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Engine Electrical Devices: Removal & Installation Suzuki Kizashi I

Engine Control Systems 19 illustrations ~1239 words

ECM Removal and Installation

Reference: PRECAUTIONS FOR ENGINE

CAUTIONThe ECM is a precision unit and can be easily damaged. Handle the ECM carefully and do not expose it to a large shock.

Note. After ECM is replaced with new one, perform PROCEDURE AFTER ECM REPLACEMENT .

Scheme 17

Scheme 17: Removal
Scheme 17: Removal

Scheme 18

Scheme 18
Scheme 18
  1. Disconnect negative (-) cable at battery.
  2. Disconnect connectors from ECM as follows. Push lock (1) to release locking of lock lever (2). Turn lock lever in arrow direction until it stops.
  3. Remove ECM (2) and bracket (3) from front fender bracket and battery tray by removing their mounting bolts (1).
  4. Remove ECM from bracket by removing ECM mounting nuts.

Scheme 19

Scheme 19: Installation
Scheme 19: Installation

Scheme 20

Scheme 20
Scheme 20

Scheme 21

Scheme 21
Scheme 21

Scheme 22

Scheme 22
Scheme 22

Scheme 23

Scheme 23
Scheme 23
  1. Install ECM (1) to bracket (2).
  2. Tighten ECM mounting nuts (3) to specified torque. Tightening torque ECM mounting nut (a): 5.5 N.m (0.56 kg-m, 4.0 lbf-ft)
  3. Install ECM and bracket (1) to front fender bracket and battery tray aligning its locating pin (2) of front fender bracket with fitting hole (3).
  4. Connect connectors to ECM as follows. Make sure that lock lever of ECM connector is in unlock position. Insert ECM connectors to ECM until it stops. Lock ECM connectors securely by setting their lock levers in their locked position.
  5. Perform electric throttle control system calibration. see «ELECTRIC THROTTLE CONTROL SYSTEM CALIBRATION»(ref-585630-S02527331412013111200000) .

Procedure After ECM Replacement

CAUTIONWhen ECM and keyless start control module are replaced with new ones at the same time, perform "Immobilizer Key Registration" instead of "ECM Registration" using SUZUKI scan tool and immobilizer cable. Refer to "SUZUKI SDT Immobilizer Control System Operator's Manual" for the immobilizer registration.

After ECM is replaced with new one, perform the following procedures

  1. Program calibration data to ECM. Refer to Suzuki ECU Programming System Operator's Manual.
  2. Register VIN data to ECM, see «VIN REGISTRATION»(ref-585630-S40767160772013111200000) .
  3. Perform ECM Registration, see «PROCEDURE AFTER ECM REPLACEMENT»(ref-585592-S23995061562013111200000) .
  4. Perform electric throttle control system calibration, see «ELECTRIC THROTTLE CONTROL SYSTEM CALIBRATION»(ref-585630-S02527331412013111200000) .

Scheme 24

Scheme 24: VIN Registration
Scheme 24: VIN Registration
  1. With ignition mode of keyless push start system in "OFF", connect SUZUKI scan tool to DLC (1) located on underside of instrument panel at driver's seat side. Special Tool SUZUKI scan tool (SUZUKI-SDT)
  2. Check VIN shown on the left side of the instrument panel.
  3. Push engine switch to change the ignition mode to "ON".
  4. Select "VIN Registration" mode of SUZUKI scan tool.
  5. Register VIN according to the instructions indicated on the SUZUKI scan tool. NOTE: For further details, refer to the operators manual for SUZUKI scan tool.
  6. Before completing VIN registration, confirm that VIN data indicated on SUZUKI scan tool is correct. If not, re-register VIN data into ECM correctly.

Scheme 25

Scheme 25: Registered VIN Data Check
Scheme 25: Registered VIN Data Check
  1. With ignition mode of keyless push start system in "OFF", connect SUZUKI scan tool to DLC (1) located on underside of instrument panel at driver's seat side. Special Tool SUZUKI scan tool (SUZUKI-SDT)
  2. Push engine switch to change ignition mode to "ON".
  3. Select "VIN Registration" mode 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 the instrument panel. If displayed VIN does not correspond to instrument panel VIN, register VIN data into ECM referring to «VIN REGISTRATION»(ref-585630-S40767160772013111200000) .
  5. Push "EXIT" button of SUZUKI scan tool.

Accelerator Pedal Assembly (Incorporating APP Sensor) Removal and Installation

CAUTIONFailure to take proper precautions when handling the APP sensor assembly may lead to malfunction of the APP sensor. Do not drop or otherwise expose the APP sensor assembly to large shock. Any APP sensor assembly that has received large shock must be replaced. Keep the sensor section of the APP sensor assembly away from water.

Note. After replacing accelerator pedal assembly (incorporating APP sensor), calibrate throttle valve position.

Removal

  1. Disconnect negative (-) cable at battery.
  2. Remove instrument panel undercover, see «STEERING COLUMN REMOVAL AND INSTALLATION»(ref-585616-S28555238922013111200000) .
  3. Disconnect connector from accelerator pedal assembly (incorporating APP sensor).
  4. Remove accelerator pedal assembly (incorporating APP sensor) from its bracket.
  5. Remove accelerator pedal assembly bracket from vehicle body.

Scheme 26

Scheme 26: Installation
Scheme 26: Installation
  1. Tighten accelerator pedal assembly bracket nuts (1) to specified torque in numerical order ("1" - "3"). Tightening torque Accelerator pedal assembly bracket nut (a): 13 N.m (1.3 kg-m, 9.5 lbf-ft)
  2. Tighten accelerator pedal assembly nuts (2) to specified torque in numerical order ("1" - "2"). Tightening torque Accelerator pedal assembly nut (b): 13 N.m (1.3 kg-m, 9.5 lbf-ft)
  3. Connect connector to APP sensor assembly securely.
  4. Install instrument panel undercover, see «STEERING COLUMN REMOVAL AND INSTALLATION»(ref-585616-S28555238922013111200000) .
  5. Connect negative cable to battery.

Scheme 27

Scheme 27: APP Sensor Inspection
Scheme 27: APP Sensor Inspection
  1. Remove accelerator pedal assembly, see «ACCELERATOR PEDAL ASSEMBLY (INCORPORATING APP SENSOR) REMOVAL AND INSTALLATION»(ref-585630-S38030633512013111200000) .
  2. Check APP sensor output voltage as follows. If faulty condition is found, replace accelerator pedal assembly (incorporated with APP sensor), see «ACCELERATOR PEDAL ASSEMBLY (INCORPORATING APP SENSOR) REMOVAL AND INSTALLATION»(ref-585630-S38030633512013111200000) . Connect 3 new 1.5 V batteries (1) in series and check that total voltage is 4.5 - 5.0 V. Connect voltmeter (2) and batteries to APP sensor as shown in figure. Check that voltage varies depending on accelerator opening angle as the following graph.

Scheme 28

Scheme 28
Scheme 28
  1. Disconnect negative cable from battery.
  2. Remove engine cover.
  3. Drain coolant, see «COOLING SYSTEM DRAINING»(ref-585577-S13391481082013111200000) .
  4. Disconnect connector from ECT sensor.
  5. Remove ECT sensor (1) from water outlet cap.

Installation

Reverse removal procedure, noting the following points

  1. Check O-ring for damage and replace if necessary.
  2. Tighten ECT sensor to specified torque. Tightening torque ECT sensor (a): 13 N.m (1.3 kg-m, 9.5 lbf-ft)
  3. Connect connector to ECT sensor.
  4. Fill radiator with coolant, see «COOLING SYSTEM REFILLING»(ref-585577-S08150924882013111200000) .
  5. Check for cooling system for leakage, see «ENGINE COOLING SYSTEM INSPECTION»(ref-585577-S39475297722013111200000) .
WARNINGTouching exhaust system components when they are still hot may cause burns. Make sure the exhaust system has cooled down before removing the A/F sensor and/or HO2S.
  1. Disconnect negative (-) cable at battery.
  2. Disconnect connector of A/F sensor and/or HO2S.
  3. Remove exhaust manifold cover, see «EXHAUST SYSTEM COMPONENTS»(ref-585626-S07679347812013111200000) .
  4. Remove A/F sensor (1) and/or HO2S (2).

Reverse removal procedure, noting the following points

Scheme 29

Scheme 29: Installation
Scheme 29: Installation
  1. Tighten A/F sensor (1) to specified torque. Tightening torque A/F sensor (a): 45 N.m (4.6 kg-m, 33.5 lbf-ft)
  2. Tighten HO2S (2) to specified torque. Tightening torque HO2S (b): 45 N.m (4.6 kg-m, 33.5 lbf-ft)
  3. After installation, check exhaust system for leakage from sensor with engine running.
  1. Disconnect negative cable from battery.
  2. Remove engine cover.
  3. Disconnect connector from CMP sensor.
  4. Remove CMP sensor from cylinder head.

Reverse removal procedure, noting the following points

Scheme 30

Scheme 30: Installation
Scheme 30: Installation
  1. Apply engine oil to O-ring of CMP sensor (1).
  2. Tighten CMP sensor bolt (2) to specified torque. Tightening torque CMP sensor bolt (a): 11 N.m (1.1 kg-m, 8.5 lbf-ft)
  1. Disconnect negative (-) cable at battery.
  2. Remove generator, see «GENERATOR REMOVAL AND INSTALLATION»(ref-585571-S40517405292013111200000) .
  3. Disconnect connector from CKP sensor.
  4. Remove CKP sensor (1) from cylinder block (2).

Reverse removal procedure, noting the following points

Scheme 31

Scheme 31: Installation
Scheme 31: Installation
  1. Apply engine oil to O-ring of sensor. CAUTION: The CKP sensor bolt is pre-coated with adhesive. If the bolt is reused, it may work loose. Be sure to replace the CKP sensor bolt with a new one it is loosened.
  2. Tighten CKP sensor bolt to specified torque. Tightening torque CKP sensor bolt (a): 11 N.m (1.1 kg-m, 8.5 lbf-ft)
  1. Disconnect negative (-) cable at battery.
  2. Remove generator, see «GENERATOR REMOVAL AND INSTALLATION»(ref-585571-S40517405292013111200000) .
  3. Disconnect knock sensor connector.
  4. Remove knock sensor (1) from cylinder block.

Reverse removal procedure, noting the following points

Scheme 32

Scheme 32: Installation
Scheme 32: Installation
  1. Install knock sensor (1) as shown in figure.
  2. Tighten knock sensor bolt (2) to specified torque. Tightening torque Knock sensor bolt (a): 25 N.m (2.5 kg-m, 18.5 lbf-ft)

Scheme 33

Scheme 33: Knock Sensor Inspection
Scheme 33: Knock Sensor Inspection

Scheme 34

Scheme 34
Scheme 34
  1. With ignition mode of keyless push start system in "OFF", disconnect connector (2) from knock sensor.
  2. Connect oscilloscope (1) as shown in figure.
  3. Check that knock sensor signal (1) shows the following waveform when plastic hammer inflicts a strong impact on the cylinder block. If faulty condition is found, replace knock sensor, see «KNOCK SENSOR REMOVAL AND INSTALLATION»(ref-585630-S37834919722013111200000) .

MAF and IAT Sensor Removal and Installation

CAUTIONFailure to take proper precautions when handling the MAF and IAT sensor may lead to malfunction of the sensor. Do not disassemble the sensors. Do not drop or otherwise expose the sensors to shock. Any MAF and IAT sensor that has been dropped must be replaced. Do not clean the sensors. Do not direct compressed air from an air gun or the like to the sensor. Do not put a finger or any other object into the sensor.
  1. Disconnect negative (-) cable at battery.
  2. Disconnect MAF and IAT sensor connector.
  3. Remove MAF and IAT sensor (1) from air cleaner case (2).

Reference: MAF AND IAT SENSOR INSPECTION

Reverse removal procedure, noting the following points

Scheme 35

Scheme 35: Installation
Scheme 35: Installation
  1. Tighten MAF and IAT sensor screws (3) to specified torque. Tightening torque MAF and IAT sensor screw (a): 0.9 N.m (0.09 kg-m, 1.0 lbf-ft)

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