Page 1: Table Of Contents
Table of Contents 1- i www.CarGarage.ir Section 1 Engine CONTENTS Precautions ..........1-1 Malfunction Indicator Lamp Does Not Come ON with Ignition Switch ON and Engine Precautions............. 1-1 Stop (but Engine Can Be Started)....1A-57 Precautions for Engine.......... 1-1 Malfunction Indicator Lamp Remains ON Engine General Information and after Engine Starts ..........1A-59 DTC P0010: Camshaft Position Actuator...
Page 2 1-ii Table of Contents www.CarGarage.ir DTC P0137 / P0138: O2 Sensor (HO2S) DTC P1603: TCM Trouble Code Detected Circuit Low Voltage / High Voltage (For J20 Engine) ...........1A-170 (Sensor-2) ............. 1A-107 DTC P1674: CAN Communication (Bus Off DTC P0140: O2 Sensor (HO2S) Circuit No Error) .............1A-171 Activity Detected (Sensor-2) ......
Page 3 Table of Contents 1-iii www.CarGarage.ir Vacuum Hose and Purge Valve Chamber Electric Load Current Sensor On-Vehicle Inspection............1B-3 Inspection (For J20 Engine) ......1C-16 EVAP Canister Purge Valve Inspection ....1B-3 Electric Load Current Sensor Removal EVAP Canister Inspection........1B-4 and Installation (For J20 Engine) ....1C-16 EGR Valve Removal and Installation ....
Page 4 1-iv Table of Contents www.CarGarage.ir Pistons, Piston Rings, Connecting Rods 1st Timing Chain and Chain Tensioner and Cylinders Disassembly and Assembly ..1D-44 Components............1D-91 Cylinders, Pistons and Piston Rings 1st Timing Chain and Chain Tensioner Inspection............1D-45 Removal and Installation.........1D-92 Piston Pins and Connecting Rods 1st Timing Chain and Chain Tensioner Inspection............1D-47 Inspection............1D-94...
Page 5 Table of Contents 1-v www.CarGarage.ir General Description ........... 1E-11 Fuel System ..........1G-1 Engine Lubrication Description ......1E-11 Precautions............1G-1 Diagnostic Information and Procedures..1E-13 Precautions on Fuel System Service ....1G-1 Oil Pressure Check ........... 1E-13 General Description ..........1G-1 Repair Instructions ..........
Page 6 1-vi Table of Contents www.CarGarage.ir Ignition Spark Test ..........1H-6 Diagnostic Information and Procedures .... 1J-3 Battery Inspection ..........1J-3 Repair Instructions ..........1H-7 Generator Symptom Diagnosis ......1J-4 High-Tension Cord Removal and Installation Generator Test (Undercharged Battery (For M16 Engine) ..........1H-7 Check)...............
Page 7: Precautions
Precautions: www.CarGarage.ir Precautions Precautions Precautions for Engine S5JB0A1000001 Air Bag Warning Refer to “Air Bag Warning: in Section 00”. Precautions on Engine Service Refer to “Precautions on Engine Service: in Section 1A”. Precautions in Diagnosing Trouble Refer to “Precautions in Diagnosing Trouble: in Section 1A”. Precautions on Fuel System Service Refer to “Precautions on Fuel System Service: in Section 1G”.
Page 8: Engine General Information And Diagnosis
• Diagnostic information stored in ECM memory can be cleared as well as checked by using SUZUKI scan • Communication of ECM, BCM, combination meter, tool or OBD generic scan tool (Vehicle without keyless start control module (if equipped) ABS diagnosis connector).
Page 9: Precautions For Dtc Troubleshooting
Engine General Information and Diagnosis: 1A-2 www.CarGarage.ir Precautions For DTC Troubleshooting • Wire colors of the special tool’s connectors are S5JB0A1100005 different from the ones of the ECM connectors. • Before performed trouble shooting, be sure to read However, the circuit arrangement of the special tool’s the “Precautions of ECM Circuit Inspection: ”.
Page 10: Engine Diagnosis General Description
ECM and malfunction indicator lamp (1) operate as follows. • It is possible to communicate by using not only SUZUKI scan tool (2) but also OBD generic scan tool. • Malfunction indicator lamp (1) lights when the ignition (Diagnostic information can be accessed by using a switch is turned ON (but the engine at stop) with the scan tool.)
Page 11 2 driving cycle detection logic. In addition, DTC can be read by not only using SUZUKI scan tool but also displayed on odometer (5) Freeze Frame Data (Vehicle Not Equipped with of the combination meter. (i.e. when diagnosis switch...
Page 12 OBD serial data line (3) (K line of ISO 9141) is used for SUZUKI scan tool or OBD generic scan tool to communicate with ECM, Air bag SDM, immobilizer control module (in ECM), BCM (Body electrical Control...
Page 13: Engine And Emission Control System Description
Engine General Information and Diagnosis: 1A-6 www.CarGarage.ir Engine and Emission Control System Description S5JB0A1101004 The engine and emission control system is divided into 4 major sub-systems: air intake system, fuel delivery system, electronic control system and emission control system. Air intake system includes air cleaner, throttle body, and intake manifold. Fuel delivery system includes fuel pump, delivery pipe, etc.
Page 14 1A-7 Engine General Information and Diagnosis: www.CarGarage.ir ECM Transmission Data Keyless Start control hydrauric Combination Control Module module unit/control (for A/T Meter (if equipped) (for J20 module model) engine) assembly Engine torque signal Accelerator pedal position Engine speed Throttle position Stand by to engage air conditioning compressor Top gear inhibit...
Page 15 Engine General Information and Diagnosis: 1A-8 www.CarGarage.ir ECM Reception Data ABS hydraulic (for A/T model) unit/control module assmbly Torque reduction request Slip control signal Transmission malfunction indication on Transmission emissions related malfunction active Transmission gear selector position Daytime running light active (if equipped with DRL) Air conditioning switch ON (if equipped with A/C)
Page 16: Air Intake System Description
1A-9 Engine General Information and Diagnosis: www.CarGarage.ir Air Intake System Description S5JB0A1101006 The main components of the air intake system are air cleaner (1), air cleaner outlet hose (2), electric throttle body (3) (for the details, refer to “Description of Electric Throttle Body System: ”.), intake manifold tuning (IMT) valve (4) which adjusts the distributor pipe length of intake manifold to (A) or (B) (for J20 engine) (for the details, refer to “IMT (Intake Manifold Tuning) System: For J20 Engine in Section 1D”.) and intake manifold (5).
Page 17: Description Of Electric Throttle Body System
Engine General Information and Diagnosis: 1A-10 www.CarGarage.ir Description of Electric Throttle Body System S5JB0A1101009 The Electric Throttle Body System consists of electric throttle body assembly, accelerator pedal position (APP) sensor assembly, ECM and throttle actuator control relay. Among them, assembly components are as follows. •...
Page 18: Description Of Electric Throttle Body System Calibration
1A-11 Engine General Information and Diagnosis: www.CarGarage.ir Description of Electric Throttle Body System Calibration S5JB0A1101010 ECM calculates controlled opening of the throttle valve on the basis of the completely closed throttle valve position of the electric throttle body system. The completely closed position data is saved in memory of ECM. However, the completely closed position of the throttle valve of the electric throttle body system (signal voltage from throttle position sensor when throttle is completely closed) differs one from the other depending on individual differences of the throttle valve and throttle position sensor.
Page 19: A/F Sensor Description
Engine General Information and Diagnosis: 1A-12 www.CarGarage.ir I5JB0A110009-01 6. Ignition switch 8. Battery A/F Sensor Description S5JB0A1101012 A/F sensor (1), in place of the conventional heated Oxygen sensor-1, is installed in the center of the exhaust manifold joining section and it consists of a zirconia element (2) which causes the output current to vary according to difference in the oxygen concentration, a heater (3) which activates the element and an adjusting resistor (4) which adjusts individual difference of the sensor.
Page 20: Electronic Control System Description
1A-13 Engine General Information and Diagnosis: www.CarGarage.ir AFS- AFS+ AFH+ AFH- AFRV AFRG I5JB0A110010-02 10. Electrode 13. Lean 11. A/F signal processing circuit 14. Rich 12. CPU 15. 0.4 V Electronic Control System Description S5JB0A1101007 The electronic control system consists of 1) various sensors which detect the state of engine and driving conditions, 2) ECM which controls various devices according to the signals from the sensors and 3) various controlled devices.
Page 21 Engine General Information and Diagnosis: 1A-14 www.CarGarage.ir Engine and Emission Control System Flow Diagram I5JB0A110011-03 www.CarGarage.ir...
Page 22 1A-15 Engine General Information and Diagnosis: www.CarGarage.ir ECM Input / Output Circuit Diagram For J20 engine BLU/ORN BLU/BLK E23-50 E23-56 E23-17 BLU/RED WHT/BLU E23-55 E23-54 C37-45 BLU/YEL ORN/BLU E23-53 C37-44 BLU/RED BLU/GRN E23-52 C37-53 BLUYEL E23-51 C37-54 C37-40 C37-41 WHT/RED C37-52 BLK/YEL C37-1...
Page 23 Engine General Information and Diagnosis: 1A-16 www.CarGarage.ir 1. Accelerator pedal position (APP) sensor 26-1. Sub fuel level sensor 52. A/C compressor (if equipped with A/C) assembly 2. Shield wire 27. Stop lamp switch 53. “CPRSR” fuse 3. CMP sensor 28. Stop lamp 54.
Page 24 1A-17 Engine General Information and Diagnosis: www.CarGarage.ir For M16 engine BLU/ORN BLU/BLK E23-50 E23-56 E23-17 BLU/RED WHT/BLU E23-55 E23-54 C37-45 BLU/YEL ORN/BLU E23-53 C37-44 BLU/RED BLU/GRN E23-52 C37-53 BLUYEL E23-51 C37-54 C37-40 C37-41 WHT/RED C37-52 C37-1 C37-51 WHT/BLU BLK/YEL C37-2 PNK/BLK PNK/GRN C37-16...
Page 25 Engine General Information and Diagnosis: 1A-18 www.CarGarage.ir 1. Accelerator pedal position (APP) sensor 22. Stop lamp switch 44. Radiator cooling fan motor No.1 assembly 2. Shield wire 23. Stop lamp 45. Radiator cooling fan motor No.2 3. CMP sensor 24. DLC 46.
Page 26 1A-19 Engine General Information and Diagnosis: www.CarGarage.ir Terminal Wire color Circuit Terminal Wire color Circuit Electric load current sensor — — signal (for J20 engine) CO adjusting resistor signal (if Throttle position sensor (sub) GRN/WHT equipped) signal Oxygen signal of heated Ground for throttle position oxygen sensor-2 sensor...
Page 27 Engine General Information and Diagnosis: 1A-20 www.CarGarage.ir Terminal Wire color Circuit Terminal Wire color Circuit CAN (high) communication line (active high signal) to ABS WHT/RED — — hydraulic unit / control module assembly 12 V serial communication line PPL/WHT — —...
Page 28: Engine And Emission Control Input / Output Table
1A-21 Engine General Information and Diagnosis: www.CarGarage.ir Engine and Emission Control Input / Output Table S5JB0A1101008 ELECTRIC CONTROL DEVICE OUTPUT INPUT For detecting fuel level FUEL LEVEL SENSOR BAROMETRIC PRESSURE SENSOR STOP LAMP SWITCH START SWITCH IGNITION SWITCH A/C REFRIGERANT PRESSURE SENSOR (if equipped with A/C) BLOWER SWITCH A/C SWITCH (if equipped with A/C) A/C EVAP OUTLET AIR TEMP.
Page 29: Schematic And Routing Diagram
Engine General Information and Diagnosis: 1A-22 www.CarGarage.ir Schematic and Routing Diagram Engine and Emission Control System Diagram S5JB0A1102001 I5JB0A110015-04 www.CarGarage.ir...
Page 30: Component Location
1A-23 Engine General Information and Diagnosis: www.CarGarage.ir 1. Air cleaner 18. Radiator cooling fan motor 35. Immobilizer coil antenna (if equipped) 2. EVAP canister purge valve 19. Combination meter 36. Main relay 3. MAF and IAT sensor 20. BCM 37. Wheel speed sensor (VSS) 4.
Page 31 Engine General Information and Diagnosis: 1A-24 www.CarGarage.ir Information sensors Control devices Others 1. MAF and IAT sensor a: Fuel injector A: ECM 2. Electric throttle body assembly (built-in b: EVAP canister purge valve B: Combination meter throttle position sensor and throttle actuator) 3.
Page 32: Diagnostic Information And Procedures
1A-25 Engine General Information and Diagnosis: www.CarGarage.ir Information sensors Control devices Others 1. MAF and IAT sensor a: Fuel injector A: ECM 2. Electric throttle body assembly (built-in b: EVAP canister purge valve B: Combination meter throttle position sensor and throttle actuator) 3.
Page 33 Engine General Information and Diagnosis: 1A-26 www.CarGarage.ir Step Action Rechecking and record of DTC / Freeze frame data Go to Step 9. Go to Step 10. 1) Recheck for DTC and freeze frame data referring to “DTC Check: ”. Is there any DTC(s)? Engine basic inspection and engine symptom Go to Step 11.
Page 34 1A-27 Engine General Information and Diagnosis: www.CarGarage.ir Customer problem inspection form (Example) I2RH01110010-01 NOTE This form is a standard sample. It should be modified according to conditions characteristic of each market. www.CarGarage.ir...
Page 35: Malfunction Indicator Lamp (Mil) Check
Engine General Information and Diagnosis: 1A-28 www.CarGarage.ir Step 2: DTC / Freeze Frame Data Check, Record and Step 11: Final Confirmation Test Clearance Confirm that the problem symptom has gone and the First, check DTC (including pending DTC), referring to engine is free from any abnormal conditions.
Page 36: Dtc Clearance
1A-29 Engine General Information and Diagnosis: www.CarGarage.ir Using Scan Tool 1) Prepare SUZUKI scan tool or OBD generic scan tool (vehicle not equipped with diagnosis connector). 2) With ignition switch turned OFF, connect it to data link connector (DLC) (1) located on underside of instrument panel at driver’s seat side.
Page 37: Dtc Table
Engine General Information and Diagnosis: 1A-30 www.CarGarage.ir NOTE Without Using Scan Tool 1) Turn ignition switch to OFF position. DTC and freeze frame data stored in ECM memory are also cleared in the following 2) Disconnect battery negative cable for specified time cases.
Page 38 1A-31 Engine General Information and Diagnosis: www.CarGarage.ir Detecting condition DTC No. Detecting item (DTC will set when detecting:) 1 driving *P0102 Mass air flow circuit low input Output voltage of MAF sensor is less than specification. cycle 1 driving *P0103 Mass air flow circuit high input Output voltage of MAF sensor is more than specification.
Page 39 Engine General Information and Diagnosis: 1A-32 www.CarGarage.ir Detecting condition DTC No. Detecting item (DTC will set when detecting:) Throttle position sensor (sub) Output voltage of throttle position sensor (sub) is higher 1 driving *P0223 circuit high than specification. cycle Misfire of such level as to cause damage to three way *2 driving Random misfire detected *P0300...
Page 40 1A-33 Engine General Information and Diagnosis: www.CarGarage.ir Detecting condition DTC No. Detecting item (DTC will set when detecting:) Battery voltage is higher than specification even through generator control is maximum regulation, or battery P0620 Generator control circuit voltage is lower than specification even through generator —...
Page 41 Engine General Information and Diagnosis: 1A-34 www.CarGarage.ir Detecting condition DTC No. Detecting item (DTC will set when detecting:) Difference between the opening angle based on throttle Throttle position sensor (main / 1 driving *P2135 position sensor (main) and the opening angle based on sub) voltage correlation cycle throttle position sensor (sub) is more than specification.
Page 42 1A-35 Engine General Information and Diagnosis: www.CarGarage.ir For Vehicle Equipped with A/T When using OBD generic scan tool, not only the previous star (*) marked ECM DTC(s) but also the following DTC(s) is displayed on OBD generic scan tool simultaneously. Detecting condition DTC No.
Page 43: Fail-Safe Table
Engine General Information and Diagnosis: 1A-36 www.CarGarage.ir Fail-Safe Table S5JB0A1104006 When any of the following DTCs is detected, ECM enters fail-safe mode as long as malfunction continues to exist but that mode is canceled when ECM detects normal condition after that. DTC No.
Page 44: Scan Tool Data
1A-37 Engine General Information and Diagnosis: www.CarGarage.ir DTC No. Detected item Fail-safe operation P2122 Pedal position sensor (main) circuit low input • Throttle valve is fixed at the opening of about 7° P2123 Pedal position sensor (main) circuit high input from its completely closed position (default P2127 Pedal position sensor (sub) circuit low input...
Page 45 Engine General Information and Diagnosis: 1A-38 www.CarGarage.ir Normal condition / Scan tool data Vehicle condition reference values FUEL TANK LEVEL Ignition switch ON 0 – 100% BATTERY VOLTAGE Ignition switch ON / engine at stop 10 – 14 V At 2000 r/min. with no load after warming up 10.0 –...
Page 46 1A-39 Engine General Information and Diagnosis: www.CarGarage.ir Normal condition / Scan tool data Vehicle condition reference values 1300 – 1480 kPa (for J20 engine), 1150 – 1280 kPa (for A/C ON (A/C is operating) at M16 engine) For more details, ambient temperature: 30 °C refer to pressure of high (86 °F) and humidity: 50%...
Page 47 Engine General Information and Diagnosis: 1A-40 www.CarGarage.ir Normal condition / Scan tool data Vehicle condition reference values APP SENSOR 2 VOLT Accelerator pedal released 0.3 – 0.4 V Ignition switch ON (ACCELERATOR PEDAL after warmed up Accelerator pedal depressed POSITION (APP) SENSOR 1.7 –...
Page 48 1A-41 Engine General Information and Diagnosis: www.CarGarage.ir BRAKE SW (ON/OFF) ACTIVE: Activating This parameter indicates the state of the brake switch. INACTIVE: warming up or at stop. INTAKE TUNING SOL (INTAKE MANIFOLD TUNING A/F B1 S1 ACT (A/F SENSOR, ACTIVE / INACTIVE): VALVE, ON/OFF): This parameter indicates activation condition of A/F ON: Command for intake manifold tuning valve being...
Page 49 Engine General Information and Diagnosis: 1A-42 www.CarGarage.ir A/C SWITCH (ON/OFF) APP SENSOR 2 VOLT (ACCELERATOR PEDAL ON: Command for A/C operation being output from ECM POSITION (APP) SENSOR (SUB) OUTPUT VOLTAGE, to HVAC. OFF: Command for A/C operation not being output. The Accelerator Pedal Position (APP) Sensor (Sub) reading provides accelerator pedal opening information A/C COMP RELAY (A/C COMPRESSOR RELAY, ON/...
Page 50: Visual Inspection
1A-43 Engine General Information and Diagnosis: www.CarGarage.ir Visual Inspection S5JB0A1104008 Visually check the following parts and systems. Inspection item Reference section • Engine oil – level, leakage “Engine Oil and Filter Change: in Section 0B” • Engine coolant – level, leakage “Coolant Level Check: in Section 1F”...
Page 51: Engine Basic Inspection
Engine General Information and Diagnosis: 1A-44 www.CarGarage.ir Engine Basic Inspection S5JB0A1104009 This check is very important for troubleshooting when ECM has detected no DTC and no abnormality has been found in “Visual Inspection: ”. Follow the flow carefully. Step Action Was “Engine and Emission Control System Check”...
Page 52 Check ignition timing Go to “Engine Symptom Check ignition control Diagnosis: ”. related parts referring to 1) Using SUZUKI scan tool, select “Misc Test” mode on “Ignition Timing SUZUKI scan tool and fix ignition timing to initial one. Inspection: in Section 1H”.
Page 53 Engine General Information and Diagnosis: 1A-46 www.CarGarage.ir Step Action 10 Check fuel supply Go to Step 12. Go to Step 11. 1) Check to make sure that enough fuel is filled in fuel tank. 2) Turn ON ignition switch for 2 seconds and then OFF. 3) Repeat Step 2) a few times.
Page 54 1A-47 Engine General Information and Diagnosis: www.CarGarage.ir Step Action 13 Check fuel injector for operation Go to “Engine Symptom Go to “Fuel Injector Diagnosis: ”. Circuit Check: ”. 1) Install spark plugs and connect injector connectors. 2) Using sound scope (1), check operating sound of each injector (2) when cranking engine.
Page 55: Engine Symptom Diagnosis
Engine General Information and Diagnosis: 1A-48 www.CarGarage.ir Engine Symptom Diagnosis S5JB0A1104010 Perform troubleshooting referring to the followings when ECM has detected no DTC and no abnormality has been found in “Visual Inspection: ” and “Engine Basic Inspection: ”. Condition Possible cause Correction / Reference Item Hard starting (Engine Faulty spark plug...
Page 56 1A-49 Engine General Information and Diagnosis: www.CarGarage.ir Condition Possible cause Correction / Reference Item Low oil pressure Improper oil viscosity “Engine Oil and Filter Change: in Section 0B” Malfunctioning oil pressure switch “Oil Pressure Switch Inspection: in Section 9C” Clogged oil strainer “Oil Pan and Oil Pump Strainer Cleaning: For J20 Engine in Section 1E”...
Page 57 Engine General Information and Diagnosis: 1A-50 www.CarGarage.ir Condition Possible cause Correction / Reference Item Engine noise – Worn piston, ring and cylinder bore “Pistons, Piston Rings, Connecting Rods and Connecting rod noise Cylinders Inspection and Cleaning: For J20 Engine in Section 1D” or “Cylinders, Pistons NOTE and Piston Rings Inspection: For M16A Engine Before checking...
Page 58 1A-51 Engine General Information and Diagnosis: www.CarGarage.ir Condition Possible cause Correction / Reference Item Engine overheating Inoperative thermostat “Thermostat Inspection: in Section 1F” Poor water pump performance “Water Pump Inspection: in Section 1F” Clogged or leaky radiator “Radiator On-Vehicle Inspection and Cleaning: in Section 1F”...
Page 59 Engine General Information and Diagnosis: 1A-52 www.CarGarage.ir Condition Possible cause Correction / Reference Item Excessive engine oil Blown cylinder head gasket “Cylinder Head Inspection: For J20 Engine in consumption – Oil Section 1D” or “Cylinder Head Inspection: For leakage M16A Engine with VVT in Section 1D” Leaky camshaft oil seals “Camshaft, Tappet and Shim Inspection: For J20 Engine in Section 1D”...
Page 60 1A-53 Engine General Information and Diagnosis: www.CarGarage.ir Condition Possible cause Correction / Reference Item Surge – Engine power Leaky or loosely connected high-tension “High-Tension Cord Removal and Installation variation under steady cord (for M16 engine) (For M16 Engine): in Section 1H” throttle or cruise.
Page 61 Engine General Information and Diagnosis: 1A-54 www.CarGarage.ir Condition Possible cause Correction / Reference Item Engine has no power Faulty spark plug “Spark Plug Inspection: in Section 1H” Faulty ignition coil with ignitor “Ignition Coil Assembly (Including ignitor) Inspection: in Section 1H” Leaks, loose connection or “High-Tension Cord Removal and Installation disconnection of high-tension cord (for...
Page 62 1A-55 Engine General Information and Diagnosis: www.CarGarage.ir Condition Possible cause Correction / Reference Item Improper engine idling or Faulty spark plug “Spark Plug Inspection: in Section 1H” engine fails to idle Leaky or disconnected high-tension cord “High-Tension Cord Removal and Installation (for M16 engine) (For M16 Engine): in Section 1H”...
Page 63 Engine General Information and Diagnosis: 1A-56 www.CarGarage.ir Condition Possible cause Correction / Reference Item Excessive hydrocarbon Faulty spark plug “Spark Plug Inspection: in Section 1H” (HC) emission or carbon Leaky or disconnected high-tension cord “High-Tension Cord Removal and Installation monoxide (CO) (for M16 engine) (For M16 Engine): in Section 1H”...
Page 64: Malfunction Indicator Lamp Does Not Come On With Ignition Switch On And Engine Stop (But Engine Can Be Started)
1A-57 Engine General Information and Diagnosis: www.CarGarage.ir Malfunction Indicator Lamp Does Not Come ON with Ignition Switch ON and Engine Stop (but Engine Can Be Started) S5JB0A1104011 Wiring Diagram E23-4 WHT/RED WHT/RED E23-19 WHT/BLU WHT/BLU G28-13 G28-15 PPL/RED BLK/YEL BLK/WHT E23-29 C37-15 BLK/ORN...
Page 65 Engine General Information and Diagnosis: 1A-58 www.CarGarage.ir Troubleshooting NOTE • Before performed troubleshooting, be sure to read the “Precautions of ECM Circuit Inspection: ”. • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits: ”. Step Action MIL power supply check...
Page 66: Malfunction Indicator Lamp Remains On After Engine Starts
1A-59 Engine General Information and Diagnosis: www.CarGarage.ir Step Action Combination meter circuit check Substitute a known- “BLK” wire is open or good combination meter high resistance circuit. 1) Turn ignition switch to OFF position. and recheck. If MIL still 2) Measure resistance between “G28-15” terminal of remains OFF, substitute combination meter connector and vehicle body ground.
Page 67: Dtc P0010: Camshaft Position Actuator Circuit (For M16 Engine)
Engine General Information and Diagnosis: 1A-60 www.CarGarage.ir DTC P0010: Camshaft Position Actuator Circuit (For M16 Engine) S5JB0A1104013 System and Wiring Diagram BRN/WHT C37-60 C37-15 BLK/ORN C37-59 BRN/YEL C37-30 BLK/ORN C37-29 BLK/YEL C37-48 BLK/YEL C37-58 BLK/YEL [A]: 39 38 32 31 39 38 32 31 54 53...
Page 68 1A-61 Engine General Information and Diagnosis: www.CarGarage.ir DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions For DTC Troubleshooting: ”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control...
Page 69: Dtc P0011 / P0012: Camshaft Position - Timing Over-Advanced Or System Performance / -Retarded (For M16 Engine)
Engine General Information and Diagnosis: 1A-62 www.CarGarage.ir Step Action Oil control valve check Substitute a known- Faulty oil control valve. Check oil control valve referring to “Oil Control Valve good ECM and recheck. Inspection: For M16A Engine with VVT in Section 1D”. Is resistance within specified value? DTC P0011 / P0012: Camshaft Position - Timing Over-Advanced or System Performance / -Retarded (For M16 Engine)
Page 70 Engine with VVT in 3) Select menu to DATA LIST. Section 1D”. If OK, go to 4) Check that “VVT GAP” displayed on SUZUKI scan tool is Step 5. 0 – 5°. Is it OK? Camshaft position control check Substitute a known- Go to Step 5.
Page 71: Dtc P0030: Ho2S Heater Control Circuit (Sensor-1)
Engine General Information and Diagnosis: 1A-64 www.CarGarage.ir Step Action Oil control valve check Replace camshaft Replace oil control timing sprocket. valve. 1) Check oil control valve referring to “Oil Control Valve Inspection: For M16A Engine with VVT in Section 1D”. Is it in good condition? DTC P0030: HO2S Heater Control Circuit (Sensor-1) S5JB0A1104088...
Page 72: Dtc P0031 / P0032: Ho2S Heater Control Circuit Low / High (Sensor-1)
1A-65 Engine General Information and Diagnosis: www.CarGarage.ir DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions For DTC Troubleshooting: ”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control...
Page 73 Engine General Information and Diagnosis: 1A-66 www.CarGarage.ir DTC Confirmation Procedure 1) With ignition switch turned OFF, connect scan tool. 2) Turn ON ignition switch and clear DTC using scan tool. 3) Start engine and warm up to normal operating temperature. 4) Run engine at idle speed for 1 min.
Page 74 1A-67 Engine General Information and Diagnosis: www.CarGarage.ir Step Action A/F sensor and HO2S heater resistance check Go to Step 6. Replace defective sensor. 1) Disconnect connector from HO2S-2 with ignition switch turned OFF. 2) Check heater resistance of A/F sensor and HO2S referring to “Air Fuel Ratio (A/F) Sensor On-Vehicle Inspection: in Section 1C”...
Page 75 Engine General Information and Diagnosis: 1A-68 www.CarGarage.ir Step Action HO2S heater relay circuit check Output wire of relay Repair or replace connector is open or defective circuit. 1) Measure wire resistance between coil ground terminal of short to ground. relay connector and vehicle body ground. Ω...
Page 76: Dtc P0037 / P0038: Ho2S Heater Control Circuit Low / High (Sensor-2)
1A-69 Engine General Information and Diagnosis: www.CarGarage.ir DTC P0037 / P0038: HO2S Heater Control Circuit Low / High (Sensor-2) S5JB0A1104016 Wiring Diagram BLK/WHT *GRN BLK/RED C37-47 C37-11 GRY/GRN C37-57 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I5JB0A110032-01...
Page 77 Engine General Information and Diagnosis: 1A-70 www.CarGarage.ir DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions For DTC Troubleshooting: ”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control...
Page 78 1A-71 Engine General Information and Diagnosis: www.CarGarage.ir Step Action HO2S heater relay power circuit check Go to Step 6. Power circuit is open. 1) Remove integration relay No.2 (for J20 engine) (1) or HO2S heater relay (for M16 engine) (2) with ignition switch turned OFF.
Page 79: Dtc P0101: Mass Air Flow Circuit Range / Performance
Engine General Information and Diagnosis: 1A-72 www.CarGarage.ir Step Action 10 HO2S heater control circuit check Go to Step 11. Repair or replace defective wire circuit. 1) Disconnect connector from ECM with ignition switch turned OFF. 2) Check for proper connection of HO2S-2 heater circuit terminal to ECM connector.
Page 80 1A-73 Engine General Information and Diagnosis: www.CarGarage.ir DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area • MAF volume is greater than 25 g/sec even if engine • Air intake system (clog or leakage) revolution is less than 900 rpm and intake manifold •...
Page 81 Engine General Information and Diagnosis: 1A-74 www.CarGarage.ir Step Action MAF sensor and its circuit check Go to Step 11. Go to Step 4. 1) With ignition switch turned OFF, connect scan tool to DLC. 2) Start engine and warm up to normal operation temperature.
Page 82: Dtc P0102: Mass Air Flow Circuit Low Input
1A-75 Engine General Information and Diagnosis: www.CarGarage.ir Step Action MAF sensor signal circuit check Go to Step 9. “RED” wire is shorted to others circuit. 1) Disconnect connectors from ECM with ignition switch turned OFF. 2) Turn ON ignition switch, measure voltage between “RED”...
Page 83 Engine General Information and Diagnosis: 1A-76 www.CarGarage.ir DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions For DTC Troubleshooting: ”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control...
Page 84: Dtc P0103: Mass Air Flow Circuit High Input
1A-77 Engine General Information and Diagnosis: www.CarGarage.ir Step Action MAF sensor output signal check Substitute a known- Faulty MAF and IAT good ECM and recheck. sensor. 1) Connect connectors to MAF and IAT sensor and ECM with ignition switch turned OFF. 2) Measure voltage between “C37-26”...
Page 85 Engine General Information and Diagnosis: 1A-78 www.CarGarage.ir DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions For DTC Troubleshooting: ”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control...
Page 86: Dtc P0106: Manifold Absolute Pressure Range / Performance
1A-79 Engine General Information and Diagnosis: www.CarGarage.ir DTC P0106: Manifold Absolute Pressure Range / Performance S5JB0A1104020 Wiring Diagram GRY/RED GRY/RED C37-14 RED/WHT C37-55 C37-15 BLK/ORN C37-30 BLK/ORN GRY/GRN GRY/GRN C37-57 C37-29 BLK/YEL C37-48 BLK/YEL C37-58 BLK/YEL 39 38 32 31 39 38 32 31 54 53...
Page 87: Dtc P0107: Manifold Absolute Pressure Circuit Low Input
Engine General Information and Diagnosis: 1A-80 www.CarGarage.ir DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions For DTC Troubleshooting: ”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control...
Page 88 1A-81 Engine General Information and Diagnosis: www.CarGarage.ir DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions For DTC Troubleshooting: ”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control...
Page 89: Dtc P0108: Manifold Absolute Pressure Circuit High Input
Engine General Information and Diagnosis: 1A-82 www.CarGarage.ir Step Action MAP sensor signal circuit check Go to Step 7. “RED/WHT” wire is shorted to ground 1) Disconnect connectors from ECM with ignition switch circuit. turned OFF. 2) Measure resistance between “C37-55” terminal of ECM connector and vehicle body ground.
Page 90 1A-83 Engine General Information and Diagnosis: www.CarGarage.ir Step Action MAP sensor power supply voltage check Go to Step 4. “GRY/RED” wire shorted to power circuit. 1) Disconnect connector from MAP sensor with ignition switch turned OFF. 2) Check for proper connection of MAP sensor at “GRY/ RED”, “RED/WHT”...
Page 91: Dtc P0111: Intake Air Temperature Circuit Range / Performance
Engine General Information and Diagnosis: 1A-84 www.CarGarage.ir DTC P0111: Intake Air Temperature Circuit Range / Performance S5JB0A1104023 Wiring Diagram BLU/BLK C37-26 C37-27 C37-25 LT GRN GRY/GRN C37-57 GRY/GRN 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I5JB0A110036-01...
Page 92 1A-85 Engine General Information and Diagnosis: www.CarGarage.ir DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions For DTC Troubleshooting: ”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control...
Page 93 Engine General Information and Diagnosis: 1A-86 www.CarGarage.ir Step Action Wire circuit check Go to Step 6. “LT GRN” wire is shorted to ground or 1) Disconnect connectors from ECM with ignition switch other circuit. turned OFF. If wire is OK, substitute 2) Measure resistance between “LT GRN”...
Page 94: Dtc P0112: Intake Air Temperature Sensor Circuit Low
1A-87 Engine General Information and Diagnosis: www.CarGarage.ir DTC P0112: Intake Air Temperature Sensor Circuit Low S5JB0A1104024 Wiring Diagram Refer to “DTC P0111: Intake Air Temperature Circuit Range / Performance: ”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area DTC will be set when all of following conditions are detected for •...
Page 95 Engine General Information and Diagnosis: 1A-88 www.CarGarage.ir Step Action ECM voltage check Go to Step 6. Go to Step 4. 1) Disconnect connector from MAF and IAT sensor with ignition switch turned OFF. 2) Check for proper connection to MAF and IAT sensor at “LT GRN”...
Page 96: Dtc P0113: Intake Air Temperature Sensor Circuit High
1A-89 Engine General Information and Diagnosis: www.CarGarage.ir DTC P0113: Intake Air Temperature Sensor Circuit High S5JB0A1104025 Wiring Diagram Refer to “DTC P0111: Intake Air Temperature Circuit Range / Performance: ”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area DTC will be set when all of following conditions are detected for •...
Page 97 Engine General Information and Diagnosis: 1A-90 www.CarGarage.ir Step Action IAT sensor voltage check Go to Step 7. Go to Step 4. 1) Disconnect connector from MAF and IAT sensor with ignition switch turned OFF. 2) Check for proper connection to MAF and IAT sensor at “LT GRN”...
Page 98: Dtc P0116: Engine Coolant Temperature Circuit Range / Performance
1A-91 Engine General Information and Diagnosis: www.CarGarage.ir Step Action Ground circuit check “GRY/GRN” wire is Faulty ECM ground open circuit or high circuit. If circuit is OK, 1) Remove ECM from its bracket with ECM connectors resistance circuit. Poor substitute a known- connected.
Page 99 Engine General Information and Diagnosis: 1A-92 www.CarGarage.ir DTC Confirmation Procedure WARNING • When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. •...
Page 100 1A-93 Engine General Information and Diagnosis: www.CarGarage.ir Step Action Wire harness check Go to Step 9. Go to Step 6. 1) Disconnect ECT sensor connector with ignition switch turned OFF. 2) Check for proper connection to ECT sensor connector at “PPL/YEL”...
Page 101: Dtc P0117: Engine Coolant Temperature Circuit Low
Engine General Information and Diagnosis: 1A-94 www.CarGarage.ir Step Action 10 Ground circuit check “GRY/GRN” wire is high Faulty ECM ground resistance circuit. circuit. 1) Remove ECM from its bracket with ECM connectors connected. Poor “C37-57” If circuit is OK, connection. substitute a known- 2) Measure resistance between “C37-57”...
Page 102: Dtc P0118: Engine Coolant Temperature Circuit High
1A-95 Engine General Information and Diagnosis: www.CarGarage.ir Step Action ECM voltage check Go to Step 6. Go to Step 4. 1) Disconnect connector from ECT sensor with ignition switch turned OFF. 2) Check for proper connection to ECT sensor at “PPL/ YEL”...
Page 103 Engine General Information and Diagnosis: 1A-96 www.CarGarage.ir DTC Confirmation Procedure 1) With ignition switch turned OFF, connect scan tool. 2) Turn ON ignition switch and clear DTC using scan tool. 3) Start engine and run it for 10 sec. or more. 4) Check DTC and pending DTC.
Page 104 1A-97 Engine General Information and Diagnosis: www.CarGarage.ir Step Action ECT sensor harness voltage check Go to Step 6. “PPL/YEL” wire is shorted to other circuit. 1) Disconnect connectors from ECM with ignition switch turned OFF. If wire is OK, substitute a known-good ECM and 2) Turn ON ignition switch.
Page 105: Dtc P0122: Throttle Position Sensor (Main) Circuit Low
Engine General Information and Diagnosis: 1A-98 www.CarGarage.ir DTC P0122: Throttle Position Sensor (Main) Circuit Low S5JB0A1104073 Wiring Diagram BLK/WHT E23-29 BLK/YEL C37-15 BLK/ORN C37-30 BLK/ORN C37-29 BLK/YEL BLK/RED BLK/RED E23-60 C37-48 BLK/YEL BLK/YEL C37-58 BLU/BLK BLU/BLK E23-1 BLK/RED BLU/BLK BLU/BLK E23-16 WHT/GRN E23-50...
Page 106 1A-99 Engine General Information and Diagnosis: www.CarGarage.ir DTC Confirmation Procedure 1) With ignition switch turned OFF, connect scan tool. 2) Turn ON ignition switch and clear DTC using scan tool. 3) Keep the accelerator pedal at idle position for 2 seconds. 4) Keep the accelerator pedal at fully depressed position for 2 seconds.
Page 107 Engine General Information and Diagnosis: 1A-100 www.CarGarage.ir Step Action ECM voltage check “WHT” wire is open or Go to Step 5. high resistance circuit. 1) Turn OFF ignition switch. 2) Remove ECM from its bracket with ECM connectors connected. 3) Check for proper connection of ECM connector at “C37- 53”...
Page 108: Dtc P0123: Throttle Position Sensor (Main) Circuit High
1A-101 Engine General Information and Diagnosis: www.CarGarage.ir DTC P0123: Throttle Position Sensor (Main) Circuit High S5JB0A1104074 Wiring Diagram Refer to “DTC P0122: Throttle Position Sensor (Main) Circuit Low: ”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Output voltage of throttle position sensor (main) is more than •...
Page 109 Engine General Information and Diagnosis: 1A-102 www.CarGarage.ir Step Action ECM voltage check Go to Step 5. Go to Step 4. 1) Disconnect connector from electric throttle body assembly with ignition switch turned OFF. 2) Check for proper connection to electric throttle body assembly at “WHT”, “GRN”...
Page 110 1A-103 Engine General Information and Diagnosis: www.CarGarage.ir Step Action Wire harness check Go to Step 8. “BLK” wire is shorted to “WHT” wire. 1) Disconnect connectors from ECM with ignition switch turned OFF. 2) Measure resistance between “BLK” and “WHT” wire terminals of electric throttle body assembly connector.
Page 111: Dtc P0131 / P0132 / P0134: O2 Sensor (Ho2S) Circuit Low Voltage / High Voltage / No Activity Detected (Sensor-1)
Engine General Information and Diagnosis: 1A-104 www.CarGarage.ir DTC P0131 / P0132 / P0134: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage / No Activity Detected (Sensor-1) S5JB0A1104032 Wiring Diagram BLK/WHT *GRN C37-38 C37-37 RED/YEL C37-35 RED/BLU C37-34 PNK/BLU C37-32 C37-31 BLK/YEL 39 38...
Page 112: Dtc P0133: O2 Sensor (Ho2S) Circuit Slow Response (Sensor-1)
1A-105 Engine General Information and Diagnosis: www.CarGarage.ir DTC Confirmation Procedure 1) With ignition switch turned OFF, connect scan tool. 2) Turn ON ignition switch and clear DTC using scan tool. 3) Start engine and warm up to normal operating temperature. 4) Run engine at idle speed for 1 min.
Page 113 Engine General Information and Diagnosis: 1A-106 www.CarGarage.ir A/F Sensor Description Refer to “A/F Sensor Description: ”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Ratio between integrated value of A/F sensor output variation and integrated value of •...
Page 114: Dtc P0137 / P0138: O2 Sensor (Ho2S) Circuit Low Voltage / High Voltage (Sensor-2)
1A-107 Engine General Information and Diagnosis: www.CarGarage.ir DTC P0137 / P0138: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-2) S5JB0A1104035 Wiring Diagram BLK/WHT *GRN BLK/RED C37-47 C37-11 GRY/GRN C37-57 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46...
Page 115 Engine General Information and Diagnosis: 1A-108 www.CarGarage.ir DTC Confirmation Procedure WARNING • When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. •...
Page 116 1A-109 Engine General Information and Diagnosis: www.CarGarage.ir Step Action HO2S-2 ground check Go to Step 5. “GRN” and/or “GRY/ GRN” wire is open or 1) Disconnect connector from HO2S-2 with ignition switch high resistance circuit. turned OFF. Poor “C37-57” terminal 2) Check for proper connection to HO2S-2 connector at connection.
Page 117: Dtc P0140: O2 Sensor (Ho2S) Circuit No Activity Detected (Sensor-2)
Engine General Information and Diagnosis: 1A-110 www.CarGarage.ir DTC P0140: O2 Sensor (HO2S) Circuit No Activity Detected (Sensor-2) S5JB0A1104036 Wiring Diagram Refer to “DTC P0137 / P0138: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-2): ”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area HO2S-2 voltage is higher than specified value after warming up engine...
Page 118: Dtc P0171 / P0172 / P2195 / P2196: Fuel System Too Lean / Rich / Stuck Lean / Stuck Rich
1A-111 Engine General Information and Diagnosis: www.CarGarage.ir Step Action HO2S-2 signal circuit check Go to Step 5. “RED” wire is shorted to other circuit. 1) Turn ON ignition switch. 2) Measure voltage between “RED” wire terminal of HO2S- 2 connector and vehicle body ground. Is voltage 0 V? HO2S-2 heater circuit check Go to Step 6.
Page 119 Engine General Information and Diagnosis: 1A-112 www.CarGarage.ir DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area DTC P0171: • Vacuum leakage Total fuel trim (short term fuel trim + long term fuel trim) is higher • Exhaust gas leakage than specified range for 30 to 90 sec (depending on ECT) •...
Page 120 1A-113 Engine General Information and Diagnosis: www.CarGarage.ir DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions For DTC Troubleshooting: ”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control...
Page 121 Engine General Information and Diagnosis: 1A-114 www.CarGarage.ir Step Action A/F sensor adjusting resistor power /ground circuit Go to step 11. Go to Step 10. check 1) Disconnect connector from A/F sensor with ignition switch turned OFF. 2) Check for proper connection to A/F sensor connector. 3) If connections are OK, check A/F sensor adjusting resistor circuit for the following.
Page 122: Dtc P0222: Throttle Position Sensor (Sub) Circuit Low
1A-115 Engine General Information and Diagnosis: www.CarGarage.ir DTC P0222: Throttle Position Sensor (Sub) Circuit Low S5JB0A1104075 Wiring Diagram BLK/WHT E23-29 BLK/YEL C37-15 BLK/ORN C37-30 BLK/ORN C37-29 BLK/YEL BLK/RED BLK/RED E23-60 C37-48 BLK/YEL BLK/YEL C37-58 BLU/BLK BLU/BLK E23-1 BLK/RED BLU/BLK BLU/BLK E23-16 WHT/GRN E23-50...
Page 123 Engine General Information and Diagnosis: 1A-116 www.CarGarage.ir DTC Confirmation Procedure 1) With ignition switch turned OFF, connect scan tool. 2) Turn ON ignition switch and clear DTC using scan tool. 3) Keep the accelerator pedal at idle position for 2 seconds. 4) Keep the accelerator pedal at fully depressed position for 2 seconds.
Page 124 1A-117 Engine General Information and Diagnosis: www.CarGarage.ir Step Action ECM voltage check “WHT” wire is open or Go to Step 5. high resistance circuit. 1) Turn OFF ignition switch. 2) Remove ECM from its bracket with ECM connectors connected. 3) Check for proper connection of ECM connector at “C37- 53”...
Page 125: Dtc P0223: Throttle Position Sensor (Sub) Circuit High
Engine General Information and Diagnosis: 1A-118 www.CarGarage.ir DTC P0223: Throttle Position Sensor (Sub) Circuit High S5JB0A1104076 Wiring Diagram Refer to “DTC P0222: Throttle Position Sensor (Sub) Circuit Low: ”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Output voltage of throttle position sensor (sub) is more than specified value •...
Page 126 1A-119 Engine General Information and Diagnosis: www.CarGarage.ir Step Action ECM voltage check Go to Step 5. Go to Step 4. 1) Disconnect connector from electric throttle body assembly with ignition switch turned OFF. 2) Check for proper connection to electric throttle body assembly at “RED”, “WHT”...
Page 127 Engine General Information and Diagnosis: 1A-120 www.CarGarage.ir Step Action Wire harness check Go to Step 8. “RED” wire is shorted to “WHT” wire. 1) Disconnect connectors from ECM with ignition switch turned OFF. 2) Measure resistance between “WHT” and “RED” wire terminals of electric throttle body assembly connector.
Page 128: Dtc P0300 / P0301 / P0302 / P0303 / P0304: Random Misfire Detected / Cylinder 1 / Cylinder 2 / Cylinder 3 / Cylinder 4 Misfire Detected
1A-121 Engine General Information and Diagnosis: www.CarGarage.ir DTC P0300 / P0301 / P0302 / P0303 / P0304: Random Misfire Detected / Cylinder 1 / Cylinder 2 / Cylinder 3 / Cylinder 4 Misfire Detected S5JB0A1104038 System Description ECM measures the angle of the crankshaft based on the pulse signal from the CKP sensor and CMP sensor for each cylinder.
Page 129 Engine General Information and Diagnosis: 1A-122 www.CarGarage.ir Step Action Does fuel level meter indicate “E” level (empty)? Add fuel and recheck. Go to Step 3. Fuel quality check Go to Step 4. Clean in fuel system circuit and change fuel. 1) Check that there is fuel of good quality in the fuel tank.
Page 130: Dtc P0327 / P0328: Knock Sensor Circuit Low / High
1A-123 Engine General Information and Diagnosis: www.CarGarage.ir DTC P0327 / P0328: Knock Sensor Circuit Low / High S5JB0A1104039 Wiring Diagram C37-56 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I5JB0A110046-01 1. Knock sensor 2.
Page 131 Engine General Information and Diagnosis: 1A-124 www.CarGarage.ir Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check: ”. Knock sensor circuit check Intermittent trouble. Go to Step 3. Check for intermittent 1) Remove ECM from its bracket with ECM connectors referring to “Intermittent...
Page 132: Dtc P0335: Crankshaft Position (Ckp) Sensor Circuit (For J20 Engine)
1A-125 Engine General Information and Diagnosis: www.CarGarage.ir DTC P0335: Crankshaft Position (CKP) Sensor Circuit (For J20 Engine) S5JB0A1104089 Wiring Diagram BLK/WHT BLK/YEL E23-29 BLK/YEL BLK/YEL [A]: BLK/RED [B]: BLK BLK/YEL C37-22 BLK/YEL BLK/RED WHT/RED BLK/YEL WHT/GRN C37-15 BLK/ORN C37-30 BLK/ORN C37-29 BLK/YEL C37-48...
Page 133 Engine General Information and Diagnosis: 1A-126 www.CarGarage.ir DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions For DTC Troubleshooting: ”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control...
Page 134: Dtc P0335: Crankshaft Position (Ckp) Sensor Circuit (For M16 Engine)
1A-127 Engine General Information and Diagnosis: www.CarGarage.ir DTC P0335: Crankshaft Position (CKP) Sensor Circuit (For M16 Engine) S5JB0A1104040 Wiring Diagram BLK/WHT BLK/YEL E23-29 BLK/YEL BLK/YEL BLK/YEL C37-22 BLK/YEL BLK/RED WHT/RED BLK/YEL WHT/GRN C37-15 BLK/ORN C37-30 BLK/ORN C37-29 BLK/YEL C37-48 BLK/RED BLK/RED BLK/YEL E23-60...
Page 135 Engine General Information and Diagnosis: 1A-128 www.CarGarage.ir DTC Confirmation Procedure 1) With ignition switch turned OFF, connect scan tool. 2) Turn ON ignition switch and clear DTC using scan tool. 3) Crank engine for 3 – 5 sec. 4) Check DTC and pending DTC. DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to...
Page 136 1A-129 Engine General Information and Diagnosis: www.CarGarage.ir Step Action Ground circuit check Go to Step 6. “BLK/YEL” wire is open or high resistance. 1) Turn ignition switch to OFF position. 2) Measure resistance between “BLK/YEL” wire terminal of CKP sensor connector and engine ground. Ω...
Page 137: Dtc P0340: Camshaft Position (Cmp) Sensor Circuit
Engine General Information and Diagnosis: 1A-130 www.CarGarage.ir DTC P0340: Camshaft Position (CMP) Sensor Circuit S5JB0A1104041 Wiring Diagram BLK/WHT E23-29 BLK/YEL C37-15 BLK/ORN C37-30 BLK/ORN C37-29 BLK/YEL WHT/GRN C37-48 BLK/YEL BLK/RED BLK/RED E23-60 BLK/YEL C37-58 BLU/BLK BLU/BLK E23-1 BLK/RED E23-16 BLU/BLK BLU/BLK WHT/RED C37-52...
Page 138 1A-131 Engine General Information and Diagnosis: www.CarGarage.ir DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions For DTC Troubleshooting: ”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control...
Page 139 Engine General Information and Diagnosis: 1A-132 www.CarGarage.ir Step Action Was terminal “Vout” voltage in Step 3 within specification? Go to Step 5. “WHT/RED” wire is open or shorted to ground / power supply circuit. If wire and connection are OK, substitute a known-good ECM and recheck.
Page 140: Dtc P0401 / P0402: Exhaust Gas Recirculation Flow Insufficient Detected / Excessive Detected
1A-133 Engine General Information and Diagnosis: www.CarGarage.ir DTC P0401 / P0402: Exhaust Gas Recirculation Flow Insufficient Detected / Excessive Detected S5JB0A1104042 System and Wiring Diagram I5JB0A110051-01 1. EGR valve 4. Sensed information 7. “IG COIL” fuse 10. Main relay 2. Intake manifold 5.
Page 141 Engine General Information and Diagnosis: 1A-134 www.CarGarage.ir DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area DTC P0401: • EGR valve Difference in intake manifold absolute pressure between opened EGR valve • EGR passage and closed EGR valve is smaller than specified value. •...
Page 142 Go to Step 5. EGR valve operation check Go to Step 4. Go to Step 5. 1) With ignition switch turned OFF, install SUZUKI scan tool to DTC. 2) Check EGR system referring to “EGR System Inspection: in Section 1B”.
Page 143: Dtc P0403: Exhaust Gas Recirculation Control Circuit
Engine General Information and Diagnosis: 1A-136 www.CarGarage.ir DTC P0403: Exhaust Gas Recirculation Control Circuit S5JB0A1104043 Wiring Diagram Refer to “DTC P0401 / P0402: Exhaust Gas Recirculation Flow Insufficient Detected / Excessive Detected: ”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area EGR valve output voltage is different from output command with more •...
Page 144 1A-137 Engine General Information and Diagnosis: www.CarGarage.ir Step Action Wire circuit check Go to Step 5. Faulty wire(s) are shorted to ground 1) With ignition switch turned OFF, measure resistance circuit. between engine ground and each “YEL/BLK”, “YEL/ RED”, “YEL/GRN”, “YEL” wire terminals of EGR valve If wires are OK, connector.
Page 145: Dtc P0420: Catalyst System Efficiency Below Threshold
Engine General Information and Diagnosis: 1A-138 www.CarGarage.ir DTC P0420: Catalyst System Efficiency below Threshold S5JB0A1104044 System and Wiring Diagram C37-38 C37-37 C37-57 C37-11 BLU WHT I5JB0A110053-02 1. A/F sensor 3. Warm up three way catalytic converter 5. ECM 2. HO2S-2 4.
Page 146 1A-139 Engine General Information and Diagnosis: www.CarGarage.ir DTC Confirmation Procedure WARNING • When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. •...
Page 147: Dtc P0443: Evaporative Emission System Purge Control Valve Circuit
Engine General Information and Diagnosis: 1A-140 www.CarGarage.ir DTC P0443: Evaporative Emission System Purge Control Valve Circuit S5JB0A1104045 Wiring Diagram I5JB0A110054-02 1. EVAP canister purge valve 4. Fuse box No.2 7. “FI” fuse 2. Main relay 5. Ignition switch 8. “IGN” fuse 3.
Page 148 1A-141 Engine General Information and Diagnosis: www.CarGarage.ir DTC Troubleshooting WARNING In order to reduce risk of fire and personal injury, this work must be performed in a well ventilated area and away from any open flames such as gas water heater. NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions For DTC Troubleshooting: ”.
Page 149: Dtc P0462: Fuel Level Sensor Circuit Low
Engine General Information and Diagnosis: 1A-142 www.CarGarage.ir DTC P0462: Fuel Level Sensor Circuit Low S5JB0A1104047 Wiring Diagram BLK/RED BLK/RED E23-60 BLU/BLK BLU/BLK E23-1 BLK/RED E23-16 BLU/BLK E23-15 WHT/GRN BLK/WHT BLK/YEL BLU/BLK 12 V YEL/RED E23-24 WHT/GRN YEL/GRN BLK/YEL 39 38 32 31 39 38 32 31...
Page 150 Go to Step 5. Intermittent trouble. tool Check for intermittent referring to “Intermittent 1) Connect SUZUKI scan tool to DLC with ignition switch and Poor Connection turned OFF. Inspection: in Section 2) Turn ON ignition switch and check fuel level displayed 00”.
Page 151: Dtc P0463: Fuel Level Sensor Circuit High
Go to Step 6. Intermittent trouble. tool Check for intermittent referring to “Intermittent 1) Connect SUZUKI scan tool to DLC with ignition switch and Poor Connection turned OFF. Inspection: in Section 2) Turn ON ignition switch and check fuel level displayed 00”.
Page 152 1A-145 Engine General Information and Diagnosis: www.CarGarage.ir Step Action Short circuit check for fuel level sensor output signal Go to Step 8. “YEL/RED” wire shorted circuit to other circuit. 1) Turn ON ignition switch and measure voltage between “E23-24” terminal of ECM connector and vehicle body ground.
Page 153: Dtc P0480: Fan 1 (Radiator Cooling Fan) Control Circuit
Engine General Information and Diagnosis: 1A-146 www.CarGarage.ir DTC P0480: Fan 1 (Radiator Cooling Fan) Control Circuit S5JB0A1104048 Wiring Diagram YEL/GRN RED/BLK E23-46 BLU/WHT BLU/RED BLU/YEL YEL/GRN E23-47 C37-15 BLK/ORN C37-30 BLK/ORN C37-29 BLK/YEL C37-48 BLK/YEL BLU/BLK BLK/YEL C37-58 E23-48 YEL/GRN RED/YEL PPL/YEL C37-24...
Page 154 1A-147 Engine General Information and Diagnosis: www.CarGarage.ir DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions For DTC Troubleshooting: ”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control...
Page 155 Engine General Information and Diagnosis: 1A-148 www.CarGarage.ir Step Action Wire circuit check Go to Step 7. “RED/BLK” wire is shorted to other circuit. 1) Measure voltage between “RED/BLK” wire terminal of radiator cooling fan relay No.1 connector and vehicle body ground with ignition switch turned ON. Is voltage 0 V? Wire circuit check Go to Step 20.
Page 156 1A-149 Engine General Information and Diagnosis: www.CarGarage.ir Step Action 12 Wire circuit check Go to Step 13. “RED” wire is shorted to other circuit. 1) Measure voltage between “RED” wire terminal of radiator cooling fan relay No.2 connector and vehicle body ground with ignition switch turned ON.
Page 157: Dtc P0500: Vehicle Speed Sensor (Vss) Malfunction
Engine General Information and Diagnosis: 1A-150 www.CarGarage.ir Step Action 18 Wire circuit check Go to Step 19. “RED/YEL” wire is shorted to other circuit. 1) Measure voltage between “RED/YEL” wire terminal of radiator cooling fan relay No.3 connector and vehicle body ground with ignition switch turned ON.
Page 158 1A-151 Engine General Information and Diagnosis: www.CarGarage.ir DTC Confirmation Procedure WARNING • When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. •...
Page 159: Dtc P0504: Brake Switch "A"/"B" Correlation (For J20 Engine)
Engine General Information and Diagnosis: 1A-152 www.CarGarage.ir DTC P0504: Brake Switch “A”/“B” Correlation (For J20 Engine) S5JB0A1104096 Wiring Diagram BLK/YEL BLU/BLK YEL/GRN E23-8 WHT/GRN GRN/WHT GRN/WHT E23-20 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I5JB0A110107-02 1.
Page 160 1A-153 Engine General Information and Diagnosis: www.CarGarage.ir DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions For DTC Troubleshooting: ”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control...
Page 161: Dtc P0532: A/C Refrigerant Pressure Sensor Circuit Low
Engine General Information and Diagnosis: 1A-154 www.CarGarage.ir DTC P0532: A/C Refrigerant Pressure Sensor Circuit Low S5JB0A1104051 Wiring Diagram GRY/RED GRY/RED C37-14 GRY/BLK C37-12 C37-15 BLK/ORN C37-30 BLK/ORN GRY/GRN GRY/GRN C37-57 C37-29 BLK/YEL C37-48 BLK/YEL C37-58 BLK/YEL 39 38 32 31 39 38 32 31 54 53...
Page 162 1A-155 Engine General Information and Diagnosis: www.CarGarage.ir DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions For DTC Troubleshooting: ”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control...
Page 163: Dtc P0533: A/C Refrigerant Pressure Sensor Circuit High
Engine General Information and Diagnosis: 1A-156 www.CarGarage.ir DTC P0533: A/C Refrigerant Pressure Sensor Circuit High S5JB0A1104052 Wiring Diagram Refer to “DTC P0532: A/C Refrigerant Pressure Sensor Circuit Low: ”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area A/C refrigerant pressure sensor signal voltage is higher •...
Page 164: Dtc P0601 / P0602 / P0607: Internal Control Module Memory Check Sum Error / Control Module Programming Error / Control Module Performance
1A-157 Engine General Information and Diagnosis: www.CarGarage.ir Step Action A/C refrigerant pressure sensor ground circuit check Go to Step 7. Go to Step 6. 1) Turn OFF ignition switch, measure resistance between engine ground and “GRY/GRN” wire terminal of A/C refrigerant pressure sensor connector.
Page 165: Dtc P0616: Starter Relay Circuit Low
Engine General Information and Diagnosis: 1A-158 www.CarGarage.ir Step Action DTC recheck Go to Step 2. Intermittent trouble. 1) Clear DTC referring to “DTC Clearance: ”. Check for intermittent referring to “Intermittent 2) Turn OFF ignition switch. and Poor Connection 3) Turn ON ignition switch and check DTC. Inspection: in Section 00”...
Page 166 1A-159 Engine General Information and Diagnosis: www.CarGarage.ir DTC Confirmation Procedure 1) With ignition switch turned OFF, connect scan tool. 2) Turn ON ignition switch and clear DTC using scan tool. 3) Start engine. 4) Check DTC and pending DTC. DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions For DTC Troubleshooting: ”.
Page 167: Dtc P0617: Starter Relay Circuit High
Engine General Information and Diagnosis: 1A-160 www.CarGarage.ir DTC P0617: Starter Relay Circuit High S5JB0A1104055 Wiring Diagram Refer to “DTC P0616: Starter Relay Circuit Low: ”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Engine starter signal is high voltage for 180 seconds •...
Page 168: Dtc P0620: Generator Control Circuit
1A-161 Engine General Information and Diagnosis: www.CarGarage.ir DTC P0620: Generator Control Circuit S5JB0A1104090 System and Wiring Diagram BRN/BLK C37-8 C37-28 BRN/BLK 39 38 32 31 39 38 32 31 47 46 54 53 47 46 54 53 I5JB0A110063-01 1. Generator 3.
Page 169 Engine General Information and Diagnosis: 1A-162 www.CarGarage.ir DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions For DTC Troubleshooting: ”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control...
Page 170: Dtc P0625 / P0626: Generator Field Terminal Circuit Low / High
1A-163 Engine General Information and Diagnosis: www.CarGarage.ir DTC P0625 / P0626: Generator Field Terminal Circuit Low / High S5JB0A1104091 System and Wiring Diagram Refer to “DTC P0620: Generator Control Circuit: ”. Generator Control System Description Refer to “Generator Control System Description: ”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area...
Page 171 Engine General Information and Diagnosis: 1A-164 www.CarGarage.ir DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions For DTC Troubleshooting: ”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control...
Page 172: Dtc P0660: Intake Manifold Tuning Valve Control Circuit / Open (For J20 Engine)
1A-165 Engine General Information and Diagnosis: www.CarGarage.ir DTC P0660: Intake Manifold Tuning Valve Control Circuit / Open (For J20 Engine) S5JB0A1104092 Wiring Diagram I5JB0A110064-02 1. IMT vacuum solenoid valve 4. Fuse box No.2 7. “FI” fuse 2. Main relay 5. Ignition switch 8.
Page 173 Engine General Information and Diagnosis: 1A-166 www.CarGarage.ir DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions For DTC Troubleshooting: ”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control...
Page 174: Dtc P1501 / P1502: Electric Load Current Sensor Circuit Low / High
1A-167 Engine General Information and Diagnosis: www.CarGarage.ir DTC P1501 / P1502: Electric Load Current Sensor Circuit Low / High S5JB0A1104093 System and Wiring Diagram GRY/RED C37-14 GRY/RED C37-9 GRY/GRN C37-57 GRY/GRN GRY/GRN 39 38 32 31 39 38 32 31 54 53 47 46 54 53...
Page 175 Engine General Information and Diagnosis: 1A-168 www.CarGarage.ir DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions For DTC Troubleshooting: ”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control...
Page 176: Dtc P1510: Ecm Back-Up Power Supply Malfunction
1A-169 Engine General Information and Diagnosis: www.CarGarage.ir DTC P1510: ECM Back-Up Power Supply Malfunction S5JB0A1104056 Wiring Diagram E23-2 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I5JB0A110066-01 1. ECM 2. “DOME” fuse Circuit Description Battery voltage is supplied so that DTC memory, values for engine control learned by ECM, etc.
Page 177: Dtc P1603: Tcm Trouble Code Detected (For J20 Engine)
Engine General Information and Diagnosis: 1A-170 www.CarGarage.ir DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions For DTC Troubleshooting: ”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control...
Page 178: Dtc P1674: Can Communication (Bus Off Error)
1A-171 Engine General Information and Diagnosis: www.CarGarage.ir DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions For DTC Troubleshooting: ”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control...
Page 179 Engine General Information and Diagnosis: 1A-172 www.CarGarage.ir [A]: Keyless start control module connector (if equipped) (viewed from harness side) 2. ABS hydraulic unit / control module assembly [B]: ECM connector (viewed from harness side) 3. Combination meter [C]: TCM connector (for A/T model) (viewed from harness side) 4.
Page 180 1A-173 Engine General Information and Diagnosis: www.CarGarage.ir Step Action ECM, TCM (for A/T model), BCM, ABS hydraulic unit / Go to Step 4. Intermittent trouble. control module assembly, 4WD control module (for J20 Check for intermittent engine), combination meter and keyless start control referring to “Intermittent module (if equipped) connectors check and Poor Connection...
Page 181 Engine General Information and Diagnosis: 1A-174 www.CarGarage.ir Step Action DTC check in ECM Go to Step 10. “G44-19” or “G44-18” circuit wire between 1) Disconnect connector from keyless start control module keyless start control (if equipped) with ignition switch turned OFF. module and CAN circuit 2) Check ECM for DTC.
Page 182 1A-175 Engine General Information and Diagnosis: www.CarGarage.ir Step Action 15 CAN communication line circuit continuity check Go to Step 16. Repair open or high resistance of CAN 1) Measure resistance at following connector terminals. communication line • Between “E23-4” terminal of ECM connector and circuit referring to “E03-10”...
Page 183: Dtc P1676: Can Communication (Reception Error For Tcm (For A/T Model))
Engine General Information and Diagnosis: 1A-176 www.CarGarage.ir Step Action 17 Check for short circuit of CAN communication line to Substitute a known- Repair short to power power circuit good ABS hydraulic unit supply of CAN / control module and communication line 1) Measure voltage at following connector terminals with recheck.
Page 184 1A-177 Engine General Information and Diagnosis: www.CarGarage.ir DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions For DTC Troubleshooting: ”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control...
Page 185 Engine General Information and Diagnosis: 1A-178 www.CarGarage.ir Step Action DTC check in ECM Go to Step 9. “E92-17” or “E92-7” circuit wire between 1) Disconnect connectors from TCM (for A/T model) with TCM and CAN circuit ignition switch turned OFF. junction connector is 2) Check ECM for DTC.
Page 186 1A-179 Engine General Information and Diagnosis: www.CarGarage.ir Step Action 13 CAN communication line circuit continuity check Go to Step 14. Repair open or high resistance of CAN 1) Disconnect connectors from all control modules communication line communicating by CAN with ignition switch turned OFF. circuit referring to 2) Measure resistance at following connector terminals.
Page 187: Dtc P1678: Can Communication (Reception Error For Bcm)
Engine General Information and Diagnosis: 1A-180 www.CarGarage.ir Step Action 17 DTC check in BCM Check TCM power and Substitute a known- ground circuit. If circuit good ECM and recheck. 1) Connect connectors to all control modules is OK, substitute a communicating by CAN with ignition switch turned OFF.
Page 188 1A-181 Engine General Information and Diagnosis: www.CarGarage.ir Step Action ECM, ABS hydraulic unit / control module and BCM Go to Step 5. Intermittent trouble. connector check Check for intermittent referring to “Intermittent 1) Check for proper connection at each ECM, ABS and Poor Connection hydraulic unit / control module and BCM connector Inspection: in Section...
Page 189 Engine General Information and Diagnosis: 1A-182 www.CarGarage.ir Step Action DTC check in ECM Go to Step 12. “E91-22” or “E91-23” circuit wire between 1) Disconnect connector from 4WD control module (for J20 4WD control module engine) with ignition switch turned OFF. and CAN circuit junction 2) Check ECM for DTC.
Page 190 1A-183 Engine General Information and Diagnosis: www.CarGarage.ir Step Action 15 CAN communication line circuit ground short check Go to Step 16. Repair short to ground of CAN communication 1) Measure resistance at following connector terminals. line circuit referring to • Between “E23-4” terminal of ECM connector and “Precaution for CAN vehicle body ground Communication...
Page 191: Dtc P1685: Can Communication (Reception Error For Abs Control Module)
Engine General Information and Diagnosis: 1A-184 www.CarGarage.ir DTC P1685: CAN Communication (Reception Error for ABS Control Module) S5JB0A1104094 Wiring Diagram Refer to “DTC P1674: CAN Communication (Bus Off Error): ”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Reception error of communication data for ABS hydraulic •...
Page 192 1A-185 Engine General Information and Diagnosis: www.CarGarage.ir Step Action ECM power and ground circuit check Go to Step 6. Repair ECM power and/ or ground circuits. 1) Check ECM power and ground circuits referring to “ECM Power and Ground Circuit Check: ”. Are they in good condition? DTC check in ABS hydraulic unit / control module Go to “DTC U1073:...
Page 193 Engine General Information and Diagnosis: 1A-186 www.CarGarage.ir Step Action DTC check in ECM Go to Step 12. “E91-22” or “E91-23” circuit wire between 1) Disconnect connector from 4WD control module (for J20 4WD control module engine) with ignition switch turned OFF. and CAN circuit junction 2) Check ECM for DTC.
Page 194: Dtc P2101: Throttle Actuator Control Motor Circuit Range / Performance
1A-187 Engine General Information and Diagnosis: www.CarGarage.ir Step Action 17 ABS warning lamp check Substitute a known- Substitute a known- good ABS hydraulic unit good ECM and recheck. 1) Connect connectors to all control modules / control module communicating by CAN. assembly and recheck.
Page 195 Engine General Information and Diagnosis: 1A-188 www.CarGarage.ir DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Monitor signal of throttle actuator output (duty output) is • Throttle actuator circuit inconsistent with throttle actuator control command. • Electric throttle body assembly (1 driving detection logic) •...
Page 196: Dtc P2102: Throttle Actuator Control Motor Circuit Low
1A-189 Engine General Information and Diagnosis: www.CarGarage.ir Step Action Throttle actuator circuit check Go to Step 4. “BLU/YEL” wire and/or “BLU/RED” wire is 1) Turn OFF ignition switch. shorted to ground 2) Measure resistance between “BLU/YEL” wire terminal of circuit. electric throttle body assembly connector and engine ground, between “BLU/RED”...
Page 197 Engine General Information and Diagnosis: 1A-190 www.CarGarage.ir DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions For DTC Troubleshooting: ”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control...
Page 198: Dtc P2103: Throttle Actuator Control Motor Circuit High
1A-191 Engine General Information and Diagnosis: www.CarGarage.ir DTC P2103: Throttle Actuator Control Motor Circuit High S5JB0A1104079 Wiring Diagram Refer to “DTC P2101: Throttle Actuator Control Motor Circuit Range / Performance: ”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Power supply voltage of throttle actuator control circuit is •...
Page 199: Dtc P2111: Throttle Actuator Control System - Stuck Open
Engine General Information and Diagnosis: 1A-192 www.CarGarage.ir DTC P2111: Throttle Actuator Control System - Stuck Open S5JB0A1104080 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Throttle valve default opening is greater than 7° from • Electric throttle body assembly complementary closed position when diagnosing throttle •...
Page 200: Dtc P2119: Throttle Actuator Control Throttle Body Range / Performance
1A-193 Engine General Information and Diagnosis: www.CarGarage.ir DTC P2119: Throttle Actuator Control Throttle Body Range / Performance S5JB0A1104081 Wiring Diagram Refer to “DTC P2101: Throttle Actuator Control Motor Circuit Range / Performance: ”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Difference between the measured (actual) throttle valve •...
Page 201 Engine General Information and Diagnosis: 1A-194 www.CarGarage.ir Step Action Throttle actuator circuit check Go to Step 4. “BLU/YEL” wire and/or “BLU/RED” wire is open 1) Disconnect connector from electric throttle body or high resistance. assembly with ignition switch turned OFF. 2) Check for proper connection to electric throttle body assembly at “BLU/YEL”...
Page 202: Dtc P2122: Pedal Position Sensor (Main) Circuit Low Input
1A-195 Engine General Information and Diagnosis: www.CarGarage.ir DTC P2122: Pedal Position Sensor (Main) Circuit Low Input S5JB0A1104082 Wiring Diagram E23-56 WHT/BLU E23-55 E23-54 ORN/BLU E23-53 BLU/GRN E23-52 BLU/YEL E23-51 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I5JB0A110070-01...
Page 203 Engine General Information and Diagnosis: 1A-196 www.CarGarage.ir DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions For DTC Troubleshooting: ”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control...
Page 204 1A-197 Engine General Information and Diagnosis: www.CarGarage.ir Step Action Wire harness check Substitute a known- “WHT” wire is shorted to good ECM and recheck. ground circuit. 1) Disconnect connectors from ECM with ignition switch turned OFF. 2) Measure resistance between “E23-56” terminal of ECM connector and engine ground.
Page 205: Dtc P2123: Pedal Position Sensor (Main) Circuit High Input
Engine General Information and Diagnosis: 1A-198 www.CarGarage.ir DTC P2123: Pedal Position Sensor (Main) Circuit High Input S5JB0A1104083 Wiring Diagram Refer to “DTC P2122: Pedal Position Sensor (Main) Circuit Low Input: ”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Output voltage of accelerator pedal position sensor (main) •...
Page 206 1A-199 Engine General Information and Diagnosis: www.CarGarage.ir Step Action ECM voltage check Go to Step 6. Go to Step 5. 1) Disconnect connector from accelerator pedal position (APP) sensor assembly with ignition switch turned OFF. 2) Check for proper connection to accelerator pedal position (APP) sensor assembly at “WHT”, “WHT/BLU”...
Page 207: Dtc P2127: Pedal Position Sensor (Sub) Circuit Low Input
Engine General Information and Diagnosis: 1A-200 www.CarGarage.ir Step Action Ground circuit check “ORN” wire is open or Faulty ECM ground high resistance circuit. circuit. If circuit is OK, 1) Remove ECM from its bracket with ECM connectors substitute a known- connected.
Page 208 1A-201 Engine General Information and Diagnosis: www.CarGarage.ir DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions For DTC Troubleshooting: ”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control...
Page 209: Dtc P2128: Pedal Position Sensor (Sub) Circuit High Input
Engine General Information and Diagnosis: 1A-202 www.CarGarage.ir Step Action Wire harness check Substitute a known- “ORN/BLU” wire is good ECM and recheck. shorted to ground 1) Disconnect connectors from ECM with ignition switch circuit. turned OFF. 2) Measure resistance between “E23-53” terminal of ECM connector and engine ground.
Page 210 1A-203 Engine General Information and Diagnosis: www.CarGarage.ir DTC Confirmation Procedure 1) With ignition switch turned OFF, connect scan tool. 2) Turn ON ignition switch and clear DTC using scan tool. 3) Keep the accelerator pedal at idle position for 2 seconds. 4) Keep the accelerator pedal at fully depressed position for 2 seconds.
Page 211 Engine General Information and Diagnosis: 1A-204 www.CarGarage.ir Step Action Wire harness check Substitute a known- “ORN/BLU” wire is good ECM and recheck. shorted to power circuit. 1) Disconnect connectors from ECM with ignition switch turned OFF. 2) Check for proper connection of ECM connector at “E23- 53”...
Page 212: Dtc P2135: Throttle Position Sensor (Main / Sub) Voltage Correlation
1A-205 Engine General Information and Diagnosis: www.CarGarage.ir DTC P2135: Throttle Position Sensor (Main / Sub) Voltage Correlation S5JB0A1104086 Wiring Diagram BLK/WHT E23-29 BLK/YEL C37-15 BLK/ORN C37-30 BLK/ORN C37-29 BLK/YEL BLK/RED BLK/RED E23-60 C37-48 BLK/YEL BLK/YEL C37-58 BLU/BLK BLU/BLK E23-1 BLK/RED BLU/BLK BLU/BLK E23-16...
Page 213 Engine General Information and Diagnosis: 1A-206 www.CarGarage.ir DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions For DTC Troubleshooting: ”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control...
Page 214 1A-207 Engine General Information and Diagnosis: www.CarGarage.ir Step Action Wire harness check Substitute a known- “WHT” wire is shorted to good ECM and recheck. other circuit. 1) Measure voltage between “C37-53” terminal of ECM connector and engine ground with ignition switch turned Is voltage 0 V? Wire harness check Go to Step 9.
Page 215: Dtc P2138: Pedal Position Sensor (Main / Sub) Voltage Correlation
Engine General Information and Diagnosis: 1A-208 www.CarGarage.ir DTC P2138: Pedal Position Sensor (Main / Sub) Voltage Correlation S5JB0A1104087 Wiring Diagram E23-56 WHT/BLU E23-55 E23-54 ORN/BLU E23-53 BLU/GRN E23-52 BLU/YEL E23-51 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46...
Page 216 1A-209 Engine General Information and Diagnosis: www.CarGarage.ir DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions For DTC Troubleshooting: ”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control...
Page 217: Dtc P2227 / P2228 / P2229: Barometric Pressure Circuit Malfunction
Engine General Information and Diagnosis: 1A-210 www.CarGarage.ir Step Action Wire harness check Substitute a known- “WHT” wire or “ORN/ good ECM and recheck. GRN” wire is shorted to 1) Measure voltage between “E23-56” terminal of ECM other circuit. connector and engine ground, between “E23-53” terminal of ECM connector and engine ground with ignition switch turned ON.
Page 218 1A-211 Engine General Information and Diagnosis: www.CarGarage.ir DTC Confirmation Procedure DTC P2227: WARNING • When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. •...
Page 219: Inspection Of Ecm And Its Circuits
Engine General Information and Diagnosis: 1A-212 www.CarGarage.ir Inspection of ECM and Its Circuits S5JB0A1104063 ECM and its circuits can be checked by measuring voltage, pulse signal and resistance with special tool connected. CAUTION ECM cannot be checked by itself. It is strictly prohibited to connect voltmeter or ohmmeter to ECM with ECM connectors disconnected from it.
Page 220 1A-213 Engine General Information and Diagnosis: www.CarGarage.ir Terminal Wire Circuit Normal voltage Condition Remarks color 10 – 14 V Ignition switch turned ON. — *0 – 0.6 V ↑↓ 10 – 14 V Output signal is active low (“Reference C37-1 Fuel injector No.1 Engine running at idle pulse.
Page 221 Engine General Information and Diagnosis: 1A-214 www.CarGarage.ir Terminal Wire Circuit Normal voltage Condition Remarks color 0.5 – 1.0 V Ignition switch turned ON. Run engine at 2000 rpm, Electric load 1.3 – 1.7 V headlight switch turned current sensor C37-9 —...
Page 222 1A-215 Engine General Information and Diagnosis: www.CarGarage.ir Terminal Wire Circuit Normal voltage Condition Remarks color 10 – 14 V Ignition switch turned ON. — *0 – 0.6 V ↑↓ Output signal is active low PNK/ 10 – 14 V C37-16 Fuel injector No.3 Engine running at idle pulse.
Page 223 Engine General Information and Diagnosis: 1A-216 www.CarGarage.ir Terminal Wire Circuit Normal voltage Condition Remarks color Ignition switch turned ON, 3.3 – 3.8 V ECT at 0 °C, 32 °F. Engine coolant PPL/ Ignition switch turned ON, C37-24 temp. (ECT) 1.38 – 1.72 V —...
Page 224 1A-217 Engine General Information and Diagnosis: www.CarGarage.ir Terminal Wire Circuit Normal voltage Condition Remarks color 2.6 – 2.8 V A/F sensor signal Engine running at idle C37-37 (“Reference — (–) after warmed up engine. waveform No.18: ”) 3.0 – 3.2 V A/F sensor signal Engine running at idle C37-38...
Page 225 Engine General Information and Diagnosis: 1A-218 www.CarGarage.ir Terminal Wire Circuit Normal voltage Condition Remarks color 0 – 1 V or 4 – 5 V Ignition switch turned ON. — *4 – 5 V Sensor signal is pulse. ↑↓ Pulse frequency which WHT/ CKP sensor signal 0 –...
Page 226 1A-219 Engine General Information and Diagnosis: www.CarGarage.ir Terminal Wire Circuit Normal voltage Condition Remarks color *0 – 0.6 V ↑↓ Output signal is active Oil control valve 10 – 14 V BRN/ At the moment of ignition high pulse. Duty ratio C37-60 output (for M16 (“Reference...
Page 227 Engine General Information and Diagnosis: 1A-220 www.CarGarage.ir Terminal Wire Circuit Normal voltage Condition Remarks color For 2 sec. from the time ignition switch is turned 0 – 2.5 V ON or while engine is WHT/ Fuel pump relay running. E23-15 —...
Page 228 1A-221 Engine General Information and Diagnosis: www.CarGarage.ir Terminal Wire Circuit Normal voltage Condition Remarks color E23-40 — — — — — E23-41 — — — — — E23-42 — — — — — E23-43 — — — — — E23-44 —...
Page 229 Engine General Information and Diagnosis: 1A-222 www.CarGarage.ir Terminal Wire Circuit Normal voltage Condition Remarks color BLU/ Throttle actuator E23-50 0 – 1 V Ignition switch turned ON. — control relay output Ground for BLU/ accelerator pedal E23-51 Below 0.3 V Ignition switch turned ON.
Page 230 1A-223 Engine General Information and Diagnosis: www.CarGarage.ir Reference waveform No.1 Reference waveform No.3 Fuel injector signal (1) with engine idling No.2 fuel injector signal (2) with engine idling Measurement Measurement CH1: “C37-52” to “C37-58” CH1: “C37-2” to “C37-58” terminal terminal CH2: “C37-2”...
Page 231 Engine General Information and Diagnosis: 1A-224 www.CarGarage.ir Reference waveform No.5 Reference waveform No.7 Generator field coil monitor signal (1) at engine idling Heated oxygen sensor-2 signal (1) with engine idling Measurement CH1: “C37-8” to “C37-58” Measurement CH1: “C37-11” to “C37-57” terminal CH2: “C37-28”...
Page 232 1A-225 Engine General Information and Diagnosis: www.CarGarage.ir Reference waveform No.9 Reference waveform No.11 EVAP canister purge valve signal No.4 fuel injector signal (2) with engine idling Measurement Measurement CH1: “C37-52” to “C37-58” CH1: “C37-13” to “C37-58” terminal terminal CH2: “C37-17” to “C37-58” Oscilloscope CH1: 10 V/DIV Oscilloscope...
Page 233 Engine General Information and Diagnosis: 1A-226 www.CarGarage.ir Reference waveform No.12 Reference waveform No.13 Ignition coil signal (1) with engine idling Ignition coil No.4 signal (2) with engine idling (for J20 engine) Measurement CH1: “C37-20” to “C37-58” terminal Measurement CH1: “C37-52” to “C37-58” Oscilloscope CH1: 2 V/DIV terminal...
Page 234 1A-227 Engine General Information and Diagnosis: www.CarGarage.ir Reference waveform No.15 Reference waveform No.16 • Ignition coil No.2 signal (1) with engine idling (for J20 • Ignition coil No.1 signal (1) with engine idling (for J20 engine) engine) • Ignition coil No.2 and No.3 signal (2) with engine idling •...
Page 235 Engine General Information and Diagnosis: 1A-228 www.CarGarage.ir Reference waveform No.19 Reference waveform No.17 Mass air flow sensor signal (1) with engine racing Intake manifold tuning vacuum solenoid valve signal with engine racing (for J20 engine) Measurement CH1: “C37-26” to “C37-27” terminal CH2: “C37-54”...
Page 236 1A-229 Engine General Information and Diagnosis: www.CarGarage.ir Reference waveform No.20 Reference waveform No.21 CMP sensor signal with engine idling CMP sensor signal with engine idling CH1: “C37-52” to “C37-58” CH1: “C37-52” to “C37-58” Measurement Measurement CH2: “C37-51” to “C37-36” (for J20 CH2: “C37-51”...
Page 237 Engine General Information and Diagnosis: 1A-230 www.CarGarage.ir Reference waveform No.22 Reference waveform No.23 Throttle actuator output signal with ignition switch turned Throttle actuator output signal with ignition switch turned Measurement CH1: “C37-45” to “C37-58” Measurement CH1: “C37-45” to “C37-58” terminal CH2: “C37-44”...
Page 238 1A-231 Engine General Information and Diagnosis: www.CarGarage.ir Reference waveform No.25 Reference waveform No.27 Manifold absolute pressure sensor signal (1) with engine Knock sensor signal at engine speed 4000 r/min. racing Measurement CH1: “C37-56” to “C37-58” Measurement CH1: “C37-55” to “C37-57” terminal terminal CH2: “C37-54”...
Page 239 Engine General Information and Diagnosis: 1A-232 www.CarGarage.ir Reference waveform No.31 Reference waveform No.29 Oil control valve signal with engine racing (for M16 Ignition coil signal and fuel injector signal with engine engine) cranking Measurement CH1: “C37-52” to “C37-58” CH1: “C37-60” to “C37-59” terminal Measurement CH2: “C37-21”...
Page 240 1A-233 Engine General Information and Diagnosis: www.CarGarage.ir Resistance Check 1) Remove ECM from its bracket referring to “Engine Control Module (ECM) Removal and Installation: in Section 1C”. CAUTION Never touch terminals of ECM itself or connect voltmeter or ohmmeter (2). 2) Connect special tool to ECM connectors securely.
Page 241: Ecm Power And Ground Circuit Check
Engine General Information and Diagnosis: 1A-234 www.CarGarage.ir ECM Power and Ground Circuit Check S5JB0A1104064 Wiring Diagram E23-2 BLK/YEL BLK/WHT E23-29 C37-15 BLK/ORN C37-30 BLK/ORN WHT/GRN C37-29 BLK/YEL C37-48 BLK/YEL BLK/RED BLK/RED E23-60 C37-58 BLK/YEL BLU/BLK BLU/BLK E23-1 BLK/RED BLU/BLK E23-16 GRY/RED C37-14 C37-9...
Page 242 1A-235 Engine General Information and Diagnosis: www.CarGarage.ir Circuit Description When the ignition switch is turned ON, the main relay turns ON (the contact point closes) and the main power is supplied to ECM. And then ECM supplies 5 V power to each sensor (electric load current sensor (for J20 engine), MAP sensor, A/C refrigerant pressure sensor, APP sensor and TP sensor).
Page 243 Engine General Information and Diagnosis: 1A-236 www.CarGarage.ir Step Action Main relay circuit check Go to Step 5. Go to Step 9. 1) Turn ignition switch to OFF position. 2) Check “FI” fuse (1) (20 A) in fuse box No.2 for blowing. For J20 engine I5JB0A110097-02 For M16 engine...
Page 244 1A-237 Engine General Information and Diagnosis: www.CarGarage.ir Step Action Main relay circuit check Go to Step 9. “BLU/BLK” wire is open circuit or high resistance 1) Remove main relay (1) from fuse box No.2. circuit. For J20 engine I5JB0A110099-02 For M16 engine I5JB0A110100-02 2) Check for proper connection to main relay connector at “BLU/YEL”...
Page 245: Fuel Injector Circuit Check
Engine General Information and Diagnosis: 1A-238 www.CarGarage.ir Step Action 12 Sensor 5 V power source circuit check Check internal short “GRY/RED”, “WHT” circuit of TP sensor, and/or “ORN/BLU” wire 1) Disconnect connectors from ECM, TP sensor, MAP MAP sensor, A/C is shorted to ground sensor, A/C refrigerant pressure sensor (if equipped with refrigerant pressure...
Page 246 1A-239 Engine General Information and Diagnosis: www.CarGarage.ir Troubleshooting NOTE • Before performed troubleshooting, be sure to read the “Precautions of ECM Circuit Inspection: ”. • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits: ”. Step Action Fuel injector check for operating sound...
Page 247: Fuel Pump And Its Circuit Check
Engine General Information and Diagnosis: 1A-240 www.CarGarage.ir Fuel Pump and Its Circuit Check S5JB0A1104066 Wiring Diagram BLK/WHT E23-29 BLK/YEL BLK/WHT BLK/WHT E23-15 WHT/GRN WHT/GRN BLK/RED C37-15 BLK/ORN C37-30 BLK/ORN BLU/BLK C37-29 BLK/YEL C37-48 BLK/YEL C37-58 BLK/YEL BLU/BLK BLU/BLK E23-1 BLK/RED BLU/BLK E23-16 BLK/RED...
Page 248 1A-241 Engine General Information and Diagnosis: www.CarGarage.ir Troubleshooting NOTE • Before performed troubleshooting, be sure to read the “Precautions of ECM Circuit Inspection: ”. • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits: ”. Step Action Fuel pump control system check for operation...
Page 249 Engine General Information and Diagnosis: 1A-242 www.CarGarage.ir Step Action Fuel pump relay drive signal check Go to Step 7. Substitute a known- good ECM and recheck. 1) Measure voltage within 2 second after ignition switch is turned ON. Is voltage 0 – 1 V? Wire circuit check Go to Step 8.
Page 250: Fuel Pressure Check
1A-243 Engine General Information and Diagnosis: www.CarGarage.ir Fuel Pressure Check S5JB0A1104067 System Diagram Special tool (A): 09912–58442 (B): 09912–58432 (C): 09912–58490 I2RH01110133-01 1. Injector 2. Delivery pipe 3. Fuel pressure regulator 4. Fuel filter and fuel pump www.CarGarage.ir...
Page 251 Engine General Information and Diagnosis: 1A-244 www.CarGarage.ir Troubleshooting NOTE Before using following flow, check to make sure that battery voltage is higher than 11 V. If battery voltage is low, pressure becomes lower than specification even if fuel pump and line are in good condition.
Page 252: A/C System Circuits Check
1A-245 Engine General Information and Diagnosis: www.CarGarage.ir A/C System Circuits Check S5JB0A1104069 Wiring Diagram WHT/BLU WHT/RED PNK/GRN YEL/RED WHT/BLK WHT/RED E23-4 BLK/RED WHT/BLU E23-19 *RED WHT/RED YEL/GRN YEL/GRN E23-49 RED/BLK E23-46 BLU/WHT BLU/RED BLU/YEL YEL/GRN E23-47 BLU/BLK RED/YEL E23-48 YEL/GRN C37-14 GRY/RED GRY/BLK...
Page 253 Engine General Information and Diagnosis: 1A-246 www.CarGarage.ir Troubleshooting NOTE • Before performed troubleshooting, be sure to read the “Precautions of ECM Circuit Inspection: ”. • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits: ”. •...
Page 254 1A-247 Engine General Information and Diagnosis: www.CarGarage.ir Step Action A/C refrigerant pressure sensor voltage check Go to Step 10. Check amount of refrigerant. If OK, 1) Check A/C refrigerant pressure sensor voltage referring replace A/C refrigerant to “Inspection of ECM and Its Circuits: ”. pressure sensor.
Page 255: Electric Load Signal Circuit Check
Engine General Information and Diagnosis: 1A-248 www.CarGarage.ir Electric Load Signal Circuit Check S5JB0A1104070 Wiring Diagram WHT/RED E23-4 WHT/BLU E23-19 C37-7 BLU/ORN E03-8 WHT/BLU WHT/RED E03-10 G31-1 E03-12 E03-6 G31-3 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I5JB0A110104-02...
Page 256 1A-249 Engine General Information and Diagnosis: www.CarGarage.ir Troubleshooting NOTE • Before performed troubleshooting, be sure to read the “Precautions of ECM Circuit Inspection: ”. • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits: ”. Step Action DTC check...
Page 257: Radiator Cooling Fan Low Speed Control System Check
Engine General Information and Diagnosis: 1A-250 www.CarGarage.ir Radiator Cooling Fan Low Speed Control System Check S5JB0A1104071 Wiring Diagram YEL/GRN RED/BLK E23-46 BLU/WHT BLU/RED BLU/YEL YEL/GRN E23-47 C37-15 BLK/ORN C37-30 BLK/ORN C37-29 BLK/YEL C37-48 BLK/YEL BLU/BLK BLK/YEL C37-58 E23-48 YEL/GRN RED/YEL PPL/YEL C37-24 GRY/GRN...
Page 258 1A-251 Engine General Information and Diagnosis: www.CarGarage.ir Step Action Is there DTC(s) of ECT sensor circuit (DTC P0116 / P0117 / Go to corresponding Go to Step 2. P0118) and/or radiator cooling fan circuit (DTC P0480)? DTC flow. Low speed radiator cooling fan control circuit check Radiator cooling fan low Perform from Step 2 to speed control system is...
Page 259 Engine General Information and Diagnosis: 1A-252 www.CarGarage.ir Step Action Wire circuit check Go to Step 8. “BLU/YEL” wire is shorted to ground 1) Disconnect radiator cooling fan motor No.1 connector circuit. with ignition switch turned OFF. 2) Measure resistance between “BLU/YEL” wire terminal of radiator cooling fan relay No.2 connector and vehicle body ground.
Page 260: Radiator Cooling Fan High Speed Control System Check
1A-253 Engine General Information and Diagnosis: www.CarGarage.ir Step Action 15 Radiator cooling fan relay check Substitute a known- Replace radiator cooling good ECM and recheck. fan relay. 1) Check radiator cooling fan relay referring to “Radiator Cooling Fan Relay Inspection: in Section 1F”. Is it in good condition? 16 Radiator cooling fan motor check Substitute a known-...
Page 261 Engine General Information and Diagnosis: 1A-254 www.CarGarage.ir Step Action Wire circuit check Go to Step 5. “BLU/BLK” wire is open circuit. 1) Disconnect radiator cooling fan relay No.3 from relay box with ignition switch turned OFF. 2) Turn ON ignition switch. 3) Measure voltage between “BLU/BLK”...
Page 262: Repair Instructions
1A-255 Engine General Information and Diagnosis: www.CarGarage.ir Repair Instructions Idle Speed and IAC Throttle Valve Opening 1) Connect SUZUKI scan tool to DLC (1) with ignition switch turned OFF. Inspection S5JB0A1106001 Special tool Before idle speed check, make sure of the following.
Page 263: Special Tools And Equipment
58413). 09912–58490 09930–76420 3-way joint & hose Timing-light (dry cell type) 09933–06320 SUZUKI scan tool ECM check harness (120P) — This kit includes following items. 1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5. Cigarette cable, 6.
Page 264: Aux. Emission Control Devices
Aux. Emission Control Devices Diagnostic Information and Procedures EGR System Inspection S5JB0A1204001 1) Connect SUZUKI scan tool to data link connector (DLC) with ignition switch turned OFF. 2) Turn ON ignition switch and erase DTC using “CLEAR DTC” in “TROUBLE CODES” menu.
Page 265: Evap Canister Purge Valve And Its Circuit Inspection
1) Prepare to operate EVAP canister purge valve as passage for clog when valve is switched ON and follows. OFF by using SUZUKI scan tool or service wire. If check result is not satisfactory, check vacuum a) When using SUZUKI scan tool:...
Page 266: Vacuum Hose And Purge Valve Chamber Inspection
1B-3 Aux. Emission Control Devices: www.CarGarage.ir 3) Check resistance between two terminals of EVAP canister purge valve. If resistance is not as specified, replace EVAP canister purge valve. EVAP canister purge valve resistance 30 – 34 Ω at 20 °C (68 °F) I3RM0A120008-01 4) With coupler disconnected, apply vacuum (–60 kPa I5JB0A120006-01...
Page 267: Evap Canister Inspection
Aux. Emission Control Devices: 1B-4 www.CarGarage.ir EVAP Canister Inspection EGR Valve Inspection S5JB0A1206006 S5JB0A1206008 1) Check resistance between following terminals of WARNING EGR valve (1) in each pair. Do not suck nozzles on EVAP canister. Fuel If found faulty, replace EGR valve assembly. vapor inside EVAP canister is harmful.
Page 268: Pcv Valve Removal And Installation
1B-5 Aux. Emission Control Devices: www.CarGarage.ir PCV Valve Removal and Installation S5JB0A1206011 Removal 1) Disconnect PCV hose from PCV valve. 2) Remove PCV valve from cylinder head cover. Installation Reverse removal procedure noting the following. • For J20 engine, apply sealant to thread part of PCV valve (1).
Page 269: Specifications
For the tightening torque of fastener not specified in this section, refer to “Fastener Information: in Section 0A”. Special Tools and Equipment Recommended Service Material S5JB0A1208001 Material SUZUKI recommended product or Specification Note Sealant SUZUKI Bond No.1207F P/No.: 99000–31250 Special Tool S5JB0A1208002 09917–47011...
Page 270: Engine Electrical Devices
1C-1 Engine Electrical Devices: www.CarGarage.ir Engine Electrical Devices Repair Instructions Engine Control Module (ECM) Removal and b. Insert ECM connectors to ECM until it stops with unlocked lock lever. Installation S5JB0A1306004 CAUTION As ECM consists of precision parts, be careful not to expose it to excessive shock. Removal 1) Disconnect negative cable at battery.
Page 271: Electric Throttle Body Assembly On-Vehicle Inspection
Engine Electrical Devices: 1C-2 www.CarGarage.ir Throttle Valve Visual Check 1) Remove air cleaner outlet hose (for J20 engine) or air intake pipe (for M16 engine). 2) Check that there isn’t any foreign matter caught between throttle valve and throttle body housing. If there is, take it out after removing throttle body referring to “Electric Throttle Body Assembly Removal and Installation: For J20 Engine in Section...
Page 272 1C-3 Engine Electrical Devices: www.CarGarage.ir Electric Throttle Body Assembly Operation Check Throttle Position Sensor Performance Check 1) Remove air cleaner outlet hose (for J20 engine) or 1) Remove air cleaner outlet hose (for J20 engine) or air intake pipe (for M16 engine). air intake pipe (for M16 engine).
Page 273: Electric Throttle Body System Calibration
Engine Electrical Devices: 1C-4 www.CarGarage.ir 4.097 - 5.007 4.000 - 4.880 3.675 - 4.245 3.883 - 4.453 1.604 - 1.916 1.33 - 1.63 I5JB0A130016-01 0.724 - 1.036 [A]: For J20 engine 0.45 - 0.75 [B]: For M16 engine c) Measure output voltage variation while throttle valve is opened and closed as following I5JB0A130017-02 specification.
Page 274: Accelerator Pedal Position (App) Sensor Assembly On-Vehicle Inspection
1C-5 Engine Electrical Devices: www.CarGarage.ir Accelerator Pedal Position (APP) Sensor Accelerator Pedal Position (APP) Sensor Assembly On-Vehicle Inspection Assembly Removal and Installation S5JB0A1306024 S5JB0A1306027 1) Check that accelerator pedal position (APP) sensor CAUTION assembly has been mounted to vehicle body •...
Page 275: Accelerator Pedal Position (App) Sensor Assembly Inspection
Engine Electrical Devices: 1C-6 www.CarGarage.ir Accelerator Pedal Position (APP) Sensor Accelerator pedal position (APP) sensor (sub) output voltage [B]: 0.44 – 1.74 V, varying according Assembly Inspection to depressed extent of accelerator pedal S5JB0A1306026 Check accelerator pedal position (APP) sensor (main and sub) output voltage as following steps.
Page 276: Engine Coolant Temperature (Ect) Sensor Inspection
1C-7 Engine Electrical Devices: www.CarGarage.ir Air Fuel Ratio (A/F) Sensor On-Vehicle Installation Reverse removal procedure noting the following. Inspection S5JB0A1306028 • Clean mating surfaces of ECT sensor and water outlet Heater cap. 1) Disconnect A/F sensor connector. • Check O-ring for damage and replace, if necessary. 2) Using ohmmeter, measure resistance of Sensor •...
Page 277: Heated Oxygen Sensor (Ho2S-2) Heater On-Vehicle Inspection
Engine Electrical Devices: 1C-8 www.CarGarage.ir Heated Oxygen Sensor (HO2S-2) Heater On- Vehicle Inspection S5JB0A1306010 1) Disconnect sensor connector. 2) Using ohmmeter, measure resistance of sensor heater between terminals “V ” and “GND” at sensor connector. If found faulty, replace oxygen sensor. NOTE Temperature of sensor affects resistance 1,(a)
Page 278: Camshaft Position (Cmp) Sensor Inspection
1C-9 Engine Electrical Devices: www.CarGarage.ir 2) Connect connector to CMP sensor securely. 3) Connect negative cable to battery. Camshaft Position (CMP) Sensor Inspection S5JB0A1306012 Visual check • Check that O-ring is free from damage. • Check that end face of sensor and signal rotor tooth are free from any metal particles and damage.
Page 279: Crankshaft Position (Ckp) Sensor Inspection
Engine Electrical Devices: 1C-10 www.CarGarage.ir Installation Installation Reverse removal procedure noting the following. 1) Install crankshaft position sensor to cylinder block. • Apply engine oil to O-ring of sensor. Tighten CKP sensor bolt to specified torque. • Tighten CKP sensor bolt to specified torque. Tightening torque CKP sensor bolt (a): 10 N·m (1.0 kgf-m, 7.5 lb-ft) Tightening torque...
Page 280: Knock Sensor Removal And Installation
1C-11 Engine Electrical Devices: www.CarGarage.ir Resistance check CKP sensor resistance Resistance varies from less than 220 Ω (ON) to Measure resistance between “1” and “2” terminals of infinity (OFF) or from infinity (OFF) to less than 220 Ω CKP sensor. (ON) CKP sensor resistance 480 –...
Page 281: Control Relay Inspection
Engine Electrical Devices: 1C-12 www.CarGarage.ir Control Relay Inspection Integration Relay No.2 (For J20 Engine) S5JB0A1306018 1) Disconnect negative cable at battery. Control Relay 2) Remove included in integration relay No.2 (1) from 1) Disconnect negative cable at battery. fuse box No.2 (2). 2) Remove main relay (1), fuel pump relay (3), starting motor control relay (2), throttle actuator control relay (4) and HO2S heater relay (5) (for M16 engine) from...
Page 282: Mass Air Flow (Maf) And Intake Air Temperature (Iat) Sensor On-Vehicle Inspection
1C-13 Engine Electrical Devices: www.CarGarage.ir Mass Air Flow (MAF) and Intake Air 7) Start engine and check that voltage is lower than 5 V and it rises as engine speed increases. Temperature (IAT) Sensor On-Vehicle Inspection MAF signal voltage between “C37-26” terminal S5JB0A1306019 circuit and “C37-27”...
Page 283: Mass Air Flow (Maf) And Intake Air Temperature (Iat) Sensor Inspection
Engine Electrical Devices: 1C-14 www.CarGarage.ir Installation Reverse removal procedure noting the followings. • Tighten MAF and IAT sensor screws to specified torque. Tightening torque MAF and IAT sensor screw (a): 1.5 N·m (0.15 kgf- m, 1.1 lb-ft) I5JB0A130034-02 (2.45) • Connect MAF and IAT sensor connector securely. Mass Air Flow (MAF) and Intake Air (0.58) Temperature (IAT) Sensor Inspection...
Page 284 1C-15 Engine Electrical Devices: www.CarGarage.ir 2) Check resistance of intake manifold tuning vacuum solenoid valve. If resistance is as specified, proceed to next operation check. If not, replace intake manifold tuning vacuum solenoid valve. Resistance of intake manifold tuning vacuum solenoid valve Between two terminals: 33 –...
Page 285: Electric Load Current Sensor On-Vehicle Inspection (For J20 Engine)
If electric load current sensor circuit and charging system is in good condition, electric load current sensor is faulty. Without Using SUZUKI Scan Tool 1) Measure sensor voltage between “C37-9” terminal of ECM connector and vehicle body ground referring to “Inspection of ECM and Its Circuits: in Section 1A”.
Page 286: Specifications
1C-17 Engine Electrical Devices: www.CarGarage.ir Specifications Tightening Torque Specifications S5JB0A1307001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Accelerator pedal position (APP) sensor assembly nut APP sensor assembly bracket nut ECT sensor 12.5 1.25 A/F sensor 32.5 Heated oxygen sensor 32.5 CMP sensor bolt CKP sensor bolt...
Page 287: Engine Mechanical
Engine Mechanical: For M16A Engine with VVT 1D-1 www.CarGarage.ir Engine Mechanical For M16A Engine with VVT General Description Engine Construction Description S5JB0A1411001 The engine is water-cooled, in line 4 cylinders, 4 stroke cycle gasoline unit with its DOHC (Double overhead camshaft) valve mechanism arranged for “V”...
Page 288: Camshaft Position Control (Vvt Variable Valve Timing) System Description
1D-2 Engine Mechanical: For M16A Engine with VVT www.CarGarage.ir Camshaft Position Control (VVT Variable Valve Timing) System Description S5JB0A1411002 System Description The VVT system is an electronic control system which continuously vary and optimize the intake valve timing in response to the engine operating condition. The optimized intake valve timing produce such an air intake with high efficiency that both the higher power generation and lower fuel consumption can be attained in the whole engine speed range from low to high.
Page 289 Engine Mechanical: For M16A Engine with VVT 1D-3 www.CarGarage.ir Oil Control Valve The oil control valve switches and adjusts the hydraulic pressure applied to the cam timing sprocket by moving the spool valve (1) according to the duty pulse signals output from the ECM.
Page 290: Diagnostic Information And Procedures
1D-4 Engine Mechanical: For M16A Engine with VVT www.CarGarage.ir Targeted Timing Varying Operation Driving condition Valve timing Target of control Effect To shorten the valve opening overlap in Engine running at idle Stabilization of the engine Most retarded order to prevent the exhaust gas speed rotation at idle speed.
Page 291: Engine Vacuum Check
Engine Mechanical: For M16A Engine with VVT 1D-5 www.CarGarage.ir I2RH0B140003-01 I3RH0B140009-01 8) Disengage clutch (to lighten starting load on engine) Engine Vacuum Check for M/T vehicle, and depress accelerator pedal (1) all S5JB0A1414002 the way to make throttle fully open. The engine vacuum that develops in the intake line is a good indicator of the condition of the engine.
Page 292: Valve Lash (Clearance) Inspection
1D-6 Engine Mechanical: For M16A Engine with VVT www.CarGarage.ir 6) Run engine at specified idle speed and read vacuum gauge. Vacuum should be within specification. Vacuum specification (at sea level) 59 – 73 kPa (45 – 55 cmHg, 17.7 – 21.6 in.Hg) at specified idle speed 7) After checking, disconnect special tool (Vacuum gauge) from PCV hose.
Page 293 Engine Mechanical: For M16A Engine with VVT 1D-7 www.CarGarage.ir Special tool selection table No. on camshaft Embossed mark on housing special tool I3, I4, I5 IN345 E3, E4, E5 EX345 I2RH0B140013-01 1. Special tool 2. Magnet 5) Using a micrometer (2), measure the thickness of the removed shim (1), and determine replacement shim by calculating the thickness of new shim with the following formula and table.
Page 294: Repair Instructions
1D-8 Engine Mechanical: For M16A Engine with VVT www.CarGarage.ir 6) Select new shim No. (1) with a thickness as close as Special tool possible to calculated value. (A): 09916–67020 (A): 09916–67021 Available new shims No. Thickness mm Thickness mm Shim No. Shim No.
Page 295: Air Cleaner Filter Inspection And Cleaning
Engine Mechanical: For M16A Engine with VVT 1D-9 www.CarGarage.ir Air Cleaner Filter Inspection and Cleaning 8) Remove oil level gauge (1). S5JB0A1416002 9) Disconnect PCV hose (2) from PCV valve (3) and disconnect breather hose (4) from cylinder head Inspection cover.
Page 296 (2) as shown. Cylinder head cover bolt (a): 8 N·m (0.8 kgf-m, 6.0 lb-ft) “A”: Water tight sealant 99000–31250 (SUZUKI Bond No.1207F) 5) Connect PCV hose (2) to PCV valve (3). 6) Connect breather hose (4). 7) Install oil level gauge (1).
Page 297: Throttle Body And Intake Manifold Components
Engine Mechanical: For M16A Engine with VVT 1D-11 www.CarGarage.ir Throttle Body and Intake Manifold Components S5JB0A1416009 I5JB0A141005-05 [A]: Installing location of intake manifold bolt and nut 7. EVAP canister purge valve 14. Intake manifold bolt (short) 1. Intake manifold 8. EVAP canister purge valve hose 15.
Page 298: Electric Throttle Body Assembly Removal And Installation
1D-12 Engine Mechanical: For M16A Engine with VVT www.CarGarage.ir Electric Throttle Body Assembly Removal and Installation Installation 1) Clean mating surfaces and install new throttle body S5JB0A1416045 gasket to intake manifold. 2) Install electric throttle body assembly (1) to intake Removal manifold.
Page 299: Intake Manifold Removal And Installation
Engine Mechanical: For M16A Engine with VVT 1D-13 www.CarGarage.ir Intake Manifold Removal and Installation 8) Remove intake manifold (1) and EGR pipe bolt (2) S5JB0A1416010 from cylinder head, and then remove its gaskets. Removal 1) Relieve fuel pressure in fuel feed line referring to “Fuel Pressure Relief Procedure: in Section 1G”.
Page 300: Engine Mountings Components
1D-14 Engine Mechanical: For M16A Engine with VVT www.CarGarage.ir Engine Mountings Components S5JB0A1416012 I5JB0A141015-02 1. Engine front mounting 4. Engine rear mounting member : 55 N⋅m (5.5 kgf-m, 40.0 lb-ft) 2. Engine front mounting right bracket 5. Engine rear mounting : 17 N⋅m (1.7 kgf-m, 12.5 lb-ft) 3.
Page 301 Engine Mechanical: For M16A Engine with VVT 1D-15 www.CarGarage.ir • Each wire harness clamps 7) Disconnect MAF sensor connector (1). 8) Remove air cleaner case (2). 12) Disconnect the following hoses: • Brake booster hose (22) from intake manifold • Radiator inlet and outlet hoses (26) from each pipe •...
Page 302 1D-16 Engine Mechanical: For M16A Engine with VVT www.CarGarage.ir 17) With hose connected, detach A/C compressor from 24) Disconnect transmission from engine referring to its bracket (if equipped) referring to “Compressor “Manual Transmission Assembly Dismounting and Assembly Removal and Installation for M16 Engine Remounting: in Section 5B”, if necessary.
Page 303 Engine Mechanical: For M16A Engine with VVT 1D-17 www.CarGarage.ir 7) Remove engine jack. 17) Install air intake pipe (2). 8) Install front and rear propeller shafts referring to 18) Connect breather union (1) to air intake pipe (2). “Propeller Shaft Removal and Installation: in Section 3D”.
Page 304: Timing Chain Cover Components
1D-18 Engine Mechanical: For M16A Engine with VVT www.CarGarage.ir Timing Chain Cover Components S5JB0A1416014 I5JB0A141020-01 1. Crankshaft pulley bolt 9. Oil gallery pipe No.1 17. Oil control valve 2. Crankshaft pulley 10. Copper washer : 11 N⋅m (1.1 kgf-m, 8.0 lb-ft) 3.
Page 305: Timing Chain Cover Removal And Installation
Engine Mechanical: For M16A Engine with VVT 1D-19 www.CarGarage.ir Timing Chain Cover Removal and Installation S5JB0A1416015 CAUTION • Keep working table, tools and hands clean while overhauling. • Use special care to handle aluminum parts so as not to damage them. •...
Page 306 6) Apply engine oil to new O-rings and install them to water outlet pipe (2). “A”: Water tight sealant 99000–31140 (SUZUKI Bond No.1207B) 7) Install water outlet pipe (2) to timing chain cover (1).
Page 307: Timing Chain Cover Inspection
Engine Mechanical: For M16A Engine with VVT 1D-21 www.CarGarage.ir Timing Chain Cover Inspection 9) Install oil gallery pipes No.2 and No.3 to cylinder head (4) and timing chain cover (5). S5JB0A1416016 Tighten bolts to specified torque. Oil Seal Tightening torque Check oil seal lip for fault or other damage.
Page 308: Oil Control Valve Inspection
1D-22 Engine Mechanical: For M16A Engine with VVT www.CarGarage.ir Oil Control Valve Inspection Installation S5JB0A1416044 1) Install new O-ring (4) to oil control valve. 2) Install oil control valve to timing chain cover. Oil Control Valve Tighten nuts to specification. 1) Inspect strainer (1) and mating surface (2) of oil control valve for clog or damage.
Page 309: Timing Chain And Chain Tensioner Components
Engine Mechanical: For M16A Engine with VVT 1D-23 www.CarGarage.ir Timing Chain and Chain Tensioner Components S5JB0A1416017 I4RS0A140012-01 1. Crankshaft timing sprocket 5. Timing chain tensioner adjuster assembly : 25 N⋅m (2.5 kgf-m, 18.0 lb-ft) 2. Timing chain 6. Chain tensioner adjuster mounting bolt : 11 N⋅m (1.1 kgf-m, 8.0 lb-ft) : Apply engine oil.
Page 310 1D-24 Engine Mechanical: For M16A Engine with VVT www.CarGarage.ir Installation CAUTION After timing chain is removed, never turn crankshaft and camshafts independently more than such an extent (“a”, “b”) as shown in the figure. If turned, interference may occur between piston and valves and valves themselves, and parts related to piston and valves may be Approx.
Page 311 Engine Mechanical: For M16A Engine with VVT 1D-25 www.CarGarage.ir 6) Apply engine oil to sliding surface of chain tensioner 8) Screw in plunger (1) by turning body (2) in arrow (1) and install chain tensioner and spacer. direction and install a retainer (3) (wire) to hold Tighten tensioner bolt to specified torque.
Page 312: Timing Chain And Chain Tensioner Inspection
1D-26 Engine Mechanical: For M16A Engine with VVT www.CarGarage.ir 10) Apply engine oil to timing chain and then turn Timing Chain Tensioner crankshaft clockwise by 2 revolutions and check that Check shoe (1) for wear or damage. match marks (1) on intake and exhaust camshaft timing sprockets are in match with notches (2) on cylinder head and key (3) is in match with notch (4) on cylinder black as shown in the figure.
Page 313: Camshaft, Tappet And Shim Components
Engine Mechanical: For M16A Engine with VVT 1D-27 www.CarGarage.ir Camshaft, Tappet and Shim Components S5JB0A1416020 I4RS0A140013-01 1. Intake camshaft 5. Shim 9. Upper camshaft bearing : Shim No. on it faces tappet side. : Install a bearing half with some holes to upper side of intake camshaft No.1 bearing.
Page 314 1D-28 Engine Mechanical: For M16A Engine with VVT www.CarGarage.ir 4) Loosen camshaft housing bolts in such order as Installation indicated in the figure and remove them. 1) Install tappets and shims to cylinder head. Apply engine oil around tappet and then install it to “12”...
Page 315 Engine Mechanical: For M16A Engine with VVT 1D-29 www.CarGarage.ir 7) After applying engine oil to housing bolts, tighten them temporarily first. Then tighten them by the numerical order in the figure. Tighten a little at a time and evenly among bolts and repeat tightening “a”...
Page 316: Camshaft, Tappet And Shim Inspection
1D-30 Engine Mechanical: For M16A Engine with VVT www.CarGarage.ir Camshaft, Tappet and Shim Inspection Camshaft Runout S5JB0A1416022 Set camshaft between two “V” blocks, and measure its runout by using a dial gauge. Intake Cam Timing Sprocket Assembly If measured runout exceeds limit, replace camshaft. Fit intake cam timing sprocket assembly to camshaft (2) Camshaft runout limit and hold hexagonal section of camshaft by using...
Page 317 Engine Mechanical: For M16A Engine with VVT 1D-31 www.CarGarage.ir 6) Tighten camshaft housing bolts in such order as If measured camshaft journal clearance exceeds indicated in the figure a little at a time till they are limit, measure journal (housing) bore and outside tightened to specified torque.
Page 318 1D-32 Engine Mechanical: For M16A Engine with VVT www.CarGarage.ir Wear of Tappet and Shim Check tappet and shim for pitting, scratches, or damage. If any malcondition is found, replace. I2RH0B140085-01 Measure cylinder head bore and tappet outside diameter to determine cylinder head-to-tappet clearance. If clearance exceeds limit, replace tappet or cylinder head.
Page 319: Valves And Cylinder Head Components
Engine Mechanical: For M16A Engine with VVT 1D-33 www.CarGarage.ir Valves and Cylinder Head Components S5JB0A1416023 I4RS0A140015-01 1. Valve cotters 7. Exhaust valve 13. Cylinder head bolt (M8) : Be sure to tighten cylinder head bolt (M8) after securing the other cylinder head bolt (M10). 2.
Page 320: Valves And Cylinder Head Removal And Installation
1D-34 Engine Mechanical: For M16A Engine with VVT www.CarGarage.ir Valves and Cylinder Head Removal and Installation Installation 1) Clean mating surface of cylinder head and cylinder S5JB0A1416024 block. Remove oil, old gasket and dust from mating surface. Removal 2) Install knock pins (1) to cylinder block. 1) Remove engine assembly from vehicle referring to 3) Install new cylinder head gasket (2) to cylinder block.
Page 321: Valves And Cylinder Head Disassembly And Assembly
Engine Mechanical: For M16A Engine with VVT 1D-35 www.CarGarage.ir d) Repeat Step c). 2) Using special tools (Valve lifter), compress valve spring and then remove valve cotters (1) also by e) Tighten bolt “A” to specified torque. using special tool (Forceps). NOTE Special tool Be sure to tighten M8 bolt “A”...
Page 322 1D-36 Engine Mechanical: For M16A Engine with VVT www.CarGarage.ir 6) Using special tool (Valve guide remover), drive valve 2) Install valve guide to cylinder head. guide out from combustion chamber side to valve Heat cylinder head uniformly at a temperature of 80 to 100 °C (176 to 212 °F) so that head will not be spring side.
Page 323 Engine Mechanical: For M16A Engine with VVT 1D-37 www.CarGarage.ir 4) Install valve spring seat to cylinder head. 7) Install valve spring and spring retainer. Each valve spring has top end (large-pitch end (1)) 5) Install new valve stem seal (1) to valve guide. and bottom end (small-pitch end (2)).
Page 324: Valves And Valve Guides Inspection
1D-38 Engine Mechanical: For M16A Engine with VVT www.CarGarage.ir Valves and Valve Guides Inspection S5JB0A1416026 Valve Guide Valve stem-to-guide clearance Using a micrometer and bore gauge, take diameter readings on valve stems and guides to check stem-to- guide clearance. Be sure to take reading at more than one place along the length of each stem and guide.
Page 325 Engine Mechanical: For M16A Engine with VVT 1D-39 www.CarGarage.ir Valve head radial runout Valve seat repair Check each valve for radial runout with a dial gauge and A valve seat not producing a uniform contact with its “V” block. To check runout, rotate valve slowly. If runout valve or showing width of seating contact that is out of exceeds its limit, replace valve.
Page 326: Cylinder Head Inspection
1D-40 Engine Mechanical: For M16A Engine with VVT www.CarGarage.ir Cylinder Head Inspection S5JB0A1416027 • Remove all carbon deposits from combustion chambers. NOTE Do not use any sharp-edged tool to scrape off carbon deposits. Be careful not to scuff or nick metal surfaces when decarbonizing. The same applies to valves and valve seats, too.
Page 327: Valve Spring Inspection
Engine Mechanical: For M16A Engine with VVT 1D-41 www.CarGarage.ir Valve Spring Inspection Cylinder Head Bolt Measure each thread diameter of cylinder head bolt (1) S5JB0A1416028 at “A” on 83.5 mm (2.81 in.) from seat side of flange bolt Valve Spring Free Length and Preload and “B”...
Page 328: Pistons, Piston Rings, Connecting Rods And Cylinders Components
1D-42 Engine Mechanical: For M16A Engine with VVT www.CarGarage.ir Pistons, Piston Rings, Connecting Rods and Cylinders Components S5JB0A1416029 I2RH0B140108-01 [A]: 1) Tighten all nuts to 15 N⋅m (1.5 kgf-m). 7. Connecting rod bearing 2) Then retighten all nuts by turning through 45°. 3) Repeat Step 2) again.
Page 329 Engine Mechanical: For M16A Engine with VVT 1D-43 www.CarGarage.ir Installation 1) Apply engine oil to pistons, rings, cylinder walls, connecting rod bearings and crank pins. NOTE Do not apply oil between connecting rod and bearing or between bearing cap and bearing. 2) Install guide hoses (1) over connecting rod bolts.
Page 330: Pistons, Piston Rings, Connecting Rods And Cylinders Disassembly And Assembly
1D-44 Engine Mechanical: For M16A Engine with VVT www.CarGarage.ir Pistons, Piston Rings, Connecting Rods and Assembly Cylinders Disassembly and Assembly 1) Decarbonize piston head and ring grooves using a S5JB0A1416031 suitable tool. 2) Install piston pin to piston (1) and connecting rod (2): Disassembly a) After applying engine oil to piston pin and piston 1) Using piston ring expander, remove two...
Page 331: Cylinders, Pistons And Piston Rings Inspection
Engine Mechanical: For M16A Engine with VVT 1D-45 www.CarGarage.ir NOTE 4) After installing three rings (1st, 2nd and oil rings), distribute their end gaps as shown in the figure. If any one of four cylinders has to be rebored, rebore all four to the same next oversize. This is necessary for the sake of uniformity and balance.
Page 332 1D-46 Engine Mechanical: For M16A Engine with VVT www.CarGarage.ir Piston clearance Measure cylinder bore diameter and piston diameter to find their difference which is piston clearance. Piston clearance should be within specification as follows. If it is out of specification, rebore cylinder and use oversize piston.
Page 333: Piston Pins And Connecting Rods Inspection
Engine Mechanical: For M16A Engine with VVT 1D-47 www.CarGarage.ir Piston Pins and Connecting Rods Inspection Connecting Rod S5JB0A1416033 Big-end side clearance Piston Pin Check big-end of connecting rod for side clearance, with rod fitted and connected to its crank pin in the normal Visual inspection manner.
Page 334: Crank Pin And Connecting Rod Bearings Inspection
1D-48 Engine Mechanical: For M16A Engine with VVT www.CarGarage.ir Crank Pin and Connecting Rod Bearings Connecting rod bolt deformation (Plastic deformation tightening bolt) Inspection Measure each thread diameter of connecting rod bolt (2) S5JB0A1416034 at “A” on 32 mm (1.25 in.) from bolt mounting surface Crank Pin Diameter and “B”...
Page 335 Engine Mechanical: For M16A Engine with VVT 1D-49 www.CarGarage.ir Connecting Rod Bearing General Information a) Tighten all cap nuts to 15 N⋅m (1.5 kgf-m, 11.0 lb- Service connecting rod bearings are available in standard size and 0.25 mm (0.0098 in.) undersize b) Retighten them to 45°...
Page 336 1D-50 Engine Mechanical: For M16A Engine with VVT www.CarGarage.ir Selection of Connecting Rod Bearings 2) Next, check crankshaft pin diameter. On crank web No.3, four alphabets are stamped as shown in the NOTE figure. Three kinds of alphabet (“A”, “B” and “C”) represent •...
Page 337 Engine Mechanical: For M16A Engine with VVT 1D-51 www.CarGarage.ir 3) There are five kinds of standard bearings differing in 4) From number stamped on connecting rod and its cap thickness. To distinguish them, they are painted in and alphabets stamped on crank web No.3, the following colors at the position as indicated in the determine new standard bearing to be installed to figure.
Page 338: Main Bearings, Crankshaft And Cylinder Block Components
1D-52 Engine Mechanical: For M16A Engine with VVT www.CarGarage.ir Main Bearings, Crankshaft and Cylinder Block Components S5JB0A1416035 I5JB0A141026-02 www.CarGarage.ir...
Page 339: Main Bearings, Crankshaft And Cylinder Block Removal And Installation
Engine Mechanical: For M16A Engine with VVT 1D-53 www.CarGarage.ir 1. CKP sensor (if equipped) 10. Rear oil seal housing 19. Spring pin : See “A” : See “C” 2. Knock sensor 11. Rear oil seal 20. Sensor plate bolt 3. Cylinder block 12.
Page 340 1D-54 Engine Mechanical: For M16A Engine with VVT www.CarGarage.ir Installation 3) Install thrust bearings (1) to cylinder block between No.2 and No.3 cylinders. Face oil groove (2) sides to NOTE crank webs. • All parts to be installed must be perfectly 4) Confirm that dowel pins (3) are installed to intake side of each journal.
Page 341 8) Apply sealant to mating surface of rear oil seal Flywheel bolt (a): 70 N·m (7.0 kgf-m, 51.0 lb-ft) housing (1). “A”: Water tight sealant 99000–31250 (SUZUKI Bond No.1207F) Sealant amount for rear oil seal housing Width: “a”: 3 mm (0.12 in.) Height “b”: 2 mm (0.08 in.)
Page 342: Crankshaft Inspection
1D-56 Engine Mechanical: For M16A Engine with VVT www.CarGarage.ir Crankshaft Inspection 2) Tighten main bearing cap No.1 bolts (1) – (10) and S5JB0A1416037 main bearing cap No.2 bolts (11) – (20) gradually as follows. Crankshaft Runout Using a dial gauge, measure runout at center journal. NOTE Rotate crankshaft slowly.
Page 343: Main Bearings Inspection
Engine Mechanical: For M16A Engine with VVT 1D-57 www.CarGarage.ir NOTE Main Bearings Inspection S5JB0A1416038 After checking the thrust play, make sure that thread deformation of each bearing cap No.1 General Information bolt referring to “Main Bearing Cap No.1 • Service main bearings are available in standard size Bolt”...
Page 344 1D-58 Engine Mechanical: For M16A Engine with VVT www.CarGarage.ir 4) Tighten main bearing cap No.1 bolts (1) – (10) and main bearing cap No.2 bolts (11) – (20) gradually as follows. NOTE If main bearing cap No.1 bolt is reused, make sure to check main bearing cap No.1 bolt for deformation referring to “Main Bearing Cap No.1 Bolt”...
Page 345 Engine Mechanical: For M16A Engine with VVT 1D-59 www.CarGarage.ir 2) Next, check bearing cap bore diameter without bearing. On mating surface of cylinder block, five alphabets are stamped as shown in the figure. Three kinds of alphabets (“A”, “B” and “C”) or numbers (“1”, “2”...
Page 346 1D-60 Engine Mechanical: For M16A Engine with VVT www.CarGarage.ir Undersize bearing (0.25 mm (0.0098 in.)) • 0.25 mm (0.0098 in.) undersize bearing is available, in five kinds varying in thickness. To distinguish them, each bearing is painted in the following colors at such position as indicated in the figure. Each color represents the following thickness at the center of bearing.
Page 347: Sensor Plate Inspection
Engine Mechanical: For M16A Engine with VVT 1D-61 www.CarGarage.ir New undersize crankshaft main bearing specification Measured journal diameter 51.7440 – 51.7500 mm 51.7380 – 51.7439 mm 51.7320 – 51.7379 mm (2.0372 – 2.0373 in.) (2.0370 – 2.0371 in.) (2.0367 – 2.0369 in.) A (1) Red and Purple Red and Brown...
Page 348: Flywheel Inspection
1D-62 Engine Mechanical: For M16A Engine with VVT www.CarGarage.ir Flywheel Inspection Cylinder Block Inspection S5JB0A1416041 S5JB0A1416042 Visual Inspection Distortion of Gasketed Surface Using straightedge and thickness gauge, check • If ring gear is damaged, cracked or worn, replace gasketed surface for distortion and, if flatness exceeds flywheel.
Page 349: Specifications
Engine Mechanical: For M16A Engine with VVT 1D-63 www.CarGarage.ir Specifications Tightening Torque Specifications S5JB0A1417001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Camshaft housing bolts 8 N⋅m (0.8 kgf-m, 6.0 lb-ft) for tightening of special tool Camshaft housing bolt Cylinder head cover bolt Air intake pipe bolt Starting motor terminal nut Generator terminal nut...
Page 350: Special Tools And Equipment
1D-64 Engine Mechanical: For M16A Engine with VVT www.CarGarage.ir Special Tools and Equipment Recommended Service Material S5JB0A1418001 Material SUZUKI recommended product or Specification Note Sealant SUZUKI Bond No.1217G P/No.: 99000–31260 Water tight sealant SUZUKI Bond No.1207B P/No.: 99000–31140 SUZUKI Bond No.1207F P/No.: 99000–31250...
Page 351 Engine Mechanical: For M16A Engine with VVT 1D-65 www.CarGarage.ir 09916–34550 09916–37320 Reamer handle Valve guide outer reamer (10.5 mm) 09916–44910 09916–56011 Valve guide installer & Valve guide installer remover attachment (protrusion: 11.5 09916–58210 09916–67020 Valve guide installer handle Tappet holder (Overseas) 09916–67021 09916–77310 Tappet holder...
Page 352: For J20 Engine
1D-66 Engine Mechanical: For J20 Engine www.CarGarage.ir For J20 Engine General Description Engine Construction Description S5JB0A1421001 The engine is water-cooled, in line 4 cylinders, 4 stroke cycle gasoline unit with its DOHC (Double overhead camshaft) valve mechanism arranged for “V” type valve configuration consisting of 16 valves (4 valves/one cylinder). The double overhead camshaft is mounted over the cylinder head;...
Page 353 Engine Mechanical: For J20 Engine 1D-67 www.CarGarage.ir I5JB0A142069-02 www.CarGarage.ir...
Page 354: Air Cleaner Element Introduction
1D-68 Engine Mechanical: For J20 Engine www.CarGarage.ir Air Cleaner Element Introduction S5JB0A1421002 This air cleaner element is dry type. Remember that it needs cleaning according to “Air Cleaner Filter Inspection and Cleaning: For J20 Engine”. IMT (Intake Manifold Tuning) System S5JB0A1421003 Description I5JB0A142062-01...
Page 355 Engine Mechanical: For J20 Engine 1D-69 www.CarGarage.ir [A + B] (rpm) (rpm) [A]: [B]: I5JB0A142063-02 [A]: IMT valve open 1. IMT valve 3. Engine torque [B]: IMT valve closed 2. Intake manifold 4. Engine speed IMT (Intake manifold tuning) system varies effective length of intake pipe by opening and closing IMT valve in order to improve air volumetric efficiency.
Page 356: Diagnostic Information And Procedures
1D-70 Engine Mechanical: For J20 Engine www.CarGarage.ir System Operation IMT vacuum solenoid valve open: When IMT vacuum solenoid valve is OFF, the actuator side of IMT vacuum solenoid valve is lead to relief port. Under this condition, the negative pressure is not applied to IMT valve actuator. The IMT valve, therefore, is totally opened due to the force of return spring in IMT valve actuator.
Page 357: Engine Vacuum Check
12) After checking, install spark plugs (2) and ignition Special tool coils (1). (A): 09915–67311 (B): 09918–08210 (C): 09355–35754–600 Hose, SUZUKI GENUINE PARTS (D): 09367–04002 3-way joint, SUZUKI GENUINE PARTS I2RH01140002-01 13) Install ignition coil couplers. 14) Connect injector wire harness at coupler. 15) Install engine cover. I5JB0A142002-01 5) Start engine and run engine at specified idle speed, and read vacuum gauge.
Page 358: Valve Lash (Clearance) Inspection
1D-72 Engine Mechanical: For J20 Engine www.CarGarage.ir Valve Lash (Clearance) Inspection 5) Check valve lashes with thickness gauge (4) S5JB0A1424003 according to the following procedure. 1) Remove negative cable at battery. a) Check valve lashes of cylinder No.1. 2) Remove cylinder head cover referring to “Cylinder b) Turn crankshaft pulley by 180°...
Page 359 Engine Mechanical: For J20 Engine 1D-73 www.CarGarage.ir Replacement of Shim c) Hold down the tappet so as not to contact the shim by installing special tool on camshaft 1) Close the valve whose shim (2) is to be replaced by housing with housing bolt (1) tighten housing turning crankshaft, then turn tappet (3) till its cut bolts to specified torque.
Page 360 1D-74 Engine Mechanical: For J20 Engine www.CarGarage.ir 5) Using a micrometer (2), measure the thickness of 7) Install new shim facing shim No. side with tappet. the removed shim (1), and determine replacement shim by calculating the thickness of new shim with the following formula and table.
Page 361: Repair Instructions
Engine Mechanical: For J20 Engine 1D-75 www.CarGarage.ir Repair Instructions Air Cleaner Assembly Removal and Installation Air Cleaner Filter Removal and Installation S5JB0A1426044 S5JB0A1426002 Removal Removal 1) Disconnect breather hose (1) from air cleaner outlet 1) Remove air cleaner upper case (1) from lower case hose (2).
Page 362: Throttle Body And Intake Manifold Components
1D-76 Engine Mechanical: For J20 Engine www.CarGarage.ir Throttle Body and Intake Manifold Components S5JB0A1426007 I5JB0A142005-01 1. Intake manifold 4. Electric throttle body assembly : Never disassemble intake manifold. Disassembly will spoil its original performance. If faulty condition is found, replace it with new one. 2.
Page 363: Throttle Body Cleaning
Engine Mechanical: For J20 Engine 1D-77 www.CarGarage.ir 6) Disconnect connector (3) from electric throttle body 9) Perform calibration of electric throttle body assembly assembly. referring to “Electric Throttle Body System Calibration: in Section 1C” if replaced. Throttle Body Cleaning S5JB0A1426010 Clean electric throttle body assembly referring to “Throttle Valve Operation Check”...
Page 364: Cylinder Head Cover Removal And Installation
1D-78 Engine Mechanical: For J20 Engine www.CarGarage.ir Cylinder Head Cover Removal and Installation 9) Remove EVAP canister purge valve bracket (10) form intake manifold. S5JB0A1426013 Removal 1) Disconnect negative cable at battery. 2) Remove engine cover. 3) Disconnect ignition coil couplers (1). 4) Remove ignition coils (4).
Page 365 4) Apply sealant “A” to cylinder head sealing surface “5”, (a) “1”, (a) “3”, (a) area as shown in figure. “A”: Water tight sealant 99000–31250 (SUZUKI Bond No.1207F) “4”, (a) “2”, (a) “6”, (a) I5JB0A142014-01 8) Install oil level gauge (1).
Page 366: Engine Mountings Components
1D-80 Engine Mechanical: For J20 Engine www.CarGarage.ir Engine Mountings Components S5JB0A1426043 I5JB0A142016-01 1. Engine front mounting 6. Engine splash cover 2. Engine front mounting right bracket 7. Engine front mounting nut 3. Engine front mounting left bracket 8. Engine rear mounting member bolt 4.
Page 367: Engine Assembly Removal And Installation
Engine Mechanical: For J20 Engine 1D-81 www.CarGarage.ir Engine Assembly Removal and Installation 10) Disconnect the following hoses: S5JB0A1426019 • Brake booster hose (21) from intake manifold • Radiator inlet and outlet hoses (22) from each Removal pipe 1) Relieve fuel pressure according to “Fuel Pressure •...
Page 368 1D-82 Engine Mechanical: For J20 Engine www.CarGarage.ir 12) For M/T model, remove shift control lever referring to 20) Remove engine rear mounting member bolts (1). “Transmission Shift Control Lever Removal and Installation: in Section 5B”. 13) Remove exhaust No.1, No.2 and center pipes referring to “Exhaust System Components: in Section 1K”.
Page 369 Engine Mechanical: For J20 Engine 1D-83 www.CarGarage.ir Installation 13) Install water pump and generator drive belt referring to “Water Pump and Generator Drive Belt Removal 1) Install clutch cover and clutch disk referring to and Installation (For J20 Engine): in Section 1J”. “Clutch Cover, Clutch Disc and Flywheel Removal and Installation: in Section 5C”, if removed.
Page 370: Timing Chain Cover Components
1D-84 Engine Mechanical: For J20 Engine www.CarGarage.ir Timing Chain Cover Components S5JB0A1426020 1207B 1207F I5JB0A142021-01 1. Crankshaft pulley bolt 6. Timing chain cover bolt and nut : 150 N⋅m (15.0 kgf-m, 108.5 lb-ft) 2. Crankshaft pulley 7. Idler pulley : 11 N⋅m (1.1 kgf-m, 8.0 lb-ft) 3.
Page 371 Engine Mechanical: For J20 Engine 1D-85 www.CarGarage.ir 5) Remove crankshaft pulley (1). Installation To remove crankshaft pulley, use special tools 1) Clean sealing surfaces on timing chain cover, (Steering wheel remover, Bearing puller attachment) cylinder block and cylinder head. with it as shown in figure. Remove oil, oil sealant and dust from sealing surface.
Page 372 4) Apply engine oil to oil seal lip, then install timing in figure. chain cover (1). Tighten bolts and nut to specified torque. “A”: Water tight sealant 99000–31250 (SUZUKI Bond No.1207F) NOTE “B”: Water tight sealant 99000–31140 (SUZUKI Before installing timing chain cover, check Bond No.1207B)
Page 373: Timing Chain Cover Cleaning And Inspection
Engine Mechanical: For J20 Engine 1D-87 www.CarGarage.ir NOTE 11) Install engine assembly to vehicle referring to “Engine Assembly Removal and Installation: For J20 Be sure to use the following bolts instead of Engine”. pins in order to fix crank pulley by special tool.
Page 374: 2Nd Timing Chain And Chain Tensioner Removal And Installation
1D-88 Engine Mechanical: For J20 Engine www.CarGarage.ir 2nd Timing Chain and Chain Tensioner 5) Turn crankshaft clockwise to meet the following conditions. Removal and Installation S5JB0A1426024 • Key on crankshaft match with mark on cylinder block (I). CAUTION • Arrow mark on idler sprocket points upward (II). After 2nd timing chain is removed, never turn •...
Page 375 Engine Mechanical: For J20 Engine 1D-89 www.CarGarage.ir 7) Remove intake and exhaust camshaft timing 4) Install 2nd timing chain by aligning yellow plate (1) of sprocket bolts (1). To remove them, fit a spanner (4) 2nd timing chain and match marks on idler sprocket. to hexagonal part (3) at the center of camshaft to hold it stationary.
Page 376: 2Nd Timing Chain And Chain Tensioner Inspection
1D-90 Engine Mechanical: For J20 Engine www.CarGarage.ir At this time, check timing marks (3, 5 and 7) of 6) Tighten intake and exhaust camshaft timing sprocket bolts (1) to specified torque. To tighten it, fit a sprockets are in match with timing marks (4, 6 and 8) spanner (2) to hexagonal part (3) at the center of of cylinder head, cylinder block and lower crank camshaft to hold it stationary.
Page 377: 1St Timing Chain And Chain Tensioner Components
Engine Mechanical: For J20 Engine 1D-91 www.CarGarage.ir Timing Chain Check timing chain for wear or damage. I2RH01140077-01 Tensioner Adjuster No.2 I2RH01140075-01 Check shoe (1) for wear or damage and latch functions 1. Timing chain guide No.2 properly. Camshaft Sprocket Check teeth of sprocket for wear or damage. I2RH01140078-01 I2RH01140076-01 1st Timing Chain and Chain Tensioner Components...
Page 378: 1St Timing Chain And Chain Tensioner Removal And Installation
1D-92 Engine Mechanical: For J20 Engine www.CarGarage.ir 1st Timing Chain and Chain Tensioner Removal 2) Check that match mark (1) on crankshaft timing sprocket is in match with timing mark (2) on lower and Installation crankcase. S5JB0A1426027 CAUTION After timing chain is removed, never turn crankshaft and camshafts independently more than its allowable turning range described referring to “2nd Timing Chain and...
Page 379 Engine Mechanical: For J20 Engine 1D-93 www.CarGarage.ir I2RH01140086-01 I2RH01140089-01 2. Spacer 12) Check that dark blue and yellow plates of 1st timing chain are in match with match marks on sprockets 8) With latch of tensioner adjuster No.1 returned and respectively.
Page 380: 1St Timing Chain And Chain Tensioner Inspection
1D-94 Engine Mechanical: For J20 Engine www.CarGarage.ir 1st Timing Chain and Chain Tensioner Idler Sprocket Check teeth and bush (1) of sprocket for wear or Inspection damage. S5JB0A1426028 Timing Chain Guide No.1 Check shoe for wear or damage. I2RH01140094-01 1st Timing Chain I2RH01140091-01 Check timing chain for wear or damage.
Page 381: Camshafts, Tappet And Shim Components
Engine Mechanical: For J20 Engine 1D-95 www.CarGarage.ir Camshafts, Tappet and Shim Components S5JB0A1426029 I5JB0A142028-01 1. Intake camshaft 5. Exhaust camshaft housing 9. Timing chain guide No.2 2. Exhaust camshaft 6. Shim 10. Camshaft housing bolt : Direct shim No. side toward tappet. 3.
Page 382 1D-96 Engine Mechanical: For J20 Engine www.CarGarage.ir 2) Match match mark (1) on crank timing sprocket and 5) Check position of camshaft housings. mating surface of cylinder block and lower Embossed marks are provided on each camshaft crankcase (2). housing, indicating position and direction for installation.
Page 383: Camshaft, Tappet And Shim Inspection
Engine Mechanical: For J20 Engine 1D-97 www.CarGarage.ir 9) Install timing chain cover. Refer to “Timing Chain Camshaft Journal Wear Cover Removal and Installation: For J20 Engine” for Check camshaft journals and camshaft housings for installation. pitting, scratches, wear or damage. If any malcondition is found, replace camshaft or cylinder 10) Install cylinder head cover.
Page 384 1D-98 Engine Mechanical: For J20 Engine www.CarGarage.ir 6) Remove housing, and using scale (2) on gauging plastic envelop (1), measure gauging plastic width at its widest point. Journal clearance Standard Limit 0.020 – 0.074 mm (0.0008 – 0.12 mm (0.0047 in.) 0.0029 in.) I2RH0B140085-01 Measure cylinder head bore and tappet outside diameter...
Page 385: Valves And Cylinder Head Components
Engine Mechanical: For J20 Engine 1D-99 www.CarGarage.ir Valves and Cylinder Head Components S5JB0A1426032 I5JB0A142039-01 1. Cylinder block 7. Valve stem seal 13. Cylinder head bolt (M6) : Be sure to tighten cylinder head bolt (M8) after securing cylinder head bolt (M10). 2.
Page 386 1D-100 Engine Mechanical: For J20 Engine www.CarGarage.ir 7) Loosen cylinder head bolts (M10) in such order as numbered in figure and remove them. NOTE Don’t forget to remove cylinder head bolt (M6) (3) as shown in figure. “5” “9” “11” “7”...
Page 387: Valves And Cylinder Head Disassembly And Assembly
Engine Mechanical: For J20 Engine 1D-101 www.CarGarage.ir Valves and Cylinder Head Disassembly and d) Tighten cylinder head bolts (M10) to 52 N⋅m (5.2 kgf-m, 38.0 lb-ft) according to numerical order in Assembly figure. S5JB0A1426034 e) In the same manner as in step b), retighten Disassembly cylinder head bolts (M10) to 103 N⋅m (10.3 kgf- 1) When servicing cylinder head, remove intake...
Page 388 1D-102 Engine Mechanical: For J20 Engine www.CarGarage.ir 3) Release special tool, and remove spring retainers Assembly and valve springs. 1) Before installing valve guide into cylinder head, ream 4) Remove valve from combustion chamber side. guide hole with special tool (11 mm reamer) so as to remove burrs and make it truly round.
Page 389 Engine Mechanical: For J20 Engine 1D-103 www.CarGarage.ir 3) Ream valve guide bore with special tool (6.0 mm 6) Install valve to valve guide. reamer). After reaming, clean bore. Before installing valve to valve guide, apply engine oil to stem seal, valve guide bore, and valve stem. Special tool (A): 09916–34542 (B): 09916–37810...
Page 390: Valves And Valve Guides Inspection
1D-104 Engine Mechanical: For J20 Engine www.CarGarage.ir 9) Install intake manifold referring to “Intake Manifold Removal and Installation: For J20 Engine”. 10) Install exhaust manifold referring to “Exhaust Manifold Removal and Installation (For J20 Engine Model): in Section 1K”. 11) Install injectors referring to “Fuel Injector Removal and Installation: in Section 1G”. Valves and Valve Guides Inspection S5JB0A1426035 Valve Guide...
Page 391 Engine Mechanical: For J20 Engine 1D-105 www.CarGarage.ir Valve Valve head radial runout Check each valve for radial runout with a dial gauge and Visual inspection “V” block. To check runout, rotate valve slowly. If runout exceeds its limit, replace valve. •...
Page 392: Cylinder Head Inspection
1D-106 Engine Mechanical: For J20 Engine www.CarGarage.ir Cylinder Head Inspection Valve seat repair A valve seat not producing a uniform contact with its S5JB0A1426047 • Remove all carbon deposits from combustion valve or showing width of seating contact that is out of chambers.
Page 393: Valve Spring Inspection
Engine Mechanical: For J20 Engine 1D-107 www.CarGarage.ir Valve Spring Inspection S5JB0A1426048 Valve Spring Free Length and Preload Referring to data, check to be sure that each spring is in sound condition, free of any evidence of breakage or weakening. Remember, weakened valve springs can cause chatter, not to mention possibility of reducing power output due to gas leakage caused by decreased seating pressure.
Page 394: Pistons, Piston Rings, Connecting Rods And Cylinders Components
1D-108 Engine Mechanical: For J20 Engine www.CarGarage.ir Pistons, Piston Rings, Connecting Rods and Cylinders Components S5JB0A1426036 I5JB0A142048-02 1. Top ring 8. Piston pin : “TOP” mark provided on piston ring comes to facing up. 2. 2nd ring 9. Piston pin circlip : “TOP”...
Page 395: Pistons, Piston Rings, Connecting Rods And Cylinders Disassembly And Assembly
Engine Mechanical: For J20 Engine 1D-109 www.CarGarage.ir 3) Install piston and connecting rod assembly into 5) Install cylinder head. Refer to “Valves and Cylinder cylinder bore. Use special tool (Piston ring Head Removal and Installation: For J20 Engine” for compressor) to compress rings. Guide connecting installation.
Page 396 1D-110 Engine Mechanical: For J20 Engine www.CarGarage.ir Assembly NOTE Two sizes of piston are available as standard size spare part so as to ensure proper piston-to-cylinder clearance. When installing a standard size piston, make sure to match piston with cylinder as follows. 1) Each piston (1) has stamped number (2) as shown.
Page 397 Engine Mechanical: For J20 Engine 1D-111 www.CarGarage.ir 4) Install piston pin to piston (1) and connecting rod (3): 5) Install piston rings to piston: After applying engine oil to piston pin and piston pin • As indicated in figure at the left, 1st and 2nd rings holes in piston and connecting rod, fit connecting rod have “TOP”...
Page 398: Pistons, Piston Rings, Connecting Rods And Cylinders Inspection And Cleaning
1D-112 Engine Mechanical: For J20 Engine www.CarGarage.ir Pistons, Piston Rings, Connecting Rods and Pistons Cylinders Inspection and Cleaning • Inspect piston for faults, cracks or other damages. S5JB0A1426039 Damaged or faulty piston should be replaced. • Piston diameter: Inspection As indicated in figure, piston diameter should be measured at a position 26.5 mm (1.04 in.) (“a”) from Cylinder piston skirt end in the direction perpendicular to piston...
Page 399 Engine Mechanical: For J20 Engine 1D-113 www.CarGarage.ir Piston rings To measure end gap, insert piston ring (2) into cylinder bore and then measure the gap by using thickness gauge (1). If measured gap is out of specification, replace ring. NOTE Clean carbon and any other dirt from top of cylinder bore before inserting piston ring.
Page 400 1D-114 Engine Mechanical: For J20 Engine www.CarGarage.ir Connecting rod Crank pin and connecting rod bearings • Big-end side clearance: • Inspect crank pin for uneven wear or damage. Check big-end of connecting rod for side clearance, Measure crank pin for out-of-round or taper with a with rod fitted and connected to its crank pin in the micrometer.
Page 401 Engine Mechanical: For J20 Engine 1D-115 www.CarGarage.ir • Connecting rod bearing clearance: e. Remove connecting rod bearing cap, and using a scale (2) on gauging plastic envelope, measure a. Before checking bearing clearance, clean bearing gauging plastic (1) width at the widest point and crank pin.
Page 402 1D-116 Engine Mechanical: For J20 Engine www.CarGarage.ir • Selection of connecting rod bearings: b. Next, check crank pin diameter. On crank web of No. 3 cylinder, four alphabets are stamped as NOTE shown in the figure. Three kinds of alphabet (“A”, “B” and “C”) •...
Page 403 Engine Mechanical: For J20 Engine 1D-117 www.CarGarage.ir • Connecting rod bolt Measure each thread diameter of connecting rod bolts (1) at “A” on 28.5 mm (1.12 in.) from bolt mounting surface and “B” on 42.0 mm (1.65 in.) from bolt mounting surface by using a micrometer (2).
Page 404: Main Bearings, Crankshaft And Cylinder Block Components
1D-118 Engine Mechanical: For J20 Engine www.CarGarage.ir Main Bearings, Crankshaft and Cylinder Block Components S5JB0A1426040 I5JB0A142056-02 www.CarGarage.ir...
Page 405: Main Bearings, Crankshaft And Cylinder Block Removal And Installation
Engine Mechanical: For J20 Engine 1D-119 www.CarGarage.ir 1. Cylinder block 9. Check valve 17. Knock sensor 2. Lower crankcase 10. Flywheel : Tighten 40 N⋅m (4.0 kgf-m, 29.0 lb-ft), 0 : Apply sealant 99000-31250 to mating N⋅m (0 kgf-m, 0 lb-ft), 40 N⋅m (4.0 kgf-m, surface.
Page 406 Make sure that two halves are painted in the same surface area as shown in figure. color. “A”: Water tight sealant 99000–31250 (SUZUKI 2) Install new O-ring (2) to cylinder block. Bond No.1207F) 3) Install knock pins (5) to cylinder block.
Page 407 Engine Mechanical: For J20 Engine 1D-121 www.CarGarage.ir 9) Pull out dowel pin (2) from crankshaft (1) and then install rear oil seal (3) by using special tools and plastic hammer. Special tool (A): 09911–97710 (B): 09911–97811 10) Install dowel pin (2). I2RH01140176-01 2.
Page 408: Main Bearings, Crankshaft And Cylinder Block Inspection
1D-122 Engine Mechanical: For J20 Engine www.CarGarage.ir 12) Install flywheel (drive plate for A/T). 18) Install, timing chain sprockets, timing chains, timing Using special tool, lock flywheel or drive plate, and chain tensioner, tensioner adjusters, timing chain tighten flywheel or drive plate bolts (1) applied with guides, timing chain cover, crankshaft pulley, water sealant to specification.
Page 409 Engine Mechanical: For J20 Engine 1D-123 www.CarGarage.ir Crankshaft thrust play Out-of-round and taper (uneven wear) of journals Measure this play with crankshaft set in cylinder block in An unevenly worn crankshaft journal shows up as a the normal manner, that is, with thrust bearing and lower difference in diameter at a cross section or along its crankcase installed.
Page 410 1D-124 Engine Mechanical: For J20 Engine www.CarGarage.ir Selection of main bearings Main bearing clearance Check clearance by using gauging plastic according to STANDARD BEARING: the following procedure. If engine is under the following conditions, select a new standard bearing as followings and install it. 1) Remove lower crankcase.
Page 411 Engine Mechanical: For J20 Engine 1D-125 www.CarGarage.ir 2) Next, check journal bore diameter. On lower 3) There are 5 kinds of standard bearings differing in crankcase five alphabets are stamped as shown in thickness. To distinguish them, they are painted (1) figure.
Page 412 1D-126 Engine Mechanical: For J20 Engine www.CarGarage.ir 4) From number stamped on crank web No.2 and alphabets stamped on lower crankcase, determine new standard bearing to be installed to journal by referring to table shown. For example, if number stamped on crank web No.2 is “5” and alphabet stamped on lower crankcase is “A”, install new standard bearings painted in “Green”...
Page 413 Engine Mechanical: For J20 Engine 1D-127 www.CarGarage.ir • If necessary, regrind crankshaft journal and select under-size bearing to use with it as follows. a. Regrind journal to the following finished diameter. Finished journal diameter 57.7380 – 57.7560 mm (2.27315 – 2.27385 in.) b.
Page 414 1D-128 Engine Mechanical: For J20 Engine www.CarGarage.ir Oil Pump Chain 2) Using micrometer, measure piston diameter. Check oil pump chain for wear or damage. 3) Calculate cylinder bore diameter to be rebored as follows. D = A + B – C D: Cylinder bore diameter to be rebored.
Page 415: Specifications
Engine Mechanical: For J20 Engine 1D-129 www.CarGarage.ir Specifications Tightening Torque Specifications S5JB0A1427001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Camshaft housing bolts 11 N⋅m (1.1 kgf-m, 8.0 lb-ft) for tightening of special tool Camshaft housing bolt Cylinder head cover nut Starting motor terminal nut Generator terminal nut Timing chain cover bolt and nut...
Page 416: Special Tools And Equipment
1D-130 Engine Mechanical: For J20 Engine www.CarGarage.ir Special Tools and Equipment Recommended Service Material S5JB0A1428001 Material SUZUKI recommended product or Specification Note Water tight sealant SUZUKI Bond No.1207B P/No.: 99000–31140 SUZUKI Bond No.1207F P/No.: 99000–31250 NOTE Required service material is also described in the following.
Page 417 Engine Mechanical: For J20 Engine 1D-131 www.CarGarage.ir 09916–16510 09916–34542 Valve lifter attachment Reamer handle 09916–37810 09916–38210 Valve guide reamer (6 mm) Valve guide reamer (11 mm) 09916–46020 09916–57340 Valve guide remover Valve guide installer attachment 09916–57350 09916–66510 Valve guide installer handle Tappet holder (6 mm) 09916–77310...
Page 418 1D-132 Engine Mechanical: For J20 Engine www.CarGarage.ir 09944–36011 Steering wheel remover www.CarGarage.ir...
Page 419: Engine Lubrication System
Engine Lubrication System: For M16A Engine with VVT 1E-1 www.CarGarage.ir Engine Lubrication System For M16A Engine with VVT General Description Engine Lubrication Description S5JB0A1511001 The oil pump is of a trochoid type, and mounted on the crankshaft. Oil is drawn up through the oil pump strainer and passed through the pump to the oil filter.
Page 420 1E-2 Engine Lubrication System: For M16A Engine with VVT www.CarGarage.ir I3RH0B150001-01 www.CarGarage.ir...
Page 421: Diagnostic Information And Procedures
Engine Lubrication System: For M16A Engine with VVT 1E-3 www.CarGarage.ir Diagnostic Information and Procedures Oil Pressure Check 3) Install special tools (oil pressure gauge) to vacated S5JB0A1514001 threaded hole of oil pressure switch. NOTE Special tool Prior to checking oil pressure, check the (A): 09915–77310 following.
Page 422: Repair Instructions
1E-4 Engine Lubrication System: For M16A Engine with VVT www.CarGarage.ir 8) Start engine and check oil pressure switch for oil leakage. If oil leakage is found, repair it. 9) Connect oil pressure switch coupler (1). I5JB0A151003-01 Repair Instructions Oil Pan and Oil Pump Strainer Components S5JB0A1516001 I5JB0A151005-01 1.
Page 423: Oil Pan And Oil Pump Strainer Removal And Installation
3) Apply sealant continuously to oil pan mating surface as shown in the figure. I5JB0A151006-01 5) Remove oil pan, and then oil pump strainer (1) from “A”: Sealant 99000–31260 (SUZUKI Bond cylinder block. No.1217G) Sealant amount for oil pan Width “a”: 3 mm (0.12 in.) Height “b”: 2 mm (0.08 in.)
Page 424: Oil Pan And Oil Pump Strainer Cleaning
1E-6 Engine Lubrication System: For M16A Engine with VVT www.CarGarage.ir 4) Install oil pan to cylinder block temporarily. 9) Install clutch housing lower plate No.1 (1) and clutch housing lower plate No.2 (2). 5) Insert knock pin (1) in hole (2) of oil pan in order to locate oil pan precisely.
Page 425: Oil Pump Components
Engine Lubrication System: For M16A Engine with VVT 1E-7 www.CarGarage.ir Oil Pump Components S5JB0A1516004 I4RS0A150010-01 1. Rotor plate 6. Rotor plate bolt 10. Circlip 2. O-ring 7. Relief valve : 11 N⋅m (1.1 kgf-m, 8.0 lb-ft) 3. Outer rotor 8. Spring : Do not reuse.
Page 426: Oil Pump Inspection
1E-8 Engine Lubrication System: For M16A Engine with VVT www.CarGarage.ir Oil Pump Inspection Reassembly S5JB0A1516007 1) Wash, clean and then dry all disassembled parts. 2) Apply thin coat of engine oil to inner and outer rotors, Oil Seal oil seal lip portion, inside surfaces of oil pump case Check oil seal lip for fault or other damage.
Page 427 Engine Lubrication System: For M16A Engine with VVT 1E-9 www.CarGarage.ir Radial clearance Relief valve spring free length and load Check radial clearance between outer rotor (1) and case Check relief valve spring free length and load as shown (2) using thickness gauge (3). in the figure.
Page 428: Specifications
For the tightening torque of fastener not specified in this section, refer to “Fastener Information: in Section 0A”. Special Tools and Equipment Recommended Service Material S5JB0A1518001 Material SUZUKI recommended product or Specification Note Sealant SUZUKI Bond No.1217G P/No.: 99000–31260 NOTE Required service material is also described in the following.
Page 429: For J20 Engine
Engine Lubrication System: For J20 Engine 1E-11 www.CarGarage.ir For J20 Engine General Description Engine Lubrication Description S5JB0A1521001 The oil pump is trochoid type, and mounted under the crankshaft. Oil is drawn up through the oil pump strainer and passed through the pump to the oil filter. The filtered oil flows into two paths in cylinder block.
Page 430 1E-12 Engine Lubrication System: For J20 Engine www.CarGarage.ir I5JB0A151013-01 www.CarGarage.ir...
Page 431: Diagnostic Information And Procedures
Engine Lubrication System: For J20 Engine 1E-13 www.CarGarage.ir Diagnostic Information and Procedures Oil Pressure Check S5JB0A1524001 WARNING To avoid danger of being burned, do not touch exhaust manifold when exhaust system is hot. When servicing, be sure to perform it after exhaust system has cooled down.
Page 432: Repair Instructions
1E-14 Engine Lubrication System: For J20 Engine www.CarGarage.ir Repair Instructions Oil Pan and Oil Pump Strainer Components S5JB0A1526001 1217G I5JB0A152004-02 1. Oil pan 8. Gasket : Apply sealant 99000-31260 to mating surface. 2. Oil pump strainer 9. Baffle plate 3. O-ring : 11 N⋅m (1.1 kgf-m, 8.0 lb-ft) 4.
Page 433: Oil Pan And Oil Pump Strainer Removal And Installation
Installation 1) Apply sealant to oil pan (1) mating surface S5JB0A1526002 continuously as shown in figure. Removal “A”: Water tight sealant 99000–31250 (SUZUKI Bond No.1207F) 1) Remove oil level gauge. 2) Raise vehicle. Sealant amount for oil pan Width “a”: 3 mm (0.12 in.) 3) Remove engine under cover (1).
Page 434: Oil Pan And Oil Pump Strainer Cleaning
1E-16 Engine Lubrication System: For J20 Engine www.CarGarage.ir 5) Install front suspension frame referring to “Front 4) Install new gasket and drain plug (2) to oil pan after applying engine oil. Suspension Frame, Stabilizer Bar and/or Bushings Tighten drain plug to specified torque. Removal and Installation: in Section 2B”.
Page 435: Oil Pump Removal And Installation
Engine Lubrication System: For J20 Engine 1E-17 www.CarGarage.ir Oil Pump Removal and Installation 2) Install oil pump chain guide (1), and tighten bolts to S5JB0A1526005 specified torque. CAUTION Tightening torque Don’t remove sprocket and inner rotor from Oil pump chain guide nut (a): 11 N·m (1.1 kgf-m, oil pump, otherwise damage of oil pump 8.0 lb-ft) center shaft and abnormal operation of oil...
Page 436: Oil Pump Inspection
1E-18 Engine Lubrication System: For J20 Engine www.CarGarage.ir 5) Install oil pump case pins (5) to oil pump case No.2. • Measure free length and tension of oil relief spring. If the measured values of length or tension is less than the specification, replace oil pump relief valve set.
Page 437: Specifications
Engine Lubrication System: For J20 Engine 1E-19 www.CarGarage.ir Side Clearance Using straightedge (5) and thickness gauge (4), measure side clearance. If side clearance exceeds its limit, replace oil pump assembly. Limit on side clearance 0.11 mm (0.0043 in.) I2RH01150025-01 1. Oil pump case No.1 3.
Page 438: Special Tools And Equipment
1E-20 Engine Lubrication System: For J20 Engine www.CarGarage.ir Special Tools and Equipment Recommended Service Material S5JB0A1528001 Material SUZUKI recommended product or Specification Note Water tight sealant SUZUKI Bond No.1207F P/No.: 99000–31250 NOTE Required service material is also described in the following.
Page 439: Engine Cooling System
Engine Cooling System: 1F-1 www.CarGarage.ir Engine Cooling System General Description Cooling System Description This 50/50 mixture coolant solution provides freezing protection to –36 °C (–33 °F). S5JB0A1601001 The cooling system consists of the radiator cap, radiator, • Maintain cooling system freeze protection at –36 °C coolant reservoir, hoses, water pump, cooling fan and (–33 °F) to ensure protection against corrosion and thermostat.
Page 440: Schematic And Routing Diagram
1F-2 Engine Cooling System: www.CarGarage.ir Schematic and Routing Diagram Coolant Circulation S5JB0A1602001 While the engine is warmed up (thermostat closed), coolant circulates as follows. I5JB0A161001-01 1. Radiator inlet hose 5. Thermostat 9. Heater core inlet hose 2. Radiator outlet hose 6.
Page 441: Diagnostic Information And Procedures
Engine Cooling System: 1F-3 www.CarGarage.ir Diagnostic Information and Procedures Engine Cooling Symptom Diagnosis S5JB0A1604001 Condition Possible cause Correction / Reference Item Engine overheats Loose or broken water pump belt Adjust or replace. (Radiator fan operates) Not enough coolant Check coolant level and add as necessary. Faulty thermostat Replace.
Page 442: Repair Instructions
1F-4 Engine Cooling System: www.CarGarage.ir Repair Instructions Cooling System Components S5JB0A1606001 I5JB0A161003-03 www.CarGarage.ir...
Page 443 Engine Cooling System: 1F-5 www.CarGarage.ir I5JB0A161004-03 [A]: M16 engine model 14. Thermostat 29. To cylinder head [B]: J20 engine model 15. Thermostat cap 30. To water pump 1. Radiator 16. Radiator inlet No.2 hose 31. To heater core 2. Reservoir 17.
Page 444: Coolant Level Check
1F-6 Engine Cooling System: www.CarGarage.ir Coolant Level Check Engine Cooling System Inspection and S5JB0A1606002 Cleaning WARNING S5JB0A1606003 WARNING To help avoid danger of being burned, do not remove radiator cap while engine and To help avoid danger of being burned, do not radiator are still hot.
Page 445: Cooling System Draining
Engine Cooling System: 1F-7 www.CarGarage.ir Cooling System Draining 7) Remove reservoir (1) and remove cap (2) from S5JB0A1606019 reservoir (1). 1) Remove radiator cap. 8) Pour out any fluid, scrub and clean inside of 2) Drain coolant from radiator drain plug (1). reservoir with soap and water.
Page 446: Cooling Water Pipes Or Hoses Removal And Installation
1F-8 Engine Cooling System: www.CarGarage.ir Cooling Water Pipes or Hoses Removal and 5) Remove thermostat cap (4) from thermostat case (3). Installation S5JB0A1606005 6) Remove thermostat from thermostat case (3). Removal 1) Drain coolant referring to “Cooling System Draining: ”. 2) To remove these pipes or hoses, loosen clamp on each hose and pull hose end off.
Page 447: Thermostat Removal And Installation
Engine Cooling System: 1F-9 www.CarGarage.ir Thermostat Removal and Installation (For J20 Thermostat Inspection S5JB0A1606007 Engine Model) • Make sure that air bleed valve (1) of thermostat is S5JB0A1606022 Removal clean. Should this valve be clogged, engine would tend to 1) Drain coolant referring to “Cooling System Draining: overheat.
Page 448: Radiator Cooling Fan Motor On-Vehicle Inspection
1F-10 Engine Cooling System: www.CarGarage.ir Radiator Cooling Fan Motor On-Vehicle Radiator Cooling Fan Relay Inspection S5JB0A1606020 Inspection 1) Disconnect negative (–) cable at battery. S5JB0A1606010 1) Check main and/or sub fan operation of radiator 2) Remove radiator cooling fan relay No.1 (1), No.3 (2) cooling fan as follows.
Page 449: Radiator Cooling Fan Assembly Removal And Installation
Engine Cooling System: 1F-11 www.CarGarage.ir 3) With hose connected, detach P/S fluid reservoir with reservoir bracket. 4) Remove air cleaner case and air cleaner suction pipe (2). 5) Remove reservoir (1) from radiator. “C” “A” “B” “A” I5JB0A161015-01 “B” 6) Remove cooling fan assembly. “D”...
Page 450: Radiator Removal And Installation
Section 5A”. Installation 1) Apply sealant to mating surface of water pump (1) as shown in the figure. “A”: Water tight sealant 99000–31250 (SUZUKI Bond No.1207F) Sealant quantity (to mating surface of water pump) Width “a”: 3 mm (0.12 in.) Height “b”: 2 mm (0.08 in.)
Page 451: Water Pump Removal And Installation
Engine Cooling System: 1F-13 www.CarGarage.ir Water Pump Removal and Installation (For J20 2) Install water pump assembly (1) to cylinder block and tighten bolts and nut to specified torque. Engine Model) S5JB0A1606023 Tightening torque Removal Water pump bolt and nut (a): 25 N·m (2.5 kgf-m, 1) Disconnect negative cable at battery.
Page 452: Water Pump Inspection
For the tightening torque of fastener not specified in this section, refer to “Fastener Information: in Section 0A”. Special Tools and Equipment Recommended Service Material S5JB0A1608001 Material SUZUKI recommended product or Specification Note Water tight sealant SUZUKI Bond No.1207F P/No.: 99000–31250...
Page 453: Fuel System
Fuel System: 1G-1 www.CarGarage.ir Fuel System Precautions Precautions on Fuel System Service S5JB0A1700001 WARNING Before attempting service of any type on fuel system, the following should be always observed in order to reduce the risk or fire and personal injury. •...
Page 454: Fuel Pump Description
1G-2 Fuel System: www.CarGarage.ir Fuel Pump Description S5JB0A1701003 The fuel pump (1) is an in-tank type electric pump. Incorporated in the pump assembly are; a fuel filter (2) included and a fuel level gauge (3) attached. Also, the jet pump (4) installed in the fuel pump sucks up the fuel from the sub fuel level sensor side to main fuel level sensor side through the fuel suction pipe / hose by using the negative pressure produced when the part of...
Page 455: Diagnostic Information And Procedures
Fuel System: 1G-3 www.CarGarage.ir Diagnostic Information and Procedures Fuel Pressure Inspection 4) Check that battery voltage is 11 V or more. S5JB0A1704001 5) Measure fuel pressure at each condition. WARNING If measured pressure is out of specification, refer to “Fuel Pressure Check: in Section 1A” and check Before starting the following procedure, be each possibly defective part.
Page 456: Fuel Cut Operation Inspection
1G-4 Fuel System: www.CarGarage.ir Fuel Cut Operation Inspection 6) After checking fuel pressure, remove fuel pressure gauge. S5JB0A1704002 NOTE WARNING Before inspection, make sure that gear shift lever is in neutral position (shift select lever As fuel feed line is still under high fuel is “P”...
Page 457: Repair Instructions
Fuel System: 1G-5 www.CarGarage.ir Repair Instructions Fuel System Components S5JB0A1706001 I5JB0A170001-03 www.CarGarage.ir...
Page 458 1G-6 Fuel System: www.CarGarage.ir I5JB0A170002-03 www.CarGarage.ir...
Page 459 Fuel System: 1G-7 www.CarGarage.ir [A]: For M16 engine model 11. Fuel pump gasket 24. To fuel tank [B]: For J20 engine model 12. Fuel tank bolt 25. To EVAP canister purge valve [C]: View A 13. Fuel pump bolt 26. Sub fuel level sensor 1.
Page 460: Fuel Hose Disconnecting And Reconnecting
1G-8 Fuel System: www.CarGarage.ir Fuel Hose Disconnecting and Reconnecting S5JB0A1706023 WARNING Before starting the following procedure, be sure to observe “Precautions on Fuel System Service: ” in order to reduce the risk or fire and personal injury. Be sure to connect and clamp each hose correctly as shown in figure. For Normal Clamp Fuel tank system NOTE...
Page 461 Fuel System: 1G-9 www.CarGarage.ir The other than fuel tank system [A]: With short pipe, fit hose as far as it reaches pipe joint as shown. [B]: With the following type pipe, fit hose as far as its peripheral projection as shown. [C]: With bent pipe, fit hose as its bent part as shown or till depth “b”.
Page 462: Fuel Pressure Relief Procedure
1G-10 Fuel System: www.CarGarage.ir Fuel Pressure Relief Procedure For Quick Joint (Fuel Vapor Line) S5JB0A1706002 CAUTION Disconnecting 1) Remove mud, dust and/or foreign material between This work must not be done when engine is pipe (1) and quick joint (fuel vapor line) (2) by hot.
Page 463: Fuel Lines On-Vehicle Inspection
Fuel System: 1G-11 www.CarGarage.ir Fuel Lines On-Vehicle Inspection Installation S5JB0A1706004 1) Install clamps to marked®® location on pipes. If CAUTION clamp is deformed, its claw is bent or broken, replace it with new one. Due to the fact that fuel feed line (1) is under high pressure, use special care when 2) Install pipes with pipe clamps to vehicle.
Page 464: Fuel Injector Removal And Installation
O-ring. Relief Procedure: ”. Replace O-ring with new one. 2) Disconnect negative cable at battery. “A”: Oil 99000–25320 (SUZUKI DI O RING 3) Disconnect fuel injector couplers. OIL(500CC)) 4) Disconnect fuel feed hose from fuel delivery pipe (1).
Page 465: Fuel Injector Inspection
Fuel System: 1G-13 www.CarGarage.ir Fuel Injector Inspection S5JB0A1706008 WARNING Before starting the following procedure, be sure to observe “Precautions on Fuel System Service: ” in order to reduce the risk or fire and personal injury. 1) Install injector to special tool (injector checking tool). 2) Install pressure regulator to special tool (injector checking tool).
Page 466 Turn ignition switch ON, clear DTC and select “MISC TEST” mode on scan tool. iii) Turn fuel pump ON by using scan tool. Special tool (A): SUZUKI scan tool I5JB0A171010-01 iii) Turn ignition switch ON. 8) Apply battery voltage to injector (1) for 15 seconds and measure injected fuel volume with graduated cylinder.
Page 467: Fuel Pressure Regulator Removal And Installation
Fuel System: 1G-15 www.CarGarage.ir Fuel Pressure Regulator Removal and Installation Reverse removal procedure for installation noting the Installation following. S5JB0A1706024 WARNING • Replace O-ring with new one using care not to damage it. Before starting the following procedure, be • Apply thin coat of fuel to O-ring and then install fuel sure to observe “Precautions on Fuel System pressure regulator (1) to delivery pipe.
Page 468: Fuel Filler Cap Inspection
1G-16 Fuel System: www.CarGarage.ir Fuel Filler Cap Inspection 3) Hoist vehicle, and remove clamp (2) and fuel filler S5JB0A1706011 hose (1) from fuel filler neck. WARNING Before starting the following procedure, be sure to observe “Precautions on Fuel System Service: ” in order to reduce the risk or fire and personal injury.
Page 469: Fuel Tank Inlet Valve Inspection
Fuel System: 1G-17 www.CarGarage.ir Fuel Tank Inlet Valve Inspection S5JB0A1706016 WARNING Before starting the following procedure, be sure to observe “Precautions on Fuel System Service: ” in order to reduce the risk or fire and personal injury. Check fuel tank inlet valve for the following. If any damage or malfunction is found, replace.
Page 470 1G-18 Fuel System: www.CarGarage.ir 12) Support fuel tank (1) with jack (2) and remove its 3) Install fuel tank to vehicle. mounting bolts. Tightening torque Fuel tank bolt (a): 50 N·m (5.0 kgf-m, 36.5 lb-ft) I5JB0A171018-01 13) For M16 engine, lower fuel tank a little as to disconnect connectors (1) of fuel pump (2) and sub I5JB0A171020-01 fuel level gauge (3), then remove fuel tank.
Page 471: Fuel Tank Inspection
Fuel System: 1G-19 www.CarGarage.ir Fuel Pump On-Vehicle Inspection 7) Install parking brake cable clamp to fuel tank cover referring to “Parking Brake Cable Location: in S5JB0A1706017 WARNING Section 4D” 8) Install rear propeller shaft referring to “Propeller Before starting the following procedure, be Shaft Removal and Installation: in Section 3D”...
Page 472: Fuel Pump Assembly Removal And Installation
1G-20 Fuel System: www.CarGarage.ir Fuel Pump Assembly Removal and Installation Installation S5JB0A1706019 CAUTION WARNING When connecting joint, clean outside surface Before starting the following procedure, be of pipe where joint is to be inserted, push sure to observe “Precautions on Fuel System joint into pipe till joint lock clicks and check Service: ”...
Page 473: Main Fuel Level Sensor Removal And Installation
Fuel System: 1G-21 www.CarGarage.ir Main Fuel Level Sensor Removal and Fuel Pump Inspection S5JB0A1706021 Installation • Check fuel pump assembly for damage. S5JB0A1706022 CAUTION • Check fuel suction filter for evidence of dirt and contamination. • Do not touch resister plate (1) and deform If present, replace or clean and check for presence of arm (2).
Page 474: Sub Fuel Level Sensor Inspection
1G-22 Fuel System: www.CarGarage.ir Removal Installation Reverse removal procedure for installation noting the 1) Remove fuel tank from vehicle Referring to “Fuel following. Tank Removal and Installation: ” • Replace O-ring with new one using care not to 2) Disconnect sub fuel level sensor connector (1). damage it.
Page 475: Special Tools And Equipment
Fuel System: 1G-23 www.CarGarage.ir Special Tools and Equipment Recommended Service Material S5JB0A1708001 Material SUZUKI recommended product or Specification Note SUZUKI DI O RING OIL(500CC) P/No.: 99000–25320 NOTE Required service material is also described in the following. “Fuel System Components: ”...
Page 476: Ignition System
1H-1 Ignition System: www.CarGarage.ir Ignition System General Description Ignition System Construction For M16 engine, this ignition system does not have a S5JB0A1801001 distributor, it has two ignition coil assemblies (one is for The ignition system is an electronic (distributor less) No.1 and No.4 spark plugs and the other is for No.2 and ignition system.
Page 477: Schematic And Routing Diagram
Ignition System: 1H-2 www.CarGarage.ir Schematic and Routing Diagram Ignition System Wiring Circuit Diagram S5JB0A1802001 BLK/WHT BLK/WHT BLK/ORN BLK/ORN C37-21 BRN/BLK C37-20 BLK/WHT E23-29 BLK/YEL E23-60 BLK/RED BLK/RED BLU/BLK BLU/BLK E23-1 BLK/RED BLU/BLK E23-16 WHT/GRN C37-15 BLK/ORN C37-30 BLK/ORN WHT/RED C37-52 C37-29 BLK/YEL C37-48...
Page 478: Component Location
1H-3 Ignition System: www.CarGarage.ir 2. Main relay 10. No.4 spark plug 18. Ignition coil assembly for No.1 3. Ignition coil assembly for No.1 and No.4 spark 11. Sensed information (MAP sensor, ECT 19. Ignition coil assembly for No.2 plugs sensor, MAF and IAT sensor, TP sensor, Knock sensor, wheel speed signal (ABS), Electric load signal, Engine start signal, Torque reduction signal (TCM))
Page 479: Diagnostic Information And Procedures
Ignition System: 1H-4 www.CarGarage.ir [A]: For M16 engine 7. ECT sensor 15. Ignition coil assembly for No.1 (for J20 engine) [B]: For J20 engine 8. MAF and IAT sensor 16. Ignition coil assembly for No.2 (for J20 engine) 1. ECM 9.
Page 480 1H-5 Ignition System: www.CarGarage.ir Step Action DTC check Go to applicable DTC Go to Step 4. diag. flow. 1) Perform DTC check referring to “DTC Check: in Section 1A”. Is DTC stored in ECM? Electrical connection check Go to Step 5 for M16 Connect securely.
Page 481 Ignition System: 1H-6 www.CarGarage.ir Step Action 13 Knock sensor check Check CMP sensor, Substitute a known- CMP sensor rotor tooth good knock sensor and 1) Confirm that knock sensor circuit is in good condition of camshaft, CKP recheck. referring to “DTC P0327 / P0328: Knock Sensor Circuit sensor, CKP sensor Low / High: in Section 1A”.
Page 482: Repair Instructions
1H-7 Ignition System: www.CarGarage.ir Repair Instructions High-Tension Cord Removal and Installation High-Tension Cord Inspection (For M16 Engine) S5JB0A1806002 (For M16 Engine) Measure resistance of high-tension cord (1) by using S5JB0A1806001 ohmmeter. Removal If resistance exceeds specification, replace high-tension 1) Remove engine cover. cord(s).
Page 483: Spark Plug Inspection
Ignition System: 1H-8 www.CarGarage.ir Spark Plug Inspection Ignition Coil Assembly (Including ignitor) S5JB0A1806004 Removal and Installation S5JB0A1806005 CAUTION Removal 1) Disconnect negative cable at battery. • When servicing the iridium / platinum spark plugs (slender center electrode type 2) Remove engine cover. plugs), do not touch the center electrode 3) Disconnect ignition coil coupler.
Page 484: Ignition Coil Assembly (Including Ignitor) Inspection
1H-9 Ignition System: www.CarGarage.ir Ignition Coil Assembly (Including ignitor) Installation Inspection 1) Install ignition coil assembly (2). S5JB0A1806006 2) Tighten ignition coil bolts (1) to specified torque, and then connect ignition coil coupler. For M16 Engine Measure secondary coil for resistance. Tightening torque If resistance is out of specification, replace ignition coil Ignition coil bolt for M16 engine (a): 10 N·m (1.0...
Page 485: Special Tool
No.1 cylinder and check that ignition timing is within • CKP sensor specification. • CKP sensor plate Initial ignition timing (fixed with SUZUKI scan • TP sensor tool) 5° – 15° BTDC (at specified idle speed) (for J20 • CMP sensor engine) •...
Page 486 For the tightening torque of fastener not specified in this section, refer to “Fastener Information: in Section 0A”. Special Tools and Equipment Special Tool S5JB0A1808001 09930–76420 SUZUKI scan tool Timing-light (dry cell type) — This kit includes following items. 1. Tech 2, 2. PCMCIA card, 3.
Page 487: Starting System
Starting System: 1I-1 www.CarGarage.ir Starting System Precautions Cranking System Note S5JB0A1900001 NOTE Starting motor varies depending on specifications, etc. Therefore, be sure to check model and specification of the vehicle being serviced before replacing parts. General Description Cranking Circuit Introduction S5JB0A1901001 The cranking circuit consists of the battery, starting motor, ignition switch, and related electrical wiring.
Page 488: Diagnostic Information And Procedures
1I-2 Starting System: www.CarGarage.ir Diagnostic Information and Procedures Cranking System Symptom Diagnosis S5JB0A1904001 Possible symptoms due to starting system trouble would be as follows: • Starting motor does not run (or runs slowly) • Starting motor runs but fails to crank engine •...
Page 489: Starting Motor Performance Test
Starting System: 1I-3 www.CarGarage.ir Condition Possible cause Correction / Reference Item Starting motor running, Insufficient contact of magnetic switch Replace magnetic switch. but too slow (small main contacts torque) – Battery and Layer short-circuit of armature Replace. wiring are satisfactory Disconnected, burnt or worn Repair commutator or replace armature.
Page 490 1I-4 Starting System: www.CarGarage.ir Hold-In Test 1) While connected as above with plunger out, disconnect negative lead (2) from terminal “M” (1). 2) Check that plunger and pinion remain out. If plunger and pinion return inward, replace magnetic switch. IYSQ01190004-01 Plunger and Pinion Return Test 1) Disconnect negative lead (1) from switch body (2).
Page 491: Repair Instructions
Starting System: 1I-5 www.CarGarage.ir Repair Instructions Starting Motor Dismounting and Remounting S5JB0A1906001 I5JB0A190001-02 [A]: For M16 Engine : 11 N⋅m (1.1 kgf-m, 8.0 lb-ft) : 55 N⋅m (5.5 kgf-m, 40.0 lb-ft) [B]: For J20 Engine : 25 N⋅m (2.5 kgf-m, 18.5 lb-ft) Dismounting 1) Disconnect negative (–) battery lead at battery.
Page 492: Starting Motor Components
1I-6 Starting System: www.CarGarage.ir Starting Motor Components S5JB0A1906005 The starting motor consists of parts shown in below and has permanent magnets mounted in starting motor yoke (frame). The magnetic switch assembly and parts in the starting motor are enclosed in the housings so that they will be protected against possible dirt and water splash.
Page 493: Starting Motor Inspection
Starting System: 1I-7 www.CarGarage.ir Starting Motor Inspection Hold-In coil open circuit test S5JB0A1906004 Check for continuity across magnetic switch “S” terminal and coil case. If no continuity exists, coil is open and Plunger should be replaced. Inspect plunger for wear. Replace if necessary. IYSQ01190030-01 IYSQ01190027-01 Rear Bracket Bush...
Page 494 1I-8 Starting System: www.CarGarage.ir Brush Holder • Check movement of brush in brush holder. If brush movement within brush holder is sluggish, check brush holder for distortion and sliding faces for contamination. Clean or correct as necessary. • Check for continuity across insulated brush (positive side) and grounded brush (negative side).
Page 495 Starting System: 1I-9 www.CarGarage.ir Ground test Pinion and Over-Running Clutch Check the commutator and armature core. If there is • Inspect pinion for wear, damage or other abnormal continuity, armature is grounded and must be replaced. conditions. Check that clutch locks up when turned in direction of drive and rotates smoothly in reverse direction.
Page 496: Specifications
1I-10 Starting System: www.CarGarage.ir Specifications Starting Motor Specifications S5JB0A1907001 1.2 kW Type [1.4 kW Type] Voltage 12 volts Output 1.2 kW [1.4 kW] Rating 30 seconds Direction of rotation Clockwise as viewed from pinion side Brush length Standard: 12.3 mm (0.48 in.) Limit: 5.5 mm (0.22 in.) Number of pinion teeth Performance...
Page 497: Charging System
Charging System: 1J-1 www.CarGarage.ir Charging System General Description Battery Description S5JB0A1A01001 The battery has three major functions in the electrical system. • It is a source of electrical energy for cranking the engine. • It acts as a voltage stabilizer for the electrical system. •...
Page 498: Generator Description
1J-2 Charging System: www.CarGarage.ir • Green Dot: Battery is sufficiently charged for testing. • Dark: Battery must be charged before testing. If there is a cranking complaint, battery should be tested as described in “Battery Inspection: ”. Charging and electrical systems should also be checked at this time. •...
Page 499: Diagnostic Information And Procedures
Charging System: 1J-3 www.CarGarage.ir Charging System Circuit The generator features a solid state regulator that is mounted inside the generator. All regulator components are enclosed into a solid mold, and this unit along with the brush holder assembly is attached to the rear housing. The regulator voltage is being controlled by ECM under some conditions while driving.
Page 500: Generator Symptom Diagnosis
1J-4 Charging System: www.CarGarage.ir Generator Symptom Diagnosis S5JB0A1A04001 A charging circuit wiring diagram for generator connection is shown in “Generator Description: ”. To avoid damage, always follow these precautions: CAUTION • Do not mistake polarities of “IG” terminal and “L” terminal. •...
Page 501: Check)
Charging System: 1J-5 www.CarGarage.ir No-Load Check Load Check 1) Run engine from idling up to 2000 rpm and read 1) Run engine at 2000 rpm and turn on head light and meters. heater motor. 2) Measure current and if it is less than 30 A repair or NOTE replace generator.
Page 502: Repair Instructions
1J-6 Charging System: www.CarGarage.ir Repair Instructions Jump Starting in Case of Emergency 1) Set parking brake and place automatic transmission S5JB0A1A06004 in PARK (NEUTRAL on manual transmission). With Auxiliary (Booster) Battery 2) Turn OFF ignition switch, turn OFF lights and all other electrical loads.
Page 503: Battery Dismounting And Remounting
Charging System: 1J-7 www.CarGarage.ir Battery Dismounting and Remounting Water Pump and Generator Drive Belt Removal S5JB0A1A06005 and Installation (For M16 Engine) WARNING S5JB0A1A06011 Removal When handling battery, following safety 1) Disconnect negative cable at battery. precautions should be followed: 2) If vehicle equipped with A/C, remove compressor •...
Page 504: Water Pump And Generator Drive Belt Tension Inspection And Adjustment (For M16 Engine)
1J-8 Charging System: www.CarGarage.ir Water Pump and Generator Drive Belt Tension 3) If belt is too tight or too loose, adjust it to proper tension by displacing generator position. Inspection and Adjustment (For M16 Engine) S5JB0A1A06012 4) To adjust belt tension, loosen generator adjusting WARNING bolt (3) and displace generator position by loosening on tightening adjuster bolt.
Page 505: Water Pump And Generator Drive Belt On-Vehicle Inspection (For J20 Engine)
Charging System: 1J-9 www.CarGarage.ir Water Pump and Generator Drive Belt On-Vehicle Inspection (For J20 Engine) S5JB0A1A06013 [Type A] 1) Disconnect negative cable at battery. 2) Inspect belt for cracks, cuts, deformation, wear and cleanliness. If any of above conditions are found, replace belt, referring to “Water Pump and Generator Drive Belt Removal and Installation (For J20 Engine): ”.
Page 506: Water Pump And Generator Drive Belt Removal And Installation (For J20 Engine)
1J-10 Charging System: www.CarGarage.ir Water Pump and Generator Drive Belt Removal Installation and Installation (For J20 Engine) 1) Loosen tensioner by turning the tensioner pulley (2) S5JB0A1A06014 clockwise. Removal 2) While holding the tensioner, install generator belt (1). WARNING NOTE Disconnect negative (–) cable at battery •...
Page 507: Generator Dismounting And Remounting
Charging System: 1J-11 www.CarGarage.ir Generator Dismounting and Remounting S5JB0A1A06006 I5JB0A1A0003-02 [A]: For M16 Engine 4. Generator adjusting bolt (For M16 Engine) 9. Generator [B]: For J20 Engine 5. Generator mounting bolt (For J20 Engine) : 7.0 N⋅m (0.7 kgf-m, 5.0 lb-ft) 1.
Page 508: Generator Components
1J-12 Charging System: www.CarGarage.ir Dismounting 1) Disconnect negative (–) cable at battery. 2) Disconnect MAF sensor coupler (For J20 Engine). 3) Remove air cleaner case and air cleaner outlet hose (For J20 Engine). 4) Disconnect generator lead wire (“B” terminal wire) and coupler from generator. 5) Remove generator belt.
Page 509: Generator Inspection
Charging System: 1J-13 www.CarGarage.ir Generator Inspection S5JB0A1A06009 Rotor • Using ohmmeter, connect positive terminal to “FR” terminal and connect negative terminal to “B” terminal of generator, check that continuity between “B” terminal and “FR” terminal. If there is no continuity, replace rotor or regulator.
Page 510 1J-14 Charging System: www.CarGarage.ir Stator • Using ohmmeter, check all leads for continuity. If there is no continuity, replace stator (1). IYSQ011A0037-01 • Using ohmmeter, check that there is no continuity between coil leads (2) and stator core (1). If there is continuity, replace stator.
Page 511 Charging System: 1J-15 www.CarGarage.ir Rectifier 1) Using ohmmeter, check continuity between each of upper and lower rectifier bodies and each diode lead (2). Check both directions by reversing probes of ohmmeter and there should be only one-way continuity in each case. If check result is not satisfactory, replace rectifier (1).
Page 512: Tightening Torque Specifications
1J-16 Charging System: www.CarGarage.ir Specifications Charging System Specifications S5JB0A1A07001 Battery NOTE The battery used in each vehicle is one of the following two types, depending on specification. Battery type 55B24R (S) 55D23L Rated Capacity AH/5HR, 12 Volts Electrolyte L (US/Imp. pt) (6.55/5.46) (8.24/6.86) 1.28 when fully charged at 20 °C (68 °F)
Page 513: Exhaust System
Exhaust System: 1K-1 www.CarGarage.ir Exhaust System General Description Exhaust System Description S5JB0A1B01001 The exhaust system consists of an exhaust manifold, three-way catalytic converter (TWC) in catalyst case, exhaust pipes, a muffler and seals, gasket and etc. The three-way catalytic converter is an emission control device added to the exhaust system to lower the levels of Hydrocarbon (HC), Carbon Monoxide (CO), and Oxides of Nitrogen (NOx) pollutants in the exhaust gas.
Page 514 1K-2 Exhaust System: www.CarGarage.ir For M16 Engine Model I5JB0A1B1002-03 [A]: Installing location of exhaust manifold bold and nut. 9. Exhaust pipe No.2 18. Exhaust pipe No.1 bracket bolt 1. Exhaust manifold gasket 10. Exhaust center pipe 19. Exhaust center pipe nut 2.
Page 515 Exhaust System: 1K-3 www.CarGarage.ir For J20 Engine Model I5JB0A1B1003-05 [A]: Installing location of exhaust manifold bold and nut. 10. Exhaust center pipe 20. Exhaust center pipe gasket 1. Exhaust manifold gasket 11. Muffler 21. Muffler mounting 2. Exhaust manifold 12. Mounting 22.
Page 516: Exhaust Manifold Removal And Installation (For M16 Engine Model)
1K-4 Exhaust System: www.CarGarage.ir Exhaust Manifold Removal and Installation (For 2) Install exhaust pipe No.1 bracket (1). M16 Engine Model) Tightening torque S5JB0A1B06003 Exhaust pipe No.1 bracket bolt and nut (a): 50 N·m (5.0 kgf-m, 36.5 lb-ft) Removal WARNING To avoid danger of being burned, do not service exhaust system while it is still hot.
Page 517: Exhaust Pipe And Muffler Removal And Installation
Exhaust System: 1K-5 www.CarGarage.ir 7) Remove exhaust pipe No.1 bracket (1). 3) Install exhaust manifold cover (1). 8) Remove exhaust manifold (2) and its gasket (3) from 4) Connect water outlet pipe (2) from radiator inlet cylinder head. hose. 5) Connect fuel pipe (3) from fuel hoses. I5JB0A1B1008-01 6) Refill cooling system referring to “Cooling System I5JB0A1B1006-01...
Page 518: Specifications
1K-6 Exhaust System: www.CarGarage.ir Specifications Tightening Torque Specifications S5JB0A1B07001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Exhaust manifold bolt and nut 36.5 Exhaust pipe No.1 bracket bolt and nut 36.5 Exhaust No.1 pipe nut 36.5 NOTE The specified tightening torque is also described in the following. “Exhaust System Components: ”...

Suzuki Grand Vitara Service Manual

Precautions

Engine General Information and Diagnosis

Precautions

General Description

Schematic and Routing Diagram

Component Location

Diagnostic Information and Procedures

1 II Table of Contents

Repair Instructions

Special Tools and Equipment

Aux. Emission Control Devices

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Engine Electrical Devices

Repair Instructions

Specifications

Engine Mechanical

For M16A Engine with VVT

General Description

Diagnostic Information and Procedures

Repair Instructions

1 IV Table of Contents

Specifications

Special Tools and Equipment

For J20 Engine

General Description

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Engine Lubrication System

For M16A Engine with VVT

General Description

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

General Description

Quick Links

Related Manuals for Suzuki Grand Vitara

Summary of Contents for Suzuki Grand Vitara