Engine Electrical Devices: Removal & Installation Suzuki Aerio I

Idle Air Control (IAC) Valve Removal and Installation

Reference: IDLE AIR CONTROL (IAC) VALVE OPERATION CHECK

Scheme 14

1. Remove throttle body from intake manifold referring to «THROTTLE BODY REMOVAL AND INSTALLATION»(ref-251061-S04904592962007032000000) .
2. Remove IAC valve (1) from throttle body.

Installation

Reference: IDLE AIR CONTROL (IAC) VALVE INSPECTION

For installation, reverse removal procedure noting the followings

Scheme 15

1. Install new gasket (1) to throttle body.
2. Tighten IAC valve screw to specified torque. Tightening torque IAC valve screw a: 4.0 N.m (0.4 kg-m, 3.0 lb-ft)
3. Install throttle body to intake manifold referring to «THROTTLE BODY REMOVAL AND INSTALLATION»(ref-251061-S04904592962007032000000) .

Scheme 16

Scheme 17

1. Remove air cleaner outlet hose.
2. Disconnect connector from IAC valve.
3. Check for proper connection to IAC valve at each terminal.
4. Check each coil of IAC valve for resistance. If resistances is out of specification, replace. IAC valve resistance Between terminals "1" and "2": 20 - 24 ohm at 20 °C (68 °F) Between terminals "3" and "2": 20 - 24 ohm at 20 °C (68 °F) Between terminals "4" and "5": 20 - 24 ohm at 20 °C (68 °F) Between terminals "6" and "5": 20 - 24 ohm at 20 °C (68 °F)
5. Remove IAC valve from throttle body referring to «IDLE AIR CONTROL (IAC) VALVE REMOVAL AND INSTALLATION»(ref-251060-S30565037032007032000000) .
6. Connect connector to IAC valve.
7. Check that plunger (1) of IAC valve moves once and then stops as soon as ignition switch (2) is turned from ON position to OFF position. If plunger (1) of IAC valve does not operate at all, check wire harnesses for open and short. If wire harnesses are in good condition, replace IAC valve and recheck. NOTE: This check should be performed by two people, one person operates ignition switch while the other checks plunger operation.
8. Install IAC valve to throttle body referring to «IDLE AIR CONTROL (IAC) VALVE REMOVAL AND INSTALLATION»(ref-251060-S30565037032007032000000) .
9. Perform the following steps in order to set the IAC valve plunger on the initial position. Turn OFF ignition switch and connect scan tool to DLC. Turn ON ignition switch. Disconnect connector from IAC valve. Connect connector to IAC valve. Clear DTC using scan tool. Start engine and warm up to normal operating temperature. Check for engine idle speed referring to «IDLE SPEED / IDLE AIR CONTROL (IAC) DUTY INSPECTION»(ref-251058-S10907683132007032000000) .

Engine Control Module (ECM) Removal and Installation

Note. If ECM is replaced with new one (VIN data is still not registered) or with used one (VIN data of other vehicle has been registered previously), make sure that re-register VIN data correctly by performing VIN REGISTRATION . Otherwise, MIL remains on even if the engine started or it causes the inconsistency between registered VIN data in ECM and actual VIN.

Scheme 18

1. Disconnect battery negative cable at battery.
2. Disable air bag system, refer to «AIR BAG SYSTEM -- AERIO»(ref-251097) .
3. Remover glove box, referring to Step 5) of «INSTRUMENT PANEL REMOVAL AND INSTALLATION»(ref-251100-S22921662052007032000000) .
4. Disconnect connectors (1) from ECM while releasing connectors lock.
5. Remove ECM from body after removing its nuts (2). NOTE: Be careful not to damage ventilation duct.

Reverse removal procedure noting the following

1. Connect connectors to ECM securely until a click is heard.
2. When installing each part, be careful not to catch any cable or wiring harness.

Scheme 19

1. Connect SUZUKI scan tool to data link connector (DLC) (1) located on under side of instrument panel at drive's seat side. Special Tool SUZUKI scan tool
2. Check the VIN shown on the left side of instrument panel.
3. Turn ignition switch to ON position.
4. Select " «VIN REGISTRATION»(ref-251060-S32321093102007032000000) " command in SELECT MODE menu of SUZUKI scan tool.
5. Register VIN according to the instructions indicated on the SUZUKI scan tool.
6. Before completed the VIN registration, check that VIN data indicated on the SUZUKI scan tool is correct. If not, re-register VIN data into ECM correctly.

Scheme 20

1. Connect SUZUKI scan tool to data link connector (DLC) (1) located on underside of instrument panel at driver's seat side. Special Tool SUZUKI scan tool
2. Turn ignition switch to ON position.
3. Select " «VIN REGISTRATION»(ref-251060-S32321093102007032000000) " command in SELECT MODE menu of SUZUKI scan tool.
4. Confirm whether code of 17 digits displayed on SUZUKI scan tool is corresponding to VIN shown on the left side of instrument panel. If does not correspond, register VIN (vehicle identification number) data into ECM referring to «VIN REGISTRATION»(ref-251060-S32321093102007032000000) .
5. Push "EXIT" button of SUZUKI scan tool.

Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor Removal and Installation

Reference: MASS AIR FLOW (MAF) AND INTAKE AIR TEMPERATURE (IAT) SENSOR ON-VEHICLE INSPECTION

Scheme 21

1. Disconnect negative battery cable at battery.
2. Disconnect coupler (1) from MAF and IAT sensor (2).
3. Remove MAF and IAT sensor (2) from air cleaner assembly.

Reference: MASS AIR FLOW (MAF) AND INTAKE AIR TEMPERATURE (IAT) SENSOR INSPECTION

Reverse removal procedure noting the following

1. Connect coupler to MAF and IAT sensor securely until a click is heard.

Throttle Position (TP) Sensor Removal and Installation

Reference: THROTTLE POSITION (TP) SENSOR ON-VEHICLE INSPECTION

Removal

1. Disconnect battery negative cable at battery.
2. Disconnect coupler from TP sensor.
3. Remove TP sensor from throttle body.

Scheme 22

1. Install TP sensor (1) to throttle body (2). Fit TP sensor (1) to throttle body (2) in such way that its holes are a little away from TP sensor screw holes as shown in the figure and turn TP sensor (1) clockwise so that those holes align.
2. Tighten TP sensor screw to specified torque. Tightening torque TP sensor screw a: 2.5 N.m (0.25 kg-m, 1.8 lb-ft)
3. Connect coupler to TP sensor securely.
4. Connect battery negative cable to battery.

Scheme 23

1. Disconnect negative cable from battery.
2. Drain coolant referring to «COOLING SYSTEM FLUSH AND REFILL»(ref-251063-S04981760882007032000000) .
3. Disconnect connector from ECT sensor (1).
4. Remove ECT sensor from water outlet cap.

Reference: ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION

Reverse removal procedure noting the following.

Scheme 24

1. Clean mating surfaces of sensor and water outlet cap.
2. Tighten ECT sensor (1) to specified torque. Tightening torque ECT sensor a: 13 N.m (1.3 kg-m, 9.5 lb-ft)
3. Connect connector to sensor securely.
4. Refill cooling system.

1. Disconnect negative cable from battery.
2. Disconnect connector of heated oxygen sensor and release its wire harness from clamps.
3. For sensor-2, hoist vehicle.
4. For sensor-1, remove exhaust manifold cover.
5. Remove heated oxygen sensor (1) from exhaust manifold or exhaust No.1 pipe.

Reference: HEATED OXYGEN SENSOR (SENSOR-1 AND SENSOR-2) INSPECTION

Reverse removal procedure noting the following.

Scheme 25

1. Tighten heated oxygen sensor to specified torque. Tightening torque Heated oxygen sensor-1 and sensor-2 a: 45 N.m (4.5 kg-m, 32.5 lb-ft)
2. Connect connector of heated oxygen sensor and clamp wire harness securely.
3. After installing heated oxygen sensor, start engine and check that no exhaust gas leakage exists.

CMP (Camshaft Position) Sensor Removal and Installation

Scheme 26

1. Remove engine cover from cylinder head cover referring to «ENGINE COVER REMOVAL AND INSTALLATION»(ref-251061-S38205840632007032000000) .
2. Disconnect CMP sensor coupler.
3. Remove CMP sensor (1) by removing two bolts (2).

Scheme 27

Scheme 28

Scheme 29

1. Install a new O-ring (2) with engine oil applied to CMP sensor (1).
2. Install CMP sensor (1) to camshaft (3). Fit the dog of CMP sensor coupling (2) into the slots of camshaft, when installing. The dogs of CMP sensor coupling are offset (A). Therefore, if the dogs can not be fitted into the slots, turn the CMP sensor shaft by 180 degree and try again.
3. Hand tighten CMP sensor (1) bolts (2) temporarily.
4. Connect CMP sensor coupler.
5. Check and adjust ignition timing according to Ignition Timing Inspection and Adjustment .
6. Tighten CMP sensor (1) bolts (2) to specified torque. Tightening torque CMP sensor bolt a: 15 N.m (1.5 kg-m, 11.0 lb-ft)
7. Install engine cover to cylinder head cover referring to «ENGINE COVER REMOVAL AND INSTALLATION»(ref-251061-S38205840632007032000000) .

1. Remove engine with transmission from vehicle referring to «ENGINE ASSEMBLY REMOVAL AND INSTALLATION»(ref-251061-S06663757622007032000000) .
2. Remove transmission from engine and then remove flywheel or drive plate from crankshaft.
3. Disconnect connector from crankshaft position sensor.
4. Remove crankshaft position sensor (1) from cylinder block (2).

Reverse removal procedure noting the following.

Scheme 30

1. Check to make sure that crankshaft position sensor (1) is free from any metal particles and damage.
2. Apply engine oil to O-ring of sensor.
3. Install crankshaft position sensor to cylinder block (2) with specified torque. Tightening torque Crankshaft position sensor bolt a: 6 N.m (0.6 kg-m, 4.5 lb-ft)
4. Connect connector and fix wire harness with clamp securely.