suzuki SF310, SF413 workshop manual

IMPORTANT

WARNING /CAUTION/ NOTE

Please read this manual and follow its instructions carefully. To emphasize special information, the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the messages highlighted by these signal words.

NOTE: Indicates special information to make maintenance easier or instructions clearer.

WARNING: Indicates a potential hazard that could result in death or injury.

CAUTION: Indicates a potential hazard that could result in vehicle damage.

WARNING: This service manual is intended for authorized SUZUKI dealers and qualified service mechanics only. Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to properly perform the services described in this manual. Improper repair may result in injury to the mechanic and may render the vehicle unsafe for the driver and passengers.

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FOREWORD

This SUPPLEMENTARY SERVICE MANUAL is a supplement to SF SERIES SERVICE MANUALS mentioned in next page and has been prepared exclusively for the following applicable model.

Applicable model: SF310/SF413 of and after the vehicle identification numbers below.

Vehicle Identification Number (Vehicle Specification)

TSMMAA44S00600001 (SF310 3 door H/B 2WD) TSMMAB44S00600001 (SF310 5 door H/B 2WD) TSMMAA35S00600001 (SF413 3 door H/B 2WD) TSMMAB35S00600001 (SF413 5 door H/B 2WD) TSMMAB35S10600001 (SF413 5 door H/B 2WD) TSMMSF35S00600001 (SF413 3 door H/B 4WD) TSMMSG35S00600001 (SF413 5 door H/B 4WD) TSMMAH35S00600001 (SF413 4 door N/B 2WD) TSMMAH35S10600001 (SF413 4 door N/B 2WD)

When servicing the above applicable models, refer to this SUPPLEMENTARY SERVICE MANUAL first. If necessary information is not found in this SUPPLEMENTARY SERVICE MANUAL, refer to RELATED MANUALS specified next page.

All information, illustrations and specifications contained in this literature are based on the latest product information available at the time of publication approval. And used as the main subject of description is the vehicle of standard specifications among others. Therefore, note that illustrations may differ from the vehicle being actually serviced. The right is reserved to make changes at any time without notice.

OVERSEAS SERVICE DEPARTMENT

 COPYRIGHT SUZUKI MOTOR CORPORATION 2000

RELATED MANUALS

Related manuals listed below are in the chronological order with the latest one at the top. For the efficient 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 found.

MODEL

NO. RELATED SERVICE MANUAL APPLICABILITY

SF310/ SF413

SF310/SF413 WIRING DIAGRAM MANUAL (99512-80E10-019)

This manual is prepared exclusively for the applicable model mentioned in FOREWORD of this supplementary service manual.

SF SERIES

SF SERIES SUPPLEMENTARY SERVICE MANUAL (99501-80E00-xxx)

This manual describes the updated information from the SF310 and SF413 Service Manuals below.

SF310

SF310 SUPPLEMENTARY SERVICE MANUAL (99501-60B00-xxx)

This manual describes the items that are updated (modified and added) from the Service Manual (99500-60B01).

(1,000 cc)

SF310 SERVICE MANUAL (99500-60B01-xxx)

This manual is the base manual for the above manual.

SF413 SUPPLEMENTARY SERVICE MANUAL (99501-63B30-xxx) [Pub. No. G4203GE]

This manual describes the items that are updated (modified and added) from the Service Manual (99500-63B01).

SF413

(1,300 cc)

SF413 SUPPLEMENTARY SERVICE MANUAL (99501-63B20-xxx) [Pub. No. G4202GE]

This manual describes the items for 4WD model that are updated (modified and added) from the Service Manual (99500-63B01).

(, )

SF413 SUPPLEMENTARY SERVICE MANUAL (99501-63B10-xxx)

This manual describes the items for SEDAN model that are updated (modified and added) from the Service Manual (99500-63B01).

SF413 SERVICE MANUAL (99500-63B01-xxx) [Pub. No. G4200GE]

This manual is the base manual for the above manuals.

SF SERIES (A/C)

AIR CONDITIONING BASIC MANUAL (99520-02130-xxx)

This manual is the base manual of A/C system.

6-1

6A1

6B 6C

6E1

6E2

6F 6F

6F1

6H 6K

GENERAL INFORMATION

General Information Maintenance and Lubrication

1A 1B

TABLE OF CONTENTS SECTION

0A 0B

HEATING AND AIR CONDITIONING

Heater and Ventilation Air Conditioning (Oprional)

ENGINE

General Information and Diagnosis (TBI for G10)

General Information and Diagnosis (TBI for G13)

General lnformation and Diagnosis (SFI for G13)

Engine Mechanical (G10 Engine) Engine Mechanical

(G13 1-cam 16-valves Engine) Engine Cooling Engine Fuel Engine and Emission Control System

(TBI for G10) Engine and Emission Control System

(TBI for G13) Engine and Emission Control System

(SFI for G13) Ignition System (TBI for G10) Ignition System (TBI for G13) Ignition System (SFI for G13) Cranking System Charging System Exhaust System

TRANSMISSION, CLUTCH AND DIFFERENTIAL

Automatic Transmission

BODY ELECTRICAL SYSTEM

Wiring Diagram

IMMOBILIZER CONTROL SYSTEM

6E1

6A1

6-1

6E2

6F1

6E1

NOTE: The screen toned Section 8A is contained in WIRING DIAGRAM MANUAL mentioned in RELATED MANUALS.

GENERAL INFORMATION 0A-1

SECTION 0A

GENERAL INFORMATION

CONTENTS

HOW TO USE THIS MANUAL 0A- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PRECAUTIONS 0A- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Precaution for Vehicles Equipped with a Supplemental Restraint (Air Bag) System 0A- 3. . . . . . . . . . . . . . . .

General Precautions 0A- 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Precautions for Catalytic Converter 0A- 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Precautions for Electrical Circuit Service 0A- 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Circuit Inspection Procedure 0A-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Intermittent and Poor Connection 0A-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Precaution for Installing Mobile Communication Equipment 0A-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Precaution in Servicing Full-Time 4WD Vehicle 0A-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IDENTIFICATION INFORMATION 0A-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Vehicle Identification Number 0A-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Identification Whether Vehicle Equipped with WU-TWC or Not 0A-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Identification Number 0A-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission Identification Number 0A-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARNING, CAUTION AND INFORMATION LABELS 0A-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VEHICLE LIFTING POINTS 0A-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ABBREVIATIONS AND SYMBOLS MAY BE USED IN THIS MANUAL 0A-22. . . . . . . . . . . . . . . . . . . . . . . . . . .

FASTENER INFORMATION 0A-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Metric Fasteners 0A-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fasteners Strength Identification 0A-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Standard Tightening Torque 0A-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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 Tool (A): 09924-17810 Tightening Torque (c): 78 N

m (7.8 kg-m, 56.0 lb-ft)

0A-2 GENERAL INFORMATION

HOW TO USE THIS MANUAL

1) There is a TABLE OF CONTENTS FOR THE WHOLE MANUAL on the third page of this manual, whereby you can easily find the section that offers the information you need. Also, there is a CONTENTS on the first page of EACH SECTION, where the main items in that section are listed.

2) Each section of this manual has its own pagination. It is indicated at the top of each page along with the Section name.

3) The SPECIAL TOOL usage and TIGHTENING TORQUE SPECIFICATION are given as shown in figure below.

4) A number of abbreviations are used in the text. For their full explanations, refer to “ABBREVIATIONS AND SYMBOLS MAY BE USED IN THIS MANUAL” of this section.

5) The SI, metric and foot-pound systems are used as units in this manual.

6) DIAGNOSIS are included in each section as necessary.

7) At the end of each section, there are descriptions of SPECIAL TOOLS, REQUIRED SERVICE MATERIALS and TIGHTENING TORQUE SPECIFICATIONS that should be used for the servicing work described in that section.

1. Air bag wire harness

2. Driver air bag (inflator) module

3. Passenger air bag (inflator) module

4. SDM

GENERAL INFORMATION 0A-3

PRECAUTIONS

PRECAUTION FOR VEHICLES EQUIPPED WITH A SUPPLEMENTAL RESTRAINT (AIR BAG) SYSTEM

WARNING: D The configuration of air bag system parts are as shown in

the figure. When it is necessary to service (remove, reinstall and inspect) these parts, be sure to follow procedures described in Section 9J. Failure to follow proper procedures could result in possible air bag deployment, personal injury, damage to parts or air bag being unable to deploy when necessary.

D If the air bag system and another vehicle system both

need repair, Suzuki recommends that the air bag system be repaired first, to help avoid unintended air bag deployment.

D Do not modify the steering wheel, dashboard, or any other

air bag system component. Modifications can adversely affect air bag system performance and lead to injury.

D If the vehicle will be exposed to temperatures over 93_C,

200_F (for example, during a paint baking process), remove the air bag system components (air bag (inflator) modules, sensing and diagnostic module) beforehand to avoid component damage or unintended deployment.

DIAGNOSIS

D When troubleshooting air bag system, be sure to follow

“DIAGNOSIS” in Section 9J. Bypassing these procedures may result in extended diagnostic time, incorrect diagnosis, and incorrect parts replacement.

D Never use electrical test equipment other than that specified

in this manual.

WARNING: Never attempt to measure the resistance of the air bag (inflator) modules (driver and passenger). It is very dangerous as the electric current from the tester may deploy the air bag.

1. Slit on workbench

2. Workbench vise

3. Lower mounting bracket

ALWAYS CARRY AIR BAG (INFLATOR) MODULE WITH TRIM COVER (AIR BAG OPENING) AWAY FROM BODY.

ALWAYS PLACE AIR BAG (INFLATOR) MODULE ON WORKBENCH WITH TRIM COVER (AIR BAG OPENING) UP, AWAY FROM LOOSE OBJECTS.

0A-4 GENERAL INFORMATION

HANDLING AND SERVICING

WARNING: D Many of service procedures require disconnection of

“AIR BAG” fuse and air bag (inflator) modules (driver and passenger) from deployment loop to avoid an accidental deployment.

Driver and Passenger Air Bag (Inflator) Modules D For handling and storage of a live air bag (inflator) module,

select a place where the ambient temperature below 65_C (150_F), without high humidity and away from electric noise.

D When carrying a live air bag (inflator) module, make sure

the bag opening is pointed away from you. In case of an accidental deployment, the bag will then deploy with minimal chance of injury. Never carry the air bag (inflator) module by the wires or connector on the underside of the module. When placing a live air bag (inflator) module on a bench or other surface, always face the bag up, away from the surface. As the live passenger air bag (inflator) module must be placed with its bag (trim cover) facing up, place it on the workbench with a slit or use the workbench vise to hold it securely at its lower mounting bracket. This is necessary so that a free space is provided to allow the air bag to expand in the unlikely event of accidental deployment. Otherwise, personal injury may result.

D Never dispose of live (undeployed) air bag (inflator) mod-

ules (driver and passenger). If disposal is necessary, be sure to deploy them according to deployment procedures described in Section 9J before disposal.

D The air bag (inflator) module immediately after deploy-

ment is very hot. Wait for at least half an hour to cool it off before proceeding the work.

D After an air bag (inflator) module has been deployed, the

surface of the air bag may contain a powdery residue. This powder consists primarily of cornstarch (used to lubricate the bag as it inflates) and by-products of the chemical reaction. As with many service procedures, gloves and safety glasses should be worn.

SDM D During service procedures, be very careful when handling

a Sensing and Diagnostic Module (SDM). Never strike or jar the SDM. Never power up the air bag system when the SDM is not rigidly attached to the vehicle. All SDM and mounting bracket fasteners must be carefully torqued and the arrow must be pointing toward the front of the vehicle to ensure proper operation of the air bag system. The SDM could be activated when powered while not rigidly attached to the vehicle which could cause deployment and result in personal injury.

GENERAL INFORMATION 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 air bag system component parts, remove those parts beforehand.

D When handling the air bag (inflator) modules (driver and

passenger) or SDM, be careful not to drop it or apply an impact to it. If an excessive impact was applied (e.g., dropped from a height of 91.4 cm (3 feet) or more), never attempt disassembly or repair but replace it with a new one.

D When grease, cleaning agent, oil, water, etc. has got onto

air bag (inflator) modules (driver and passenger), wipe off immediately with a dry cloth.

D Air bag wire harness can be identified easily as it is cov-

ered with a yellow protection tube. Be very careful when handling it.

D When an open in air bag wire harness, damaged wire har-

ness, connector or terminal is found, replace wire harness, connectors and terminals as an assembly.

D Do not apply power to the air bag system unless all com-

ponents are connected or a diagnostic chart requests it, as this will set a diagnostic trouble code.

D Never use air bag system component parts from another

vehicle.

D When using electric welding, be sure to temporarily dis-

able air bag system referring to “Disabling Air Bag System” under “Service Precaution” in Section 9J.

D Never expose air bag system component parts directly to

hot air (drying or baking the vehicle after painting) or flames.

D WARNING/CAUTION labels are attached on each part of

air bag system components. Be sure to follow the instructions.

D After vehicle is completely repaired, perform “Air Bag

Diagnostic System Check” described in “Diagnosis” in Section 9J.

0A-6 GENERAL INFORMATION

GENERAL PRECAUTIONS

The WARNING 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.

WARNING: D Whenever raising a vehicle for service, be sure to follow the instructions under “VEHICLE LIFTING

POINTS” on SECTION 0A.

D When it is necessary to do service work with the engine running, make sure that the parking brake

is set fully and the transmission is in Neutral (for manual transmission vehicles) or Park (for automatic transmission vehicles). Keep hands, hair, clothing, tools, etc. away from the fan and belts when the engine is running.

D When it is necessary to run the engine indoors, make sure that the exhaust gas is forced outdoors. D Do not perform service work in areas where combustible materials can come in contact with a hot

exhaust system. When working with toxic or flammable materials (such as gasoline and refrigerant), make sure that the area you work in is well-ventilated.

D To avoid getting burned, keep away from hot metal parts such as the radiator, exhaust manifold, tail-

pipe, muffler, etc.

D New and used engine oil can be hazardous. Children and pets may be harmed by swallowing new or

used oil. Keep new and used oil and used engine oil filters away from children and pets. Continuous contact with used engine oil has been found to cause [skin] cancer in laboratory animals. Brief contact with used oil may irritate skin. To minimize your exposure to used engine oil, wear a long-sleeve shirt and moisture-proof gloves (such as dish washing gloves) when changing engine oil. If engine oil contacts your skin, wash thoroughly with soap and water. Launder any clothing or rags if wet with oil, recycle or properly dispose of used oil and filters.

D Make sure the bonnet is fully closed and latched before driving. If it is not, it can fly up unexpectedly

during driving, obstructing your view and resulting in an accident.

CAUTION: D Before staring any service work, cover fenders, seats and

any other parts that are likely to get scratched or stained during servicing. Also, be aware that what you wear (e.g. buttons) may cause damage to the vehicle’s finish.

D When performing service to electrical parts that does not re-

quire use of battery power, disconnect the negative cable of the battery.

GENERAL INFORMATION 0A-7

D When removing the battery, be sure to disconnect the nega-

tive cable first and then the positive cable. When reconnecting 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 orderly manner so that they may be reinstalled in the proper order and position.

D Whenever you use oil seals, gaskets, packing, O-rings, lock-

ing washers, split pins, self-locking nuts, and certain other parts as specified, be sure to use new ones. Also, before installing new gaskets, packing, etc., be sure to remove any residual material from the mating surfaces.

D Make sure that all parts used in reassembly are perfectly

clean.

D When use of a certain type of lubricant, bond or sealant is

specified, be sure to use the specified type.

“A”: Sealant 99000-31150

D Be sure to use special tools when instructed.

Special Tool (A): 09917-98221 (B): 09916-58210

0A-8 GENERAL INFORMATION

D When disconnecting vacuum hoses, attach a tag describing

the correct installation positions so that the hoses can be reinstalled 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 dis-

connect the fuel line between the fuel pump and injector without first releasing the fuel pressure, or fuel can be sprayed out under pressure.

D When performing a work that produces a heat exceeding

80_C in the vicinity of the electrical parts, remove the heat sensitive electrical part(s) beforehand.

D Use care not to expose connectors and electrical parts to wa-

ter which will be a cause of a trouble.

GENERAL INFORMATION 0A-9

D Always be careful not to handle electrical parts (computer,

relay, etc.) in a rough manner or drop them.

PRECAUTIONS FOR CATALYTIC CONVERTER

For vehicles equipped with a catalytic converter, use only unleaded gasoline and be careful not to let a large amount of unburned gasoline enter the converter or it can be damaged. – Conduct a spark jump test only when necessary, make it as

short as possible, and do not open the throttle.

– Conduct engine compression checks within the shortest

possible time.

– Avoid situations which can result in engine misfire (e.g.

starting the engine when the fuel tank is nearly empty.).

PRECAUTIONS FOR ELECTRICAL CIRCUIT SERVICE

D When replacing a fuse, make sure to use a fuse of the speci-

fied capacity. Use of a fuse with a larger capacity will cause a damage to the electrical parts and a fire.

D When disconnecting and connecting coupler, make sure to

turn ignition switch OFF, or electronic parts may get damaged.

0A-10 GENERAL INFORMATION

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 with clamps so that

no slack is left.

D When installing vehicle parts, be careful so that the wiring

harness is not interfered with or caught by any other part.

GENERAL INFORMATION 0A-11

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 coupler is disconnected. Attempt to do it may cause damage to it.

D Never connect an ohmmeter to electronic control unit with

its coupler connected to it. Attempt to do it may cause damage to electronic control unit and sensors.

D Be sure to use a specified voltmeter / ohmmeter. Otherwise,

accurate measurements may not be obtained or personal injury may result. If not specified, use a voltmeter with high-impedance (MΩ /V minimum) or a digital type voltmeter.

D When taking measurements at electrical connectors using a

tester probe (2), be sure to insert the probe from the wire harness side (backside) of the connector (1).

D When connecting meter probe (2) from terminal side of cou-

pler (1) because it can’t be connected from harness side, use extra care not to bend male terminal of coupler of force its female terminal open for connection. In case of such coupler as shown connect probe as shown to avoid opening female terminal. Never connect probe where (3) male terminal is supposed to fit.

D To avoid damage to the harness, protect its part which may

contact against a part forming a sharp angle by winding tape or the like around it.

1. Check for loose connection

Sensor

ECM

0A-12 GENERAL INFORMATION

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 11 V or higher. Such terminal voltage check at low battery voltage will lead to erroneous diagnosis.

ELECTRICAL CIRCUIT INSPECTION PROCEDURE

While there are various electrical circuit inspection methods, described here is a general method to check its open and short circuit by using an ohmmeter and a voltmeter.

OPEN CIRCUIT CHECK

Possible causes for the open circuit are as follows. As the cause is in the connector or terminal in many cases, they need to be checked particularly carefully.

D Loose connection of connector. D Poor contact of terminal (due to dirt, corrosion or rust on it, poor

contact tension, entry of foreign object etc.).

D Wire harness being open.

When checking system circuits including an electronic control unit such as ECM, TCM, ABS control module, etc., it is important to perform careful check, starting with items which are easier to check.

1) Disconnect negative cable from battery.

2) Check each connector at both ends of the circuit being checked for loose connection. Also check lock condition of connector if equipped with connector lock.

1. Looseness of crimping

2. Open

3. Thin wire (single strand of wire)

Check contact tension by inserting and removing just for once

GENERAL INFORMATION 0A-13

3) Using a test male terminal, check both terminals of the circuit being checked for contact tension of its female terminal. Check each terminal visually for poor contact (possibly caused by dirt, corrosion, rust, entry of foreign object, etc.). At the same time, check to make sure that each terminal is locked in the connector fully.

4) Using continuity check or voltage check procedure described in the following page, check the wire harness for open circuit and poor connection with its terminals. Locate abnormality, if any.

Continuity Check

1) Measure resistance between connector terminals at both ends of the circuit being checked (between A-1 and C-1 in the figure). If no continuity is indicated (infinity or over limit), that means that the circuit is open between terminals A-1 and C-1.

2) Disconnect the connector included in the circuit (connector-B in the figure) and measure resistance between terminals A-1 and B-1. If no continuity is indicated, that means that the circuit is open between terminals A-1 and B-1. If continuity is indicated, there is an open circuit between terminals B-1 and C-1 or an abnormality in connector-B.

Voltage Check

If voltage is supplied to the circuit being checked, voltage check can be used as circuit check.

1) With all connectors connected and voltage applied to the circuit being checked, measure voltage between each terminal and body ground.

1. Other parts

1. To other parts

2 V voltage drop

0A-14 GENERAL INFORMATION

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 between terminals B-1 and A-1.

Voltage Between:

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

Also, if measured values were as listed below, it means that there is a resistance (abnormality) of such level that corresponds to the voltage drop in the circuit between terminals A-1 and B-1.

Voltage Between:

C-1 and body ground: Approx. 5 V B-1 and body ground: Approx. 5 V A-1 and body ground: Approx. 3 V

SHORT CIRCUIT CHECK (wire harness to ground)

1) Disconnect negative cable from battery.

2) Disconnect connectors at both ends of the circuit to be checked.

NOTE: If the circuit to be checked is connected to other parts, disconnect all connectors of those parts. Otherwise, diagnosis will be misled.

3) Measure resistance between terminal at one end of circuit (A-1 terminal in figure) and body ground. If continuity is indicated, it means that there is a short to ground between terminals A-1 and C-1 of the circuit.

4) Disconnect the connector included in circuit (connector B) and measure resistance between A-1 and body ground. If continuity is indicated, it means that the circuit is shorted to the ground between terminals A-1 and B-1.

1. Check contact tension by inserting and removing just once

2. Check each terminal for bend and proper alignment

GENERAL INFORMATION 0A-15

INTERMITTENT AND POOR CONNECTION

Most intermittent are caused by faulty electrical connections or wiring, although a sticking relay or solenoid can occasionally be at fault. When checking it for proper connection, perform careful check of suspect circuits for:

D Poor mating of connector halves, or terminals not fully seated in

the connector body (backed out).

D Dirt or corrosion on the terminals. The terminals must be clean

and free of any foreign material which could impede proper terminal contact. However, cleaning the terminal with a sand paper or the like is prohibited.

D Damaged connector body, exposing the terminals to moisture

and dirt, as well as not maintaining proper terminal orientation with the component or mating connector.

D Improperly formed or damaged terminals.

Check each connector terminal in problem circuits carefully to ensure good contact tension by using the corresponding mating terminal. If contact tension is not enough, reform it to increase contact tension or replace.

D Poor terminal-to-wire connection.

Check each wire harness in problem circuits for poor connection by shaking it by hand lightly. If any abnormal condition is found, repair or replace.

D Wire insulation which is rubbed through, causing an intermittent

short as the bare area touches other wiring or parts of the vehicle.

D Wiring broken inside the insulation. This condition could cause

continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand-type wire are intact, resistance could be far too high. If any abnormality is found, repair or replace.

0A-16 GENERAL INFORMATION

PRECAUTION FOR INSTALLING MOBILE COMMUNICATION EQUIPMENT

When installing mobile communication equipment such as CB (Citizens-Band)-radio or cellular-telephone, be sure to observe the following precautions. Failure to follow cautions may adversely affect electronic control system. D Keep the antenna as far away as possible from the vehicle’s elec-

tronic control unit.

D Keep the antenna feeder more than 20 cm (7.9 in.) away from

electronic control unit and its wire harnesses.

D Do not run the antenna feeder parallel with other wire harnesses. D Confirm that the antenna and feeder are correctly adjusted.

1. Transfer lock bolt

2. Shift fork shaft

Testing following items

D Speedometer D Chassis dynamo D Brake D Wheel balance (on car type)

Towing vehicle with front or rear wheels lifted up

Driving front wheels which are jacked up

4WD

2WD

GENERAL INFORMATION 0A-17

PRECAUTION IN SERVICING FULL-TIME 4WD VEHICLE

When performing any of the following types of work, be sure to make the vehicle as front wheel drive by cutting transmission of driving force to the rear wheels. Otherwise, rear wheels are driven and vehicle accidents, damage and personal injury may result.

SWITCHING FROM 4WD TO 2WD

Set 4WD/2WD select lever located at lower side of transfer driven case to 2WD as follows.

1) Loosen transfer lock bolt.

2) Push in shift fork shaft fully.

3) With shift fork shaft pushed in, tighten transfer lock bolt.

Tightening Torque (a): 19 N

m (1.9 kg-m, 14.0 lb-ft)

NOTE: D If shift fork shaft is hard to move, try to move it while turning

it to the right and left little by little. Do the same when setting back to 4WD after servicing vehicle.

D Upon completion of servicing, always set shift fork shaft

back to 4WD.

M/T A/T

G10 G13

[A] [A]

[B] [B]

0A-18 GENERAL INFORMATION

IDENTIFICATION INFORMATION

VEHICLE IDENTIFICATION NUMBER

The number is punched on the front dash panel in the engine room.

IDENTIFICATION WHETHER VEHICLE EQUIPPED WITH WU-TWC OR NOT

It can be identified by the shape of exhaust manifold (1) and exhaust pipe (2).

[A]: Vehicle equipped with WU-TWC (3) [B]: Vehicle not equipped with WU-TWC

ENGINE IDENTIFICATION NUMBER

The number is punched on the cylinder block.

TRANSMISSION IDENTIFICATION NUMBER

The number is punched on the transmission case.

NOTE: Air bag CAUTION / WARNING labels are attached on the vehicle equipped with air bag system only.

Air bag caution label

Tire 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 driver air bag (inflator) module

Air bag warning label on combination switch / contact coil assembly

Air bag caution label on steering column

Air bag warning label on passenger air bag (inflator) module

Air bag warning label on SDM

Radiator cap warning label

GENERAL INFORMATION 0A-19

WARNING, CAUTION AND INFORMATION LABELS

The figure below shows main labels among others that are attached to vehicle component parts. When servicing and handling parts, refer to WARNING/ CAUTION instructions printed on labels. If any WARNING/ CAUTION label is found stained or damaged, clean or replace it as necessary.

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

110 mm (4.3 in.)

SUPPORT LOCATION Forward of embossed-mark

120 mm (4.7 in.)

SUPPORT LOCATION Rearward of embossed-mark

: Support position for frame contact hoist and safety stand

: Floor jack position

Bolt

0A-20 GENERAL INFORMATION

VEHICLE LIFTING POINTS

WARNING: D Before applying hoist to underbody, always take vehicle balance throughout service into consider-

ation. Vehicle balance on hoist may change depending of what part to be removed.

D Before lifting up the vehicle, check to be sure that end of hoist arm is not in contact with brake pipe,

fuel pipe, bracket or any other part.

D When using frame contact hoist, apply hoist as shown (right and left at the same position). Lift up the

vehicle till 4 tires are a little off the ground and make sure that the vehicle will not fall off by trying to move vehicle body in both ways. Work can be started only after this confirmation.

D Make absolutely sure to lock hoist after vehicle is hoisted up.

When using floor jack:

GENERAL INFORMATION 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).

WARNING: D Never apply jack against suspension parts (i.e., stabilizer,

etc.) or vehicle floor, or it may get deformed.

D If the vehicle to be jacked up only at the front or rear end,

be sure to block the wheels on ground in order to ensure safety. After the vehicle is jacked up, be sure to support it on stands. It is extremely dangerous to do any work on the vehicle raised on jack alone.

To perform service with either front or rear vehicle end jacked up, be sure to place safety stands under body so that body is securely supported. And then check to ensure that body does not slide on safety stands and the vehicle is held stable for safety’s sake.

0A-22 GENERAL INFORMATION

ABS : Anti-Lock Brake System ATDC : After Top Dead Center API : American Petroleum Institute ATF : Automatic Transmission Fluid ALR : Automatic Locking Retractor AC : Alternating Current A/T : Automatic Transmission A/C : Air Conditioning ABDC : After Bottom Dead Center A/F : Air Fuel Mixture Ratio A-ELR : Automatic-Emergency Locking

Retractor

B+ : Battery Positive Voltage BTDC : Before Top Dead Center BBDC : Before Bottom Dead Center

CKT : Circuit CMP Sensor : Camshaft Position Sensor

(Crank Angle Sensor, CAS) CO : Carbon Monoxide CPP Switch : Clutch Pedal Position Switch

(Clutch Switch, Clutch Start

Switch) CPU : Central Processing Unit CRS : Child Restraint System

DC : Direct Current DLC : Data Link Connector (Assembly

Line Diag. Link, ALDL, Serial

Data Link, SDL) DOHC : Double Over Head Camshaft DOJ : Double Offset Joint DRL : Daytime Running Light DTC : Diagnostic Trouble Code

(Diagnostic Code)

EBCM : Electronic Brake Control

Module, ABS Control Module ECM : Engine Control Module ECT Sensor : Engine Coolant Temperature

Sensor (Water Temp. Sensor,

WTS) EGR : Exhaust Gas Recirculation EGRT Sensor : EGR Temperature Sensor

(Recirculated Exhaust

Gas Temp. Sensor, REGTS) EFE Heater : Early Fuel Evaporation Heater

(Positive Temperature

Coefficient, PTC Heater) ELR : Emergency Locking Retractor EPS : Electronic Power Steering EVAP : Evaporative Emission EVAP Canister : Evaporative Emission Canister

(Charcoal Canister)

4WD : 4 Wheel Drive

GEN : Generator GND : Ground

HC : Hydrocarbons HO2S : Heated Oxygen Sensor

IAC Valve : Idle Air Control Valve (Idle

Speed Control Solenoid Valve,

ISC Solenoid Valve) IAT Sensor : Intake Air Temperature Sensor

(Air temperature Sensor, ATS) ICM : Immobilizer Control Module IG : Ignition ISC Actuator : Idle Speed Control Actuator

(Motor)

ABBREVIATIONS AND SYMBOLS MAY BE USED IN THIS MANUAL

ABBREVIATIONS

GENERAL INFORMATION 0A-23

LH : Left Hand LSPV : Load Sensing Proportioning

Valve

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 Indicator Lamp M/T : Manual Transmission

NOx : Nitrogen Oxides

OBD : On-Board Diagnostic System

(Self-Diagnosis Function) O/D : Overdrive OHC : Over Head Camshaft

PNP : Park /Neutral Position P/S : Power Steering PSP Switch : Power Steering Pressure Switch

(P/S Pressure Switch) PCM : Powertrain Control Module PCV : Positive Crankcase Ventilation

RH : Right Hand

SAE : Society of Automotive

Engineers SDM : Sensing and Diagnostic Module

(Air Bag Controller, Air Bag

Control Module) SFI : Sequential Multiport Fuel

Injection SOHC : Single Over Head Camshaft

TBI : Throttle Body Fuel Injection

(Single-Point Fuel Injection,

SPI) TCC : Torque Converter Clutch TCM : Transmission Control Module

(A/T Controller, A/ T Control

Module) TP Sensor : Throttle Position Sensor TVV : Thermal Vacuum Valve

(Thermal Vacuum Switching

Valve, TVSV, Bimetal Vacuum

Switching Valve, BVSV) TWC : Three-Way Catalytic Converter

(Three-Way Catalyst) 2WD : 2 Wheel Drive

VIN : Vehicle Identification Number VSS : Vehicle Speed Sensor

WU-OC : Warm Up Oxidation Catalytic

Converter WU-TWC : Warm Up Three-Way Catalytic

Converter

G (Base Color)

Y (Stripe Color)

0A-24 GENERAL INFORMATION

SYMBOLS

SYMBOL DEFINITION SYMBOL DEFINITION

Tightening torque Apply SUZUKI BOND NO. 1216

99000-31160

Apply oil (Engine, transmission, transfer, differential)

Apply SILICONE SEALANT 99000-31120

Apply fluid (Brake, power steering or automatic transmission fluid)

Apply SEALING COMPOUND 366E 99000-31090

Apply SUZUKI SUPER GREASE A 99000-25010

Apply SUZUKI SUPER GREASE C 99000-25030

Apply THREAD LOCK 1322 99000-32110

Apply SUZUKI SUPER GREASE E 99000-25050

Apply THREAD LOCK 1333B 99000-32020

Apply SUZUKI SUPER GREASE H 99000-25120

Apply THREAD LOCK 1342 99000-32050

Apply SUZUKI SUPER GREASE I 99000-25210

Apply SUZUKI BOND NO. 1215 99000-31110

Do not reuse

Apply SUZUKI BOND NO. 1207C 99000-31150

Note on reassembly

WIRE COLOR SYMBOLS

Symbol Wire Color Symbol Wire Color

B BLK Black O, Or ORN Orange

Bl BLU Blue R RED Red

Br BRN Brown W WHT White

G GRN Green Y YEL Yellow

Gr GRY Gray P PNK Pink

Lbl LT BLU Light blue V PPL Violet

Lg LT GRN Light green

There are two kinds of colored wire used in this vehicle. One is single-colored wire and the other is dual-colored (striped) wire. The single-colored wire uses only one color symbol (i.e. “G”). The dual-colored wire uses two color symbols (i.e. “G/Y”). The first symbol represents the base color of the wire (“G” in the figure) and the second symbol represents the color of the stripe (“Y” in the figure).

GENERAL INFORMATION 0A-25

METRIC BOLTS-IDENTIFICATION CLASS NUMBERS OR MARKS CORRESPOND TO BOLT STRENGTH-INCREASING NUMBERS REPRESENT INCREASING STRENGTH.

NUT STRENGTH IDENTIFICATION

FASTENERS INFORMATION

METRIC FASTENERS

Most of the fasteners used for this vehicle are metric fasteners. When replacing any fasteners, it is most important that replacement fasteners be the correct diameter, thread pitch and strength.

FASTENER STRENGTH IDENTIFICATION

Most commonly used metric fastener strength property classes are 4T, 6.8, 7T, 8.8 and radial line with the class identification embossed on the head of each bolt. Some metric nuts will be marked with punch, 6 or 8 mark strength identification on the nut face. Figure shows the different strength markings. When replacing metric fasteners, be careful to use bolts and nuts of the same strength or greater than the original fasteners (the same number marking or higher). It is likewise important to select replacement fasteners of the correct diameter and thread pitch. Correct replacement bolts and nuts are available through the parts division.

0A-26 GENERAL INFORMATION

Self-lock nut

STANDARD TIGHTENING TORQUE

Each fastener should be tightened to the torque specified in each section of this manual. If no description or specification is provided, refer to the following tightening torque chart for the applicable torque for each fastener. When a fastener of greater strength than the original one is used, however, use the torque specified for the original fastener.

NOTE: D For the flanged bolt, flanged nut and self-lock nut of 4T and 7T strength, add 10% to the tightening torque

given in the chart below.

D The chart below is applicable only where the fastened parts are made of steel or light alloy.

Tightening torque chart

Thread Diameter (Nominal Diameter)

(mm)

4 5 6 8 10 12 14 16 18

Strength

A equivalent of 4T strength fastener

N.m 1.5 3.0 5.5 13 29 45 65 105 160

kg-m 0.15 0.30 0.55 1.3 2.9 4.5 6.5 10.5 16

lb-ft 1.0 2.5 4.0 9.5 21.0 32.5 47.0 76.0 116.0

A equivalent of 6.8 strength fastener without flange

N.m 2.4 4.7 8.4 20 42 80 125 193 280

kg-m 0.24 0.47 0.84 2.0 4.2 8.0 12.5 19.3 28

lb-ft 2.0 3.5 6.0 14.5 30.5 58.0 90.5 139.5 202.5

A equivalent of 6.8 strength fastener with flange

N.m 2.4 4.9 8.8 21 44 84 133 203 298

kg-m 0.24 0.49 0.88 2.1 4.4 8.4 13.3 20.3 29.8

lb-ft 2.0 3.5 6.5 15.5 32.0 61.0 96.5 147.0 215.5

A equivalent of 7T strength fastener

N.m 2.3 4.5 10 23 50 85 135 210 240

kg-m 0.23 0.45 1.0 2.3 5.0 8.5 13.5 21 24

lb-ft 2.0 3.5 7.5 17.0 36.5 61.5 98.0 152.0 174.0

A equivalent of 8.8 strength fastener without flange

N.m 3.1 6.3 11 27 56 105 168 258 373

kg-m 0.31 0.63 1.1 2.7 5.6 10.5 16.8 25.8 37.3

lb-ft 2.5 4.5 8.0 19.5 40.5 76.0 121.5 187.0 270.0

A equivalent of 8.8 strength fastener with flange

N.m 3.2 6.5 12 29 59 113 175 270 395

kg-m 0.32 0.65 1.2 2.9 5.9 11.3 17.5 27 39.5

lb-ft 2.5 5.0 9.0 21.0 43.0 82.0 126.5 195.5 286.0

MAINTENANCE AND LUBRICATION 0B-1

SECTION 0B

MAINTENANCE AND LUBRICATION

WARNING: 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 View” under “General Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring. Please observe all WARNINGS and “Service Precautions” under “On-Vehicle Service” in air bag system section before performing service on or around the air bag system components or wiring. Failure to follow WARNINGS could result in unintentional activation of the system or could render the system inoperative. Either of these two conditions may result in severe injury.

D Technical service work must be started at least 90 seconds after the ignition switch is turned to the

“LOCK” position and the negative cable is disconnected from the battery. Otherwise, the system may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).

CONTENTS

MAINTENANCE SCHEDULE 0B- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Normal Condition Schedule 0B- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance Recommended Under Severe Driving Conditions 0B- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE SERVICE 0B- 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine 0B- 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ignition System 0B-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel System 0B-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Emission Control System 0B-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brake 0B-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chassis and Body 0B-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Final Inspection 0B-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RECOMMENDED FLUIDS AND LUBRICANTS 0B-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0B-2 MAINTENANCE AND LUBRICATION

MAINTENANCE SCHEDULE

NORMAL CONDITION SCHEDULE

Interval: This interval should be

judg

ed b

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 ( 1,000) 15

30 45 60 75 90

whichever comes first.

Miles ( 1,000) 9

18 27 36 45 54

Months 12

24 36 48 60 72

1. ENGINE

1-1. Drive belt (tension,

V-belt I

R I R I R

damage)

V-rib belt (Flat type)

–

– I – – R

1-2. Camshaft timing belt Replace every 100,000 km (60,000 miles).

1-3. Valve lash (1.3 liter engine) – I – I – I

1-4. Engine oil

Vehicle with O2S (SG, SH, SJ) R

R R R R R

and oil filter

Vehicle with O2S (SE, SF) Vehicle without O2S

Replace every 10,000 km (6,000 miles) or 8 months

1-5. Engine coolant – R – R – R

1-6. Exhaust system (leakage, damage, tightness) – I – I – I

2. IGNITION SYSTEM

2-1. Spark plugs When unleaded

fuel is used

Vehicle without O2S

– R – R – R

Vehicle with O2S

– – R – – R

When leaded fuel is used Refer to “Severe Driving Condition” schedule.

2-2. Distributor cap and rotor (if equipped) – – I – – I

3. FUEL SYSTEM

3-1. Air cleaner filter

Paved-road I

I R I I R

Dusty condition Refer to “Severe Driving Condition” schedule.

3-2. Fuel lines (deterioration, leakage, damage) – I – I – I

3-3. Fuel tank – – I – – I

NOTES:

D For Item 2-1 “spark plugs”, replace every 50,000 km if the local law requires. D For Sweden, Item 2-1, 4-1 and 4-2 should be performed by odometer reading only. D For Item 1-2 Camshaft timing belt: This belt may be replaced every 90,000 km (54,000 miles) according

to customer’s maintenance convenience.

MAINTENANCE AND LUBRICATION 0B-3

Interval: This interval should be

judg

ed b

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 90

whichever comes first.

Miles ( 1,000)

9 18 27 36 45 54

Months

12 24 36 48 60 72

4. EMISSION CONTROL SYSTEM

4-1. PCV (Positive Crankcase Ventilation)

Valve

Vehicle without O2S

– – I – – I

Vehicle with O2S

– – – – – I

4-2. Fuel evaporative emission control system – – – – – I

5. BRAKE

5-1.

Brake discs and pads

I I I I I I

Brake drums and shoes

– I – I – I

5-2. Brake hoses and pipes – I – I – I

5-3. Brake fluid – R – R – R

5-4. Brake lever and cable Inspect at first 15,000 km (9,000 miles) only.

6. CHASSIS AND BODY

6-1. Clutch pedal (for manual transmission) – I – I – I

6-2. Tires/wheel discs I I I I I I

6-3. Propeller shaft (4WD) and drive shafts – – I – – I

6-4. Suspension system – I – I – I

6-5. Steering system – I – I – I

6-6. Power steering (if equipped) I I I I I I

6-7. Manual transmission oil I – R – – R

6-8. Automatic transmission

Fluid level

– I – I – I

Fluid change Replace every 165,000 km (99,000 miles).

Fluid hose

– – – R – –

6-9. Rear differential oil (4WD) (R: 1st 15,000 km only) R or I – I – I –

6-10. All latches, hinges and locks – I – I – I

NOTES:

D “R”: Replace or change D “I”: Inspect and correct or replace if necessary

0B-4 MAINTENANCE AND LUBRICATION

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 – Repeated short trips F – Leaded fuel use B – Driving on rough and/or muddy roads G – (For Diesel engine) Town use/ Towing a trailer/ C – Driving on dusty roads Sustained high speed driving/ D – Driving in extremely cold weather and/or Hot climates above 30_C (86_F)/

salted roads Low quality lubricants or fuel

E – Repeated short trips in extremely cold weather H – Trailer towing (if admitted)

Severe

Condition Code

Maintenance

Operation

Maintenance Interval

ITEM 1-1

Every 15,000 km (9,000 miles) or 12 months

– B C D – – – –

Drive belt (V-rib belt)

Every 45,000 km (27,000 miles) or 36 months

A – C D E F – H

ITEM 1-4 Engine oil and filter

Every 5,000 km (3,000 miles) or 4 months

A B C – E F – H

ITEM 2-1 Spark plugs

Every 10,000 km (6,000 miles) or 8 months

Every 2,500 km (1,500 miles)

– – C – – – – –

ITEM 3-1

Air cleaner filter *1

Every 30,000 km (18,000 miles) or 24 months

– B C D – – – H

ITEM 6-2 Wheel bearings

Every 15,000 km (9,000 miles) or 12 months

– B – D E – – H

ITEM 6-3 Propeller shaft (4WD) and drive shafts

Every 15,000 km (9,000 miles) or 12 months

– B – – E – – H

ITEM 6-7/6-8 Manual transmission oil and differential oil (4WD)

Every 30,000 km (18,000 miles) or 24 months

– B – – E – – H

ITEM 6-9 Automatic transmission fluid

Every 30,000 km (18,000 miles) or 24 months

NOTES:

D “R”: Replace or change D “I”: Inspect and correct or replace if necessary D *1: Inspect or replace more frequently if necessary

Vehicle with A/C

Vehicle with A/C and power steering

Vehicle with power steering

1. A/C compressor pulley

2. Power steering pump pulley

3. Tension pulley

4. Crankshaft pulley

MAINTENANCE AND LUBRICATION 0B-5

MAINTENANCE SERVICE

ENGINE

ITEM 1-1

Drive Belt Inspection and Replacement

WARNING: Disconnect negative cable at battery before checking and replacing belt.

A/C Compressor and/or Power Steering Pump Drive Belt

Inspection (If equipped)

1) Detach air cleaner assembly from vehicle body and shift its position.

2) Inspect belt for wear, deterioration and tension. Replace or adjust, if necessary.

A/C compressor and / or power steering pump drive belt tension “a”: 7 – 9 mm (0.28 – 0.35 in.) deflection under 10 kg or 22 lb pressure

A/C Compressor and/ or Power Steering Pump Drive Belt

Replacement

1) Disconnect negative cable from battery.

2) Remove engine under cover of right side.

3) Loosen belt tension and replace belt with new one.

4) Adjust belt tension to specification referring to SECTION 1B or SECTION 3B1.

5) Install engine under cover and connect negative cable to battery.

Water Pump Belt Inspection

1) Inspect belt for cracks, cuts, deformation, wear and cleanliness. Replace, if necessary.

2) Check pump belt for tension and adjust it as necessary.

Water pump belt tension “a”: 6 – 8 mm (0.24 – 0.32 in.) deflection under 10 kg or 22 lb pressure

1. Thickness gauge

0B-6 MAINTENANCE AND LUBRICATION

Water 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 to SECTION 6A or 6A1 for replacement procedure.

CAUTION:

D Do not bend or twist timing belt. D Do not allow timing belt to come into contact with oil, wa-

ter, etc.

ITEM 1-3

Valve Lash Inspection (1.3 liter engine only)

1) Remove cylinder head cover.

2) Inspect intake and exhaust valve lash and adjust as necessary. Refer to SECTION 6A1 for valve lash inspection and adjustment procedure.

Valve lash

When cold

(Coolant temperature is

15 – 25_C or 59 – 77_F)

When hot

(Coolant temperature is

60 – 68_C or

140 – 154_F)

(

gap

)

specifi-

Intake

0.13 – 0.17 mm

(0.005 – 0.007 in.)

0.17 – 0.21 mm

(0.007 – 0.008 in.)

cation

Exhaust

0.23 – 0.27 mm

(0.009 – 0.011 in.)

0.28 – 0.32 mm

(0.011 – 0.013 in.)

Special Tool (A): 09917-18211

Tightening Torque (a): 12 N

m (1.2 kg-m, 8.5 lb-ft)

3) Install cylinder head cover and tighten bolts to specification.

MAINTENANCE AND LUBRICATION 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

WARNING: New and used engine oil can be hazardous. Be sure to read “WARNING” in General Precaution in SEC- TION 0A and observe what in written there.

Use engine oil of SE, SF, SG, SH or SJ grade. Select the appropriate oil viscosity according to the left chart.

Before draining engine oil, check engine for oil leakage. If any evidence of leakage is found, make sure to correct defective part before proceeding to following work.

1) Drain engine oil by removing drain plug.

2) After draining oil, wipe drain plug clean. Reinstall drain plug, and tighten it securely as specified below.

Tightening Torque (a): 35 N

m (3.5 kg-m, 25.5 lb-ft)

3) Loosen oil filter by using oil filter wrench (Special tool).

Special Tool (A): 09915-47330

4) Apply engine oil to new oil filter O-ring.

5) Screw new filter on oil filter stand by hand until filter O-ring contacts mounting surface.

CAUTION: To tighten oil filter properly, it is important to accurately identify the position at which filter O-ring first contacts mounting surface.

6) Tighten filter 3/ 4 turn from the point of contact with mounting surface using an oil filter wrench.

Special Tool (A): 09915-47330

Tightening Torque (Reference) (a): 14 N

m (1.4 kg-m, 10.5 lb-ft)

1. Full level mark (hole)

2. Low level mark (hole)

Oil pan capacity

Oil filter capacity

Others

Total

1.0 L and 1.3 L Engine

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 LUBRICATION

7) Replenish oil until oil level is brought to FULL level mark on dipstick (oil pan and oil filter capacity). Filler inlet is at the top of cylinder head cover.

8) Start engine and run it for three minutes. Stop it and wait another 5 minutes before checking oil level. Add oil, as necessary, to bring oil level to FULL level mark on dipstick.

Engine Oil Capacity

NOTE: Engine oil capacity is specified as left table. However, note that amount of oil required when actually changing oil may somewhat differ from data in left table depending on various conditions (temperature, viscosity, etc.).

9) Check oil filter and drain plug for oil leakage.

ITEM 1-5

Engine Coolant Change

WARNING: To help avoid danger of being burned, do not remove radiator cap while engine and radiator are still hot. Scalding fluid and steam can be blown out under pressure if cap is taken off too soon.

CAUTION: When changing engine coolant, use mixture of 50% water and 50% ethylene-glycol base coolant (Anti-Freeze/Anticorrosion coolant) for the market where ambient temperature falls lower than –16_C (3_F) in winter and mixture of 70% water and 30% ethylene-glycol base coolant for the market where ambient temperature doesn’t fall lower than –16_C (3_F). Even in a market where no freezing temperature is anticipated, mixture of 70% water and 30% ethylene-glycol base coolant should be used for the purpose of corrosion protection and lubrication.

Refer to SECTION 6B for COOLANT CAPACITY.

For A / T

For M / T

MAINTENANCE AND LUBRICATION 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) Tighten 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 cap removed, until radiator upper hose is hot. This drives out any air which may still be trapped within cooling system. Add coolant as necessary until coolant level reaches filler throat of radiator. Reinstall radiator cap.

6) Add coolant to reservoir (1) so that its level aligns with Full mark (2). Then, reinstall cap to reservoir aligning match marks (3) on reservoir and cap.

ITEM 1-6

Exhaust System Inspection

WARNING: To avoid danger of being burned, do not touch exhaust system when it is still hot. Any service on exhaust system should be performed when it is cool.

When carrying out periodic maintenance or vehicle is raised for other service, check exhaust system as follows:

D Check rubber mountings for damage and deterioration. D Check exhaust system for leakage, loose connections, dents,

and damages. If bolts or nuts are loose, tighten them to specification. Refer to SECTION 6K for torque specification of bolts and nuts.

D Check nearby body areas for damaged, missing or mispositioned

parts, open seams, holes, loose connections or other defects which could permit exhaust fumes to seep into vehicle.

D Make sure that exhaust system components have enough clear-

ance from underbody to avoid overheating and possible damage to floor carpet.

D Any defects should be fixed at once.

0B-10 MAINTENANCE AND LUBRICATION

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 terminals for wear. D Check rotor for cracks and its electrode for wear.

Repair or replace any component which is found to be in malcondition.

FUEL SYSTEM

ITEM 3-1

Air Cleaner Filter Inspection

1) Take out air cleaner filter as follows. For 1.0 liter engine: i) Remove air cleaner upper case after removing case nut and

clamps.

ii) Remove air cleaner filter.

For 1.3 liter engine: i) Disconnect air cleaner outlet hose from case after loosening

its clamp and removing bolt (1) shown in figure.

ii) Remove air cleaner case cap (3) from case by unhooking its

clamps (2), then take out air cleaner filter.

1.0 liter engine

1.3 liter engine

MAINTENANCE AND LUBRICATION 0B-11

2) Visually check that air cleaner filter is not excessively dirty, damaged 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 Cleaner Filter Replacement

Replace air cleaner filter with new one according to steps 1), 4) and

5) of Air Cleaner Filter Inspection.

ITEM 3-2

Fuel Lines Inspection

D Check fuel lines for loose connection, deterioration or damage

which could cause leakage. Make sure all clamps are secure.

D Replace any damaged or deteriorate parts.

There should be no sign of fuel leakage or moisture at any fuel connection.

ITEM 3-3

Fuel Tank Inspection

Check fuel tank for damage, cracks, fuel leakage, corrosion and tank bolts looseness. If a problem is found, repair or replace.

0B-12 MAINTENANCE AND LUBRICATION

EMISSION CONTROL SYSTEM

ITEM 4-1

PCV (Positive Crankcase Ventilation) Valve Inspection

Check crankcase ventilation hoses and PCV hoses for leaks, cracks or clog, and PCV valve (1) for stick or clog. Refer to ON-VEHICLE SERVICE of SECTION 6E1 or 6E2 for PCV valve checking procedure.

ITEM 4-2

Fuel Evaporative Emission Control System Inspection

1) Visually inspect hoses for cracks, damage or excessive bends. Inspect all clamps for damage and proper position.

2) Check EVAP canister for operation and clog, referring to SECTION 6E1 or 6E2. If a malfunction is found, repair or replace.

BRAKE

ITEM 5-1

Brake Discs, Pads, Drums and Shoes Inspection

Brake discs and pads

NOTE: If noise is heard from brake when brake pedal is depressed, check brake pad lining for wear. If it is worn, both right and left brake pads should be replaced with new ones.

1) Remove wheel and caliper but don’t disconnect brake hose from caliper.

2) Check disc brake pads and discs for excessive wear, damage and deflection. Replace parts as necessary. For the details, refer to SECTION 5.

3) Install caliper and wheel.

Brake drums and shoes

1) Remove wheel and brake drum.

2) Check rear brake drums and brake linings for excessive wear and damage. At the same time, check wheel cylinders for leakage. Replace as necessary. For the details, refer to SECTION 5.

3) Install brake drum and wheel.

MAINTENANCE AND LUBRICATION 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 tightness and connections for leakage. D Check that hoses and pipes are clear of sharp edges, moving

parts.

CAUTION: After replacing any brake pipe or hose, be sure to carry out air purge operation.

ITEM 5-3

Brake Fluid Change

CAUTION: Since brake system of this vehicle is factory-filled with brake fluid indicated on reservoir cap, do not use or mix different type of fluid when refilling; otherwise serious damage will occur. Do not use old or used brake fluid, or any fluid from a unsealed container.

Change brake fluid as follows. Drain existing fluid from brake system completely, fill system with specified fluid and carry out air purge operation. For air purging procedure, refer to SECTION 5.

“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 LUBRICATION

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 parking lever.

D Check parking brake lever for proper operation and stroke, and

adjust it if necessary. For checking and adjusting procedures, refer to PARKING BRAKE INSPECTION AND ADJUSTMENT of SECTION 5.

Parking brake cable

Inspect brake cable for damage and smooth movement. Replace cable if it is in deteriorated condition.

CHASSIS AND BODY

ITEM 6-1

Clutch Pedal Free Travel Inspection

Check clutch pedal free travel. Refer to SECTION 7C for procedure to check and adjust it.

ITEM 6-2

Tire and Wheel Disc Inspection

[Tire inspection]

1) Check tire for uneven or excessive wear, or damage. If defective, replace.

2) Check inflating pressure of each tire and adjust pressure to specification as necessary.

NOTE: D Tire inflation pressure should be checked when tires are

cool.

D Specified tire inflation pressure should be found on tire

placard or in owner’s manual which came with vehicle.

1. Drive shaft

2. Boot

MAINTENANCE AND LUBRICATION 0B-15

[Wheel disc inspection] Inspect each wheel disc for dents, distortion and cracks. A disc in badly damaged condition must be replaced.

[Tire rotation] Rotate tires referring to SECTION 3F.

Wheel Bearing Inspection

1) Check front wheel bearing for wear, damage, abnormal noise or rattles. For details, refer to SECTION 3D.

2) Check rear wheel bearing for wear, damage abnormal noise or rattle. For details, refer to SECTION 3E.

ITEM 6-3

Propeller Shaft Inspection (4WD vehicle only)

1) Check propeller shaft connecting bolts for looseness. If looseness is found, tighten to specified torque.

2) Check propeller shaft joints for wear, play and damage. If any defect is found, replace.

3) Check propeller shaft center support (1) for biting of foreign matter, crack, abnormal noise and damage. If any defect is found, replace.

Drive Shaft Boot Inspction

Check drive shaft boots (wheel side and differential side) for leakage, detachment, tear or any other damage. Replace boot as necessary.

ITEM 6-4

Suspension System Inspection

D Inspect front & rear struts for evidence of oil leakage, dents or any

other damage on sleeves; and inspect anchor ends for deterioration. Replace defective parts, if any.

1. Ball joint stud dust seal (boot)

2. Suspension arm

1. Tie-rod end boot

2. Steering gear case boot

3. Universal joint

0B-16 MAINTENANCE AND LUBRICATION

D Check front and rear suspension systems for damaged, loose or

missing parts; also for parts showing signs of wear or lack of lubrication. Repair or replace defective parts, if any.

D Check front suspension arm ball joint stud dust seals for leakage,

detachment, tear or any other damage. Replace defective boot, if any.

ITEM 6-5

Steering System Inspection

1) Check steering wheel for play and rattle, holding vehicle straight on ground.

Steering wheel play “a”: 0 – 30 mm (0 – 1.1 in.)

2) Check steering linkage for looseness and damage. Repair or replace defective parts, if any.

3) Check boots of steering linkage and steering gear case for damage (leaks, detachment, tear, etc.). If damage is found, replace defective boot with new one.

4) Check universal joints of steering shaft for rattle and damage. If rattle or damage is found, replace defective part with a new one.

ITEM 6-6

Power Steering (P/S) System Inspection (if equipped)

1) Visually check power steering system for fluid leakage and hose for damage and deterioration. Repair or replace defective parts, if any.

2) With engine stopped, check fluid level indicated on fluid tank, which should be between MAX and MIN marks. If it is lower than MIN, fill fluid up to MAX mark.

NOTE

D Be sure to use specified P / S fluid. D Fluid level should be checked when fluid is cool.

3) Visually check pump drive belt for cracks and wear.

4) Check belt for tension, referring to item 1-1 in this section. If necessary, adjust or replace.

2WD

4WD

1. Oil filler / level plug

2. Oil drain plug

MAINTENANCE AND LUBRICATION 0B-17

ITEM 6-7

Manual Transmission 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) Check oil level. Oil level can be checked roughly by means of filler/level plug hole. That is, if oil flows out of level plug hole or if oil level is found up to hole when level plug is removed, oil is properly filled. If oil is found insufficient, pour specified oil up to level hole. For specified oil, refer to description of oil change under ON-VEHICLE SERVICE in SECTION 7A or 7A1.

5) Tighten level plug to specified torque.

[Change]

1) Place the vehicle level and drain oil by removing drain plug.

2) Apply sealant to drain plug and tighten drain plug to specified torque.

3) Pour specified oil up to level hole.

4) Tighten filler plug to specified torque. For recommended oil, its amount and tightening torque data, refer to ON-VEHICLE SERVICE of SECTION 7A or 7A1.

ITEM 6-8

Rear Differential Oil Inspection and Change (4WD vehicle only)

[Inspection]

1) Inspect rear differential case for evidence of oil leakage. Repair leaky point, if any.

2) Make sure that the vehicle is placed level for oil level check.

3) Remove level plug (1) of differential. Oil level can be checked roughly by means of level plug hole. That is, if oil flows out of level plug hole or if oil level is found up to hole when level plug is removed, oil is properly filled. If oil is found insufficient, pour specified amount of specified oil as given in SECTION 7E.

4) Tighten it to specified torque.

[Change] Place the vehicle level and drain oil by removing drain plug (2). Pour specified amount of specified oil, tighten drain plug and filler plug to specified torque, referring to ON-VEHICLE SERVICE in SECTION 7E.

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 LUBRICATION

ITEM 6-9

Automatic Transmission

[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) Check fluid level. For fluid level checking procedure, refer to ON-VEHICLE SERVICE in SECTION 7B and be sure to perform it under specified conditions. If fluid level is low, replenish specified fluid.

[Fluid change]

1) Perform steps 1) and 2) of above Fluid Level Inspection.

2) Change fluid. For its procedure, refer to ON-VEHICLE SERVICE in SECTION 7B.

CAUTION: Use of specified fluid is absolutely necessary.

[Fluid cooler hose change] Replace inlet and outlet hoses (1) of cooler hose and their clamps. For replacement procedure, refer to ON-VEHICLE SERVICE in SECTION 7B.

“A”: Oil point

1. Upper hinge

2. Lower hinge

3. Door

4. Body

MAINTENANCE AND LUBRICATION 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.

Engine hood

Check that secondary latch operates properly (check that secondary latch keeps hood from opening all the way even when pulling hood release handle inside vehicle.). Also check that hood opens and closes smoothly and properly and hood locks securely when closed. If any malfunction is found, lubricate hinge and latch, or repair hood lock system.

0B-20 MAINTENANCE AND LUBRICATION

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 BELT” label on belt is visible, replace belt. Check that seat belt is securely locked.

Battery Electrolyte Level Check

Check that the electrolyte level of all battery cells is between the upper and lower level lines on the case. If battery is equipped with built-in indicator, check battery condition by the indicator.

Accelerator Pedal Operation

Check that pedal operates smoothly without getting caught or interfered by and other part.

Engine Start

Check engine start for readiness.

On automatic transmission vehicles, try to start the engine in each gear. The starter should crank only in “P” (Park) or “N” (Neutral). On manual transmission vehicles, place the shift lever in “Neutral,” depress clutch pedal fully and try to start.

Exhaust System Check

Check for leakage, cracks or loose supports.

Clutch (For manual transmission)

Check for the following. D Clutch is completely released when depressing

clutch pedal.

D No slipping clutch occurs when releasing pedal and

accelerating.

D Clutch itself is free from any abnormal condition.

Gearshift or Select Lever (Transmission)

Check gear shift or select lever for smooth shifting to all positions and for good performance of transmission in any position. With automatic transmission equipped vehicle, also check that shift indicator indicates properly according to which position select lever is shifted to.

CAUTION: With automatic transmission equipped vehicle, make sure that vehicle is at complete stop when shifting select lever to “P” range position and release all brakes.

Brake

[Foot brake] Check the following;

D that brake pedal has proper travel, D that brake works properly, D that it is free from noise, D that vehicle does not pull to one side when brake is

applied,

D and that brake does not drag.

WARNING: When carrying out road tests, select a safe place where no man or no running vehicle is seen so as to prevent any accident.

WARNING: Before performing the following check, be sure to have enough room around the vehicle. Then, firmly apply both the parking brake and the regular brakes. Do not use the accelerator pedal. If the engine starts, be ready to turn off the ignition promptly. Take these precautions because the car could move without warning and possibly cause personal injury or property damage.

MAINTENANCE AND LUBRICATION 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 vehicle does not wander or pull to

one side.

Engine

D Check that engine responds readily at all speeds. D Check that engine is free from abnormal noise and

abnormal vibration.

Body, Wheels and Power Transmitting System

Check that body, wheels and power transmitting system are free from abnormal noise and abnormal vibration or any other abnormal condition.

Meters and Gauge

Check that speedometer, odometer, fuel meter, temperature gauge, etc. are operating accurately.

Lights

Check that all lights operate properly.

Windshield Defroster

Periodically check that air comes out from defroster outlet when operating heater or air conditioning. Set fan switch lever to “HI” position and mode lever to defroster position for this check.

WARNING: With vehicle parked on a fairly steep slope, make sure nothing is in the way downhill to avoid any personal injury or property damage. Be prepared to apply regular brake quickly even if vehicle should start to move.

RECOMMENDED FLUIDS AND LUBRICANTS

Engine oil SE, SF, SG, SH or SJ (Refer to engine oil viscosity chart in item 1-4.)

Engine coolant Ethylene-glycol base coolant (“Antifreeze /Anticorrosion coolant”)

Brake fluid DOT3

Manual transmission oil See SECTION 7A

Rear differential oil See SECTION 7E

Automatic transmission fluid An equivalent of DEXRONR-IIE or DEXRONR-III

Power steering fluid See material table on SECTION 3B1

Door hinges Engine oil

Engine hood latch Engine oil

Key lock cylinder Spray lubricant

ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-1

GENERAL INFORMATION 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. . . . . . . .

ENGINE DIAGNOSIS 6- 6. . . . . . . . . . . . . . . . . . .

General Description 6- 6. . . . . . . . . . . . . . . . . . .

On-Board Diagnostic System 6- 6. . . . . . . . . .

Precaution in Diagnosing Trouble 6- 9. . . . . . .

Engine Diagnostic Flow Table 6-10. . . . . . . . . .

Customer Problem Inspection From 6-12. . . . .

Malfunction Indicator Lamp Check 6-13. . . . . .

Diagnostic Trouble Code Check 6-13. . . . . . . .

SECTION 6

ENGINE GENERAL INFORMATION

AND DIAGNOSIS

(TBI FOR G10)

WARNING: 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-

D Technical service work must be started at least 90 seconds after the ignition switch is turned to the

“LOCK” position and the negative cable is disconnected from the battery. Otherwise, the system may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).

ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI for G10) 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI for G13) 6-1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE MECHANICAL (G10) 6A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE MECHANICAL (G13 1 cam 16 valves) 6A1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE COOLING 6B-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE FUEL 6C-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE AND EMISSION CONTROL SYSTEM (TBI for G10) 6E1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE AND EMISSION CONTROL SYSTEM (SFI for G13) 6E2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IGNITION SYSTEM (G10 ENGINE) 6F-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IGNITION SYSTEM (G13 ENGINE) 6F1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CRANKING SYSTEM 6G-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHARGING SYSTEM 6H-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EXHAUST SYSTEM 6K-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

NOTE: For the descriptions for vehicle without warm up three way catalytic converter (WUTWC), refer to Section 6 and 6E1 of the Service Manual mentioned in the FOREWORD of this manual.

CONTENTS

Diagnostic Trouble Code Clearance 6-14. . . . .

Diagnostic Trouble Code Table 6-15. . . . . . . . .

Fail-safe Table 6-18. . . . . . . . . . . . . . . . . . . . . . .

Visual Inspection 6-19. . . . . . . . . . . . . . . . . . . . .

Engine Basic Inspection 6-20. . . . . . . . . . . . . . .

Engine Diagnosis Table 6-22. . . . . . . . . . . . . . .

Scan Tool Data 6-29. . . . . . . . . . . . . . . . . . . . . . .

Scan Tool Data Definitions 6-31. . . . . . . . . . . . .

Inspection of ECM (PCM) and Its Circuits 6-33

Voltage Check 6-33. . . . . . . . . . . . . . . . . . . . .

Resistance Check 6-37. . . . . . . . . . . . . . . . . .

Component Location 6-38. . . . . . . . . . . . . . . . . .

Table A-1 MIL Circuit Check

(Lamp does not come on) 6-39. . . . . . . . . . . .

Table A-2 MIL Circuit Check

(Lamp remains ON) 6-40. . . . . . . . . . . . . . . . . .

Table A-3 ECM (PCM) Power and Ground

Circuit Check 6-42. . . . . . . . . . . . . . . . . . . . . . .

DTC P0105 MAP Circuit Malfunction 6-44. . . .

DTC P0110 IAT Circuit Malfunction 6-46. . . . .

DTC P0115 ECT Circuit Malfunction 6-48. . . .

DTC P0120 Throttle Position Circuit

Malfunction 6-50. . . . . . . . . . . . . . . . . . . . . . . . .

DTC P0121 Throttle Position Circuit

Range/Performance Problem 6-52. . . . . . . . .

DTC P0130 HO2S Circuit Malfunction

(Sensor-1) 6-54. . . . . . . . . . . . . . . . . . . . . . . . . .

DTC P0133 HO2S Circuit Slow

Response (Sensor-1) 6-56. . . . . . . . . . . . . . . .

DTC P0135 HO2S Heater Circuit

Malfunction (Sensor-1) 6-57. . . . . . . . . . . . . . .

DTC P0136 HO2S Circuit Malfunction

(Sensor-2) 6-59. . . . . . . . . . . . . . . . . . . . . . . . . .

DTC P0141 HO2S Heater Circuit

Malfunction (Sensor-2) 6-62. . . . . . . . . . . . . . .

DTC P0171 Fuel System Too Lean 6-64. . . . .

DTC P0172 Fuel System Too Rich 6-64. . . . . .

DTC P0300 Random Misfire Detected 6-68. . . DTC P0301 Cylinder 1 Misfire Detected 6-68.

DTC P0302 Cylinder 2 Misfire Detected 6- 68. DTC P0303 Cylinder 3 Misfire Detected 6- 68. DTC P0335 CKP Sensor Circuit

Malfunction 6- 72. . . . . . . . . . . . . . . . . . . . . . . . .

DTC P0340 CMP Sensor Circuit

Malfunction 6- 74. . . . . . . . . . . . . . . . . . . . . . . . .

DTC P0420 Catalyst System Efficiency

Below Threshold 6- 76. . . . . . . . . . . . . . . . . . . .

DTC P0443 Purge Control Valve Circuit

Malfunction 6- 79. . . . . . . . . . . . . . . . . . . . . . . . .

DTC P0480 Radiator Fan Control

System Malfunction 6- 80. . . . . . . . . . . . . . . . . .

DTC P0500 Vehicle Speed Sensor

Malfunction (M/T) 6- 82. . . . . . . . . . . . . . . . . . .

DTC P0500 Vehicle Speed Sensor

Malfunction (A/T) 6- 84. . . . . . . . . . . . . . . . . . .

DTC P0505 Idle Control System

Malfunction 6- 86. . . . . . . . . . . . . . . . . . . . . . . . .

DTC P0510 Closed Throttle Position

Switch Malfunction 6- 88. . . . . . . . . . . . . . . . . .

DTC P0601 Internal Control Module

Memory Check Sum Error 6- 89. . . . . . . . . . . .

DTC P1250 EFE Heater Circuit

Malfunction 6- 90. . . . . . . . . . . . . . . . . . . . . . . . .

DTC P1450 Barometric Pressure

Sensor Low/High Input 6- 92. . . . . . . . . . . . . .

DTC P1451 Barometric Pressure Sensor

Performance Problem 6- 92. . . . . . . . . . . . . . . .

DTC P1500 Engine Starter Signal

Circuit Malfunction 6- 93. . . . . . . . . . . . . . . . . . .

DTC P1510 ECM (PCM) Back-up Power

Supply Malfunction 6- 94. . . . . . . . . . . . . . . . . .

Table B-1 Fuel Injector Circuit Check 6- 96. . . .

Table B-2 Fuel Pump and Its Circuit

Check 6- 98. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table B-3 Fuel Pressure Check 6-100. . . . . . . . .

Table B-4 A/C Signal Circuits Check 6-102. . . .

Table B-5 Power Steering Pressure

Switch Signal Circuit Check 6-103. . . . . . . . . . .

SPECIAL TOOL 6-104. . . . . . . . . . . . . . . . . . . . . . .

6-2 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10)

1. No.1 cylinder

2. No.2 cylinder

3. No.3 cylinder

ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-3

GENERAL INFORMATION

STATEMENT 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 parts are serviced, care and cleanliness are important. Throughout this section, it should be understood that proper cleaning and protection of machined surfaces and friction areas is part of the repair procedure. This is considered standard shop practice even if not specifically stated. D A liberal coating of engine oil should be applied to friction areas

during assembly to protect and lubricate the surfaces on initial operation.

D Whenever valve train components, pistons, piston rings, con-

necting rods, rod bearings, and crankshaft journal bearings are removed for service, they should be retained in order. At the time of installation, they should be installed in the same locations and with the same mating surfaces as when removed.

D Battery cables should be disconnected before any major work is

performed on the engine. Failure to disconnect cables may result in damage to wire harness or other electrical parts.

D Throughout this manual, the four cylinders of the engine are iden-

tified by numbers; No.1 (1), No.2 (2) and No.3 (3) counted from crankshaft pulley side to flywheel side.

GENERAL INFORMATION ON ENGINE SERVICE

THE FOLLOWING INFORMATION ON ENGINE SERVICE SHOULD BE NOTED CAREFULLY, AS IT IS IMPORTANT IN PREVENTING DAMAGE, AND IN CONTRIBUTING TO RELIABLE ENGINE PERFORMANCE. D When raising or supporting engine for any reason, do not use a

jack under oil pan. Due to small clearance between oil pan and oil pump strainer, jacking against oil pan may cause it to be bent against strainer resulting in damaged oil pick-up unit.

D It should be kept in mind, while working on engine, that 12-volt

electrical system is capable of violent and damaging short circuits. When performing any work where electrical terminals can be grounded, ground cable of the battery should be disconnected at battery.

D Any time the air cleaner, throttle body or intake manifold is re-

moved, the intake opening should be covered. This will protect against accidental entrance of foreign material which could follow intake passage into cylinder and cause extensive damage when engine is started.

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 position

3 to 7 mm (0.12–0.27 in.)

from hose end.

With bent pipe, fit hose as its bent part as shown or till pipe is about 20 to 30 mm (0.79–1.18 in.) into the hose.

Clamp securely at a position 3 to 7 mm (0.12–0.27 in.) from hose end.

With straight pipe, fit hose till pipe is, about 20 to 30 mm (0.79–1.18 in.) into the hose.

Hose

20 to 30 mm (0.79–1.18 in.)

Clamp

6-4 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10)

PRECAUTION ON FUEL SYSTEM SERVICE

D Work must be done with no smoking, in a well-ventilated area and

away from any open flames.

D As fuel feed line (between fuel pump and fuel delivery pipe) is still

under high fuel pressure even after engine was stopped, loosening or disconnecting fuel feed line directly may cause dangerous spout of fuel to occur where loosened or disconnected. Before loosening or disconnecting fuel feed line, make sure to release fuel pressure according to “FUEL PRESSURE RELIEF PROCEDURE”. A small amount of fuel may be released after the fuel line is disconnected. In order to reduce the chance of personal injury, cover the fitting to be disconnected with a shop cloth. Put that cloth in an approved container when disconnection is completed.

D Never run engine with fuel pump relay disconnected when engine

and exhaust system are hot.

D Fuel or fuel vapor hose connection varies with each type of pipe.

When reconnecting fuel or fuel vapor hose, be sure to connect and clamp each hose correctly referring to left figure Hose Connection. After connecting, make sure that it has no twist or kink.

D When installing injector or fuel delivery pipe, lubricate its O-ring

with spindle oil or gasoline.

D When connecting fuel pipe flare nut, first tighten flare nut by hand

and then tighten it to specified torque.

ENGINE GENERAL INFORMATION 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 follows.

1) Place transmission gear shift lever in “Neutral” (Shift selector lever to “P” range for A/T model), set parking brake, and block drive wheels.

2) Remove relay box cover.

3) Disconnect fuel pump relay (1) from relay box (2).

4) Remove fuel filler cap to release fuel vapor pressure in fuel tank and then reinstall it.

5) Start engine and run it till it stops for lack of fuel. Repeat cranking engine 2-3 times for about 3 seconds each time to dissipate fuel pressure in lines. Fuel connections are now safe for servicing.

6) Upon completion of servicing, connect fuel pump relay to relay box and install relay box cover.

FUEL LEAKAGE CHECK PROCEDURE

After performing any service on fuel system, check to make sure that there are no fuel leakages as follows.

1) Turn ON ignition switch for 2 seconds (to operate fuel pump) and then turn it OFF. Repeat this (ON and OFF) 3 or 4 times and apply fuel pressure to fuel line. (till fuel pressure is felt by hand placed on fuel feed hose.)

2) In this state, check to see that there are no fuel leakages from any part of fuel system.

6-6 ENGINE GENERAL INFORMATION 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 OnBoard Diagnostic system which detects a malfunction in this system and abnormality of those parts that influence the engine exhaust emission. When diagnosing engine troubles, be sure to have full understanding of the outline of “On-Board Diagnostic System” and each item in “Precaution in Diagnosing Trouble” and execute diagnosis ac- cording to “ENGINE DIAGNOSTIC FLOW TABLE”. There is a close relationship between the engine mechanical, engine cooling system, ignition system, exhaust system, etc. and the engine and emission control system in their structure and operation. In case of an engine trouble, even when the malfunction indicator lamp (MIL) doesn’t turn ON, it should be diagnosed according to this flow table.

ON-BOARD DIAGNOSTIC SYSTEM

ECM (PCM) in this vehicle has following functions. D When the ignition switch is turned ON with the engine at a stop,

malfunction indicator lamp (MIL) (1) turns ON to check the bulb of the malfunction indicator lamp (1).

D When ECM (PCM) detects a malfunction which gives an adverse

effect to vehicle emission while the engine is running, it makes the malfunction indicator lamp (1) in the meter cluster of the instrument panel turn ON or flash (flashing only when detecting a misfire which can cause damage to the catalyst) and stores the malfunction area in its memory. (If it detects that continuously 3 driving cycles are normal after detecting a malfunction, however, it makes MIL (1) turn OFF although DTC stored in its memory will remain.)

D As a condition for detecting a malfunction in some areas in the

system being monitored by ECM (PCM) and turning ON the malfunction indicator lamp (1) due to that malfunction, 2 driving cycle detection logic is adopted to prevent erroneous detection.

D When a malfunction is detected, engine and driving conditions

then are stored in ECM (PCM) memory as freeze frame data. (For the details, refer to description on Freeze frame data.)

D It is possible to communicate by using not only SUZUKI scan tool

(Tech-1) (2) but also generic scan tool. (Diagnostic information can be accessed by using a scan tool.)

An Example of Freeze Frame Data

1. Trouble Code P0102 (1st)

2. Engine Speed 782 RPM

3. Eng Cool Tmp. 80_C

4. Vehicle Spd. 0 km/h

5. MAP Sensor 39 kPa

6. St. Term FT1 – 0.8% Lean

7. Lg. Term 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 position in the order the malfunction is detected.

ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-7

Warm-up Cycle

A warm-up cycle means sufficient vehicle operation such that the coolant temperature has risen by at least 22_C (40_F) from engine starting and reaches a minimum temperature of 70_C (160_F).

Driving Cycle

A “Driving Cycle” consists of engine startup, driving mode where a malfunction would be detected if present and engine shutoff.

2 Driving Cycles Detection Logic

The malfunction detected in the first driving cycle is stored in ECM (PCM) memory (in the form of pending DTC and freeze frame data) but the malfunction indicator lamp does not light at this time. It lights up at the second detection of same malfunction also in the next driving cycle.

Pending DTC

Pending DTC means a DTC detected and stored temporarily at 1 driving cycle of the DTC which is detected in the 2 driving cycles detection logic.

Freeze Frame Data

ECM (PCM) stores the engine and driving conditions (in the from of data as shown at the left) at the moment of the detection of a malfunction in its memory. This data is called “Freeze frame data”. Therefore, it is possible to know engine and driving conditions (e.g., whether the engine was warm or not, where the vehicle was running or stopped, where air/fuel mixture was lean or rich) when a malfunction was detected by checking the freeze frame data. Also, ECM (PCM) has a function to store each freeze frame data for three different malfunctions in the order as the malfunction is detected. Utilizing this function, it is possible to know the order of malfunctions that have been detected. Its use is helpful when rechecking or diagnosing a trouble.

Priority of freeze frame data:

ECM (PCM) has 4 frames where the freeze frame data can be stored. The first frame stores the freeze frame data of the malfunction which was detected first. However, the freeze frame data stored in this frame is updated according to the priority described below. (If malfunction as described in the upper square “1” below is detected while the freeze frame data in the lower square “2” has been stored, the freeze frame data “2” will be updated by the freeze frame data “1”.)

PRIORITY

FREEZE FRAME DATA IN FRAME 1

Freeze frame data at initial detection of malfunction among misfire detected (P0300-P0303), fuel system too lean (P0171) and fuel system too rich (P0172)

Freeze frame data when a malfunction other than those in “1” above is detected

Body ground

ECM (PCM) ground

Serial data line (K line of ISO 9141)

SUZUKI serial data line

6-8 ENGINE GENERAL INFORMATION 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 of how freeze frame data are stored when two or more malfunctions are detected.

FRAME 1 FRAME 2 FRAME 3 FRAME 4

FRAME

MALFUNCTION DETECTED ORDER

FREEZE FRAME

DATA

to be updated

1st FREEZE

FRAME DATA

2nd FREEZE

FRAME DATA

3rd FREEZE

FRAME DATA

No malfunction No freeze frame data

P0400 (EGR) detected

Data at P0400 detection

– –

P0171 (Fuel system) detected

Data at P0171 detection

Data at P0400 detection

Data at P0171 detection

–

P0300 (Misfire) detected

Data at P0171 detection

Data at P0400 detection

Data at P0171 detection

Data at P0300 detection

P0301 (Misfire) detected

Data at P0171 detection

Data at P0400 detection

Data at P0171 detection

Data at P0300 detection

Freeze frame data clearance:

The freeze frame data is cleared at the same time as clearance of diagnostic trouble code (DTC).

Data Link Connector (DLC)

DLC (1) is in compliance with SAEJ1962 in its installation position, the shape of connector and pin assignment.

Serial data line (K line of ISO 9141) is used for SUZUKI scan tool (Tech-1) or generic scan tool to communicate with ECM (PCM). SUZUKI serial data line is used for SUZUKI scan tool (Tech-1) to communicate with ABS control module and air bay SDM.

ENGINE GENERAL INFORMATION 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 erase memorized information in ECM (PCM) memory.

D Diagnostic information stored in ECM (PCM) memory can be

cleared as well as checked by using SUZUKI scan tool (Tech-1) or generic scan tool. Before using scan tool, read its Operator’s (Instruction) Manual carefully to have good understanding as to what functions are available and how to use it.

D Priorities for diagnosing troubles.

If two or more DTCs are stored, proceed to the flow table of the DTC which has detected earliest in the order and follow the instruction in that table. If no instructions are given, troubleshoot diagnostic trouble codes according to the following priorities.

1. Diagnostic trouble codes (DTCs) other than DTC P0171/ P0172 (Fuel system too lean/too rich) and DTC P0300/ P0301/P0302/ P0303 (Misfire detected)

2. DTC P0171/P0172 (Fuel system too lean / too rich)

3. DTC P0300/P0301 / P0302 / P0303 (Misfire detected)

D Be sure to read “Precautions for Electrical Circuit Service” in Sec-

tion 0A before inspection and observe what is written there.

D ECM (PCM) Replacement

When substituting a known-good ECM (PCM), check for following conditions. Neglecting this check may cause damage to a knowngood ECM (PCM). – Resistance value of all relays, actuators is as specified respec-

tively.

– MAP sensor and TP sensor are in good condition and none of

power circuits of these sensors is shorted to ground.

6-10 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10)

ENGINE DIAGNOSTIC FLOW TABLE

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.

Was customer complaint analysis performed?

Go to Step 2. Perform customer

complaint analysis.

2 Diagnostic Trouble Code (DTC) and Freeze Frame Data

Check, Record and Clearance

1) Check for DTC (including pending DTC) referring to the next page.

Is there any DTC(s)?

1) Print DTC and freeze frame data or write them down and clear them by referring to “DTC Clearance” section.

2) Go to Step 3.

Go to Step 4.

3 Visual Inspection

1) Perform visual inspection referring to the next page. Is there any faulty condition?

1) Repair or replace malfunction part.

2) Go to Step 11.

Go to Step 5.

4 Visual Inspection

1) Perform visual inspection referring to the next page. Is there any faulty condition?

Go to Step 8.

5 Trouble Symptom Confirmation

1) Confirm trouble symptom referring to the next page. Is trouble symptom identified?

Go to Step 6. Go to Step 7.

6 Rechecking and Record of DTC / Freeze Frame Data

1) Recheck for DTC and freeze frame data referring to “DTC Check” section.

Is there any DTC(s)?

Go to Step 9.

Go to Step 8.

7 Rechecking and Record of DTC / Freeze Frame Data

1) Recheck for DTC and freeze frame data referring to “DTC Check” section.

Is there any DTC(s)?

Go to Step 10.

8 Engine Basic Inspection and Engine Diag. Table

1) Check and repair according to “Engine Basic Check” and “Engine Diag. Table” section.

Are check and repair complete?

Go to Step 11. 1) Check and repair

malfunction part(s).

2) Go to Step 11.

9 Trouble shooting for DTC

1) Check and repair according to applicable DTC diag. flow table.

Are check and repair complete?

10 Check for Intermittent Problems

1) Check for intermittent problems referring to the next page.

Is there any faulty condition?

1) Repair or replace malfunction part(s).

2) Go to Step 11.

Go to Step 11.

11 Final Confirmation Test

1) Clear DTC if any.

2) Perform final confirmation test referring to the next page.

Is there any problem symptom, DTC or abnormal condition?

Go to Step 6. End.

ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-11

1. CUSTOMER COMPLAINT ANALYSIS

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. DIAGNOSTIC TROUBLE CODE (DTC) / FREEZE FRAME DATA CHECK, RECORD AND CLEARANCE

First, check DTC (including pending DTC), referring to “DTC check” section. If DTC is indicated, print it and freeze frame data or write them down and then clear them by referring to “DTC clearance” section. DTC indicates malfunction that occurred in the system but does not indicate whether it exists now or it occurred in the past and the normal condition has been restored now. To check which case applies, check the symptom in question according to Step 4 and recheck DTC according to Step 5. Attempt to diagnose a trouble based on DTC in this step only or failure to clear the DTC in this step will lead to incorrect diagnosis, trouble diagnosis of a normal circuit or difficulty in troubleshooting.

NOTE: If only Automatic transmission DTCs (P0705/P0720/ P0753 / P0758 /P0751/P0756) or Immobilizer DTCs (P1620 – P1623) are indicated in this step, perform trouble diagnosis according to “Diagnosis” in Section 7B or Section 8G.

3. and 4. VISUAL INSPECTION

As a preliminary step, be sure to perform visual check of the items that support proper function of the engine referring to “Visual Inspection” section.

5. TROUBLE SYMPTOM CONFIRMATION

Based on information obtained in Step 1 Customer complaint analysis and Step 2 DTC/freeze frame data check, confirm trouble symptoms. Also, reconfirm DTC according to “DTC Confirmation Procedure” described in each DTC Diagnosis section.

6. and 7. RECHECKING AND RECORD OF DTC/FREEZE FRAME DATA

Refer to “DTC check” section for checking procedure.

8. ENGINE BASIC INSPECTION AND ENGINE DIAGNOSIS TABLE

Perform basic engine check according to the “Engine Basic Inspection Flow Table” first. When the end of the flow table has been reached, check the parts of the system suspected as a possible cause referring to ENGINE DIAGNOSIS FLOW TABLE and based on symptoms appearing on the vehicle (symptoms obtained through steps of customer complaint analysis, trouble symptom confirmation and/or basic engine check) and repair or replace faulty parts, if any.

9. TROUBLESHOOTING FOR DTC (See each DTC Diag. Flow Table)

Based on the DTC indicated in Step 5 and referring to the applicable DTC diag. flow table in this section, locate the cause of the trouble, namely in a sensor, switch, wire harness, connector, actuator, ECM (PCM) or other part and repair or replace faulty parts.

10. CHECK FOR INTERMITTENT PROBLEM

Check parts where an intermittent trouble is easy to occur (e.g., wire harness, connector, etc.), referring to “INTERMITTENT AND POOR CONNECTION” in Section 0A and related circuit of DTC recorded in Step 2.

11. FINAL CONFIRMATION TEST

Confirm that the problem symptom has gone and the engine is free from any abnormal conditions. If what has been repaired is related to the DTC, clear the DTC once, perform DTC confirmation procedure and confirm that no DTC is indicated.

6-12 ENGINE GENERAL INFORMATION 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

(jcold jwarm jalways)

j Other

j Poor Driveability j Hesitation on acceleration j Back fire /jAfter fire j Lack of power j Surging j abnormal knocking j Other

j Poor Idling j Poor fast idle j Abnormal idling speed

(jHigh jLow) ( r/min.) j Unstable j Hunting ( r / min. to r / min.) j Other

j Engine Stall when j Immediately after start j Accel. pedal is depressed j Accel. pedal is released j Load is applied

j A/C jElectric load jP/S j Other

j Other

j OTHERS:

VEHICLE/ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS

Environmental Condition

Weather Temperature Frequency Road

jFair jCloudy jRain jSnow jAlways jOther jHot jWarm jCool jCold ( _F/ _C) jAlways jAlways jSometimes ( times/ day, month) jOnly once jUnder certain condition jUrban jSuburb jHighway jMountainous (jUphill jDownhill) jTarmacadam jGravel jOther

Vehicle Condition

Engine condition

jCold jWarming up phase jWarmed up jAlways jOther at starting jImmediately after start jRacing without load jEngine speed ( r/min.)

Vehicle condition

During driving: jConstant speed jAccelerating jDecelerating

jRight hand corner jLeft hand corner jWhen shifting (Lever position ) jAt stop jVehicle speed when problem occurs ( km/h, Mile/ h) jOther

Malfunction indicator lamp condition

jAlways ON jSometimes ON jAlways OFF jGood condition

Diagnostic trouble

First check: jNo code jMalfunction code ( )

code

Second check: jNo code jMalfunction code ( )

NOTE: The above form is a standard sample. It should be modified according to conditions characteristic of each market.

ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-13

MALFUNCTION INDICATOR LAMP (MIL) CHECK

1) Turn 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 Table A-1” for troubleshooting.

2) Start engine and check that MIL turns OFF. If MIL remains ON and no DTC is stored in ECM (PCM), go to “Diagnostic Flow Table A-2” for troubleshooting.

DIAGNOSTIC TROUBLE CODE (DTC) CHECK

1) Prepare SUZUKI scan tool (Tech-1) or generic scan tool.

2) With ignition switch OFF, connect it to data link connector (DLC) (1) located on underside of instrument panel at driver’s seat side.

Special Tool: (A): SUZUKI scan tool (B): Mass storage cartridge (C): 16/14 pin DLC cable

3) Turn ignition switch ON and confirm that MIL lights.

4) Read DTC, pending DTC and freeze frame data according to instructions displayed on scan tool and print it or write it down. Refer to scan tool operator’s manual for further details. If communication between scan tool and ECM (PCM) is not possible, check if scan tool is communicable by connecting it to ECM (PCM) in another vehicle. If communication is possible in this case, scan tool is in good condition. Then check data link connector and serial data line (circuit) in the vehicle with which communication was not possible.

5) After completing the check, turn ignition switch off and disconnect scan tool from data link connector.

6-14 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10)

DIAGNOSTIC TROUBLE CODE (DTC) CLEARANCE

1) Connect SUZUKI scan tool (Tech-1) or generic scan tool to data link connector in the same manner as when making this connection for DTC check.

2) Turn ignition switch ON.

3) Erase DTC and pending DTC according to instructions displayed on scan tool. Refer to scan tool operator’s manual for further details.

4) After completing the clearance, turn ignition switch off and disconnect scan tool from data link connector.

NOTE: DTC and freeze frame data stored in ECM (PCM) memory are also cleared in following cases. Be careful not to clear them before keeping their record. D When power to ECM (PCM) is cut off (by disconnecting

battery cable, removing fuse or disconnecting ECM (PCM) connectors for 30 sec. or longer)

D When the same malfunction (DTC) is not detected again

during 40 engine warm-up cycles.

ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-15

DIAGNOSTIC TROUBLE CODE (DTC) TABLE

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 MAP sensor circuit open)

1 driving cycle

P0110

Intake air temp. circuit malfunction

Intake air temp. circuit low input Intake air temp. circuit high input

1 driving cycle

P0115

Engine coolant temp. circuit malfunction

Engine coolant temp. circuit low input Engine coolant temp. circuit high input

1 driving cycle

P0120

Throttle position circuit malfunction

Throttle position circuit low input Throttle position circuit high input

1 driving cycle

P0121

Throttle position circuit performance problem

Poor performance of TP sensor 2 driving cycles

P0130

HO2S circuit malfunction (Sensor-1)

Min. output voltage of HO2S-higher than specification Max. output voltage of HO2S-lower than specification

2 driving cycles

P0133

HO2S circuit slow response (Sensor-1)

Response time of HO2S-1 output voltage between rich and lean is longer than specification.

2 driving cycles

P0135

HO2S heater circuit malfunction (Sensor-1)

Terminal voltage is lower than specification at heater OFF or it is higher at heater ON.

2 driving cycles

P0136

HO2S circuit malfunction (Sensor-2)

Max. voltage of HO2S-2 is lower than specification or its min. voltage is higher than specification

2 driving cycles

P0141

HO2S heater circuit malfunction (Sensor-2)

Terminal voltage is lower than specification at heater OFF or it is higher at heater ON. (or heater circuit or short)

2 driving cycles

P0171 Fuel system too lean

Short term fuel trim or total fuel trim (short and long terms added) is larger than specification for specified time or longer. (fuel trim toward rich side is large.)

2 driving cycles

P0172 Fuel system too rich

Short term fuel trim or total fuel trim (short and long term added) is smaller than specification for specified time or longer. (fuel trim toward lean side is large.)

2 driving cycles

P0300 P0301

Random misfire detected Cylinder 1 misfire detected

Misfire of such level as to cause damage to three way catalyst

MIL flashing

during misfire

detection

P0302

P0303

Cylinder 2 misfire detected

Cylinder 3 misfire detected

Misfire of such level as to deteriorate emission but not to cause damage to three way catalyst

2 driving cycles

6-16 ENGINE GENERAL INFORMATION 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

P0420

Catalyst system efficiency below threshold

Output waveforms of HO2S-1 and HO2S-2 are similar. (Time from output voltage change of HO2S-1 to that of HO2S-2 is shorter than specification.)

2 driving cycles

P0443

EVAP Purge control valve circuit malfunction

Purge control valve circuit is open or shorted to ground

2 driving cycles

P0480

Radiator fan control circuit malfunction

Radiator cooling fan relay terminal voltage is low when cooling temp. is lower than specification

2 driving cycles

P0500

Vehicle speed sensor malfunction

No signal while running in “D” range or during fuel cut at decelerating

2 driving cycles

P0505 Idle control system malfunction

Throttle opening change is small as compared with electrically live time. Throttle valve opening is not within its target range with CTP switch ON or drive voltage exists though ECM (PCM) is not outputting ISC drive command.

1 driving cycle

P0510

Closed throttle position switch malfunction

Switch does not change from ON to OFF (or from OFF to ON) even when vehicle speed reaches over (or below) specification.

2 driving cycle

P1250

Early Fuel Evaporation Heater Circuit Malfunction

Heater monitor terminal voltage is higher than specified value when EFE OFF or it is lower than specified value when EFE ON.

2 driving cycles

P1450

Barometric pressure sensor circuit malfunction

Barometric pressure is lower or higher than specification. (or sensor malfunction)

1 driving cycle

P1451

Barometric pressure sensor performance problem

Difference between manifold absolute pressure (MAP sensor value) and barometric pressure (barometric pressure sensor value) is larger than specification during cranking.

2 driving cycles

P1500

Starter signal circuit malfunction

Starter signal is not inputted from engine cranking till its start and after or it is always inputted

2 driving cycles

P1510

ECM (PCM) backup power source malfunction

No backup power after starting engine 1 driving cycle

ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-17

DTC

NO.

DETECTING ITEM

DETECTING CONDITION

(DTC will set when detecting:)

MIL

P0705

Transmission 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)

No signal while running vehicle with “D” or “2” range.

1 driving cycle

P0751

Shift solenoid A (#1) performance or stuck off

While running in “D” range, engine speed as

2 driving

P0756

Shift solenoid B (#2) performance or stuck off

com ared to vehicle s eed is higher or

lower than specified value.

cycles

P0753 Shift solenoid A (#1) electrical (A / T)

Output command from PCM and output

1 driving

P0758 Shift solenoid B (#2) electrical (A / T)

voltage do not agree. (solenoid circuit

shorted to ground or open)

cycle

P1620 ECU code not registered

P1621

No ECU code transmitted from Immobilizer Control Module

Refer to Section 8A.

P1622 Fault in ECM (PCM)

P1623 ECU code not matched

6-18 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10)

FAIL-SAFE TABLE

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 FAIL-SAFE OPERATION

P0105

Manifold absolute pressure circuit malfunction

D ECM (PCM) uses value determined by throttle

opening and engine speed.

D ECM (PCM) stops EVAP purge control.

P0110 Intake air temp. circuit malfunction

ECM (PCM) controls actuators assuming that intake air temperature is 20_C (68_F).

P0115 Engine coolant temp. circuit malfunction

D ECM (PCM) controls actuators assuming that

engine coolant temperature is 80_C (176_F).

D ECM (PCM) operates radiator fan. D ECM (PCM) stops A / C and idle speed control.

P0120 Throttle position circuit malfunction

D ECM (PCM) controls actuators assuming that

throttle opening is 20_.

D ECM (PCM) stops idle speed control.

P0500 Vehicle speed sensor malfunction ECM (PCM) stops idle air control.

P1450

Barometric pressure sensor low/ high input

ECM (PCM) controls actuators assuming that barometric pressure is 100 kPa (760 mmHg).

ENGINE GENERAL INFORMATION 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 cleaner element ––––– dirt, clogging D Battery ––––– fluid level, corrosion of terminal D Water pump belt ––––– tension, damage D Throttle cable ––––– play, installation D Vacuum hoses of air intake system ––––– disconnection,

looseness, deterioration, bend

D Connectors of electric wire harness ––––– disconnection, friction D Fuses ––––– burning D Parts ––––– installation, bolt ––––– looseness D Parts ––––– deformation D Other parts that can be checked visually

Also check following items at engine start, if possible

D Malfunction indicator lamp D Charge warning lamp D Engine oil pressure warning lamp D Engine coolant temp. meter D Fuel level meter D Tachometer, if equipped D Abnormal air being inhaled from air intake system D Exhaust system ––––– leakage of exhaust gas, noise D Other parts that can be checked visually

Section 0B Section 0B Section 0B Section 0B Section 0B

Section 0B Section 6E1

Section 8

Section 6 Section 6H Section 8 (section 6 for pressure check) Section 8 Section 8

6-20 ENGINE GENERAL INFORMATION 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 Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG.

FLOW TABLE”.

2 Check battery voltage.

Is it 11 V or more?

Go to Step 3. Charge or replace

battery.

3 Is engine cranked? Go to Step 4. Go to “DIAGNOSIS”

in Section 6G.

4 Does engine start? Go to Step 5. Go to Step 7.

5 Check idle speed as follows.

1) Warm up engine to normal operating temp.

2) Shift transmission to neutral position for M / T (“P” position for A/T).

3) All of electrical loads are switched off.

4) Check engine idle speed with scan tool. See Fig. 1.

Is it 800 – 900 r/min.?

Go to Step 6. Go to “ENGINE

DIAGNOSIS TABLE”.

6 Check ignition timing as follows.

1) Select “MISC” mode on SUZUKI scan tool and fix ignition timing to initial one. See Fig. 2.

2) Using timing light (1), check initial ignition timing. See Fig. 3.

Is it 5_ ± 3_ BTDC at specified idle speed?

Go to “ENGINE DIAGNOSIS TABLE”.

Check ignition control related parts referring to Section 6F.

7 Check immobilizer system malfunction as follows.

1) Check immobilizer indicator lamp for flashing.

Is it flashing when ignition switch is turned to ON position?

Go to “DIAGNOSIS” in Section 8A.

Go to Step 8.

8 Check fuel supply as follows.

1) Check to make sure that enough fuel is filled in fuel tank.

2) Turn ON ignition switch for 2 seconds and then OFF. See Fig. 4.

Is fuel return pressure (returning sounds) felt from fuel feed hose (1) when ignition switch is turned ON?

Go to Step 10. Go to Step 9.

9 Check fuel pump for operating.

1) Was fuel pump operating sound heard from fuel filler for about 2 seconds after ignition switch ON and stop?

Go to “DIAG. FLOW TABLE B-3”.

Go to “DIAG. FLOW TABLE B-2”.

10 Check ignition spark as follows.

1) Disconnect injector coupler.

2) Remove spark plugs and connect them to high tension cords.

3) Ground spark plugs.

4) Crank engine and check if each spark plug sparks.

Is it in good condition?

Go to Step 11. Go to “DIAGNOSIS”

in Section 6F.

11 Check fuel injector for operation as follows.

1) Install spark plugs and connect injector connectors.

2) Check that fuel is injected out in conical shape from fuel injector when cranking.

Is it in good condition?

Go to “ENGINE DIAGNOSIS TABLE”.

Go to “DIAG. FLOW TABLE B-1”.

Select “DATA LIST” mode

SELECT MENU F4: MISC TEST

ENGINE GENERAL INFORMATION 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 11

6-22 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10)

ENGINE DIAGNOSIS TABLE

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 system out of order

D Faulty spark plug D Leaky high-tension cord D Loose connection or disconnection of high-

tension cords or lead wires

D Faulty ignition coil

Fuel system out of order

D Dirty or clogged fuel hose or pipe D Malfunctioning fuel pump D Air inhaling from intake manifold gasket or

throttle body gasket

D Fuel injector resistor malfunction

Engine and emission control system out of order

D Faulty idle control system D Faulty ECT sensor or MAP sensor

D Faulty ECM (PCM)

Low compression

D Poor spark plug tightening or faulty gasket D Compression leak from valve seat D Sticky valve stem

D Weak or damaged valve springs

D Compression leak at cylinder head gasket

D Sticking or damaged piston ring

D Worn piston, ring or cylinder

Others

D Malfunctioning PCV valve

Spark plugs in Section 6F High-tension cords in Section 6F High-tension cords in Section 6F

Ignition coil in Section 6F

Diagnostic Flow Table B-3 Diagnostic Flow Table B-3

Fuel injector resistor in Section 6E1

Diagnostic Flow Table P0505 ECT sensor or MAP sensor in Section 6E1

Compression check in Section 6A Spark plugs in Section 6F Valves inspection in Section 6A Valves inspection in Section 6A

Valve springs inspection in Section 6A Cylinder head inspection in Section 6A Cylinders, pistons and piston rings inspection in Section 6A Cylinders, pistons and piston rings inspection in Section 6A

PCV system in Section 6E1

ENGINE GENERAL INFORMATION 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 in Section 0B Oil pressure switch inspection in Section 8 Oil pan and oil pump strainer cleaning in Section 6A Oil pump in Section 6A Oil pump in Section 6A

Engine noise

Note: Before checking mechanical noise, make sure that: D Specified spark

plug in used.

D Specified fuel is

used.

Valve noise

D Improper valve lash D Worn valve stem and guide D Weak or broken valve spring

D Warped or bent valve

Piston, ring and cylinder noise

D Worn piston, ring and cylinder bore

Connecting rod noise

D Worn rod bearing

D Worn crank pin

D Loose connecting rod nuts

D Low oil pressure

Crankshaft noise

D Low oil pressure D Worn bearing

D Worn crankshaft journal

D Loose bearing cap bolts

D Excessive crankshaft thrust play

Valve lash in Section 6A Valves inspection in Section 6A Valve springs inspection in Section 6A Valves inspection in Section 6A

Pistons and cylinders inspection in Section 6A

Crank pin and connecting rod bearing inspection in Section 6A Crank pin and connecting rod bearing inspection in Section 6A Connecting rod installation in Section 6A Previously outlined

Previously outlined Crankshaft and bearing inspection in Section 6A Crankshaft and bearing inspection in Section 6A Crankshaft inspection in Section 6A Crankshaft thrust play inspection in Section 6A

6-24 ENGINE GENERAL INFORMATION 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 Slipping clutch D Blown cylinder head gasket

Thermostat in Section 6B Water pump in Section 6B Radiator in Section 6B Engine oil and oil filter change in Section 0B Oil pressure check in Section 6A Oil pressure check in Section 6A Radiator fan control system in Section 6E1 Trouble diagnosis in Section 5 Trouble diagnosis in Section 7C Cylinder head in Section 6A

Poor gasoline mileage

Ignition system out of order

D Leaks or loose connection of high-tension cord D Faulty spark plug (improper gap, heavy deposits

and burned electrodes, etc.)

Engine and emission control system out of order

D High idle speed

D Poor performance of TP sensor, ECT sensor or

MAP sensor

D Faulty fuel injector D Faulty fuel injector resistor D Faulty ECM (PCM)

Low compression Others

D Poor valve seating D Dragging brakes D Slipping clutch D Thermostat out of order D Improper tire pressure

High-tension cords in Section 6F Spark plugs in Section 6F

Refer to item “Improper engine idle speed” previously outlined TP sensor, ECT sensor or MAP sensor in Section 6E1 Diagnostic Flow Table B-1 Fuel injector resistor in Section 6E1

Previously outlined

Valves inspection in Section 6A Trouble diagnosis in Section 5 Trouble diagnosis in Section 7C Thermostat in Section 6B Refer to Section 3F

Excessive engine oil consumption

Oil leakage

D Blown cylinder head gasket D Leaky camshaft oil seals

Oil entering combustion chamber

D Sticky piston ring D Worn piston and cylinder

D Worn piston ring groove and ring D Improper location of piston ring gap D Worn or damaged valve stem seal

D Worn valve stem

Cylinder head in Section 6A Camshaft in Section 6A

Piston cleaning in Section 6A Pistons and cylinders inspection in Section 6A Pistons inspection in Section 6A Pistons assembly in Section 6A Valves removal and installation in Section 6A Valves inspection in Section 6A

ENGINE GENERAL INFORMATION 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 out of adjustment D Leaky high-tension cord

Fuel system out of order

D Fuel pressure out of specification

Engine and emission control system out of order

D Poor performance of TP sensor, ECT sensor or

MAP sensor

D Faulty fuel injector D Faulty ECM (PCM)

Engine overheating Low compression

Spark plugs in Section 6F High-tension cords in Section 6F

Diagnostic Flow Table B-3 Trouble diagnosis in Section 6

TP sensor, ECT sensor or MAP sensor in Section 6E1 Diagnostic Flow Table B-1

Refer to “Overheating” section Previously outlined

Surge

(Engine power variation under steady throttle or cruise. Feels like vehicle speeds up and down with no change in accelerator pedal.)

Ignition system out of order

D Leaky or loosely connected high-tension cord D Faulty spark plug (excess carbon deposits,

improper gap, and burned electrodes, etc.)

Fuel system out of order

D Variable fuel pressure D Kinky or damaged fuel hose and lines D Faulty fuel pump (clogged fuel filter)

Engine and emission control system out of order

D Poor performance of MAP sensor D Faulty fuel injector D Faulty ECM (PCM)

High-tension cords in Section 6F Spark plugs in Section 6F

Diagnostic Flow Table B-3

MAP sensor in Section 6E1 Diagnostic Flow Table B-1

Excessive detonation

(Engine makes continuously sharp metallic knocks that change with throttle opening. Sounds like pop corn popping.)

Engine overheating Ignition system out of order

D Faulty spark plug D Loose connection of high-tension cord

Fuel system out of order

D Clogged fuel filter (faulty fuel pump) or fuel lines D Air inhaling from intake manifold or throttle body

gasket

Engine and emission control system out of order

D Poor performance of ECT sensor or MAP sensor

D Faulty fuel injector D Faulty ECM (PCM) D Excessive combustion chamber deposits

Refer to “Overheating” section

Spark plugs in Section 6F High-tension cords in Section 6F

Diagnostic Flow Table B-1 or B-2

Trouble diagnosis in Section 6

ECT sensor or MAP sensor in Section 6E1 Diagnostic Flow Table B-1

Piston and cylinder head cleaning in Section 6A

6-26 ENGINE GENERAL INFORMATION 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 Malfunctioning fuel pump D Air inhaling from intake manifold gasket or

throttle body gasket

Engine and emission control system out of order

D Maladjusted accelerator cable play

D Poor performance of TP sensor, ECT sensor or

MAP sensor

D Faulty fuel injector D Faulty ECM (PCM)

Low compression Others

D Dragging brakes D Slipping clutch

Spark plugs in Section 6F Ignition coil in Section 6F High-tension cords in Section 6F

Refer to “Overheating” section

Diagnostic Flow Table B-3 in Section 6 Diagnostic Flow Table B-2

Accelerator cable play in Section 6E1 TP sensor, ECT sensor or MAP sensor in Section 6E1 Diagnostic Flow Table B-1

Previously outlined

Trouble diagnosis in Section 5 Trouble diagnosis in Section 7C

ENGINE GENERAL INFORMATION 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 manifold, throttle body, or cylinder head

gasket

Engine and emission control system out of order

D Faulty idle control system D Faulty evaporative emission control system

D Faulty fuel injector D Faulty fuel injector resistor D Poor performance of ECT sensor, TP sensor or

MAP sensor

D Faulty ECM (PCM)

Engine overheating Low compression Others

D Loose connection or disconnection of vacuum

hoses

D Malfunctioning PCV valve

Spark plugs in Section 6F High-tension cords in Section 6F Ignition coil in Section 6F

Diagnostic Flow Table B-3 in Section 6

Diagnostic Flow Table P0505 EVAP control system in Section 6E Diagnostic Flow Table B-1 Fuel injector resistor in Section 6E1 ECT sensor, TP sensor or MAP sensor in Section 6E1

Refer to “Overheating” section Previously outlined

PCV system in Section 6E1

6-28 ENGINE GENERAL INFORMATION 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 order

D Lead contamination of three way catalytic

converter

D Faulty evaporative emission control system

D Fuel pressure out of specification D Closed loop system (A / F feed back

compensation) fails

– Faulty TP sensor – Poor performance of ECT sensor or MAP

sensor

D Faulty injector D Faulty fuel injector resistor D Faulty ECM (PCM)

Others

D Engine not at normal operating temperature D Clogged air cleaner D Vacuum leaks

Spark plugs in Section 6F High-tension cords in Section 6F Ignition coil assembly in Section 6F Refer to “Low compression” section

Check for absence of filler neck restrictor EVAP control system in Section 6E1 Diagnostic Flow Table B-3

TP sensor in Section 6E1 ECT sensor or MAP sensor in Section 6E1 Diagnostic Flow Table B-1 Fuel injector resistor in Section 6E1

Excessive nitrogen oxides (NOx) emission

Ignition system out of order

D Improper ignition timing

Engine and emission control system out of order

D Lead contamination of catalytic converter

D Fuel pressure out of specification D Closed loop system (A / F feed back

compensation) fails

– Faulty TP sensor – Poor performance of ECT sensor or MAP

sensor

D Faulty injector D Faulty fuel injector resistor D Faulty ECM (PCM)

See section 6F1

Check for absence of filler neck restrictor. Diagnostic Flow Table B-3

TP sensor in Section 6E1 ECT sensor or MAP sensor in Section 6E1 Diagnostic Flow Table B-1 Fuel injector resistor in Section 6E1

ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-29

Ambient temp.

SCAN TOOL DATA

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 does not fall within each specified data range. Therefore, judgment as abnormal should not be made by checking with these data alone. Also, conditions in the below table that can be checked by the scan tool are those detected by ECM (PCM) and output from ECM (PCM) as commands and there may be cases where the engine or actuator is not operating (in the condition) as indicated by the scan tool. Be sure to use the timing light to check the ignition timing.

NOTE:

D With the generic scan tool, only star (l) marked data in the table below can be read. D When checking the data with the engine running at idle or racing, be sure to shift M / T gear to the neutral

gear position and A/T gear to the “Park” position and pull the parking brake fully. Also, if nothing or “no load” is indicated, turn OFF A/C, all electric loads, P/ S and all the other necessary switches.

SCAN TOOL DATA VEHICLE CONDITION

NORMAL CONDITION/

REFERENCE VALUES

FUEL SYSTEM B1 (FUEL SYSTEM STATUS)

At specified idle speed after warming up CLOSED (closed loop)

CALC LOAD (CALCULATED LOAD

At specified idle speed with no load after warming up

3 – 5%

(

VALUE)

At 2500 r/min with no load after warming up 10 – 18%

COOLANT TEMP. (ENGINE COOLANT TEMP.)

At specified idle speed after warming up 85 – 95_C, 185 – 203_F

SHORT FT BI (SHORT TERM FUEL TRIM)

At specified idle speed after warming up –20 – +20%

LONG FT BI (LONG TERM FUEL TRIM)

At specified idle speed after warming up –15 – +15%

MAP (INTAKE MANIFOLD ABSOLUTE PRESSURE)

At specified idle speed with no load after warming up

29 – 48 kPa,

220 – 360 mmHg

ENGINE SPEED At idling with no load after warming up

Desired idle speed

± 50 r/min

VEHICLE SPEED At stop 0 km/h, 0 MPH

IGNITION ADVANCE (IGNITION TIMING ADVANCE FOR NO.1 CYLINDER)

At specified idle speed with no load after warming up

–1 – 18_ BTDC

INTAKE AIR TEMP. At specified idle speed after warming up

+35_C (+63_F)

–5_C (–9_F)

MAF (MASS AIR FLOW

At specified idle speed with no load after warming up

1.0 – 3.0 gm/sec

RATE)

At 2500 r/min with no load after warming up 3.0 – 6.0 gm / sec

THROTTLE POS

Ignition switch ON/

Throttle valve fully closed 7 – 18%

(ABSOLUTE

THROTTLE POSITION)

engine stopped

Throttle valve fully open 70 – 90%

O2S B1 S1 (HEATED OXYGEN SENSOR-1)

At specified idle speed after warming up 0.05 – 0.95 V

O2S B1 S2 (HEATED OXYGEN SENSOR-2)

When engine is running at 2000 r/min. for 3 min. or longer after warming up.

0 – 0.95 V

O2S FT B1 S1 At specified idle speed after warning up –20 – +20%

DIS. WITH MIL ON —— ——

6-30 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10)

SCAN TOOL DATA CONDITION

NORMAL CONDITION/

REFERENCE VALUES

DESIRED IDLE At idling with no load after warming up, M /T (DESIRED IDLE SPEED)

gg,

at neutral, A/T at “P” range

850 r/min

TP SENSOR VOLT (THROTTLE POSITION

Ignition switch

Throttle valve fully closed More than 0.2 V

(

SENSOR OUTPUT VOLTAGE)

ON/engine

stopped

Throttle valve fully open Less than 4.8 V

INJ PULSE WIDTH (FUEL INJECTION

At specified idle speed with no load after warming up

0.8 – 2.3 msec.

(

PULSE WIDTH)

At 2500 r/min with no load after warming up 0.8 – 2.3 msec.

IAC FLOW DUTY (IDLE AIR CONTROL FLOW DUTY)

At idling with no load after warming up 20 – 40%

TOTAL FUEL TRIM At specified idle speed after warming up –35 – +35% BATTERY VOLTAGE Ignition switch ON /engine stop 10 – 14 V CANIST PRG DUTY

(EVAP CANISTER PURGE FLOW DUTY)

At specified idle speed after warming up

0 – 100%

CLOSED THROT POS

Throttle valve at idle position ON

(CLOSED THROTTLE

POSITION)

Throttle valve opens larger than idle position OFF

When engine is at fuel cut condition ON

FUEL CUT

Other than fuel cut condition OFF

RAD FAN (RADIATOR FAN

Ignition switch

Engine coolant temp.:

Lower than 92.5_C

(199_F)

OFF

(

CONTROL RELAY)

Engine coolant temp.:

97.5_C (208_F) or higher

Ignition switch ON/Headlight, small light, heater fan and rear window defogger all turned OFF

OFF

ELECTRIC LOAD

Ignition switch ON/Headlight, small light, heater fan or rear window defogger turned ON

Engine running after warming up, A/C not operating

OFF

A/C SWITCH

Engine running after warming up, A/C operating

PSP SWITCH

Engine running at idle speed and steering wheel at straight-ahead position.

OFF

(if equipped).

Engine running at idle speed and steering wheel turned to the right or left as far as it stops.

FUEL TANK LEVEL

––––––––––––

0 – 100%

BAROMETRIC PRESS –––––––––––– Display the barometric pressure

FUEL PUMP

Within 3 seconds after ignition switch ON or engine running

Engine stop at ignition switch ON. OFF

ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-31

SCAN TOOL DATA CONDITION

NORMAL CONDITION/

REFERENCE VALUES

VSS (for 4-A/T) (Vehicle 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) MON (Monitor Signal)

Ignition switch ON, selector lever is shifted at D range and vehicle stops

THROT POS LEVEL (THROTTLE POSITION LEVER FOR A/T)

“0” (about idle position), “1”, “2”, “3”, “4”, “5”, “6” or “7” (about full open) appears according to throttle valve opening.

TRANS. RANGE (TRANSMISSION RANGE SENSOR)

“P”, “R”, “N”, “D”, “2” or “L” appears according tho selector lever position.

Select lever at D, 2 or L range 1

GEAR POSITION

Select lever at P, N or R range –

6-32 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10)

SCAN TOOL DATA DEFINITIONS

FUEL SYSTEM (FUEL SYSTEM STATUS)

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 sensor feedback.

CALC LOAD (CALCULATED LOAD VALUE, %)

Engine load displayed as a percentage of maximum possible load. Value is calculated mathematically using the formula: actual (current) intake air volume B maximum possible intake air volume x 100%.

COOLANT TEMP. (ENGINE COOLANT TEMPERATURE, _C, _F)

It is detected by engine coolant temp. sensor

SHORT FT B1 (SHORT TERM FUEL TRIM, %)

Short term fuel trim value represents short term corrections to the air/fuel mixture computation. A value of 0 indicates no correction, a value greater than 0 means an enrichment correction, and a value less than 0 implies an enleanment correction.

LONG FT B1 (LONG TERM FUEL TRIM, %)

Long term fuel trim Value represents long term corrections to the air/fuel mixture computation. A value of 0 indicates no correction, a value greater than 0 means an enrichment correction, and a value less than 0 implies an enleanment correction.

MAP (INTAKE MANIFOLD ABSOLUTE PRESSURE, kPa, inHg)

It is detected by manifold absolute pressure sensor and used (among other things) to compute engine load.

ENGINE SPEED (rpm)

It is computed by reference pulses from crankshaft position sensor.

VEHICLE SPEED (km/h, MPH)

It is computed based on pulse signals from vehicle speed sensor.

IGNITION ADVANCE (IGNITION TIMING ADVANCE FOR NO.1 CYLINDER, _)

Ignition timing of NO.1 cylinder is commanded by ECM (PCM). The actual ignition timing should be checked by using the timing light.

INTAKE AIR TEMP. (_C, _F)

It is detected by intake air temp. sensor and used to determine the amount of air passing into the intake manifold as air density varies with temperature.

MAF (MASS AIR FLOW RATE, gm / s, lb/min)

It represents total mass of air entering intake manifold which is computed based on signals from MAP sensor, IAT sensor, TP sensor, etc.

THROTTLE POS (ABSOLUTE THROTTLE POSITION, %)

When throttle position sensor is fully closed position, throttle opening is indicated as 0% and 100% full open position.

OXYGEN SENSOR B1 S1 (HEATED OXYGEN SENSOR-1, V)

It indicates output voltage of HO2S-1 installed on exhaust manifold (pre-catalyst).

OXYGEN SENSOR B1 S2 (HEATED OXYGEN SENSOR-2, V)

It indicates output voltage of HO2S-2 installed on exhaust pipe (post-catalyst). It is used to detect catalyst deterioration.

DESIRED IDLE (DESIRED IDLE SPEED, rpm)

The Desired Idle Speed is an ECM (PCM) internal parameter which indicates the ECM (PCM) requested idle. If the engine is not running, this number is not valid.

TP SENSOR VOLT (THROTTLE POSITION SENSOR OUTPUT VOLTAGE, V)

The Throttle Position Sensor reading provides throttle valve opening information in the form of voltage.

INJ PULSE WIDTH (FUEL INJECTION PULSE WIDTH, msec.)

This parameter indicates time of the injector drive (valve opening) pulse which is output from ECM (PCM) (but injector drive time of NO.1 cylinder for multiport fuel injection).

IAC FLOW DUTY (IDLE AIR (SPEED) CONTROL DUTY, %)

This parameter indicates opening of the throttle valve in terms of percentage to opening controllable by the ISC actuator.

TOTAL FUEL TRIM (%)

The value of Total Fuel Trim is obtained by putting values of short Term Fuel Trim and Long Term Fuel Trim together. This value indicates how much correction is necessary to keep the air/fuel mixture stoichiometrical.

BATTERY VOLTAGE (V)

This parameter indicates battery positive voltage inputted from main relay to ECM (PCM).

ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-33

CANIST PURGE DUTY (EVAP CANISTER PURGE FLOW DUTY, %)

This parameter indicates valve ON (valve open) time rate within a certain set cycle of EVAP purge solenoid valve which controls the amount of EVAP purge. 0% means that the purge valve is completely closed while 100% is a fully open valve.

CLOSED THROTTLE POSITION (ON/OFF)

This parameter will read ON when throttle valve is fully closed, or OFF when the throttle is not fully closed.

FUEL CUT (ON/OFF)

ON : Fuel being cut (output signal to injector is

stopped)

OFF : Fuel not being cut

RAD FAN (RADIATOR FAN CONTROL RELAY, ON/OFF)

ON : Command for radiator fan control relay opera-

tion being output.

OFF : Command for relay operation not being out-

put.

ELECTRIC LOAD (ON/OFF)

ON : Headlight, small light, heater fan or rear win-

dow defogger ON signal inputted.

OFF : Above electric loads all turned OFF.

A/C SWITCH (ON/ OFF)

ON : Command for A/ C operation being output

from ECM (PCM) to A/C amplifier.

OFF : Command for A /C operation not being output.

FUEL TANK LEVEL (%)

This parameter indicates approximate fuel level in the fuel tank. As the detectable range of the fuel level sensor is set as 0 to 100%, however, with some models whose fuel tank capacity is smaller, the indicated fuel level may be only 70% even when the fuel tank is full.

PSP SWITCH (ON/OFF)

ON : PSP switch detects P/S operation (high PS

pressure).

OFF : PSP switch not detects P /S operation.

BAROMETRIC PRESS (kPa, inHg)

This parameter represents a measurement of barometric air pressure and is used for altitude correction of the fuel injection quantity and ISC actuator control.

FUEL PUMP (ON/OFF)

ON is displayed when the ECM (or PCM) activates the fuel pump via the fuel pump relay switch.

VSS (A/T) (km/ h, MPH)

If is computed by using pulse signals from vehicle (output) speed sensor on automatic transmission.

TRANS RANGE (TRANSMISSION RANGE SENSOR, P, R, N, D, 2 OR L)

It is indicated transmission range detected by transmission range sensor.

SHIFT SOL 1-CON (SHIFT SOLENOID-1, ON/OFF)

ON : ON command being output to shift solenoid-1 OFF : ON command not being output.

SHIFT SOL 2-CON (SHIFT SOLENOID-2, ON/OFF)

ON : ON command being output to shift solenoid-2 OFF : ON command not being output.

SHIFT SOL 1-MON (SHIFT SOLENOID-1, ON/OFF)

The monitor result of the shift solenoid-1 circuit is displayed. ON : Electricity being passed to shift solenoid-1 or

circuit open.

OFF : Electricity not being passed or circuit short.

SHIFT SOL 2-MON (SHIFT SOLENOID-2, ON/OFF)

The monitor result of the shift solenoid-2 circuit is displayed. ON : Electricity being passed to shift solenoid-2 or

circuit open.

OFF : Electricity not being passed or circuit short.

THROT POS LEVEL (THROTTLE POSITION LEVEL FOR A/T, “0”, “1”, “2”, “3”, “4”, “5”, “6” or “7”)

This parameter indicates which level (zone) the throttle valve opening is in. The throttle opening is divided into 8 levels (zones) from “0” (about idle position) to “7” (about full open) and signals are assigned to each opening level (zone). ECM (PCM) control the automatic gear change of the automatic transmission by using these signals according to the signal from the TP sensor.

GEAR POSITION

This parameter indicates the A/T gear position which is computed on signals from the Transmission Range Switch, VSS, TP Sensor, and so forth.

6-34 ENGINE GENERAL INFORMATION 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

C03C02 C01

456

9101112

34567

345678910

111213

131415

1617

202122910

1112

131415

1415

1617

181920212223

2526

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 prohibited to connect voltmeter or ohmmeter to ECM (PCM) with coupler disconnected from it.

Voltage Check

1) Remove ECM (PCM) (1) from body referring to Section 6E.

2) Check voltage at each terminal of couplers (2) connected.

NOTE: As each terminal voltage is affected by the battery voltage, confirm that it is 11 V or more when ignition switch is ON.

ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-35

CONNECTOR “C02”

TER-

MINAL

WIRE

COLOR

CIRCUIT

STANDARD

VOLTAGE

CONDITION

1 B ECM (PCM) ground – –

2 W/Bl Power source 10 – 14 V Ignition switch ON

3 — Blank — —

4 — Blank — —

5 — Blank — —

6 — Blank — —

7 R/G EVAP canister purge valve 10 – 14 V Ignition switch ON

0 V

Ignition switch ON, selector lever at “P” range

G/Or

Shift solenoid-B (A/T)

10 – 14 V

Ignition switch ON, selector lever at “D” range

0 V

Ignition switch ON, selector lever at “P” range

G/W

Shift solenoid-A (A/T)

10 – 14 V

Ignition switch ON, selector lever at “D” range

10 Or Igniter (IGT) — —

11 Gr/Y ISC actuator — —

12 Y/B Fuel injector 10 – 14 V Ignition switch ON

13 B/Bl Ground for injector — —

14 W Power source for back-up 10 – 14 V Ignition switch ON and OFF

15 W/Bl Power source 10 – 14 V Ignition switch ON

16 Gr /B ISC actuator relay 0.3 – 1.0 V Ignition switch ON

0.2 – 2.0 V Ignition switch ON

V/Y

Malfunction indicator lamp

10 – 14 V When engine running

0.2 – 2.0 V Ignition switch ON

V/G

Immobilizer indicator lamp

10 – 14 V When engine running at idle

19 Lg /B Heater of H02S-2 10 – 14 V Ignition switch ON

10 – 14 V

Ignition switch ON, Engine coolant temp: Below 91.5_C (197_F)

20BlRadiator fan control relay

0.3 – 1.0 V

Ignition switch ON, Engine coolant temp: 96.0_C (205_F) or higher

0.3 – 1.3 V For 2 seconds after ignition switch ON

P/W

Fuel pump relay

10 – 14 V After the above time

22 Bl/B Main relay 0.4 – 1.5 V Ignition switch ON

23 – Blank — —

24 Gr / R ISC actuator — —

25 Y/R EFE heater relay 10 – 14 V Ignition switch ON

26 B/R Ground for injector — —

6-36 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10)

CONNECTOR “C01”

TER-

MINAL

WIRE

COLOR

CIRCUIT

STANDARD

VOLTAGE

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 (+)

— —

Closed throttle position switch

0 – 1 V

Ignition switch ON, ISC actuator plunger is in contact with throttle lever screw

Gr/G

(In ISC actuator)

4 – 6 V

Ignition switch ON Plunger is apart from throttle lever screw

5 Lg/R

Manifold absolute pressure sensor

3.3 – 4.0 V

Ignition switch ON Barometric pressure: 100 kPa, 760 mmHg

6 Lg/ W Throttle position sensor

0.2 – 1.0 V

Ignition switch ON, when clearance between throttle lever and throttle stop screw is less than 0.35 mm (0.014 in.)

2.8 – 4.8 V

Ignition switch ON Throttle valve at full open position

7 Gr / W Engine coolant temp. sensor 0.55 – 0.95 V

Ignition switch ON Engine coolant temp.: 80_C (176_F)

8 P/B Heater of H02S-1 10 – 14 V Ignition switch ON

9 G Ground for sensors — —

10 W Camshaft position sensor (–) — —

11 W/R

Crankshaft position sensor (+)

— —

0 – 1 V Heater relay OFF

W/B

EFE heater monitor

10 – 14 V Heater relay ON

13 R Heated oxygen sensor-1 Refer to DTC flow chart

14 Gr Intake air temp. sensor 2.0 – 2.7 V

Ignition switch ON Sensor ambient temp. (Intake air temp): 20_C (68_F)

10 – 14 V Ignition switch ON

15 Bl / W

Power steering pressure switch (If equipped)

0 – 1 V

With engine running at idle speed, turning steering wheel to the right or left as far as it stops, repeating it a few times

Engine start switch

6 – 12 V While engine cranking

B/Y

(Engine start signal)

0 – 1 V Other than above

ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-37

CONNECTOR “C03”

TER-

MINAL

WIRE

COLOR

CIRCUIT

STANDARD

VOLTAGE

CONDITION

1 V/W

Data link connector (SUZUKI serial data line)

4 – 6 V Ignition switch ON

Bl Vehicle speed sensor (+) (A/ T) 0.4 – 0.8 V Ignition switch ON

Y/G Vehicle speed sensor (M/ T)

Indicator

deflection

repeated

0 V and

4 – 6 V

Ignition switch ON Front left tire turned slowly with front right tire locked

3 G

Transmis-

“2” range

Ignition switch ON, Selector lever at “2” range

4 Or/Y

sion range sensor

“N” range

10 – 14 V

Ignition switch ON, Selector lever at “N” range

5 Or/B

(switch)

(A/T only).

“P” range

Ignition switch ON, Selector lever at “P” range

6 — Blank – —

7 — Blank – —

8 R Heated oxygen sensor-2 Refer to DTC flow chart

9 — — — —

– 1.5

Ignition switch ON, fuel tank fully filled

Y/R

Fuel level sensor (gauge)

– 5.5

Ignition switch ON, fuel tank emptied

11 — Blank — —

12 R/G

Data link connector (OBD serial data line)

10 – 14 V Ignition switch ON

13 P Vehicle speed sensor (–) (A/T) 0.4 – 0.8 V Ignition switch ON

14 G/Bl

Transmis-

“L” range

Selector lever at “L” range

15 G/R

sion range sensor

“D” range

10 – 14 V

Ignition switch ON

Selector lever at “D” range

16 R

(switch)

(A/T)

“R” range

Selector lever at “R” range

17 Lg/R

A/C ON (output) signal for A / C

0 – 1 V

While engine running and A/C not operating

controller (if equipped)

10 – 14 V While engine running and A/C operating

0 –1 V

Ignition switch ON Headlight, small light, heater fan and rear window defogger turned OFF

Br/Y

Electric load signal

10 – 14 V

Ignition switch ON Headlight, small light, heater fan and rear window defogger turned ON

19 Bl / R

A/C (input) signal for A / C

10 – 14 V

While engine running and A/C not operating

amplifier

0 – 0.6 V While engine running and A /C operating

20 B/W Ignition switch 10 – 14 V Ignition switch ON

21 — Blank — —

22 — Blank — —

6-38 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10)

1. ECM (PCM) coupler disconnected

2. Ohmmeter

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 disconnected.

CAUTION: D Be sure to connect ohmmeter probe from wire harness

side of coupler.

D Be sure to turn OFF ignition switch for this check. D Resistance in table below represents that when parts

temperature is 20_C (68_F).

TERMINALS CIRCUIT STANDARD RESISTANCE

C01-8 to C03-20 H02S-1 heater 11.7 – 14.3 Ω

C02-19 to C03-20 H02S-2 heater 11.7 – 14.3 Ω

C02-12 to C02-2/15 Fuel injector 2.4 – 3.6 Ω

C02-7 to C02-2/15 EVAP canister purge valve 30 – 34 Ω

C02-21 to C03-20 Fuel pump relay 100 – 120 Ω

C02-16 to C02-2/15 ISC actuator relay 100 – 120 Ω

C02-25 to C02-2/15 EFE heater relay 100 – 120 Ω

C02-8 to Body ground Shift solenoid-B 8 – 20 Ω

C02-9 to Body ground Shift solenoid-A 8 – 20 Ω

C02-20 to C02-2/15 Radiator fan control relay 100 – 120 Ω

C02-22 to C02-14 Main relay 100 – 120 Ω

C02-1 to Body ground Ground Continuity

C02-13 to Body ground Ground Continuity

C02-26 to Body ground Ground Continuity

ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-39

INFORMATION SENSORS

-1. MAP sensor

-2. TP sensor

-3. IAT 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)

-11. CKP sensor

-12. CTP switch (in ISC actuator)

-13. Heated oxygen sensor-2

OTHERS

A: ECM (PCM) B: Main relay C: EVAP canister D: Injector resistor E: EFE heater F: Electric load diode

CONTROL DEVICES

a: Fuel injector b: EVAP canister purge valve c: Fuel pump relay d: Malfunction indicator lamp e: ISC actuator f: Radiator fan control relay g: Igniter h: EFE heater relay i: ISC actuator relay

COMPONENT LOCATION

6-40 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10)

“IG COIL METER”

Main relay

Ignition switch

In fuse

Malfunction indicator lamp in combination meter

TABLE A-1 MALFUNCTION INDICATOR LAMP CIRCUIT CHECK – LAMP DOES

NOT COME “ON” AT IGNITION SWITCH ON (BUT ENGINE AT STOP)

CIRCUIT DESCRIPTION

When the ignition switch is turned ON, ECM (PCM) causes the main relay to turn ON (close the contact point). Then, ECM (PCM) being supplied with the main power, turns ON the malfunction indicator lamp (MIL). When the engine starts to run and no malfunction is detected in the system, MIL goes OFF but if a malfunction was or is detected, MIL remains ON even when the engine is running.

INSPECTION

STEP ACTION YES NO

1 MIL Power Supply Check

1) Turn ignition switch ON. Do other indicator/warning lights in combination meter comes ON?

Go to Step 2. “IG COIL METER” fuse blown,

main fuse blown, ignition switch malfunction, “B/W” circuit between “IG COIL METER” fuse and combination meter or poor coupler connection at combination meter.

2 ECM (PCM) Power and Ground Circuit

Check Does engine start?

Go to Step 3. Go to TABLE A-3 ECM (PCM)

POWER AND GROUND CIRCUIT CHECK. If engine is not cranked, go to DIAGNOSIS in SECTION 8A.

3 MIL Circuit Check

1) Turn ignition switch OFF and disconnect connectors from ECM (PCM).

2) Check for proper connection to ECM (PCM) at terminal C02-17.

3) If OK, then using service wire, ground terminal C02-17 in connector disconnected.

Does MIL turn on at ignition switch ON?

Substitute a knowngood ECM (PCM) and recheck.

Bulb burned out or “V/Y” wire circuit open.

ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-41

TABLE A-2 MALFUNCTION INDICATOR LAMP CIRCUIT CHECK – LAMP

REMAINS “ON” AFTER ENGINE STARTS

WIRING DIAGRAM/CIRCUIT DESCRIPTION – Refer to table A-1.

INSPECTION

STEP ACTION YES NO

1 Diagnostic Trouble Code (DTC) check

1) Check DTC referring to DTC CHECK section.

Is there any DTC(s)?

Go to Step 2 of ENGINE DIAG. FLOW TABLE.

Go to Step 2.

2 DTC check

Start engine and recheck DTC while engine running. Is there any DTC(s)?

Go to Step 3.

3 MIL Circuit check

1) Turn OFF ignition switch.

2) Disconnect connectors from ECM (PCM).

Does MIL turn ON at ignition switch ON?

“V/Y” wire circuit shorted to ground.

Substitute a known-good ECM (PCM) and recheck.

Main fuseIgnition switch

Main fuse

Malfunction indicator lamp in combination meter

Relay box

“IG COIL METER”

6-42 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10)

TABLE A-3 ECM (PCM) POWER AND GROUND CIRCUIT CHECK – MIL

DOESN’T LIGHT AT IGNITION SWITCH ON AND ENGINE DOESN’T START THOUGH IT IS CRANKED UP

CIRCUIT DESCRIPTION

When the ignition switch tuned ON, the main relay turns ON (the contact point closes) and the main power is supplied to ECM (PCM).

INSPECTION

STEP ACTION YES NO

1 Main Relay Operating Sound Check

Is operating sound of main relay heard at ignition switch ON?

Go to Step 5. Go to Step 2.

2 Main Relay Check

1) Turn OFF ignition switch and remove main relay (1).

2) Check for proper connection to main relay (1) at terminal

3 and 4.

3) Check resistance between each two terminals. See Fig. 1

and 2. Between terminals 1 and 2: Infinity Between terminals 3 and 4: 100 – 120 Ω

4) Check that there is continuity between terminals 1 and 2

when battery is connected to terminals 3 and 4. See Fig. 3.

Is main relay in good condition?

Go to Step 3. Replace main

relay.

3 Fuse Check

Is main “FI” fuse in good condition?

Go to Step 4. Check for short in

circuits connected to this fuse.

4 ECM (PCM) Power Circuit Check

1) Turn OFF ignition switch, disconnect connectors from ECM

(PCM) and install main relay.

2) Check for proper connection to ECM (PCM) at terminals

C03-20, C02-2, C02-15 and C02-22.

3) If OK, then measure voltage between terminal C03-20 and

ground, C02-22 and ground with ignition switch ON.

Is each voltage 10 – 14 V?

Go to Step 5. “B/W”, “W/R” or

“Bl/B” circuit open.

ENGINE GENERAL INFORMATION 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 circuits “Bl/B” and “W/ Bl” for open. If OK, then substitute a known-good ECM (PCM) and recheck.

Go to Step 6.

6 Is operating sound of main relay heard in Step 1? Go to Step 7. “W/R” or “W / Bl” wire

open.

7 Main Relay Check

1) Check main relay according to procedure in

Step 2.

Is main relay in good condition?

“W/R” or “W / Bl” wire open.

Replace main relay.

MAP sensor

To TP sensor

To other sensors

6-44 ENGINE GENERAL INFORMATION 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 pressure – Low vacuums – High voltage)

D “G” circuit open D “Lg” circuit open or shorted to ground D “Lg / R” circuit open or shorted to ground D MAP sensor malfunction D ECM (PCM) malfunction

NOTE:

D When DTC P0105, and / or P0120, P0510 are indicated together, it is possible that “Lg” circuit is open. D When DTC P0105, P0110, P0115 and /or P0120 are indicated together, it is possible that “G” circuit is

open.

DTC CONFIRMATION PROCEDURE

1) Clear DTC, start engine and keep it at idle for 1 min.

2) Select “DTC” mode on scan tool and check DTC.

ENGINE GENERAL INFORMATION 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 Was “ENGINE DIAG. FLOW TABLE”

performed?

Go to Step 2. Go to “ENGINE DIAG.

FLOW TABLE”.

2 Check MAP Sensor and Its Circuit.

1) Connect scan tool to DLC with ignition

switch OFF.

2) Turn ignition switch ON.

3) Check intake manifold pressure.

See Fig. 1.

Is it 130 kPa or more or 5 kPa or less?

Go to Step 3. Intermittent trouble.

Check for intermittent referring to “INTERMITTENT AND POOR CONNECTION” in Section 0A.

3 Check Wire Harness.

1) Disconnect MAP sensor connector with

ignition switch OFF.

2) Check for proper connection of MAP

sensor at “Lg/R” and “G” wire terminals.

3) If OK, then with ignition switch ON, check

voltage at each of “Lg” and “Lg/R” wire terminals. See Fig. 2.

Is voltage about 4 – 6 V at each terminal?

Go to Step 4. “Lg” wire open or

shorted to ground circuit or shorted to power circuit, “Lg/R” wire open or shorted to ground, poor C01-5 connection or C01-1 connection. If wire and connection are OK, confirm that MAP sensor is normal and then substitute a known-good ECM (PCM) and recheck.

NOTE: When battery voltage is applied to “Lg” wire, it is possible that MAP sensor is also faulty.

4 Check MAP sensor according to “MAP

Sensor Individual Check” in Section 6E1. Is it in good condition?

“Lg” wire shorted to “Lg/R” wire, “G” wire

open, poor C01-9 connection. If wire and connection are OK, substitute a knowngood ECM (PCM) and recheck.

Replace MAP sensor.

To other sensors

IAT sensor

6-46 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10)

DTC P0110 INTAKE AIR TEMP. (IAT) 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 open or shorted to power D “G” circuit open D IAT sensor malfunction D ECM (PCM) malfunction

NOTE:

D When DTC P0105, P0110, P0115 and P0120 are indicated together, it is possible that “G” circuit is open. D Before inspecting, be sure to check that ambient temperature is higher than – 40_C (– 40_F).

DTC CONFIRMATION PROCEDURE

1) Clear DTC, start engine and keep it at idle for 1 min.

2) Select “DTC” mode no scan tool and check DTC.

ENGINE GENERAL INFORMATION 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 Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG.

FLOW TABLE”.

2 Check IAT Sensor and Its Circuit.

1) Connect scan tool to DLC with ignition switch

OFF.

2) Turn ignition switch ON.

3) Check intake air temp. displayed on scan tool.

See Fig. 1.

Is –40_C (–40_F) or 119_C (246_F) indicated?

Go to Step 3. Intermittent trouble.

Check for intermittent referring to “Intermittent and Poor Connection” in Section 0A.

3 Check Wire Harness.

1) Disconnect IAT sensor connector with ignition

switch OFF.

2) Check for proper connection to IAT sensor at

“Gr” and “G” wire terminals.

3) If OK, then with ignition switch ON, is voltage

applied to “Gr” wire terminal about 4 – 6 V? See Fig. 2.

Go to Step 5. “Gr” wire open or

shorted to power, or poor C01-14 connection. If wire and connection are OK, substitute a known-good ECM (PCM) and recheck.

4 Does scan tool indicate –40_C (–40_F) at Step 2. Go to Step 6. Go to Step 5.

5 Check Wire Harness.

1) Check intake air temp. displayed on scan tool

with ignition switch ON.

Is –40_C (–40_F) indicated?

Replace IAT sensor. “Gr” wire shorted to

ground. If wire is OK, substitute a known-good ECM (PCM) and recheck.

6 Check Wire Harness.

1) Using service wire, connect IAT sensor

connector terminals.

2) Check intake air temp. displayed on scan tool

with ignition switch ON. See Fig. 3.

Is 119_C (246_F) indicated?

Replace IAT sensor. “Gr” wire open or poor

C01-9 connection. If wire and connection are OK, substitute a known-good ECM (PCM) and recheck.

ECT sensor

To combination (ECT) meter

To other sensors

6-48 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10)

DTC P0115 ENGINE COOLANT TEMPERATURE (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 voltage-Low resistance)

D “Gr / W” circuit open or shorted to power D “G” circuit open D ECT sensor malfunction D ECM (PCM) malfunction

NOTE: Before inspecting, be sure to check that coolant temp. meter in combination meter indicates normal operating temperature (Engine is not overheating).

DTC CONFIRMATION PROCEDURE

1) Clear DTC, start engine and keep it at idle for 1 min.

2) Select “DTC” mode on scan tool and check DTC.

ENGINE GENERAL INFORMATION 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 Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG.

FLOW TABLE”.

2 Check ECT Sensor and Its Circuit.

1) Connect scan tool with ignition switch OFF.

2) Turn ignition switch ON.

3) Check engine coolant temp. displayed on scan

tool. See Fig. 1.

Is –40_C (–40_F) or 119_C (246_F) indicated?

Go to Step 3. Intermittent trouble.

Check for intermittent referring to “Intermittent and Poor Connection” in Section 0 A.

3 Check Wire Harness.

1) Disconnect ECT sensor connector.

2) Check engine coolant temp. displayed on scan

tool.

Is –40_C (–40_F) indicated?

Replace ECT sensor. “Gr /W” wire shorted to

ground. If wire is OK, substitute a known-good ECM (PCM) and recheck.

4 Does scan tool indicate –40_C (–40_F) at Step 2. Go to Step 6. Go to Step 5.

5 Check Wire Harness.

1) Disconnect ECT sensor connector with

ignition switch OFF.

2) Check for proper connection to ECT sensor at

“G” and “Gr/W” wire terminals.

3) If OK, then with ignition switch ON, is voltage

applied to “G” wire terminal about 4 – 6 V? See Fig. 2.

Go to Step 4. “Gr / W” wire open or

shorted to power, or poor C01-7 connection. If wire and connection are OK, substitute a known-good ECM (PCM) and recheck.

6 Check Wire Harness.

1) Using service wire, connect ECT sensor

connector terminals. See Fig. 3.

2) Turn ignition switch ON and check engine

coolant temp. displayed on scan tool.

Is 119_C (246_F) indicated?

Replace ECT sensor. “G” wire open or

poor C01-9 connection. If wire and connection are OK, substitute a known-good ECM (PCM) and recheck.

suzuki SF310, SF413 workshop manual

Specifications and Main Features

Frequently Asked Questions

User Manual