Suzuki Aerio, Verona 2002-06

Ignition Coils

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Removal & Installation



  1. Remove engine cover from cylinder head cover.
  2.  
  3. Disconnect ignition coil coupler.
  4.  
  5. Remove ignition coil bolt (1).
  6.  
  7. Pull out ignition coil.

    Click image to see an enlarged view

    Fig. Removing ignition coil and spark plugs

  8.  

To install:

  1. Install the ignition coil (2) securely.
  2.  
  3. Tighten ignition coil bolt. Tighten to 2.5 ft. lbs. (3 Nm). Then connect the ignition coil coupler.
  4.  
  5. Install engine cover to cylinder head cover.
  6.  

5-Cylinder Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Charge air pipe over the engine. Seal the openings.
     
    Upper timing belt cover
     
    Cover over the ignition coils
     
    Ignition coil connector
     
    Ignition coil mounting bolt
     
    Carefully pull coil up and out

    Click image to see an enlarged view

    Fig. Charge Air Pipe Location-5-Cylinder Engine



    Click image to see an enlarged view

    Fig. Removing ignition coil and small bolt-5-Cylinder Engine

     

  4.  

To install:

  1. Align the coil and press it down.
  2.  
  3. Install ignition coil mounting bolt and tighten to 88 inch lbs. (10 Nm).
  4.  
  5. Press in the connector until a click sound is heard.
  6.  
  7. Install the cover over the ignition coil.
  8.  
  9. Replace the upper timing belt cover.
  10.  
  11. Remove the seals from the charge air pipe and reinstall over the engine.
  12.  

6-Cylinder Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    Seal the open ends of pipes.



    Plastic charge air pipes of turbocharger
     
    Air cleaner.
     



    Upper camshaft belt cover
     
    Cover over the ignition coils
     
    Ignition coil connector
     
    Ignition coil mounting bolt
     
    Carefully pull coil up and out
     

  4.  

To install:

  1. Align the coil and press it down.
  2.  
  3. Install ignition coil mounting bolt and tighten to 88 inch lbs. (10 Nm).
  4.  
  5. Press in the connector until a click sound is heard.
  6.  
  7. Install the ignition coil cover.
  8.  
  9. Install the upper camshaft belt cover.
  10.  
  11. Remove the seals from the plastic charge air and turbocharger pipes and reinstall over the engine.
  12.  
  13. Replace air cleaner.

    Click image to see an enlarged view

    Fig. Charge air and turbocharger pipes location-6-Cylinder Engine

  14.  

8-Cylinder Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove upper engine covers by pulling straight up
  4.  
  5. For ignition coils 1, 3, 5, and 7 (Bank 1), remove or disconnect the following:

    Ignition coil connector
     
    Ignition coil mounting bolt
     
    Carefully pull coil up and out
     

  6.  
  7. For ignition coils 2, 4, 6, and 8 (Bank 2), remove or disconnect the following:

    Two bolts of the cable harness
     
    Retaining bolt of the upper engine cover
     
    Carefully bend aside the cable harness
     
    Ignition coil connector
     
    Ignition coil mounting bolt
     
    Carefully pull coil up and out

    Click image to see an enlarged view

    Fig. Location of cable harness-8-Cylinder Engine

     

  8.  

To install:

  1. Align the coil and press it down.
  2.  
  3. Install ignition coil mounting bolt and tighten to 88 inch lbs. (10 Nm).
  4.  
  5. Press in the connector until a click sound is heard.
  6.  
  7. Remaining installation is reverse of removal.
  8.  

Testing



The engine control module (ECM) regulates the ignition coils and checks their function via a separate diagnostic cable. The diagnostic trouble code is generated if the control module detects that the signal for an ignition coil is faulty.

  1. Fault symptoms may include:

    Malfunction indicator lamp (MIL) lit
     
    The engine is not firing on all cylinders
     

  2.  

The diagnostic trouble code can be diagnosed when the engine is running and will indicate which ignition coil is involved.

 
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