Suzuki Swift (2000) manual

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. NOTE: Indicates special information to make mainte- nance easier or instruction[...]

() 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. Applicable model: SF310 / SF413 of and after the vehicle identification [...]

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.e., the latest one). If desired section, item or description is not found in it, try next one in the list and do the same one by one till what is being searched is f[...]

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 Heater and V entilation Air Conditioning (Oprional) ENGINE General Information and Diagnosis (TBI for G10) General Information and Diagnosis (TBI for[...]

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. Special T ool (A): 09924-17810 Tightening T orque (c): 78 [...]

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. When it is necessary to service (remove, re[...]

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. 0A-4 GENERAL INFORMA TION HANDLING AND SERVICING W ARNING: D Many of [...]

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. D When servicing parts other than air bag system, if shocks may be applied to a[...]

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 . W ARNING: D W[...]

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 . D When removing parts that are to be reused, be sure to keep them arranged in an orderl[...]

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. D For vehicles equipped with fuel injection systems, never[...]

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 a catalytic converter , use only un- leaded gasoline and be careful not to let a large amount of un- burned gasoline enter the converter or it can be[...]

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). D When installing the wiring harness, fix it wit[...]

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.). The static electricity from your body can damage these parts. D Never connect any tester (voltmeter , ohmmeter , or whatever) to electronic control unit when its c[...]

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. D Before measuring voltage to check for electrical system, check to make sure that battery voltage is 1 1 V or higher [...]

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. Check each terminal visually for poor contact (possibly caused b[...]

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. 5 V B-1 and body ground: Approx. 5 V A-1 and body ground: 0 V[...]

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. When checking it for proper conne[...]

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. D Keep the antenna as far away as p[...]

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 front wheels which are jacked up 4WD 2WD GENERAL INFORMA TION 0A-17 PRECAUTION IN SERVICING FULL-TIME 4WD VEHICLE When performing any of the following ty[...]

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). [A]: V ehicle equipped [...]

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 Emission control information label (if equipped) A / C warning label (if equipped with A / C) Engine cooling fan warning label Air bag warning label on drive[...]

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 (4.7 in.) SUPPORT LOCA TION Rearward of embossed-mark : Support position for frame contact hois[...]

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.e., stabilizer , etc.) or vehicle floor , or it may get deformed. D If the ve[...]

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 : Alternating Current A / T : Automatic T ransmission A / C : Air Conditioning ABDC : After Bottom Dead Center A / F : Air Fuel Mixture Ratio A-ELR : Au[...]

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 Pressure Sensor (Pressure Sensor , PS) Max : Maximum MFI : Multiport Fuel Injection (Multipoint Fuel Injection) Min : Minimum MIL : Malfunction Indicato[...]

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. 1216 99000-31 160 Apply oil (Engine, transmission, transfer , differential) Apply SILICONE SEALANT 99000-31 120 Apply fluid (Brake, power steering or automatic transmission fluid) Apply SEALI[...]

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. When replacing any fasteners, it is most important tha[...]

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 . When a fastener of greater strength than the or[...]

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 . Refer to “Air Bag System Components and Wiring Location V iew” under [...]

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 . jg y odometer reading or months, Km ( 1,0[...]

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 . This interval should be judged by odometer reading or months, Km ( 1,000) 15 30 45 60 75[...]

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 . Severe condition code A ?[...]

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. Crankshaft pulley MAINTENANCE AND LUBRICA TION 0B-5 MAINTENANCE SER VICE ENGINE ITEM 1-1 Drive Belt Inspection and Replacement W ARNING: Disconnect negative cable at battery before checking[...]

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 (0.20 – 0.27 in.). ITEM 1-2 Camshaft Timing Belt Replacement Replace belt with new one. Refer t[...]

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. Use engine oil of SE, SF , SG, SH or SJ gra[...]

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.) About 3.6 liters (7.5 / 6.3 US / lmp pt.) 0B-8 MAINTENANCE AND LUBRICA TION 7) Replenish oil unt[...]

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. 4) T ighten drain plug securely . Also install reservoir . 5) Slowly pour specified amount of coolant to the base of radiator filler neck, and run engine, with radiator [...]

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. D Clean dusty and stained parts using a dry , soft cloth. D Check center electrode and t[...]

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. 5) Clamp case cap securely and install hose to case and bracket if removed. Air C[...]

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. ITEM 4-2 Fuel Evaporative Em[...]

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. Replace any of these parts as necessary . D Check all clamps for [...]

“ 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 . If any damage or wear is found, replace parkin[...]

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. Fo[...]

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. Repair or replace defective parts, if any . D Check [...]

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. 3) Remove oil level plug of transmission. 4)[...]

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. Repair leaky point, if any . 2) Make sure that vehicle is placed level for fluid level check. 3)[...]

“ 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. If any malfunction is found, lubricate hinge and latch or repair door lock system[...]

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 . If “ REPLACE B[...]

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. D Check that the v[...]

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 . . . . . Fuel Pressure Relief Procedure 6- 5 . . . . . . . . Fuel Leakage Check Procedure 6- 5 . .[...]

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 . . . . . . . . . . . . . . . Engine Diagnosis T able 6-22 . . . . . . . . . . . . [...]

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 combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the thousands of an millimeter (ten thousands o[...]

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. Clamp securely at a posit[...]

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. 1) Place transmission gear shift lever in “ Neutral ” (Shift selector l[...]

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). ECM (PCM) has an On- Board Diagnostic system which detects a ma[...]

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. Not used 10. Load value 25.5% 1st, 2nd or 3rd in parentheses here represents which positio[...]

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. These data are not updated. Shown in the table below are examples o[...]

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.) stored in ECM (PCM) memory . Such disconnection will [...]

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. W as customer complaint analysis performed? Go to Step 2. Perform customer complaint[...]

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. 2. DIAGNO[...]

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. Date of problem: Mileage: PROBLEM SYMPTOMS j Difficult Starting j No cranking j No initial combustion j No combustion j Poor starting at ( j cold j warm j always) j Other j Poor Driveability j Hesit[...]

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. 2) Start engine and check that MIL turns OFF . If MIL remains ON a[...]

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. 3) Erase DTC and pending DTC according to instructions dis- played on s[...]

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 pressure circuit malfunction Low pressure-high vacuum-low voltage (or MAP sensor circuit shorted to ground) High pressure-low vacuum-high voltage (or [...]

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. during engine cranking 1 driving cycle[...]

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 (A / T) No signal or multiple signals inputted with shifted in “ D ” range 1 driving cycle P0720 Output speed sensor circuit malfunction (A / T) [...]

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. DTC NO. DETECTED ITEM F AIL-SAFE OPERA TION P0105 Manifold absolute pressur[...]

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 ––––– level, leakage D Engine coolant ––––– level, leakage D Fuel ––––– level, leakage D A / T fluid ––––– level, leakage D Air cl[...]

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 . STEP ACTION YES NO 1 W as “ ENGINE DIAG. FLOW T ABLE ” performed? Go to Step 2. Go to ?[...]

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. 3 for Step 6 Fig. 4 for Step 8 Fig. 5 for Step 1 1[...]

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 . Condition Possible Cause Referring Item Hard Starting (Engine cranks OK) Ignition[...]

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 strainer D Functional deterioration of oil pump D Worn oil pump relief valve D Excessive clearance in various sliding parts Engine oil and oil filter change[...]

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 Improper engine oil grade D Clogged oil filter or oil strainer D Poor oil pump performance D Faulty radiator fan control system D Dragging brakes D Slip[...]

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.) Ignition system out of order D Spark plug faulty or plug gap[...]

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 ignitor D Leaks, loose connection or disconnection of high-tension cord Engine overheating Fuel system out of order D Clogged fuel hose or pipe D Malfun[...]

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 Leaky or disconnected high-tension cord D Faulty ignition coil with ignitor Fuel system out of order D Fuel pressure out of specification D Leaky manif[...]

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 spark plug D Leaky or disconnected high-tension cord D Faulty ignition coil with ignitor Low compression Engine and emission control system out of orde[...]

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. Even when the vehicle is in good condition, there may be cases where the che[...]

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 (DESIRED IDLE SPEED) gg , at neutral, A / T at “ P ” range 850 r / min TP SENSOR VOL T (THROTTLE POSITION Ignition switch ON / engine Throttle valve[...]

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. 0 km / h 0 MPH SHIFT SOL1 CON (Command Signal) MON (Monitor Signal) Ignition switch ON, selector lever is shifted at P , R or N range OFF (g ) SHIFT SOL2 CON (Command Signal[...]

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 . Closed indicates final injection duration is corrected for oxygen [...]

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. 0% means that the purge valve is completely closed while 100% is a fully open [...]

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. Service wire 16 C03 C02 C01 1 2 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 11 12 13 12 13 14 15 16 17 18 19 20 21 22 9 10 11 12 13 14 15 14 15 16 17 18 19 20 21 22 23[...]

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 – 14 V Ignition switch ON 3 — Blank — — 4 — Blank — — 5 — Blank — — 6 — Blank — — 7 R/G EV AP canister purge valve 10 – 14 V I[...]

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 4.75 – 5.25 V Ignition switch ON 2 Or Camshaft position sensor (+) — — 3 W/B Crankshaft position sensor (+) — — 4 Gr / G Closed throttle position switch 0 – 1 V Ignit[...]

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) 0.4 – 0.8 V Ignition switch ON 2 Y/G V ehicle speed sensor (M / T) Indicator deflection[...]

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 . 2) Check resistance between each terminal of couplers discon[...]

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. A/C contoller (if equipped) - 1 1. CKP sensor - 12. CTP switch (in ISC actuator) - 13. Heated ox[...]

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 LAMP CIRCUIT CHECK – LAMP DOES NOT COME “ ON ” A T IGNITION SWITCH ON (BUT ENGINE A T STOP) CIRCUIT DESCRIPTION When the ignition switch is turn[...]

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. Is there any[...]

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) POWER AND GROUND CIRCUIT CHECK – MIL DOESN ’ T LIGHT A T IGNITION SWITCH ON AND ENGINE DOESN ’ T ST ART THOUGH IT IS CRANKED UP CIRCUIT DESCRIPTIO[...]

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. Is it 10 – 14 V? Check ground ci[...]

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, 37.5 mmHg or less (Low pressure – High vacuums – Low voltage) or D MAP: 130 kPa, 975 mmHg or more (High pr[...]

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. 1) Connect scan tool to DLC with ignition switch OFF . 2) T urn ign[...]

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 CAUSE D Low intake air temperature (High voltage-High resistance) or D High intake air temperature (Low voltage-Low resistance) D “ Gr ” circuit [...]

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 ” . 2 Check IA T Sensor and Its Circuit. 1) Connect scan tool to DLC with ignition switch[...]

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 DESCRIPTION DTC DETECTING CONDITION POSSIBLE CAUSE D Low engine coolant temperature (High voltage-High resistance) or D High engine coolant temperature (Low vo[...]

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 ” . 2 Check ECT Sensor and Its Circuit. 1) Connect scan tool with ignition switch OFF . 2[...]

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 DETECTING CONDITION POSSIBLE CAUSE D Signal voltage high or D Signal voltage low D “ G ” circuit open D “ Lg / W ” circuit open or shorted to ground[...]

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. Go to “ ENGINE DIAG. FLOW T ABLE ” . 2 Check TP Sensor and Its Circuit. [...]

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. D While vehicle running at specified engine speed. D No change in intake manifo[...]

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 0.35 mm (0.014 in.). clearance “ 1 ” “ 3 ”“ 4 ” INSPECTION STEP ACTION YES [...]

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) CIRCUIT DESCRIPTION DTC DETECTING CONDITION POSSIBLE CAUSE D When running at idle speed after engine warmed up and running at specified vehicle speed, HO2S[...]

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. Go to “ ENGINE DIAG. FLOW T ABLE ” . 2 Is there DTC(s) other than HO2S-1 (DTC P0130)? Go to[...]

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 ” . 2 Is there DTC(s) other than HO2S-1 (DTC P0133)? Go to applicable DTC Diag. Flow T able. Repl[...]

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. A: D Low voltage at ter[...]

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. 1) Check voltage at terminal C01-8. See Fig. 1. 2) W arm up engine to normal oper[...]

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. A. Ma[...]

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. (under driving condition other than high-load, high-engine speed, rapid accelerating and decelerating) 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 1 1) and 50 mph (80 km / h) Above 20 mph (32 km[...]

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. Is it good condition? Go to Step 3. Repair or replace. 3 Check HO2S-2 and Its Circuit. W[...]

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. A.[...]

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. 1) W arm up engine to normal operating temperature. 2) Stop engine. 3) T urn ignition switch ON [...]

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 injection High voltage Low voltage INJECTOR HEA TED OXYGEN SENSOR-1 A / F mixture becomes richer Oxygen concentration decreases A / F mixture becomes lean[...]

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. D Road test should be carried out with 2 persons, a driver and a tester[...]

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. Flow T able. Go to Step 3. 3 Check HO2S-1 Output V oltage. 1) Co[...]

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). Is it in good condition? Go to Step 9. Replace engine coolant temp. sensor . 9 [...]

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 GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) DTC P0300 RANDOM MISFIRE DETECTED (Misfire detected at 2 or more cylinders) DTC P0301 CYLINDER 1 MISFIRE[...]

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 Engine speed changing rate D Manifold absolute pressure changing rate D Throttle opening changing rate D Misfire rate per 200 or 1000 engine revolutions ([...]

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. Flow T able. Go to Step 3. 3 Check Ig[...]

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. 7 Check EV AP Canister Purge V alve for Closing. 1) Disconnect purge hose (1) from EV AP can[...]

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 POSITION (CKP) SENSOR CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION DTC DETECTING CONDITION POSSIBLE CAUSE D No CKP sensor signal during 1 revolution of ca[...]

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 . 2) Then check for proper connection to CKP sensor at “[...]

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 rotor in distributor Camshaft position sensor 6-74 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) DTC P0340 CAMSHAFT POSITION (CMP) SENSOR CIRCUI[...]

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 ” . 2 Is DTC P1500 (Engine starter signal circuit malfunction) detected? Go to DTC P1500 Diag. Flow T[...]

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 0.5 V / Div 2 sec. / Div Heated oxygen sensor-1 W arm up three way catalytic converter (if equipped) Three way catalytic converter T o other sensor T o other sensors Heated oxygen sensor-2 G DTC P[...]

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 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 acc[...]

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. Check fuel[...]

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 vapor separator Fuel filter cap Fuel level sensor Fuel tank EV AP canister DTC P0443 PURGE CONTROL V AL VE CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION DTC D[...]

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. is below 91 _ [...]

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 ” . 2 Check Radiator Cooling Fan Relay and Its Circuit. 1) T urn ignition switch ON. 2[...]

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. : 2 driving cyc[...]

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. Speedometer cable disconnected or broken. 3 Check VSS and I[...]

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. DTC DETECTING CONDITION POSSIBLE CAUSE D While fuel is kept cut[...]

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. 1) Disconnect VSS connection with ignition switch OFF . 2) Check for proper connection to[...]

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. A: Throttle opening change is small as compared with e[...]

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. FLOW T ABLE ” . 2 Check Idle Control System. 1) Connect SUZUKI scan tool to DL[...]

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 contact with ISC actuator plunger Condition “ B ” : Throttle lever is apart from plunger DTC P0510 CLOSED THROTTLE POSITION (CTP) SWITCH MALFUNCTION C[...]

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. ECM (PCM) DTC CONFIRMA TION PROCEDURE 1) T urn ignition s[...]

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 DTC DETECTING CONDITION POSSIBLE CAUSE D V oltage low at terminal C01-12 during engine warming up or D V oltage high at terminal C01-12 after engine w[...]

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. Check for voltage at terminal C01-12 of ECM (PCM) connector connected, under following ea[...]

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). DTC DETECTING CONDITION POSSIBLE CAUSE DTC P1450: D Barometric pressu[...]

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 AND DIAGNOSIS (TBI FOR G10) 6-93 DTC P1500 ENGINE ST ARTER SIGNAL CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION DTC DETECTING CONDITION POSSIBLE CAUSE D High [...]

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. are kept in ECM (PCM) even when the ignition switch is turned [...]

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. FLOW T ABLE ” performed? Go to Step 2. Go to “ ENGINE DIAG. FLOW T ABLE ” . 2 In[...]

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. Is resistance 1.9 – 2.1 Ω (at 20 _ C, 68 _ F)? “ W/B l ”[...]

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. T ABLE B-2 FUEL PUMP AND ITS CIRCUIT CHECK INSPECTION STEP AC[...]

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. Fuel return line 6-100 ENGINE GENERAL INFORMA TION AND DIAGNOSIS (TBI FOR G10) T ABLE B-3 FUEL PRESSURE CHECK INSPECTION STEP ACTION YES NO 1 Check Fuel Pressure (Refer to Section 6E1 [...]

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 . Shortage of fuel or fuel pump or its circuit defective (refer to B-2 FUEL PUMP AN[...]

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. While engine running and A / C switch and / or heater blower sw[...]

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 . 2) Start engine and select “ DA T A LIST ” [...]

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. Self-test adaptor - 1. Pressure gauge 09912-58441 - 2. Pressure hose 09912-58431[...]

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 . . . . . . . . . . Precaution in Diagnosing T rouble 6-1- 9 . . . [...]

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 . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0302 Cylinder 2 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). Accordingly , when any internal engine part[...]

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. Clamp securely at a posit[...]

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. 1) Place transmission gear shift lever in “ Neutral ” (Shift selector[...]

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). ECM (PCM) has an On- Board Diagnostic system which detects a [...]

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. Not used 10. Load value 25.5% 1st, 2nd or 3rd in parentheses here represents which positio[...]

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. These data are not updated. Shown in the table below are examples of how freeze frame [...]

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.) stored in ECM (PCM) memory . Such disconnection wil[...]

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. W as customer complaint analysis performed? Go to Step 2. Perform customer complai[...]

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. 2. DIAG[...]

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. Date of problem: Mileage: PROBLEM SYMPTOMS j Difficult Starting j No cranking j No initial combustion j No combustion j Poor starting at ( j cold j warm j always) j Other j Poor Driveability j [...]

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. 2) Start engine and check that MIL turns OFF . If MIL remains ON[...]

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. 2) T urn ignition switch ON. 3) Erase DTC and pending DTC according to instructions dis- played [...]

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. 2 driving cycles: MIL lights up when the same DTC is detected also in the next driving cycle after DTC is detected and stored temporarily 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. During engine cranking 1 driving cycle P0340 Camshaft position sensor circuit malfunction No signal during engine running 1 driving cyc[...]

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 Output Speed Sensor Circuit Malfunction P0751 Shift Solenoid A Performance or Stuck Off Refer to Section 7B P0753 Shift Solenoid A Circuit P0756 Shift[...]

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. DTC NO. DETECTED ITEM F AIL-SAFE OPERA TION P0105 Manifold absolute press[...]

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 ––––– level, leakage D Engine coolant ––––– level, leakage D Fuel ––––– level, leakage D A / T fluid ––––– level, leakage D Air [...]

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 . STEP ACTION YES NO 1 W as “ ENGINE DIAG. FLOW T ABLE ” performed? Go to Step 2. Go to[...]

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. 1 for Step 5 Fig. 2 for Step 6 Fig. 3 for Step 6 Fig. 4 for Step 7 Fig. 5 for Step 10[...]

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 . Condition Possible Cause Referring Item Hard Starting (Engine cranks OK) Igniti[...]

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 strainer D Functional deterioration of oil pump D Worn oil pump relief valve D Excessive clearance in various sliding parts Engine oil and oil filter cha[...]

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 Improper engine oil grade D Clogged oil filter or oil strainer D Poor oil pump performance D Faulty radiator fan control system D Dragging brakes D Sl[...]

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.) Ignition system out of order D Spark plug faulty or plug g[...]

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 ignitor D Leaks, loose connection or disconnection of high-tension cord Engine overheating Fuel system out of order D Clogged fuel hose or pipe D Malf[...]

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 Leaky or disconnected high-tension cord D Faulty ignition coil with ignitor Fuel system out of order D Fuel pressure out of specification D Leaky man[...]

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 spark plug D Leaky or disconnected high-tension cord D Faulty ignition coil with ignitor Low compression Engine and emission control system out of or[...]

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. Even when the vehicle is in good condition, there may be cases where the checked value d[...]

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 up, M / T at neutral, A / T at “ P ” range 750 r / min TP SENSOR VOL T ( THROTTLE POSITION Ignition switch ON / engine Throttle valve fully closed [...]

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 . Closed indicates final injection duration is corrected for oxyge[...]

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. 0% means that the purge valve is completely closed while 100% is a fully ope[...]

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. CAUTION: ECM (PCM) cannot be checked by itself. It is strictly prohib- ited [...]

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 purge valve 10 – 14 V Ignition switch ON Indication deflection 5 Power steering switch deflection repeated 0 V and Ignition switch ON 0 V an d 10 ?[...]

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 (stepper motor 10 – 14 V Ignition switch ON 2 coil 1) 0 – 1 V Engine running at idle speed 3 Data link connector 10 – 14 V Ignition switch ON 4 Heater [...]

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 Malfunction indicator lamp 10 – 14 V When engine running 2 V ehicle speed sensor (M / T) Indicator deflection repeated 0 V and 4 – 6 V Ignition switch O[...]

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 . 2) Check resistance between each terminal of couplers disco[...]

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. PSP switch - 13. A / C control module (if equipped) [...]

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 MALFUNCTION INDICA TOR LAMP CIRCUIT CHECK – LAMP DOES NOT COME “ ON ” A T IGNITION SWITCH ON (BUT ENGINE A T STOP) CIRCUIT DESCRIPTION When the igni[...]

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. Is there a[...]

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 GROUND CIRCUIT CHECK – MIL DOESN ’ T LIGHT A T IGNITION SWITCH ON AND ENGINE DOESN ’ T ST ART THOUGH IT IS CRANKED UP CIRCUIT DESCRIPTION When the[...]

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. Is it 10 – 14 V? Check ground circuits “ B/Y ” an[...]

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 14.7 kpa, 860 mmHg or more (High [...]

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). 3) Arrange 3 new 1.5 V batteries (2) in series (check that total volt- age is 4.5 – 5.0 V) and connect its positive terminal to “ Vin ” termi- nal of sensor and negative terminal to ?[...]

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. 1) Connect scan tool to DLC with ignition switch OFF . 2) T urn ignition switch[...]

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 POSSIBLE CAUSE D Low intake air temperature (High voltage-High resistance) D High intake air temperature (Low voltage-Low resistance) D “ Gr / R ” circu[...]

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 ” . 2 Check IA T Sensor and Its Circuit. 1) Connect scan tool to DLC with ignition switch OFF . 2) T [...]

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). DTC P01 15 ENGINE COOLANT TEMPERA TURE (ECT) CIRCUIT MALFUNCTION CIRCUIT DESCRIPT[...]

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 ” . 2 Check ECT Sensor and Its Circuit. 1) Connect scan tool with ignition switch OFF . 2) T urn igni[...]

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 DETECTING CONDITION POSSIBLE CAUSE D Signal voltage high D Signal voltage low D “ G ” circuit open D “ Gr ” circuit open or shorted to ground D “ P[...]

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 ” . 2 Check TP Sensor and Its Circuit. 1) Connect scan tool to DLC with ignition switch OFF and then [...]

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. D While vehicle running at specified engine speed. D No change in intake mani[...]

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. FLOW T ABLE ” performed? Go to Step 2. [...]

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 (SENSOR-1) CIRCUIT DESCRIPTION DTC DETECTING CONDITION POSSIBLE CAUSE D When running at idle speed after engine warmed up and running at specified vehi[...]

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. Flow T able. Go to Step 3. 3 1) [...]

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. DTC DETECTING CONDITION POSSIBLE CAUSE D When running at specified idle speed after engine[...]

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. D While running under other than high load and high engine speed conditions or [...]

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. A: D Low voltage at terminal C[...]

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. 1) Check voltage at terminal C01-7. See Fig. 1. 2) W arm up engine to normal operati[...]

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. A. Max. output voltage of HO2S-2 is lower [...]

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. (under driving condition other than high-load, high-engine speed, rapid accelerating and decelerating) 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 1 1) and 50 mph (80 km / h) Above 20 mph (32 [...]

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. Is it good condition? Go to Step 3. Repair or replace. 3 Check HO2S-2 and Its Circuit.[...]

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. A. Low voltage at terminal C02-4 for sp[...]

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. 1) W arm up engine to normal operating temperature. 2) Stop engine. 3) T urn ignition switch O[...]

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.2 injector No.3 injector No.4 injector Fuse box Signal to decrease amount of fuel injection Signal to increase amount of fuel injection High voltage Low voltage A / F mixture becomes ric[...]

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. D Road test should be carried out with 2 persons, a driver and a test[...]

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. Flow T able. Go to Step 3. 3 Check HO2S-1 Output V oltage. 1) [...]

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. sensor for performance (See Section 6E2). Is it in[...]

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.1 injector No.2 injector No.3 injector No.4 injector Fuse box DTC P0300 RANDOM MISFIR[...]

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. Fuel injection time Display of fuel injection signal using oscilloscope W aveforms at specified idle speed 5ms/Div DTC DETECTING CONDITION POSSIBLE CAUSE D Engine under other than hig[...]

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. Flow T able. Go to Step 3. 3 Check [...]

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). Is it in good condition? Go to Step 7. Replace PCV valve. 7 Check EV AP Canister Purg[...]

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 0.5 V / Div . 10 ms / Div . 0.5 V / Div . 5 ms / Div . DTC P0335 CR[...]

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. When starter motor fails to run and this DTC appears, check starter circuit first. STE[...]

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 . Crank angle 20 ms / Div . 180 _ 720 _ DTC P0340 CAMSHAFT POSITION (CMP) SENSOR CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION DTC DETECTING CONDITION POS[...]

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. Is CMP sensor installed properly and connector connected securely? Go to Step 3. Correct. 3 C[...]

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). Check for intermittent referring to “ Intermit[...]

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 DTC DETECTING CONDITION POSSIBLE CAUSE D While running at specified vehicle speed after engine warm-up D During deceleration (engine speed high with c[...]

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 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[...]

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. 3 EGR V alve Operation Check 1) With ignition switch OFF , install SUZUKI scan tool. 2) [...]

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 0.5 V / Div 2 sec. / Div DTC P0420 CA T AL YST SYSTEM EFFICIEN[...]

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 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 a[...]

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. Check fu[...]

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. 1 for Step 1 DTC P0443 EV AP PURGE CONTROL V AL VE CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION DTC DET[...]

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 COOLING F AN CONTROL SYSTEM MALFUNCTION CIRCUIT DESCRIPTION DTC DETECTING CONDITION POSSIBLE CAUSE D Low voltage at terminal C02-18 when engine coolant temp[...]

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 ” . 2 Check Radiator Cooling Fan Relay and Its Circuit. 1) T urn ignition switch ON. 2) Check for vol[...]

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. D VSS signal not inputted. : 2 driving cycl[...]

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. Speedometer cable disconnected or broken. 3 Check VSS and [...]

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. D VSS signal not inputted. : 2[...]

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. 1) Disconnect VSS connection with ignition switch OFF . 2) Check for proper connection [...]

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. : 2 driving cycle detection logic, continuous monitoring. D “ R[...]

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. Go to “ ENGINE DIAG. FLOW T ABLE ” . 2 Check Idle Air Control System. When using SUZUKI sc[...]

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. ECM (PCM) DTC CONFIRMA TION PROCEDURE 1) T urn ignition[...]

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). DTC DETECTING CONDITION POSSIBLE CAUSE[...]

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. 2 for Step 2 STEP ACTION YES NO 2 Che[...]

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 switch (starter switch) DTC P1500 ENGINE ST ARTER SIGNAL CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION DTC DETECTING CONDITION POSSIBLE CAUSE D Low voltage[...]

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. are kept in ECM (PCM) even when the ignition swi[...]

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. FLOW T ABLE ” performed? Go to Step 2. Go to “ ENGINE DIAG. FLOW T ABLE ” . [...]

ENGINE GENERAL INFORMA TION AND DIAGNOSIS (SFI FOR G13) 6-1-99 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. T ABLE B-2 FUEL PUMP AND ITS CIRCUIT CHECK INSPECTION STEP ACTION Y[...]

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. 2) Ins[...]

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. 8 With fuel pump operated and fuel return hose blocked by pinching it, is fuel pressure[...]

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. 1) Check voltage at terminal C02-16. See Fig. 1. While engine running and A / C switch and / or he[...]

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. When using SUZUKI scan tool: 1) Connect SUZUKI scan[...]

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. When using SUZUKI scan tool[...]

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. 1) Connect scan tool to DLC with ignition switch OFF . 2) Start[...]

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. Battery 2. Radiator fan motor coupler[...]

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. T ech 1 A 4. DLC cable (14 / 26 pin, 09931-76040) 5. T est lead / probe 6. Po[...]

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 . Refer to “Air Bag System Compon[...]

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. 2) With engine stopped, remove blind plug hose from i[...]

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. 4) Reinstall oil filter . 5) Start engine and [...]

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 . 5) Remove cylinder head cover nuts and then seal washers (1). 6) Remove[...]

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. 2) Disconnect negative [...]

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. gauge 6) Dis[...]

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.) 2) Install intake manifold gasket to cylinder head. Use a new gas- ket. 3) Install intake mani[...]

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. Service [...]

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. Tightening T orque (a): 23 N . m (2.3 kg-m, 17.0[...]

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. T ensioner spring screw : T ightening T orque 6A-10 ENGINE MECHANICAL (G10, 1-CAM[...]

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). 9) Remove timing belt outside cover (1). 10) Align 4 tim[...]

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. CAUTION: After timing belt [...]

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). If not, align two marks by turning camshaft but be careful not to turn it more than its allowable turning rang[...]

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 . m (1.1 kg-m, 8.0 lb-ft) 8) Install crankshaft pulley (2). T ighten crankshaft pull[...]

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. Camshaft housing bolt 1. Crankshaft timing belt pulley : T ightening T orque [...]

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 . D Don ’ t apply force to body of adjuster , for oil in high pres- sure chamb[...]

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. Never replace cylinder head without replacing housings. Check clearance by using gaging plastic[...]

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. 6A-18 ENGINE MECHANICAL (G10, 1-CAM 6-V AL VES ENGINE) INST ALLA TION 1) Before installing valve lash adjuster to cylinder head, fill oil pas- sage of cyl[...]

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 . D After applying engine oil to housing bolts, tighten them tem- porarily f[...]

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. As it takes time for valves to settle in place, operating engine within half an hour after their installation may cause[...]

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. V alve spring retainer 10. V alve spring: Be sure to position spring in place with its bottom end [...]

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. Remember , weakened valve springs can cause chatter , not to mention possibility of reducing power output due to gas leakage caused by decre[...]

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. ENGINE MECHANICAL (G10, 1-CAM 6-V AL VES ENGIN[...]

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. 3) Disconnect battery cables at battery and remove battery and it[...]

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. Left mounting 7. Left mounting No.2 bracket 8. Right mounting bracket 9. Right mounting 10. T [...]

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. Rear mounting 2. Rear mounting No.2 bracket 3. Rear mounting No.1 bracket 4. Left mounting No.1 b[...]

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. Housing bolt 15. Input shaft bearing 16. Flywheel 17. Flywheel bolt : T ightening T or[...]

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. D Journal bearings, bearing caps, conne[...]

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. After installing oil seal housing, gasket edges might bulge out; if so, cut them off to make them[...]

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. 09915-7731 1 Oil pressure gauge 2. 09915-7821 1 Oil pressure gauge attachment 1. 0[...]

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 resin) ENGINE MECHANICAL (G10, 1-CAM 6-V AL VES ENGINE) 6A-31 REQUIRED SER VICE MA TERIALS MA TERIALS RECOMMENDED SUZUKI PRODUCT USE Sealant SUZUKI BOND[...]

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 . Refer to “Air Bag System C[...]

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). The single overhead cams[...]

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. In one path, oil reaches crankshaft journal b[...]

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 . CRANKSHAFT AND MAIN BEARINGS A monoblock casting [...]

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. 2) Stop engine after warming up. NOTE: After warming up engine, place transmission gear shift le- ver in “ Neutral ” (shift selector lever to “ P ” range for A / [...]

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. NOTE: After warming up engine, place transmission gear shift le- ver i[...]

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 . If oil is discolored, or deteriorated, change it. For particular oil to be used, refer to the tab[...]

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. Tightening T orque (a): 13 N . m (1.3 kg-m, 9.5 lb-ft) 7) Start [...]

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 . 4) Using special tool and wrench (1), turn crankshaft pulley clock- wise until “ [...]

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. After adjustment, tighten lock nut to specified torque while hold- ing adjusting screw stationary , and then make sure again that val[...]

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. INSPECTION Check air cleaner element for di[...]

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 . 5) Remove bolt and then air cleaner outlet hose after loosening [...]

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). 5) Remove cylinder head cover (1) with[...]

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. MAP sensor 10. O-ring 1 1. Gasket 12. Cushion : T ightening T orque : Do not reuse 1 2 6A1-14 ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) THROTTLE BODY AND INT AKE MANIFOLD REMOV AL 1) [...]

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 Fuel injectors D EV AP canister purge valve (2) D MAP sensor (6) D EGR valve (1) 8) Disconnect the following hoses: D Brake booster hose (1) from intak[...]

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. INST ALLA TION Reverse removal procedure for installation noti[...]

: 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. Service should be performed after system c[...]

(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). 4) Connect oxygen sensor coupler (3) and clamp (2) its wi[...]

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. W ater pump pulley : T ightening T orque ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) 6A1-1[...]

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. T ensioner stud 6. Damper 6 6A1-20 ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) 8) Lock crankshaft inserting flat end rod or the like (2) between fly- wheel ring [...]

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. ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) 6A1-21 CAUTION: D After timing belt is remo[...]

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. If no associated movement b[...]

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. Then confirm again that two set[...]

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. Refer to Section 0B. 15) Install P / S hos[...]

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) Drain engine oil by removing drain plug (1). 3) Re[...]

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. D Clean oil pump strainer screen. INST ALLA TION 1) Apply sealant to oil pan mating surf[...]

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. 5) Install CKP sensor (1) and connect its coupler , then clamp its harness. Tightening T or[...]

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. 12. Plate screw 13. Bolt (short) 14. Bolt [...]

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). 3) Remove outer rotor (1) and inner rotor (2). INSPECTION D Check oil seal lip for fault or other[...]

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. MEASUREMENT D Radial clearance Check radial clearance between outer rotor (1) and case, us[...]

(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 . m (1.1 kg-m, 8.0 lb-ft) 5) Apply engine oil to guide seal (3) and install[...]

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. Tightening T orqu[...]

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. ENGINE ME[...]

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. 6) After loosening all valve adjusting screw lock nuts (2), turn ad- ju[...]

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 . INSPECTION Adjusting Screw and Rocker Arm If tip of adjusting screw (1) is badly worn, rep[...]

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. If limit is exceeded, replace shaft or arm, or both. Item Standard Limit Rocker[...]

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). 4) Install camshaft housing referring to “ [...]

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. 2) Check O-ring for damage or deterioration. Install O-ring to rock- er arm shaft. 3) Install rocker arm shaft (3) with shaft bolt holes (4) facing up, rocker arm (exhaust side) (2) a[...]

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. D Embossed marks are provided on each camshaft housing, in- dicating position and direction for [...]

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. 12) Aft[...]

: 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. Intake valve 8. Cylinder head bolt 9. Camshaft housing bolt 10. Camshaft housing: Apply seala[...]

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 wires at the coupler D Heated oxygen sensor 1 D MAP sensor 5) Remove intake manifold rear stiffener (1) and generator adjust arm reinforcement (2) from [...]

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. Loosen all valve lash adjusting screws fully . 10) Remove timing belt and camshaf[...]

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. 3) Using special tools (V alve lifter), compress valve s[...]

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. If clearance exceeds limit, replace valve and valve guide. It[...]

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. D Seating contact width: Create contact pattern on each val[...]

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. 1) EXHAUST V AL VE SEA T : Use valve seat cutters (1) [...]

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. If distortion limit, given below , is exceeded, cor- rect gasketed surface with a surface plate and abrasive paper of about #400 (W aterproof silicon carbide abrasive paper): [...]

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. Remember , weakened valve springs can cause chatter , not to mention possibility of reducing power output due to gas leakage caused by de[...]

“ 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. Special T ool (A): 09916-34542 (B): 09916-38210 2) Install valve guide to cylinder head. He[...]

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. After applying engine oil to seal and spindle of special tool (V alve guide installer handle), fit oil seal to spindle, and then install seal to valve guide by pushing special tool by[...]

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. INST ALLA TION 1) Remove oil gasket and oil o[...]

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. Refer to Section 0B. 7) Adjust intake and exhaust valve lashes as p[...]

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. 6 10 6A1-54 ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) PIST[...]

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. D Force piston pin out. CLEANING Clean carbon from piston head and ring grooves, using a [...]

“ 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 . If cylinder bore is very rough or deeply scratched, or ridged, rebore cylinder and use over[...]

“ 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 . If it is out of specification, re- bore cylinder and use oversize piston. P[...]

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. NOTE: Decarbon and clean top of cylinder bore before inser[...]

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 . If crank pin is dam- aged, or out-of-round or taper is out of limit, replace crankshaft or regrind crank pin to undersize and use undersize bea[...]

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). If clearance exceeds its limit, use a new standard size [...]

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. Oil ring lower rail gap 6. Intake side 7. Exhaust side Crankshaft pulley side Circlip or ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) 6A1-61 c) Stamped number on piston a[...]

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. 2) Install guide hoses over co[...]

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. Refer to Section 0B. 9) Adjust accelerator cable play . Refer to[...]

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. 4) Drain cooling system. W ARNING: T o help avoid danger of being burned, do not rem[...]

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. sensor D Fuel injectors D Power steering pressure switch (if equipped) D Oxygen sensor-1 D [...]

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. 19) Disconnect drive shaft joints from differential gears of trans- mission or center be[...]

(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. Rear mounting 7. Rear mounting bracket 8. Rear torque rod 9. Rear torque rod bracket ENGINE MECHANICAL (G13B, 1-CAM 16-V AL VES ENGINE) 6A1-67 INST ALLA TION 1) Lift engine[...]

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. Crankshaft: Apply engine oil to crankshaft journals. 8. Thrust bearing: Set oil groov[...]

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 . 4) Remove cylinder [...]

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 (0.0023 in.) Crankshaft thrust play Measure this play with crankshaft set in cylinder block in [...]

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. D Upper half of bearing (2) has oil groove (3) as shown in figure. Install this ha[...]

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. A new standard bearing may produce proper clearance. If not, it will b[...]

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. Alphabet stamped Bearing cap[...]

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 . For example, if numeral stamped on crank web[...]

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 (1.761 1 – 1.7618 in.) 2) Using micrometer , measure reground journal diameter . Measurement [...]

“ 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. If runout exceeds its limit, replace flywheel. Limi[...]

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. INST ALLA TION NOTE: D All parts to be installed must be perfectly c[...]

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. After installing [...]

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 1) Install camshaft, crankshaft timing belt pulley , timing belt, crankshaft pulley ,[...]

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. 0[...]

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.1207C (99000-31 150) D Mating surfaces of cylinder block and oil p[...]

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 1.1 8.0 Intake manifold bolts and nuts 23 2.3 17.0 T iming belt tensioner stud 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. W ater intake pipe 4. Thermostat 5. W ater pump 6. IAC valve (throttle body) 7. Breather pipe (air cleaner outlet hose) 6B-2 ENGINE COOLING GENERAL DESCRIPTION COOLING SYSTEM CIRCULA TION D[...]

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. A wax pellet element is hermetically contained in a metal case, and expands when heated and contracts when co[...]

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. meter in the instrument cluster . DIAGNOSIS Condition Possible Cause Correction Engine overheats D Loose or broken water pump belt D Not enough coolant D Faulty thermostat D Faulty water pump [...]

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. When the system cools down, the coolant is drawn back into the radiator . The cooling system [...]

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) Remove radiator cap when engine is cool: T[...]

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. COOLING W A TER PIPES OR HOSES REMOV AL 1) Drain cooling system. 2) T o remo[...]

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. 3) Che[...]

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. 5) Remove water pump assembly (1). INSPECTION NOTE: Do not disassemble water p[...]

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 . 10) Fill cooling system. 1 1) After installation, check each part for[...]

6C ENGINE FUEL 6C-1 GENERAL DESCRIPTION 6C-1 . . . . . . . . . . . . . . Fuel System 6C-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Pump Assembly 6C-1 . . . . . . . . . . . . . . . . . . . ON-VEHICLE SERVICE 6C-2 . . . . . . . . . . . . . . . . Fuel Lines 6C-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel T ank 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. Fuel cut valve 10. Fuel tank pad 1 1. Fuel tank fixer bolt : T ightening T orque 6C-2 ENGINE FUEL ON-VEHICLE SER VICE FUEL LINES INSPECTION Visually inspect fuel lines for evidence of fuel le[...]

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. 8) Disconnect fuel[...]

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. INSPECTION Check fuel pump assembly for damage. [...]

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 . . . . . . . . . . . . . . . . General 6E1- 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Accelerator Cable [...]

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. Electronic control system includes ECM, various sens[...]

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. TP sensor 12. ISC actuator (including CTP switch) 13. PCV valve 14. Exhaust manifold 15[...]

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. Fuel return line 1 1. Air 12. Fuel 13. Air/fuel mixture 6E1-4 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) The main components of this system are fuel tank, fuel pump, fuel filter , thrott[...]

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. Heated oxygen sensor-2 CONTROLLED DEVICES a : Fuel injector b : EV AP canister purge valve c : F[...]

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 Blank Blank Blank EV AP canister purge valve Shift solenoid-B (A / T) Shift solenoid-A (A / T) Igniter Idle speed control actuator Fuel injector Inject[...]

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. Refer to Emission Control Information Label for proper connection of hoses (if equippe[...]

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. 1) W arm up engine to normal operating temperature. 2) Set tachometer . [...]

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. NOTE: Check that battery voltage is 1 1 V or more before operating [...]

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. 1[...]

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. Injector wire cover CAUTION: As throttle stop screw and throttle lever screw are fac- tory a[...]

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. V acuum passage for MAP sensor 6. Air induction passage 7. V acuum passage 8. Fresh air pass[...]

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. T ighten injector wire coupler screw to specified torque. Tightening T orque (a): 2.0 N . m (0.[...]

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. Tightening T orque (a): 23 N . m (2.3 kg-m, 17.0 lb-ft) 3) Instal[...]

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. Also, because injector is an electrical component, it should not be immersed in any type of liquid solve[...]

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. Install injector wire and tighten new wire screw to specified torque. Tig[...]

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 . 2) Disconnect coupler from MAP sensor . 3) Remove MAP sensor . 4) Arra[...]

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. If malf[...]

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. a) Connect SUZUKI scan tool to DLC with ignition switch OFF . b) Select “ Data List ?[...]

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 – 2.69 (1.14) (0.58) 0.29 – 0.35 2 1 1. ECT sensor 2. Distributor INSPECTION Immerse temperature sensing part of IA T sensor in water (or ice) and measure resistance between sensor terminals while heat[...]

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 – 2.61 (1.15) (0.584) 0.303 – 0.326 1. ECT sensor 2. Distributor INSPECTION Immerse temperature sensing part of ECT sensor in water (or ice) and measure resistance between sensor terminals while heatin[...]

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 . 2) Using ohmmeter , measure resistance between terminals “ V B ” and “ GND ” of senso[...]

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. 3) Connect ohmmeter between “ VSS ” terminal (2) and “ GND ” ter- minal (3) of combination meter and turn cable joint (1) of speedometer with a s[...]

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. 2) Remove fender apron extension on right side. 3) Disconnect connector from cranksh[...]

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 . Check its resistance and operation using the same procedure as that for main relay . If f[...]

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 ” . 4) Apply load to engine as described below and check that idle speed is kept at specified l[...]

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. CAUTION: D Make[...]

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. 3) Structure of ISC actuator relay is the same as that of main relay[...]

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 . D Check heater and insulator for crack, corrosion or any other dam- age. Replace a[...]

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 . Check its resistance and operation using the same procedure as that for ma[...]

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 that gear shift lever is in neutral position (with A / T model, selector lever in “ P ” range) and that parking brake lever is pulled all the way [...]

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. 2) Check resistance between two terminals of EV AP canister purge valve. Resist[...]

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 . Fuel vapor inside EV AP canister is harmful. 1) Disconnect vacuum hoses[...]

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. If there is no vacuum, check for clogged valve. Replace as nec- essary . 4) After check[...]

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. Operator ’ s manual 3. T ech 1A 4. DLC cable (14 / 26 pin, 09931-76040) 5. T est lead / probe [...]

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 . . . . . . Engine and Emission Control Input / Output T able 6E2- 9 . . . . . . . . [...]

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. Fuel delivery system includes fue[...]

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). The air (by the amount corresponding to the throttle valve (6) opening and engine speed) is filtered by the air cleaner (1), pass[...]

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). The fuel in the fuel tank (1 1) is pumped up by the fuel pump (12), filtered by the fuel filter (10) a[...]

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. Battery - 9. CMP sensor - 10. CKP sensor - 1 1. Fuel level sensor (gauge) (in fuel tank) - 1[...]

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 RADIA TOR F AN RELA Y MIL MAIN RELA Y SIGNAL FROM SENSOR, SWITCH AND CONTROL MODULE OUTPUT INPUT ENGINE & EMISSION CONTROL INPUT / OUTPUT T ABLE ELE[...]

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 motor coil 4) 18 P / G Radiator fan relay 19 Y / Bl Fuel pump relay 20 —— ——— 21 W / B “P”-range signal (A / T) 22 P / Bl Fuel level gauge 2[...]

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 (0.08 – 0.27 in.) If measured value is out of specification, adjust[...]

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 . D Accelerator cable has some play , that is, it is not tight. D V[...]

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. TP sensor 4. O-ring 5. Idle air control valve 6. IAC valve screws : T ightening[...]

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. 7) Disconnect engine coolant hoses (1) from throttle body . Disassembly NOTE: While disassembling and assembling throttle body , use spe- cial care not to deform levers on thr[...]

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. 6) Connect accelerator cable and adjust cable play to specifica- tion. 7) Refill cooling s[...]

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): 3.3 N . m (0.33 kg-m, 2.5 lb-ft) 3) Install throttle body to intake manifold referring to “ Throt[...]

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 2.0 – 2.4 kPa 28.4 – 34.1 psi ENGINE AND EMISSION CONTROL SYSTEM (SF[...]

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. D V ehicle speed = 0 KPH D Engine speed = 0 RPM D Fuel tank level y 15%[...]

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. NOTE: The fuel pressure regulator is the one body with the fuel pump as[...]

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). 4) Disconnect fuel return hose (2) from fuel pressure regulator (1). CAUT[...]

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. If no sound or an unusual sound is heard, check injector circuit (wire or coupler) [...]

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 . 1) Install injector (1) and fuel pressure regulator (2) to special [...]

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. 5) Put graduated cylinder under injector as shown. 6) Operate fuel pump and apply fuel pressur[...]

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. If it is, replace with new one. D Apply thin coat of fuel to O-rings (1) and then in[...]

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 . 2) Disable air bag system, refer to “ DISABLING[...]

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 . 2) Using ohmmeter , check resistance between terminals under each condition given[...]

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). Inspection Immerse temperature sensing part of IA T sensor in water (or ice) and measu[...]

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 . 2) Drain coolant referring to Section 6B. W ARNING: T o help avoid danger of being burned, do not remove ra- diator cap while engine and radiator are still [...]

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 . NOTE : T [...]

(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 . 2) Disconnect connector from camshaft position sensor . 3) Remove camshaft positio[...]

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. Removal / Installation Refer to Section 6C. MAIN[...]

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) W arm up engine to normal operating temperature.[...]

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 . If radiator fan motor does not operate smoothly , replace motor . EMISSION CON[...]

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 . 2) Remove carbon f[...]

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. 4) Disconne[...]

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 . 3) Check that there should be no restriction of flow through purge pipe (2) an[...]

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. Checking tool set 09912-58421 4-1. T ool body & washer 4-[...]

6F IGNITION SYSTEM 6F-1 GENERAL DESCRIPTION 6F- 1 . . . . . . . . . . . . . . DIAGNOSIS 6F- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . ON-VEHICLE SERVICE 6F- 5 . . . . . . . . . . . . . . . . Ignition Spark T est 6F- 5 . . . . . . . . . . . . . . . . . . . . High-T ension Cords 6F- 5 . . . . . . . . . . . . . . . . . . . Spark Plugs 6F[...]

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. Spark plug T o combination meter 6F-2 IGNITION SYSTEM[...]

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 high-tension cord(s) D Faulty high-tension cord(s) D Faulty spark plug(s) D Cracked rotor or cap D Maladjusted signal rotor air gap D Faulty ignition[...]

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. Are circuits in good condition? Go to Step 7. Repair or replace. 7 Ignition Coil Check 1) Check ignition coil for resistance, referring to “ Ignition Coil ” in this sec[...]

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. W ARNING: Without disconnection of injector coupler , combustible gas may come out from spark[...]

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. SP ARK PLUGS 1) Pull out high-tens[...]

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 : 0.87 – 1.05 Ω Secondary : 1 1.2 – 15.2 k Ω 4) If resistance is out of specificati[...]

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 . 2) Using thickness gauge, measur[...]

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. INSPECTION AND ADJUSTMENT[...]

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 . 2) Remove distributor cap screws and cap. 3) Remove distributor [...]

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. T est lead/probe 6. Power source cable 7. DLC cable adaptor 8. Self-test adaptor 09900-27[...]

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 . . . . . . . . . . . . . . . . . . . . High-T ension Cords 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. High-tension cords 13. VSS (speedometer) (M / T) 14. Data link connector 6F1-2 IG[...]

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. Sensed information D MAP sensor D ECT sensor D IA T sensor D TP sensor D VSS D Park / Neutral p[...]

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. 2) If OK, perform ignition spar[...]

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. 2) Remove spark plug and check it for condition and typ[...]

“ 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. SP ARK PLUGS 1) Pull out high-tension [...]

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 . 7) T ighten ignition coil bolts, and then connect ignition coil coupler . 8) Install high-tension[...]

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. 7) Using timing light (1), check that ignition timing is within specifi- cati[...]

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. DLC cable adaptor 8. Self-test adaptor Mass storage cartridge 09931-76030 16 / 14 pin DLC cable IGNITION SYSTEM (SFI FOR G13) 6F1-9 SPECIAL T OOLS[...]

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 1.0 ȏ 2WD H / B model] EXHAUST SYSTEM 6K-1 SECTION 6K EXHAUST SYSTEM NOTE: For the descriptions (items) not found in this section, refer to the same section of Service Manual men- tione[...]

[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. Exhaust No.1 pipe 6K-2 EXHAUST SYSTEM[...]

: 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 . m (4.5 kg-m) EXHAUST SYSTEM 6K-3[...]

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 . . . . . . . . . . . Precaution in Diagnosing T rouble 7B-12 . . . . .[...]

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 . . . . . . . . . . . . . . T ransmission range sensor[...]

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. V alve body assembly 10. Oil strainer AUTOMA TIC TRANSMISSION (3 A / T) (VEHICLE WITH [...]

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 Parking – – – ** f ** – f R Reverse – f – f – – N Neutral – – – – – – 1st f – – – f – D 2nd f – f – – – 3[...]

[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. Data link connector (DLC) 9. Shift solenoid-A (No.1, Direct clutch solenoid valve) 10. Sh[...]

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. Malfunction indicator lamp (MIL) 8. Data link connector (DLC) 9.[...]

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. Ground terminal 4. Reference voltage terminal 5. Output voltage terminal 6. TP sensor C: Outpu[...]

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. Oil strainer 7B-8 AUTOMA TIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) TRANSMISSION RANGE SENSOR (SHIFT SWITCH) Being linked with the selector lever , this sensor changes [...]

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 Full open km / h m i l e/h km / h m i l e/h Throttle Speed Gear Selector VEHICLE SPEED Upshift Downshift THROTTLE V AL VE OPENING [G10 Engine Model] AUT[...]

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 km / h m i l e/h km / h m i l e/h Throttle Speed Gear Selector VEHICLE SPEED Upshift Downshift THROTTLE V AL VE OPENING [G13 Engine Model][...]

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. suitably to vehicle driving conditions. PCM [...]

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.) stored in PCM memory . Such disconnection will clear memorized[...]

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. W as customer complaint analysis performed according to instructi[...]

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 . For this purpose, use of such an inspection form (shown in next page) will facilitate collecting information to the point required for proper analysis and[...]

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. Date of problem: Mileage: PROBLEM SYMPTOMS j V ehicle does not move (R, D, 2, L range) j No upshift automatically ( j 1st to 2nd j 2nd to 3rd j 2 range j D range) j No downshift automatically ( j 3[...]

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. DIAGNOSTIC TROUBLE CODE(S) CHECK 1) T urn ignition switch OFF . 2) After setting cartri[...]

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. g cycle P0720 Output speed [...]

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, leakage, color D A / T fluid hoses – – – – – disconnection, looseness, deterioration D Throttle cable – – – – – play , installation[...]

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 TRANSMISSION BASIC CHECK This check is very important for troubleshooting when PCM (ECM) has detected no DTC and no abnormality has been found in visual[...]

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 any drive range A / T DIAGNOSTIC FLOW T ABLE A-1 Gear change failure A / T DIAGNOSTIC FLOW T ABLE A-2 Excessive shock at range selection or gear chang[...]

*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 harness side) Gr / Bl (*1), R / B (*2) AUTOMA TIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) 7B-21 DTC P0705 TRANSMISSION RANGE SENSOR (SWITCH) CIRCUI[...]

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. Go to “ AUTOMA TIC TRANSMISSION DIAGNOS[...]

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 TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) DTC P0720 OUTPUT SPEED SENSOR (A / T VSS) CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION – Refer to “ GENERAL DESCRIPTI[...]

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 ” . 2 Check Output Shaft Speed Sensor for Resistan[...]

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.1) ELECTRICAL DTC P0758 SHIFT SOLEN[...]

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 solenoid-B (C29-2) T erminal for solenoid-A (C29-1) TROUBLESHOOTING STEP ACTION YES NO 1 Was “ AUTOMA TIC TRANSMISSION DIAGNOSTIC FLOW T ABLE ” perform[...]

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.2) PERFORMANCE OR STUCK OFF CIRCUIT DESCRIPTION PCM moni[...]

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. G[...]

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 ” . 2 Is engine rpm at stall test normal? T ransmission failure. Go t[...]

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 ” . 2 Disconnect solenoid valve wire coupler and perform manual road test. Is upshift from 1[...]

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. Be sure to perform this test only when transmission fluid is at normal operating temperature (70 – 80 _ C / 158 – 176 _ F) and its level is be- tween[...]

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. NOTE: D Make sure that transmiss[...]

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. Check each part which is suspected to be the cause. Line pressure Possible causes Higher than specification in D and R ranges D Regulator valve defective D Throttle valve in valve bod[...]

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. D The test requires 2 persons, a driver and a tester . 1) W arm up [...]

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. T est drive vehicle on a level road. 1) With selector lever in P range, start engine and warm it[...]

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 TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) 7B-37 “ P ” RANGE TEST 1) Stop vehicle on a slope, shift selector lever to P range and at the same tim[...]

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. Go to Step 4. 3 Perform vehicle speed sensor check refer to “ OUT[...]

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. 2) Disconnect coupler(s) from powertrain control module. 3) Bring ohmmeter probes in tou[...]

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 . NOTE: D Function of output shaft speed sensor can be checked by measuring generated pulse as voltage[...]

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. Shift solenoid-B. (2nd brake solenoid valve) 6. Shift solenoid-A. (Direct clutch solenoid valve) AUTOMA TIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) 7B-41 3) Disconnect shift solen[...]

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 . Refer to “Air Bag System Components and Wiring Location V iew” under “Gener- al De[...]

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. Blank — 1 1. T o SDM (if equipped) Bl 12. Blank — 13. Blank — 14. Blank — 15.[...]

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 . The door locks can not operated with t[...]

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 . As the battery power is consumed[...]

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. 4) T urn the door switch ON and OFF 3 times within 20 seconds af- ter the [...]

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSTIC[...]

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. D Engine Control Module (E[...]

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. Diagnostic output terminal 4-2. Ground terminal 5. Malfunction indicator lamp 6. Main rel[...]

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 SYSTEM (SELF-DIAGNOSIS FUNCTION) Immobilizer Control Module & ECM diagnose troubles which may occur in the area including the following parts when th[...]

IMMOBILIZER CONTROL SYSTEM 8G-5 0.5 TIME (sec.) Ignition switch ON High Immobilizer control system is normal Immobilizer control system is abnormal Low 0.5 0.5 0.5 0.5 High Low <V ehicle not equipped with monitor coupler> With the ignition switch turned ON (but the engine at stop) regard- less of the condition of the engine and emission contr[...]

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. PRECAUTIONS IN DIAGNOSING TROUBLES [PRECA[...]

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. In such case, it may occur that good parts are[...]

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. 4 for Step 3 “ CHECK ENGINE ” light 0.5 ON OFF TIME (sec.) DIAGNOSTIC FLOW T ABLE <V ehicle equipped with monitor coupler> STEP ACTION YES NO 1 1) Make sure that diag[...]

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. D If immobilizer indicator lamp remains ON, go to Step 2. D If immobilizer indicator l[...]

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. Monitor coupler 2. Service wire A: Diagnosis switch terminal B: Ground terminal DIAGNOSTIC TRO[...]

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 . [Using SUZUKI scan tool] (V ehicle n[...]

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. VOL TMETER INDICA TION DIAGNOSTIC AREA DIAGNO[...]

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. Is it 10 – 14 V? “ f ” wire open. 1. Connect voltmeter between A5 terminal and body ground[...]

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 engine A-2 IMMOBILIZER INDICA TOR LAMP CHECK (IMMOBILIZER INDICA TOR LAMP DOSE NOT LIGHT A T IGNITION SWITCH ON) STEP ACTION YES NO 1 1) Turn ignition sw[...]

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-15 A-3 IMMOBILIZER INDICA TOR LAMP CHECK (IMMOBILIZER INDICA TOR LAMP REMAINS ON AFTER ENGINE ST ARTS) STEP ACTION YES NO 1 1) With ignition switch O[...]

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. 1) Prepare Suzuki scan tool (TECH 1A kit and cartridge for immobi- lizer control system). 2) Wit[...]

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. D It is not possible to register the same T ransponder code for ignition key with[...]

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. DLC cable adapter 8. Self-test adapter Immobilizer cartridge of version 1.1 or more NOTE: Use this[...]

Prepared by Overseas Service Department 1st Ed. July , 2000 Printed in Japan Printing: 556[...]