Manuale d’uso / di manutenzione del prodotto Swift (2000) del fabbricante Suzuki
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IMPORT ANT W ARNING / CAUTION / NOTE Please read this manual and follow its instructions carefully . T o emphasize special information, the words W ARNING, CAUTION and NOTE have spe- cial meanings. Pay special attention to the messages highlighted by these signal words.
() x () x () x () x () x () x () x () x () x () x () x () x () x () x () x () x () x () x FOREWORD This SUPPLEMENT AR Y SERVICE MANUAL is a supplement to SF SERIES SER VICE MANU- ALS mentioned in next page and has been prepared exclusively for the following applicable mod- el.
RELA TED MANUALS Related manuals listed below are in the chronological order with the latest one at the top. For the ef ficient use of manuals, start with one at the top of the list (i.
6 6 6-1 6A 6A1 6B 6C 6E1 6E1 6E2 6F 6F 6F1 6G 6H 6K GENERAL INFORMA TION General Information Maintenance and Lubrication 1A 1B T ABLE OF CONTENTS SECTION 0A 0B 7B 8 8A 8G HEA TING AND AIR CONDITIONING.
GENERAL INFORMA TION 0A-1 0A SECTION 0A GENERAL INFORMA TION CONTENTS HOW TO USE THIS MANUAL 0A- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRECAUTIONS 0A- 3 . . . . .
1. Flywheel bolts or drive plate bolts for A / T vehicle 6) Install oil pump. Refer to “Oil pump”. 7) Install flywheel (for M / T vehicle) or drive plate (for A / T vehicle). Using special tool, lock flywheel or drive plate, and tighten flywheel or drive plate bolts to specified torque.
1. Air bag wire harness 2. Driver air bag (inflator) module 3. Passenger air bag (inflator) module 4. SDM GENERAL INFORMA TION 0A-3 PRECAUTIONS PRECAUTION FOR VEHICLES EQUIPPED WITH A SUPPLEMENT AL RESTRAINT (AIR BAG) SYSTEM W ARNING: D The configuration of air bag system parts are as shown in the figure.
1. Slit on workbench 2. Workbench vise 3. Lower mounting bracket AL WA YS CARRY AIR BAG (INFLA TOR) MODULE WITH TRIM COVER (AIR BAG OPENING) A WA Y FROM BODY . AL WA YS PLACE AIR BAG (INFLA TOR) MODULE ON WORKBENCH WITH TRIM COVER (AIR BAG OPENING) UP , AW A Y FROM LOOSE OBJECTS.
GENERAL INFORMA TION 0A-5 CAUTION: D Even when the accident was light enough not to cause air bags to deploy , be sure to inspect system parts and other related parts according to instructions under “ Repair and Inspection Required after an Accident ” in Section 9J.
0A-6 GENERAL INFORMA TION GENERAL PRECAUTIONS The W ARNING and CAUTION below describe some general precautions that you should observe when servicing a vehicle. These general precautions apply to many of the service procedures described in this manual, and they will not necessarily be repeated with each procedure to which they apply .
GENERAL INFORMA TION 0A-7 D When removing the battery , be sure to disconnect the nega- tive cable first and then the positive cable. When reconnect- ing the battery , connect the positive cable first and then the negative cable, and replace the terminal cover .
0A-8 GENERAL INFORMA TION D When disconnecting vacuum hoses, attach a tag describing the correct installation positions so that the hoses can be re- installed correctly . D After servicing fuel, oil, coolant, vacuum, exhaust or brake systems, check all lines related to the system for leaks.
GENERAL INFORMA TION 0A-9 D Always be careful not to handle electrical parts (computer , relay , etc.) in a rough manner or drop them. PRECAUTIONS FOR CA T AL YTIC CONVERTER For vehicles equipped with.
0A-10 GENERAL INFORMA TION D When disconnecting connectors, never pull the wiring har- ness. Unlock the connector lock first and then pull them apart by holding connectors themselves. D When connecting connectors, also hold connectors and put them together until they lock securely (a click is heard).
GENERAL INFORMA TION 0A-1 1 D Be careful not to touch the electrical terminals of parts which use microcomputers (e.g. electronic control unit like as ECM, PCM, P / S controller , etc.
1. Check for loose connection Sensor ECM 0A-12 GENERAL INFORMA TION D When checking connection of terminals, check its male half for bend and female half for excessive opening and both for locking (looseness), corrosion, dust, etc.
1. Looseness of crimping 2. Open 3. Thin wire (single strand of wire) Check contact tension by inserting and removing just for once GENERAL INFORMA TION 0A-13 3) Using a test male terminal, check both terminals of the circuit be- ing checked for contact tension of its female terminal.
1. Other parts 1. T o other parts 2 V voltage drop 0A-14 GENERAL INFORMA TION If measurements were taken as shown in the figure at the left and results were as listed below , it means that the circuit is open be- tween terminals B-1 and A-1. V oltage Between: C-1 and body ground: Approx.
1. Check contact tension by inserting and removing just once 2. Check each terminal for bend and proper alignment GENERAL INFORMA TION 0A-15 INTERMITTENT AND POOR CONNECTION Most intermittent are caused by faulty electrical connections or wir- ing, although a sticking relay or solenoid can occasionally be at fault.
0A-16 GENERAL INFORMA TION PRECAUTION FOR INST ALLING MOBILE COMMUNICA TION EQUIPMENT When installing mobile communication equipment such as CB (Citi- zens-Band)-radio or cellular-telephone, be sure to observe the fol- lowing precautions. Failure to follow cautions may adversely af fect electronic control system.
1. T ransfer lock bolt 2. Shift fork shaft T esting following items D Speedometer D Chassis dynamo D Brake D Wheel balance (on car type) T owing vehicle with front or rear wheels lifted up Driving fro.
M/T A/T G10 G13 [A] [A] [B] [B] 0A-18 GENERAL INFORMA TION IDENTIFICA TION INFORMA TION VEHICLE IDENTIFICA TION NUMBER The number is punched on the front dash panel in the engine room. IDENTIFICA TION WHETHER VEHICLE EQUIPPED WITH WU-TWC OR NOT It can be identified by the shape of exhaust manifold (1) and ex- haust pipe (2).
NOTE: Air bag CAUTION / W ARNING labels are attached on the vehicle equipped with air bag system only . Air bag caution label T ire information placard Child lock caution label Fuel limitation Emissio.
1. Front left tire 2. Rear left tire 3. Front 4. Front fender left panel 5. Rear left panel 6. Embossed-mark When using frame contact hoist: Front Support Location Rear Support Location 11 0 m m (4.3 in.) SUPPORT LOCA TION Forward of embossed-mark 120 mm (4.
When using floor jack: GENERAL INFORMA TION 0A-21 In raising front or rear vehicle end off the floor by jacking, be sure to put the jack against the center portion of front cross member (1) or rear cross member (2). W ARNING: D Never apply jack against suspension parts (i.
0A-22 GENERAL INFORMA TION A ABS : Anti-Lock Brake System A TDC : After T op Dead Center API : American Petroleum Institute A TF : Automatic T ransmission Fluid ALR : Automatic Locking Retractor AC : .
GENERAL INFORMA TION 0A-23 L LH : Left Hand LSPV : Load Sensing Proportioning V alve M MAF Sensor : Mass Air Flow Sensor (Air Flow Sensor , AFS, Air Flow Meter , AFM) MAP Sensor : Manifold Absolute Pr.
G (Base Color) G (Base Color) Y (Stripe Color) 0A-24 GENERAL INFORMA TION SYMBOLS SYMBOL DEFINITION SYMBOL DEFINITION T ightening torque Apply SUZUKI BOND NO.
GENERAL INFORMA TION 0A-25 METRIC BOL TS-IDENTIFICA TION CLASS NUMBERS OR MARKS CORRESPOND TO BOL T STRENGTH-INCREASING NUMBERS REPRESENT INCREASING STRENGTH. NUT STRENGTH IDENTIFICA TION F ASTENERS INFORMA TION METRIC F ASTENERS Most of the fasteners used for this vehicle are metric fasteners.
0A-26 GENERAL INFORMA TION Self-lock nut ST ANDARD TIGHTENING T ORQUE Each fastener should be tightened to the torque specified in each section of this manual. If no description or specifi- cation is provided, refer to the following tightening torque chart for the applicable torque for each fastener .
0B MAINTENANCE AND LUBRICA TION 0B-1 SECTION 0B MAINTENANCE AND LUBRICA TION W ARNING: For vehicles equipped with Supplemental Restraint (Air Bag) System: D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer .
0B-2 MAINTENANCE AND LUBRICA TION MAINTENANCE SCHEDULE NORMAL CONDITION SCHEDULE Interval: This interval should be j ud g ed b y This table includes services as scheduled up to 90,000 km (54,000 miles) mileage. Beyond 90,000 km (54,000 miles), carry out the same services at the same intervals respectively .
MAINTENANCE AND LUBRICA TION 0B-3 Interval: This interval should be j ud g ed b y This table includes services as scheduled up to 90,000 km (54,000 miles) mileage. Beyond 90,000 km (54,000 miles), carry out the same services at the same intervals respectively .
0B-4 MAINTENANCE AND LUBRICA TION MAINTENANCE RECOMMENDED UNDER SEVERE DRIVING CONDITIONS If the vehicle is usually used under the conditions corresponding to any severe condition code given below , it is recommended that applicable maintenance operation be performed at the particular interval as given in the chart below .
V ehicle with A/C V ehicle with A/C and power steering V ehicle with power steering 1. A/C compressor pulley 2. Power steering pump pulley 3. T ension pulley 4.
1. Thickness gauge IN EX 0B-6 MAINTENANCE AND LUBRICA TION W ater Pump Belt Replacement Replace belt with a new one. Refer to SECTION 6B for replacement procedure of pump belt. NOTE: When replacing belt with a new one, adjust belt tension to 5 – 7 mm (0.
MAINTENANCE AND LUBRICA TION 0B-7 Proper Engine Oil Viscosity Chart 1. Oil pan 2. Oil drain plug 1. Oil filter ITEM 1-4 Engine Oil and Filter Change W ARNING: New and used engine oil can be hazardous. Be sure to read “ W ARNING ” in General Precaution in SEC- TION 0A and observe what in written there.
1. Full level mark (hole) 2. Low level mark (hole) Oil pan capacity Oil filter capacity Others T otal 1. 0 L an d 1. 3 L En gin e About 3.1 liters (6.5 / 5.5 US / lmp pt.) About 0.2 liter (0.4 / 0.3 US / lmp pt.) About 0.3 liter (0.6 / 0.5 US / lmp pt.
For A / T For M / T MAINTENANCE AND LUBRICA TION 0B-9 1) Remove radiator cap when engine is cool. 2) Loosen radiator drain plug (1) to drain coolant. 3) Remove reservoir and drain.
0B-10 MAINTENANCE AND LUBRICA TION IGNITION SYSTEM ITEM 2-1 Spark Plugs Replacement Replace spark plugs with new ones referring to SECTION 6F or 6F1. ITEM 2-2 Distributor Cap and Rotor Inspection (if equipped) D Check distributor cap and rubber caps for cracks.
1.0 liter engine 1.3 liter engine MAINTENANCE AND LUBRICA TION 0B-1 1 2) Visually check that air cleaner filter is not excessively dirty , dam- aged or oily . 3) Clean filter with compressed air from air outlet side of filter . 4) Install air cleaner filter into case.
0B-12 MAINTENANCE AND LUBRICA TION EMISSION CONTROL SYSTEM ITEM 4-1 PCV (Positive Crankcase V entilation) V alve Inspection Check crankcase ventilation hoses and PCV hoses for leaks, cracks or clog, and PCV valve (1) for stick or clog. Refer to ON-VE- HICLE SERVICE of SECTION 6E1 or 6E2 for PCV valve checking procedure.
MAINTENANCE AND LUBRICA TION 0B-13 ITEM 5-2 Brake Hoses and Pipes Inspection Perform this inspection where there is enough light and use a mirror as necessary . D Check brake hoses and pipes for proper hook-up, leaks, cracks, chafing, wear , corrosion, bends, twists and other damage.
“ a ” : Parking brake lever stroke: 4 – 9 notches (With 20 kg or 44 lbs of pull pressure) 1. Wear indicator 1. Clutch pedal “ a ” : Free travel 0B-14 MAINTENANCE AND LUBRICA TION ITEM 5-4 Brake Lever and Cable Inspection Parking brake lever D Check tooth tip of each notch for damage or wear .
1. Drive shaft 2. Boot MAINTENANCE AND LUBRICA TION 0B-15 [Wheel disc inspection] Inspect each wheel disc for dents, distortion and cracks. A disc in badly damaged condition must be replaced. [T ire rotation] Rotate tires referring to SECTION 3F . Wheel Bearing Inspection 1) Check front wheel bearing for wear , damage, abnormal noise or rattles.
1. Ball joint stud dust seal (boot) 2. Suspension arm 1. T ie-rod end boot 2. Steering gear case boot 3. Universal joint 0B-16 MAINTENANCE AND LUBRICA TION D Check front and rear suspension systems for damaged, loose or missing parts; also for parts showing signs of wear or lack of lu- brication.
2WD 4WD 1. Oil filler / level plug 2. Oil drain plug MAINTENANCE AND LUBRICA TION 0B-17 ITEM 6-7 Manual T ransmission Oil Inspection and Change [Inspection] 1) Inspect transmission case for evidence of oil leakage. Repair leaky point if any . 2) Make sure that vehicle is placed level for oil level check.
1. Oil level gauge 2. FULL HOT mark 3. LOW HOT mark 4. FULL COLD mark 5. LOW COLD mark 1. Drain plug 0B-18 MAINTENANCE AND LUBRICA TION ITEM 6-9 Automatic T ransmission [Fluid level inspection] 1) Inspect transmission case for evidence of fluid leakage.
“ A ” : Oil point 1. Upper hinge 2. Lower hinge 3. Door 4. Body MAINTENANCE AND LUBRICA TION 0B-19 ITEM 6-10 All Latches, Hinges and Locks Inspection Doors Check that each door of front, rear and back doors opens and closes smoothly and locks securely when closed.
0B-20 MAINTENANCE AND LUBRICA TION FINAL INSPECTION Seats Check that seat slides smoothly and locks securely at any position. Also check that reclining mechanism of front seat back allows it to be locked at any angle. Seat Belt Inspect belt system including webbing, buckles, latch plates, retractors and anchors for damage or wear .
MAINTENANCE AND LUBRICA TION 0B-21 [Parking brake] Check that lever has proper travel. Check to ensure that parking brake is fully effective when the vehicle is stopped on the safe slope and brake lever is pulled all the way . Steering D Check to ensure that steering wheel is free from in- stability , or abnormally heavy feeling.
6 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) 6-1 GENERAL INFORMA TION 6- 3 . . . . . . . . . . . . . . Statement on Cleanliness and Care 6- 3 . . . . . General Information on Engine Service 6- 3 . . Precaution on Fuel System Service 6- 4 .
Diagnostic T rouble Code Clearance 6-14 . . . . . Diagnostic T rouble Code T able 6-15 . . . . . . . . . Fail-safe T able 6-18 . . . . . . . . . . . . . . . . . . . . . . . Visual Inspection 6-19 . . . . . . . . . . . . . . . . . . . . . Engine Basic Inspection 6-20 .
1. No.1 cylinder 2. No.2 cylinder 3. No.3 cylinder 1 2 3 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) 6-3 GENERAL INFORMA TION ST A TEMENT ON CLEANLINESS AND CARE An automobile engine is a .
HOSE CONNECTION Clamp securely at a position 3 to 7mm (0.12–0.27 in.) from hose end. With short pipe, fit hose as far as it reaches pipe joint as shown. Hose Pipe Clamp Clamps securely at a position 3 to 7 mm (0.12–0.27 in.) from hose end. With following type pipe, fit hose as far as its peripheral projection as shown.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) 6-5 FUEL PRESSURE RELIEF PROCEDURE CAUTION: This work must not be done when engine is hot. If done so, it may cause adverse effect to catalyst. After making sure that engine is cold, release fuel pressure as fol- lows.
6-6 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) ENGINE DIAGNOSIS GENERAL DESCRIPTION This vehicle is equipped with an engine and emission control system which are under control of ECM (PCM). The engine and emission control system in this vehicle are controlled by ECM (PCM).
An Example of Freeze Frame Data 1. T rouble Code P0102 (1st) 2. Engine Speed 782 RPM 3. Eng Cool Tmp. 80 _ C 4. V ehicle Spd. 0 km/h 5. MAP Sensor 39 kPa 6. St. T erm FT1 – 0.8% Lean 7. Lg. T erm FT1 – 1.6% Lean 8. Fuel 1 Stat. Closed Loop 9. Fuel 2 Stat.
Body ground ECM (PCM) ground Serial data line (K line of ISO 9141) SUZUKI serial data line 6-8 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) In the 2nd through the 4th frames, the freeze frame data of each malfunction is stored in the order as the malfunction is detected.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) 6-9 PRECAUTION IN DIAGNOSING TROUBLE D Don ’ t disconnect couplers from ECM (PCM), battery cable from battery , ECM (PCM) ground wire harness from engine or main fuse before confirming diagnostic information (DTC, freeze frame data, etc.
6-10 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) ENGINE DIAGNOSTIC FLOW T ABLE Refer to the following pages for the details of each step. STEP ACTION YES NO 1 Customer Complaint Analysis 1) Perform customer complaint analysis referring to the next page.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) 6-1 1 1. CUSTOMER COMPLAINT ANAL YSIS Record details of the problem (failure, complaint) and how it occurred as described by the customer . For this purpose, use of such an inspection form will facilitate collecting information to the point required for proper analysis and diagnosis.
6-12 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) CUSTOMER PROBLEM INSPECTION FORM (EXAMPLE) User name: Model: VIN: Date of issue: Date Reg.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) 6-13 MALFUNCTION INDICA T OR LAMP (MIL) CHECK 1) T urn ON ignition switch (but the engine at stop) and check that MIL lights. If MIL does not light up (or MIL dims), go to “ Diagnostic Flow T able A-1 ” for troubleshooting.
6-14 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) DIAGNOSTIC TROUBLE CODE (DTC) CLEARANCE 1) Connect SUZUKI scan tool (T ech-1) or generic scan tool to data link connector in the same manner as when making this connec- tion for DTC check. 2) T urn ignition switch ON.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) 6-15 DIAGNOSTIC TROUBLE CODE (DTC) T ABLE DTC NO. DETECTING ITEM DETECTING CONDITION (DTC will set when detecting:) MIL P0105 Manifold absolute .
6-16 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) DTC NO. DETECTING ITEM DETECTING CONDITION (DTC will set when detecting:) MIL P0335 Crankshaft position sensor circuit malfunction No signal during engine running 1 driving cycle P0340 Camshaft position sensor circuit malfunction No signal for 2 sec.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) 6-17 DTC NO. DETECTING ITEM DETECTING CONDITION (DTC will set when detecting:) MIL P0705 T ransmission range sensor (switch) circuit malfunction.
6-18 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) F AIL-SAFE T ABLE When any of the following DTCs is detected, ECM (PCM) enters fail-safe mode as long as malfunction continues to exist but that mode is canceled when ECM (PCM) detects normal condition after that.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) 6-19 Operation VISUAL INSPECTION Visually check following parts and systems. INSPECTION ITEM REFERRING SECTION D Engine oil ––––– leve.
6-20 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) ENGINE BASIC INSPECTION This check is very important for troubleshooting when ECM (PCM) has detected no DTC and no abnormality has been found in visual inspection. Follow the flow table carefully .
Select “ DA T A LIST ” mode SELECT MENU F4: MISC TEST ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) 6-21 Fig. 1 for Step 5 Fig. 2 for Step 6 Fig.
6-22 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) ENGINE DIAGNOSIS T ABLE Perform troubleshooting referring to following table when ECM (PCM) has detected no DTC and no abnormality has been found in visual inspection and engine basic inspection previously .
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) 6-23 Condition Possible Cause Referring Item Low oil pressure D Improper oil viscosity D Malfunctioning oil pressure switch D Clogged oil strain.
6-24 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) Condition Possible Cause Referring Item Overheating D Inoperative thermostat D Poor water pump performance D Clogged or leaky radiator D Im.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) 6-25 Condition Possible Cause Referring Item Engine hesitates (Momentary lack of response as accelerator is depressed. Can occur at all vehicle speeds. Usually most severe when first trying to make vehicle move, as from a stop sign.
6-26 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) Condition Possible Cause Referring Item Engine has no power Ignition system out of order D Faulty spark plug D Faulty ignition coil with ig.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) 6-27 Condition Possible Cause Referring Item Improper engine idling or engine fails to idle Ignition system out of order D Faulty spark plug D L.
6-28 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) Condition Possible Cause Referring Item Excessive hydrocarbon (HC) emission or carbon monoxide (CO) Ignition system out of order D Faulty s.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) 6-29 Ambient temp. SCAN TOOL DA T A As the data values given below are standard values estimated on the basis of values obtained from the normally operating vehicles by using a scan tool, use them as reference values.
6-30 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) SCAN T OOL DA T A CONDITION NORMAL CONDITION / REFERENCE V ALUES DESIRED IDLE At idling with no load after warming up, M / T 850 r / min (D.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) 6-31 SCAN T OOL DA T A CONDITION NORMAL CONDITION / REFERENCE V ALUES VSS (for 4-A / T) (V ehicle Speed Sensor) At stop.
6-32 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) SCAN TOOL DA T A DEFINITIONS FUEL SYSTEM (FUEL SYSTEM ST A TUS) Air / fuel ratio feedback loop status displayed as either open or closed loop. Open indicates that ECM (PCM) ignores feedback from the exhaust oxygen sensor .
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) 6-33 CANIST PURGE DUTY (EV AP CANISTER PURGE FLOW DUTY , %) This parameter indicates valve ON (valve open) time rate within a certain set cycle of EV AP purge solenoid valve which controls the amount of EV AP purge.
6-34 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) 1. ECM (PCM) 2. ECM (PCM) couplers (Viewed from harness side) 1. ECM (PCM) 2. Couplers 3. Body ground 4.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) 6-35 CONNECTOR “ C02 ” TER- MINAL WIRE COLOR CIRCUIT ST ANDARD VOL T AGE CONDITION 1 B ECM (PCM) ground – – 2 W/B l Power source 10 – .
6-36 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) CONNECTOR “ C01 ” TER- MINAL WIRE COLOR CIRCUIT ST ANDARD VOL T AGE CONDITION 1 Lg Power source for sensor 4.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) 6-37 CONNECTOR “ C03 ” TER- MINAL WIRE COLOR CIRCUIT ST ANDARD VOL T AGE CONDITION 1 V/W Data link connector (SUZUKI serial data line) 4 – 6 V Ignition switch ON Bl V ehicle speed sensor (+) (A / T) 0.
6-38 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) 1 2 1. ECM (PCM) coupler disconnected 2. Ohmmeter RESIST ANCE CHECK 1) Disconnect ECM (PCM) couplers from ECM (PCM) with ignition switch OFF . CAUTION: Never touch terminals of ECM (PCM) itself or connect voltmeter or ohmmeter .
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) 6-39 INFORMA TION SENSORS - 1. MAP sensor - 2. TP sensor - 3. IA T sensor - 4. ECT sensor - 5. Heated oxygen sensor-1 - 6. VSS - 7. Ignition coil - 8. Battery - 9. CMP sensor (in Distributor) - 10.
6-40 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) “ IG COIL METER ” Main relay Ignition switch In fuse Malfunction indicator lamp in combination meter T ABLE A-1 MALFUNCTION INDICA TOR .
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) 6-41 T ABLE A-2 MALFUNCTION INDICA TOR LAMP CIRCUIT CHECK – LAMP REMAINS “ ON ” AFTER ENGINE ST ARTS WIRING DIAGRAM / CIRCUIT DESCRIPTION – Refer to table A-1. INSPECTION STEP ACTION YES NO 1 Diagnostic T rouble Code (DTC) check 1) Check DTC referring to DTC CHECK section.
Main fuse Ignition switch Main fuse Malfunction indicator lamp in combination meter Relay box “ IG COIL METER ” 6-42 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) T ABLE A-3 ECM (PCM) PO.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) 6-43 Fig. 1 for Step 2 Fig. 2 for Step 2 Fig. 3 for Step 2 1. Main relay 2. Relay box STEP ACTION YES NO 5 ECM (PCM) Power Circuit Check 1) Using service wire, ground terminal C02-22 and measure voltage between terminal C02-2 and ground at ignition switch ON.
MAP sensor T o TP sensor T o other sensors 6-44 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) DTC P0105 MANIFOLD ABSOLUTE PRESSURE (MAP) CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION DTC DETECTING CONDITION POSSIBLE CAUSE D MAP: 5 kPa, 37.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) 6-45 Fig. 1 for Step 2 Fig. 2 for Step 3 Scan tool DLC INSPECTION STEP ACTION YES NO 1 Wa s “ ENGINE DIAG. FLOW T ABLE ” performed? Go to Step 2. Go to “ ENGINE DIAG. FLOW T ABLE ” . 2 Check MAP Sensor and Its Circuit.
T o other sensors IA T sensor 6-46 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) DTC P01 10 INT AKE AIR TEMP . (IA T) CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION DTC DETECTING CONDITION POSSIBLE.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) 6-47 Fig. 1 for Step 2 Fig. 2 for Step 3 Fig. 3 for Step 4 Scan tool DLC INSPECTION STEP ACTION YES NO 1 Wa s “ ENGINE DIAG. FLOW T ABLE ” performed? Go to Step 2. Go to “ ENGINE DIAG. FLOW T ABLE ” .
ECT sensor T o combination (ECT) meter T o other sensors 6-48 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) DTC P01 15 ENGINE COOLANT TEMPERA TURE (ECT) CIRCUIT MALFUNCTION CIRCUIT DESCRIPTI.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) 6-49 Fig. 1 for Step 2 Fig. 2 for Step 3 Fig. 3 for Step 4 Scan tool DLC INSPECTION STEP ACTION YES NO 1 Wa s “ ENGINE DIAG. FLOW T ABLE ” performed? Go to Step 2. Go to “ ENGINE DIAG. FLOW T ABLE ” .
T o other sensors Throttle position sensor T o other sensors 6-50 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) DTC P0120 THROTTLE POSITION CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION DTC DETECT.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) 6-51 Fig. 1 for Step 2 Fig. 2 for Step 3 Fig. 3 for Step 4 Scan tool “ Lg ” “ Lg/W ” “ 3 ” “ 4 ” “ 1 ” INSPECTION STEP ACTION YES NO 1 Wa s “ ENGINE DIAG. FLOW T ABLE ” performed? Go to Step 2.
T o other sensors Throttle position sensor T o other sensors 6-52 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) DTC P0121 THROTTLE POSITION CIRCUIT RANGE / PERFORMANCE PROBLEM CIRCUIT DESCRIPTION DTC DETECTING CONDITION POSSIBLE CAUSE D After engine warmed up.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) 6-53 Fig. 1 for Step 2 Fig. 2 for Step 2 Fig. 3 for Step 3 Closed (condition “ A ” ) Fully open Throttle Opening Condition “ A ” Clearance between throttle lever and throttle stop screw is less than 0.
T o generator T o other sensor Main fuse Ignition switch Heater 6-54 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) DTC P0130 HEA TED OXYGEN SENSOR (HO2S) CIRCUIT MALFUNCTION (SENSOR-1) CIRCU.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) 6-55 Fig. 1 for Step 3 Fig. 2 for Step 3 Normal Fig. 1 HO2S-1 Output voltage 1 cycle time Response time INSPECTION STEP ACTION YES NO 1 Wa s “ ENGINE DIAG. FLOW T ABLE ” performed? Go to Step 2.
6-56 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) DTC CONFIRMA TION PROCEDURE – Refer to DTC P0130 section. INSPECTION STEP ACTION YES NO 1 Wa s “ ENGINE DIAG. FLOW T ABLE ” performed? Go to Step 2. Go to “ ENGINE DIAG. FLOW T ABLE ” .
T o generator T o other sensor Heater Ignition switch Main fuse “ IG COIL METER ” ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) 6-57 DTC P0135 HEA TED OXYGEN SENSOR (HO2S) HEA TER CIRCUIT MALFUNCTION (SENSOR-1) CIRCUIT DESCRIPTION DTC DETECTING CONDITION POSSIBLE CAUSE DTC will set when A or B condition is met.
6-58 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) Fig. 1 for Step 2 Fig. 2 for Step 3 C01-8 INSPECTION STEP ACTION YES NO 1 W as “ ENGINE DIAG. FLOW T ABLE ” performed? Go to Step 2. Go to “ ENGINE DIAG. FLOW T ABLE ” . 2 Check Heater for Operation.
T o other sensor Heater Ignition switch Main fuse “ IG COIL METER ” T o ignition coil T o other sensor ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) 6-59 DTC P0136 HEA TED OXYGEN SENSOR (HO2S) CIRCUIT MALFUNCTION (SENSOR-2) CIRCUIT DESCRIPTION DTC DETECTING CONDITION POSSIBLE CAUSE DTC will set when A or B condition is detected.
6-60 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) L Usual driving: Driving at 30 – 40 mph, 50 – 60 km/h including short stop according to traffic signal.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) 6-61 INSPECTION STEP ACTION YES NO 1 Wa s “ ENGINE DIAG. FLOW T ABLE ” performed? Go to Step 2. Go to “ ENGINE DIAG. FLOW T ABLE ” . 2 Check exhaust system for leakage, loose connection and damage.
6-62 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) T o other sensor Heater Ignition switch Main fuse “ IG COIL METER ” T o ignition coil T o other sensor DTC P0141 HEA TED OXYGEN SENSOR (HO2S) HEA TER CIRCUIT MALFUNCTION (SENSOR-2) CIRCUIT DESCRIPTION DTC DETECTING CONDITION POSSIBLE CAUSE DTC will set when A or B condition it met.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) 6-63 Fig. 1 for Step 2 INSPECTION STEP ACTION YES NO 1 W as “ ENGINE DIAG. FLOW T ABLE ” performed? Go to Step 2. Go to “ ENGINE DIAG. FLOW T ABLE ” . 2 Check HO2S-2 Heater and Its Circuit.
6-64 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) Sensed information Exhaust gas Fuel injector A/F mixture Signal to decrease amount of fuel injection Signal to increase amount of fuel inje.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) 6-65 DTC CONFIRMA TION PROCEDURE W ARNING: D When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident.
6-66 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) INSPECTION STEP ACTION YES NO 1 Wa s “ ENGINE DIAG. FLOW T ABLE ” performed? Go to Step 2. Go to “ ENGINE DIAG. FLOW T ABLE ” . 2 Is there DTC(s) other than fuel system (DTC P0171 / P0172)? Go to applicable DTC Diag.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) 6-67 Fig. 1 for Step 3 Fig. 2 for Step 4 Fig. 3 for Step 5 Fig. 4 for Step 6 1. Throttle body 2. Fuel feed hose Good No good STEP ACTION YES NO 8 Check engine coolant temp. sensor for performance (See Section 6E1).
Ignition coil Igniter Ignition switch Main fuse Injector resistor Fuel injector Crankshaft position sensor Camshaft position sensor Ground at engine “ I / G COIL METER ” Main relay 6-68 ENGINE GEN.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) 6-69 Below specified value DTC DETECTING CONDITION POSSIBLE CAUSE D Engine under other than high revolution condition D Not on rough road D Engi.
6-70 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) INSPECTION STEP ACTION YES NO 1 Wa s “ ENGINE DIAG. FLOW T ABLE ” performed? Go to Step 2. Go to “ ENGINE DIAG. FLOW T ABLE “ . 2 Is there DTC other than Fuel system (DTC P0171 / P0172) and misfire (DTC P0300-P0303)? Go to applicable DTC Diag.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) 6-71 1. Throttle body 2. Fuel feed hose Good No good 1. Injector connector STEP ACTION YES NO 6 Check PCV valve for clogging (See Section 6E1). Is it in good condition? Go to Step 7. Replace PCV valve.
Oscilloscope W aveforms Crankshaft timing belt pulley CKP sensor 2V/Div . 5ms/Div . W aveforms at specified idle speed 6-72 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) DTC P0335 CRANKSHAFT.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) 6-73 INSPECTION STEP ACTION YES NO 1 Wa s “ ENGINE DIAG. FLOW T ABLE ” performed? Go to Step 2. Go to “ ENGINE DIAG. FLOW T ABLE ” . 2 Check CKP Sensor for Resistance. 1) Disconnect CKP sensor connector with ignition switch OFF .
Display of fuel injection signal using oscilloscope 1. CMP sensor signal 2. Fuel injector signal 3. Fuel injection time 2V/Div . 20V/Div . 1 2 10ms/Div W aveforms at specified idle speed 3 Sensor roto.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) 6-75 Fig. 1 for Step 3 Fig. 2 for Step 5 “ a ” : Air gap INSPECTION STEP ACTION YES NO 1 Wa s “ ENGINE DIAG. FLOW T ABLE ” performed? Go to Step 2. Go to “ ENGINE DIAG. FLOW T ABLE ” .
6-76 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) Oscilloscope W aveforms Engine running at Closed loop condition Fuel Cut Idle after fuel cut 0.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) 6-77 1) 2) 3) 4) 35 – 45 mph (55 – 65 km / h) 30 – 40 mph (50 – 60 km / h) DTC CONFIRMA TION PROCEDURE W ARNING: D When performing a roa.
6-78 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) INSPECTION STEP ACTION YES NO 1 Wa s “ ENGINE DIAG. FLOW T ABLE ” performed? Go to Step 2. Go to “ ENGINE DIAG. FLOW T ABLE ” . 2 Check Short T erm Fuel T rim. Did short term fuel trim vary within – 20% – +20% range in step 3) of DTC confirmation test? Go to Step 3.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) 6-79 Main fuse Main relay T o other valves EV AP canister purge valve EV AP canister purge valve Surge tank T ank pressure control valve Fuel va.
6-80 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) Fig. 1 for Step 1 Main fuse Ignition switch “ IG COIL METER ” Radiator fan relay Radiator fan motor DTC P0480 RADIA T OR F AN CONTROL SYSTEM MALFUNCTION CIRCUIT DESCRIPTION DTC DETECTING CONDITION POSSIBLE CAUSE D Low voltage at terminal C02-20 when engine coolant temp.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) 6-81 Fig. 1 for Step 2 Fig. 2 for Step 3 1. Radiator fan relay 2. Relay box INSPECTION STEP ACTION YES NO 1 Wa s “ ENGINE DIAG. FLOW T ABLE ” performed? Go to Step 2. Go to “ ENGINE DIAG. FLOW T ABLE ” .
6-82 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) V ehicle speed sensor in combination meter C03-2 C03-2 DTC P0500 VEHICLE SPEED SENSOR (VSS) MALFUNCTION (M / T) CIRCUIT DESCRIPTION DTC DETECTING CONDITION POSSIBLE CAUSE D VSS signal not inputted while vehicle running in “ D ” range or during fuel cut at deceleration.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) 6-83 Fig. 1 for Step 3 Fig. 2 for Step 4 C03-2 INSPECTION STEP ACTION YES NO 1 W as “ENGINE DIAG. FLOW T ABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW T ABLE”. 2 Does speedometer indicate vehicle speed? Go to Step 3.
6-84 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) V ehicle speed sensor (on A / T) Counter shaft gear PCM C03-2 C03-13 Bl P C03-2 C03-13 DTC P0500 VEHICLE SPEED SENSOR (VSS) MALFUNCTION FOR A / T VEHICLE (A / T) CIRCUIT DESCRIPTION – Refer to Section 6E1 for VSS operation.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) 6-85 Fig. 1 for Step 2 Fig. 2 for Step 3 INSPECTION STEP ACTION YES NO 1 W as “ ENGINE DIAG. FLOW T ABLE ” performed? Go to Step 2. Go to “ ENGINE DIAG. FLOW T ABLE ” . 2 Check VSS for Resistance.
Main fuse Main relay Idle speed control relay T o TP sensor Idle speed control actuator 6-86 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) DTC P0505 IDLE CONTROL SYSTEM MALFUNCTION CIRCUIT DESCRIPTION DTC DETECTING CONDITION POSSIBLE CAUSE DTC will set when A, B or C condition is met.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) 6-87 Fig. 1 for Step 3 Fig. 2 for Step 3 Fig. 3 for Step 3 1. ISCA relay 2. Relay box DTC P0505 INSPECTION STEP ACTION YES NO 1 Wa s “ ENGINE DIAG. FLOW T ABLE ” performed? Go to Step 2. Go to “ ENGINE DIAG.
6-88 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) Fig. 1 for Step 2 Fig. 2 for Step 3 Lever is apart from plunger Lever contacts with plunger Condition “ A ” : throttle lever is in cont.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) 6-89 DTC P0601 INTERNAL CONTROL MODULE MEMOR Y CHECK SUM ERROR DTC DETECTING CONDITION POSSIBLE CAUSE DTC P0601: Data write error (or check sum error) when written into ECM (PCM) : 2 driving cycle detection logic, continuous monitoring.
Main fuse Main relay EFE heater EFE heater relay 6-90 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) DTC P1250 EARL Y FUEL EV APORA TION (EFE) HEA TER CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION .
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) 6-91 1. Relay box 2. “ PTC ” INSPECTION STEP ACTION YES NO 1 Wa s “ ENGINE DIAG. FLOW T ABLE ” performed? Go to Step 2. Go to “ ENGINE DIAG. FLOW T ABLE ” . 2 Check EFE Heater and Its Circuit.
6-92 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) Fig. 1 for Step 1 DTC P1450 BAROMETRIC PRESSURE SENSOR LOW / HIGH INPUT DTC P1451 BAROMETRIC PRESSURE SENSOR PERFORMANCE PROBLEM WIRING DIAGRAM / CIRCUIT DESCRIPTION Barometric pressure sensor is installed in ECM (PCM).
Main fuse M / T vehicle Ignition switch (starter switch) Starter A / T vehicle Main fuse Ignition switch (starter switch) T ransmission range sensor (switch) Starter PCM ENGINE GENERAL INFORMA TION AN.
T o DLC “ DOME ” Main fuse 6-94 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) DTC P1510 ECM (PCM) BACK-UP POWER SUPPL Y MALFUNCTION CIRCUIT DESCRIPTION Battery voltage is supplied so that diagnostic trouble code memory , values for engine control learned by ECM (PCM), etc.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) 6-95 BLANK.
“ IG COIL METER ” Main fuse Ignition switch Main relay T o other circuits Injector resistor Fuel injector 6-96 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) T ABLE B-1 FUEL INJECTOR CIRCUIT CHECK INSPECTION STEP ACTION YES NO 1 Wa s “ ENGINE DIAG.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) 6-97 STEP ACTION YES NO 6 Check Injector Resistor for Resistance. 1) Disconnect resistor connector with ignition switch OFF . 2) Check for proper connection to resistor at each terminals. 3) If connection is OK, check resistance.
6-98 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) Main fuse Ignition switch T o other circuits Main relay Fuel pump relay Fuel pump CAUTION: Check to make sure that connection is made between correct terminals. Wrong connection can cause damage to ECM (PCM), wire harness, etc.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) 6-99 Fig. 1 for Step 2 Fig. 2 for Step 3 1. Service wire 2. Relay box Fig. 3 for Step 4 Fig. 4 for Step 4.
1. Fuel pump 2. Fuel filter 3. Throttle body 4. Fuel injector 5. Fuel pressure regulator 6. Special tool (Fuel pressure gauge & 3-way joint) 7. Fuel feed line 8.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) 6-101 Fig. 1 for Step 1 1. Fuel pressure gauge & 3way joint STEP ACTION YES NO 8 With fuel pump operated and fuel return hose blocked by pinching it, is fuel pressure applied? Faulty fuel pressure regulator .
A/C amplifier (A / C ON output signal) (A / C input signal) 6-102 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) T ABLE B-4 A / C SIGNAL CIRCUITS CHECK (VEHICLE WITH A / C) INSPECTION STEP ACTION YES NO 1 Check A / C (Input) Signal Circuit. 1) Check voltage at terminal C03-19.
Power steering pressure switch ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) 6-103 T ABLE B-5 POWER STEERING PRESSURE (PSP) SWITCH SIGNAL CIRCUIT CHECK (IF EQUIPPED) INSPECTION STEP ACTION YES NO 1 Check PSP Switch Signal Circuit. 1) Connect SUZUKI scan tool to DLC with ignition switch OFF .
6-104 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) 09931-7601 1 SUZUKI scan tool (T ech 1 A) kit 1. Storage case 2. Operator ’ s manual 3. T ech 1 A 4. DLC cable (14 / 26 pin, 09931-76040) 5. T est lead / probe 6. Power source cable 7. DLC cable adaptor 8.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G13) 6-1 SECTION 6 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G13) NOTE: For the details of this section, refer to same section of the Service Manual mentioned in the FOREWORD of this manual.
6-1 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) 6-1-1 GENERAL INFORMA TION 6-1- 3 . . . . . . . . . . . . . . ENGINE DIAGNOSIS 6-1- 6 . . . . . . . . . . . . . . . . . . . General Description 6-1- 6 . . . . . . . . . . . . . . . . . . . On-Board Diagnostic System 6-1- 6 .
6-1-2 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) DTC P0300 Random Misfire Detected 6-1- 69 . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0301 Cylinder 1 Misfire Detected 6-1- 69 . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) 6-1-3 GENERAL INFORMA TION ST A TEMENT ON CLEANLINESS AND CARE An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the thousands of an millimeter (ten thousands of an inch).
HOSE CONNECTION Clamp securely at a position 3 to 7mm (0.12–0.27 in.) from hose end. With short pipe, fit hose as far as it reaches pipe joint as shown. Hose Pipe Clamp Clamps securely at a position 3 to 7 mm (0.12–0.27 in.) from hose end. With following type pipe, fit hose as far as its peripheral projection as shown.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) 6-1-5 FUEL PRESSURE RELIEF PROCEDURE CAUTION: This work must not be done when engine is hot. If done so, it may cause adverse effect to catalyst. After making sure that engine is cold, release fuel pressure as fol- lows.
6-1-6 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) ENGINE DIAGNOSIS GENERAL DESCRIPTION This vehicle is equipped with an engine and emission control system which are under control of ECM (PCM). The engine and emission control system in this vehicle are controlled by ECM (PCM).
An Example of Freeze Frame Data 1. T rouble Code P0102 (1st) 2. Engine Speed 782 RPM 3. Eng Cool Tmp. 80 _ C 4. V ehicle Spd. 0 km/h 5. MAP Sensor 39 kPa 6. St. T erm FT1 – 0.8% Lean 7. Lg. T erm FT1 – 1.6% Lean 8. Fuel 1 Stat. Closed Loop 9. Fuel 2 Stat.
B+ Body ground ECM (PCM) ground Serial data line (K line of ISO 9141) 6-1-8 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) In the 2nd through the 4th frames, the freeze frame data of each malfunction is stored in the order as the malfunction is detected.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) 6-1-9 PRECAUTION IN DIAGNOSING TROUBLE D Don ’ t disconnect couplers from ECM (PCM), battery cable from battery , ECM (PCM) ground wire harness from engine or main fuse before confirming diagnostic information (DTC, freeze frame data, etc.
6-1-10 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) ENGINE DIAGNOSTIC FLOW T ABLE Refer to the following pages for the details of each step. STEP ACTION YES NO 1 Customer Complaint Analysis 1) Perform customer complaint analysis referring to the next page.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) 6-1-1 1 1. CUSTOMER COMPLAINT ANAL YSIS Record details of the problem (failure, complaint) and how it occurred as described by the customer . For this purpose, use of such an inspection form will facilitate collecting information to the point required for proper analysis and diagnosis.
6-1-12 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) CUSTOMER PROBLEM INSPECTION FORM (EXAMPLE) User name: Model: VIN: Date of issue: Date of Reg.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) 6-1-13 MALFUNCTION INDICA T OR LAMP (MIL) CHECK 1) T urn ON ignition switch (but the engine at stop) and check that MIL lights. If MIL does not light up (or MIL dims), go to “ Diagnostic Flow T able A-1 ” for troubleshooting.
6-1-14 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) DIAGNOSTIC TROUBLE CODE (DTC) CLEARANCE [Using SUZUKI scan tool] 1) Connect SUZUKI scan tool (T ech-1) to data link connector in the same manner as when making this connection for DTC check.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) 6-1-15 DIAGNOSTIC TROUBLE CODE (DTC) T ABLE NOTE: 1 driving cycle: MIL lights up when DTC is detected in the first driving cycle.
6-1-16 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) DTC NO. DETECTING ITEM DETECTING CONDITION (DTC will set when detecting:) MIL P0335 Crankshaft position sensor circuit malfunction No signal for 2 sec.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) 6-1-17 DTC NO. DETECTING ITEM DETECTING CONDITION (DTC will set when detecting:) MIL P0705 T ransmission Range Sensor Circuit Malfunction P0720 .
6-1-18 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) F AIL-SAFE T ABLE When any of the following DTCs is detected, ECM (PCM) enters fail-safe mode as long as malfunction continues to exist but that mode is canceled when ECM (PCM) detects normal condition after that.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) 6-1-19 Operation VISUAL INSPECTION Visually check following parts and systems. INSPECTION ITEM REFERRING SECTION D Engine oil ––––– le.
6-1-20 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) ENGINE BASIC INSPECTION This check is very important for troubleshooting when ECM (PCM) has detected no DTC and no abnormality has been found in visual inspection. Follow the flow table carefully .
Select “ DA T A LIST ” mode SELECT MENU F4: MISC TEST When using SUZUKI scan tool ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) 6-1-21 Fig.
6-1-22 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) ENGINE DIAGNOSIS T ABLE Perform troubleshooting referring to following table when ECM (PCM) has detected no DTC and no abnormality has been found in visual inspection and engine basic inspection previously .
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) 6-1-23 Condition Possible Cause] Referring Item Low oil pressure D Improper oil viscosity D Malfunctioning oil pressure switch D Clogged oil str.
6-1-24 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) Condition Possible Cause Referring Item Overheating D Inoperative thermostat D Poor water pump performance D Clogged or leaky radiator D .
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) 6-1-25 Condition Possible Cause Referring Item Engine hesitates (Momentary lack of response as accelerator is depressed. Can occur at all vehicle speeds. Usually most severe when first trying to make vehicle move, as from a stop sign.
6-1-26 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) Condition Possible Cause Referring Item Engine has no power Ignition system out of order D Faulty spark plug D Faulty ignition coil with .
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) 6-1-27 Condition Possible Cause Referring Item Improper engine idling or engine fails to idle Ignition system out of order D Faulty spark plug D.
6-1-28 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) Condition Possible Cause Referring Item Excessive hydrocarbon (HC) emission or carbon monoxide (CO) Ignition system out of order D Faulty.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) 6-1-29 SCAN TOOL DA T A As the data values given below are standard values estimated on the basis of values obtained from the normally operating vehicles by using a scan tool, use them as reference values.
6-1-30 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) SCAN T OOL DA T A CONDITION NORMAL CONDITION / REFERENCE V ALUES DESIRED IDLE (DESIRED IDLE SPEED) At idling with no load after warming u.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) 6-1-31 SCAN TOOL DA T A DEFINITIONS FUEL SYSTEM (FUEL SYSTEM ST A TUS) Air / fuel ratio feedback loop status displayed as either open or closed loop. Open indicates that ECM (PCM) ignores feedback from the exhaust oxygen sensor .
6-1-32 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) CANIST PURGE DUTY (EV AP CANISTER PURGE FLOW DUTY , %) This parameter indicates valve ON (valve open) time rate within a certain set cycle of EV AP purge solenoid valve which controls the amount of EV AP purge.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) 6-1-33 1. ECM (PCM) 2. ECM (PCM) couplers (Viewed from harness side) INSPECTION OF ECM (PCM) AND ITS CIRCUITS ECM (PCM) and its circuits can be checked at ECM (PCM) wiring couplers by measuring voltage and resistance.
6-1-34 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) CONNECTOR “ C01 ” TERMINAL NO. CIRCUIT NORMAL VOL T AGE CONDITION 1 Ground — — 2 Ground — — 3 Ground — — 4 EV AP canister.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) 6-1-35 CONNECTOR “ C02 ” TERMINAL NO. CIRCUIT NORMAL VOL T AGE CONDITION 1 A / C ON output signal 0 V Ignition switch ON 2 EGR valve (steppe.
6-1-36 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) CONNECTOR “ C03 ” TERMINAL NO. CIRCUIT NORMAL VOL T AGE CONDITION 1 Malfunction indicator lam p 0 – 1 V Ignition switch ON 1 Malfun.
1 2 1. ECM (PCM) coupler disconnected 2. Ohmmeter ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) 6-1-37 Resistance Check 1) Disconnect ECM (PCM) couplers from ECM (PCM) with ignition switch OFF . CAUTION: Never touch terminals of ECM (PCM) itself or connect voltmeter or ohmmeter .
INFORMA TION SENSORS - 1. MAP sensor - 2. TP sensor - 3. IA T sensor - 4. ECT sensor - 5. Heated oxygen sensor-1 5-1. Heated oxygen sensor-2 - 6. VSS (A / T) - 7. T ransmission range switch (A / T) - 8. Battery - 9. CMP sensor - 10. CKP sensor - 1 1. Fuel level sensor (gauge) (in fuel tank) - 12.
Main fuse Ignition switch Main relay Malfunction indicator lamp in combination meter Relay box Fuse box C01-1 C01-2 C01-3 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) 6-1-39 T ABLE A-1 MALF.
6-1-40 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) T ABLE A-2 MALFUNCTION INDICA TOR LAMP CIRCUIT CHECK – LAMP REMAINS “ ON ” AFTER ENGINE ST ARTS WIRING DIAGRAM / CIRCUIT DESCRIPTION – Refer to table A-1. INSPECTION STEP ACTION YES NO 1 Diagnostic T rouble Code (DTC) check 1) Check DTC referring to DTC CHECK section.
Main fuse Ignition switch Main relay Malfunction indicator lamp in combination meter Relay box Fuse box ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) 6-1-41 T ABLE A-3 ECM (PCM) POWER AND GR.
6-1-42 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) Fig. 1 for Step 2 Fig. 2 for Step 2 Fig. 3 for Step 2 STEP ACTION YES NO 5 ECM (PCM) Power Circuit Check 1) Using service wire, ground terminal C02-10 and measure voltage between terminal C02-5 / 6 and ground at ignition switch ON.
MAP sensor T o other sensors T o TP sensor ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) 6-1-43 DTC P0105 MANIFOLD ABSOLUTE PRESSURE (MAP) CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION DTC DETECTING CONDITION POSSIBLE CAUSE D MAP: 4.9 kpa, 37 mmHg or less (Low pressure – High vacuums – Low voltage) D MAP: 1 14.
6-1-44 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) MAP Sensor Individual Check 1) Disconnect coupler from MAP sensor (1). 2) Remove MAP sensor (1).
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) 6-1-45 Fig. 1 for Step 2 Fig. 2 for Step 3 INSPECTION STEP ACTION YES NO 1 W as “ ENGINE DIAG. FLOW T ABLE ” performed? Go to Step 2. Go to “ ENGINE DIAG. FLOW T ABLE ” . 2 Check MAP Sensor and Its Circuit.
6-1-46 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) IA T sensor T o other sensors DTC P01 10 INT AKE AIR TEMP . (IA T) CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION DTC DETECTING CONDITION POSSIB.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) 6-1-47 Fig. 1 for Step 2 Fig. 2 for Step 3 Fig. 3 for Step 4 INSPECTION STEP ACTION YES NO 1 Wa s “ ENGINE DIAG. FLOW T ABLE ” performed? Go to Step 2. Go to “ ENGINE DIAG. FLOW T ABLE ” .
6-1-48 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) T o combination (ECT) meter T o other sensors NOTE: Before inspecting, be sure to check that cool- ant temp. meter in combination meter indi- cates normal operating temperature (Engine is not overheating).
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) 6-1-49 Fig. 1 for Step 2 Fig. 2 for Step 5 Fig. 3 for Step 6 INSPECTION STEP ACTION YES NO 1 Wa s “ ENGINE DIAG. FLOW T ABLE ” performed? Go to Step 2. Go to “ ENGINE DIAG. FLOW T ABLE ” .
Throttle position sensor T o MAP sensor T o other sensors 6-1-50 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) DTC P0120 THROTTLE POSITION CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION DTC DETECTI.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) 6-1-51 Fig. 1 for Step 2 Fig. 2 for Step 3 Fig. 3 for Step 4 INSPECTION STEP ACTION YES NO 1 W as “ ENGINE DIAG. FLOW T ABLE ” performed? Go to Step 2. Go to “ ENGINE DIAG. FLOW T ABLE ” .
6-1-52 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) Throttle position sensor T o other sensors T o other sensors DTC P0121 THROTTLE POSITION CIRCUIT RANGE / PERFORMANCE PROBLEM CIRCUIT DESCRIPTION DTC DETECTING CONDITION POSSIBLE CAUSE D After engine warmed up.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) 6-1-53 Fig. 1 for Step 2 Fig. 2 for Step 2 Fig. 3 for Step 2 Fig. 4 for Step 3 Closed (condition “ A ” ) Fully open Throttle Opening When using SUZUKI scan tool: When not using SUZUKI scan tool: INSPECTION STEP ACTION YES NO 1 Wa s “ ENGINE DIAG.
6-1-54 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) Ignition switch Main fuse T o HO2S-2 heater T o other sensor Heater Fuse box DTC P0130 HEA TED OXYGEN SENSOR (HO2S) CIRCUIT MALFUNCTION (.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) 6-1-55 Fig. 1 for Step 3 Fig. 2 for Step 3 Normal INSPECTION STEP ACTION YES NO 1 Wa s “ ENGINE DIAG. FLOW T ABLE ” performed? Go to Step 2. Go to “ ENGINE DIAG. FLOW T ABLE ” . 2 Is there DTC(s) other than HO2S-1 (DTC P0130)? Go to applicable DTC Diag.
6-1-56 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) Fig. 1 HO2S-1 Output voltage 1 cycle time Response time DTC P0133 HEA TED OXYGEN SENSOR (HO2S) CIRCUIT SLOW RESPONSE (SENSOR-1) WIRING DIAGRAM / CIRCUIT DESCRIPTION – Refer to DTC P0130 section.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) 6-1-57 Fig. 1 for Step 3 DTC P0134 HEA TED OXYGEN SENSOR (HO2S) CIRCUIT NO ACTIVITY DETECTED (SENSOR-1) CIRCUIT DESCRIPTION – Refer to DTC P0130 section. DTC DETECTING CONDITION POSSIBLE CAUSE D Engine warmed up.
Ignition switch Main fuse T o HO2S-2 heater T o other sensor Heater Fuse box 6-1-58 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) DTC P0135 HEA TED OXYGEN SENSOR (HO2S) HEA TER CIRCUIT MALFUNCTION (SENSOR-1) CIRCUIT DESCRIPTION DTC DETECTING CONDITION POSSIBLE CAUSE DTC will set when A or B condition is met.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) 6-1-59 Fig. 1 for Step 2 Fig. 2 for Step 3 INSPECTION STEP ACTION YES NO 1 W as “ ENGINE DIAG. FLOW T ABLE ” performed? Go to Step 2. Go t o “ ENGINE DIAG. FLOW T ABLE ” . 2 Check Heater for Operation.
6-1-60 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) T o other sensor Main fuse Ignition switch Heater T o HO2S-1 heater DTC P0136 HEA TED OXYGEN SENSOR (HO2S) CIRCUIT MALFUNCTION (SENSOR-2) CIRCUIT DESCRIPTION DTC DETECTING CONDITION POSSIBLE CAUSE DTC will set when A or B condition is detected.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) 6-1-61 L Usual driving: Driving at 30 – 40 mph, 50 – 60 km/h including short stop according to traffic signal.
6-1-62 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) INSPECTION STEP ACTION YES NO 1 Wa s “ ENGINE DIAG. FLOW T ABLE ” performed? Go to Step 2. Go to “ ENGINE DIAG. FLOW T ABLE ” . 2 Check exhaust system for leakage, loose connection and damage.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) 6-1-63 T o other sensor Main fuse Ignition switch Heater T o HO2S-1 heater DTC P0141 HEA TED OXYGEN SENSOR (HO2S) HEA TER CIRCUIT MALFUNCTION (SENSOR-2) CIRCUIT DESCRIPTION DTC DETECTING CONDITION POSSIBLE CAUSE DTC will set when A or B condition it met.
6-1-64 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) Fig. 1 for Step 2 INSPECTION STEP ACTION YES NO 1 W as “ ENGINE DIAG. FLOW T ABLE ” performed? Go to Step 2. Go to “ ENGINE DIAG. FLOW T ABLE ” . 2 Check HO2S-2 Heater and Its Circuit.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) 6-1-65 Ignition switch Main fuse Main relay T o ignition switch T o other sensor Relay box No.1 injector No.
6-1-66 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) DTC CONFIRMA TION PROCEDURE W ARNING: D When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) 6-1-67 INSPECTION STEP ACTION YES NO 1 Wa s “ ENGINE DIAG. FLOW T ABLE ” performed? Go to Step 2. Go to “ ENGINE DIAG. FLOW T ABLE ” . 2 Is there DTC(s) other than fuel system (DTC P0171 / P0172)? Go to applicable DTC Diag.
6-1-68 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) Fig. 1 for Step 3 Fig. 2 for Step 4 Fig. 3 for Step 5 Fig. 4 for Step 5 Fig. 5 for Step 5 Fig. 6 for Step 6 1. Fuel delivery pipe 2. Fuel feed hose 3. Fuel pressure gauge & 3 way joint STEP ACTION YES NO 8 Check engine coolant temp.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) 6-1-69 Ignition coil assembly for No.1 & No.4 spark plugs Ignition coil assembly for No.2 & No.3 spark plugs Ignition switch Main relay Main fuse Relay box T o ignition switch CKP sensor CMP sensor No.
Below specified value 6-1-70 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) 1. CKP sensor signal 2. No.1 fuel injector signal 3. No.3 fuel injector signal 4.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) 6-1-71 INSPECTION STEP ACTION YES NO 1 Wa s “ ENGINE DIAG. FLOW T ABLE ” performed? Go to Step 2. Go to “ ENGINE DIAG. FLOW T ABLE “ . 2 Is there DTC other than Fuel system (DTC P0171 / P0172) and misfire (DTC P0300-P0304)? Go to applicable DTC Diag.
6-1-72 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) Disconnect connectors when checking plugs for spark 1. Fuel delivery pipe 2. Fuel feed hose 3. FUel pressure gauge & 3 way joint STEP ACTION YES NO 6 Check PCV valve for clogging (See Section 6E2).
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) 6-1-73 Crankshaft timing belt pulley CKP sensor Oscilloscope W aveforms W aveforms at engine cranking (260 r/min) W aveforms at specified idle speed 16 waives for 10 _ signals 13 waives for 10 _ signals 30 _ signal 30 _ signal 0.
6-1-74 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) INSPECTION NOTE: If starter circuit is open (i.e., start signal circuit is OK but starter fails to run), this DTC is stored in memory at starter switch ON, even though CKP sensor is in good condition.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) 6-1-75 T o ignition switch Signal rotor on Camshaft Camshaft position sensor W aveforms at specified idle speed Oscilloscope W aveforms 2 V / Div .
6-1-76 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) INSPECTION STEP ACTION YES NO 1 Wa s “ ENGINE DIAG. FLOW T ABLE ” performed? Go to Step 2. Go to “ ENGINE DIAG. FLOW T ABLE ” . 2 Check CMP Sensor and connector for proper installation.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) 6-1-77 GND V out B+ Magnetic substance (iron) Mirror STEP ACTION YES NO 7 Check signal rotor for the following, using mirror . See Fig. 4. D Damage D No foreign material attached Is it in good condition? Intermittent trouble or faulty ECM (PCM).
6-1-78 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) Ignition switch Main fuse Relay box Main relay EGR valve 2 C13 DTC P0400 EXHAUST GAS RECIRCULA TION FLOW MALFUNCTION CIRCUIT DESCRIPTION .
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) 6-1-79 1) 2) 3) 4) 5) 6) 7) Engine speed 4000 r/min 0 V ehicle speed 0 50 – 55 mph 80 – 88 km/h (Keep throttle valve opening constantly) DTC.
6-1-80 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) 1. EGR valve coupler INSPECTION STEP ACTION YES NO 1 Was ENGINE DIAG. FLOW T ABLE performed? Go to Step 2. Go to ENGINE DIAG. FLOW T ABLE. 2 Do you have SUZUKI scan tool? Go to Step 3. Go to Step 5.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) 6-1-81 Oscilloscope W aveforms Heated oxygen sensor-1 T o other sensor Heated oxygen sensor-2 W arm up three way catalytic converter Three way catalytic converter Engine running at Closed loop condition Fuel Cut Idle after fuel cut 0.
6-1-82 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) 1) 2) 3) 4) 41 – 46 mph (65 – 75 km / h) 28 – 34 mph (45 – 55 km / h) DTC CONFIRMA TION PROCEDURE W ARNING: D When performing a r.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) 6-1-83 INSPECTION STEP ACTION YES NO 1 Wa s “ ENGINE DIAG. FLOW T ABLE ” performed? Go to Step 2. Go to “ ENGINE DIAG. FLOW T ABLE ” . 2 Check Short T erm Fuel T rim. Did short term fuel trim vary within – 20% – +20% range in step 3) of DTC confirmation test? Go to Step 3.
6-1-84 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) 1. EV AP canister purge valve 2. T o main relay 3. ECM (PCM) 4. Sensed information 5. Intake manifold 6. EV AP canister 7. T ank pressure control valve 8. Fuel vapor line 9. Fuel tank Fig.
Radiator cooling fan relay To ECM Main relay Relay box “ RDTR ” (Radiator fan) Radiator cooling Fan motor ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) 6-1-85 DTC P0480 RADIA T OR COOLIN.
6-1-86 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) Fig. 1 for Step 2 Fig. 2 for Step 3 Fig. 3 for Step 3 INSPECTION STEP ACTION YES NO 1 Wa s “ ENGINE DIAG. FLOW T ABLE ” performed? Go to Step 2. Go to “ ENGINE DIAG. FLOW T ABLE ” .
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) 6-1-87 V ehicle speed sensor in combination meter DTC P0500 VEHICLE SPEED SENSOR (VSS) MALFUNCTION FOR M / T VEHICLE CIRCUIT DESCRIPTION DTC DETECTING CONDITION POSSIBLE CAUSE D While fuel is kept cut at lower than 4000 r / min for longer than 4 sec.
6-1-88 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) Fig. 1 for Step 3 Fig. 2 for Step 4 INSPECTION STEP ACTION YES NO 1 W as “ ENGINE DIAG. FLOW T ABLE ” performed? Go to Step 2. Go to “ ENGINE DIAG. FLOW T ABLE ” . 2 Does speedometer indicate vehicle speed? Go to Step 3.
Output shaft speed sensor (on A / T) Counter shaft gear ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) 6-1-89 DTC P0500 VEHICLE SPEED SENSOR (VSS) MALFUNCTION FOR A / T VEHICLE CIRCUIT DESCRIPTION DTC DETECTING CONDITION POSSIBLE CAUSE D While fuel is kept cut at lower than 4000 r / min for longer than 4 sec.
6-1-90 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) Fig. 1 for Step 2 Fig. 2 for Step 3 INSPECTION STEP ACTION YES NO 1 W as “ ENGINE DIAG. FLOW T ABLE ” performed? Go to Step 2. Go to “ ENGINE DIAG. FLOW T ABLE ” . 2 Check VSS for Resistance.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) 6-1-91 Relay box Main fuse Main relay IAC valve T o other valve DTC P0505 IDLE CONTROL SYSTEM MALFUNCTION CIRCUIT DESCRIPTION DTC DETECTING CONDITION POSSIBLE CAUSE D No closed signal to IAC valve is detected after engine start.
6-1-92 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) Fig. 1 for Step 1 Fig. 2 for Step 2 When using SUZUKI scan tool: When not using SUZUKI scan tool: INSPECTION STEP ACTION YES NO 1 Wa s “ ENGINE DIAG. FLOW T ABLE ” performed? Go to Step 2.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) 6-1-93 DTC P0601 INTERNAL CONTROL MODULE MEMOR Y CHECK SUM ERROR DTC DETECTING CONDITION POSSIBLE CAUSE DTC P0601: Data write error (or check sum error) when written into ECM (PCM) : 1 driving cycle detection logic, continuous monitoring.
6-1-94 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) Fig. 1 for Step 1 When using SUZUKI scan tool: DTC P1450 BAROMETRIC PRESSURE SENSOR LOW / HIGH INPUT DTC P1451 BAROMETRIC PRESSURE SENSOR PERFORMANCE PROBLEM WIRING DIAGRAM / CIRCUIT DESCRIPTION Barometric pressure sensor is installed in ECM (PCM).
Applying V acuum Displayed V alue on Scan T ool 0 Barometric pressure (Approx. 100 kPa, 760 mmHg) 27 kPa 200 mmHg Barometric pressure – 27 kPa (Approx. 73 kPa, 560 mmHg 67 kPa 500 mmHg Barometric pressure – 67 kPa (Approx. 33 kPa, 260 mmHg) ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) 6-1-95 Fig.
6-1-96 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) Main fuse M/T vehicle A/T vehicle Ignition switch (starter switch) Starter Starter T ransmission range sensor (switch) Main fuse Ignition.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) 6-1-97 Fuse box Main fuse DOME RADIO “ LAMP ” DTC P1510 ECM (PCM) BACK-UP POWER SUPPL Y MALFUNCTION CIRCUIT DESCRIPTION Battery voltage is supplied so that diagnostic trouble code memory , values for engine control learned by ECM (PCM), etc.
6-1-98 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) Ignition switch Main fuse Main relay Relay box No.1 injector No.2 injector No.3 injector No.4 injector Fuse box T ABLE B-1 FUEL INJECTOR CIRCUIT CHECK INSPECTION STEP ACTION YES NO 1 Wa s “ ENGINE DIAG.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) 6-1-99 Main fuse Ignition switch Main relay Fuel pump relay Main relay Fuel pump CAUTION: Check to make sure that connection is made between correct terminals. Wrong connection can cause damage to ECM (PCM), wire harness, etc.
6-1-100 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) Fig. 1 for Step 2 Fig. 2 for Step 3 Fig. 3 for Step 4.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) 6-1-101 1. Fuel injector 2. Delivery pipe 3. Fuel regulator 4. Fuel filter 5. Fuel pump Special T ool (A) Gauge (09912-58441) (B) Hose (09912-58431) (C) 3-way joint (09912-58490) T ABLE B-3 FUEL PRESSURE CHECK INSPECTION STEP ACTION YES ON 1 1) Release fuel pressure from fuel feed line.
6-1-102 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) 1. Fuel delivery pipe 2. Fuel feed hose 3. Fuel return hose Special T ool (A) Gauge (B) Hose (C) 3-way joint STEP ACTION YES ON 7 W as no fuel pressure applied in step 1? Go to Step 8. Go to Step 9.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) 6-1-103 A/C amplifier (A / C ON output signal) (A / C input signal) T ABLE B-4 A / C SIGNAL CIRCUITS CHECK (VEHICLE WITH A / C) INSPECTION STEP ACTION YES NO 1 Check A / C (input) Signal Circuit.
6-1-104 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) Power steering pressure switch Power steering pump Fig. 1 for Step 1 Fig. 2 for Step 2 T ABLE B-5 POWER STEERING PRESSURE (PSP) SWITCH SIGNAL CIRCUIT CHECK (If equipped) INSPECTION STEP ACTION YES NO 1 Check PSP Switch Signal Circuit.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) 6-1-105 Heater blower switch Rear defogger switch T ail light relay (Lighting switch) Diodes in junction/ fuse block Fig. 1 for Step 1 Fig. 2 for Step 1 T ABLE B-6 ELECTRIC LOAD SIGNAL CIRCUIT CHECK INSPECTION STEP ACTION YES NO 1 Check Electric Load Signal Circuit.
6-1-106 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) Radiator cooling fan relay To ECM Main relay Relay box “ RDTR ” (Radiator fan) Radiator cooling Fan motor T ABLE B-7 RADIA TOR COOLING F AN CONTROL SYSTEM CHECK INSPECTION STEP ACTION YES NO 1 Check Fan Control System.
ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) 6-1-107 Fig. 1 for Step 1 Fig. 2 for Step 3 Fig. 3 for Step 4 When using SUZUKI scan tool: 1. Radiator cooling fan relay 1.
6-1-108 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) 09917-47910 V acuum pump gauge 09930-88530 Injector test lead 09931-7601 1 SUZUKI scan tool (T ech 1 A) kit Mass storage cartridge 09931-76030 16 / 14 pin DLC cable 1. Storage case 2. Operator ’ s manual 3.
6A ENGINE MECHANICAL (G10, 1-CAM 6-V AL VES ENGINE) 6A-1 SECTION 6A ENGINE MECHANICAL (G10, 1-CAM 6-V AL VES ENGINE) W ARNING: For vehicles equipped with Supplemental Restraint (Air Bag) System: D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer .
6A-2 ENGINE MECHANICAL (G10, 1-CAM 6-V AL VES ENGINE) ON-VEHICLE SER VICE ENGINE V ACUUM CHECK The engine vacuum that develops in the intake line is a good indica- tor of the condition of the engine. The vacuum checking procedure is as follows: 1) W arm up engine to normal operating temperature.
3 / 4 turn ENGINE MECHANICAL (G10, 1-CAM 6-V AL VES ENGINE) 6A-3 3) Install special tool (Oil pressure gauge) to vacated threaded hole. Special T ool (A): 09915-7731 1 (B): 09915-7821 1 NOTE: At this time, be very careful not to exert force to where heated oxygen sensor and its lead wire are connected.
6A-4 ENGINE MECHANICAL (G10, 1-CAM 6-V AL VES ENGINE) CYLINDER HEAD COVER REMOV AL 1) Disconnect negative cable at battery . 2) Remove air cleaner assembly . 3) Remove high-tension cord clamps (2) from cylinder head cover . 4) Disconnect breather hose from cylinder head cover .
1. Stay 2. Throttle body 3. Gasket 4. EFE heater 5. Intake manifold 6. Gasket : T ightening T orque : Do not reuse ENGINE MECHANICAL (G10, 1-CAM 6-V AL VES ENGINE) 6A-5 THROTTLE BODY AND INT AKE MANIFOLD REMOV AL 1) Relieve fuel pressure according to procedure described in “ FUEL PRESSURE RELIEF PROCEDURE ” of Section 6.
1. Throttle body 1. Throttle body 2. ISC actuator 5. Clamp 6A-6 ENGINE MECHANICAL (G10, 1-CAM 6-V AL VES ENGINE) 4) Remove air cleaner assembly . 5) Disconnect the following electric lead wires: D EGR valve D ISC actuator (2) D Ground wires from intake manifold D Fuel injector (4) D TP sensor (3) D EFE heater (5) D Engine coolant temp.
2. Ground 1. Throttle body 2. ISC actuator coupler 3. TP sensor coupler 4. Fuel injector coupler 5. EFE heater coupler ENGINE MECHANICAL (G10, 1-CAM 6-V AL VES ENGINE) 6A-7 INST ALLA TION 1) Install throttle body to intake manifold. (Refer to Section 6E.
1. Exhaust manifold 2. Gasket 3. Cover 4. Heated oxygen sensor 5. Pipe seal 6. Exhaust pipe 7. WU-TWC (if equipped) 8. Exhaust pipe bolt : T ightening T orque : Do not reuse 6A-8 ENGINE MECHANICAL (G10, 1-CAM 6-V AL VES ENGINE) EXHAUST MANIFOLD W ARNING: T o avoid danger of being burned, do not service exhaust system while it is still hot.
2. WU-TWC ENGINE MECHANICAL (G10, 1-CAM 6-V AL VES ENGINE) 6A-9 INST ALLA TION 1) Install manifold gasket to cylinder head. Before installing gasket, check it for deterioration or damage, and replace as necessary . 2) Install exhaust manifold (1). T ighten manifold bolts and nuts to specified torque.
1. T iming belt 2. T ensioner 3. T ensioner plate 4. T ensioner spring 5. Spring damper 6. Camshaft timing pulley 7. Pin 8. Pulley bolt 9. Seal 10. Inside cover seal 1 1. Inside cover 12. Outside cover seal 13. Outside cover 14. T ensioner stud 15. T ensioner bolt 16.
1. “ V ” mark on cylinder head cover 2. T iming mark on camshaft timing belt pulley 3. Arrow mark on oil pump case 4. Punch mark on crankshaft timing belt pulley ENGINE MECHANICAL (G10, 1-CAM 6-V AL VES ENGINE) 6A-1 1 8) Loosen crankshaft pulley bolts (1) and remove crankshaft pulley (2).
6A-12 ENGINE MECHANICAL (G10, 1-CAM 6-V AL VES ENGINE) 1. Camshaft allowable turning range – – – By timing mark, within 90 _ from “ V ” mark on head cover on both right and left. 2. Crankshaft allowable turning range – – – by punch mark, within 90 _ from arrow mark on oil pump case on both right and left.
1. Crank timing belt pulley bolt Direction of crankshaft ENGINE MECHANICAL (G10, 1-CAM 6-V AL VES ENGINE) 6A-13 3) Check that timing mark (3) on camshaft timing belt pulley (1) is aligned with “ V ” mark (2) on cylinder head cover (4).
6A-14 ENGINE MECHANICAL (G10, 1-CAM 6-V AL VES ENGINE) 7) Install timing belt outside cover . Before installing, make sure that rubber seal (1) is between wa- ter pump and oil pump case and another between water pump and cylinder head. Tightening T orque (c): 1 1 N .
1. Cylinder head cover 2. Gasket 3. Cylinder head 4. Camshaft housing No.1: Apply sealant 99000-31 1 10 to mating surface. 5. Camshaft housing No.2 6. Camshaft housing No.3: Apply sealant 99000-31 1 10 to mating surface. 7. Camshaft 8. Oil seal 9. V alve lash adjuster 10.
Don ’ t apply force 6A-16 ENGINE MECHANICAL (G10, 1-CAM 6-V AL VES ENGINE) 6) Remove camshaft housings from cylinder head. 7) Remove camshaft from cylinder head. 8) Remove valve lash adjuster from cylinder head. NOTE: D Never disassemble hydraulic valve lash adjuster .
ENGINE MECHANICAL (G10, 1-CAM 6-V AL VES ENGINE) 6A-17 INSPECTION Camshaft journal wear: D Check camshaft journals and camshaft housings for pitting, scratches, wear or damage. If any malcondition is found, replace camshaft or cylinder head with housing.
D Indicates position from timing belt side. Install in numerical order starting from timing belt side. D Indicates direction of housing. Install so that arrow is directed toward timing belt side.
2. No.2 housing 3. No.3 housing 3. Rod 4. Shop cloth ENGINE MECHANICAL (G10, 1-CAM 6-V AL VES ENGINE) 6A-19 D As camshaft housing No.1 (1) retains camshaft in proper position as to thrust direction, make sure to first fit No.1 hous- ing to No.1 journal of camshaft securely .
6A-20 ENGINE MECHANICAL (G10, 1-CAM 6-V AL VES ENGINE) CAUTION: D Don ’ t turn camshaft or start engine (i.e., valves should not be operated) for about half an hour after reinstalling hydraulic valve lash adjusters and camshaft.
1. Cylinder head 2. Cylinder head bolt 3. V alve guide 4. Cylinder head gasket: “ TOP ” mark provided on gasket comes to crankshaft pulley side, facing up (toward cylinder head side). 5. Pin 6. Camshaft 7. V alve lash adjuster 8. V alve cotters 9.
6A-22 ENGINE MECHANICAL (G10, 1-CAM 6-V AL VES ENGINE) V alve Springs D Referring to data given below , check to be sure that each spring is in sound condition, free of any evidence of breakage or weak- ening.
1. Cylinder block 2. Feeler gauge 3. Piston ring 4. 120 mm (4.72 in.) 1. T op ring 2. 2nd ring 3. Oil ring 4. Piston 5. Connecting rod 6. Connecting rod bearing cap 7. Connecting rod bearing 8. Piston pin 9. Connecting rod nut : T ightening T orque : Apply engine oil to sliding : surfaces of each part.
6A-24 ENGINE MECHANICAL (G10, 1-CAM 6-V AL VES ENGINE) UNIT REP AIR OVERHAUL ENGINE ASSEMBL Y REMOV AL 1) Relieve fuel pressure according to procedure described in “ FUEL PRESSURE RELIEF PROCEDURE ” of Section 6. 2) Remove engine hood after disconnecting front window washer hose.
1. Rear mounting 2. Left mounting 3. Left mounting bracket 4. Right mounting 5. Right mounting bracket For M / T model For A / T model 1. Rear mounting 2. Rear mounting No.2 bracket 3. Rear mounting No.1 bracket 4. Left mounting No.1 bracket 5. Stopper 6.
1. Rear mounting 2. Rear mounting No.2 bracket 3. Rear mounting No.1 bracket 4. Rear mounting bracket 5. Left mounting body bracket 6. Left mounting 7. Left mounting bracket 8. Right mounting bracket 9. Right mounting For M / T model For A / T model 1.
1. Cylinder block 2. Front oil seal 3. Main bearing 4. Bearing cap 5. Cap washer 6. Cap bolt 7. T iming pulley key 8. Crankshaft 9. Thrust bearing: Set oil grooves of bearing to weds. 10. Rear oil seal 1 1. Pin 12. Oil seal housing gasket 13. Oil seal housing 14.
2. Upper half of bearing (a) 6A-28 ENGINE MECHANICAL (G10, 1-CAM 6-V AL VES ENGINE) INST ALLA TION NOTE: D All parts to be installed must be perfectly clean. D Be sure to oil crankshaft journals, journal bearings, thrust bearings, crankpins, connecting rod bearings, pistons, pis- ton rings and cylinder bores.
ENGINE MECHANICAL (G10, 1-CAM 6-V AL VES ENGINE) 6A-29 5) Install oil seal housing and its gasket. Install new gasket. Do not reuse gasket removed in disassem- bly . Oil lip portion of oil seal before installing. Tighten housing bolts to specification.
09915-47310 Oil filter wrench 09915-64512 Compression gauge 09910-3821 1 Piston pin remover and installer 1. Base 2. Base cap 3. Driver handle 4. Piston pin guide for installation 5. Piston pin guide for removal 6. Spring 7. Spring guide 09915-6731 1 V acuum gauge 1.
09916-5601 1 V alve guide installer 09917-98221 V alve stem seal installer 09918-08210 V acuum gauge hose joint 09919-16010 Deep socket 09924-17810 Flywheel holder 09926-18210 Oil seal guide (Vinyl re.
6A1 ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) 6A1-1 SECTION 6A1 ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) W ARNING: For vehicles equipped with Supplement Restraint (Air Bag) System: D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer .
6A1-2 ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) GENERAL DESCRIPTION ENGINE The engine is a water-cooled, in line 4 cylinders, 4 stroke cycle gasoline unit equipped with its S.O.H.C. (Single Overhead Camshaft) valve mechanism arranged for “V”-type valve configuration and 16 valves (IN 2 and EX 2 / one cylinder).
ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) 6A1-3 ENGINE LUBRICA TION The oil pump is of a trochoid type, and mounted on crankshaft at crankshaft pulley side. Oil is drawn up through oil pump strainer and passed through pump to oil filter . The filtered oil flows into two paths in cylinder block.
1. Rocker arm shaft 2. Rocker arm (EX) 3. Intake valve 4. Exhaust valve 5. Rocker arm (IN) 6. Camshaft 7. Clip 8. Pivot Ex In CYLINDER BLOCK The cylinder block is made of cast aluminum alloy and has 4 cylinders arranged “ In-Line ” . A cylindrical cast iron sleeve is installed in each cylinder .
1 2 ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) 6A1-5 ON-VEHICLE SER VICE COMPRESSION CHECK Check compression pressure on all four cylinders as follows: 1) W arm up engine.
6A1-6 ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) ENGINE V ACUUM CHECK The engine vacuum that develops in the intake line is a good indica- tor of the condition of the engine. The vacuum checking procedure is as follows: 1) W arm up engine to normal operating temperature.
ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) 6A1-7 OIL PRESSURE CHECK NOTE: Prior to checking oil pressure, check the following items. D Oil level in oil pan. If oil level is low , add oil up to Full level mark on oil level gauge. D Oil quality .
6A1-8 ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) 6) Before reinstalling oil pressure switch (1), be sure to wrap its screw threads with sealing tape (2) and tighten switch to speci- fied torque. NOTE: If sealing tape edge is bulged out from screw threads of switch, cut it off.
2 IN EX (A) 1 ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) 6A1-9 V AL VE LASH (CLEARANCE) 1) Remove negative cable at battery . 2) Remove cylinder head cover referring to item “ Cylinder Head cover ” . 3) Remove engine under cover of right side from body .
1. Thickness gauge IN EX 360 _ IN EX 6A1-10 ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) 6) If valve lash is out of specification, adjust it to specification by turning adjusting screw after loosening lock nut.
3 ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) 6A1-1 1 AIR CLEANER ELEMENT REMOV AL 1) Disconnect air cleaner outlet hose from case after loosening its clamp (2) and removing bolt (1) shown in figure. 2) Remove air cleaner cap (3) from case by unhooking its clamps, then take out air cleaner element.
6A1-12 ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) AIR CLEANER OUTLET HOSE REMOV AL 1) Disconnect negative cable at battery . 2) Disconnect resonator after loosening its clamp. 3) Disconnect breather hose from air cleaner outlet hose. 4) Disconnect IA T sensor wire at coupler .
3 3 ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) 6A1-13 CYLINDER HEAD COVER REMOV AL 1) Disconnect negative cable at battery . 2) Disconnect breather hose (2) and PCV valve (3) from head cov- er . 3) Disconnect ignition coil couplers (6). 4) Remove ignition coil assemblies (5) with high-tension cord (4).
1. Intake manifold 2. Throttle body 3. Gasket 4. EGR valve 5. Fuel delivery pipe 6. Fuel injector 7. Fuel pressure regulator 8. EV AP canister purge valve 9.
ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) 6A1-15 7) Disconnect the following electric lead wires and release clamp: D Ground wires (5) from intake manifold D TP sensor (3) D IAC valve (4) D F.
1. Long bolt 2. Short bolt 6A1-16 ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) 10) Remove intake manifold rear stiffener (1) and generator adjust arm reinforcement (2) from intake manifold (3). 1 1) Remove intake manifold with throttle body from cylinder head, and then its gasket.
: T ightening T orque : Do not reuse 1. Exhaust manifold 2. Gasket 3. Cover 4. Heated oxygen sensor 7. Gasket 8. Exhaust No.1 pipe. 2 1 ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) 6A1-17 EXHAUST MANIFOLD W ARNING: T o avoid danger of being burned, do not service exhaust system while it is still hot.
(b) (a) 6A1-18 ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) INST ALLA TION 1) Install new gaskets to cylinder head. 2) Install exhaust manifold. Tighten bolts and nuts to specified torque. Tightening T orque (a): 32 N . m (3.2 kg-m, 23.5 lb-ft) 3) Install exhaust manifold cover(s) (1).
1. T iming belt 2. T ensioner 3. T ensioner plate 4. T ensioner spring 5. Camshaft timing pulley 6. T ensioner bolt 7. Pulley bolt 8. Seal 9. Inside cover seal 10. Inside cover 1 1. Outside cover seal 12. Outside cover 13. T ensioner stud 14. Damper 1.
1. “ V ” mark on cylinder head cover 2. T iming mark by “ E ” on camshaft timing belt pulley 3. Arrow mark on oil pump case 4. Punch mark on crankshaft timing belt pulley 4.
1. Camshaft allowable turning range - - - By timing mark, within 90 _ from “ V ” mark on head cover on both right and left. 2. Crankshaft allowable turning range - - - By punch mark, within 90 _ from arrow mark on oil pump case on both right and left.
4. Damper 6A1-22 ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) 2) Install tensioner (2) and tensioner plate (3): Do not tighten tensioner bolt (1) with wrench yet. Hand tighten only at this time. Check to ensure that plate movement in arrow direction as shown in figure causes tensioner to move in the same direction.
1. Clamp 1. Long bolt 2. Short bolt ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) 6A1-23 6) T o take up slack of timing belt, turn crankshaft two rotations clockwise after installing it. After making sure that belt is free from slack, tighten tensioner stud first and then tensioner bolt to each specified torque.
6A1-24 ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) 12) Install water pump pulley (1) and drive belt. Tightening T orque (a): 1 1 N . m (1.1 kg-m, 8.0 lb-ft) 13) Adjust drive belt tension referring to Section 6B. 14) Adjust power steering pump belt tension or A/C compressor belt tension, if equipped.
1. Oil pan: Apply sealant 99000-31 150 to oil pan mating surface. 2. Oil pump strainer 3. Seal 4. Drain plug gasket 5. Drain plug 6. CKP sensor : T ightening T orque : Do not reuse ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) 6A1-25 OIL P AN AND OIL PUMP STRAINER REMOV AL 1) Raise vehicle.
2. O-ring 6A1-26 ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) 6) Remove oil pan (3) and then oil pump strainer (1). CLEANING D Clean mating surfaces of oil pan and cylinder block. Remove oil, old sealant, and dusts from mating surfaces and oil pan inside.
ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) 6A1-27 3) Install new gasket and drain plug to oil pan. Tighten drain plug to specified torque. Tightening T orque (a): 50 N . m (5.0 kg-m, 36 lb-ft) 4) Install clutch (torque converter) housing lower plate.
1. Rotor plate 2. Inner rotor: Apply thin coat of engine oil. 3. Outer rotor: Apply thin coat of engine oil. 4. Gasket 5. Pin 6. Pin 7. Relief valve: Apply thin coat of engine oil. 8. Spring 9. Retainer 10. Retainer ring 1 1. Front oil seal: Apply engine oil to contact part of crankshaft with oil seal lip.
4. Guide seal ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) 6A1-29 7) Remove oil pump assembly (1) after removing bolts (2). DISASSEMBL Y 1) Remove oil level gauge guide bolt (3) and pull out guide (2) from oil pump (1). 2) Remove rotor plate (1).
6A1-30 ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) NOTE: When installing oil seal (1), press-fit it till its end face is flush with oil pump case (2) end face. D Check outer and inner rotors, rotor plate, and oil pump case for excessive wear or damage.
(a) 1. Oil pump 1. No. 1 bolts (short) 2. No. 2 bolts (long) ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) 6A1-31 4) Install rotor plate. Tighten 5 screw securely . After installing plate, check to be sure that gears turn smoothly by hand. Tightening T orque (a): 1 1 N .
6A1-32 ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) 5) Install timing pulley key (2) and crank timing belt pulley (3) and crankshaft pulley pin (1). Refer to figure for proper installation of these parts. With crankshaft locked using flat end rod or the like (5), tighten crank timing belt pulley bolt (4) to specified torque.
1. Camshaft 2. Camshaft oil seal 3. Rocker arm shaft 4. O-ring 5. Rocker shaft bolt 6. Rocker arm (IN) 7. Rocker arm No.1 (EX) 8. Rocker arm No.2 (EX) 9. V alve adjusting screw 10. V alve adjusting screw 1 1. Clip 12. Lock nut 13. Rocker arm spring : T ightening T orque : Do not reuse : Apply engine oil to sliding : surfaces of each part.
1. Oil plug 6A1-34 ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) 4) Disconnect CMP sensor coupler from CMP sensor . 5) Remove CMP sensor case (1) from cylinder head. Place a container or rag under CMP sensor case, for a small amount of oil flows out during removal of case.
EX IN 2. Rocker arm shaft ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) 6A1-35 10) Remove rocker arm shaft bolts (1). 1 1) Remove exhaust rocker arms (1) and rocker arm spring (2) by pulling out rocker arm shaft to battery side after removing bat- tery .
6A1-36 ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) Rocker Arm-to-Rocker Arm Shaft Clearance Using a micrometer and a bore gauge, measure rocker shaft dia. and rocker arm l.D. Difference between two readings is arm-to-shaft clearance on which a limit is specified.
ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) 6A1-37 Check clearance by using gaging plastic. The procedure is as follows. 1) Clean housing and camshaft journals. 2) Install camshaft to cylinder head. 3) Place a piece of gaging plastic the full width of journal of cam- shaft (parallel to camshaft).
A: Timing belt side B: Flywheel side 6A1-38 ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) INST ALLA TION 1) Apply engine oil to rocker arm shaft and rocker arms.
ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) 6A1-39 D Indicates position from timing belt side. Install in numerical order starting from timing belt side. D Indicates direction of housing. Install so that arrow is directed toward timing belt side.
6A1-40 ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) 1. O-ring 2 10) Using special tool, tighten pulley bolt to specified torque. Tightening T orque (a): 60 N . m (6.0 kg-m, 43.5 lb-ft) Special T ool (A): 09917-68221 1 1) Install belt tensioner , timing belt, outside cover , crankshaft pulley and water pump belt as previously outlined.
: Do not reuse 1. V alve cotters 2. V alve spring retainer 3. V alve spring: be sure to position spring in place with its bottom end (small-pitch end) facing the bottom (valve spring seat side). 4. V alve stem seal 5. V alve spring seat 6. Exhaust valve 7.
6A1-42 ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) D Ignition coil assembly D Ground wires from intake manifold D EV AP canister purge valve D ECT sensor D Injectors, TP sensor and IAC valve wi.
3 2. Breather hose 3. PCV valve 4. High-tension cords 5. Ignition coil assembly 6. Ignition coil coupler A: Camshaft pulley side B: CMP sensor case side ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) 6A1-43 9) Remove cylinder head cover (1) as previously outlined.
6A1-44 ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) DISASSEMBL Y 1) For ease in servicing cylinder head, remove CMP sensor case, intake manifold with throttle body and exhaust manifold from cyl- inder head. 2) Remove rocker arms and washers by pulling its shaft out to transmission side.
ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) 6A1-45 INSPECTION V alve Guides Using a micrometer and bore gauge, take diameter readings on valve stems and guides to check stem-to-guide clearance. Be sure to take reading at more than one place along the length of each stem and guide.
6A1-46 ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) D Inspect valve stem end face for pitting and wear . If pitting or wear is found there, valve stem end may be resurfaced, but not so much as to grind off its chamfer . When it is worn so much that its chamfer is gone, replace valve.
ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) 6A1-47 D V alve seat repair: A valve seat (2) not producing a uniform contact with its valve or showing width of seating contact that is out of specified range must be repaired by regrinding or by cutting and regrinding and finished by lapping.
6A1-48 ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) D Flatness of gasketed surface: Using a straightedge and thickness gauge, check surface at a to- tal of 6 locations.
ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) 6A1-49 V alve Springs D Referring to data given below , check to be sure that each spring is in sound condition, free of any evidence of breakage or weak- ening.
“ a ” : V alve guide protrusion (1 1.5 mm) 6A1-50 ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) ASSEMBL Y 1) Before installing valve guide into cylinder head, ream guide hole with special tool (1 1 mm reamer) to remove burrs and make it truly round.
A: V alve spring retainer side B: V alve spring seat side ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) 6A1-51 5) Install new valve stem seal (1) to valve guide.
A: Crankshaft pulley side B: Flywheel side A: Camshaft pulley side B: CMP sensor case side 6A1-52 ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) 9) Install rocker arms, washers, rocker arm shaft and camshaft as previously outlined. 10) Install CMP sensor case, intake manifold and exhaust man- ifold.
ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) 6A1-53 4) Reverse removal procedure for installation. 5) Adjust water pump drive belt tension by referring to “ ENGINE COOLING ” section. 6) Adjust power steering pump belt tension or A / C compressor belt tension, if equipped.
1. T op ring 2. 2nd ring 3. Oil ring 4. Piston 5. Connecting rod 6. Connecting rod bearing cap 7. Connecting rod bearing 8. Piston pin 9. Piston pin circlip 10. connecting rod bearing cap nut : Do not reuse : T ightening T orque : Apply engine oil to sliding : surface of each part.
ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) 6A1-55 DISASSEMBL Y 1) Using piston ring expander , remove two compression rings (T op and 2nd) and oil ring from piston. 2) Remove piston pin from connecting rod. D Ease out piston pin circlips (1), as shown.
“ a ” : 50 mm (1.96 in.) “ b ” : 95 mm (3.74 in.) “ a ” : 23 mm (0.91 in.) 6A1-56 ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) INSPECTION Cylinders D Inspect cylinder walls for scratches, roughness, or ridges which indicate excessive wear .
“ a ” : 23 mm (0.91 in.) ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) 6A1-57 D Piston clearance: Measure cylinder bore diameter and piston diameter to find their difference which is piston clearance. Piston clearance should be within specification as given below .
1. Cylinder block “ a ” : 120 mm (4.72 in.) 6A1-58 ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) Piston Rings T o measure end gap, insert piston ring (3) into cylinder bore and then measure the gap by using thickness gauge (2). If measured gap is out of specification, replace ring.
ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) 6A1-59 Crank Pin and Connecting Rod Bearings D Inspect crank pin for uneven wear or damage. Measure crank pin for out-of-round or taper with a micrometer .
1 or 2 Piston No.1 Cylinder No.2 Cylinder No.3 Cylinder No.4 Cylinder Crank pulley side Flywheel side 6A1-60 ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) 5) Remove cap and using a scale (2) on gaging plastic (1) enve- lope, measure gaging plastic width at the widest point (clear- ance).
2. Arrow mark 4. Oil hole The oil hole should come on intake side 1. Arrow mark 2. 1st ring end gap 3. 2nd ring end gap and oil ring spacer gap 4. Oil ring upper rail gap 5.
A: Crankshaft pulley side B: Flywheel side 6A1-62 ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) INST ALLA TION OR CONNECTION 1) Apply engine oil to pistons, rings, cylinder walls, connecting rod bearings and crankpins. NOTE: Do not apply oil between connecting rod and bearing or be- tween bearing cap and bearing.
ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) 6A1-63 6) Reverse removal procedure for installation, as previously out- lined. 7) Adjust water pump drive belt tension referring to Section 6B. 8) Adjust power steering pump belt tension or A / C compressor belt tension, if equipped.
1 2 6A1-64 ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) UNIT REP AIR OVERHAUL ENGINE ASSEMBL Y REMOV AL 1) Release fuel pressure in fuel feed line by referring to Section 6. 2) Remove battery . 3) Remove engine hood after disconnecting windshield washer hose.
ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) 6A1-65 12) Disconnect the following electric wires: D Ignition coil assembly D Ground wires from intake manifold D Engine oil pressure switch D EV AP canister purge valve (if equipped) D Engine coolant temp.
6A1-66 ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) 15) Remove exhaust No.1 pipe. 16) Remove right and left engine under covers. 17) Remove gear shift control shaft from transmission and remove extension rod (M / T). 18) Drain engine and transmission oil.
(a) 1 2 3 (a) (a) 6 7 4 5 (a) M/T M/T 9 (a) 4 7 (a) 8 1. Right mounting 2. Right mounting bracket 3. Left mounting 4. Left mounting bracket 5. Left mounting bracket stiffener 6.
1. Cylinder block 2. Front oil seal: Apply engine oil to contact part of crankshaft with oil seal lip. 3. Main bearing: Apply engine oil to bearing inside surfaces. 4. Bearing cap 5. Cap bolt: Apply engine oil to bolt and bearing surfaces. 6. T iming pulley key 7.
1. Flywheel bolt 2. Bolt ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) 6A1-69 REMOV AL 1) Remove engine assembly from body as previously outlined. 2) Remove clutch cover , clutch disc and flywheel (drive plate for A / T). Special T ool (A): 09924-17810 3) Remove crankshaft pulley , timing belt and crankshaft timing pulley .
6A1-70 ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) INSPECTION Crankshaft Crankshaft runout Using a dial gauge, measure runout at center journal. Rotate crank- shaft slowly . If runout exceeds its limit, replace crankshaft. Limit on runout: 0.06 mm (0.
1. Gaging plastic ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) 6A1-71 Main Bearings General information D Service main bearings are available in standard size and 0.25 mm (0.0098 in.) undersize, and each of them has 5 kinds of bear- ings differing in tolerance.
6A1-72 ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) 5) Remove cap and using scale (2) on gaging plastic (1) envelope, measure gaging plastic width at its widest point. If clearance ex- ceeds its limit, replace bearing. Always replace both upper and lower inserts as a unit.
1. Paint ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) 6A1-73 2) Next, check bearing cap bore diameter without bearing. On mat- ing surface of cylinder block, four alphabets are stamped as shown in figure. Three kinds of alphabets ( “ A ” , “ B ” and “ C ” ) represent the follow- ing cap bore diameters.
2. Scale 1. Paint 6A1-74 ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) 4) From numerals stamped on crank webs (1) of No.2 and No.3 cyl- inders and the alphabets stamped on mating surface of cylinder block, determine new standard bearing to be installed to journal, by referring to table given below .
ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) 6A1-75 D If necessary , regrind crankshaft journal and select under-size bearing to use with it as follows. 1) Regrind journal to the following finished diameter . Finished diameter: 44.732 – 44.750 mm (1.
“ a ” : 23 mm (0.91 in.) 6A1-76 ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) Flywheel D If ring gear is damaged, cracked or worn, replace flywheel. D If the surface contacting clutch disc is damaged, or excessively worn, replace flywheel. D Check flywheel for face runout with dial gauge.
ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) 6A1-77 5) Rebore and hone cylinder to calculated dimension. NOTE: Before reboring, install all main bearing caps in place and tighten to specification to avoid distortion of bearing bores. 6) Measure piston clearance after honing.
1. Short bolts 2. Long bolts 6A1-78 ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) 3) Install crankshaft to cylinder block. 4) Install bearing cap to cylinder block, making sure to point arrow mark (on each cap) to crankshaft pulley side. Fit them sequen- tially in ascending order , 1, 2, 3, 4 and 5, starting from pulley side.
ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) 6A1-79 8) Install pistons and connecting rods as previously outlined. 9) Install oil pump strainer and oil pan as previously outlined. 10) Install cylinder head assembly to cylinder block as previously outlined.
1. 09915-64510-001 Compression gauge 2. 09915-64510-002 Connector 3. 09915-64530 Hose 4. 09915-67010 Attachment 09915-6731 1 V acuum gauge 09918-08210 V acuum gauge hose joint 09915-7731 1 Oil pressure gauge 09917-1821 1 T appet adjuster wrench 09919-16020 17 mm socket 09926-18210 Oil seal guide (Vinyl resin) 09917-68221 Camshaft pulley holder 1.
09917-98221 V alve stem seal installer 09916-77310 Piston ring compressor 09924-17810 Flywheel holder 09915-47330 Oil filter wrench ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) 6A1-81 REQUIRED SER VICE MA TERIALS MA TERIALS RECOMMENDED SUZUKI PRODUCT USE Sealant SUZUKI BOND NO.
6A1-82 ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) TIGHTENING T ORQUE SPECIFICA TIONS F ASTENING P ARTS TIGHTENING TORQUE F ASTENING PA R T S N . m kg-m lb-ft Oil pressure switch 13 1.3 9.5 V alve adjusting screw lock nuts 12 1.2 9.0 Cylinder head cover bolts 11 1.
6B ENGINE COOLING 6B-1 SECTION 6B ENGINE COOLING NOTE: For the descriptions (items) not found in this section, refer to the same section of Service Manual men- tioned in FOREWORD of this manual. CONTENTS GENERAL DESCRIPTION 6B-2 . . . . . . . . . . . .
8. Heater inlet hose 9. Heater outlet hose 10. Radiator 1 1. Oil cooler (A / T only) 12. Engine 13. ECT sensor 1. Radiator inlet hose 2. Radiator outlet hose 3.
1. Cooling fan motor 2. Radiator ENGINE COOLING 6B-3 THERMOST A T A wax pellet type thermostat is used in the coolant outlet passage to control the flow of engine coolant, to provide fast engine warm up and to regulate coolant temperatures.
6B-4 ENGINE COOLING COOLANT (W A TER) TEMP . GAUGE The coolant temp. gauge is included in engine coolant temp. (ECT) sensor (1). This gauge activates a temp.
ENGINE COOLING 6B-5 ANTI-FREEZE PROPOR- TIONING CHART COOLANT CAP ACITY G13 engine G10 engine MAINTENANCE COOLANT The coolant recovery system is standard. The coolant in the radiator expands with heat, and the overflow is col- lected in the reservoir tank.
2. Outlet hose 6B-6 ENGINE COOLING COOLING SYSTEM FLUSH AND REFILL W ARNING: T o help avoid danger of being burned, do not remove radia- tor cap while engine and radiator cap while engine and ra- diator are still hot. Scalding fluid and steam can be blown out under pressure if cap is taken off too soon.
1. Radiator hose 2. Clamp ENGINE COOLING 6B-7 ON-VEHICLE SER VICE W ARNING: D Check to make sure that engine coolant temperature is cold before removing any part of cooling system. D Also be sure to disconnect negative cord from battery ter- minal before removing any part.
2. Thermostat case 2. Thermometer 3. Heater Upside 6B-8 ENGINE COOLING 4) Remove thermostat (1). INSPECTION 1) Make sure that air bleed valve (1) of thermostat is clean. Should this valve be clogged, engine would tend to overheat. 2) Check to make sure that valve seat is free from foreign matters which would prevent valve from seating tight.
ENGINE COOLING 6B-9 W A TER PUMP 1) Disconnect negative cable at battery . 2) Drain cooling system. 3) Remove timing belt and tensioner according to procedure de- scribed in “ TIMING BEL T AND TENSIONER ” of Section 6A or 6A1. 4) Remove water pump belt adjusting arm.
6B-10 ENGINE COOLING 5) Install crankshaft pulley , water pump pulley , and pump drive belt referring to Section 6A or 6A1. 6) Adjust water pump belt tension. 7) Install fender apron extension on right side. 8) Install air cleaner assembly . 9) Connect negative cable at battery .
6C ENGINE FUEL 6C-1 GENERAL DESCRIPTION 6C-1 . . . . . . . . . . . . . . Fuel System 6C-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Pump Assembly 6C-1 . . . . . . . . . . . . . . . . . . . ON-VEHICLE SERVICE 6C-2 . . . . . . . . . . .
1. Fuel tank 2. Fuel pump and level gauge 3. Fuel filler cap 4. 2-way check valve 5. Breather hose 6. Fuel feed line 7. Fuel return line 8. Fuel vapor line 9.
1. Return hose 2. V apor hose 3. Feed hose 4. Fuel tank ENGINE FUEL 6C-3 7) As fuel tank has no drain plug, drain fuel tank by pumping fuel out through fuel tank filler or fuel tank inlet. Use hand operated pump to drain fuel tank. W ARNING: Never drain or store fuel in an open container to avoid possibility of fire or explosion.
6C-4 ENGINE FUEL FUEL PUMP ASSEMBL Y REMOV AL 1) Remove fuel tank (1) from vehicle referring to “ FUEL T ANK ” in this section. 2) Disconnect fuel feed hose (2), fuel return hose (3) and breather hose (4) from fuel pump assembly (5). 3) Remove fuel pump assembly from fuel tank by removing screws.
ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6E1-1 GENERAL DESCRIPTION 6E1- 2 . . . . . . . . . . . . . . AIR AND FUEL DELIVERY SYSTEM 6E1- 4 . . . . . ELECTRONIC CONTROL SYSTEM 6E1- 5 . . . . . . ON-VEHICLE SERVICE 6E1- 8 . . . . . . . . . . . . .
6E1-2 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) GENERAL DESCRIPTION The engine and emission control system is divided into 3 major sub-systems: air/fuel delivery system, electronic control system and emission control system. Air/fuel delivery system includes fuel pump, throttle body , etc.
ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6E1-3 1. T ank pressure control valve 2. Fuel liquid separator 3. Fuel tank 4. Fuel pump 5. Fuel level sensor (gauge) 6. Fuel filter 7. Fuel pressure regulator 8. Throttle body 9. Fuel injector 10. MAP sensor 1 1.
1. Air cleaner 2. Throttle body 3. Fuel injector 4. Fuel pressure regulator 5. Intake manifold 6. Fuel filter 7. Fuel tank 8. Fuel pump 9. Fuel feed line 10.
INFORMA TION SENSORS 1. MAP sensor 2. TP sensor 3. IA T sensor 4. ECT sensor 5. Heated oxygen sensor-1 6. VSS 7. Ignition coil 8. Battery 9. Distributor (CMP sensor) 10. A / C controller (if equipped) 1 1. CKP sensor 12. CTP switch (in ISC actuator) 13.
6E1-6 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) IG COIL METER FI.
ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6E1-7 CON- NECTOR C02 TERMI- NAL 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 ECM ground Power source (from main relay) Blank B.
6E1-8 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) ON-VEHICLE SER VICE GENERAL When the hoses have been disconnected and system ’ s component removed for service, be sure to reinstall component properly , and route and connect hoses correctly after service.
ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6E1-9 1. Throttle body 2. Fuel feed hose NOTE: Before starting engine, place transmission gear shift lever in “ Neutral ” (shift selector lever to “ P ” range for A/T model), and set parking brake and block drive wheels.
6E1-10 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6) Start engine and warm it up to normal operating temperature. If engine doesn ’ t start, turn ignition switch ON to operate fuel pump and after 2 seconds turn it OFF . Repeat this 3 or 4 times and then check fuel pressure.
ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6E1-1 1 1. Fuel filler 2. Ignition switch 3. Fuel return hose 4. Fuel feed hose 1. Fuel pump 2. Filter 3. Fuel tank FUEL PUMP ON-VEHICLE INSPECTION W ARNING: When fuel filler cap is removed in any procedure, work must be done with no smoking, in a well-ventilated area and away from any open flames.
6E1-12 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 1. Fuel injector wire 2. Fuel injector 3. Upper O-ring 4. Lower O-ring 5. Throttle upper body 6. Gasket 7. Throttle lower body 8. ISC actuator 9. TP sensor 10. Injector sub wire coupler 1 1. O-ring 12.
ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6E1-13 1. Fuel injector wire 2. Fuel pressure regulator 3. TP sensor 4. Screws 5. ISC actuator 1. Injector chamber 2. Fuel return passage 3. Fuel feed passage 4. V acuum passage for fuel pressure regulator 5.
6E1-14 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) (a) 1. Lower body 2. Gasket 1. Wire cover 2. Fuel injector wire 3. Screws 2. EFE heater 3. Gasket 1. Intake manifold ASSEMBL Y 1) Install injector wire and coupler to throttle body . Use new O-ring.
ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6E1-15 1. Injector coupler 2. TP sensor 3. W ater hose 4. V acuum hose 5. ISC actuator 6. Fuel return hose 7. Fuel feed hose 1. Injector coupler Good No good 2) Install throttle body to EFE heater and tighten bolts to specified torque.
6E1-16 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 1. Injector 1 3 2 1. Injector cavity 2. Lower O-ring 3. Upper O-ring 1. Positive terminal REMOV AL NOTE: Use care when handling fuel injector especially not to damage filter and its needle.
ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6E1-17 1. ECM 2. Instrument panel 3. Steering wheel 1. Injector wire 2. Screws 1. Stay 3) Make sure that injector wire O-ring is free from any damage and deterioration, and apply thin coat of spindle oil or gasoline to O- ring.
6E1-18 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 1 2 4 3 1. MAP sensor 2. 1.5 V battery (4.5 V in total) 3. V acuum pump 4. Digital type voltmeter MANIFOLD ABSOLUTE PRESSURE SENSOR (MAP SENSOR) MAP SENSOR INDIVIDUAL CHECK 1) Disconnect MAP sensor vacuum hose from filter .
ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6E1-19 1. TP sensor 2. TP sensor adjusting holes 3. TP sensor screw holes 4. T urn TP sensor after fitting and align holes. 1. Throttle stop screw 2. Throttle lever 3. Thickness gauge THROTTLE POSITION SENSOR (TP SENSOR) INSPECTION Check TP sensor referring to step 2 of DTC P0121 Flow T able.
6E1-20 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 1. Plunger 2. Throttle lever screw 2) Check to make sure that plunger of ISC actuator and throttle le- ver screw are not in contact with each other . If they are, warm up engine. 3) Loosen TP sensor screws.
ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6E1-21 ( ) for reference k Ω TEMPERA TURE 0 32 20 68 40 104 60 140 80 _ C 176 _ F (5.88) 2.21 – 2.
6E1-22 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) ( ) for reference k Ω TEMPERA TURE 0 32 20 68 40 104 60 140 80 _ C 176 _ F (5.74) 2.28 – 2.
ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6E1-23 1. Viewed from terminal side 1. Exhaust manifold 2. Heated oxygen sensor Sensor-1 Sensor-2 HEA TED OXYGEN SENSOR (SENSOR-1 AND SENSOR-2) OXYGEN SENSOR HEA TER INSPECTION 1) Disconnect sensor coupler .
6E1-24 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) VEHICLE SPEED SENSOR (VSS) For M / T INSPECTION 1) Disconnect negative cable at battery . 2) Remove combination meter from instrument panel.
ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6E1-25 1. Main relay 2. Relay box CRANKSHAFT POSITION SENSOR INSPECTION Check crankshaft position sensor referring to step 1 and 2 of DTC P0335 Flow Chart. If malfunction is found, replace. REMOV AL 1) Hoist vehicle.
6E1-26 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 1. Throttle body FUEL PUMP RELA Y INSPECTION 1) Disconnect negative cable at battery . 2) Remove fuel pump relay (1) from relay box (2). 3) Structure of fuel pump relay is the same as that of main relay .
ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6E1-27 1) Connect scan tool to DLC with ignition switch OFF , if it is avail- able. 2) W arm up engine to normal operating temperature. 3) Select “ Data List ” mode on scan tool to check “ IAC duty ” .
6E1-28 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 1. 1.5 V battery (6.0 V in total) “ A ” “ B ” “ C ” 3) Arrange 4 new 1.5 V batteries in series (6.0 V in total). With throttle lever in contact with plunger of ISC actuator , con- nect these batteries to ISC actuator terminals and check ISC ac- tuator for operation.
ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6E1-29 1. ISC actuator relay 2. Relay box 1. EFE heater 2. Rubber cover 3. “ Red ” wire 4. “ Black ” wire ISC ACTUA TOR RELA Y INSPECTION 1) Disconnect negative cable at battery . 2) Remove ISC actuator relay from relay box.
6E1-30 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 1. Insulator 2. Lower gasket 3. Heater 1. Intake manifold 2. EFE heater 1. EFE heater relay 2. Relay box 1. Radiator fan motor INSPECTION D Check lower gasket for damage and deterioration. Replace as necessary .
ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6E1-31 1. RFC relay 2. Relay box RADIA TOR F AN CONTROL RELA Y (RFC RELA Y) INSPECTION 1) Disconnect negative cable at battery . 2) Remove RFC relay from relay box. 3) Structure of RFC relay is the same as that of main relay .
6E1-32 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) RH LH EMISSION CONTROL SYSTEM EV APORA TIVE EMISSION CONTROL SYSTEM EV AP CANISTER PURGE INSPECTION NOTE: Before inspection, check to make sure .
ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6E1-33 EV AP CANISTER PURGE V AL VE INSPECTION W ARNING: Do not suck the air through valve. Fuel vapor inside valve is harmful. 1) With the ignition switch OFF position, disconnect coupler from EV AP canister purge valve.
6E1-34 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 1. T ank pipe 2. Purge pipe 3. Air pipe 4. Blow air 1. T ank pressure control valve 2. Orange side 3. Black side 4. T o canister 5. From fuel tank EV AP CANISTER INSPECTION W ARNING: DO NOT SUCK nozzles on EV AP canister .
ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6E1-35 1. PCV valve 1. Proper size hose 2. Blow air 3. PCV valve PCV V AL VE INSPECTION 1) Disconnect PCV hose from PCV valve. 2) Run engine at idle. 3) Place your finger over end of PCV valve to check for vacuum.
09913-7601 1 SUZUKI scan tool (T ech 1A) kit Mass storage cartridge 09931-76030 16 / 14 pin DLC cable 1. Fuel pressure gauge 09912-58441 2. Pressure hose 09912-58431 3. 3-way joint & hose 09912-58490 09917-47010 V acuum pump gauge 1. Storage case 2.
ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G13) 6E1-1 SECTION 6E1 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G13) NOTE: For the details of this section, refer to the same section of the Service Manual mentioned in the FORE- WORD of this manual.
6E2 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) 6E2-1 GENERAL DESCRIPTION 6E2- 2 . . . . . . . . . . . . . . AIR INT AKE SYSTEM 6E2- 6 . . . . . . . . . . . . . . . . . . FUEL DELIVERY SYSTEM 6E2- 7 . . . . . . . . . . . . . . ELECTRONIC CONTROL SYSTEM 6E2- 8 .
6E2-2 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) The engine and emission control system is divided into 4 major sub-systems: air intake system, fuel de- livery system, electronic control system and emission control system. Air intake system includes air cleaner , throttle body , IAC valve and intake manifold.
ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) 6E2-3.
6E2-4 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13).
ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) 6E2-5.
6E2-6 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) The main components of the air intake system are air cleaner (1), air cleaner outlet hose (2), throttle body (3), idle air control valve (4) and intake manifold (5).
6. EV AP canister purge valve ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) 6E2-7 The fuel delivery system consists of the fuel tank (1 1), fuel pump (12), fuel filter (10), fuel pressure regulator (3), delivery pipe (2) and fuel injectors (1).
6E2-8 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) INFORMA TION SENSORS - 1. MAP sensor - 2. TP sensor - 3. IA T sensor - 4. ECT sensor - 5. Heated oxygen sensor-1 5-1. Heated oxygen sensor-2 - 6. VSS (A / T) - 7. T ransmission range switch (A / T) - 8.
ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) 6E2-9 FUEL PUMP RELA Y FUEL INJECTOR HO2S HEA TER IAC V AL VE IGNITION COIL WITH IGNITER EGR V AL VE EV AP CANISTER PURGE V AL VE A/C CONTROL MODULE RA.
6E2-10 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) P R N D 2 L.
ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) 6E2-1 1.
12 W / R “N”-range signal (A / T) 13 R Heated oxygen sensor-2 14 Y / R “D”-range signal (A / T) 15 R / W “R”-range signal (A / T) 16 Lg / B A / C SW signal 17 R / W EGR valve (stepper moto.
1. Accelerator cable 3. Lock nut ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) 6E2-13 ON-VEHICLE SER VICE ACCELERA TOR CABLE ADJUSTMENT 1) With throttle valve closed, check accelerator pedal play which should be within following specification. Pedal play “ a ” : 2 – 7 mm (0.
6E2-14 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) IDLE SPEED / IDLE AIR CONTROL (IAC) DUTY INSPECTION Before idle speed / IAC duty check, make sure of the following. D Lead wires and hoses of Electronic Fuel Injection and engine emission control systems are connected securely .
ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) 6E2-15 CAUTION: Do not disassemble IAC valve. Disassembly spoils its original performance CAUTION: Do not remove or adjust throttle stop screw as it is factory adjusted precisely 1. Throttle body 2. Throttle stop screw 3.
6E2-16 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) 1 2 5) Disconnect electric coupler from TP sensor (2) and IAC valve (3). 6) Remove throttle body from intake manifold.
2 1 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) 6E2-17 2) Connect engine coolant hoses (1). 3) Install throttle body (4) to intake manifold. 4) Connect coupler to TP sensor (2) and IAC valve (3) securely . 5) Install air cleaner outlet hose (1) and pipe.
3. Fuel return pipe 6E2-18 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) Installation 1) Install new O-ring (2) to IAC valve (1). 2) Install IAC valve (1) to throttle body (3). T ighten IAC valve screws to specified torque. Tightening T orque (a): 3.
270 – 310 kPa 2.7 – 3.1 kg / cm 2 38.4 – 44.0 psi At specified idle speed With 1 min. after engine (fuel pump) stop (Pressure re- duces as time passes) over 200 kPa 2.0 kg / cm 2 28.4 psi CONDITION FUEL PRESSURE With fuel pump operating and engine stopped 200 – 240 kPa 2.
6E2-20 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) [Using SUZUKI scan tool] a) Connect SUZUKI scan tool to DLC with ignition switch OFF . b) T urn ignition switch ON and then select “ DA T A LIST ” mode on scan tool. c) Make sure that vehicle condition is as following.
1. Fuel filler 2. Ignition switch ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) 6E2-21 FUEL PUMP On-V ehicle Inspection CAUTION: When fuel filler cap is removed in any procedure, work must be done in a well-ventilated area, keep away from any open flames and without smoking.
6E2-22 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) FUEL PRESSURE REGULA TOR Removal 1) Relieve fuel pressure according to procedure described in sec- tion 6. 2) Disconnect battery negative cable at battery . 3) Disconnect vacuum hose (3) from fuel pressure regulator (1).
ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) 6E2-23 FUEL INJECTOR On-V ehicle Inspection 1) Using sound scope (1) or such, check operating sound of injec- tor (2) when engine is running or cranking. Cycle of operating sound should vary according to engine speed.
6E2-24 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) Inspection W ARNING: As fuel is injected in this inspection, perform in a well venti- lated area and away from open flames. Use special care to prevent sparking when connecting and disconnecting test lead to and from battery .
When not using SUZUKI scan tool : When using SUZUKI scan tool : 4. Keep as far apart as possible ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) 6E2-25 4) Install suitable vinyl tube onto injector nozzle to prevent fuel from splashing out when injecting.
6E2-26 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) Installation For installation, reverse removal procedure and note following pre- cautions. D Replace injector O-ring (1) with new one using care not to dam- age it. D Check if cushion (2) is scored or damaged.
ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) 6E2-27 ELECTRONIC CONTROL SYSTEM ENGINE CONTROL MODULE (POWERTRAIN CONTROL MODULE) [ECM (PCM)] CAUTION: As ECM (PCM) consists of precision parts, be careful not to expose it to excessive shock. Removal 1) Disconnect battery negative cable at battery .
1 2 3 1. Ground terminal 2. Reference voltage terminal 3. Output voltage terminal (a) 1 2 3 4 6E2-28 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) THROTTLE POSITION SENSOR (TP SENSOR) Inspection 1) Disconnect negative cable at battery and coupler from TP sen- sor .
ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) 6E2-29 INT AKE AIR TEMPERA TURE SENSOR (IA T SENSOR) Removal 1) Disconnect battery negative cable at battery . 2) Disconnect coupler from IA T sensor (1). 3) Remove IA T sensor (1) from air cleaner outlet hose (2).
2.297 – 2.595 0.298 – 0.320 6E2-30 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) ENGINE COOLANT TEMPERA TURE SENSOR (ECT SENSOR) Removal 1) Disconnect battery negative cable at battery .
ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) 6E2-31 1. Viewed from terminal side Sensor-1 Sensor-2 “ V B ” “ GND ” HEA TED OXYGEN SENSOR (Sensor-1 and Sensor-2) Oxygen Sensor Heater Inspection 1) Disconnect sensor coupler . 2) Using ohmmeter , measure resistance between terminals “ V B ” and “ GND ” of sensor coupler .
(a) 6E2-32 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) CAMSHAFT POSITION SENSOR Inspection Check camshaft position sensor referring to DTC P0340 Dia g. Fl ow T able in Section 6. If malfunction is found, replace. Removal 1) Disconnect negative cable at battery .
ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) 6E2-33 VEHICLE SPEED SENSOR (VSS) Inspection Check vehicle speed sensor referring to step 3 of DTC P0500 Flow T able. If malfunction is found, replace. Removal / Installation Refer to Section 7A. FUEL LEVEL SENSOR (GAUGE) Inspection Refer to Section 8.
6E2-34 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) FUEL CUT OPERA TION Inspection NOTE: Before inspection, check to make sure that gear shift lever is in neutral position (with A / T model, selector lever in “ P ” range), A / C is OFF and that parking brake lever is pulled all the way up.
1 2 1. SUZUKI scan tool display 2. EGR valve opening (0: Close, 100: Full Open) ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) 6E2-35 2) Connect battery (1) to radiator fan motor coupler (2) as shown in figure, then check that the radiator fan motor operates smoothly .
6E2-36 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) 1. EGR valve 2. Connector 1 2 1. EGR valve 2. V alve 3. V alve seat 3 Inspection 1) Check resistance between following terminals of EGR valve in each pair . T erminal Standard resistance A – B C – B F – E D – E 20 – 24 Ω If found faulty , replace EGR valve assy .
ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) 6E2-37 1) Disconnect purge hose (1) from EV AP canister . 2) Place finger against the end of disconnected hose and check that vacuum is not felt there when engine is cool and running at idle speed. 3) Connect purge hose to EV AP canister and warm up engine to normal operating temperature.
6E2-38 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) EV AP Canister Inspection W ARNING: DO NOT SUCK nozzles on EV AP canister . Fuel vapor inside EV AP canister is harmful. 1) Check outside of EV AP canister visually . 2) Disconnect vacuum hoses from EV AP canister .
ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) 6E2-39 09930-88530 Injector test lead 09931-7601 1 SUZUKI scan tool (T ech 1A) kit Mass storage cartridge 09931-76030 16 / 14 pin DLC cable 1. Pressure gauge 09912-58441 2. Pressure hose 09912-58431 3. 3-way joint & hose 09912-58490 4.
6F IGNITION SYSTEM 6F-1 GENERAL DESCRIPTION 6F- 1 . . . . . . . . . . . . . . DIAGNOSIS 6F- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . ON-VEHICLE SERVICE 6F- 5 . . . . . . . . . . . . . . . . Ignition Spark T est 6F- 5 . . . . . . . . . .
1. Battery 2. Main fuse 3. Ignition switch 4. Main relay 5. Ignition coil 6. Igniter 7. Noise suppressor 8. Distributor 9. Rotor 10. Signal rotor 1 1. Pick up coil 12.
IGNITION SYSTEM 6F-3 DIAGNOSIS Condition Possible Cause Correction Engine cranks, but will not start or hard to start D Blown fuse for ignition coil D Loose connection or disconnection of lead wire or.
6F-4 IGNITION SYSTEM STEP ACTION YES NO 6 Ignition Coil Power Supply and Ground Circuit Check 1) Check ignition coil power supply ( “ B/W ” wire) circuit for open and short.
1. Injector coupler 2. Throttle body 3. Air cleaner case 4. Cylinder head cover 1. High-tension code 2. Cap 1. High-tension cord 2. Ohmmeter IGNITION SYSTEM 6F-5 ON-VEHICLE SER VICE IGNITION SP ARK TEST 1) Disconnect injector coupler at throttle body side.
6F-6 IGNITION SYSTEM 6) If resistance exceeds specification, inspect distributor terminal and replace high-tension cord(s) and/or distributor cap as re- quired. CAUTION: D Never attempt to use metal conductor high-tension cords as replacing parts. D Insert each cap portion fully when installing high-tension cords.
PRIMAR Y SECONDARY 1. Ohmmeter IGNITION SYSTEM 6F-7 IGNITION COIL 1) Pull out high-tension cord by gripping its cap. 2) Disconnect ignition coil coupler . 3) Measure primary and secondary coil resistances. Ignition coil resistance (at 20 _ C, 68 _ F) Primary : 0.
1. Pickup coil 2. Signal rotor 3. Screws 1. Distributor 2. Coupler 3. Ohmmeter 6F-8 IGNITION SYSTEM DISTRIBUTOR DISTRIBUTOR CAP AND ROT OR INSPECTION Check cap and rotor for crack and their terminals for corrosion and wear . Replace as necessary . SIGNAL ROTOR AIR GAP INSPECTION 1) Remove distributor cap and rotor .
1. Crankshaft pulley 2. W ater pump pulley A: T o be advanced B: T o be retarded 1. Distributor flange bolt 2. Distributor IGNITION SYSTEM 6F-9 IGNITION TIMING NOTE: Before starting engine, place transmission gear shift lever in “ Neutral ” (shift selector lever to “ P ” range for A/T model), and set parking brake.
1. Cap 2. Cap seal 3. Cap screw 4. Rotor 5. CMP sensor (Signal generator) 6. Screw 7. Cover 8. Housing 9. O-ring A: Slot offset 1. Distributor case 2. O-ring 3. Distributor coupling 4. Camshaft 6F-10 IGNITION SYSTEM DISTRIBUTOR UNIT DISMOUNTING 1) Disconnect distributor lead coupler .
IGNITION SYSTEM 6F-1 1 09913-7601 1 SUZUKI scan tool (T ech 1A) kit Mass storage cartridge 09931-76030 16 / 14 pin DLC cable 09930-76420 T iming light (Dry cell type) 1. Storage case 2. Operator ’ s manual 3. T ech 1A 4. DLC cable (14/26 pin, 09931-76040) 5.
IGNITION SYSTEM (TBI FOR G13) 6F-1 SECTION 6F IGNITION SYSTEM (TBI FOR G13) NOTE: For the details of this section, refer to the same section of the Service manual mentioned in the FORE- WORD of this manual.
6F1 IGNITION SYSTEM (SFI FOR G13) 6F1-1 GENERAL DESCRIPTION 6F1-2 . . . . . . . . . . . . . . DIAGNOSIS 6F1-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . ON-VEHICLE SERVICE 6F1-5 . . . . . . . . . . . . . . . . Ignition Spark T est 6F1-5 . .
1. ECM (PCM) 2. Ignition coil assembly for No.1 and No.4 spark plugs 3. Ignition coil assembly for No.2 and No.3 spark plugs 4. CMP sensor 5. CKP sensor 6. MAP sensor 7. ECT sensor 8. IA T sensor 9. TP sensor 10. VSS (A / T) 1 1. T ransmission range switch (A / T) 12.
1. Ignition switch 2. Main relay 3. Ignition coil assembly for No.1 and No.4 spark plugs 4. Ignition coil assembly for No.2 and No.3 spark plugs 5. CMP sensor 6. CKP sensor 7. No.1 spark plug 8. No.2 spark plug 9. No.3 spark plug 10. No.4 spark plug 1 1.
6F1-4 IGNITION SYSTEM (SFI FOR G13) IGNITION SYSTEM DIAGNOSTIC FLOW T ABLE STEP ACTION YES NO 1 W as “ENGINE DIAG. FLOW T ABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW T ABLE” in section 6. 2 Ignition Spark T est 1) Check all spark plugs for condition and type referring to “Spark Plugs” section.
IGNITION SYSTEM (SFI FOR G13) 6F1-5 ON-VEHICLE SER VICE IGNITION SP ARK TEST 1) Disconnect all injector couplers (1) from injectors (2). W ARNING: Without disconnection of injector couplers, combustible gas may come out from spark plug holes during this test and may get ignited in engine room.
“ a ” 6F1-6 IGNITION SYSTEM (SFI FOR G13) 5) Install high-tension cords (1) to spark plugs and ignition coil as- semblies (2) while gripping each cap. CAUTION: D Never attempt to use metal conductor high-tension cords as replacing parts. D Insert each cap portion fully when installing high-ten- sion cords.
IGNITION SYSTEM (SFI FOR G13) 6F1-7 5) Measure secondary coil for resistance. Secondary coil resistance : 7.6 – 10.2 k Ω at 20 _ C, 68 _ F If resistance is out of specification, replace ignition coil assem- bly . 6) Install ignition coil assembly .
6F1-8 IGNITION SYSTEM (SFI FOR G13) 5) Fix ignition timing to initial one as follow . Select “ MISC ” mode on SUZUKI scan tool and fix ignition tim- ing to initial one. 6) Detach air cleaner case and shift air cleaner case and hose position to observe ignition timing.
09931-7601 1 SUZUKI scan tool (T ech 1A) kit 1. Storage case 2. Operator ’ s manual 3. T ech 1A 4. DLC cable (14 / 26 pin, 09931-76040) 5. T est lead / probe 6.
6K 1. Exhaust manifold 2. Seal 3. WU-TWC 4. Exhaust pipe 5. Muffler 6. Muffler mounting 7. Gasket 8. Heated oxygen sensor : T ightening T orque : Do not reuse [For 1.
[For 1.0 ȏ 2WD N / B model] [For 1.3 ȏ 2WD H / B model] : Do not reuse : T ightening T orque 6. Exhaust No.2 pipe 7. Gasket 8. Muffler 9. Muffler mounting 10. Heated oxygen sensor 1 1. Exhaust center pipe 1. Exhaust manifold 2. Seal 3. WU-TWC 4. Exhaust pipe 5.
: Do not reuse : T ightening T orque 1. Exhaust manifold 2. Seal 3. Exhaust No.1 pipe 4. Exhaust No.2 pipe 5. Gasket 6. Exhaust center pipe 7. Muffler 8. Muffler mounting 9. Heated oxygen sensor [For 1.3 ȏ 4WD model] [For 1.3 ȏ 2WD N / B model] 45 N .
7B AUTOMA TIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) 7B-1 GENERAL DESCRIPTION 7B- 3 . . . . . . . . . . . . . . Electronic Shift Control System 7B- 5 . . . . . . . . . DIAGNOSIS 7B-1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . On-board diagnostic system 7B-1 1 .
7B-2 AUTOMA TIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) T able B-1 Gear Shift Failure in “ D ” or “ 2 ” Range 7B-38 . . . . . . . . . . . . . . . . . . . . . . . . . . T able B-2 Gear is Shifted to 2nd Gear in “ L ” Range V ehicle Does Not Move Backward in “ R ” Range 7B-38 .
1. Final gear 2. Differential gear assembly 3. Counter shaft 4. 1st and reverse brake 5. Counter driven gear 1 1. Forward clutch 12. Direct clutch 13. Input shaft 14. T orque converter 15. Oil pump 6. Output shaft 7. Rear planetary gear 8. Front planetary gear 9.
7B-4 AUTOMA TIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) COMPONENTS OPERA TION CHART Range Gear Forward Clutch Direct Clutch Second Brake 1st & Reverse Brake One-way Clutch Parking Lock Pawl P.
[G10 Engine Model] 1. PCM 2. Camshaft position (CMP) sensor 3. Throttle position (TP) sensor 4. Engine coolant temperature (ECT) sensor 5. T ransmission range sensor (shift switch) 6. Output shaft speed sensor (A / T VSS) 7. Malfunction indicator lamp (MIL) 8.
7B-6 AUTOMA TIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) [G13 Engine Model] 1. PCM 2. Camshaft position (CMP) sensor 3. Throttle position (TP) sensor 4. Engine coolant temperature (ECT) sensor 5. T ransmission range sensor (shift switch) 6. Output shaft speed sensor (A / T VSS) 7.
1. PCM 2. Instrument panel TP sensor T ransmission range sensor Output shaft speed sensor (A / T VSS) Shift solenoid-B (2nd brake solenoid valve) Shift solenoid-A (Direct clutch solenoid valve) PCM 1. Throttle position sensor 2. Throttle body A: Ground 3.
1. T ransmission range sensor 2. Select cable 1. T ransmission 2. Shift solenoid-B (No.2, 2nd brake solenoid valve) 3. Shift solenoid-A (No.1, direct clutch solenoid valve) 4.
1. Countershaft gear 2. Output shaft speed sensor A: Magnetic core end D or 2 1 → 2 18 11 52 33 D 2 → 3 33 21 97 61 3 → 2 14 9 82 51 D or 2 2 → 1 14 9 37 23 L 2 → 1 37 23 37 23 Full close Fu.
7B-10 AUTOMA TIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) D or 2 1 → 2 18 11 58 36 D 2 → 3 30 19 11 0 69 3 → 2 14 9 97 61 D or 2 2 → 1 14 9 40 25 L 2 → 1 40 25 40 25 Full close Full open.
1. Malfunction indicator lamp (MIL) 2. Data link connector (DLC) 3. SUZUKI scan tool (T ech-1) AUTOMA TIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) 7B-1 1 DIAGNOSIS This vehicle is equipped with an electronic transmission control system, which control the automatic shift up and shift down timing, etc.
7B-12 AUTOMA TIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) PRECAUTION IN DIAGNOSING TROUBLE D Don ’ t disconnect couplers from PCM, battery cable from battery , PMC ground wire harness from engine or main fuse before checking the diagnosis information (DTC, freeze frame data, etc.
AUTOMA TIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) 7B-13 AUT OMA TIC TRANSMISSION DIAGNOSTIC FLOW T ABLE Refer to the following pages for the details of each step. STEP ACTION YES NO 1 Customer Complaint Analysis 1) Perform customer complaint analysis referring to the next page.
7B-14 AUTOMA TIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) 1. CUSTOMER COMPLAINT ANAL YSIS Record details of the problem (failure, complaint) and how it occurred as described by the customer .
AUTOMA TIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) 7B-15 CUSTOMER PROBLEM INSPECTION FORM (EXAMPLE) User name: Model: VIN: Date of issue: Date Reg.
1. Malfunction indicator lamp (MIL) 1. Data link connector (DLC) 1. Data link connector (DLC) 7B-16 AUTOMA TIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) MALFUNCTION INDICA TOR LAMP (MIL) CHECK Refer to the same item in Section 6 or 6-1 for checking procedure.
AUTOMA TIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) 7B-17 DIAGNOSTIC TROUBLE CODE (DTC) T ABLE DTC NO. DETECTING ITEM DETECTING CONDITION (DTC will set when detecting:) MIL P0705 T ransmission range sensor No signal or multiple signals inputted with shifted in 1 driving P0705 g circuit malfunction gg “ D ” range.
7B-18 AUTOMA TIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) VISUAL INSPECTION Visually check following parts and systems. INSPECTION ITEM REFERRING SECTION D A / T fluid – – – – – level, l.
AUTOMA TIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) 7B-19 Fig. 1 for Step 5. Fig. 2 for Step 5. Fig. 3 for Step 5. When not using SUZUKI scan tool: lever position T erminal Selector AUT OMA TIC TR.
7B-20 AUTOMA TIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) SYMPTOM-T O-INSPECTION T ABLE SYMPT OM APPLICABLE DIAGNOSTIC FLOW T ABLE. OR CHECK (DESCRIBED IN THIS SECTION) No starting or slipping in .
*1: For G10 engine model *2: For G13 engine model 1. PCM 2. T ransmission range sensor 3. From ignition switch 4. Shift indicator 5. Backup lamp 6. T erminal arrangement of PCM coupler (Viewed from ha.
7B-22 AUTOMA TIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) Fig. 1 for Step 2. Fig. 2 for Step 2. Fig. 3 for Step 2. When not using SUZUKI scan tool: l ever position T erminal Selector TROUBLESHOOTING STEP ACTION YES NO 1 Wa s “ AUTOMA TIC TRANSMISSION DIAGNOSTIC FLOW T ABLE ” performed? Go to Step 2.
AUTOMA TIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) 7B-23 Fig. 4 for Step 4. Fig. 5 for Step 4. Range T erminal 6 5 1 8 2 3 4 9 10 P P R N N D 2 L.
Counter shaft gear *1: For G10 engine model *2: For G13 engine model 1. PCM 2. Output shaft speed sensor 3. T erminal arrangement of PCM coupler (Viewed from harness side) 7B-24 AUTOMA TIC TRANSMISSIO.
AUTOMA TIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) 7B-25 Fig. 1 for Step 2. Fig. 2 for Step 3. Fig. 3 for Step 3. TROUBLESHOOTING STEP ACTION YES NO 1 W as “ AUTOMA TIC TRANSMISSION DIAGNOSTIC FLOW T ABLE ” performed? Go to Step 2. Go to ” AUTOMA TIC TRANSMISSION DIAGNOSTIC FLOW T ABLE ” .
1. PCM 2. Shift solenoid-A (No.1, Direct clutch solenoid) 3. Shift solenoid-B (No.2, 2nd brake solenoid) 4. T erminal arrangement of PCM coupler (Viewed from harness side) *1: For G10 engine model *2: For G13 engine model 7B-26 AUTOMA TIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) DTC P0753 SHIFT SOLENOID-A (NO.
AUTOMA TIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) 7B-27 Fig. 1 for Step 2. Fig. 2 for Step 2. Fig. 3 for Step 3. When using SUZUKI scan tool: When not using SUZUKI scan tool: T erminal for solen.
ACCEPT ABLE RANGE 1st gear (solenoids ON and ON) 2nd gear (solenoids ON and OFF) 3rd gear (solenoids OFF and OFF) V ehicle speed Engine speed 7B-28 AUTOMA TIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) DTC P0751 SHIFT SOLENOID-A (No.1) PERFORMANCE OR STUCK OFF DTC P0756 SHIFT SOLENOID-B (No.
AUTOMA TIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) 7B-29 TROUBLESHOOTING STEP ACTION YES NO 1 Was “ AUTOMA TIC TRANSMISSION DIAGNOSTIC FLOW T ABLE ” performed? Go to Step 2. Go to “ AUTOMA TIC TRANSMISSION DIAGNOSTIC FLOW T ABLE ” . 2 Is DTC other than shift malfunction (DTC P0751 / P0756) displayed? Go to applicable DTC Flow T able.
7B-30 AUTOMA TIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) T ABLE A-1 NO ST ARTING OR SLIPPING IN ANY DRIVE RANGE STEP ACTION YES NO 1 Was “ AUTOMA TIC TRANSMISSION DIAGNOSTIC FLOW T ABLE ” performed? Go to Step 2. Go to “ AUTOMA TIC TRANSMISSION DIAGNOSTIC FLOW T ABLE ” .
AUTOMA TIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) 7B-31 T ABLE A-2 GEAR CHANGE F AILURE STEP ACTION YES NO 1 Was “ AUTOMA TIC TRANSMISSION DIAGNOSTIC FLOW T ABLE ” performed? Go to Step 2. Go to “ AUTOMA TIC TRANSMISSION DIAGNOSTIC FLOW T ABLE ” .
7B-32 AUTOMA TIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) ST ALL TEST This test is to check overall performance of automatic transmission and engine by measuring stall speed at D and R ranges.
1. Front drive shaft (LH) 2. Oil pan AUTOMA TIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) 7B-33 LINE PRESSURE TEST This test is to check oil pressure system for operation by measuring oil pressure in oil pressure line. Make sure to perform this test only when transmission fluid is at normal operating temperature.
1. Drive shaft (LH) 2. Oil pan 7B-34 AUTOMA TIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) 9) Possible causes for out-of-specification line pressure are as follows.
AUTOMA TIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) 7B-35 ROAD TEST This test is to check if upshift and downshift take place at specified speeds while actually driving vehicle on a level road. W ARNING: D Carry out the test in very little traffic area to prevent an ac- cident.
1. Solenoid valve wire coupler (Disconnected) 2. T ransmission 7B-36 AUTOMA TIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) MANUAL ROAD TEST This test checks the gears being used in L, 2 or D range when driven with unoperated gear shift control system.
WITHOUT BA TTER Y VOL T AGE WITH BA TTER Y VOL T AGE 1. Oiler (with transmission fluid) 2. Solenoid valve 3. 12V battery “ A ” : Side hole (Should be dry) “ B ” : Exhausting fluid AUTOMA TIC T.
7B-38 AUTOMA TIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) T ABLE B-1 GEAR SHIFT F AILURE IN “ D ” OR “ 2 ” RANGE STEP ACTION YES NO 1 Was “ T ABLE A-2 GEAR CHANGE F AILURE ” performed? Go to Step 2. Go to “ T ABLE A-2 ” . 2 Is gear no shift at all? Go to Step 3.
1. PCM coupler disconnected AUTOMA TIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) 7B-39 TRANSMISSION RANGE SENSOR CHECK Check transmission range sensor referring to Step 2 of DTC P0705 Flow T able. OUTPUT SHAFT SPEED SENSOR CHECK 1) T urn OFF ignition switch.
1. Output shaft speed sensor 1. PCM coupler disconnected 7B-40 AUTOMA TIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) Separately from the above inspection, output shaft speed sensor itself can be checked on its resistance by disconnecting coupler .
1. Solenoid valve wire coupler 2. T erminal for shift solenoid-A. (direct clutch solenoid) 3. T erminal for shift solenoid-B. (2nd brake solenoid) 4. 12 V battery 5.
7B-42 AUTOMA TIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) TIGHTENING T ORQUE SPECIFICA TIONS Refer to the same section of the service manual mentioned in the “ FOREWORD ” of this manual. SPECIAL T OOLS Refer to the same section of the service manual mentioned in the “ FOREWORD ” of this manual.
8 BODY ELECTRICAL SYSTEM 8-1 SECTION 8 BODY ELECTRICAL SYSTEM W ARNING: For vehicles equipped with Supplemental Restraint (Air Bag) System: D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer .
NOTE: T erminal arrangement of coupler viewed from harness side. Coupler A 1. T o generator W / R 2. T o ignition switch B / W 3. T o ECM V / G 4. T o ECM V 5. Blank – 6. T o ECT sensor Y / W 7. Blank — 8. T o engine oil pressure switch Y / B 9. T o ECM Br 10.
TYPE 1 TYPE 2 BODY ELECTRICAL SYSTEM 8-3 KEYLESS ENTR Y SYSTEM (IF EQUIPPED) The keyless entry system uses radio wave. When the button on the transmitter is pressed, a signal is transmitted in the form of radio wave to the receiver . Then the signal causes the door lock controller to lock and unlock the door .
1. Slot 1. T o power door lock controller (Unlock) 2. T o power door lock controller (Lock) 3. T o IG switch 5. T o door switch 6. T o GND 8. T o battery 8-4 BODY ELECTRICAL SYSTEM KEYLESS ENTR Y SYSTEM (IF EQUIPPED) TRANSMITTER REPLACEMENT OF THE BA TTERY If the transmitter becomes unreliable, replace the battery .
BODY ELECTRICAL SYSTEM 8-5 CODE REGISTRA TION PROCEDURE 1) Start of code registration (Initial conditions: IG switch OFF , all doors closed) 2) Open the door and then turn ON the IG switch within 10 seconds. 3) T urn OFF the IG switch within 10 seconds after it is turned ON.
8G IMMOBILIZER CONTROL SYSTEM 8G-1 GENERAL DESCRIPTION 8G- 2 . . . . . . . . . . . . . . On-Board Diagnostic System (Self-Diagnosis Function) 8G- 4 . . . . . . . . . . . . . DIAGNOSIS 8G- 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . Precautions in Diagnosing T roubles 8G- 6 .
Ignition key T ransponder code Immobilizer Control Module ECM (1) (2) (3) (4) 1. Coil antenna 2. Immobilizer Control Module 3. Engine Control Module (ECM) 4. Ignition key 8G-2 IMMOBILIZER CONTROL SYSTEM GENERAL DESCRIPTION The immobilizer control system designed to prevent vehicle burglar consists of following components.
IMMOBILIZER CONTROL SYSTEM 8G-3 V ehicle without monitor coupler 1. Coil antenna 2. Immobilizer Control Module 3-1. ECM (G10 engine) 3-2. ECM (G13 engine without monitor coupler) 3-3. ECM (G13 engine with monitor coupler) 4. Immobilizer diagnostic coupler 4-1.
0.5 TIME (sec.) Ignition switch ON High Immobilizer control system is normal Immobilizer control system is abnormal Low 0.5 0.5 0.5 0.5 High Low 8G-4 IMMOBILIZER CONTROL SYSTEM ON-BOARD DIAGNOSTIC SYS.
IMMOBILIZER CONTROL SYSTEM 8G-5 0.5 TIME (sec.) Ignition switch ON High Immobilizer control system is normal Immobilizer control system is abnormal Low 0.
8G-6 IMMOBILIZER CONTROL SYSTEM DIAGNOSIS ECM and Immobilizer Control Module have on-board diagnostic system (a system self-diagnosis function) as described previously . Investigate where the trouble is by referring to “ DIAGNOSTIC FLOW T ABLE ” and “ DIAGNOSTIC TROUBLE CODE T ABLE ” on later pages.
IMMOBILIZER CONTROL SYSTEM 8G-7 [INTERMITTENT TROUBLES] <V ehicle equipped with monitor coupler> D There are cases where output of diagnostic output terminal and / or malfunction indicator lamp indicate a diagnostic trouble code representing a trouble which occurred only temporarily and has gone.
8G-8 IMMOBILIZER CONTROL SYSTEM Fig. 1 for Step 1 Fig. 2 for Step 1 Fig. 3 for Step 2 1. Monitor coupler 2. Service wire A: Diagnosis switch terminal B: Ground terminal Fig.
IMMOBILIZER CONTROL SYSTEM 8G-9 <V ehicle not equipped with monitor coupler> STEP ACTION YES NO 1 1) Check immobilizer indicator lamp while ignition switch is ON (but without starting engine). See Fig. 1. Dose immobilizer indicator lamp flash? Go to Step 3.
8G-10 IMMOBILIZER CONTROL SYSTEM 1. Immobilizer diagnostic coupler EXAMPLE : D COIL ANTENNA F AILURE (CODE NO.13) V oltmeter indicator D NORMAL (No code) V oltmeter indicator TIME (sec.) TIME (sec.) CODE No. 13 CODE No. 13 CODE No. 13 High Low High Low 1.
IMMOBILIZER CONTROL SYSTEM 8G-1 1 EXAMPLE: When serial data link wire is defective (Code No.83) ON OFF Malfunction indicator lamp Code No.83 Code No.83 Code No.83 T ime (sec.) 1. Data link connector (DLC) 3) After completing the check, turn ignition switch OFF and discon- nect service wire from monitor coupler .
8G-12 IMMOBILIZER CONTROL SYSTEM EXAMPLE: D COIL ANTENNA F AILURE (CODE NO.13) EXAMPLE: D NORMAL V oltmeter Indicator V oltmeter Indicator High Low High Low CODE No. 13 CODE No. 13 CODE No. 13 DIAGNOSTIC TROUBLE CODE T ABLE Immobilizer Control Module DIAGNOSTIC TROUBLE CODE DIAGNOSTIC AREA DIAGNOSIS NO.
3 T o ECM A5 A7 A3 1. Main fuse 2. Main relay 3. Immobilizer Control Module 4. Immobilizer diagnostic coupler 4-1. Diagnostic output terminal 4-2. Ground terminal In cabin Check voltage between A3 terminal and body ground with ignition switch turned ON.
8G-14 IMMOBILIZER CONTROL SYSTEM 1. Main fuse 2. Main relay 3. ECM 4. Immobilizer indicator lamp (V ehicle not equipped with monitor coupler) For G10 engine For G13B engine For G10 engine For G13B eng.
1. Main fuse 2. Main relay 3. ECM 4. Immobilizer indicator lamp (V ehicle not equipped with monitor coupler) For G10 engine For G13B engine For G10 engine For G13B engine IMMOBILIZER CONTROL SYSTEM 8G.
1 1. Ignition key with built-in transponder 1. Data link connector (DLC) 8G-16 IMMOBILIZER CONTROL SYSTEM HOW T O REGISTER IGNITION KEY Register the ignition key with a built-in transponder in Immobilizer Control Module by using the following procedure.
IMMOBILIZER CONTROL SYSTEM 8G-17 7) If any other T ransponder code for ignition key with a built-in transponder needs to be registered, repeat above Steps 3), 5) and 6). NOTE: D Up to 4 T ransponder codes for ignition key with a built-in transponder can be registered.
8G-18 IMMOBILIZER CONTROL SYSTEM 09931-76030 16 / 14 pin DLC cable 09931-7601 1 Suzuki scan tool (T ech 1A kit) 1. Storage case 2. Operator ’ s manual 3. T ech 1A 4. DLC cable (14 / 26 pin, 09931-76040) 5. T est lead / probe 6. Power source cable 7.
Prepared by Overseas Service Department 1st Ed. July , 2000 Printed in Japan Printing: 556.
Un punto importante, dopo l’acquisto del dispositivo (o anche prima di acquisto) è quello di leggere il manuale. Dobbiamo farlo per diversi motivi semplici:
Se non hai ancora comprato il Suzuki Swift (2000) è un buon momento per familiarizzare con i dati di base del prodotto. Prime consultare le pagine iniziali del manuale d’uso, che si trova al di sopra. Dovresti trovare lì i dati tecnici più importanti del Suzuki Swift (2000) - in questo modo è possibile verificare se l’apparecchio soddisfa le tue esigenze. Esplorando le pagine segenti del manuali d’uso Suzuki Swift (2000) imparerai tutte le caratteristiche del prodotto e le informazioni sul suo funzionamento. Le informazioni sul Suzuki Swift (2000) ti aiuteranno sicuramente a prendere una decisione relativa all’acquisto.
In una situazione in cui hai già il Suzuki Swift (2000), ma non hai ancora letto il manuale d’uso, dovresti farlo per le ragioni sopra descritte. Saprai quindi se hai correttamente usato le funzioni disponibili, e se hai commesso errori che possono ridurre la durata di vita del Suzuki Swift (2000).
Tuttavia, uno dei ruoli più importanti per l’utente svolti dal manuale d’uso è quello di aiutare a risolvere i problemi con il Suzuki Swift (2000). Quasi sempre, ci troverai Troubleshooting, cioè i guasti più frequenti e malfunzionamenti del dispositivo Suzuki Swift (2000) insieme con le istruzioni su come risolverli. Anche se non si riesci a risolvere il problema, il manuale d’uso ti mostrerà il percorso di ulteriori procedimenti – il contatto con il centro servizio clienti o il servizio più vicino.
