNECTOR LAYOUT DIAGRAM") ("CONNECTOR LIST")
-Connector location. -Connector shape and terminal position.
C02
C02 C02
C02
C02
C02
CROSS-REFERENCE
8A-1-4
How to Read Ground (Earth) Point
Section 8A-6 ("SYSTEM CIRCUIT DIAGRAM")

YEL/BLU Section 8A-4 ("GROUND (EARTH) POINT")
E40
10
16 20 5 6 7 10 11 12
BLU/BLK BLK BLU BLU/RED BLU/WHT
E09 2 E20 2 1 3 4
Windoshield Windoshield
washer wiper
M motor motor
M
1
Off
BLK BLK BLK On
Circuit
breaker
60A-B003-
1 10 9 Left side shown
10
CROSS-REFERENCE Device body grounding is not given the ground point number.
8A-1-5
How to Read Power Supply Diagram
Section 8A-5 ("POWER SUPPLY DIAGRAM")

Fuse number
Battery
- + BLK
Main fuse box Supplementary fuse box
1 2 3 4 5 6 7 8 29 9
80A 15A 15A 15A 25A 50A 30A 60A 30A 60A
32
E44 3 2 1 B01 1 E45 1 E40 2 1 15A
WHT/BLU WHT/RED BLU/RED RED WHT/BLU WHT/YEL WHT/GRN
WHT/GRN WHT/GRN
2 3 4
BLU
Individual circuit fuse box 11 12 13 14 15 16 17 18 19 20 21

15A 15A 15A 20A 20A 15A 15A 15A 15A 15A 15A
WHT WHT/GRN WHT/BLK YEL YEL/GRN PNK/BLK BLU/RED

GRN RED BLK/WHT YEL/BLU LT GRN YEL/BLK
1 2
11 12 13 14 15 16 17 18 19 20 21 29 32
Connection to the system

indicated.
Section 8A-6 ("SYSTEM CIRCUIT DIAGRAM")
13 17
15A 15A
WHT/GRN YEL RED/YEL
Fuse
8A-1-6
How to Read System Circuit Diagram

The circuit diagram is designed so the current flows from the top of the diagram (power source) to the bottom of
the diagram (ground (earth)) as if giving an image of water flow.
A 4-DOOR
[I] [J] [K] [L] [M] [N] [O]
B 2-DOOR
3 1 6
Fuse Fuse
15A 15A 20A
[A] "XX"
GB
[B] 3 BLK/RED
GRN/BLK
BLU ORN
C40 1
GB GR E08 2 1
C71 A 5
E03 B 6 Solenoid
Main
4 relay
4 3 2
[C] YEL
BLU GRN/BLK GRN/RED GRN
[D] GRN
GRN
2 E34 2 1
E33 1 E34 7 5 1 O06
XX
Cont.M
GRN GRN
[E] 2 5 6 4 4 6
GRN
2
GRN/BLK ORN WHT BLK YEL C26
2 1 2 A B Switch
[F] RED BRN/RED

OFF ON
Sensor E52 1 E52 1

Y
[G] 1
M M Motor
BLK
[H] 2 2
BLK BRN/RED C31
5
E19
Y Y
G20 3
GRN/RED
YEL/RED YEL
L50 1 3 RED BRN/RED BRN/RED BLK
GR GR P 8
5 5 6 1
2 4
[A] Fuse No.

[B] Circuit jumping page / direction
[C] Circuit jumping point / direction
[D] Terminals-in-one-connector mark
[E] Wire color
[F] Shield wire
8A-1-7
[G] Ground (earth) point

[H] “From” or “To”
[I] Specification variation
[J] “From” (With ID letter(s))
[K] “To” (With ID letter(s))
[L] Connector code
[M] Terminal No.
[N] Symbol mark
[O] “SEE” mark
Circuit jumping page / direction
This means “Jump to the page directed with the arrow(s) by their number.(For example:” Two arrows
[B] directing left” means” Jump to two pages before”.)
You will find the same symbol with the arrows directing opposite in the referenced page.
The circuit continues between the symbols.
Circuit jumping point / direction
[C] The circuit continues to the same symbol with opposite direction within the page.
You will find the other symbol in the direction of the arrow.
[I] The white arrow between A and B means “or”.
8A-1-8
Symbols and Marks
Battery Ring-terminal ground Ground Normal fuse Slow blow fuse
Circuit breaker Coil, Solenoid Heater Bulb Bulb
Cigarette lighter Motor Pump Horn Speaker
Buzzer Chime Condenser Thermistor Reed switch
Resistance Variable resistance Variable resistance Transistor NPN Transistor PNP
Photo transistor Diode Zener diode Light emitting diode Photo diode
Piezoelectric element Connected harnesses Crossing harnesses Ring terminal Connector
Normally-open relay Normally-closed relay Normally-open switch Normally-closed switch

8A-1-9
Ignition switch Keyless entry Immobilizer system Combination meter Lighting switch
Head light leveling Hazard warning light Front fog light Rear fog light Spark plug
Radiator cooling fan Fuel pump Fuel injector XX control module Windshield wiper
Petrol CNG
XX
Cont M
Windshield washer Rear wiper Rear washer Rear defogger Power window
Power door lock Power mirror A/B Pretensioner Passenger side
Driver side Seat heater A/C Power steering Side air bag (R)
Side air bag (L) Side curtain air bag (R) Side curtain air bag (L) Glow plug
8A-1-10
Abbreviations
Abbreviation Full term Abbreviation Full term
2WD 2 wheel drive vehicles ILL Illumination
4WD 4 wheel drive vehicles IND Indicator
A/B Air bag INT Intermittent
A/C Air conditioning ISC Idle speed control
A/T Automatic transaxle J/B Junction fuse block
ACC Accessory J/C Joint connector
CKP Crank shaft position L Left
CMP Cam shaft position LED Light emitting diode
COMB Combination LHD Left hand drive vehicle
DLC Data link connector LO Low
DRL Daytime running light MAP Manifold absolute pressure
DSL Diesel engine M/T Manual transaxle
ECM Engine control module O/D Over drive
ECT Engine coolant temperature P/N Power/Normal
EGR Exhaust gas recirculation P/S Power steering
EVAP Evaporative PSP Power steering pressure
FWD Forward R Right
HI High RHD Right hand drive vehicle
IAC Idle air control SDM Sensing and diagnostic module
IAT Intake air temperature ST Starter
ICM Immobilizer control module TCC Torque converter clutch
IF EQPD If equipped TCM Transmission control module
IG Ignition VSS Vehicle speed sensor
IG COIL Ignition coil VSV Vacuum switching valve
8A-1-11
Wire / Connector Color Symbols

Symbol Wire / Connector Color
BLK Black
BLU Blue
BRN Brown
GRN Green
GRY Gray
LT BLU Light blue
LT GRN Light green
ORN Orange
RED Red
WHT White
YEL Yellow
PNK Pink
PPL Purple
N Natural
GRN (Base color)
GRN (Base color)

YEL (Stripe color)
GRN / YEL
8A-1-12
Memo
8A-3-1
Connector Layout Diagram

Front
B: Joint Harness
10
B01 B02 B04 B03

8A-3
B05
(To L07)
B
L B6
(To L65)
B: Joint Harness
No. Connective position Remarks
B01 Condenser fan motor With A/C
B02 Condenser fan relay With A/C
B03 A/C compressor relay With A/C
B04 Dual pressure switch With A/C
B05 Floor harness (To L07) With A/C
B06 Floor harness (To L65) With A/C
8A-3-2
E: Main Harness
E06 E12 7
E13
E56
E55
E91
E58
E60
E72
E57
5
E64 E70 E11 E10
E63
E08
E
E: Main Harness
E06 Front washer motor
E08 Front position light (L)
E10 Front turn signal light (L)
E11 Headlight (L)
E12 Wiper motor
E13 Side turn signal light (L)
E55 Side turn signal light (R)
E56 Brake fluid level switch
E57 Headlight (R)
E58 Front turn signal light (R)
E60 Front position light (R)
E63 Horn #1
E64 Horn #2
E70 Headlight Leveling Actuator (L)
E72 Headlight Leveling Actuator (R)
E91 Siren If equipped
8A-3-3
Engine Compartment
A: Battery Cable / C: Engine Harness (Petrol Model) / L: Floor Harness
L84 {C27
L67
{ C26
L66
L85
C16 C17
L87
C L86
C18
C37
C13
L19
C11 L24
C12
4
C06 C09
C07
C08
C38
L82
BATTERY CABLE L83
L81
L80
C02
8A-3-4
A: Battery Cable / C: Engine Harness (Bi-Fuel CNG Model) / L: Floor Harness
L76 L77
L84 {C27
L67
{ C26
L66
L85
C16 C17
L87
C L86
C18
C37
C13
L19
C11 L24
C12
4
C06 C09
C07
C08
C38
L82
BATTERY CABLE L83
L81
L92
L89
L88 L80
L90
L91
C02 L95
L96
C: Engine Harness
C02 IG COIL #2, #3
C06 Injector #1
C07 Injector #2
C08 Injector #3
C09 Injector #4
C11 Generator
C12 ECT sensor
C13 EVAP canister purge valve
C16 A/C Compressor With A/C
C17 CKP sensor
C18 IAC valve
C26 Floor harness (To L66)
C27 Floor harness (To L67)
C37 Knock sensor
C38 Oil pressure switch
8A-3-5
L: Floor Harness
L19 Generator (BATT)
L24 Parking brake switch
L66 Engine harness (To C26)
L67 Engine harness (To C27)
L76 CNG control module Bi-fuel CNG model
L77 CNG control module Bi-fuel CNG model
L80 Battery +
L81 IG COIL #1, #4
L82 Heated Oxygen Sensor
L83 CMP sensor
L84 IAT sensor
L85 MAP sensor
L86 Throttle position sensor
L87 EGR valve
L88 MAP sensor Bi-fuel CNG model
L89 Injector #1 Bi-fuel CNG model
L95 Fuel shutoff valve relay Bi-fuel CNG model
L96 Fuel lid switch Bi-fuel CNG model
8A-3-6
Instrument Panel
E: Main Harness, Heater Blower Joint Wire
HEATER BLOWER JOINT WIRE E

E68 E39 E86
8 E20 E87
E34
E88
E43
E92
E93
E76
E01
(To L01)
E04 E17 E14 E85
(To K03) (To L02) E89 E75
E22 E84
E82 E83 E44
E23 E47
E24 { E80
E81
E: Main Harness
E01 Floor harness (To L01)
E04 Roof wire (To K03)
E14 Evaporator temperature sensor With A/C
E17 Floor harness (To L02)
E20 Fan switch
E22 Radio If equipped
E23 Cigar lighter If equipped
E24 Cigar lighter If equipped
E34 Main switch (Key switch)
E39 Combination meter
E43 Turn signal relay
E44 Brake light switch
E47 DLC
E68 A/C Switch With A/C
E75 Headlight leveling switch
E76 CNG select switch Bi-fuel CNG model
E80 Heater joint wire (To E81)
E86 Combination switch (light)
E87 Combination switch (turn signal)
E88 Combination switch (wiper)
E89 Horn
E: Heater Blower Joint Wire
E81 Main herness (To E80)
E82 Heater resistor
8A-3-7

E83 Heater fan motor
E84 Heater main relay
E85 Heater high relay
8A-3-8
Roof
K: Roof Wire
K
K01 K07
K05
K03
(To E04)
K: Roof Wire
K01 Room light (front)
K03 MAIN harness (To E04)
K05 Door switch (driver side)
K07 Room light (rear)
8A-3-9
L: Floor Harness, Fuel Pump Wire, CNG Tank Wire
A: CNG 5-seater model

B: CNG 2-seater model
L52 L30
L31
L25
L40 L18 L01
L16
L71 L70 L69
L02
{ L37
L47
10
L07
L43 (To B05)
(To O09)
L65
(To B06)
L08
L B
L46
A
L75
{ L74
L73
L93 L94
L14
L35
9 FUEL PUMP WIRE

L48
CNG TANK WIRE
L: Floor Harness
L01 Main harness (To E01)
L02 Main harness (To E17)
L07 Joint harness (To B05) With A/C
L08 Radiator cooling fan motor
L14 Radiator cooling fan relay
L16 Main relay
L18 Fuel pump relay
L25 Starting motor relay
L30 Starting motor
L31 Starting motor
L35 Vehicle speed sensor
L37 Fuel pump wire (To L47)
L40 Rear combination light (R)
L43 Rear end door harness (To O09)
L46 Rear combination light (L)
L52 Back-up light switch
8A-3-10

L65 Joint harness (To B06) With A/C
L69 ECM
L70 ECM
L71 ECM
L73 CNG tank wire (To L74) Bi-fuel CNG model
L93 Regulator shutoff valve Bi-fuel CNG model
L94 Fuel remaining pressure sensor Bi-fuel CNG model
L: Fuel Pump Wire
L47 Floor harness (To L37)
L48 Fuel pump and gauge
L: CNG Tank Wire
L74 Floor harness (To L73) Bi-fuel CNG model
L75 Fuel shutoff valve Bi-fuel CNG model
8A-3-11
Rear
O: Rear Door Wire
O01 O02
O09
(To L43)
O07
O06
O: Rear Door Wire

O01 High mounted stop light
O02 High mounted stop light (GND)
O06 License plate light #1
O07 License plate light #2
O09 Floor harness (To L43)
8A-3-12
8A-4-1
Ground (Earth) Point

Body & Engine Compartment
8A-4
2
9
3
5
7 10
8A-4-2
Instrument Panel
8
8A-5-1
Power Supply Diagram

Power Supply Diagram
Battery
L80
1 2 3 4 5 6 7 8 Main
fuse
70A 60A 60A 30A 30A 30A 20A 15A box
8A-5
BLK BLK
WHT WHT WHT/RED RED BLU/WHT BLU RED BLK/YEL
Generator
"A-2"
4 5 6 7 8
L02
Starting motor
"A-1" E17 1 2
1 WHT/RED
Individual 21 20 9 10 11 16 17 18 15
circuit
fuse 7.5A 10A 10A 15A 10A 10A 15A 7.5A
box
RED BRN/BLK WHT/RED WHT/BLU WHT/GRN RED/GRN GRN WHT RED/BLK BLK/RED
BLK
21 20 9 10 11 16 17 18 15 15
1 2 3
8A-5-2
WHT
E34 5
Treminal Key
reminder
+B1 +B2 ACC IG1 IG2 ST SW
Key Position K1 K2
Out
Lock
ACC
In ON
ST
4 3 7 6
BLU BLK/YEL YEL/BLK BLK/YEL
12 13 14 23 22 19 Individual
15A 10A 15A 15A 10A 10A circuit
fuse
box
WHT/BLK BRN/YEL BLK/WHT YEL/BLU LT GRN RED/GRN
12 13 14 23 22 19
8A-5-3
Fuses and The Protected Parts

The chart below describes what parts each fuse protects.
Main Fuse Box
Radiator cooling fan relay Main relay Fuel pump relay

Starting motor relay
No. Amperage Protected circuit No. Amperage Protected circuit

Generator 5 30A Radiator fan relay
1 70A Battery 6 30A Starting motor relay
All electric circuit 7 20A Compressor relay
2 60A Ignition switch 8 15A Main relay
3 60A Individual circuit fuse box
4 30A Heater relay
Circuit Fuse Box

8A-5-4
No. Amperage Description on the cover Protected circuit

9 10A H/L R Headlight (R)
10 10A H/L L Headlight (L)
Horn relay
11 15A HORN. HAZARD
Hazard switch
Cigar lighter
12 15A ACC
Radio
Turn signal relay
13 10A TURN. BACK
Back-up light switch
Combination meter
IG COIL #1, #4
IG COIL #2, #3
14 15A IG. METER
Generator
ECM
CNG control module (Bi-fuel CNG model)
CNG control module (Bi-fuel CNG model)
Fuel injector #1 (Bi-fuel CNG model)
15 7.5A CNG Fuel injector #2 (Bi-fuel CNG model)
16 10A TAIL Combination switch
17 10A STOP Brake light switch
Radio
Interior light (Front)
18 15A RADIO. DOME Interior light (Rear)
Combination meter
ECM
19 10A ST. SIG Starting motor relay
20 7.5A CNG VLV Fuel shutoff valve relay (Bi-fuel CNG model)
21 BLANK DOOR. LOCK BLANK
Heater relay
22 10A IG2. SIG
Heater fan motor
Combination switch
23 15A WIPER. WASHER Front wiper motor
Front washer motor
8A-6-1
System Circuit Diagram

A-1 Cranking System
A Petrol model
B Bi-fuel CNG model
L80
Main Individual
fuse 6 19 circuit
box ST fuse
30A 10A box
Battery
RED/GRN
E01 A 19
L01 B 15
BLU RED/GRN
8A-6
BLK BLK BLK
L25 1 3
1 2 3 Starting
motor
relay
2 4
BLK/YEL
BLK/YEL
BY
ECM
BLK
"A-5"
L30 1 L31 1
Starting
motor
9 10
8A-6-2
A-2 Charging System
A Petrol model
Individual
Main 1 14 IG. B Bi-fuel CNG model
circuit
fuse fuse METER
box 70A box 15A
BLK/WHT
BLK/WHT BLK/WHT
E39 1
CHARGE
31
A 1 WHT/RED
E01 B 14 6
L01
WHT BLK/WHT WHT/RED
L66 13 9
C26
BLK/WHT WHT/RED
WR
L19 2 1
1 C11
IC
regulator
Generator
8A-6-3
A-3 Ignition System
A Petrol model
Individual
B Bi-fuel CNG model
14 IG. circuit
METER fuse
15A box
BLK/WHT
E01 A 1
L01 B 14
ECM
L69 29 30
WB WHT/BLK PPL V
L66 2
C26
WHT/BLK BLK/WHT
BLK/WHT
L66 13
C26
PPL
BLK/WHT BLK/WHT
L81 1 3 C02 1 3
IG COIL IG COIL
#1,#4 #2,#3
2 2
BLK BLK
L67 4
C27
BLK
4
8A-6-4
A-4 Cooling System
Main
5 fuse
30A box
Main relay
"A-5"
BR
BLK/RED BLU/WHT
L14 3 1
Relay
4 2
RED/GRN BLU/RED
BR
2
L08
M
Motor
BLK
RG
ECM
"A-5"
10
8A-6-5
Memo
8A-6-6
A-5 Engine & A/C Control System (Petrol Model)

(1/4)
A With A/C
Individual
7 8 Main circuit
fuse
14 IG. fuse
20A 15A box 15A METER box
RED BLK/YEL BLK/WHT
A L16 3 1
Main
1
relay
L07 1
4 2
E01 1 BLK/RED
B05 L01
BLK/RED
BLK/RED
L65 2
B06
RED LT GRN BLK/ORN BLK/RED BLK/RED
B03 2 1 L18 1 3
Compressor Relay
relay 4 3 2 4
PNK PNK/BLU
B06 4 1
L65
PNK/BLU PNK PNK/BLU BLK/WHT BLK/RED BLK/RED
P
L69 11 10 13 L70 33 1 2
PNK
L67 8
L37 1
C27 L47 ECM
PNK
PNK
3 L70 8 9 10 7 16 30 19
L48
BLU
BLU BLK/WHT 2
P
and
fuel gauge L67 3 7 11
C27 BLK/RED RED GRN
4
C16 1 BLK
BLU BLK/WHT
L82 4 3 2 1
3
BLK BLK C37 2
Knock Heated oxygen sensor

sensor
Compressor
1
10 9
8A-6-7
(2/4)
5 Main
fuse
30A box
BLK/RED 4
L66 C26
1 BLK/RED BLK/RED
4
BR BLK/RED BLK/RED 3
BLK/RED BLU/WHT BLK/RED BLK/RED BLK/RED BLK/RED BLK/RED

L14 3 1 C06 2 C07 2 C08 2 C09 2
Relay
RG 4 2 #1 1 #2 1 #3 1 #4 1
RED/GRN BLU/RED BRN/BLK BRN BRN/WHT BRN/YEL
C26 5 6 7 8
BR
L66
Motor
"A-4"
BRN/BLK BRN BRN/WHT BRN/YEL
L69 12 5 4 3 2
ECM
L70 13 14 6 15 31 12 20 26 35 27
LT GRN
L66 12
C26
2 BRN YEL
LT GRN LT GRN/BLK LT GRN/RED GRY/BLU BLU/YEL GRY/RED LT GRN/RED

L67 10 2 1
C12 2 L84 2 L86 1 2 L85 3 1
C27
Open
ECT IAT TP MAP
sensor sensor sensor sensor BRN YEL
Close
1 1 3 2 C17 1 2
BLU/YEL BLU/YEL BLU/YEL BLU/YEL BLU/YEL
C27 5
L67
BLU/YEL
CKP sensor
8A-6-8
(3/4)
Individual
17 18 RADIO. circuit
STOP DOME fuse
10A 15A box
GRN 5
3 BLK/RED
1
E44
BLK/RED BLK/RED BLK/RED WHT BLK/RED
Brake
light
switch
C13 1 C18 2 3 L83 3 L35 1

BLK/RED
EVAP IAC Vehicle
canister valve CMP speed
purge sensor sensor
valve 1 3
2 GRN/WHT 1 2 2 3
BLK/RED BLK/RED
GRN/YEL ORN
Starting
16 15 BLK GRN/RED motor
C26 E01 14 E01 20 relay
L66 L01 L01 "A-1"
L87 2 5
BY
EGR
valve
GRN/YEL ORN BLK GRN/WHT

3 1 4 6 BLK/YEL YEL
BLK/YEL
RED RED/BLU WHT
GW
BLK RED/WHT RED/YEL
L69 14 8 L71 1 L70 4 34 L69 16 17 34 33 L71 6 5 L70 32
ECM
L69 6 7
5
BLK BLK/BLU BLK/BLU
"C-1"
R W
E01 L01
BLK/YEL
5
WHT WHT
RED BLK/YEL
L66 3 14 11
E47 1 3 11 12 13
C26
BLK BLK/BLU BLK/YEL

DLC BLK
BLK
BLK BLK
5 7 4
8A-6-9
(4/4)
A With A/C
"C-1"
RB WB
(CAN)
RED/BLK WHT/BLK
E01 9 10
L01
(CAN)
RED/BLK WHT/BLK
L71 35 34
ECM
L69 22 L71 33 7 3 L69 29 30 L71 16
WHT BLU/YEL WHT/BLK ORN WHT/BLK PPL PNK/BLU

L02 5 6 L65 3 L66 2 L01 18
E17 B06 C26 E01
W BLU/YEL WHT/BLK ORN
PPL
E14 1
O WB V PB
Condenser
fan relay Evaporator Dual Ignition coil Ignition coil Heater
temperature pressure #1, #4 #2, #3 blower
"E-1" motor
sensor switch "A-3"
"E-1" switch
2 "E-1"
A
8A-6-10
A-5 Engine & A/C Control System (Bi-Fuel CNG Model)

(1/4)
A With A/C
7 8 Main Individual
fuse
14 IG. circuit
20A 15A box 15A METER fuse
box
RED BLK/YEL
BLK/WHT
L16 3 1
Main 1
A relay
L07 1
4 2
E01 14 BLK/RED
B05 L01
BLK/RED
BLK/RED
L65 2
B06
RED LT GRN BLK/ORN BLK/RED BLK/RED
B03 2 1 L18 1 3
Compressor Relay
relay 4 3 2 4
PNK PNK/BLU
B06 4 1
L65
PNK/BLU PNK PNK/BLU BLK/WHT BLK/RED BLK/RED
L69 11 10 13 L70 33 1 2
PNK
L67 8
L37 1 ECM
C27 L47
PNK
PNK
L70 8 9 10 7 16 30 19
3
L48 BLU
BLU BLK/WHT 2
P
and
fuel gauge
L67 3 7 11
C27 BLK/RED RED GRN
4
C16 1 BLK
BLU BLK/WHT
L82 4 3 2 1
C37 2
BLK BLK
Knock Heated oxygen sensor
sensor
Compressor
1
10 9
8A-6-11
(2/4)
Individual
5 Main 15 CNG circuit
fuse fuse
30A box 7.5A box
4 BLK/RED RED/BLK
E01 19 20
L66 C26 L01
1 BLK/RED BLK/RED
4 RED/BLK
BLK/RED BLK/RED 3
Petrol CNG
BLK/RED BLU/WHT BLK/RED BLK/RED BLK/RED BLK/RED BLK/RED RED/BLK RED/BLK RED/BLK RED/BLK RED/BLK
L14 3 1 C06 2 C07 2 C08 2 C09 2 L89 1 L90 1 L91 1 L92 1
Relay
RG 4 2 #1 1 #2 1 #3 1 #4 1 #1 2 #2 2 #3 2 #4 2
RED/GRN BLU/RED BRN/BLK BRN BRN/WHT BRN/YEL BLU RED/BLU GRN YEL RED/BLK RED/BLK
C26 5 6 7 8
BR
L66
BRN/BLK BRN BRN/WHT BRN/YEL
L77 3 10 2 9 1 7 14 20 L76 1 7
Motor
CNG
"A-4" Cont.M
L76 9 3 8 2 L77 18 23 6 13 19
BRN/BLK BRN BRN/WHT BRN/YEL BLK/YEL ORN BLK/BLU BLK/BLU BLK/BLU
L69 12 5 4 3 2 L70 29 28
ECM
L70 13 14 6 15 31 12 20 26 35 27
LT GRN
L66 12 L67 6
C26 C27
2
BRN YEL
LT GRN LT GRN/BLK LT GRN/RED GRY/BLU GRY/RED LT GRN/RED BLK/BLU
10 2 1
C12 2 L84 2 L86 1 2 L85 3 1 L67
Open
C27
ECT IAT TP MAP
sensor sensor sensor sensor
BRN YEL
Close
1 1 3 2 C17 1 2
BLU/YEL BLU/YEL BLU/YEL BLU/YEL BLU/YEL
C27 5
L67
BLU/YEL
4
CKP sensor
8A-6-12
(3/4)
Individual
17 18 RADIO. circuit
STOP DOME fuse
10A 15A box
GRN 5
3 BLK/RED
E44 1
BLK/RED BLK/RED BLK/RED WHT BLK/RED

Brake
light
switch
C13 1 C18 2 3 L83 3 L35 1

BLK/RED
EVAP IAC Vehicle
canister valve CMP speed
purge sensor sensor
valve 1 3
2 GRN/WHT 1 2 2 3
BLK/RED BLK/RED
GRN/YEL ORN
Starting
16 15 motor
C26 E01 13 BLK GRN/RED E01 17 relay
L66 L01 L01 "A-1"
L87 2 5
BY
EGR
valve
GRN/YEL ORN GRN/WHT

3 1 4 6 BLK YEL
BLK/YEL
RED RED/BLU WHT
GW
BLK RED/WHT RED/YEL
L69 14 8 L71 1 L70 4 34 L69 16 17 34 33 L71 6 5 L70 32
ECM
L69 6 7
5
BLK BLK/BLU BLK/BLU
"C-1"
R W
E01 L01
BLK
WHT 4
WHT BLK
RED
L66 3 14
E47 1 3 11 12 13
C26
DLC
BLK BLK BLK/BLU
BLK
BLK BLK
5 7 4
8A-6-13
(4/4)
A With A/C
Individual
circuit
20 CNG 14
fuse
VLV IG.
box METER
7.5A 15A
BRN BRN/BLK
L73 1 E01 21
L74 L01
BRN BRN BRN/BLK BLK BLK/WHT BLK/WHT BLK
L93 1 L75 1 L95 2 3 E76 4 5

Fuel
Regulator Fuel CNG
shutoff
shutoff shutoff select
valve
valve valve switch
relay
E01 14
2 2 4 1 L01 2 1
BLU/WHT BRN BLU/YEL BLK/WHT RED LT GRN
E01 22 8
2 L01
PNK/BLK BLU/WHT RED LT GRN
L76 19 24 4 15 21 16
CNG
Cont.M
5 11 10 18 6 12 17 23 22
BLK/GRN BLU/BLK ORN WHT GRN LT BLU BLK/RED GRN PNK/BLU

"C-1"
RB WB
L88 3 4 2 L94 1 2 L96 1 2
(CAN)
Fuel RED/BLK WHT/BLK
CLOSE OPEN
MAP remaining
pressure E01 23 24
sensor
(CNG) sensor L01
Fuel lid (CAN)
3 4 RED/BLK WHT/BLK
switch
1
BLK L71 35 34
ECM
L69 22 L71 33 7 3 L69 29 30 L71 16
WHT BLU/YEL WHT/BLK ORN WHT/BLK PPL PNK/BLU

L02 5 6 L65 3 L66 2 L01 16
E17 B06 C26 E01
W BLU/YEL WHT/BLK ORN
PPL PNK/BLU
E14 1
O WB V PB
Condenser
fan relay Evaporator Dual Ignition coil Ignition coil Heater
temperature pressure #1, #4 #2, #3 blower
"E-1" motor
sensor switch "A-3"
"E-1" switch
2 "E-1"
BLK BLK BLK
10 9 5
8A-6-14
B-1 Windshield Wiper and Washer
Individual
23 WIPER. circuit
WASHER fuse
15A box
YEL/BLU
YEL/BLU
E88 2
Washer Switch
Relay
12V
B3 +2 +1 1 INT1 INT2
OFF
INT
LO
Hi
5 3 4 1
YEL/BLU BLU/WHT BLU/RED BLU BLK/BLU

2
E06
M
Motor
E12 4 3 1 2
1
H
M
L
BLK
Motor
7
8A-6-15
Memo
8A-6-16
B-7 Horn / Optional Security System
Individual
11 HORN. circuit 21 BLANK 11 HORN.
HAZARD fuse HAZARD
15A box 15A
RED WHT/GRN
E93 1 2
WHT/GRN
SC OP#1
OP SIREN
E92 1 2
BRN BLK
1 2
E91
E64 1
SIREN
H Horn
E63 1
BLU/YEL
E89 1
Combination
switch
(Horn)
8A-6-17
C-1 Combination Meter (Meter and Gauge)
A Petrol model
B Bi-fuel CNG model
Individual
circuit 14 IG. 18 RADIO.
fuse METER DOME
box 15A 15A
"D-4"
RY
BLK/WHT WHT
RED/YEL
E39 3 1 2
SPEED
CAN
CPU FUEL
ILL
I/F
LCD
4 6 7 9 8 5 21
BY
YEL/RED BLK/YEL
BLK RED RED/BLK WHT/BLK WHT
(CAN) (CAN)
A 9 A 10 YR
E01 B 23 B 24
L01 Relay
"A-5" A 8 A 7
P
E01 B 7 B 5
RED/BLK WHT/BLK
L01
PNK YEL/RED BLK/YEL
RB WB
ECM ECM L37 1 2 4

L47
"A-5" "A-5"
PNK YEL/RED BLK/YEL
L48 3 1 2
B
P 1
BLK
and
fuel 4
E47 3 11 gauge BLK
3
BLK
DLC
"A-5"
BLK BLK
5 10 9
8A-6-18
C-2 Combination Meter (Indicator Lamp)
Individual
RADIO.
circuit 14 IG. 18 DOME
fuse
15A METER 15A
box
Combination switch
"D-6"
GR GY
GRN/RED GRN/YEL BLK/WHT WHT
E39 10 11 1 2
TURN R
TURN L
SPEED
BEAM
FUEL CPU
LCD
4 16
BLK RED
(Dimmer & passing)

"D-1"
BLK
5
8A-6-19
C-3 Combination Meter (Warning Lamp)
A Petrol model
Individual
B Bi-fuel CNG model
circuit 14 IG. 18 RADIO.
fuse DOME
METER
box 15A 15A
BLK/WHT WHT
E39 2 1
(COOL)
TEMP
SPEED
BRAKE
TEMP
(HOT)
FUEL
CHARGE
BRAKE
OIL
FUEL CPU
LCD
31 32 28 29
WHT/RED YEL/BLK RED/BLK BLU
A 3 A 4
E01 6 B 2 B 3
L01
WHT/RED YEL/BLK RED/BLK
2
E56
L66 9 L67 12 Brake

fluid
C26 C27 level
switch
1
WHT/RED YEL/BLK
WR
Generator BLK
"A-2"
C38 1 L24 1
Oil Parking
pressure brake
switch switch
5 7
8A-6-20
D-1 Headlight System

A Petrol model
B Bi-fuel CNG model
Individual
18 RADIO. 10 H/L L 9 H/L R 16 TAIL
circuit
DOME fuse
15A 10A 10A 10A box
WHT WHT/BLU WHT/RED RED/GRN
E11 3 E57 3
Headlight Headlight
(L) (R)
E39 2
2 1 1 2
BEAM
RED RED/WHT RED/WHT RED
16
R
RED
RED RED/WHT
RED
E86 4 9 7
PASS HEAD
LO TAIL
Hi OFF
Dimmer & passing switch Lighting switch
5 6
BLK RED/YEL
RED/YEL
E01 A 13
L01 B 12
RED/YEL RED/YEL RED/YEL
RED/YEL
RED/YEL L43 4
BLK BLK O09
RED/YEL
RY RY RY RY
Rear combination light License Front position light (L) Front position light (R)
(Tail light) plate light "D-2" "D-2"
5 7 "D-2" "D-2"
8A-6-21
D-2 Position, Tail and License Plate Light
A Petrol model
Individual B Bi-fuel CNG model
16 TAIL circuit
fuse
10A box
RED/GRN
7
E86
HEAD
OFF
TAIL
RED/YEL
RY
RED/YEL
RY E01 A 13
L01 B 12
RED/YEL RED/YEL RED/YEL
RED/YEL
RY
RED/YEL
L43 4
O09
RED/YEL
RY
RED/YEL RED/YEL RED/YEL RED/YEL
1 1 1 3 3 E60 1
E08 O06 O07 L46 L40
Front Front
position position
light (L) light (R)
2 #1 #2 2
License plate
BLK BLK
light 4 4
2 2
Rear combination
BLK
light
(L) (R)
BLK BLK BLK
1
BLK
BLK
BLK BLK
7 9 5
8A-6-22
D-4 Illumination Light
A Petrol model
Individual B Bi-fuel CNG model
circuit 16 TAIL
fuse
box 10A
RED/GRN
7
E86
HEAD
OFF
TAIL
RED/YEL
RY
RED/YEL RED/YEL 1
RED/YEL
E01 A 13
L01 B 12
RED/YEL
RED/YEL
L43 4
O09
RED/YEL RED/YEL RED/YEL RED/YEL
RED/YEL RED/YEL
RY RY RY RY RY
Front License plate License plate Rear Front

position light (L) light (R) combination position
light (L) "D-2" "D-2" light light (R)
"D-2" (Tail light) "D-2"
"D-2"
8A-6-23
1 RED/YEL RED/YEL
RY RY
RED/YEL RED/YEL
E20 3
Heater
blower
E39 3
motor
switch
6
ILL
BLK BLK
7 5
8A-6-24
D-5 Interior Light
Individual
circuit 18 RADIO.
fuse DOME
box 15A
WHT
E04 1
K03
WHT
WHT WHT
K01 2 K07 2
Interior light Interior light

(Front) OFF ON OFF ON (Rear)
DOOR DOOR
1 3 1 3
BLK/RED BLK BLK/RED BLK
BLK/RED BLK
K05 1
Front
door
switch
8
8A-6-25
D-6 Turn Signal and Hazard Warning Light
A Petrol model
Individual
circuit B Bi-fuel CNG model
11 HORN. 13 TURN.
fuse
box 15A HAZARD 10A BACK
WHT/GRN BRN/YEL
E87 5 6
OFF
Hazard switch
ON
3 4
YEL/RED
Turn signal relay
GRN Turn signal switch
1 3
E43 2 OFF R
ON N
L
1 2
GRN/RED GRN/YEL
GRN/RED GRN/YEL GRN/RED GRN/YEL GRN/RED GRN/YEL

GR GY
A 12 A 11
E01 B 11 B 10
"C-2"
L01
GRN/RED GRN/YEL GRN/RED GRN/YEL GRN/RED GRN/YEL
2 2 2 2 L46 2 L40 2
E10 E58 E13 E55
Front turn
signal light
(L) (R)
1 1 (L) 1 1 (R)
Side turn
signal light 4
(L) 4 (R)
Rear combination
BLK BLK BLK BLK BLK BLK light BLK
BLK
BLK
BLK BLK
5 7 9
8A-6-26
D-7 Brake Light
A Petrol model
Individual
circuit
B Bi-fuel CNG model
17 STOP
fuse
10A box
GRN
E44 1
Brake light
switch
GRN/WHT
E01 A 14
L01 B 13
GRN/WHT
GRN/WHT
GRN/WHT GRN/WHT
GW
L43 3
O09
ECM GRN/WHT GRN/WHT
GRN/WHT
"A-5"
L46 6 L40 6
1
O01
Brake Brake
light light High mounted
(L) (R) stop light
O02 1
4 4
BLK BLK BLK
1
BLK
BLK
9
8A-6-27
D-8 Back-up Light
A Petrol model
Individual
circuit TURN. B Bi-fuel CNG model
13
fuse BACK
box 10A
BRN/YEL
E01 A 2
L01 B 1
BRN/YEL
L52 1
Back-up light
switch
RED
RED RED
5 5
L46 L40
4 4
Back-up light
(L) (R)
BLK BLK
BLK
9
8A-6-28
D-9 Headlight Beam Leveling System
Individual
circuit 16 TAIL
fuse
box 10A
RED/GRN
7
E86
HEAD
OFF
TAIL
RED/YEL
RED/YEL RED/YEL
E70 3 E72 3
Actuator (L) Actuator (R)
2 1 1 2
YEL BLK BLK YEL
RED/YEL
YEL
E75 4 3
Switch
5
BLK BLK
BLK BLK
5 7
8A-6-29
Memo
8A-6-30
E-1 Heater and Air Conditioner
A Petrol model
Individual Main
B Bi-fuel CNG model circuit fuse
13 TURN. 22 IG2. 4
C With A/C fuse BACK box
box 10A 10A SIG 30A
BRN/YEL LT GRN RED
Heater resistor L01 A 15

4 E01 B 9
E82 3 1 2 E80 4 5
E81
PNK/BLK RED/GRN LT GRN
PNK/BLU RED/GRN RED/GRN LT GRN RED LT GRN

2 E85 2 1 E84 2 1
ECM E83
Heater fan motor Heater Heater
"A-5" high main
M relay relay
PB
4 3 4 3
1
PNK/BLU BLK PNK RED/BLK BLK
RED/BLK
L01 A 18 3 6 2 1
E01 B 16
C 4
PNK/BLU
"D-4"
RY
PNK/BLK PNK/BLU PNK RED/YEL BRN/YEL BLK
E20 4 5 2 3 E68 1
1 2 3
Heater
ILL
blower
motor
switch Switch
1 6 2
BLK BLK
BLK
GRN/BLK 5
7
8A-6-31
A Petrol model
Main
fuse B Bi-fuel CNG model
7 C With A/C
box
20A
C
RED BLK/RED
L07 1
B05
RED L65 2
B06
LT GRN
RED LT GRN RED LT GRN

B02 2 1 B03 2 1
Condenser
fan relay
Compressor
relay
4 3 4 3
WHT
PNK PNK/BLU
B05 3
4 1
L07 W
WHT
RED/BLU PNK PNK/BLU BLK/RED
2 22 3 11 1
L69 L70
ECM
L71 3 2 3 7 33
ORN RED/BLU PNK WHT/BLK BLU/YEL

L65 3
B06
ORN
C 2 1 L67 L02
B04 B01 8 6 5
C27 E17
Condenser WHT/BLK
Dual M
pressuve fan motor
switch 1
E14
2
1 Evaporator
BLK temperature BLU/YEL
GRN/BLK PNK
sensor
B05 4 2
B05 2
L07 L07
GRN/BLK BLK
L02 4 C16 1
E17
BLK BLK
Compressor
5 GRN/BLK
9 10
8A-6-32
F-1 Warning Buzzer
Individual
circuit 14 IG.
fuse METER
box 15A
"D-4"
RY
RED/YEL BLK/WHT
E39 3 1
Warning buzzer
BLK
5
8A-6-33
G-1 Radio / Cigar Lighter Circuit Diagram
Individual
12 ACC 18 RADIO. circuit
DOME fuse
15A 15A box
WHT/BLK WHT/BLK WHT
E24 1 E22 1 3
Cigar
Radio
lighter
E23 1 2
BLK BLK
5 8
8A-6-34
Memo
8A-7-1
List of Connectors
B Connector
B01 B02 B03 B04 B05 (To L07) B06 (To L65)
1 2 1 2 2 1 2 1
1 2 1 2
3 4 3 4 4 3 4 3
With A/C With A/C With A/C With A/C With A/C With A/C
C Connector
C02 C06 C07 C08 C09 C11
1 2 3 1 2 1 2 1 2 1 2 1 2
8A-7
C12 C13 C16 C17 C18 C26 (To L66)
1 2 3 4
5 6 7 8
1 2 1 2 1 1 2 1 2 3
9 10 11 12
13 14 15 16
With A/C
C27 (To L67) C37 C38
1 2 3 4
5 6 7 8 1 2 1
9 10 11 12
8A-7-2
E Connector
E01 (To L01) E01 (To L01) E04 (To K03) E06 E08
1 2 3 4 1 2 3 4
5 6 7 8 9 10 5 6 7 8 9 10 1 1
2 1
11 12 13 14 11 12 13 14 15 16 17 18 2 2
15 16 17 18 19 20 19 20 21 22 23 24
Bi-fuel CNG model
E10 E11 E12 E13 E14 E17 (To L02)
1 1 1 2 1 1 2
2 3 1 2
2 3 4 2
3 4 5 6
With A/C With A/C

E17 (To L02) E20 E22 E23 E24 E34
1 2 3 1 1 2 3 4
1 2 1
4 5 6 2 3 1 5 6 7
If equipped If equipped If equipped

E39 E43 E44
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 1 2
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 2 3 3 4
E47 E55 E56 E57 E58
1 2 3 4 5 6 7 8 1 1 1
1 2 2 3
9 10 11 12 13 14 15 16 2
2
E60 E63 E64 E68 E70 E72
1
1 1 1 2 1 2 3 1 2 3
2
With A/C
E75 E76 E80 E81 E82 E83
1 2 1 2 1 2 3 3 2 1 1 1
3 4 5 6 3 4 5 6 4 5 6 6 5 4 2 3 2
Bi-fuel CNG
model
E84 E85 E86 E87 E88
1 2 1 2 1 2 3 4
1 2 3 4 5 6 1 2 3 4 5
3 4 3 4 5 6 7 8 9 10
8A-7-3
E89 E91 E92 E93
1 1 1
1 2 2 2
If equipped If equipped
8A-7-4
K Connector
K01 K03 (To E04) K05 K07
1 1
2 1 2 1 2
3 3
8A-7-5
L Connector
L01 (To E01) L01 (To E01) L02 (To E17) L02 (To E17) L07 (To B05)
4 3 2 1 4 3 2 1
10 9 8 7 6 5 10 9 8 7 6 5 2 1 1 2
2 1
14 13 12 11 18 17 16 15 14 13 12 11 3 4
20 19 18 17 16 15 24 23 22 21 20 19 6 5 4 3
Bi-fuel CNG model With A/C With A/C

L08 L14 L16 L18 L19 L24
1 1 1
1 1
2 2 2 1
2
3 4 3 4 3 4
L25 L30 L31 L35 L37 (To L47) L40
1
1 2 1 2 3
2 1 1 1 2 3
3 4 4 5 6
3 4
L43 (To O09) L46 L47 (To L37) L48 L52 L65 (To B06)
2 1 1 2 3 1 2 1 2 1 2
1 2
4 3 4 5 6 3 4 3 4 3 4
With A/C
L66 (To C26) L67 (To C27) L69 L70
4 3 2 1
4 3 2 1 1 2 3 4 5 6 7 1 2 3 4 5 6 7
8 7 6 5 8 9 10 11 12 13 14 15 1617 8 9 10 11 12 13 14 15 16 17 18 19
8 7 6 5
12 11 10 9 18 19 20 21 22 23 24 25 26 27 20 21 22 23 24 25 26 27
12 11 10 9
16 15 14 13 28 29 30 31 32 33 34 28 29 30 31 32 33 34 35
L71 L73 (To L74) L74 (To L73) L75
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16 1 2 2 1
17 18 19 20 21 22 23 24 25 26 27 1 2
28 29 30 31 32 33 34 35
Bi-fuel CNG Bi-fuel CNG Bi-fuel CNG

model model model
L76 L77 L80 L81
1 2 3 4 5 6 1 2 3 4 5 6
7 8 9 10 11 12 7 8 9 10 11 12 13
1 1 2 3
13 14 15 16 17 18 19 14 15 16 17 18 19
20 21 22 23 24 20 21 22 23
Bi-fuel CNG model Bi-fuel CNG model

8A-7-6
L82 L83 L84 L85 L86 L87
1 2 1 2 3
1 2 3 1 2 1 2 3 1 2 3
3 4 4 5 6
L88 L89 L90 L91 L92 L93
1 2 3 4 1 2 1 2 1 2 1 2 1 2
Bi-fuel CNG
model
L94 L95 L96
1
1 2 1 2
2
3 4 3 4
3
Bi-fuel CNG
model
8A-7-7
O Connector
O01 O02 O06 O07 O09 (To L43)
1 1 1 2
1 1 2 2 3 4
Prepared by
1st Ed. Apr. 2010
Printed in Japan
090

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IMPORTANT

Manual Name Manual No.

MARUTI SUZUKI INDIA LIMITED

© 2010 COPYRIGHT MARUTI SUZUKI INDIA LIMITED All righst reserved.

GENERAL INFORMATION ENGINE

General Information 0A Engine 6 0A 6

Maintenance and Lubrication 0B Engine Mechanical 6A 0B 6A

STEERING, SUSPENSION, WHEELS Ignition System 6F 6F

CNG System ..................................................... 0A-5 VEHICLE LIFTING POINTS ................................... 0A-*

HOW TO USE THIS MANUAL

6) Install oil pump. Refer to OIL PUMP.

4) A number of abbrevations are used in the text.

• When performing service to electrical parts that does not

• When removing the battery, be sure to disconnect the

• When removing parts that are to be reused, be sure to keep

• Whenever you use oil seals, gaskets, packing, O-rings,

• Make sure that all parts used in reassembly are perfectly

“A”: Sealant 99000M31150

• Be sure to use special tools when instructed.

• When disconnecting vacuum hoses, attach a tag describing

• After servicing fuel, oil, coolant, vacuum, exhaust or brake

Precautions for Vehicles Equipped with

• In AUTO MODE, It is programmed to start the vehicle in petrol and

Safety Precautions (Don’ts)

PRECAUTIONS FOR CATALYTIC

PRECAUTIONS FOR ELECTRICAL

• Be careful not to touch the electrical terminals of parts which

• Never connect any tester (voltmeter, ohmmeter, or whatever)

• When taking measurements at electrical connectors using a

• When connecting meter probe from terminal side of coupler

• When checking connection of terminals, check its male half

• Before measuring voltage to check for electrical system,

ELECTRICAL CIRCUIT INSPECTION

OPEN CIRCUIT CHECK

When checking system circuits including an electronic control unit

3) Using a test male terminal, check both terminals of the circuit

4) Using continuity check or voltage check procedure described in

2) Disconnect the connector included in the circuit (connector-B in

If measurements were taken as shown in the figure and results were

Short circuit check (wire harness to ground)

3) Measure resistance between terminal at one end of circuit (A-1

4) Disconnect the connector included in circuit (connector B) and

INTERMITTENT AND POOR CONNECTION

• Poor mating of connector halves, or terminals not fully seated in the

• Improperly formed or damaged terminals.

1. Check contact tension by inserting and

• Poor terminal-to-wire connection.

• Wire insulation which is rubbed through, causing an intermittent

PRECAUTIONS FOR INSTALLING MOBILE

ENGINE IDENTIFICATION NUMBER

CNG COMPONENT LOCATION

1 Changeover switch 7 Vent hose 13 Water hose

WARNING, CAUTION AND INFORMATION LABELS

CNG Label on dashboard CNG Cylinder Warning Labels

(a) (b) (c)

(a) Manual Shut off valve label

ABBREVIATIONS MAY USED IN THIS MANUAL

A ECT Sensor : Engine Coolant Temperature

FASTENER STRENGTH IDENTIFICATION