Engine Electrical Devices: Removal & Installation Suzuki SX4 I

Engine Control Module (ECM) Removal and Installation

Note. For vehicle equipped with EVAP leak check system: 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 (EVAP Leak Check Model) . Otherwise, MIL remains on even if the engine stared or it causes the inconsistency between registered VIN data in ECM and actual VIN. For vehicle equipped with immobilizer control system: If ECM is replaced with new one or with another one, make sure to register immobilizer transponder code to ECM correctly according to Procedure after ECM Replacement .

Scheme 13

Scheme 14

1. Disconnect negative cable at battery.
2. Remove ECM cover.
3. Disconnect connectors from ECM as follows. Push lock (1) to release locking of lock lever (2). Turn lock lever to arrow direction until it stops.
4. Remove ECM (1) from its bracket by removing its mounting bolts (2).

Installation

Reverse removal procedure noting the following

Scheme 15

Scheme 16

Scheme 17

1. Connect connectors to ECM as follows. Make sure that lock lever of ECM connector is unlock position. Insert ECM connectors to ECM until it stops with unlocked lock lever. Lock ECM connectors securely by pulling its lock lever up.

Scheme 18

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 (A): SUZUKI scan tool (SUZUKI-SDT)
2. Check the VIN shown on the left side of instrument panel.
3. Turn ignition switch to ON position.
4. Select "VIN registration" under "Utility" menu of SUZUKI scan tool.
5. Register VIN according to the instructions indicated on the SUZUKI scan tool. NOTE: For details, refer to the operator's manual for 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 19

1. Connect SUZUKI scan tool to data link connector (DLC) (1) located on underside of instrument panel at driver's seat side. Special Tool (A): SUZUKI scan tool (SUZUKI-SDT)
2. Turn ignition switch to ON position.
3. Select "VIN registration" under "Utility" 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 displayed VIN does not correspond to instrument panel VIN, register VIN (vehicle identification number) data into ECM referring to «VIN REGISTRATION (EVAP LEAK CHECK MODEL)»(ref-268895-S14418214942007102700000) .

Accelerator Pedal Position (APP) Sensor Assembly Removal and Installation

Note. After replacing APP sensor assembly, perform calibration of throttle valve referring to ELECTRIC THROTTLE BODY SYSTEM CALIBRATION .

Removal

1. Disconnect negative cable at battery.
2. Disconnect connector from APP sensor assembly.
3. Remove APP sensor assembly from its bracket.

Reverse removal procedure for installation noting the following.

Scheme 20

1. Tighten APP sensor assembly upper nut (1) first and then lower nuts (2) to specified torque. Tightening torque APP sensor assembly nut a: 6 N.m (0.6 kg-m, 4.5 lb-ft)
2. Connect connector to APP sensor assembly securely.

Reference: ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION

Reverse removal procedure noting the following.

Scheme 21

1. Clean mating surfaces of ECT sensor and water outlet cap.
2. Check O-ring for damage and replace, if necessary.
3. Tighten ECT sensor (1) to specified torque. Tightening torque ECT sensor a: 12.5 N.m (1.25 kg-m, 9.0 lb-ft)
4. Connect connector to ECT sensor securely.
5. Refill coolant referring to «COOLING SYSTEM FLUSH AND REFILL»(ref-268900-S38679149692007102700000) .

Air Fuel Ratio (A/F) Sensor, Heated Oxygen Sensor (HO2S) Removal and Installation

Reference: AIR FUEL RATIO (A/F) SENSOR ON-VEHICLE INSPECTION

Reference: HEATED OXYGEN SENSOR (HO2S) HEATER ON-VEHICLE INSPECTION

1. Disconnect negative cable at battery.
2. Disconnect connector of A/F sensor and/or HO2S.
3. Remove A/F sensor (1) and/or HO2S (2) from exhaust No.1 pipe.

Reverse removal procedure noting the following.

Scheme 22

1. Tighten A/F sensor (1) to specified torque. Tightening torque A/F sensor a: 45 N.m (4.5 kg-m, 32.5 lb-ft)
2. Tighten HO2S (2) to specified torque. Tightening torque HO2S b: 45 N.m (4.5 kg-m, 32.5 lb-ft)

1. Disconnect negative cable at battery.
2. Remove air cleaner case referring to «AIR CLEANER ASSEMBLY REMOVAL AND INSTALLATION»(ref-268922-S04053940252007102700000) .
3. Disconnect connector from CMP sensor.
4. Remove camshaft position sensor from cylinder head cover.

Scheme 23

1. Install CMP sensor to cylinder head cover. Tightening torque CMP sensor bolt a: 11 N.m (1.1 kg-m, 8.0 lb-ft)
2. Connect connector to CMP sensor securely.
3. Install air cleaner case referring to «AIR CLEANER ASSEMBLY REMOVAL AND INSTALLATION»(ref-268922-S04053940252007102700000) .
4. Connect negative cable to battery.

1. Remove transmission assembly from vehicle referring to «AUTOMATIC TRANSAXLE UNIT DISMOUNTING AND REMOUNTING»(ref-268912-S17398199982007102700000) or «MANUAL TRANSAXLE ASSEMBLY DISASSEMBLY AND REASSEMBLY»(ref-268911-S37340395012007102700000) .
2. Remove drive plate or flywheel from crankshaft.
3. Disconnect connector from crankshaft position sensor.
4. Remove CKP sensor (1) from cylinder block (2).

Reverse removal procedure noting the following.

Scheme 24

1. Apply engine oil to O-ring of sensor.
2. Tighten CKP sensor bolt to specified torque. Tightening torque CKP sensor bolt a: 11 N.m (1.1 kg-m, 8.0 lb-ft)
3. Connect connector and fix wire harness with clamp securely.

1. Disconnect negative cable at battery.
2. Hoist vehicle.
3. Remove right side drive shaft referring to «FRONT DRIVE SHAFT ASSEMBLY REMOVAL AND INSTALLATION: FRONT»(ref-268926-S03899698032007102700000) .
4. Disconnect knock sensor connector (1).
5. Remove knock sensor (2) from cylinder block.

Reverse removal procedure for installation.

Tightening torque

Knock sensor a: 22 N.m (2.2 kg-m, 16.0 lb-ft)

Scheme 25

Scheme 26

1. Disconnect negative cable at battery.
2. Remove main relay (1), fuel pump relay (3), starting motor control relay (2), throttle actuator control relay (4) and/or radiator cooling fan relay (5) from individual circuit fuse box No.1.
3. Check that there is no continuity between terminal "C" and "D". If there is continuity, replace relay.
4. Connect battery positive (+) terminal to terminal "B" of relay. Connect battery negative (-) terminal to terminal "A" of relay. Check for continuity between terminal "C" and "D". If there is no continuity when relay is connected to the battery, replace relay.

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 27

1. Disconnect negative cable at battery.
2. Disconnect MAF and IAT sensor connector.
3. Remove air cleaner case referring to «AIR CLEANER ASSEMBLY REMOVAL AND INSTALLATION»(ref-268922-S04053940252007102700000) .
4. Remove MAF and IAT sensor (1) from air cleaner case.

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

Reverse removal procedure noting the followings.

Scheme 28

1. Tighten MAF and IAT sensor screws to specified torque. Tightening torque MAF and IAT sensor screw a: 1.2 N.m (0.12 kg-m, 0.9 lb-ft)
2. Connect MAF and IAT sensor connector securely.