Automotive FORENZA / RENO October 6, 2014 Technical Service Bulletin Engine Bulletin No. TS R1

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Robyn Preston
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1 Service Automotive FORENZA / RENO October 6, 2014 SUBJECT: MODEL(S): YEAR: Revisions: Throttle Position Sensor Replacement Forenza (RQ420) Reno (RQ420) Forenza Reno R1-10/08/14. This revision adds the Idle Learn Procedure and Tooth Error Learn of CKP Sensor Procedure. To improve the flexibility in repair opportunity for the Forenza and Reno the Throttle Position Sensor (TPS), is now available as a separate assembly from the Throttle Body. If the entire Throttle Body is needed for the repair the Throttle Body Assembly will continue to be available with the TPS attached. PART(S) INFORMATION Description Part Number Qty. Comment Body A, Throttle Z21 1 Throttle Body with TPS Sensor, Thrtl Pos Z10 1 TPS only Gasket, Thrtl Body Z Affected Departments: The following departments in your dealership should be notified of this information: Management Service Warranty Sales Parts Accessories Suzuki bulletins are intended for use by professional technicians, NOT a do-it-yourselfer. They are written to inform these technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the equipment, tools, safety instructions, and know-how to do a job properly and safely. If a condition is described, DO NOT assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See your authorized Suzuki Service Provider for information on whether your vehicle may benefit from the information. Suzuki reserves the right to change technical specifications at any time without prior notice. - 1 / 7 -

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Removal Procedure 1. Disconnect the battery negative (-) cable. 2. Remove the throttle body from the vehicle and then remove the 3 Security Torx screws to loosen the TPS. Discard the screws.

3 Removal Procedure 1. Disconnect the battery negative (-) cable. 2. Remove the throttle body from the vehicle and then remove the 3 Security Torx screws to loosen the TPS. Discard the screws. Do not reuse them. 3. Separate the TPS from the throttle body and remove the TPS o-ring(s) from the throttle body if it has remained attached to the throttle body. Discard the o-ring(s). Do not reuse it. NOTE: The early TPS has only one o-ring at the TPS motor shaft interface. The late TPS will have two o-rings; one at the TPS motor shaft interface and one at the throttle shaft interface. - 3 / 7 -

4. Remove the TPS coupling connectors from the throttle body if they have remained in the throttle body. Discard the coupling connectors. Do not reuse them.

Furthermore, make sure the throttle blade is in the normal at rest position during installation of the new TPS onto the throttle body. 1.

4 4. Remove the TPS coupling connectors from the throttle body if they have remained in the throttle body. Discard the coupling connectors. Do not reuse them. Installation Procedure NOTE: The TPS is shipped with proper orientation and calibration. DO NOT DISTURB the orientation of the TPS. Furthermore, make sure the throttle blade is in the normal at rest position during installation of the new TPS onto the throttle body. 1. After checking that the new o-rings are in place on the new TPS, match the TPS to the motor shaft interface and to the throttle shaft interface. 2. Align the shoulder of the TPS screw hole at the throttle shaft interface. - 4 / 7 -

3. Slide the TPS into place onto the throttle body. CAUTION Using excessive force to install the TPS onto the throttle body can damage the TPS and throttle body.

interface, and screw hole shoulder. 4. Install the 3 new Security Torx screws supplied with the TPS service kit. Be careful not to use the 4 th screw hole circled in red.

5 3. Slide the TPS into place onto the throttle body. CAUTION Using excessive force to install the TPS onto the throttle body can damage the TPS and throttle body. If significant force is required to install the TPS onto the throttle body, remove the TPS and inspect for proper alignment of the o-rings, coupling connectors, throttle shaft, TPS motor shaft interface, and screw hole shoulder. 4. Install the 3 new Security Torx screws supplied with the TPS service kit. Be careful not to use the 4 th screw hole circled in red. This hole is found on the late TPS and this position is not used. Tighten: 15 to 20 in/lbs (1.7 to 2.3 Nm) Early TPS No 4th Screw Hole Do Not Use This 4 th Screw Hole 5. Reinstall the throttle body to the vehicle and reconnect the battery. - 5 / 7 -

6 Clear DTCs 1. Clear DTCs using the TECH 2. Perform the following procedures to complete this repair. Initiate the TPS Procedure 1. Start the engine and let it idle. a. The flare after startup may be higher than usual. b. After startup, the idle may be higher than normal. It should return to normal within 30 seconds. 2. Let the engine idle until fully warmed up. If the engine is already warm, let it idle for 5 minutes. 3. Watch the engine speed for a high idle (>900 RPM) or an unstable idle. 4. With the transmission in NEUTRAL, press hard on the brake pedal and then press the accelerator pedal down fully for about 1 second. Confirm the engine speed increases rapidly. The ECM will limit engine speed to a safe value. 5. Turn the ignition OFF. TPS initiation procedure is complete. Idle Learn Procedure 1. Turn the ignition ON. 2. Turn the ignition OFF for 15 seconds. 3. Turn the ignition ON for 5 seconds. 4. Turn the ignition OFF for 15 seconds. 5. Start the engine in PARK or NEUTRAL. 6. Allow the engine to run until the engine coolant is above 85 o C (185 o F). 7. Turn the A/C ON for 10 seconds, if equipped. 8. If the vehicle is equipped with an automatic transmission, apply the parking brake. While pressing the brake pedal, place the transmission in D (DRIVE) for 10 seconds. 9. Turn the A/C OFF for 10 seconds, if equipped. 10. If the vehicle is equipped with an automatic transmission, while pressing the brake pedal, place the transmission in PARK or NEUTRAL. 11. Turn the ignition OFF. The idle learn procedure is complete. - 6 / 7 -

7 TEC (Tooth Error Correction) Learn of CKP Sensor Procedure 1. Place the transaxle in PARK or NEUTRAL. 2. Using the TECH 2, select TEC (Tooth Error Correction) LEARN of CKP sensor. 3. Start the engine with the A/C OFF. 4. Keep the engine coolant temperature above 65 o C (149 o F). 5. Press the accelerator pedal until fuel cut-off occurs then release the accelerator pedal. 6. Wait seconds. 7. TEC is complete. If the scan tool does not display the Complete message repeat steps 1 to Turn the ignition OFF. 9. Turn the ignition ON and clear any DTC codes. 10. Check the idle. If there is a high or an unstable idle, or if P2282 or P0507 is set, replace the Throttle Body Assembly. Then Clear DTCs, Initiate the TPS, complete the Idle Learn Procedure and CKP Sensor Learn Procedure (TEC). - 7 / 7 -

Document ID: Some customers may comment that the service rear axle message is displayed on the driver information center (DIC).

Document ID: Some customers may comment that the service rear axle message is displayed on the driver information center (DIC). Page 1 of 14 Document ID: 2789612 #PI0703: Service Rear Message Displayed on Driver Information Center (DIC), DTC C0407 with Symptom Code 64 or C0403 with Symptom Code 62 Set - (Mar 20, 2012) Subject: