Page 1 Either of these two conditions may result in severe injury. • If the air bag system and another vehicle system both need repair, SUZUKI recommends that the air bag system be repaired first, to help avoid unintended air bag system activation.
Page 2 Strict observance of the so specified items will enable one to obtain the full performance of the vehicle. When replacing parts or servicing by disassembling, it is recommended to use SUZUKI genuine parts, tools and service materials (lubricant, sealants, etc.) as specified in each description.
Page 3 RELATED MANUAL : MANUAL NAME MANUAL NO. APPLICABILITY GRAND VITARA/GRAND VITARA 99501-65D40-01E Transmission, Transfer and Differentials XL-7 (SQ416/SQ420/SQ625/JA627) (Front and Rear) of applicable model Unit Repair Manual mentioned in “Foreword” of this manual. GRAND VITARA/GRAND VITARA 99512-52D10-015 Applicable model mentioned in “Fore- XL-7 (SQ416/SQ420/SQ625/JA627) word”...
Page 4 Table of Contents GENERAL INFORMATION ENGINE General Information Engine General Information and Maintenance and Lubrication Diagnosis (G16/J20) HEATING AND AIR CONDITIONING Engine General Information and Heater and Ventilation Diagnosis (H25) Air Conditioning Engine Mechanical (G16) STEERING, SUSPENSION, WHEELS Engine Mechanical (H25) AND TIRES Engine Mechanical (J20) Front End Alignment...
Page 6: Table Of Contents
• Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
Page 7 6-2 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) Engine Diagnosis..........6-8 DTC P0136 HO2S-2 Circuit Malfunction ..6-78 DTC P0141 HO2S-2 Heater Circuit General Description ........6-8 Malfunction ............6-80 On-Board Diagnostic System (Vehicle DTC P0171 Fuel System Too Lean without Diagnosis Connector) ......6-8 DTC P0172 Fuel System Too Rich....6-82 On-Board Diagnostic System (Vehicle DTC P0300 Random Misfire Detected...
Page 8: Engine General Information And Diagnosis (G16/J20 Engines)
ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-3 Table B-8 A/C Condenser Fan Motor Special Tool........... 6-136 Relay Control System Inspection (Other than Canvas Top Model, If Equipped)..6-132 Table B-9 A/C Compressor Relay Control System Inspection (Other than Canvas Top Model, If Equipped)....6-134...
Page 9 6-4 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) General Information Statement of Cleanliness and Care An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the thousands of an millimeter (ten thousands of inch).
Page 10 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-5 General Information on Engine Service THE FOLLOWING INFORMATION ON ENGINE SERVICE SHOULD BE NOTED CAREFULLY, AS IT IS IMPORTANT IN PREVENTING DAMAGE, AND IN CONTRIBUTING TO RELI- ABLE ENGINE PERFORMANCE. • When raising or supporting engine for any reason, do not use a jack under oil pan.
Page 11: Exhaust System
6-6 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) Precaution on fuel system service • Work must be done with no smoking, in a well-ventilated area and away from any open flames. • As fuel feed line (between fuel pump and fuel pressure regu- lator) is still under high fuel pressure even after engine was stopped, loosening or disconnecting fuel feed line directly may cause dangerous spout of fuel to occur where loosened...
Page 12: Brakes
ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-7 Fuel pressure relief procedure CAUTION: This work must not be done when engine is hot. If done so, it may cause adverse effect to catalyst. After making sure that engine is cold, release fuel pressure as fol- lows.
Page 13: Engine Diagnosis
(For the details, refer to description on Freeze frame data.) • It is possible to communicate by using not only SUZUKI scan tool (3) but also generic scan tool. (Diagnostic information can be accessed by using a scan tool.)
Page 14 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-9 WARM-UP CYCLE A “warm-up cycle” means sufficient vehicle operation such that ° ° the coolant temperature has risen by at least 22 C (40 F) from ° engine starting and reaches a minimum temperature of 70 °...
Page 15 6-10 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) FREEZE FRAME DATE ECM (PCM) stores the engine and driving conditions (in the form of data as shown at the figure) at the moment of the detection of a malfunction in its memory. This data is called “Freeze frame data”. Therefore, it is possible to know engine and driving conditions (e.g.,whether the engine was warm or not, where the vehicle was running or stopped, where air/fuel mixture was lean or rich) when...
Page 16 DLC (1) in compliance with SAE J1962 in its installation position, the shape of connector and pin assignment. K line of ISO 9141 (4) is used for SUZUKI scan tool or generic scan tool to communication with ECM (PCM) and ABS control module.
Page 17: On-Board Diagnostic System (Vehicle With Diagnosis Connector)
6-12 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) On-Board Diagnostic System (Vehicle with Diagnosis Connector) ECM diagnosis troubles which may occur in the area including the following parts when the ignition switch is ON and the engine is running, and indicates the result by turning on or flashing mal- function indicator lamp (1).
Page 18: Precaution In Diagnosing Trouble
(DTC, freeze frame data, etc.) stored in ECM (PCM) memory. • Diagnostic information stored in ECM (PCM) memory can be cleared as well as checked by using SUZUKI scan tool or generic scan tool. Before using scan tool, read its Operator’s (Instruction) Manual carefully to have good understanding as to what functions are available and how to use it.
Page 19: Engine Diagnostic Flow Table
6-14 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) Engine Diagnostic Flow Table Refer to the following pages for the details of each step. Step Action Customer Complaint Analysis Go to Step 2. Perform customer com- 1) Perform customer complaint analysis refer- plaint analysis.
Page 20 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-15 Step Action Check for Intermittent Problems Repair or replace mal- Go to Step 11. 1) Check for intermittent problems referring to function part(s). “Check for Intermittent Problem” in the fol- Go to Step 11. lowing.
Page 21 6-16 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 8. ENGINE BASIC CHECK AND ENGINE DIAGNOSIS TABLE Perform basic engine check according to the “Engine Basic Check” first. When the end of the flow table has been reached, check the parts of the system suspected as a possible cause referring to “Engine Diagnosis Table”...
Page 22: Customer Problem Inspection Form (Example)
ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-17 Customer Problem Inspection Form (Example) NOTE: The above form is standard sample. It should be modified according to conditions characteristic of each market.
Page 23: Malfunction Indicator Lamp (Mil) Check
[B] : Canvas top model Diagnostic Trouble Code (DTC) Check [Using SUZUKI Scan Tool] 1) Prepare generic scan tool or SUZUKI scan tool. 2) Connect it to data link connector (DLC) (1) located on under- side of instrument panel at driver’s seat side.
Page 24 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-19 [Not using SUZUKI scan tool] (vehicle with monitor con- nector only) 1) Check malfunction indicator lamp referring to “Malfunction Indicator Lamp Check” in this section. 2) With the ignition switch OFF position, disconnect SUZUKI...
Page 25: Diagnostic Trouble Code (Dtc) Clearance
6-20 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) Diagnostic Trouble Code (DTC) Clearance [Using Scan Tool] 1) Connect generic scan tool or SUZUKI scan tool to data link connector in the same manner as when making this connec- tion for DTC check.
Page 26: Fail-Safe Table
ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-21 Fail-Safe Table When any of the following DTCs is detected, ECM (PCM) enters fail-safe mode as long as malfunction continues to exist but that mode is canceled when ECM detects normal condition after that. DTC NO.
Page 27: Diagnostic Trouble Code (Dtc) Table
6-22 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) Diagnostic Trouble Code (DTC) Table (vehicle (vehicle DETECTING CONDITION DETECTING ITEM without with moni- (DTC will set when detecting :) monitor tor connec- connector) tor) P0100 Sensor output low voltage (or MAF sensor (No.34) Mass air flow circuit mal- circuit shorted to ground) 1 driving...
Page 28 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-23 (vehicle (vehicle DETECTING CONDITION DETECTING ITEM without with moni- (DTC will set when detecting :) monitor tor connec- connector) tor) Short term fuel trim or total fuel trim (short- vand long term added) is smaller 2 driving Not applica- P0172 Fuel system too rich...
Page 29 6-24 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) (vehicle (vehicle DETECTING CONDITION DETECTING ITEM without with moni- (DTC will set when detecting :) monitor tor connec- connector) tor) Difference between manifold absolute pressure (MAP sensor value) and baro- Barometric pressure sen- 2 driving Not applica- P1451...
Page 30 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-25 DETECTING CONDITION DTC NO. DETECTING ITEM (DTC will set when detecting :) P0705 Transmission Range Switch Circuit Malfunc- (No.72) tion P0715 Input/Turbine Speed Sensor Circuit Malfunc- (No.76) tion P0720 Output Speed Sensor Circuit Malfunction (No.75) Torque Converter Clutch Circuit Performance P0741...
Page 31: Scan Tool Data
✱ • For asterisk ( ) marked item in OTHER column, item can be read only SUZUKI scan tool. • When checking the data with the engine running at idle or racing, be sure to shift M/T gear to the neutral gear position and A/T gear to the “Park”...
Page 32 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-27 NORMAL CONDITION/ SCAN TOOL DATA CONDITION OTHER REFERENCE VALUE INJ PULSE WIDTH At specified idle speed with no load after 1.5 – 4.5 msec ✱ (Fuel Injection Pulse Width) warming up. At 2500 r/min. with no load after warming 1.5 –...
Page 33 6-28 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) NORMAL CONDITION/ SCAN TOOL DATA CONDITION OTHER REFERENCE VALUE BRAKE SW Ignition switch Brake pedal is depress- Brake pedal is releas- BLOWER FAN Ignition switch Blower fan switch ON Blower fan switch OFF A/C CONDENSER FAN Ignition switch A/C not operating...
Page 34: Scan Tool Data Definitions
ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-29 NORMAL CONDITION/ SCAN TOOL DATA CONDITION OTHER REFERENCE VALUE MODE SELECT SW Ignition switch ON, P/N change switch is NORMAL (Power/Normal Change at normal position. ✱ Switch) Ignition switch ON, P/N change switch is POWER at power position.
Page 35 6-30 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) MAF (MASS AIR FLOW RATE, g/s, lb/min.) It represents total mass of air entering intake manifold which is measured by mass air flow sensor. CALC LOAD (CALCULATED LOAD VALUE, %) Engine load displayed as a percentage of maximum possible load. Value is calculated mathematically using the ÷...
Page 36 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-31 CANIST PRG DUTY (EVAP CANISTER PURGE FLOW DUTY, %) This parameter indicates valve ON (valve open) time rate within a certain set cycle of EVAP canister purge valve which controls the amount of EVAP purge. FUEL TANK LEVEL (%) This parameter indicates approximate fuel level in the fuel tank.
Page 37 6-32 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) GEAR POSITION (1ST, 2ND, 3RD or 4TH) The gear position is determined on the basis of the command state signals generated from PCM (ECM) to shift solenoids A and B ( 1 and 2) and displayed as shown in the table below.
Page 38: Visual Inspection
ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-33 MODE SELECT SW (POWER/NORMAL CHANGE SWITCH, POWER/NORMAL) POWER : Switch button is at POWER position. NORMAL : Switch button is at NORMAL position. 4WD-L SW (4WD-LOW SWITCH, ON/OFF) ON : Transfer lever is shifted to 4L position. OFF : Transfer lever is shifted to 4H or 2H position.
Page 39: Engine Basic Check
6-34 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) Engine Basic Check This check is very important for troubleshooting when ECM (PCM) has detected no DTC and no abnormality has been found in visual inspection. Follow the flow table carefully. Step Action Was “Engine Diag.
Page 40: Engine Diagnosis Table
ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-35 Engine Diagnosis Table Perform troubleshooting referring to following table when ECM (PCM) has detected no DTC and no abnormality has been found in visual inspection and engine basic inspection previously. Condition Possible Cause Correction Hard starting Engine and emission control system...
Page 41 6-36 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) Condition Possible Cause Correction Engine has no power Engine overheating. Refer to “Overheating” in this table. Ignition system out of order. • Defective spark plug. “Spark Plugs” in Section 6F1 or 6F2. •...
Page 42 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-37 Condition Possible Cause Correction Improper engine Ignition system out of order. idling or engine fails • Faulty spark plug “Spark Plugs” in Section 6F1 or 6F2. to idle • Faulty ignition coil with ignitor “Ignition Coil Assembly”...
Page 43 6-38 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) Condition Possible Cause Correction Surges Ignition system out of order. (Engine power varia- • Defective spark plug (excess carbon “Spark Plugs” in Section 6F1 or 6F2. tion under steady deposits, improper gap, and burned throttle or cruise.
Page 44 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-39 Condition Possible Cause Correction Overheating • Inoperative thermostat “Thermostat” in Section 6B. • Poor water pump performance “Water Pump” in Section 6B. • Clogged or leaky radiator “Radiator” in Section 6B. • Improper engine oil grade “Engine Oil and oil Filter Change”...
Page 45 6-40 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) Condition Possible Cause Correction Excessive engine oil Oil entering combustion chamber consumption • Sticky piston ring “Pistons, Piston Rings, Connecting Rods and Cylinders” in Section 6A1 or 6A4. • Worn piston and cylinder “Pistons, Piston Rings, Connecting Rods and Cylinders”...
Page 46 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-41 Condition Possible Cause Correction Engine noise Valve noise See NOTE below. • Faulty hydraulic valve lash adjuster “Camshafts and Valve Lash Adjuster” in Section 6A4. • Worn valve stem and guide “Valves and Cylinder Head” in Section 6A1 or 6A4.
Page 47: Inspection Of Pcm (Ecm) And Its Circuits
6-42 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) Inspection of PCM (ECM) and Its Circuits PCM (ECM) and its circuits can be checked at PCM (ECM) wiring couplers by measuring voltage, pulse signal and resistance. CAUTION: PCM/ECM cannot be checked by itself. It is strictly pro- hibited to connect voltmeter or ohmmeter to PCM (ECM) with couplers disconnected from it.
Page 48: Ignition Switch On
ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-43 WIRE NORMAL TERMINAL CIRCUIT CONDITION COLOR VOLTAGE Output of 5 V power source GRY/RED for CO adjusting resistor (if 4.5 – 5.5 V Ignition switch turned ON equipped) Power source for ECM Regardless of ignition switch posi- 10 –...
Page 49 6-44 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) WIRE NORMAL TERMINAL CIRCUIT CONDITION COLOR VOLTAGE PPL/GRN (Canvas Top model) Serial communication line PPL/RED of data link connector 12 V 10 – 14 V Ignition switch turned ON (other than (if equipped) Canvas Top model) Test switch terminal (if...
Page 50 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-45 WIRE NORMAL TERMINAL CIRCUIT CONDITION COLOR VOLTAGE Ignition switch turned ON, Engine coolant temperature under 113°C, 10 – 14 V 235°F or A/C request signal high A/C condenser fan motor input YEL/BLU relay output (Canvas Top Ignition switch turned ON, Engine model, if equipped)
Page 51 6-46 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) WIRE NORMAL TERMINAL CIRCUIT CONDITION COLOR VOLTAGE Ignition switch turned ON, A/T 0 – 1 V Power mode/Normal mode selector Selector switch signal of selected at Power mode ORN/BLU Power mode/Normal mode Ignition switch turned ON, A/T for A/T 10 –...
Page 52 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-47 WIRE NORMAL TERMINAL CIRCUIT CONDITION COLOR VOLTAGE Ignition switch turned ON with baro- 3.3 – 4.3 V metric pressure at 100kPa, Manifold absolute pressure 760mmHg RED/WHT (MAP) sensor signal (if While specified idle speed with equipped) 3.3 –...
Page 53 6-48 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) WIRE NORMAL TERMINAL CIRCUIT CONDITION COLOR VOLTAGE Ignition switch turned ON, Engine coolant temperature under 113°C, 10 – 14 V A/C condenser fan motor 235°F or A/C request signal high relay output (other than input YEL/BLU Canvas Top model, if...
Page 54 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-49 WIRE NORMAL TERMINAL CIRCUIT CONDITION COLOR VOLTAGE Ignition switch turned ON, Selector 10 – 14 V “D” position signal for trans- switch selected at “D” position YEL/GRN mission range selector Ignition switch turned ON, Selector switch (A/T) 0 –...
Page 55 6-50 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) WIRE NORMAL TERMINAL CIRCUIT CONDITION COLOR VOLTAGE Ignition switch turned ON, Transfer 0 – 1 V selector lever selected at “4L” posi- tion ORN/WHT 4WD Low (4L) switch signal Ignition switch turned ON, Transfer 10 –...
Page 56 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-51 WIRE NORMAL TERMINAL CIRCUIT CONDITION COLOR VOLTAGE Ignition switch turned ON, Transfer 10 – 14 V selector selected at “4L” or “4H” 4WD air pump assembly position output Ignition switch turned ON, Transfer 0 –...
Page 57 6-52 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) WIRE NORMAL TERMINAL CIRCUIT CONDITION COLOR VOLTAGE 10 – 14 V Ignition switch turned ON *0 – 1 V While engine running ↑ ↓ LT GRN/ EGR valve (stepper motor (Output signal is active low duty coil 2) output (if equipped) 8 –...
Page 58 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-53 WIRE NORMAL TERMINAL CIRCUIT CONDITION COLOR VOLTAGE 0 – 0.6 V Ignition switch turned ON *0 – 0.6 V Engine running ↑ ↓ Ignition coil No.4 output (for BRN/YEL (Output signal is active high pulse. J20 engine) 2 –...
Page 59 6-54 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) RESISTANCE CHECK 1) Disconnect couplers from ECM/PCM with ignition switch OFF. CAUTION: Never touch terminals of ECM/PCM itself or connect volt- meter or ohmmeter. 2) Check resistance between each pair of terminals of discon- nected couplers as listed in the following table.
Page 60 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-55 STANDARD TERMINALS CIRCUIT CONDITION RESISTANCE Ω E61-3 and C51-3-20 Heater of HO2S-2 (if equipped) 11.7 – 14.3 – Ω 79 – 95 (Canvas Top model) Ω E61-9 and E61-2 Main relay 160 – 240 (other –...
Page 61: Or Dims At Ignition Switch On (But Engine At Stop)
6-56 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) Table A-1 Malfunction Indicator Lamp Circuit Check – MIL Does Not Come “ON” or Dims at Ignition Switch On (But Engine at Stop) WIRING DIAGRAM [A] : Canvas top model 1. ECM (PCM) 3.
Page 62: Circuit Check – Mil Remains "On After Engine Starts
ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-57 INSPECTION Step Action MIL Power Supply Check : Go to Step 2. “IG” fuse blown, main fuse 1) Turn ignition switch ON. blown, Ignition switch mal- Do other indicator/warning lights in combination function, “BLK/WHT”...
Page 63: Connector)
6-58 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) Table A-3 MIL Check – MIL Flashes at Ignition Switch On (Vehicle with Monitor Connector) WIRING DIAGRAM/CIRCUIT DESCRIPTION Refer to TABLE A-1. INSPECTION Step Action MIL Flashing Pattern Check : Go to Step 2. Go to “Diagnosis”...
Page 64: Switch On And Engine Doesn't Start Though It Is Cranked Up
ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-59 Table A-5 ECM (PCM) Power and Ground Circuit Check – MIL Doesn’t Light at Ignition Switch On and Engine Doesn’t Start Though It Is Cranked Up. WIRING DIAGRAM [A] : Canvas top model 1.
Page 65 6-60 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) INSPECTION Step Action Main Relay Operating Sound Check : Go to Step 5. Go to Step 2. Is operating sound of main relay heard at igni- tion switch ON? Fuse Check : Go to Step 3.
Page 66: Dtc P0100 (Dtc No.33, 34) Mass Air Flow Circuit Malfunction
ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-61 DTC P0100 (DTC No.33, 34) Mass Air Flow Circuit Malfunction WIRING DIAGRAM 1. Main fuse 2. Main relay 3. Mass air flow sensor 4. ECM (PCM) DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Following conditions are detected for 5 sec.
Page 67 6-62 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) TROUBLESHOOTING Step Action Was “Engine Diag. Flow Table” performed? Go to Step 2. Go to “Engine Diag. Flow Table”. MAF sensor Check : Intermittent trouble. Go to Step 3. 1) Connect scan tool to DLC with ignition Check for intermittent switch OFF.
Page 68: Dtc P0110 (Dtc No.23, 25) Intake Air Temp. (Iat) Circuit Malfunction
ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-63 DTC P0110 (DTC No.23, 25) Intake Air Temp. (IAT) Circuit Malfunction WIRING DIAGRAM 1. IAT sensor 2. ECM (PCM) DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Following conditions are detected. •...
Page 69 6-64 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) TROUBLESHOOTING Step Action Was “Engine Diag. Flow Table” performed? Go to Step 2. Go to “Engine Diag. Flow Table”. Check IAT Sensor and Its Circuit. Go to Step 3. Intermittent trouble. 1) Connect scan tool with ignition switch OFF. Check for intermittent 2) Turn ignition switch ON.
Page 70: Dtc P0115 (Dtc No.14, 15) Engine Coolant Temp. Sensor Circuit Malfunction
ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-65 DTC P0115 (DTC No.14, 15) Engine Coolant Temp. Sensor Circuit Malfunction WIRING DIAGRAM 1. ECT sensor 2. To combination (ECT) meter (canvas top model) ECM (PCM) DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Following conditions are detected for 5 sec.
Page 71 6-66 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) TROUBLESHOOTING Step Action Was “Engine Diag. Flow Table” performed? Go to Step 2. Go to “Engine Diag. Flow Table”. Check ECT Sensor and Its Circuit. Go to Step 3. Intermittent trouble. 1) Connect scan tool with ignition switch OFF. Check for intermittent 2) Turn ignition switch ON.
Page 72: Dtc P0120 (Dtc No.21, 22) Throttle Position Circuit Malfunction
ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-67 DTC P0120 (DTC No.21, 22) Throttle Position Circuit Malfunction WIRING DIAGRAM 1. Throttle position sensor 2. ECM (PCM) DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Following conditions are detected for 5 sec. continuously. •...
Page 73 6-68 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) TROUBLESHOOTING Step Action Was “Engine Diag. Flow Table” performed? Go to Step 2. Go to “Engine Diag. Flow Table”. Check TP Sensor and Its Circuit. Go to Step 3. Intermittent trouble. 1) Connect scan tool to DLC with ignition Check for intermittent switch OFF and then turn ignition switch referring to “Intermittent...
Page 74: Dtc P0121 Throttle Position Range/Performance Problem
ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-69 DTC P0121 Throttle Position Range/Performance Problem WIRING DIAGRAM Refer to DTC P0120. DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Throttle opening change is smaller than specification while • TP sensor intake air volume changes and engine is •...
Page 75 Go to Step 5. Check TP Sensor and its Circuit. If voltmeter was used, Go to Step 6. 1) Turn ignition switch OFF and connect SUZUKI check terminal C51-3-9 scan tool to DLC. for poor connection. 2) Turn ignition switch ON and check TP sensor out-...
Page 76: Dtc P0130 (Dtc No.13) Ho2S-1 Circuit Malfunction
ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-71 DTC P0130 (DTC No.13) HO2S-1 Circuit Malfunction WIRING DIAGRAM 1. To ignition switch 3. Fuse box 2. HO2S-1 4. ECM (PCM) DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Following conditions are detected in idle state while running •...
Page 77 6-72 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) DTC CONFIRMATION PROCEUDRE WARNING: • When performing a road test, select a place where there is no traffic or possibility of a traffic acci- dent and be very careful during testing to avoid occurrence of an accident. •...
Page 78 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-73 TROUBLESHOOTING (DTC P0130) Step Action Was “Engine Diag. Flow Table” performed? Go to Step 2. Go to “Engine Diag. Flow Table”. HO2S-1 Output Voltage Check : Go to Step 4. Go to Step 3. 1) Connect scan tool to DLC with ignition switch OFF.
Page 79: Dtc P0133 Ho2S-1 Circuit Slow Response
6-74 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) DTC P0133 HO2S-1 Circuit Slow Response WIRING DIAGRAM Refer to DTC P0130. DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Following conditions are detected in idle state while running •...
Page 80: Dtc P0134 Ho2S-1 No Activity Detected
ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-75 DTC P0134 HO2S-1 No Activity Detected WIRING DIAGRAM Refer to DTC P0130. DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Following conditions are detected in vehicle running state • HO2S-1 or its circuit while running under driving conditions described for “DTC •...
Page 81: Dtc P0135 Ho2S-1 Heater Circuit Malfunction
6-76 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) DTC P0135 HO2S-1 Heater Circuit Malfunction WIRING DIAGRAM Refer to DTC P0130. DTC DETECTING CONDITIN AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Following condition is detected when HO2S heater is electri- •...
Page 82 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-77 TROUBLESHOOTING (DTC P0135) Step Action Was “Engine Diag. Flow Table” performed? Go to Step 2. Go to “Engine Diag. Flow Table”. HO2S-1 Heater Check : Go to Step 3. Replace HO2S-1. 1) Disconnect HO2S-1 coupler with ignition switch OFF.
Page 83: Dtc P0136 Ho2S-2 Circuit Malfunction
6-78 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) DTC P0136 HO2S-2 Circuit Malfunction WIRING DIAGRAM [A] : Canvas top model 1. To ignition switch 3. Fuse box [B] : Other than canvas top model 2. HO2S-2 4. ECM (PCM) DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA DTC will set when any one of following conditions is detected.
Page 84 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-79 NOTE: Check to make sure that the following conditions are satisfied when using this “DTC Confirmation Procedure”. • Intake air temp. : –8°C, 18°F or higher • Engine coolant temp. : –8 – 110°C (18 – 230°F) •...
Page 85: Dtc P0141 Ho2S-2 Heater Circuit Malfunction
6-80 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) DTC P0141 HO2S-2 Heater Circuit Malfunction WIRING DIAGRAM Refer to DTC P0136. DTC DETECTING CONDITION AND TROUBLE ARE DTC DETECTING CONDITION TROUBLE AREA Following condition is detected when HO2S-2 heater operates. • HO2S-2 heater or its circuit •...
Page 86 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-81 TROUBLESHOOTING (DTC P0141) Step Action Was “Engine Diag. Flow Table” performed? Go to Step 2. Go to “Engine Diag. Flow Table”. HO2S-2 Heater Check : Go to Step 3. Replace HO2S-2. 1) Disconnect HO2S-2 coupler with ignition switch OFF.
Page 87: Dtc P0171 Fuel System Too Lean Dtc P0172 Fuel System Too Rich
6-82 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) DTC P0171 Fuel System Too Lean DTC P0172 Fuel System Too Rich SYSTEM DIAGRAM Refer to “Electronic Control System Description” in Section 6E1. DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA When running after engine warmed •...
Page 88 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-83 TROUBLESHOOTING (DTC P0171/P0172) Step Action Was “Engine Diag. Flow Table” performed? Go to Step 2. Go to “Engine Diag. Flow Table”. Is there DTC(s) other than “DTC P0171/ Go to applicable “DTC Go to Step 3.
Page 89: Dtc P0300 Random Misfire Detected
6-84 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) DTC P0300 Random Misfire Detected DTC P0301 Cylinder 1 Misfire Detected DTC P0302 Cylinder 2 Misfire Detected DTC P0303 Cylinder 3 Misfire Detected DTC P0304 Cylinder 4 Misfire Detected SYSTEM DESCRIPTION ECM (PCM) measures the angle speed of the crankshaft based on the pulse signal from the CKP sensor and CMP sensor for each cylinder.
Page 90 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-85 TROUBLESHOOTING (DTC P0300/P0301/P0302/P0303/P0304) Step Action Was “Engine Diag. Flow Table” performed? Go to Step 2. Go to “Engine Diag. Flow Table”. Ignition System Inspection : Go to Step 3. Faulty ignition coil, wire 1) Check spark plug and ignition spark of cylinder harness, or other system where misfire occurs, referring to “Spark Plug”...
Page 91: Dtc P0325 (Dtc No.43) Knock Sensor Circuit Malfunction
6-86 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) DTC P0325 (DTC No.43) Knock Sensor Circuit Malfunction WIRING DIAGRAM Knock sensor 2. ECM (PCM) DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA • Knock sensor output voltage : 3.98 V or more •...
Page 92 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-87 Step Action 1) Stop engine. Substitute a known-good “RED/BLU” wire open, 2) With ignition switch at OFF position, discon- knock sensor and shorted to ground circuit nect knock sensor connector. recheck. or poor C51-3-3 connec- 3) With ignition switch at ON position, check tion.
Page 93: Dtc P0335 Crankshaft Position Sensor Circuit Malfunction
6-88 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) DTC P0335 Crankshaft Position Sensor Circuit Malfunction WIRING DIAGRAM [A] : G16 Engine 1. CKP sensor 3. Sensor plate on crankshaft [B] : J20 Engine 2. Crankshaft timing belt pulley 4. ECM (PCM) REFERENCE Connect oscilloscope between terminals C51-2-19 (+) and C51-2-20 (–) of ECM (PCM) connector connected to ECM (PCM) and check CKP sensor signal.
Page 94 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-89 DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA CKP sensor signal is not input while 20 pulses of CMP sen- • CKP sensor circuit sor signal are input after engine start. •...
Page 95 6-90 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) Step Action CKP Sensor Visual Inspection : Intermittent trouble or Replace or reinstall. 1) Check visually CKP sensor and signal rotor faulty ECM (PCM). (crankshaft timing belt pulley for G16 or CKP Recheck for intermittent sensor plate (4) on crankshaft for J20) for the referring to “Intermittent...
Page 96: Dtc P0340 (Dtc No.42) Camshaft Position Sensor Circuit Malfunction
ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-91 DTC P0340 (DTC No.42) Camshaft Position Sensor Circuit Malfunction WIRING DIAGRAM [A] : G16 Engine 1. Signal rotor on camshaft 3. To main relay [B] : J20 Engine 2. CMP sensor 4. ECM (PCM) REFERENCE Connect oscilloscope between terminals C51-2-26 and C51-3-26 (ground) of ECM (PCM) connector connected to ECM (PCM) and check CMP sensor signal.
Page 97 6-92 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) DTC CONFIRMATION PROCEDURE NOTE: Check to make sure that the following conditions are satisfied when using this “DTC Confirmation Procedure”. • Intake air temp. : –8°C, 18°F or higher • Engine coolant temp. : –8 – 110°C (18 – 230°F) •...
Page 98 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-93 Step Action Check CMP Sensor (2) for Operation as follows. Go to Step 9. Replace CMP sensor. 1) Remove CMP sensor (2) from sensor case. 2) Remove metal particles on end face of CMP sen- sor (2), if any.
Page 99 6-94 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) [A] Fig. for Step 5 / [B] Fig. for Step 8 G16 / [C] Fig. for Step 10 J20 / [D] Fig. for Step 9 G16 / [E] Fig. for Step 11 J20...
Page 100: Dtc P0400 Exhaust Gas Recirculation Flow Malfunction
ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-95 DTC P0400 Exhaust Gas Recirculation Flow Malfunction SYSTEM / WIRING DIAGRAM [A] : Canvas top model 2. Intake manifold 5. Main fuse 8. Fuse box [B] : Other than Canvas top model 3.
Page 101 6-96 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA During deceleration (engine speed high with closed throttle • EGR valve position) in which fuel cut is involved, difference in intake •...
Page 102 Go to Step 6. EGR Valve Operation Check : Go to Step 5. Go to Step 6. 1) With ignition switch OFF, install SUZUKI scan tool. 2) Check EGR system referring to “EGR Sys- tem” in Section 6E1. Is it in good condition?
Page 103: Dtc P0403 (Dtc No.51) Exhaust Gas Recirculation Circuit Malfunction
6-98 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) DTC P0403 (DTC No.51) Exhaust Gas Recirculation Circuit Malfunction WIRING DIAGRAM 1. Main fuse 3. EGR valve 2. Main relay 4. Fuse box DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Low voltage is detected at EGR valve stepping motor electri- •...
Page 104 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-99 TROUBLESHOOTING (DTC P0403/DTC No.51) Step Action Was “Engine Diag. Flow Table” performed? Go to Step 2. Go to “Engine Diag. Flow Table”. EGR Valve Check : Go to Step 3. EGR valve malfunction. 1) With ignition switch OFF, disconnect con- nector from EGR valve.
Page 105: Dtc P0420 Catalyst System Efficiency Below Threshold
6-100 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) DTC P0420 Catalyst System Efficiency Below Threshold SYSTEM DIAGRAM [A] : Canvas top model 2. Heated oxygen sensor-2 5. ECM (PCM) [B] : Other than canvas top model 3. Warm up three way catalytic converter (WU-TWC, if equipped) 1.
Page 106 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-101 DTC CONFIRMATION PROCEDURE WARNING: • When performing a road test, select a place where there is no traffic or possibility of a traffic acci- dent and be very careful during testing to avoid occurrence of an accident. •...
Page 107: Dtc P0443 Evap Control System Purge Control Valve Circuit Malfunction
6-102 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) DTC P0443 EVAP Control System Purge Control Valve Circuit Malfunction WIRING DIAGRAM 1. Main relay 3. EVAP canister purge valve 5. ECM (PCM) 2. Main fuse 4. Fuse box DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Monitor signal of EVAP canister purge valve is different from...
Page 108: Evap Canister Purge System Check
ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-103 TROUBLESHOOTING (DTC P0443) Step Action Was “Engine Diag. Flow Table” performed? Go to Step 2. Go to “Engine Diag. Flow Table”. Check EVAP canister purge system for opera- Intermittent trouble or Go to Step 3. tion referring to “EVAP Canister Purge System faulty ECM (PCM).
Page 109: Evap Canister Purge Valve Inspection
6-104 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) EVAP canister purge valve inspection 1) With ignition switch OFF, disconnect coupler from canister purge valve. 2) Check resistance between two terminals of EVAP canister purge valve. If resistance is as specified, proceed to next operation check. If not, replace.
Page 110: Dtc P0460 Fuel Level Sensor Circuit High Input
ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-105 DTC P0460 Fuel Level Sensor Circuit High Input WIRING DIAGRAM 1. Fuel level sensor 2. Fuel meter in combination meter 3. ECM (PCM) DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Fuel level sensor output voltage higher than specified •...
Page 111 6-106 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) TROUBLESHOOTING Step Action Was “Engine Diag. Flow Table” performed? Go to Step 2. Go to “Engine Diag. Flow Table” in this section. Does fuel level meter in combination meter indi- Replenish fuel tank with Go to Step 3.
Page 112: Dtc P0500 (Dtc No.24) Vehicle Speed Sensor Malfunction
ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-107 DTC P0500 (DTC No.24) Vehicle Speed Sensor Malfunction WIRING DIAGRAM 1. Speedometer for canvas top model, BCM except for canvas top model 2. To main relay 3. Vehicle speed sensor DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Vehicle speed signal not inputted although fuel is kept...
Page 113 6-108 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) TROUBLESHOOTING (DTC P0500/DTC No.24) Step Action Was “Engine Diag. Flow Table” performed? Go to Step 2. Go to “Engine Diag. Flow Table”. Does speedometer indicate vehicle speed? Faulty “BLU/YEL” wire or Go to Step 3. poor C51-2-25 connec- tion.
Page 114: Dtc P0505 Idle Air Control System Malfunction
ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-109 DTC P0505 Idle Air Control System Malfunction SYSTEM / WIRING DIAGRAM 1. Throttle body 3. ECM (PCM) 5. Main fuse 7. Fuse box 2. Idle air control valve 4. Sensed information 6. Main relay 8.
Page 115 6-110 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) DTC CONFIRMATION PROCEDURE NOTE: Check to make sure that the following conditions are satisfied when using this “DTC Confirmation Procedure”. • Intake air temp. : –8°C, 18°F or higher • Engine coolant temp. : –8 – 110°C (18 – 230°F) •...
Page 116 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-111 Step Action Was idle speed higher than specification in Check abnormal air inhal- Check parts or system Step 2? ing from intake manifold, which can cause engine throttle body, PCV valve low idle. and EVAP canister purge •...
Page 117: Dtc P0601 (Dtc No.71) Internal Control Module Memory Check Sum Error
6-112 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) DTC P0601 (DTC No.71) Internal Control Module Memory Check Sum Error SYSTEM DESCRIPTION Internal control module is installed in ECM (PCM). DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Data write error or check sum error ECM (PCM) DTC CONFIRMATION PROCEDURE...
Page 118: Dtc P1408 Manifold Absolute Pressure Sensor Circuit Malfunction
ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-113 DTC P1408 Manifold Absolute Pressure Sensor Circuit Malfunction WIRING DIAGRAM [A] : Canvas top model 1. Manifold absolute pressure sensor [B] : Other than canvas top model 2. ECM (PCM) DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA •...
Page 119 6-114 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) TROUBLESHOOTING (DTC P1408) Step Action Was “Engine Diag. Flow Table” performed? Go to Step 2. Go to “Engine Diag. Flow Table”. MAP Sensor Signal Check : Intermittent trouble or Go to Step 3. 1) Remove ECM (PCM) cover.
Page 120: Dtc P1450 Barometric Pressure Sensor Circuit Malfunction Dtc P1451 Barometric Pressure Sensor Performance Problem
ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-115 DTC P1450 Barometric Pressure Sensor Circuit Malfunction DTC P1451 Barometric Pressure Sensor Performance Problem SYSTEM DESCRIPTION Barometric pressure sensor is installed in ECM (PCM). DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA DTC P1450 : •...
Page 121: Dtc P1500 Engine Starter Signal Circuit Malfunction
6-116 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) DTC P1500 Engine Starter Signal Circuit Malfunction WIRING DIAGRAM [A] : M/T vehicle 1. To starting motor 3. Engine start switch in ignition (main) switch [B] : A/T vehicle 2. Transmission range sensor (switch) 4.
Page 122: Dtc P1510 Ecm Back-Up Power Supply Malfunction
ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-117 DTC P1510 ECM Back-Up Power Supply Malfunction WIRING DIAGRAM 1. Fuse box 2. Main fuse box 3. To DLC 4. ECM (PCM) CIRCUIT DESCRIPTION Battery voltage is supplied to keep DTC memory, values that ECM has learned to control engine, etc. in ECM even when ignition switch is turned OFF.
Page 123: Inspection
6-118 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) Table B-1 Fuel Pump Circuit Inspection WIRING DIAGRAM [A] : Canvas top model and other than canvas top model with immobilizer 2. Fuel pump relay 5. Fuel pump control system [B] : Other than canvas top model with immobilizer control system 3.
Page 124 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-119 Fig. for Step 2 [A] : Left hand steering vehicle (canvas top model) [B] : Right hand steering vehicle (canvas top model) [C] : Left hand steering vehicle (other than canvas top model) [D] : Right hand steering vehicle (other than canvas top model)
Page 125: Inspection
6-120 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) Table B-2 Fuel Injectors and Circuit Inspection WIRING DIAGRAM 1. Main relay 3. Injector No.2 5. Injector No.4 7. ECM (PCM) 2. Injector No.1 4. Injector No.3 6. To ignition switch INSPECTION Step Action Check Injector for Operating Sound.
Page 126 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-121 Step Action Check power circuit of injectors for open and Check all 4 injectors for Power circuit open or short. short. resistance respectively. Is it normal? If resistance is OK, substi- tute a known-good ECM (PCM) and recheck.
Page 127 6-122 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) Table B-3 Fuel Pressure Inspection SYSTEM DIAGRAM (A) : Gauge (C) : Attachment 2. Delivery pipe 4. Fuel filter (B) : Hose 1. Injector 3. Fuel pressure regulator 5. Fuel pump INSPECTION NOTE: Before using following flow table, check to make sure that battery voltage is higher than 11 V.
Page 128 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-123 Step Action Was no fuel pressure applied in Step 1? Go to Step 8. Go to Step 9. (Low pressure is mea- sured.) With fuel pump operated and fuel return hose Faulty fuel pressure regu- Shortage of fuel or fuel blocked by pinching it, is fuel pressure applied? lator.
Page 129 6-124 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) Table B-4 Idle Air Control System Inspection WIRING DIAGRAM 1. Throttle body 3. ECM (PCM) 5. Main relay 2. Idle air control valve 4. Sensed information 6. ECM (PCM) INSPECTION Step Action Check engine idle speed and IAC duty Go to Step 2.
Page 130 Step 1 of Table B-5 or Table B-6 A/C, if short, or A/C system mal- equipped. (A/C signal can be also function. checked by using SUZUKI scan tool.) Is it in good condition? Check ABS signal circuit for voltage if Go to step 8.
Page 131 6-126 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) Step Action Was IAC duty more than about 30% in Check parts or system which Substitute a known-good Step 1 of this table? can cause engine low idle. ECM (PCM) and recheck. •...
Page 132 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-127 Table B-5 A/C Signal Circuits Inspection (For Canvas Top Model, If Equipped) WIRING DIAGRAM 1. A/C control module (amplifier) 2. ECM (PCM) INSPECTION Step Action Check A/C Signal Circuit. Go to Step 2. “YEL/BLK”...
Page 133: Equipped)
6-128 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) Table B-6 A/C Signal Circuits Inspection (Other than Canvas Top Model, If Equipped) WIRING DIAGRAM A/C+ E61-22 YEL/WHT C51-3-24 YEL/BLU RED/BLU YEL/GRN E61-8 WHT/RED RED/BLK PNK/WHT E61-16 GRN/BLK E61-17 BLK/WHT A/C+ C51-3-20 E61-2 BLK/GRN C51-3-6...
Page 134 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-129 INSPECTION Step Action A/C Switch Signal Circuit Check : A/C signal circuit is good Faulty “GRN/BLK” wire, 1) Remove ECM (PCM) cover. condition. evaporative temperature 2) Check voltage between E61-17 and ground is below 2.5°C, 36.5°F or under following conditions.
Page 135 6-130 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) Table B-7 A/C Condenser Fan Motor Relay Control System Inspection (Canvas Top Model, If Equipped) WIRING DIAGRAM 1. To ignition switch 5. A/C condenser fan motor relay 2. “REAR DEFG” fuse for canvas top model, “HEATER” fuse except for canvas top model 6.
Page 136 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-131 Step Action 1) Remove ECM (PCM) cover. Fuse blown, “RED”, “YEL/GRN” circuit open, 2) Check voltage between E61-22 terminal of “RED/BLK” or “RED/BLU” “YEL/BLU” circuit open or ECM (PCM) connected coupler and ground. circuit open, malfunction short, or relay malfunc- Other than conditions A and B in Step 2...
Page 137 6-132 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) Table B-8 A/C Condenser Fan Motor Relay Control System Inspection (Other than Canvas Top Model, If Equipped) WIRING DIAGRAM A/C+ E61-22 YEL/WHT C51-3-24 YEL/BLU RED/BLU YEL/GRN E61-8 WHT/RED RED/BLK PNK/WHT E61-16 GRN/BLK E61-17 BLK/WHT A/C+...
Page 138 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-133 Step Action A/C condenser fan motor control circuit check Go to Step 3. Go to Step 2. 1) Remove ECM (PCM) cover. 2) Measure voltage between C51-3-24 and vehicle body ground with ignition turned Is voltage 10 –...
Page 139: Control System Inspection (Other Than Canvas Top Model, If Equipped)
6-134 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) Table B-9 A/C Compressor Relay Control System Inspection (Other than Can- vas Top Model, If Equipped) WIRING DIAGRAM A/C+ E61-22 YEL/WHT C51-3-24 YEL/BLU RED/BLU YEL/GRN E61-8 WHT/RED RED/BLK PNK/WHT E61-16 GRN/BLK E61-17 BLK/WHT A/C+ C51-3-20...
Page 140 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16/J20 ENGINES) 6-135 Step Action A/C compressor control circuit check “YEL/GRN” wire or “PNK” Faulty A/C compressor 1) Turn OFF ignition switch. wire is open circuit. relay. 2) Check for fuse blowout at “HTR 15 A” fuse. 3) If OK, check A/C compressor relay referring to “A/C Compressor Relay and Condenser Fan Motor Relay”...
Page 141 09930-88530 See NOTE “A”. Vacuum pump gauge Injector test lead Tech 2 kit (SUZUKI scan tool) (See NOTE “B”.) NOTE: • “A” : This kit includes the following items. 1. Pressure gauge 09912-58441, 2. Pressure hose 09912-58431, 3. Attachment 09919-46010, 4.
Page 142: Engine Fuel
• Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
Page 143 6-1-2 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) On-Board Diagnostic System DTC P0136 HO2S (Bank-1 Sensor-2) (Vehicle with Diagnosis Connector) ... 6-1-12 Circuit Malfunction ........6-1-79 Precaution in Diagnosing Trouble....6-1-13 DTC P0141 HO2S (Bank-1 Sensor-2) Engine Diagnostic Flow Table ....6-1-14 Heater Circuit Malfunction ......6-1-81 Malfunction Indicator Lamp (MIL) DTC P0150 (Vehicle without Diagnosis...
Page 144 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-3 DTC P0601 Internal Control Module Table B-2 Fuel Injector Circuit Check ..6-1-140 Memory Check Sum Error......6-1-129 Table B-3 Fuel Pressure Check....6-1-142 DTC P1408 Manifold Absolute Table B-4 A/C Signal Circuit Check Pressure Sensor Circuit Malfunction..
Page 145 6-1-4 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) General Information Statement of Cleanliness and Care An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the thousands of an millimeter (ten thousands of inch).
Page 146 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-5 General Information on Engine Service THE FOLLOWING INFORMATION ON ENGINE SERVICE SHOULD BE NOTED CAREFULLY, AS IT IS IMPORTANT IN PREVENTING DAMAGE, AND IN CONTRIBUTING TO RELI- ABLE ENGINE PERFORMANCE. • When raising or supporting engine for any reason, do not use a jack under oil pan.
Page 147 6-1-6 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) Precaution on Fuel System Service • Work must be done with no smoking, in a well-ventilated area and away from any open flames. • As fuel feed line (between fuel pump and fuel pressure regu- lator) is still under high fuel pressure even after engine was stopped, loosening or disconnecting fuel feed line directly may cause dangerous spout of fuel to occur where loosened...
Page 148 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-7 Fuel pressure relief procedure CAUTION: This work must not be done when engine is hot. If done so, it may cause adverse effect to catalyst. After making sure that engine is cold, relief fuel pressure as fol- lows.
Page 149 (For the details, refer to description on Freeze frame data.) • It is possible to communicate by using not only SUZUKI scan tool (2) but also generic scan tool. (Diagnostic information can be accessed by using a scan tool.)
Page 150 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-9 Warm-Up Cycle A warm-up cycle means sufficient vehicle operation such that the coolant temperature has risen by at least 22°C (40°F) from engine starting and reaches a minimum temperature of 70°C (158°F). Driving Cycle A “Driving Cycle”...
Page 151 6-1-10 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) Freeze Frame Data ECM (PCM) stores the engine and driving conditions (in the form of data as shown at the figure) at the moment of the detection of a malfunction in its memory. This data is called “Freeze frame data”. Therefore, it is possible to know engine and driving conditions (e.g., whether the engine was warm or not, where the vehicle was running or stopped, where air/fuel mixture was lean or rich) when...
Page 152 DLC (1) is in compliance with SAEJ1962 in its installation posi- tion, the shape of connector and pin assignment. Serial data line (K line of ISO 9141) (4) is used for SUZUKI scan tool or generic scan tool to communicate with ECM (PCM), Airbag SDM and ABS control module.
Page 153: On-Board Diagnostic System (Vehicle With Diagnosis Connector)
6-1-12 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) On-Board Diagnostic System (Vehicle with Diagnosis Connector) ECM diagnosis troubles which may occur in the area including the following parts when the ignition switch is ON and the engine is running, and indicates the result by turning on or flashing mal- function indicator lamp (1).
Page 154: Precaution In Diagnosing Trouble
ECM (PCM) memory. Such disconnection will erase memorized information in ECM (PCM) memory. • Diagnostic information stored in ECM (PCM) memory can be cleared as well as checked by using SUZUKI scan tool or generic scan tool. Before using scan tool, read its Operator’s (Instruction) Manual carefully to have good understanding as to what functions are available and how to use it.
Page 155: Engine Diagnostic Flow Table
6-1-14 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) Engine Diagnostic Flow Table Refer to following pages for the detail of each step. Step Action Customer Complaint Analysis Go to Step 2. Perform customer com- 1) Perform customer complaint analysis refer- plaint analysis.
Page 156 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-15 Step Action Final Confirmation Test Go to Step 6. END. 1) Clear DTC if any. 2) Perform final confirmation test referring to “Final Confirmation Test” in the following. Is there any problem symptom, malfunction DTC or abnormal condition?
Page 157 6-1-16 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 1. CUSTOMER COMPLAINT ANALYSIS Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form will facilitate collecting information to the point required for proper anal- ysis and diagnosis.
Page 158 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-17 2. DIAGNOSTIC TROUBLE CODE (DTC)/FREEZE FRAME DATA CHECK First, check DTC, referring to “Diagnostic Trouble Code Check” in this section. If DTC is indicated, record DTC and freeze frame data. • After that clear DTC referring to “Diagnostic Trouble Code Clearance” in this section. DTC indicates malfunc- tion that occurred in the system but does not indicate whether it exists now or it occurred in the past and the normal condition has been restored now.
Page 159 6-1-18 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 5. TROUBLE SYMPTOM CONFIRMATION Based on information obtained in Step 1 “CUSTOMER COMPLAINT ANALYSIS” and Step 2 “DTC/FREEZE FRAME DATA CHECK”, confirm trouble symptoms. Also, reconfirm DTC according to “DTC CONFORMATION PROCEDURE” described in each “DTC FLOW TABLE”. 6.
Page 160 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-19 Step Action Check fuel injector referring to “Fuel Injector” in Go to “Engine Diagnosis Go to “Diag. Flow Table B- Section 6E2. Table” in this section. 2” in this section. Is it in good condition? 9.
Page 161: Malfunction Indicator Lamp (Mil) Check
“Diagnostic Flow Table A-2” for troubleshooting. Diagnostic Trouble Code (DTC) Check [Using scan tool] 1) Prepare generic scan tool or SUZUKI scan tool (2). 2) With ignition switch OFF, connect it to data link connector (DLC) (1) located on underside of instrument panel at driver's seat side.
Page 162 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-21 [Not using SUZUKI scan tool] (vehicle with monitor connec- tor) 1) Check malfunction indicator lamp referring to “Malfunction Indicator Lamp Check” in this section. 2) With the ignition switch OFF position, disconnect SUZUKI...
Page 163: Diagnostic Trouble Code (Dtc) Clearance
Diagnostic Trouble Code (DTC) Clearance [Using scan tool] 1) With ignition switch OFF, connect generic scan tool or SUZUKI scan tool to data link connector (DLC). 2) Turn ignition switch ON. 3) Erase DTC according to instructions displayed on scan tool.
Page 164: Diagnostic Trouble Code (Dtc) Table
ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-23 Diagnostic Trouble Code (DTC) Table vehicle (vehicle DETECTING CONDITION DTC NO. DETECTING ITEM without with (DTC will set when detecting : ) monitor monitor connector connector) P0100 (No.34) Mass air flow circuit Sensor output too low 1 driving 1 driving...
Page 165 6-1-24 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) vehicle (vehicle DETECTING CONDITION DTC NO. DETECTING ITEM without with (DTC will set when detecting : ) monitor monitor connector connector) P0154 (vehicle without diagno- sis connector)/ Output voltage of HO2S-1 fails to HO2S (Bank 2 –...
Page 166 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-25 vehicle (vehicle DETECTING CONDITION DTC NO. DETECTING ITEM without with (DTC will set when detecting : ) monitor monitor connector connector) Crankshaft position sensor No signal for 2 sec. during engine 1 driving P0335 circuit malfunction cranking...
Page 167 6-1-26 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) DETECTING CONDITION DTC NO. DETECTING ITEM (DTC will set when detecting : ) P0705 Transmission range circuit malfunction (No.72) P0715 Input/turbine speed sensor circuit malfunction (No.76) P0720 A/T VSS signal circuit malfunction (No.75) Torque converter clutch circuit performance or P0741...
Page 168: Fail-Safe Table
ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-27 Fail-Safe Table When any of the following DTCs is detected, ECM enters fall-safe mode as long as malfunction continues to exist but that mode is canceled when ECM detects normal condition after that. FAIL SAFE MODE TROUBLE AREA FAIL SAFE OPERATION...
Page 169: Scan Tool Data
✱ • For asterisk ( ) marked item in OTHER column, item can be read only SUZUKI scan tool. • When checking the data with the engine running at idle or racing, be sure to shift M/T gear to the neutral gear position and A/T gear to the “Park”...
Page 170 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-29 NORMAL CONDITION/ SCAN TOOL DATA CONDITION OTHER REFERENCE VALUE OXYGEN SENSOR B1 S2 When engine is running at 2000 r/min. for 3 min or longer 0.05 – 0.95 V (HO2S2 Output Voltage) after warming up.
Page 171 6-1-30 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) NORMAL CONDITION/ SCAN TOOL DATA CONDITION OTHER REFERENCE VALUE TRANS RANGE Ignition switch ON, selector lever is at “R”, “N”, “D”, “2” or “L” ✱ R, N, D, 2 or L range. BRAKE SW (Brake, Ignition switch ON, brake pedal is released.
Page 172: Scan Tool Data Definitions
ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-31 Scan Tool Data Definitions COOLANT TEMP (ENGINE COOLANT TEMP., °C/°F) It is detected by engine coolant temp. sensor. INTAKE AIR TEMP (°C/°F) It is detected by intake air temp. sensor. DESIRE IDLE (DESIRED IDLE SPEED RPM) The desired idle speed is an ECM (PCM) internal parameter which indicates the ECM (PCM) requested idle.
Page 173 6-1-32 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) THROTTLE POS (ABSOLUTE THROTTLE POSITION, %) When throttle position sensor is fully closed position, throttle opening is indicated as 0% and 100% for full open position. TP SENSOR VOLT (TP SENSOR OUTPUT VOLTAGE, V) Throttle Position Sensor reading provides throttle valve opening information in the from of voltage.
Page 174 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-33 EGR VALVE (%) This parameter indicates opening rate of EGR valve which controls the amount of EGR flow. A/C SWITCH (ON/OFF) ON : Command for operation being output from A/C amplifier to compressor. OFF : Command for operation not being output.
Page 175 6-1-34 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) SHIFT SOL 1 CON/MON (SHIFT SOLENOID 1, A COMMAND/MONITOR, ON/OFF) CON-ON : ON command being output to shift solenoid 1, A. CON-OFF : ON command not being output. MON-ON : Electricity being passed to shift solenoid 1, A.
Page 176: Engine Diagnosis Table
ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-35 Engine Diagnosis Table Perform troubleshooting referring to following table when ECM (PCM) has detected no DTC and no abnormality has been found in visual inspection and engine basic inspection previously. Condition Possible Cause Correction Hard starting Engine and emission control system out of...
Page 177 6-1-36 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) Condition Possible Cause Correction Engine has no Engine overheating. Refer to “Overheating” in this table. power Ignition system out of order. • Defective spark plug “Spark Plugs” in Section 6F2. • Faulty ignition coil with ignitor “Ignition Coil Assembly”...
Page 178 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-37 Condition Possible Cause Correction Engine hesitates Ignition System out of order. (Momentary lack of • Spark plug faulty or plug gap as out of “Spark Plugs” in Section 6F2. response as the adjustment accelerator is Fuel system out of order.
Page 179 6-1-38 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) Condition Possible Cause Correction Excessive detona- Engine overheating Refer to “Overheating” in this table. tion (The engine Ignition system out of order. makes sharp • Faulty spark plug “Spark Plugs” in Section 6F2. metallic knocks •...
Page 180 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-39 Condition Possible Cause Correction Poor gasoline mile- Ignition system out of order. • Faulty spark plug (improper gap, heavy “Spark Plugs” in Section 6F2. deposits, and burned electrodes, etc.) Engine and emission control system out of order.
Page 181 6-1-40 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) Condition Possible Cause Correction Engine noise Valve noise See NOTE below. • Faulty hydraulic valve lash adjuster “Camshaft and Valve Lash Adjuster” in Sec- tion 6A2. • Worn valve stem and guide “Valves and Cylinder Heads”...
Page 182: Ecm (Pcm) Substitution
ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-41 ECM (PCM) Substitution When substituting a known-good ECM (PCM), check for following conditions. Neglecting this check may cause damage to known- good ECM (PCM). • Resistance value of all relays, actuators is as specified respectively.
Page 183 6-1-42 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 1. ECM (PCM) 2. Connector (viewed from harness side) TERMINAL WIRE NORMAL CIRCUIT CONDITION NUMBER COLOR VOLTAGE While 3 sec. after ignition switch turned Fuel pump relay output (with- 0 – 2.5 V ON or while engine running E61-1 WHT/GRN...
Page 184 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-43 TERMINAL WIRE NORMAL CIRCUIT CONDITION NUMBER COLOR VOLTAGE Ignition switch turned ON, A/T Power 0 – 1 V mode/Normal mode selector selected Selector switch signal of at Power mode E61-9 ORN/BLU Power mode/Normal mode for Ignition switch turned ON, A/T Power 10 –...
Page 185 6-1-44 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) TERMINAL WIRE NORMAL CIRCUIT CONDITION NUMBER COLOR VOLTAGE Duty output terminal (if 0 – 1 V Ignition switch turned ON equipped) E61-23 10 – 14 V While engine running Immobilizer indicator lamp Ignition switch turned ON with engine output (if equipped) 0 –...
Page 186 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-45 TERMINAL WIRE NORMAL CIRCUIT CONDITION NUMBER COLOR VOLTAGE 0 – 1 V Ignition switch turned ON Engine running at idling after warming ✱ 4 – 6 V up between CKP sensor signal (–) and ↑↓...
Page 187 6-1-46 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) TERMINAL WIRE NORMAL CIRCUIT CONDITION NUMBER COLOR VOLTAGE Engine running at idling after warming ✱ 0 – 0.6 V ↑↓ (Sensor signal is pulse. Pulse fre- Reference signal for CMP C51-3-10 YEL/BLU 4 –...
Page 188 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-47 TERMINAL WIRE NORMAL CIRCUIT CONDITION NUMBER COLOR VOLTAGE Ignition switch turned ON ✱ 0 – 0.6 V (Output signal is 1 Hz active low duty ↑↓ ECT sensor signal for combi- pulse. Duty ratio varies depending on C51-3-19 YEL/WHT 4 –...
Page 189 6-1-48 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) TERMINAL WIRE NORMAL CIRCUIT CONDITION NUMBER COLOR VOLTAGE Ignition switch turned ON, Transfer 0 – 1 V selector selected at “4H” or “4L” range C51-1-7 ORN/BLK “4WD” lamp output Ignition switch turned ON, Transfer 10 –...
Page 190 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-49 TERMINAL WIRE NORMAL CIRCUIT CONDITION NUMBER COLOR VOLTAGE Ignition switch turned ON, Transfer 10 – 14 V 4WD air pump assembly out- selector selected at “4L” or “4H” position C51-1-15 Ignition switch turned ON, Transfer 0 –...
Page 191 6-1-50 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) TERMINAL WIRE NORMAL CIRCUIT CONDITION NUMBER COLOR VOLTAGE 10 – 14 V Ignition switch turned ON ✱ 0 – 1 V While engine running. ↑↓ LT GRN/ EGR valve (stepper motor coil C51-2-4 (Output signal is active low duty pulse.
Page 192 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-51 TERMINAL WIRE NORMAL CIRCUIT CONDITION NUMBER COLOR VOLTAGE 0 – 0.6 V Ignition switch turned ON ✱ 0 – 0.6 V Engine running ↑↓ C51-2-13 Ignition coil No.1 output (Output signal is active high pulse. 2 –...
Page 193 6-1-52 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) TERMINAL WIRE NORMAL CIRCUIT CONDITION NUMBER COLOR VOLTAGE 0 – 0.6 V Ignition switch turned ON ✱ 0 – 0.6 V Engine running ↑↓ C51-2-22 BLK/BRN Ignition coil No.6 output (Output signal is active high pulse. 2 –...
Page 194 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-53 RESISTANCE CHECK 1) Disconnect ECM couplers (1) from ECM with ignition switch OFF. CAUTION: Never touch terminals of ECM itself or connect voltmeter or ohmmeter (2). 2) Check resistance between each pair of terminals of discon- nected couplers as listed in following table.
Page 195 6-1-54 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) STANDARD TERMINAL CIRCUIT CONDITION RESISTANCE C51-2-7 – C51-2-20 Fuel injector No.1 C51-2-6 – C51-2-20 Fuel injector No.2 C51-2-19 – C51-2-20 Fuel injector No.3 Ω 10 – 14 – C51-2-18 – C51-2-20 Fuel injector No.4 C51-2-28 –...
Page 196: Mil Does Not Come On Or Mil Dimms At Ignition Switch On Leaving Engine Off
ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-55 Table A-1 Malfunction Indicator Lamp Circuit Check MIL does not come on or MIL dimms at ignition switch ON leaving engine OFF WIRING DIAGRAM [A] : Terminal arrangement of ECM (PCM) 2. Ignition switch 4.
Page 197 6-1-56 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) TROUBLESHOOTING Step Action Test Switch Terminal check (vehicle with moni- Go to Step 2. Test switch terminal circuit tor connector) : is shorted to ground. 1) Check test switch terminal of monitor con- Repair or correct.
Page 198: Mil Remains On After Engine Starts
ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-57 Table A-2 Malfunction Indicator Lamp Circuit Check MIL remains on after engine starts WIRING DIAGRAM/CIRCUIT DESCRIPTION Refer to TABLE A-1. TROUBLESHOOTING Step Action DTC check : Go to Step 2 of “Engine Go to Step 2.
Page 199 6-1-58 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) Table A-4 Malfunction Indicator Lamp Check MIL does not flash or just remains on even with grounding diagnosis switch terminal (vehi- cle with monitor connector) WIRING DIAGRAM/CIRCUIT DESCRIPTION Refer to TABLE A-1. TROUBLESHOOTING Step Action...
Page 200: Mil Does Not Light At Ignition Switch On And Engine Does Not Start Though It Is Cranked Up
ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-59 Table A-5 ECM (PCM) Power and Ground Circuit Check MIL does not light at ignition switch ON and engine does not start though it is cranked up. WIRING DIAGRAM [A] : Terminal arrangement of ECM (PCM) coupler viewed from harness side 2.
Page 201 6-1-60 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) TROUBLESHOOTING Step Action Main Relay Operating Sound check : Go to Step 5. Go to Step 2. Is operating sound of main relay heard at igni- tion switch ON? Fuse check : Go to Step 3.
Page 202: Dtc P0100 Mass Air Flow Sensor Circuit Malfunction (Dtc No.33, 34)
ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-61 DTC P0100 Mass Air Flow Sensor Circuit Malfunction (DTC No.33, 34) WIRING DIAGRAM [A] : Terminal arrangement of ECM (PCM) coupler viewed from harness side 1. Main relay 2. Mass air flow sensor DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA...
Page 203 6-1-62 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) DTC CONFIRMATION PROCEDURE NOTE: Check to make sure that following conditions are satisfied when using this DTC CONFIRMATION PRO- CEDURE. WARNING: • When performing a road test, select a place where there is no traffic or possibility of a traffic acci- dent and very careful during to avoid occurrence of an accident.
Page 204: Dtc P0110 Intake Air Temp. Circuit Malfunction (Dtc No.23, 25)
ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-63 DTC P0110 Intake Air Temp. Circuit Malfunction (DTC No.23, 25) WIRING DIAGRAM [A] : Terminal arrangement of ECM (PCM) coupler viewed from harness side 1. IAT sensor DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA •...
Page 205 6-1-64 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) • Intake air temperature : between –14°C and 70°C (68°F and 158°F) • Atmospheric pressure : higher than 560 mmHg (Altitude : lower than 2790 m (9150 ft)) 1) With ignition switch OFF, connect scan tool. 2) Turn ON ignition switch, clear DTC if any.
Page 206: Dtc P0115 Engine Coolant Temp
ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-65 DTC P0115 Engine Coolant Temp. Circuit Malfunction (DTC No.14, 15) WIRING DIAGRAM [A] : Terminal arrangement of ECM (PCM) coupler viewed from harness side 1. ECT sensor DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA •...
Page 207 6-1-66 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) • Atmospheric pressure : higher than 560 mmHg (Altitude : lower than 2790 m (9150 ft)) • Intake air temperature : between –14°C and 70°C (6.8°F and 158°F) 1) With ignition switch OFF, connect scan tool. 2) Turn ON ignition switch, clear DTC if any.
Page 208: Dtc P0120 Throttle Position Circuit Malfunction (Dtc No.21, 22)
ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-67 DTC P0120 Throttle Position Circuit Malfunction (DTC No.21, 22) WIRING DIAGRAM [A] : Terminal arrangement of ECM (PCM) coupler viewed from harness side 1. Throttle position sensor DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA TP sensor signal terminal voltage continues less than 0.1 V for 1 sec.
Page 209 6-1-68 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) DTC TROUBLESHOOTING Step Action Was “Engine Diag. Flow Table” performed? Go to Step 2. Go to “Engine Diag. Flow Table”. TP Sensor Reference Voltage check : Go to Step 3. “GRY/RED” wire open or 1) Wit ignition switch OFF, disconnect TP sen- shorted to ground circuit sor coupler.
Page 210: Dtc P0121 Throttle Position Circuit Performance Problem
ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-69 DTC P0121 Throttle Position Circuit Performance Problem WIRING DIAGRAM Refer to DTC P0120 (DTC No.21, 22). DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Throttle opening is detected as small (rationality-low) while Air intake system engine is running under high road and high speed conditions TP sensor...
Page 211 6-1-70 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) DTC TROUBLESHOOTING Step Action Was “Engine Diag. Flow Table” performed? Go to Step 2. Go to “Engine Diag. Flow Table”. TP Sensor Signal check : Go to Step 3. Go to Step 4. 1) Remove ECM (PCM) cover.
Page 212: Dtc P0130 (Vehicle Without Diagnosis Connector) Ho2S (Bank-1 Sensor-1) Circuit Malfunction
ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-71 DTC P0130 (Vehicle without Diagnosis Connector) HO2S (Bank-1 Sensor-1) Circuit Malfunction WIRING DIAGRAM [A] : Terminal arrangement of ECM (PCM) coupler viewed form harness side 2. HO2S 4. “IG COIL” fuse 1. HO2S heater relay 3.
Page 213 6-1-72 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) DTC CONFIRMATION PROCEDURE WARNING: • When performing a road test, select a place where there is no traffic or possibility of a traffic acci- dent and very careful during to avoid occurrence of an accident. •...
Page 214 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-73 Step Action Fuel Injector inspection : Go to Step 7. Faulty fuel injector(s). 1) Inspect fuel injectors (No.1, 3, 5) referring to “Fuel Injector” in Section 6E2. Are they in good condition? Fuel Pressure inspection : Replace HO2S and Repair or replace.
Page 215: Dtc P0133 Ho2S (Bank-1 Sensor-1) Circuit Slow Response
6-1-74 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) DTC P0133 HO2S (Bank-1 Sensor-1) Circuit Slow Response WIRING DIAGRAM Refer to DTC P0130. DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Hi/Low switch cycle average of HO2S voltage is longer than 5 HO2S sec.
Page 216: Dtc P0134 (Vehicle Without Diagnosis Connector)/P0130 (Vehicle With Diagnosis Connector) Ho2S (Bank-1 Sensor-1) No Activity Detected (Dtc No.13)
ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-75 DTC P0134 (Vehicle without Diagnosis Connector)/P0130 (vehicle with diagno- sis connector) HO2S (Bank-1 Sensor-1) No Activity Detected (DTC No.13) WIRING DIAGRAM Refer to DTC P0130. DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA HO2S voltage is lower than 0.5 V.
Page 217 6-1-76 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) Step Action HO2S Voltage check : Poor C51-3-4 and/or C51- Go to Step 4. 1) Remove ECM (PCM) cover. 3-20 terminal connection. 2) Start engine and check voltage between C51- If OK, substitute a known- 3-4 and C51-3-20 while repeating racing good ECM (PCM) and engine.
Page 218: Dtc P0135 Ho2S (Bank-1 Sensor-1) Heater Circuit Malfunction
ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-77 DTC P0135 HO2S (Bank-1 Sensor-1) Heater Circuit Malfunction WIRING DIAGRAM Refer to DTC P0130. DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Current of HO2S heater is higher than specified value or HO2S lower than specified value.
Page 219 6-1-78 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) Step Action HO2S Heater Control Circuit check : Substitute a known-good Faulty HO2S heater relay 1) With ignition switch OFF, install HO2S ECM (PCM) and recheck. or “GRY” wire shorted to heater relay. ground circuit.
Page 220: Dtc P0136 Ho2S (Bank-1 Sensor-2) Circuit Malfunction
ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-79 DTC P0136 HO2S (Bank-1 Sensor-2) Circuit Malfunction WIRING DIAGRAM [A] : Terminal arrangement of ECM (PCM) coupler viewed from harness side 2. HO2S 4. “IG COIL” fuse 1. HO2S heater relay 3. Main fuse DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA...
Page 221 6-1-80 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) WARNING: • When performing a road test, select a place where there is no traffic or possibility of a traffic acci- dent and very careful during to avoid occurrence of an accident. •...
Page 222: Dtc P0141 Ho2S (Bank-1 Sensor-2) Heater Circuit Malfunction
ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-81 DTC P0141 HO2S (Bank-1 Sensor-2) Heater Circuit Malfunction WIRING DIAGRAM Refer to DTC P0136. DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Current of HO2S heater is higher than specified value or HO2S lower than specified value.
Page 223 6-1-82 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) Step Action HO2S Heater Control Circuit check : Substitute a known-good Faulty HO2S heater relay 1) With ignition switch OFF, install HO2S ECM (PCM) and recheck. or “WHT/BLK” wire heater relay. shorted to ground circuit. 2) With ignition switch ON leaving engine OFF, If OK, substitute a known- check voltage between C51-3-17 and...
Page 224: Dtc P0150 (Vehicle Without Diagnosis Connector) Ho2S (Bank-2 Sensor-1) Circuit Malfunction
ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-83 DTC P0150 (Vehicle without Diagnosis Connector) HO2S (Bank-2 Sensor-1) Circuit Malfunction WIRING DIAGRAM [A] : Terminal arrangement of ECM (PCM) coupler viewed from harness side 2. HO2S 4. “IG COIL” fuse 1. HO2S heater relay 3.
Page 225 6-1-84 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) DTC CONFIRMATION PROCEDURE NOTE: Check to make sure that following conditions are satisfied when using this DTC CONFIRMATION PRO- CEDURE. WARNING: • When performing a road test, select a place where there is no traffic or possibility of a traffic acci- dent and very careful during to avoid occurrence of an accident.
Page 226 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-85 Step Action Fuel Injector inspection : Go to Step 7. Faulty fuel injector(s). 1) Inspect fuel injectors (No.2, 4, 6) referring to “Fuel Injector” in Section 6E2. Are they in good condition? Fuel Pressure inspection : Replace HO2S and Repair or replace.
Page 227: Dtc P0153 Ho2S (Bank-2 Sensor-1) Circuit Slow Response
6-1-86 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) DTC P0153 HO2S (Bank-2 Sensor-1) Circuit Slow Response WIRING DIAGRAM Refer to DTC P0150. DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Hi/Low switch cycle average of HO2S voltage is longer than 5 HO2S sec.
Page 228: Dtc P0154
ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-87 DTC P0154 (Vehicle without Diagnosis Connector)/P0150 (Vehicle with Diag- nosis Connector) HO2S (Bank-2 Sensor-1) No Activity Detected (DTC No.26) WIRING DIAGRAM Refer to DTC P0150. DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA HO2S voltage is lower than 0.5 V.
Page 229 6-1-88 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) Step Action HO2S Voltage check : Poor C51-3-15 and/or Go to Step 4. 1) Remove ECM (PCM) cover. C51-3- 20 terminal con- 2) Start engine and check voltage between C51- nection. 3-15 and C51-3-20 while repeating racing If OK, substitute a known- engine.
Page 230: Dtc P0155 Ho2S (Bank-2 Sensor-1) Heater Circuit Malfunction
ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-89 DTC P0155 HO2S (Bank-2 Sensor-1) Heater Circuit Malfunction WIRING DIAGRAM Refer to DTC P0150. DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Current of HO2S heater is higher than specified value or HO2S lower than specified value.
Page 231 6-1-90 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) Step Action HO2S Heater Control Circuit check : Substitute a known-good Faulty HO2S heater relay 1) With ignition switch OFF, install HO2S ECM (PCM) and recheck. or “BLK/RED” wire heater relay. shorted to ground circuit. 2) With ignition switch ON leaving engine OFF, If OK, substitute a known- check voltage between C51-3-5 and...
Page 232: Dtc P0156 Ho2S (Bank-2 Sensor-2) Circuit Malfunction
ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-91 DTC P0156 HO2S (Bank-2 Sensor-2) Circuit Malfunction WIRING DIAGRAM [A] : Terminal arrangement of ECM (PCM) coupler viewed from harness side 2. HO2S 4. “IG COIL” fuse 1. HO2S heater relay 3. Main fuse DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA...
Page 233 6-1-92 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) WARNING: • When performing a road test, select a place where there is no traffic or possibility of a traffic acci- dent and very careful during to avoid occurrence of an accident. •...
Page 234: Dtc P0161 Ho2S (Bank-2 Sensor-2) Heater Circuit Malfunction
ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-93 DTC P0161 HO2S (Bank-2 Sensor-2) Heater Circuit Malfunction WIRING DIAGRAM Refer to DTC P0156. DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Current of HO2S heater is higher than specified value or HO2S lower than specified value.
Page 235 6-1-94 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) Step Action HO2S Heater Control Circuit check : Substitute a known-good Faulty HO2S heater relay 1) With ignition switch OFF, install HO2S ECM (PCM) and recheck. or “PNK/WHT” wire heater relay (1). shorted to ground circuit.
Page 236: Dtc P0171 Fuel System Too Lean (Bank-1) Dtc P0172 Fuel System Too Rich (Bank-1)
ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-95 DTC P0171 Fuel System Too Lean (Bank-1) DTC P0172 Fuel System Too Rich (Bank-1) DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA P0171 Vacuum leaks Total fuel trim of BANK-1 is higher than 33%. Exhaust gas leakage P0172 Fuel pressure out of specification...
Page 237 6-1-96 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) Step Action Check fuel injector circuit referring to “Table B- Go to Step 7. Repair or replace. 3” in this section. Is it in good condition? Check fuel level sensor referring to Step 3 of Go to Step 8.
Page 238: Dtc P0174 Fuel System Too Lean (Bank-2) Dtc P0175 Fuel System Too Rich (Bank-2)
ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-97 DTC P0174 Fuel System Too Lean (Bank-2) DTC P0175 Fuel System Too Rich (Bank-2) DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA P0174 Vacuum leaks Total fuel trim of BANK-2 is higher than 33%. Exhaust gas leakage P0175 Fuel pressure out of specification...
Page 239 6-1-98 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) Step Action Check fuel injector circuit referring to “Table B- Go to Step 7. Repair or replace. 3” in this section. Is it in good condition? Check fuel level sensor referring to Step 3 of Go to Step 8.
Page 240: Dtc P0300 Random Misfire Detected
ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-99 DTC P0300 Random Misfire Detected DTC P0301 Cylinder 1 Misfire Detected DTC P0302 Cylinder 2 Misfire Detected DTC P0303 Cylinder 3 Misfire Detected DTC P0304 Cylinder 4 Misfire Detected DTC P0305 Cylinder 5 Misfire Detected DTC P0306 Cylinder 6 Misfire Detected SYSTEM DESCRIPTION ECM (PCM) measure the angle of the crankshaft based on the pulse signal from the CKP sensor and CMP sen-...
Page 241 6-1-100 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) DTC TROUBLESHOOTING Step Action Was “Engine Diag. Flow Table” performed? Go to Step 2. Go to “Engine Diag. Flow Table”. Ignition System inspection : Go to Step 3. Faulty ignition coil, wire 1) Check spark plug and ignition spark of cylin- harness or spark plug.
Page 242: Dtc P0325 (Dtc No.43) Knock Sensor Circuit Malfunction
ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-101 DTC P0325 (DTC No.43) Knock Sensor Circuit Malfunction CIRCUIT DESCRIPTION [A] : Terminal arrangement of ECM (PCM) coupler viewed from harness side 1. Knock sensor 2. ECM (PCM) DTC DETECTING CONDITION TROUBLE AREA •...
Page 243 6-1-102 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) [A] Fig. 1 for Step 3 / [B] Fig. 2 for Step 3 1. Knock sensor 2. Knock sensor connector...
Page 244: Dtc P0335 Crankshaft Position Sensor Circuit Malfunction
ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-103 DTC P0335 Crankshaft Position Sensor Circuit Malfunction WIRING DIAGRAM [A] : Terminal arrangement of ECM (PCM) coupler viewed from harness side 1. CKP sensor DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA CKP sensor signal is not input for 3 sec.
Page 245 6-1-104 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) DTC TROUBLESHOOTING Step Action Was “Engine Diag. Flow Table” performed? Go to Step 2. Go to “Engine Diag. Flow Table”. CKP Sensor and Its Circuit Resistance check : Go to Step 4. Go to Step 3.
Page 246: Dtc P0340 Camshaft Position Sensor Circuit Malfunction (Dtc No.42)
ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-105 DTC P0340 Camshaft Position Sensor Circuit Malfunction (DTC No.42) WIRING DIAGRAM [A] : Terminal arrangement of ECM (PCM) coupler viewed from harness side 2. Main relay 1. CMP sensor SYSTEM DESCRIPTION CMP sensor detects REF signal and POS signal. •...
Page 247 6-1-106 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) DTC CONFIRMATION PROCEDURE NOTE: Check to make sure that following conditions are satisfied when using this DTC CONFIRMATION PRO- CEDURE. • Intake air temperature : between –14°C and 70°C (6.8°F and 158°F) •...
Page 248 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-107 Fig. for Step 4...
Page 249: Dtc P0400 Exhaust Gas Recirculation Flow Malfunction (Dtc No.51)
6-1-108 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) DTC P0400 Exhaust Gas Recirculation Flow Malfunction (DTC No.51) SYSTEM / WIRING DIAGRAM [A] : Terminal arrangement of ECM (PCM) coupler viewed from harness side 2. Intake manifold 4. EGR valve (stepper motor) 1.
Page 250 Go to Step 4. EGR Valve Operation check : Intermittent trouble. Go to Step 4. 1) With ignition switch OFF, install SUZUKI If OK, substitute a known- scan tool. good ECM (PCM) and 2) Check EGR system referring to “EGR Sys- recheck.
Page 251 6-1-110 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) Step Action EGR Valve Power Supply Circuit check : Go to Step 5. Faulty “BLU/BLK” wire. 1) With ignition switch OFF, disconnect EGR valve coupler (1). 2) With ignition switch ON, check voltage between C04-2 (“BLU/BLK”...
Page 252: Dtc P0403 (Dtc No.51) Exhaust Gas Recirculation Circuit Malfunction
ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-111 DTC P0403 (DTC No.51) Exhaust Gas Recirculation Circuit Malfunction WIRING DIAGRAM [A] : Terminal arrangement of ECM (PCM) coupler viewed from harness side 2. Main relay 4. Fuse box 1. Main fuse 3.
Page 253 6-1-112 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) TROUBLESHOOTING (DTC P0403/DTC No.51) Step Action Was “Engine Diag. Flow Table” performed? Go to Step 2. Go to “Engine Diag. Flow Table”. EGR Valve Check : Go to Step 3. EGR valve malfunction. 1) With ignition switch OFF, disconnect connector from EGR valve.
Page 254: Dtc P0420 Catalyst System (Bank-1) Efficiency Below Threshold Dtc P0430 Catalyst System (Bank-2) Efficiency Below Threshold
ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-113 DTC P0420 Catalyst System (Bank-1) Efficiency Below Threshold DTC P0430 Catalyst System (Bank-2) Efficiency Below Threshold SYSTEM / WIRING DIAGRAM [A] : Terminal arrangement of ECM (PCM) coupler viewed from harness side 3.
Page 255 6-1-114 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Output waveform of HO2S (S-2) becomes similar to that of TWC converter HO2S (S-1). Exhaust system HO2S (SENSOR 2) HO2S (SENSOR 2) circuit ECM (PCM) DTC CONFIRMATION PROCEDURE NOTE:...
Page 256 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-115 Step Action 1) Replace BANK-1 (BANK-2) warm up TWC Substitute a known-good Replace TWC converter. converter. ECM (PCM) and recheck. 2) Perform DTC confirmation procedure. Is DTC P0420 (P0430) detected?
Page 257: Dtc P0443 Evap Control System Purge Control Valve Circuit Malfunction
6-1-116 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) DTC P0443 EVAP Control System Purge Control Valve Circuit Malfunction WIRING DIAGRAM [A] : Terminal arrangement of ECM (PCM) coupler viewed from harness side 2. Main relay 1. Main fuse 3. EVAP canister purge valve DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA...
Page 258 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-117 TROUBLESHOOTING (DTC P0443) Step Action Was “Engine Diag. Flow Table” performed? Go to Step 2. Go to “Engine Diag. Flow Table”. Check EVAP canister purge system for opera- Intermittent trouble or Go to Step 3. tion referring to “EVAP Canister Purge System faulty ECM (PCM).
Page 259: Evap Canister Purge Valve And Its Circuit Check
1) Disconnect vacuum hoses from vacuum pipes. 2) With ignition switch ON, blow into hose “A”. Air should not come out of hose “B”. 3) If you have SUZUKI scan tool, perform Step a). If not, per- form Step b). a) Using SUZUKI scan tool i) Connect SUZUKI scan tool (1) to DLC (2) with ignition switch OFF.
Page 260 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-119 5) Check resistance between two terminals of EVAP canister purge valve. If resistance is as specified, proceed to next operation check. If not, replace. Resistance of EVAP canister purge valve Ω 28 – 36 at 20°C (68°F) 6) With coupler disconnected, blow into hose “A”.
Page 261: Evap Canister Purge System Check
6-1-120 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) EVAP canister purge system check 1) Warm up engine to normal operating temperature. 2) Hoist vehicle so that all wheels rotate freely. 3) Set M/T in “Neutral” or A/T in “P” position and parking brake. 4) Disconnect purge hose (1) from EVAP canister.
Page 262: Dtc P0460 Fuel Level Sensor Circuit High Input
ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-121 DTC P0460 Fuel Level Sensor Circuit High Input WIRING DIAGRAM / CIRCUIT DESCRIPTION [A] : Terminal arrangement of ECM (PCM) coupler viewed from harness side 1. Fuel level meter in combination meter 2.
Page 263 6-1-122 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) DTC TROUBLESHOOTING Step Action Was “Engine Diag. Flow Table” performed? Go to Step 2. Go to “Engine Diag. Flow Table”. Fuel Level Sensor Signal Circuit check : Go to Step 3. “BLU/WHT” wire shorted 1) With ignition switch OFF, disconnect combi- to power circuit.
Page 264: Dtc P0500 Vehicle Speed Sensor Malfunction (Dtc No.24)
ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-123 DTC P0500 Vehicle Speed Sensor Malfunction (DTC No.24) WIRING DIAGRAM [A] : Terminal arrangement of ECM (PCM) coupler viewed from harness side 1. Vehicle speed sensor 2. Main relay 3. Speedometer DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Vehicle speed sensor signal is not inputted while fuel is cut...
Page 265 6-1-124 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) WARNING: • When performing a road test, select a place where there is no traffic or possibility of a traffic acci- dent and very careful during to avoid occurrence of an accident. •...
Page 266 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-125 Step Action Speedometer Circuit check : Substitute a known-good Faulty “BLU/YEL” wire. 1) With ignition switch OFF, disconnect cou- combination meter and If OK, substitute a known- plers from combination meter. recheck. good ECM (PCM) and 2) With ignition switch ON leaving engine OFF, recheck.
Page 267: Dtc P0505 Idle Air Control System Malfunction
6-1-126 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) DTC P0505 Idle Air Control System Malfunction SYSTEM / WIRING DIAGRAM [A] : Terminal arrangement of ECM (PCM) coupler viewed from harness side 2. Fast idle control system 4. Engine coolant 6. Cold 1.
Page 268 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-127 SYSTEM DESCRIPTION Refer to “Air Intake System Description” in Section 6E2. DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Idle engine speed is lower than desired engine speed IAC valve or its circuit 100 r/min.
Page 269 6-1-128 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) Step Action IAC Valve Power Supply Voltage check : IAC valve or ECM (PCM) Faulty “BLU/BLK” wire. 1) Connect ECM (PCM) couplers. malfunction. 2) With ignition switch OFF, disconnect coupler (1) of IAC valve. 3) With ignition switch ON, check voltage between (“BLU/BLK”...
Page 270: Dtc P0601 Internal Control Module Memory Check Sum Error
ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-129 DTC P0601 Internal Control Module Memory Check Sum Error SYSTEM DESCRIPTION Internal control module is installed in ECM (PCM). DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Check sum is not equal to specified value. ECM (PCM) DTC CONFIRMATION PROCEDURE NOTE:...
Page 271: Dtc P1408 Manifold Absolute Pressure Sensor Circuit Malfunction
6-1-130 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) DTC P1408 Manifold Absolute Pressure Sensor Circuit Malfunction WIRING DIAGRAM [A] : Terminal arrangement of ECM (PCM) coupler viewed from harness side 1. MAP sensor DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA MAP sensor signal voltage continues more than 2.7 V for 5 MAP sensor and its circuit...
Page 272 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-131 • Intake air temperature : between 5°C and 70°C (6.8°F and 158°F) • Atmospheric pressure : higher than 560 mmHg (Altitude : lower than 2790 m (9150 ft)) 1) With ignition switch OFF, connect scan tool. 2) Turn ON ignition switch and clear DTC by using scan tool if any.
Page 273: Dtc P1450 Barometric Pressure Sensor Circuit Malfunction Dtc P1451 Barometric Pressure Sensor Performance Problem
6-1-132 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) DTC P1450 Barometric Pressure Sensor Circuit Malfunction DTC P1451 Barometric Pressure Sensor Performance Problem SYSTEM DESCRIPTION Barometric pressure sensor is installed in ECM (PCM). DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA P1450 Barometric pressure sensor in ECM (PCM).
Page 274 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-133 Fig. and Table for Step 3...
Page 275: Dtc P1500 Engine Start Signal Circuit Malfunction
6-1-134 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) DTC P1500 Engine Start Signal Circuit Malfunction WIRING DIAGRAM [A] : Terminal arrangement of ECM (PCM) coupler viewed from harness side 2. Transmission range switch 1. Ignition switch CIRCUIT DESCRIPTION Engine start signal is sent from engine starter circuit while engine cranking. DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA...
Page 276 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-135 DTC CONFIRMATION PROCEDURE NOTE: Check to make sure that following conditions are satisfied when using this DTC CONFIRMATION PRO- CEDURE. • Intake air temperature : between –14°C and 70°C (6.8°F and 158°F) •...
Page 277 6-1-136 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) DTC P1510 ECM Back-Up Power Supply Malfunction WIRING DIAGRAM [A] : Terminal arrangement of ECM (PCM) coupler viewed from harness side 1. “RADIO DOME” fuse CIRCUIT DESCRIPTION Battery voltage is translated to 5 V in ECM (PCM) back-up circuit. The voltage is supplied to keep DTC memory, values that ECM (PCM) has learned to control engine, etc.
Page 278 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-137 DTC TROUBLESHOOTING Step Action Was “Engine Diag. Flow Table” performed? Go to Step 2. Go to “Engine Diag. Flow Table”. Battery Voltage Supply Circuit check : Intermittent trouble. “RADIO DOME” fuse is 1) Remove ECM (PCM) cover.
Page 279 6-1-138 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) Table B-1 Fuel Pump Circuit Check WIRING DIAGRAM [A] : Terminal arrangement of ECM (PCM) coupler viewed from harness side 1. Fuel pump [B] : Vehicle without immobilizer control system 2. Fuel pump relay [C] : Vehicle with immobilizer control system 3.
Page 280 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-139 TROUBLESHOOTING Step Action Fuel Pump Operation check : Fuel pump circuit is in Go to Step 2. 1) Remove fuel filler cap. good condition. 2) Turn On ignition switch. Is fuel pump operation sound heard for 3 sec. after ignition switch ON? Fuel Pump Circuit check : Go to Step 3.
Page 281 6-1-140 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) Table B-2 Fuel Injector Circuit Check WIRING DIAGRAM [A] : Terminal arrangement of ECM (PCM) coupler viewed from harness side 1. Fuel injector 2. Main relay...
Page 282 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-141 TROUBLESHOOTING Step Action Fuel Injector Operation check : Go to Step 2. Go to Step 3. 1) Using sound scope, check each injector for operating sound at engine cranking. Do all 6 injectors make operating sound? Fuel Injector Circuit check : Fuel injector circuit is in Go to Step 3.
Page 283 6-1-142 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) Table B-3 Fuel Pressure Check SYSTEM DIAGRAM (A) : Gauge (C) : Attachment 2. Delivery pipe 4. Fuel filter (B) : Hose 1. Injector 3. Fuel pressure regulator 5. Fuel pump SYSTEM DESCRIPTION Fuel pressure regulator keeps the fuel pressure applied to injector 290 kPa higher than that in intake manifold at all times.
Page 284 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-143 Step Action Is there fuel leakage from fuel feed line hose, Fuel leakage from fuel Fuel leakage from injec- pipe or joint? feed line hose, pipe or tor, fuel pressure regula- joint. tor or fuel pump.
Page 285 6-1-144 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) Table B-4 A/C Signal Circuit Check (If Equipped) CIRCUIT DIAGRAM A/C+ [B] C51-3-19 YEL/WHT E61-5 YEL/BLU [C] C51-1-17 RED/BLU YEL/GRN E61-21 WHT/RED RED/BLK PNK/WHT E61-13 GRN/BLK E61-28 12 v BLK/WHT C51-2-3 A/C+ E61-35 C51-2-2 BLK/ORN...
Page 286 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-145 Table B-5 A/C Condenser Fan Motor Relay Control System Check (If Equipped) CIRCUIT DIAGRAM A/C+ [B] C51-3-19 YEL/WHT E61-5 YEL/BLU [C] C51-1-17 RED/BLU YEL/GRN E61-21 WHT/RED RED/BLK PNK/WHT E61-13 GRN/BLK E61-28 12 v BLK/WHT A/C+ C51-2-3...
Page 287 6-1-146 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) Step Action A/C Condenser Fan Motor Control Circuit check Go to Step 3. Go to Step 2. 1) Remove ECM (PCM) cover. 2) Measure voltage between E61-5 and vehi- cle body ground with ignition turned ON. Is voltage 10 –...
Page 288 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-147 Table B-6 A/C Compressor Relay Control System Inspection (If Equipped) WIRING DIAGRAM A/C+ [B] C51-3-19 YEL/WHT E61-5 YEL/BLU [C] C51-1-17 RED/BLU YEL/GRN E61-21 WHT/RED RED/BLK PNK/WHT E61-13 GRN/BLK E61-28 12 v BLK/WHT C51-2-3 A/C+ E61-35...
Page 289 6-1-148 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) Step Action A/C Compressor Control Signal check Go to Step 4. Go to Step 5. 1) Start engine. 2) Turn ON A/C switch and heater blower motor switch. 3) Measure voltage between E61-21 and vehi- cle body ground with engine running.
Page 290: Special Tool
09930-88521 See NOTE “A”. Vacuum pump gauge Injector test lead Tech 2 kit (SUZUKI scan tool) (See NOTE “B”.) NOTE: • “A” : This kit includes the following items. 1. Pressure gauge 09912-58441, 2. Pressure hose 09912-58431, 3. 3-way joint & hose 09912-58490, 4.
Page 291 6-1-150 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE)
Page 292: Engine Mechanical (G16 Engine)
• Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
Page 293: General Description
6A1-2 ENGINE MECHANICAL (G16 ENGINE) General Description Engine The engine is a water-cooled, in line 4 cylinders, 4 stroke cycle gasoline unit equipped with its S.O.H.C. (Single Overhead Camshaft) valve mechanism arranged for “V”-type valve configuration and 16 valves (IN 2 and EX 2/ one cylinder).
Page 294: Engine Lubrication
ENGINE MECHANICAL (G16 ENGINE) 6A1-3 Engine Lubrication The oil pump is of a trochoid type, and mounted on crankshaft at crankshaft pulley side. Oil is drawn up through oil pump strainer and passed through pump to oil filter. The filtered oil flows into two paths in cylinder block. In one path, oil reaches crankshaft journal bearings.
Page 295: On-Vehicle Service
6A1-4 ENGINE MECHANICAL (G16 ENGINE) On-Vehicle Service Compression Check Check compression pressure on all four cylinders as follows : 1) Warm up engine. 2) Stop engine after warming up. NOTE: After warming up engine, place transmission gear shift lever in “Neutral” (shift selector lever to “P” range for A/T model), and set parking brake and block drive wheels.
Page 296: Engine Vacuum Check
ENGINE MECHANICAL (G16 ENGINE) 6A1-5 6) Disengage clutch (to lighten starting load on engine) for M/T model, and depress accelerator pedal all the way to make throttle valve full-open. 7) Crank engine with fully charged battery, and read the highest pressure on compression gauge.
Page 297: Oil Pressure Check
Special tool (A) : 09915-67311 (B) : 09918-08210 SUZUKI GENUINE PARTS (C) : Hose 09355-35754 (D) : 3-way joint 09367-04002 3) Run engine at specified idle speed, and read vacuum gauge. Vacuum should be within following specification.
Page 298 ENGINE MECHANICAL (G16 ENGINE) 6A1-7 2) Install special tool (Oil pressure gauge) to vacated threaded hole. Special tool (A) : 09915-77311 3) Start engine and warm it up to normal operating tempera- ture. NOTE: Be sure to place transmission gear shift lever in “Neu- tral”...
Page 299: Valve Lash (Clearance)
6A1-8 ENGINE MECHANICAL (G16 ENGINE) Valve Lash (Clearance) 1) Remove negative cable at battery. 2) Remove cylinder head cover referring to “Cylinder Head Cover” in this section. 3) Using 17 mm socket, turn crankshaft pulley (1) clockwise until “V” mark (in white paint) (2) on pulley aligns with “0” (zero) calibrated on timing belt cover.
Page 300: Air Cleaner Element
ENGINE MECHANICAL (G16 ENGINE) 6A1-9 6) After checking and adjusting valve lashes at valves (1), (2), (5) and (7), (or (3), (4), (6) and (8)) rotate crankshaft exactly one full turn (360°) and check the same at valves (3), (4), (6) and (8) (or (1), (2), (5) and (7)).
Page 301: Cylinder Head Cover
6A1-10 ENGINE MECHANICAL (G16 ENGINE) CLEAN Blow off dust by compressed air from air outlet side of element. INSTALLATION Reverse removal procedure for installation. Cylinder Head Cover REMOVAL 1) Disconnect negative cable at battery. 2) Remove ignition coil assemblies with high-tension cord. 3) Disconnect PCV valve and breather hose from head cover.
Page 302: Throttle Body And Intake Manifold
ENGINE MECHANICAL (G16 ENGINE) 6A1-11 2) Install cylinder head cover to cylinder head and tighten cover bolts to specified torque. Tightening torque Cylinder head cover bolt (a) : 11 N·m (1.1 kg-m, 8.0 lb-ft) NOTE: When installing cylinder head cover, use care so that cyl- inder head cover gasket or O-rings will not get out of place or fall off.
Page 303 6A1-12 ENGINE MECHANICAL (G16 ENGINE) REMOVAL 1) Relieve fuel pressure according to fuel pressure relief proce- dure described in “Fuel Pressure Relief Procedure” Section 2) Disconnect negative cable at battery. 3) Drain cooling system. WARNING: To help avoid danger of being burned, do not remove drain plug and radiator cap while engine and radiator are still hot.
Page 304 ENGINE MECHANICAL (G16 ENGINE) 6A1-13 10) Remove intake manifold with throttle body from cylinder head, and then its gasket. INSTALLATION Reverse removal procedure for installation noting the followings. • Use new intake manifold gasket. • When installing intake manifold, install clamps at positions as shown in figure.
Page 305: Exhaust Manifold
6A1-14 ENGINE MECHANICAL (G16 ENGINE) • Check to ensure that all removed parts are back in place. Reinstall any necessary parts which have not been rein- stalled. • Refill cooling system referring to “Cooling System Flush and Refill” in Section 6B. •...
Page 306 ENGINE MECHANICAL (G16 ENGINE) 6A1-15 REMOVAL 1) Disconnect negative cable at battery. 2) Disconnect heated oxygen sensor-1 coupler. 3) Remove upper cover of exhaust manifold. 4) Remove exhaust pipe bolts or nuts and exhaust pipe bracket bolt (if equipped). 1. Exhaust No.1 pipe 5) Remove exhaust manifold stiffener (3) (if equipped).
Page 307: Timing Belt And Belt Tensioner
6A1-16 ENGINE MECHANICAL (G16 ENGINE) 5) Connect heated oxygen sensor-1 connector (1) and fit con- nector to bracket (2). 6) Connect negative cable at battery. Check exhaust system for exhaust gas leakage. 3. Engine hook Timing Belt and Belt Tensioner COMPONENTS 1.
Page 308 ENGINE MECHANICAL (G16 ENGINE) 6A1-17 REMOVAL 1) Disconnect negative cable at battery. 2) Drain engine coolant and disconnect inlet hose from radiator. 3) Remove power steering pump belt (4) or A/C compressor belt, if equipped. 4) Remove radiator cooling fan, water pump pulley, water pump drive belt and fan shroud.
Page 309 6A1-18 ENGINE MECHANICAL (G16 ENGINE) 8) Remove timing belt tensioner, tensioner plate (2), tensioner spring (5) and timing belt (1). 3. Tensioner bolt 4. Tensioner stud CAUTION: • After timing belt is removed, never turn camshaft and crankshaft independently more than such an extent as shown in figure.
Page 310 ENGINE MECHANICAL (G16 ENGINE) 6A1-19 INSTALLATION 1) Install tensioner plate to tensioner. Insert lug (1) of tensioner plate into hole (2) in tensioner. 2) Install tensioner (2) and tensioner plate (3) : Do not tighten tensioner bolt (1) with wrench yet. Hand tighten only at this time.
Page 311 6A1-20 ENGINE MECHANICAL (G16 ENGINE) 5) Install timing belt and tensioner spring (2). With two sets of marks aligned and tensioner plate pushed up, install timing belt on two pulleys in such a way that drive side of belt (1) is free from any slack. And then install tensioner spring as shown in figure, and handtighten tensioner stud (3).
Page 312: Oil Pan And Oil Pump Strainer
ENGINE MECHANICAL (G16 ENGINE) 6A1-21 9) Install radiator fan shroud, water pump pulley, cooling fan and water pump drive belt. Adjust water pump drive belt tension referring to “Cooling Fan Belt Tension Check and Adjustment” in Section 6B. 10) Install power steering pump belt or A/C compressor belt, if equipped.
Page 313 6A1-22 ENGINE MECHANICAL (G16 ENGINE) REMOVAL 1) Raise vehicle. 2) Remove front differential housing (1) with differential (2) referring to “Dismounting” in Section 7E. 3. Oil pan 3) Disconnect CKP sensor coupler and remove CKP sensor by removing its bolt. (if equipped) 4) Drain engine oil by removing drain plug (2).
Page 314 ENGINE MECHANICAL (G16 ENGINE) 6A1-23 CLEANING • Clean mating surfaces of oil pan and cylinder block. Remove oil, old sealant, and dusts from mating surfaces and oil pan inside. • Clean oil pump strainer screen. INSTALLATION 1) Apply sealant to oil pan mating surface continuously as “A”...
Page 315 6A1-24 ENGINE MECHANICAL (G16 ENGINE) 2) Install new seal (2) in the position as shown in figure. 3) Install oil pump strainer (1) and oil pan (3). Tighten strainer bolt first and then bracket bolt to specified torque. Tightening torque Oil pump strainer bolt (a) : 11 N·m (1.1 kg-m, 8.0 lb-ft) Oil pump strainer bracket bolt...
Page 316: Oil Pump
ENGINE MECHANICAL (G16 ENGINE) 6A1-25 7) Install CKP sensor (1) and connect its coupler. Tightening torque CKP sensor bolt (a) : 10 N·m (1.0 kg-m, 7.5 lb-ft) 8) Install front differential housing with differential referring to “Remounting” in Section 7E. 9) Refill front differential housing with gear oil referring to “Main- tenance Service”...
Page 317 6A1-26 ENGINE MECHANICAL (G16 ENGINE) REMOVAL 1) Disconnect negative cable at battery. 2) Remove timing belt referring to “Timing Belt and Belt Ten- sioner” in this section. 3) Remove generator and its bracket. NOTE: When installing bracket, fasten nut first. 4) Remove crankshaft timing belt pulley (3).
Page 318 ENGINE MECHANICAL (G16 ENGINE) 6A1-27 DISASSEMBLY 1) Remove oil level gauge guide bolt (3) and pull out guide (2) from oil pump (1). 4. Guide seal 2) Remove rotor plate (1). 3) Remove outer rotor (1) and inner rotor (2). INSPECTION •...
Page 319 6A1-28 ENGINE MECHANICAL (G16 ENGINE) NOTE: When installing oil seal (1), press-fit it till its end face is flush with oil pump case (2) end face. • Check outer and inner rotors, rotor plate, and oil pump case for excessive wear or damage. MEASUREMENT •...
Page 320 ENGINE MECHANICAL (G16 ENGINE) 6A1-29 ASSEMBLY 1) Wash, clean and then dry all disassembled parts. 2) Apply thin coat of engine oil to inner and outer rotors (1), oil seal lip portion, and inside surfaces of oil pump case and plate.
Page 321 6A1-30 ENGINE MECHANICAL (G16 ENGINE) 3) Install oil pump to cylinder block. As there are 2 types of oil pump bolts, refer to figure for their correct use and tighten them to specified torque. Tightening torque Oil pump bolt (a) : 11 N·m (1.1 kg-m, 8.0 lb-ft) 1.
Page 322: Rocker Arms, Rocker Arm Shaft And Camshaft
ENGINE MECHANICAL (G16 ENGINE) 6A1-31 10) Refill engine with engine oil referring to item “Engine Oil and Filter Change” in Section 0B. 11) Refill front differential housing with gear oil referring to “Main- tenance Service” in Section 7E. 12) Connect negative cable at battery. 13) Verify that there is no coolant leakage and each oil leakage at each connection.
Page 323 6A1-32 ENGINE MECHANICAL (G16 ENGINE) REMOVAL 1) Disconnect negative cable at battery. 2) Remove engine hood lock (1) from front upper member. 3) Remove radiator referring to “Radiator” in Section 6B. 4) Remove timing belt referring to “Timing Belt and Belt Ten- sioner”...
Page 324 ENGINE MECHANICAL (G16 ENGINE) 6A1-33 9) Remove camshaft housing and camshaft. NOTE: To remove camshaft housing bolts, loosen them in such order as indicated in figure, a little at a time. 10) Remove rocker arm shaft plug (1) and timing belt inside cover (2).
Page 325 6A1-34 ENGINE MECHANICAL (G16 ENGINE) 14) Remove exhaust rocker arms (1) and rocker arm spring (2) by pulling rocker arm shaft to front side. INSPECTION Adjusting Screw and Rocker Arm If tip of adjusting screw (1) is badly worn, replace it. Rocker arm (2) must be replaced if its cam-riding face (3) is badly worn.
Page 326 ENGINE MECHANICAL (G16 ENGINE) 6A1-35 Cam Wear Using a micrometer, measured height of cam. If measured height is below limit, replace camshaft. Cam height Standard Limit 36.184 – 36.344 mm 36.084 mm Intake cam (1.4246 – 1.4308 in.) (1.4206 in.) 35.900 –...
Page 327 6A1-36 ENGINE MECHANICAL (G16 ENGINE) Check clearance by using gaging plastic. The procedure is as follows. 1) Clean housing and camshaft journals. 2) Install camshaft to cylinder head. 3) Place a piece of gaging plastic the full width of journal of camshaft (parallel to camshaft).
Page 328 ENGINE MECHANICAL (G16 ENGINE) 6A1-37 INSTALLATION 1) Apply engine oil to rocker arm shaft and rocker arms. 2) Install rocker arm shaft, rocker arm (exhaust side) (2) and rocker arm spring (1). 3) With O-ring groove in rocker arm shaft (1) exposed to trans- mission side once, install new O-ring (2) to rocker arm shaft.
Page 329 6A1-38 ENGINE MECHANICAL (G16 ENGINE) 6) Fill small amount of engine oil into arm pivot holding part (3) of rocker arm shaft. Install rocker arm (intake side) (1) with clips (2) to rocker arm shaft. 7) Apply engine oil to cams and journals on camshaft and put camshaft on cylinder head.
Page 330 ENGINE MECHANICAL (G16 ENGINE) 6A1-39 8) Install camshaft new oil seal (1). After applying engine oil to oil seal lip, press-fit camshaft oil seal till oil seal surface becomes flush with housing surface. 9) Install rocker arm shaft plug and timing belt inside cover. Then tighten rocker arm shaft plug to specified torque.
Page 331 6A1-40 ENGINE MECHANICAL (G16 ENGINE) 13) After applying sealant to part “A” as shown in figure, install CMP sensor case to cylinder head and tighten its fixing bolts to specified torque. Connect CMP sensor connector. “A” Sealant : 99000-31110 Tightening torque CMP sensor case bolt (a) : 11 N·m (1.1 kg-m, 8.0 lb-ft) 1.
Page 332: Valves And Cylinder Head
ENGINE MECHANICAL (G16 ENGINE) 6A1-41 Valves and Cylinder Head COMPONENTS 68 N·m (6.8 kg-m) 1. Valve cotters 6. Exhaust valve 11. Oil jet 2. Valve spring retainer 7. Intake valve 12. Valve guide 3. Valve spring 8. Cylinder head bolt Tightening torque : Refer to Step 3) of “Installation”.
Page 333 6A1-42 ENGINE MECHANICAL (G16 ENGINE) 4) Remove intake manifold stiffener (1). 5) Remove air intake hose. 6) Disconnect the following electric wires, and then release above wire harnesses from clamps. • Throttle position sensor • Idle air control valve • Engine coolant temp. sensor •...
Page 334 ENGINE MECHANICAL (G16 ENGINE) 6A1-43 11) Remove timing belt and camshaft referring to “Timing Belt and Belt Tensioner” and “Rocker Arms, Rocker Arm Shaft and Camshaft” in this section. 12) Remove generator adjust arm from intake manifold. 13) Remove air conditioning compressor adjust arm from cylin- der head.
Page 335 6A1-44 ENGINE MECHANICAL (G16 ENGINE) DISASSEMBLY 1) For ease in servicing cylinder head, remove intake manifold with throttle body and exhaust manifold from cylinder head. 2) Remove rocker arms and rocker arm shaft referring to “Rocker Arms, Rocker Arm Shaft and Camshaft” in this sec- tion.
Page 336 ENGINE MECHANICAL (G16 ENGINE) 6A1-45 7) Using special tool (Valve guide remover), drive valve guide out from combustion chamber side to valve spring side. Special tool (A) : 09916-44910 NOTE: Do not reuse valve guide once disassembled. Be sure to use new valve guide (Oversize) when assembling.
Page 337 6A1-46 ENGINE MECHANICAL (G16 ENGINE) Valves • Remove all carbon from valves. • Inspect each valve for wear, burn or distortion at its face and stem and, as necessary, replace it. • Measure thickness of valve head. If measured thickness exceeds limit, replace valve.
Page 338 ENGINE MECHANICAL (G16 ENGINE) 6A1-47 • Valve seat repair : A valve seat not producing a uniform contact with its valve or showing width of seating contact that is out of specified range must be repaired by regrinding or by cutting and regrinding and finished by lapping.
Page 339 6A1-48 ENGINE MECHANICAL (G16 ENGINE) • Flatness of gasketed surface : Using a straightedge and thickness gauge, check surface at a total of 6 locations. If distortion limit, given below, is exceeded, correct gasketed surface with a surface plate and abrasive paper of about #400 (Waterproof silicon carbide abrasive paper) : place paper on and over surface plate, and rub gasketed surface against paper to grind off high spots.
Page 340 ENGINE MECHANICAL (G16 ENGINE) 6A1-49 Valve Springs • Referring to data given below, check to be sure that each spring is in sound condition, free of any evidence of break- age 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 341 6A1-50 ENGINE MECHANICAL (G16 ENGINE) ASSEMBLY 1) Before installing valve guide into cylinder head, ream guide hole with special tool (11 mm reamer) so remove burrs and make it truly round. Special tool (A) : 09916-34542 (B) : 09916-38210 2) Install valve guide to cylinder head. Heat cylinder head uniformly at a temperature of 80 to 100°C (176 to 212°F) so that head will not be distorted, and drive new valve guide into hole with special tools.
Page 342 ENGINE MECHANICAL (G16 ENGINE) 6A1-51 5) Install new valve stem seal (1) to valve guide. After applying engine oil to seal and spindle of special tool (Valve guide installer handle), fit oil seal to spindle, and then install seal to valve guide by pushing special tool by hand. After installing, check to be sure that seal is properly fixed to valve guide.
Page 343 6A1-52 ENGINE MECHANICAL (G16 ENGINE) 9) Install rocker arms, springs and rocker arm shaft referring to “Rocker Arms, Rocker Arm Shaft and Camshaft” in this sec- tion. 10) Install intake manifold and exhaust manifold. INSTALLATION 1) Remove old gasket and oil on mating surfaces and install knock pins (4) and new head gasket (1) as shown in figure, that is, “TOP”...
Page 344: Piston, Piston Rings, Connecting Rods And Cylinders
ENGINE MECHANICAL (G16 ENGINE) 6A1-53 7) Adjust intake and exhaust valve lashes referring to “Valve Lash (Clearance)” in this section. 8) Adjust accelerator cable play and A/T throttle cable play. Refer to “Accelerator Cable Adjustment” and “A/T Throttle Cable Adjustment” in Section 6E1. 9) Check to ensure that all removed parts are back in place.
Page 345 6A1-54 ENGINE MECHANICAL (G16 ENGINE) REMOVAL 1) Remove cylinder head from cylinder block referring to “Valves and Cylinder Head” in this section. 2) Drain engine oil. 3) Remove oil pan and oil pump strainer referring to “Oil Pan and Oil Pump Strainer” in this section. 4) Mark cylinder number on all pistons, connecting rods and rod bearing caps, using silver pencil or quick drying paint.
Page 346 ENGINE MECHANICAL (G16 ENGINE) 6A1-55 CLEANING Clean carbon from piston head and ring grooves using a suitable tool. INSPECTION Cylinders 1) Inspect cylinder walls for scratches, roughness or ridges which indicate excessive wear. If cylinder bore is very rough or deeply scratched or ridged, rebore cylinder and use over- size piston.
Page 347 6A1-56 ENGINE MECHANICAL (G16 ENGINE) 3) Piston clearance : Measure cylinder bore diameter and piston diameter to find their difference which is piston clearance. Piston clearance should be within specification as given below. If it is out of specification, rebore cylinder and use oversize piston. Piston clearance 0.02 –...
Page 348 ENGINE MECHANICAL (G16 ENGINE) 6A1-57 Piston Rings To measure end gap, insert piston ring (3) into cylinder bore and then measure the gap by using thickness gauge (2). If measured gap is out of specification, replace ring. NOTE: Decarbon and clean top of cylinder bore before inserting piston ring.
Page 349 6A1-58 ENGINE MECHANICAL (G16 ENGINE) Crank Pin and Connecting Rod Bearings 1) Inspect crank pin for uneven wear or damage. Measure crank pin for out-of-round or taper with a micrometer. If crank pin is damaged, or out-of-round or taper is out of limit, replace crankshaft or regrind crank pin referring to following Step f).
Page 350 ENGINE MECHANICAL (G16 ENGINE) 6A1-59 e) Remove cap and using a scale (2) on gaging plastic (1) envelope, measure gaging plastic width at the widest point (clearance). If clearance exceeds its limit, use a new standard size bear- ing and remeasure clearance. Connecting rod bearing oil clearance Standard : 0.020 –...
Page 351 6A1-60 ENGINE MECHANICAL (G16 ENGINE) c) Stamped number on piston and that on cylinder block should correspond. That is, install number 2 stamped pis- ton to cylinder which is identified with number 2 and a num- ber 1 piston to cylinder with number 1. Piston and Cylinder specification Piston Cylinder...
Page 352 ENGINE MECHANICAL (G16 ENGINE) 6A1-61 3) After installing three rings (1st, 2nd and oil rings), distribute their end gaps as shown in figure. 1. Arrow mark 5. Oil ring lower rail gap 2. 1st ring end gap 6. Intake side 3.
Page 353 6A1-62 ENGINE MECHANICAL (G16 ENGINE) 5) Install bearing cap (1) : Point arrow mark (2) on cap to crankshaft pulley side (3). Tighten cap nuts to specification. Tightening torque Connecting rod bearing cap nut (a) : 35 N·m (3.5 kg-m, 25.5 lb-ft) 6) Reverse removal procedure for installation, as previously outlined.
Page 354: Unit Repair Overhaul
ENGINE MECHANICAL (G16 ENGINE) 6A1-63 Unit Repair Overhaul Engine Assembly REMOVAL 1) Release fuel pressure in fuel feed line by referring to “Fuel Pressure Relief Procedure” in Section 6. 2) Disconnect negative cable from battery. 3) Remove engine hood. 4) Drain cooling system. 5) Remove radiator fan and fan shroud.
Page 355 6A1-64 ENGINE MECHANICAL (G16 ENGINE) 9) Disconnect the following hoses : • Canister purge hose from EVAP canister purge valve • Radiator outlet hose from inlet pipe • Brake booster hose from intake manifold • Vacuum hose from intake manifold •...
Page 356 ENGINE MECHANICAL (G16 ENGINE) 6A1-65 16) Remove right side transmission stiffener from transmission and cylinder block (A/T). 17) Remove clutch housing (torque converter housing) lower plate. 18) Remove torque converter bolts (A/T). Special tool (A) : 09927-56010 19) Remove nuts fastening cylinder block and transmission. 20) Lower vehicle.
Page 357 6A1-66 ENGINE MECHANICAL (G16 ENGINE) 22) Install lifting device. 23) Remove engine mounting bracket nuts (R & L). 24) Before lifting engine, check to ensure all hoses, electric wires and cables are disconnected from engine. 25) Remove engine assembly from chassis and transmission by lifting a little, sliding towards the front side, and then carefully hoist engine assembly.
Page 358 ENGINE MECHANICAL (G16 ENGINE) 6A1-67 5) Reverse removal procedure for installation, noting the follow- ing. • Tighten torque converter bolts to specified torque (A/T). Tightening torque Torque converter bolt (a) : 65 N·m (6.5 kg-m, 47.0 lb-ft) • Tighten nuts fastening cylinder block and transmission to specified torque.
Page 359 6A1-68 ENGINE MECHANICAL (G16 ENGINE) 9) Check to ensure that all removed parts are back in place. Reinstall any necessary parts which have not been rein- stalled. 10) Refill engine with engine oil referring to item “Engine Oil and Filter Change” in Section 0B. 11) Refill cooling system referring to “Cooling System Flush and Refill”...
Page 360: Main Bearings, Crankshaft And Cylinder Block
ENGINE MECHANICAL (G16 ENGINE) 6A1-69 Main Bearings, Crankshaft and Cylinder Block COMPONENTS...
Page 361 6A1-70 ENGINE MECHANICAL (G16 ENGINE) 1. Cylinder block 6. Timing pulley key 11. Housing bolt (short) 16. Flywheel bolt 2. Front oil seal 7. Crankshaft 12. Oil seal housing Tightening turque : Apply sealant 99000- 31250 to mating surface. 3. Main bearing 8.
Page 362 ENGINE MECHANICAL (G16 ENGINE) 6A1-71 9) Loosen crankshaft bearing cap bolts in such order as indi- cated in figure a little at a time and remove bearing caps. 10) Remove crankshaft from cylinder block. INSPECTION Crankshaft Crankshaft runout Using a dial gauge, measure runout at center journal. Rotate crankshaft slowly.
Page 363 6A1-72 ENGINE MECHANICAL (G16 ENGINE) Out-of-round and taper (uneven wear) of journals An unevenly worn crankshaft journal shows up as a difference in diameter at a cross section or along its length (or both). This dif- ference, if any, is determined by taking micrometer readings. If any one of journals is badly damaged or if amount of uneven wear in the sense explained above exceeds its limit, regrind or replace crankshaft.
Page 364 ENGINE MECHANICAL (G16 ENGINE) 6A1-73 Main bearing clearance Check clearance by using gaging plastic according to following procedure. 1) Remove bearing caps. 2) Clean bearings and main journals. 3) Place a piece of gaging plastic (1) to full width of bearing (parallel to crankshaft) on journal, avoiding oil hole.
Page 365 6A1-74 ENGINE MECHANICAL (G16 ENGINE) Selection of main bearings STANDARD BEARING : NOTE: • If bearing is in malcondition, or bearing clearance is out of specification, select a new standard bearing according to following procedure and install it. • When replacing crankshaft or cylinder block due to any reason, select new standard bearings to be installed by referring to numerals stamped on new crankshaft and/or alphabets stamped on mating sur-...
Page 366 ENGINE MECHANICAL (G16 ENGINE) 6A1-75 2) Next, check bearing cap bore diameter without bearing. On mating surface of cylinder block, five alphabets are stamped as shown in figure. Three kinds of alphabets (“A”, “B” and “C”) represent the fol- lowing cap bore diameters. Crankshaft bearing cap bore diameter specification Bearing cap bore diameter Alphabet stamped...
Page 367 6A1-76 ENGINE MECHANICAL (G16 ENGINE) 4) From numerals stamped on crank webs of No.2 and No.3 cylinders and the alphabets stamped on mating surface of cylinder block, determine new standard bearing to be installed to journal, by referring to table given below. For example, if numeral stamped on crank web is “1”...
Page 368 ENGINE MECHANICAL (G16 ENGINE) 6A1-77 • If necessary, regrind crankshaft journal and select under- size bearing to use with it as follows. 1) Regrind journal to the following finished diameter. Finished diameter of crankshaft journal 51.732 – 51.750 mm (2.0367 – 2.0373 in.) 2) Using micrometer, measure reground journal diameter.
Page 369 6A1-78 ENGINE MECHANICAL (G16 ENGINE) For oil seal installation, press-fit rear oil seal (1) so that oil seal housing (2) end face is flush with oil seal end face. Flywheel • If ring gear is damaged, cracked or worn, replace flywheel. •...
Page 370 ENGINE MECHANICAL (G16 ENGINE) 6A1-79 3) Using micrometer, measure piston diameter. 1. 23 mm (0.91 in.) 4) Calculate cylinder bore diameter to be rebored. D = A + B – C D : Cylinder bore diameter to be rebored. A : Piston diameter as measured. B : Piston clearance = 0.02 –...
Page 371 6A1-80 ENGINE MECHANICAL (G16 ENGINE) 2) Install thrust bearings (1) to cylinder block between No.2 and No.3 cylinders. Face oil groove (2) sides to crank webs. 3) Install crankshaft to cylinder block. 4) Install bearing cap to cylinder block, making sure to point arrow mark (on each cap) to crankshaft pulley side.
Page 372 ENGINE MECHANICAL (G16 ENGINE) 6A1-81 8) Install oil pump referring to “Oil Pump” in this section. 9) Install flywheel (M/T model) or drive plate (A/T model). Using special tool, lock flywheel or drive plate, and torque its bolts to specification. Special tool (A) : 09924-17811 Tightening torque...
Page 373: Special Tool
6A1-82 ENGINE MECHANICAL (G16 ENGINE) Special Tool 09915-67311 09918-08210 09915-77311 See NOTE “A”. Vacuum gauge Vacuum gauge hose joint Oil pressure gauge 09917-18211 09927-56010 09926-18210 09917-68221 Tappet adjuster wrench Gear stopper Oil seal guide (Vinyl resin) Camshaft pulley holder 09916-84511 09916-44910 09916-34542 See NOTE “B”.
Page 374: Required Service Material
“A” : 1. 09915-64510-001 Compression gauge, 2. 09915-64510-002 Connector, 3. 09915-64530 Hose, 4. 09915-67010 Attachment “B” : 1. 09916-14510 Valve lifter, 2. 09916-14910 Valve lifter attachment Required Service Material Recommended SUZUKI product Material (Part Number) • Mating surfaces of cylinder block SUZUKI BOND NO.1207F...
Page 375: Tightening Torque Specifications
6A1-84 ENGINE MECHANICAL (G16 ENGINE) Tightening Torque Specifications Tightening torque Fastening part N•m kg-m lb-ft Oil pressure switch 10.5 Rocker arm adjusting screw lock nut Cylinder head cover bolt Exhaust No.1 pipe bolt or nut 36.5 Heated oxygen sensor-1 32.5 Tensioner stud Tensioner bolt 19.5...
Page 376 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
Page 377: General Description
6A2-2 ENGINE MECHANICAL (H25 ENGINE) General Description Engine The engine is a water-cooled, 60° V6 cylinders, 4 stroke cycle gasoline unit with its DOHC (Double overhead camshaft) valve mechanism arranged for “V” type valve configuration. The double overhead camshaft is mounted over the cylinder head; it is driven from crankshaft through timing chains, and no push rods are provided in the valve train system.
Page 378: Engine Lubrication
ENGINE MECHANICAL (H25 ENGINE) 6A2-3 Engine Lubrication The oil pump is of a 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 3 paths in cylinder block. In one path, oil reaches the crankshaft journal bearings.
Page 379: On-Vehicle Service
6A2-4 ENGINE MECHANICAL (H25 ENGINE) On-Vehicle Service Compression Check Check compression pressure on all 6 cylinders as follows : 1) Warm up engine. 2) Stop engine after warming up. 3) Remove ignition coil covers and disconnect ignition coil har- ness couplers. 4) Remove all ignition coils (1) and spark plugs (2).
Page 380: Engine Vacuum Check
3way joint between vacuum hose and valve. Special tool (A) : 09915-67311 (B) : 09918-08210 SUZUKI GENUINE PARTS (C) : Hose 09355-35754 (D) : 3way joint 09367-04002 4) Start engine and run engine at specified idle speed, and read vacuum gauge. Vacuum should be within specification.
Page 381: Oil Pressure Check
6A2-6 ENGINE MECHANICAL (H25 ENGINE) Oil Pressure Check NOTE: Prior to checking oil pressure, check the followings. • Oil level in oil pan If oil level is low, add oil up to Full level hole on oil level gauge. • Oil quality If oil is discolored, or deteriorated, change it.
Page 382: Air Cleaner Element
ENGINE MECHANICAL (H25 ENGINE) 6A2-7 4) After warming up, raise engine speed to 4,000 r/min. (rpm) and measure oil pressure. Oil pressure specification 390 – 470 kPa (3.9 – 4.7 kg/cm , 55.5 – 66.8 psi) at 4,000 r/ min (rpm) 5) After checking oil pressure, stop engine and remove oil pres- sure gauge.
Page 383 6A2-8 ENGINE MECHANICAL (H25 ENGINE) CLEAN Blow off dust by blowing compressed air from air outlet side of element (i.e., the side facing up when installed in air cleaner case). INSTALLATION 1) Install element to air cleaner box. 2) Install air cleaner upper case.
Page 384: Throttle Body And Intake Manifold
ENGINE MECHANICAL (H25 ENGINE) 6A2-9 Throttle Body and Intake Manifold COMPONENTS 1. Air cleaner box 3. Intake air pipe 5. Intake manifold 7. Intake collector 9. Manifold absolute pressure (MAP) sensor 2. Intake air hose 4. Surge tank pipe 6. Throttle body 8.
Page 385 6A2-10 ENGINE MECHANICAL (H25 ENGINE) 3) Drain coolant. WARNING: To help avoid danger of being burned, do not remove drain plug (2) and radiator cap while engine and radiator (1) are still hot. Scalding fluid and steam can be blown out under pressure if plug and cap are taken off too soon.
Page 386 ENGINE MECHANICAL (H25 ENGINE) 6A2-11 11) Disconnect injector wire (1) coupler. 12) Disconnect brake booster hose (2) from intake manifold. 13) Disconnect couplers of TP sensor (1), MAF sensor (2) and IAC valve (3). 14) Disconnect earth terminal (4) from intake collector. 15) Remove clamp bracket (5) from intake collector.
Page 387 6A2-12 ENGINE MECHANICAL (H25 ENGINE) 21) Remove throttle body (1) and intake collector (2) from intake manifold (3). 22) Disconnect IAC valve hose (1) and EVAP canister purge hose valve from intake collector. 23) Remove throttle body (2) from intake collector. 24) Remove IAC valve, EGR valve and EVAP canister purge valve from intake collector.
Page 388 ENGINE MECHANICAL (H25 ENGINE) 6A2-13 2) Install intake manifold (1) tightening bolts (2) and nuts (3). 3) Install throttle body (2) to intake collector (1) with new throttle body gasket. 4) Install IAC valve (1), EGR valve (2), EVAP canister purge valve (3), manifold absolute pressure (MAP) sensor, clamps (6) and each hoses to intake collector and throttle body if removed.
Page 389 6A2-14 ENGINE MECHANICAL (H25 ENGINE) 7) Install EGR pipe (3) with new gaskets. 8) Connect EVAP canister purge valve hose (4) and heater hose (5). 9) Connect PCV hose (6), breather hose (8) and water hose (7). 10) Connect couplers of manifold absolute pressure (MAP) sen- sor, EVAP canister purge valve (1) and EGR valve (2).
Page 390 ENGINE MECHANICAL (H25 ENGINE) 6A2-15 19) Install surge tank cover (1). 20) Install air cleaner upper case. 21) Connect coupler to intake air temp. sensor. 22) Install strut tower bar (1) and tighten strut tower bar mount- ing bolts to specified torque. Tightening torque Strut tower bar mounting bolts (a): 50 N·m (5.0 kg-m, 36.5 lb-ft)
Page 391: Exhaust Manifold
6A2-16 ENGINE MECHANICAL (H25 ENGINE) Exhaust Manifold COMPONENTS [A] : Vehicle not equipped with warm up three way catalytic 1. Exhaust manifold 3. Exhaust No. 1 pipe 5. Exhaust No.1 pipe converter [B] : Vehicle equipped with warm up catalytic converter 2.
Page 392 ENGINE MECHANICAL (H25 ENGINE) 6A2-17 8) For 4WD vehicle, before disconnecting front propeller shaft, put match mark (1) on joint flange and propeller shaft to facil- itate their installation as shown in figure. 9) For 4WD vehicle, disconnect propeller shaft from front differ- ential.
Page 393 6A2-18 ENGINE MECHANICAL (H25 ENGINE) INSTALLATION 1) Install new manifold gaskets to cylinder heads and No.1 pipe gasket to exhaust No.1 pipe. 2) Install exhaust manifolds. • Always install new bolts with pre-coated adhesive to the locations with mark. • Tighten both manifold nuts and bolts to specified torque. Tightening torque Exhaust manifold nut and bolt (a) : 30 N·m (3.0 kg-m, 22.0 lb-ft)
Page 394 ENGINE MECHANICAL (H25 ENGINE) 6A2-19 Tightening torque Exhaust No.1 pipe nut (b) : 50 N·m (5.0 kg-m, 36.5 lb-ft) [A] : Vehicle not equipped with warm up three way catalytic converter [B] : Vehicle equipped with warm up catalytic converter 1.
Page 395: Cylinder Head Covers
6A2-20 ENGINE MECHANICAL (H25 ENGINE) 10) Connect negative cable to battery. 11) Upon completion of installation, start engine and check that no exhaust gas leakage exists. Cylinder Head Covers COMPONENTS 11 N·m (1.1 kg-m) 1. Cylinder head cover 4. Cylinder head cover side seal 7.
Page 396 ENGINE MECHANICAL (H25 ENGINE) 6A2-21 INSTALLATION 1) Clean sealing surfaces on cylinder heads and covers. 2) Remove oil, old sealant, and dust from sealing surfaces. After cleaning, apply sealant “A” to cylinder heads sealing surface area as shown in figure. “A”...
Page 397: Oil Pan And Oil Pump Strainer
6A2-22 ENGINE MECHANICAL (H25 ENGINE) Oil Pan and Oil Pump Strainer COMPONENTS 1. Upper oil pan 4. Bracket 7. Gasket : Apply sealant 99000-31250 to mating surface of upper oil pan and lower crankcase. 2. Lower oil pan 5. O-ring Tightening torque : Apply sealant 99000-31250 to mating surface of lower oil pan and upper oil pan.
Page 398 ENGINE MECHANICAL (H25 ENGINE) 6A2-23 9) Remove upper oil pan according to the following procedures. a) Lower upper oil pan until it stops by way of cross member and oil pump strainer and keep it at that position tempo- rarily. b) With wrench inserted between upper oil pan and lower crankcase, and oil pump strainer mounting bolt removed, remove oil pump strainer.
Page 399 6A2-24 ENGINE MECHANICAL (H25 ENGINE) 3) Apply sealant “A” to upper oil pan (1) sealing surface area as shown in figure. “A” “A” : Sealant 99000-31250 Sealant amount “A” “b” Width “a” : 3 mm (0.12 in.) Height “b” : 2 mm (0.08 in.) “a”...
Page 400 ENGINE MECHANICAL (H25 ENGINE) 6A2-25 7) Apply sealant “A” to lower oil pan sealing surface area as shown in figure. “A” : Sealant 99000-31250 Sealant amount Width “a” : 3 mm (0.12 in.) Height “b” : 2 mm (0.08 in.) 8) Install lower oil pan to upper oil pan.
Page 401: Timing Chain Cover
6A2-26 ENGINE MECHANICAL (H25 ENGINE) Timing Chain Cover COMPONENTS 1. Timing chain cover 3. Crankshaft pulley bolt 5. O-ring 7. CKP sensor bolt Tightening Apply engine oil torque 2. Crankshaft pulley 4. Oil seal 6. CKP sensor 8. Timing chain cover bolt Do not reuse REMOVAL 1) Disconnect negative cable at battery.
Page 402 ENGINE MECHANICAL (H25 ENGINE) 6A2-27 14) Remove crankshaft pulley bolt. To lock crankshaft pulley (1), use special tool (camshaft pul- ley holder) as shown in figure. Special tool (A) : 09917-68221 CAUTION: Be sure to use the following bolt (2) for fixing special tool to crankshaft pulley.
Page 403 6A2-28 ENGINE MECHANICAL (H25 ENGINE) INSTALLATION Reverse removal sequence to install timing chain cover noting the following points. • Using special tool (bearing installer), install new oil seal, its surface is flash with edge of timing chain cover. Special tool (D) : 09913-75510 •...
Page 404 ENGINE MECHANICAL (H25 ENGINE) 6A2-29 • Apply engine oil to O-ring of CKP sensor (4) and install CKP sensor to timing chain cover. Tightening torque CKP sensor bolt (b) : 6 N·m (0.6 kg-m, 4.5 lb-ft) • Install crankshaft pulley (1). To lock crankshaft pulley, use special tool (camshaft pulley holder) with it at shown in figure.
Page 405: Oil Pump
6A2-30 ENGINE MECHANICAL (H25 ENGINE) Oil Pump COMPONENTS 11 N·m (1.1 kg-m) 12 N·m (1.2 kg-m) 27 N·m (2.7 kg-m) 1. OIl pump chain 5. Oil pump No.1 case 9. Case pin Tightening torque 2. Oil pump chain guide 6. Relief valve 10.
Page 406 ENGINE MECHANICAL (H25 ENGINE) 6A2-31 5) Loosen oil pump chain guide bolts (4). 1. Oil pump assembly 2. Oil pump chain guide 3. Oil pump chain 6) Remove oil pump (1) from crankcase (2). CAUTION: Do not remove oil pump sprocket or bolt. Otherwise, oil pump sprocket and/or oil pump rotor shaft might be damaged.
Page 407 6A2-32 ENGINE MECHANICAL (H25 ENGINE) INSPECTION • Check outer rotor, inner rotor and oil pump cases for exces- sive wear or damage. • Check relief valve for excessive wear or damage. • Measure free length and tension of oil relief spring (1). Oil pump relief spring length Standard : 63.5 mm (2.5 in.) Oil pump preload...
Page 408 ENGINE MECHANICAL (H25 ENGINE) 6A2-33 ASSEMBLY 1) Wash, clean and then dry all disassembled parts. 2) Apply thin coat of engine oil to inner and outer rotors, and inside surfaces of oil pump case. 3) Assemble oil pump. After assembling oil pump check to be sure that rotor turns smoothly by hand.
Page 409: Lh (No.1) Bank 2Nd Timing Chain And Chain Tensioner
6A2-34 ENGINE MECHANICAL (H25 ENGINE) LH (No.1) Bank 2nd Timing Chain and Chain Tensioner COMPONENTS 1. LH bank 2nd timing chain 5. Camshaft sprocket bolt 9. Timing chain tensioner adjuster No.3 bolt Tightening torque 2. Timing chain tensioner adjuster No.3 6.
Page 410 ENGINE MECHANICAL (H25 ENGINE) 6A2-35 5) Turn crankshaft to meet following condition. • Key (1) on crankshaft positions as shown. • Arrow mark on idler sprocket No.2 (2) points the center of crankshaft. • The marks on sprockets (3) match with marks on cylinder head.
Page 411 6A2-36 ENGINE MECHANICAL (H25 ENGINE) 9) Remove LH bank intake camshaft sprocket. 10) Remove LH bank 2nd timing chain. INSPECTION Timing chain guide No.4 and No.5 Check shoe (3) for wear or damage. 1. Timing chain guide No.4 2. Timing chain guide No.5 Camshaft sprocket Check teeth of sprocket (1) for wear or damage.
Page 412 ENGINE MECHANICAL (H25 ENGINE) 6A2-37 • Check that latch (1) and tooth surface (2) are free from dam- age and latch functions properly. INSTALLATION 1) Check timing mark on crankshaft as shown in figure. 1. Crank timing pulley key 2. Oil jet 2) Check timing mark on idler sprocket No.2 (1) as shown in fig- ure.
Page 413 6A2-38 ENGINE MECHANICAL (H25 ENGINE) 4) Check that knock-pins of intake and exhaust camshafts are aligned with match marks on cylinder head as shown in fig- ure. 1. Knock pin of LH bank intake camshaft 2. Knock pin of LH bank exhaust camshaft 3.
Page 414 ENGINE MECHANICAL (H25 ENGINE) 6A2-39 9) Install timing chain tensioner adjuster No.3 (1) in tightening order below. Tightening torque Timing chain tensioner adjuster No.3 bolt (c) : 11 N·m (1.1 kg-m, 8.0 lb-ft) Timing chain tensioner adjuster No.3 nut (d) : 45 N·m (4.5 kg-m, 32.5 lb-ft) Tightening order for tensioner adjuster bolt and nuts →...
Page 415: 1St Timing Chain And Chain Tensioner
6A2-40 ENGINE MECHANICAL (H25 ENGINE) 12) Apply oil to timing chains, tensioner adjusters, sprockets and guides. 13) Install timing chain cover, oil pan, front differential housing, P/S system, cooling system, intake manifold with throttle body and other parts. 14) Refill cooling system, P/S system, front differential and engine with each oil/fluid.
Page 416 ENGINE MECHANICAL (H25 ENGINE) 6A2-41 REMOVAL 1) Disconnect negative cable at battery. 2) Drain engine oil. 3) Drain coolant. 4) Remove timing chain cover. Refer to “Timing Chain Cover” in this section for removal. 5) For reinstallation of timing chain, align 8 timing marks as shown in figure by turning crankshaft.
Page 417 6A2-42 ENGINE MECHANICAL (H25 ENGINE) INSPECTION Timing Chain Guides No.1 and No.2 Check shoe for wear or damage. 1. Timing chain guide No.1 2. Timing chain guide No.2 Timing Chain Tensioner Check shoe (1) for wear or damage. 1st Timing Chain Crankshaft Sprocket Check teeth of sprocket (1) for wear or damage.
Page 418 ENGINE MECHANICAL (H25 ENGINE) 6A2-43 Idler Sprocket No.1 Check teeth of sprocket (2) for wear or damage. 1. Bearing Idler Sprocket No.2 Check teeth of sprocket (2) for wear or damage. 1. Bush 1st Timing Chain Check timing chain (1) for wear or damage. Timing Chain Tensioner Adjuster No.1 Check that latch (1) and tooth surface (2) are free from damage and latch functions properly.
Page 419 6A2-44 ENGINE MECHANICAL (H25 ENGINE) INSTALLATION 1) Check timing mark on crankshaft as shown in figure. 1. Crank timing pulley key 2. Oil jet 2) Install 1st timing chain crankshaft sprocket (2) to crankshaft (1) as shown in figure. Confirm that tooth for CKP sensor are free from metal parti- cles and damage.
Page 420 ENGINE MECHANICAL (H25 ENGINE) 6A2-45 5) Install timing chain tensioner (1) as shown in figure. Tightening torque Timing chain tensioner nut (b) : 27 N·m (2.7 kg-m, 19.5 lb-ft) 2. Spacer 3. RH bank cylinder head 6) Install 1st timing chain by aligning match marks on RH silver plate (1) of 1st timing chain and RH bank 1st timing chain intake camshaft sprocket.
Page 421 6A2-46 ENGINE MECHANICAL (H25 ENGINE) 12) Install idler sprocket No.1 (1). Tightening torque Idler sprocket No.1 bolt (c) : 45 N·m (4.5 kg-m, 32.5 lb-ft) 13) With latch (2) of tensioner adjuster No.1 (4) returned and plunger (1) pushed back into body, insert stopper (3) into latch and body.
Page 422 ENGINE MECHANICAL (H25 ENGINE) 6A2-47 1. Crank timing pulley key 4. Silver plate (LH) of 1st timing chain 7. Match mark of crankshaft timing sprocket 2. Oil jet 5. Match mark of idler sprocket No.2 8. Yellow plate of 1st timing chain 3.
Page 423: Rh (No.2) Bank 2Nd Timing Chain And Chain Tensioner
6A2-48 ENGINE MECHANICAL (H25 ENGINE) RH (No.2) Bank 2nd Timing Chain and Chain Tensioner COMPONENTS 1. RH bank 2nd timing chain 6. RH bank intake camshaft 11. Timing chain guide No.3 bolt 2. Timing chain tensioner adjuster No.2 7. RH bank exhaust camshaft housing 12.
Page 424 ENGINE MECHANICAL (H25 ENGINE) 6A2-49 REMOVAL 1) For reinstallation of timing chain, align 12 timing marks as shown in figure by turning crankshaft. 2) Remove LH bank 2nd timing chain. Refer to “LH (No.1) Bank 2nd Timing Chain and Chain Ten- sioner”...
Page 425 6A2-50 ENGINE MECHANICAL (H25 ENGINE) INSPECTION Timing Chain Guide No.3 Check shoe (1) for wear or damage. RH Bank 2nd Timing Chain Sprockets Check teeth of sprocket for wear or damage. RH Bank 2nd Timing Chain Check timing chain (1) for wear or damage. Timing Chain Tensioner Adjuster No.2 •...
Page 426 ENGINE MECHANICAL (H25 ENGINE) 6A2-51 INSTALLATION 1) Check timing mark on crankshaft as shown in figure. 1. Crank timing pulley key 2. Oil jet 2) Apply oil to timing chain tensioner adjuster No.2 (1). 3) Install timing chain tensioner adjuster No.2. Tightening torque Timing chain tensioner adjuster No.2 bolt (a) : 11 N·m (1.1 kg-m, 8.0 lb-ft)
Page 427 6A2-52 ENGINE MECHANICAL (H25 ENGINE) 7) Check position of camshaft housings. Embossed marks are provided on each camshaft housing, indicating position and direction for installation. Install hous- ings as indicated by these marks. 1. I: Intake side, E: Exhaust side 2.
Page 428: Oil Pump Chain
ENGINE MECHANICAL (H25 ENGINE) 6A2-53 Oil Pump Chain COMPONENTS 1. Oil pump chain 3. Oil pump chain tensioner (oil pump guide) Tightening torque 2. Oil pump drive sprocket 4. Oil pump chain guide bolt Apply engine oil to sliding surface of each part REMOVAL 1) Disconnect negative cable at battery.
Page 429 6A2-54 ENGINE MECHANICAL (H25 ENGINE) 7) Put match marks (3) to oil pump chain (1) and oil pump sprocket (2). 8) Remove oil pump chain guide. 9) Remove oil pump chain. 10) Remove oil pump drive sprocket. INSPECTION Oil Pump Chain Guide Check shoe (1) for wear or damage.
Page 430 ENGINE MECHANICAL (H25 ENGINE) 6A2-55 Oil Pump Chain Check oil pump chain for wear or damage. INSTALLATION 1) Install oil pump drive sprocket (2) as shown in figure. 1. Crankshaft 3. Crankcase 2) Install oil pump chain (1) by aligning match marks (3) on oil pump chain and oil pump sprocket (2).
Page 431 6A2-56 ENGINE MECHANICAL (H25 ENGINE) 5) Install 1st timing chain. Refer to “1st Timing Chain and Chain Tensioner” in this sec- tion for installation. 6) Install LH bank 2nd timing chain. Refer to “LH (No.1) Bank 2nd Timing Chain and Chain Ten- sioner”...
Page 432: Camshaft And Valve Lash Adjuster
ENGINE MECHANICAL (H25 ENGINE) 6A2-57 Camshaft and Valve Lash Adjuster COMPONENTS 1. RH bank 2nd timing chain 6. LH bank intake camshaft 11. Timing chain guide No.5 2. RH bank exhaust camshaft 7. LH bank exhaust camshaft 12. Valve lash adjuster 3.
Page 433 6A2-58 ENGINE MECHANICAL (H25 ENGINE) REMOVAL 1) Disconnect negative cable at battery. 2) Drain engine oil. 3) Drain coolant. 4) Remove timing chain cover. Refer to “Timing Chain Cover” in this section for removal. 5) Remove LH bank 2nd timing chain. Refer to “LH (No.1) Bank 2nd Timing Chain and Chain Ten- sioner”...
Page 434 ENGINE MECHANICAL (H25 ENGINE) 6A2-59 INSPECTION Cam Wear Using a micrometer (1), measure cam height. If measured height is below its limit, replace camshaft. Cam height Standard Limit 39.445 – 39.605 mm 39.400 mm Intake cam (1.5530 – 1.5592 in.) (1.5511 in.) 39.428 –...
Page 435 6A2-60 ENGINE MECHANICAL (H25 ENGINE) Check clearance by using gaging plastic. The procedure is as fol- lows. 1) Clean housings and camshaft journals. 2) Make sure that all valve lash adjusters are removed and install camshaft to cylinder head. 3) Place a piece of gaging plastic the full width of journal of camshaft (parallel to camshaft).
Page 436 ENGINE MECHANICAL (H25 ENGINE) 6A2-61 Wear of Hydraulic Valve Lash Adjuster Check adjuster for pitting, scratches, or damage. If any malcondition is found, replace. Measure cylinder head bore and adjuster outside diameter to determine cylinder head-to-adjuster clearance. If clearance exceeds limit, replace adjuster or cylinder head. Hydraulic valve lash adjuster O.D.
Page 437 6A2-62 ENGINE MECHANICAL (H25 ENGINE) INSTALLATION CAUTION: • Don’t turn camshafts or start engine (i.e., valves should not be operated) for about half an hour after reinstalling hydraulic valve lash adjusters and cam- shafts. As it takes time for valves to settle in place, operating engine within half an hour after their installa- tion may cause interference to occur between valves themselves or valves and piston.
Page 438 ENGINE MECHANICAL (H25 ENGINE) 6A2-63 3) Check timing mark on crankshaft as shown in figure. 1. Crank timing pulley key 2. Oil jet 4) Install RH bank camshafts, referring to “RH (No.2) Bank 2nd Timing Chain and Chain Tensioner” in this section for instal- lation.
Page 439 6A2-64 ENGINE MECHANICAL (H25 ENGINE) 9) After applying oil to housing bolts, tighten them temporarily first. Then tighten them by following sequence as indicated in figure. Tighten a little at a time and evenly among bolts and repeat tightening sequence two or three times before they are tightened to specified torque below.
Page 440: Valve Lash Adjuster Noise Diagnosis
ENGINE MECHANICAL (H25 ENGINE) 6A2-65 Valve Lash Adjuster Noise Diagnosis In case of the followings, valve lash adjuster noise may be caused by air trapped into valve lash adjusters. • Vehicle is left for 24 hours or more. • Engine oil is changed. •...
Page 441: Valves And Cylinder Heads
6A2-66 ENGINE MECHANICAL (H25 ENGINE) Valves and Cylinder Heads COMPONENTS 1. Cylinder block 6. Exhaust valve 11. Valve stem oil seal 16. Cylinder head bolt (hex hole bolt) 2. RH bank cylinder head 7. Intake valve 12. Valve spring retainer Tightening Torque 3.
Page 442 ENGINE MECHANICAL (H25 ENGINE) 6A2-67 REMOVAL 1) Relieve fuel pressure according to procedure described in “Fuel Pressure Relief Procedure” of Section 6-1. 2) Disconnect negative cable at battery. 3) Drain engine oil. 4) Drain coolant. 5) Remove CMP sensor, camshaft and valve lash adjuster. Refer to “CMP Sensor”...
Page 443 6A2-68 ENGINE MECHANICAL (H25 ENGINE) DISASSEMBLY 1) Using special tools (A), (B) & (C), compress valve springs and then remove valve cotters (1) by using special tool (D). Special tool (A) : 09916-14510 (B) : 09916-14910 (C) : 09919-28610 (D) : 09916-84511 2) Release special tool, and remove spring retainer and valve spring.
Page 444 ENGINE MECHANICAL (H25 ENGINE) 6A2-69 5) Using special tool (E) (Valve guide remover), drive valve guide out from combustion chamber side to valve spring side. Special tool (E) : 09916-44910 NOTE: Do not reuse valve guide once disassembled. Be sure to use new valve guide (Oversize) when assembling.
Page 445 6A2-70 ENGINE MECHANICAL (H25 ENGINE) • Inspect valve stem end face for pitting and wear. If pitting or wear is found there, valve stem end may be resurfaced, but not too much to grind off its chamber. When it is worn out too much that its chamber is gone, replace valve.
Page 446 ENGINE MECHANICAL (H25 ENGINE) 6A2-71 • Valve seat repair : A valve seat not producing a uniform contact with its valve or showing width of seating contact that is out of specified range must be repaired by regrinding or by cutting and regrinding and finished by lapping.
Page 447 6A2-72 ENGINE MECHANICAL (H25 ENGINE) • Check cylinder head for cracks on intake and exhaust ports, combustion chambers, and head surface. Using straightedge and thickness gauge, check flatness of gasketed surface at a total of 6 locations. If distortion limit, given below, is exceeded, correct gasketed surface with a surface plate and abrasive paper of about #400 (Waterproof silicon carbide abrasive paper) : Place abrasive paper on...
Page 448 ENGINE MECHANICAL (H25 ENGINE) 6A2-73 Valve Springs • Referring to data given below, check to be sure that each spring is in sound condition, free of any evidence of break- age 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 449 6A2-74 ENGINE MECHANICAL (H25 ENGINE) ASSEMBLY 1) Before installing valve guide into cylinder head, ream guide hole with special tool (11 mm reamer) so as to remove burrs and make it truly round. Special tool (E) : 09916-34542 (F) : 09916-38210 2) Install valve guide to cylinder head.
Page 450 ENGINE MECHANICAL (H25 ENGINE) 6A2-75 5) Install new valve stem seal (1) to valve guide. After applying engine oil to seal and spindle of special tool (Valve guide installer handle), fit oil seal to spindle, and then install seal to valve guide by pushing special tool by hand. After installing, check to be sure that seal is properly fixed to valve guide.
Page 451 6A2-76 ENGINE MECHANICAL (H25 ENGINE) INSTALLATION 1) Clean mating surface on cylinder head and cylinder block. Remove oil, old gasket and dust from mating surface. 2) Install knock pin (4) to cylinder block. 3) Apply sealant “A” to cylinder head gasket (1) as shown in fig- ure.
Page 452 ENGINE MECHANICAL (H25 ENGINE) 6A2-77 7) Check timing mark on crankshaft as shown in figure. 1. Crank timing pulley key 2. Oil jet 8) Install valve lash adjuster, camshaft, CMP sensor and RH bank 2nd timing chain. Refer to “Camshaft and Valve Lash Adjuster” and “RH (No.2) Bank 2nd Timing Chain and Chain Tensioner”...
Page 453 6A2-78 ENGINE MECHANICAL (H25 ENGINE) 21) Refill engine with engine oil, referring to “Engine Oil and Fil- ter Change” in Section 0B. 22) Refill cooling system referring to “Cooling System Flush and Refill” in Section 6B. 23) Refill front differential housing with gear oil if drained, refer- ring to “Maintenance Service”...
Page 454: Piston, Piston Rings, Connecting Rods And Cylinders
ENGINE MECHANICAL (H25 ENGINE) 6A2-79 Piston, Piston Rings, Connecting Rods and Cylinders COMPONENTS 1. Top ring 5. Connecting rod : 9. Piston pin circlip Tightening Torque Clean bearing installing surface when install. 2. 2nd ring 6. Connecting rod bearing cap : 10.
Page 455 6A2-80 ENGINE MECHANICAL (H25 ENGINE) 5) Remove oil pump. Refer to “Oil Pump” in this section for removal. 6) Mark cylinder number on all pistons, connecting rods and connecting rod caps. 7) Remove rod bearing caps. 8) Install guide hose (1) over threads of rod bolts. This prevents damage to bearing journal and rod bolt threads when removing connecting rod.
Page 456 ENGINE MECHANICAL (H25 ENGINE) 6A2-81 INSPECTION Cylinders • Inspect cylinder walls for scratches, roughness, or ridges which indicate excessive wear. If cylinder bore is very rough or deeply scratched, or ridged, rebore cylinder and use over size piston. • Using a cylinder gauge, measure cylinder bore in thrust and axial directions at two positions as shown in figure.
Page 457 6A2-82 ENGINE MECHANICAL (H25 ENGINE) • Piston clearance : Measure cylinder bore diameter and piston diameter to find their difference which is piston clearance. Piston clearance should be within specification as given below. If it is out of specification, rebore cylinder and use oversize piston. Piston clearance 0.02 –...
Page 458 ENGINE MECHANICAL (H25 ENGINE) 6A2-83 Piston Rings To measure end gap, insert piston ring (3) into cylinder bore and then measure the gap by using thickness gauge (2). If measure gap is out of specification, replace ring. NOTE: Clean carbon and any other dirt from top of cylinder bore before inserting piston ring.
Page 459 6A2-84 ENGINE MECHANICAL (H25 ENGINE) Crank Pin and Connecting Rod Bearings • Crank pin diameter : Inspect crank pin for uneven wear or damage. Measure crank pin for out-of-round or taper with a micrometer. If crank pin is damaged, or out-of-round or taper is out of limit, replace crankshaft or regrind crank pin referring to the follow- ing Step 6).
Page 460 ENGINE MECHANICAL (H25 ENGINE) 6A2-85 4) Install rod bearing cap to connecting rod. When installing cap, be sure to point arrow mark on cap to crankshaft pulley side, as shown in the figure. After applying engine oil to rod bolts, tighten cap nuts to specified torque. Tightening torque Connecting rod bearing cap nut (a) : 45 N·m (4.5 kg-m, 32.5 lb-ft)
Page 461 6A2-86 ENGINE MECHANICAL (H25 ENGINE) 1) Check stamped numbers on connecting rod and its cap as shown. Three kinds of numbers (“1”, “2” and “3”) represent the fol- lowing connecting rod big end inside diameters. For example, stamped number “1” indicates that correspond- ing connecting rod big end inside diameter is 53.0000 –...
Page 462 ENGINE MECHANICAL (H25 ENGINE) 6A2-87 3) There are five kinds of standard bearings differing in thick- ness. To distinguish them, they are painted in the following colors at the position as indicated in figure. Each color indicated the following thickness at the center of bearing.
Page 463 6A2-88 ENGINE MECHANICAL (H25 ENGINE) 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. a) Each piston has stamped number (1 or 2) on its piston head.
Page 464 ENGINE MECHANICAL (H25 ENGINE) 6A2-89 NOTE: • Install circlip (6) with its cut part facing as shown in fig- ure. • Install so that circlip end gap comes within such range as indicated by arrow “A”. 1. Piston 2. Arrow mark 3.
Page 465 6A2-90 ENGINE MECHANICAL (H25 ENGINE) 2) Install guide hoses over connecting rod bolts. These guide hoses protect crank pin and threads of rod bolt from damage during installation of connecting rod and piston assembly. 3) When installing piston and connecting rod assembly into cyl- inder bore, point arrow mark on piston head to crankshaft pulley side.
Page 466 ENGINE MECHANICAL (H25 ENGINE) 6A2-91 8) Install 1st timing chain. Refer to “1st Timing Chain and Chain Tensioner” in this sec- tion for installation. 9) Install LH bank 2nd timing chain. Refer to “LH (No.1) Bank 2nd Timing Chain and Chain Ten- sioner”...
Page 467: Unit Repair Overhaul
6A2-92 ENGINE MECHANICAL (H25 ENGINE) Unit Repair Overhaul Engine Assembly REMOVAL 1) Release fuel pressure in fuel feed line. Refer to “Fuel Pressure Relief Procedure” in Section 6-1. 2) Disconnect negative cable at battery. 3) Remove engine hood. 4) Drain engine oil. 5) Drain coolant.
Page 468 ENGINE MECHANICAL (H25 ENGINE) 6A2-93 12) Disconnect following electric lead wires : • Injector wire coupler • CMP sensor coupler • Ignition coil couplers • CKP sensor coupler • MAP sensor coupler • TP sensor coupler (1) • MAF sensor coupler (2) •...
Page 469 6A2-94 ENGINE MECHANICAL (H25 ENGINE) 23) Remove exhaust No.1 pipe. Refer to “Exhaust Manifold” in this section for removal. 24) Remove exhaust manifold stiffener from transmission. 25) Remove A/T fluid hose clamps (1) from engine mounting bracket (2). (for A/T vehicle) 26) Remove clutch housing lower plate.
Page 470 ENGINE MECHANICAL (H25 ENGINE) 6A2-95 34) Before lifting engine, check to ensure all hoses, wires and cables are disconnected from engine. 35) Remove engine assembly from chassis and transmission by sliding toward front, and then, carefully hoist engine assem- bly. INSTALLATION Reverse removal procedure for installation, noting following points.
Page 471 6A2-96 ENGINE MECHANICAL (H25 ENGINE) 6) Tighten bolts and nuts of exhaust No.1 pipe (1) to specified torque. Tightening torque Exhaust No.1 pipe bolt and nut (d) : 50 N·m (5.0 kg-m, 36.5 lb-ft) [A] : Vehicle not equipped with warm up three way catalytic converter [B] : Vehicle equipped with warm up catalytic converter 7) Install front differential housing with differential to chassis if removed.
Page 472: Main Bearings, Crankshaft And Cylinder Block
ENGINE MECHANICAL (H25 ENGINE) 6A2-97 Main Bearings, Crankshaft and Cylinder Block COMPONENTS 1. Cylinder block 7. Flywheel (M/T) Drive 13. Cap bolt [A]: Sealant application plate (A/T) amount 2. Lower crankcase : 8. Water pump 14. Lower crankcase bolt Tightening Torque Apply sealant 99000-31250 to lower crankcase mating surface.
Page 473 6A2-98 ENGINE MECHANICAL (H25 ENGINE) REMOVAL 1) Remove engine assembly from vehicle referring to “Engine Assembly” in this section. 2) Remove clutch and flywheel (for M/T vehicle) or drive plate (for A/T vehicle). For clutch removal, refer to “Clutch Cover, Clutch Disc and Flywheel”...
Page 474 ENGINE MECHANICAL (H25 ENGINE) 6A2-99 Crankshaft thrust play 1) Measure this play with crankshaft set in cylinder block in the normal manner, that is, with thrust bearing and lower crank- case (1) installed. Tighten crankcase bolts gradually as fol- lows. a) Tighten all bolts to 42 N·m (4.2 kg-m, 30.5 lb-ft) according to numerical order in figure.
Page 475 6A2-100 ENGINE MECHANICAL (H25 ENGINE) Out-of-round and taper (uneven wear) of journals An unevenly worn crankshaft journal shows up as a difference in diameter at a cross section or along its length (or both). This dif- ference, if any, is determined by taking micrometer readings. If any one of journals is badly damaged or if amount of uneven wear in the sense explained above exceeds its limit, regrind or replace crankshaft.
Page 476 ENGINE MECHANICAL (H25 ENGINE) 6A2-101 Main bearing clearance Check clearance by using gaging plastic according to following procedure. 1) Remove crankcase. 2) Clean bearings and main journals. 3) Place a piece of gaging plastic (1) to full width of bearing (parallel to crankshaft) on journal, avoiding oil hole.
Page 477 6A2-102 ENGINE MECHANICAL (H25 ENGINE) 5) Remove crankcase and using scale (2) on gaging plastic (1) envelop, measure gaging plastic width at its widest point. If clearance exceeds its limit, replace bearing. Always replace both upper and lower inserts as a unit. A new standard bearing may produce proper clearance.
Page 478 ENGINE MECHANICAL (H25 ENGINE) 6A2-103 2) Next, check crankcase (bearing cap) bore diameter without bearing. On lower surface of lower crankcase 4 alphabets are stamped as shown in figure. Three kinds of alphabets (A, B and C) represent following cap bore diameters. Main bearing cap bore diameter specification Bearing cap bore diameter Stamped alphabet...
Page 479 6A2-104 ENGINE MECHANICAL (H25 ENGINE) 4) From number stamped on crank webs at its center and alphabets stamped on crankcase lower side, determine new standard bearing to be installed to journal, by referring to table shown below. For example, if number stamped on crank webs is “1” and alphabet stamped on crankcase is “B”, install a new stan- dard bearing painted in “Black”...
Page 480 ENGINE MECHANICAL (H25 ENGINE) 6A2-105 b) Using micrometer, measure reground journal diameter. Measurement should be taken in two directions perpendic- ular to each other in order to check for out-of-round. c) Using journal diameter measured above and alphabets stamped on lower crankcase, select an undersize bearing by referring to table given below.
Page 481 6A2-106 ENGINE MECHANICAL (H25 ENGINE) Cylinder Block Distortion of gasketed surface • Using straightedge and thickness gauge, check gasketed surface for distortion and, if flatness exceeds its limit, correct Flatness limit of cylinder block 0.06 mm (0.0024 in.) Honing or reboring cylinders 1) When any cylinder needs reboring, all other cylinders must also be rebored at the same time.
Page 482 ENGINE MECHANICAL (H25 ENGINE) 6A2-107 INSTALLATION NOTE: • All parts to be installed must be perfectly clean. • Be sure to oil crankshaft journals, journal bearings, thrust bearings, crank pins, connecting rod bearings, pistons, piston rings and cylinder bores. • Journal bearings, crankcase (bearings caps), connect- ing rods, rod bearings, rod bearing caps, pistons and piston rings are in combination sets.
Page 483 6A2-108 ENGINE MECHANICAL (H25 ENGINE) 6) Install crankcase (1) to cylinder block. Apply oil to crankcase bolts before installing them. Tighten crankcase bolts gradu- ally as follows. a) Tighten all bolts to 42 N·m (4.2 kg-m, 30.5 lb-ft) according to numerical order in figure. b) Loosen all bolts until tightening torque is reduced to 0 in reverse order of tightening.
Page 484 ENGINE MECHANICAL (H25 ENGINE) 6A2-109 8) Install flywheel (M/T vehicle) or drive plate (A/T vehicle). Using special tool, lock flywheel or drive plate, and tighten flywheel or drive plate bolts (1) applied with sealant to speci- fication. “A” : Sealant 1215 99000-31110 Special tool (A) : 09924-17811 Tightening torque...
Page 485: Special Tool
6A2-110 ENGINE MECHANICAL (H25 ENGINE) Special Tool 09911-97811 09913-75510 09915-47311 09915-64512 Oil seal installer Bearing installer Oil filter wrench Compression gauge 09915-64530 09915-67010 09915-67311 09915-77311 Compression gauge hose Compression gauge Vacuum gauge Oil pressure gauge attachment (c) 09916-34542 09916-37810 09916-38210 See NOTE.
Page 486 ENGINE MECHANICAL (H25 ENGINE) 6A2-111 09917-68221 09917-87810 09917-98221 09918-08210 Camshaft lock holder Valve guide installer Valve stem seal installer Vacuum gauge hose joint 09919-28610 09924-17811 09926-58010 09944-36011 Protective sleeve Flywheel holder Bearing puller attachment Steering wheel remover 09911-97710 09915-76510 Oil seal guide Oil pressure gauge attachment NOTE:...
Page 487: Required Service Material
Required Service Material Recommended SUZUKI product Material (Part Number) Sealant SUZUKI BOND No. 1207F • To apply to mating surfaces of cylin- 99000-31250 der block and oil pan. • To apply to mating surfaces of cylin- der block and timing chain cover.
Page 488 ENGINE MECHANICAL (H25 ENGINE) 6A2-113 Tightening Torque Specifications Tightening torque Fastening part N•m kg-m lb-ft Oil pressure switch 10.5 Strut tower bar mounting bolt 36.5 Exhaust manifold nut and bolt 22.0 Cylinder head cover nut Exhaust No.1 pipe bolt or nut 36.5 Front propeller shaft universal join flange bolt 40.0...
Page 489 6A2-114 ENGINE MECHANICAL (H25 ENGINE)
Page 490: Engine Mechanical (J20 Engine)
• Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
Page 491: General Description
6A4-2 ENGINE MECHANICAL (J20 ENGINE) General Description Engine 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 and 16 valves (4 valves/one cylinder). The double overhead camshaft is mounted over the cylinder head;...
Page 492: Engine Lubrication
ENGINE MECHANICAL (J20 ENGINE) 6A4-3 Engine Lubrication The oil pump is of a 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 2 paths in cylinder block. In one path, oil reaches the crankshaft journal bearings.
Page 493: On-Vehicle Service
6A4-4 ENGINE MECHANICAL (J20 ENGINE) On-Vehicle Service Compression Check Check compression pressure on all 4 cylinders as follows : 1) Warm up engine. 2) Stop engine after warming up. NOTE: After warming up engine, place transmission gear shift lever in “Neutral” (shift selector lever to “P” range for A/T model), and set parking brake and block drive wheels.
Page 494 ENGINE MECHANICAL (J20 ENGINE) 6A4-5 10) Crank engine with fully charged battery, and read the highest pressure on compression gauge. NOTE: For measuring compression pressure, crank engine at least 250 r/min. by using fully charged battery. Compression pressure specification 1400 kPa Standard (14.0 kg/cm , 199.0 psi)
Page 495: Engine Vacuum Check
Special tool (A) : 09915-67311 (B) : 09918-08210 SUZUKI GENUINE PARTS (C) : Hose 09355-35754 (D) : 3-way joint 09367-04002 4) Start engine and run engine at specified idle speed (see “Idle Speed/Idle Air Control Duty Inspection” in Section 6E1), and read vacuum gauge.
Page 496: Oil Pressure Check
ENGINE MECHANICAL (J20 ENGINE) 6A4-7 Oil Pressure Check 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 sys- tem has cooled down. NOTE: Prior to checking oil pressure, check the followings.
Page 497: Air Cleaner Element
6A4-8 ENGINE MECHANICAL (J20 ENGINE) 3) Start engine and warm it up to normal operating tempera- ture. NOTE: Be sure to place transmission gear shift lever in “Neu- tral” (shift selector lever to “P” range for A/T model), and set parking brake and block drive wheels. 4) After warming up, raise engine speed to 4,000 r/min and measure oil pressure.
Page 498: Throttle Body And Intake Manifold
ENGINE MECHANICAL (J20 ENGINE) 6A4-9 CLEAN Blow off dust by compressed air from air outlet side of element. INSTALLATION Reverse removal procedure for installation. Throttle Body and Intake Manifold COMPONENTS 1. Intake manifold 4. Fuel delivery pipe 7. Intake manifold front stiffener 2.
Page 499 6A4-10 ENGINE MECHANICAL (J20 ENGINE) 3) Drain coolant. WARNING: To help avoid danger of being burned, do not remove drain plug and radiator cap while engine and radiator are still hot. Scalding fluid and steam can be blown out under pressure if plug and cap are taken off too soon.
Page 500 ENGINE MECHANICAL (J20 ENGINE) 6A4-11 INSTALLATION Reverse removal procedure for installation noting the followings. • Use new intake manifold gasket (1). • Install fuel delivery pipe with fuel injectors to cylinder head referring to “Fuel Injector” in Section 6E1. • Adjust accelerator cable play and A/T throttle cable play (for vehicle with A/T) referring to “Accelerator Cable Adjustment”...
Page 501: Exhaust Manifold
6A4-12 ENGINE MECHANICAL (J20 ENGINE) Exhaust Manifold COMPONENTS [A] : Vehicle not equipped with warm up three way catalytic converter 3. Heated oxygen sensor-1 Tightening torque [B] : Vehicle equipped with warm up three way catalytic converter 4. Exhaust manifold upper cover Do not reuse.
Page 502 ENGINE MECHANICAL (J20 ENGINE) 6A4-13 4) Remove exhaust manifold stiffener (1) if equipped. 5) Remove exhaust No.1 pipe bolts or nuts and exhaust pipe bracket bolt (if equipped). 1. Exhaust No.1 pipe 6) Remove exhaust manifold (1) and its gasket (2) from cylinder head.
Page 503 6A4-14 ENGINE MECHANICAL (J20 ENGINE) 2) Install exhaust manifold. 3) Install seal ring and install exhaust No.1 pipe (1) to exhaust manifold. Before installing seal ring, check it for deterioration or dam- age, and replace as necessary. Use new lock nuts if used. Tighten pipe fasteners to specified torque.
Page 504: Cylinder Head Cover
ENGINE MECHANICAL (J20 ENGINE) 6A4-15 Cylinder Head Cover REMOVAL 1) Disconnect negative cable at battery. 2) Disconnect ignition coil couplers. 3) Remove ignition coils. 4) Disconnect accelerator cable from clamp (For LH steering vehicle only). 5) Remove oil level gauge (1). 6) Disconnect breather hose (2) and PCV hose (3) from cylin- der head cover.
Page 505: Oil Pan And Oil Pump Strainer
6A4-16 ENGINE MECHANICAL (J20 ENGINE) 5) Install cylinder head cover to cylinder head. Tighten nuts (3) in such order as indicated in figure a little at a time till they are tightened to specified torque. • Use new seal washers (1). Tightening torque Cylinder head cover nut (a) : 11 N·m (1.1 kg-m, 8.0 lb-ft) 6) Install ignition coils and connect ignition coil couplers.
Page 506 ENGINE MECHANICAL (J20 ENGINE) 6A4-17 REMOVAL 1) Remove oil level gauge. 2) Raise vehicle and remove both front wheels. 3) Remove steering gear box (4) from vehicle referring to “Power Steering Gear Box Assembly” in Section 3B1. 4) Remove front differential housing (1) with differential (2) from chassis.
Page 507 6A4-18 ENGINE MECHANICAL (J20 ENGINE) INSTALLATION 1) To facilitate and ensure installation of oil pan, increase clear- ance between engine and vehicle body according to follow- ing procedure. a) Remove strut tower bar. b) Disconnect exhaust pipe from exhaust manifold. c) Remove engine mounting nuts (Right &...
Page 508 ENGINE MECHANICAL (J20 ENGINE) 6A4-19 6) Install new gasket and drain plug (2) to oil pan (1). Tighten drain plug to specified torque. Tightening torque Drain plug (a) : 50 N·m (5.0 kg-m, 36.5 lb-ft) 7) Install clutch (torque converter) housing lower plate. 8) Connect exhaust No.1 pipe to exhaust manifold referring to “Exhaust Manifold”...
Page 509: Oil Pump
6A4-20 ENGINE MECHANICAL (J20 ENGINE) Oil Pump COMPONENTS 1. Cylinder block 3. Oil pump sprocket 5. Oil pump bolt Tightening torque 2. Oil pump 4. Oil pump sprocket cover 6. Oil pump sprocket cover bolt REMOVAL 1) Disconnect negative cable at battery. 2) Drain engine oil.
Page 510 ENGINE MECHANICAL (J20 ENGINE) 6A4-21 DISASSEMBLY • Disassemble oil pump as shown in figure. 1. Oil pump case No.1 4. Relief valve 2. Oil pump case No.2 5. Relief spring 3. Outer rotor 6. Retainer INSPECTION • Check outer rotor, inner rotor and oil pump cases for exces- sive wear or damage.
Page 511 6A4-22 ENGINE MECHANICAL (J20 ENGINE) Radial Clearance Check radial clearance between outer rotor (2) and case (1) using thickness gauge (4). If clearance exceeds its limit, replace outer rotor or case. Limit on radial clearance between outer rotor and case 0.15 mm (0.0059 in.) 3.
Page 512 ENGINE MECHANICAL (J20 ENGINE) 6A4-23 INSTALLATION 1) Install oil pump (2) to lower crankcase (1) and tighten bolts to specified torque. NOTE: When installing oil pump, be careful not to allow pins to fall off. Tightening torque Oil pump bolt (a) : 27 N·m (2.7 kg-m, 19.5 lb-ft) 2) Install oil pump sprocket cover (1), and tighten bolts to speci- fied torque.
Page 513: Timing Chain Cover
6A4-24 ENGINE MECHANICAL (J20 ENGINE) Timing Chain Cover COMPONENTS 1. Cylinder head cover 7. Timing chain cover 13. Oil pan bolt and nut : Apply sealant 99000-31250 to mating surface of cover. : Apply sealant 99000-31140 to mating surface of cylinder head and cylinder block.
Page 514 ENGINE MECHANICAL (J20 ENGINE) 6A4-25 REMOVAL 1) Disconnect negative cable at battery. 2) Drain engine oil. 3) Drain coolant. 4) Remove oil pan and oil pump strainer referring to “Oil Pan and Oil Pump Strainer” in this section. 5) Remove cylinder head cover referring to “Cylinder Head Cover”...
Page 515 6A4-26 ENGINE MECHANICAL (J20 ENGINE) 16) Remove crankshaft pulley (1). If it is hard to remove, use special tools (Steering wheel remover and Bearing puller attachment) as shown in figure. If bolts of steering wheel remover are too long, replace them with those of suitable length.
Page 516 ENGINE MECHANICAL (J20 ENGINE) 6A4-27 2) Apply sealant “A” and “B” to area as shown in figure. “A” : Sealant 99000-31250 “B” : Sealant 99000-31140 “a” : 3 mm (0.12 in.) “b” : 2 mm (0.08 om/) 1. Timing chain cover 2.
Page 517 6A4-28 ENGINE MECHANICAL (J20 ENGINE) 5) Install A/C compressor bracket (2) if equipped. Tighten bracket bolts to specified torque. Tightening torque Compressor bracket bolt (a) : 55 N·m (5.5 kg-m, 40.0 lb-ft) 6) Install generator belt idler pulley (1). Tighten nut to specified torque. Tightening torque Generator belt idler pulley nut (b) : 42 N·m (4.2 kg-m, 30.5 lb-ft)
Page 518: 2Nd Timing Chain And Chain Tensioner
ENGINE MECHANICAL (J20 ENGINE) 6A4-29 2nd Timing Chain and Chain Tensioner COMPONENTS 1. 2nd timing chain 6. Timing chain guide No.2 11. Timing chain tensioner adjuster No.2 bolt 2. Timing chain tensioner adjuster No.2 7. Tensioner adjuster No.2 gasket Tightening torque 3.
Page 519 6A4-30 ENGINE MECHANICAL (J20 ENGINE) REMOVAL 1) Disconnect negative cable at battery. 2) Drain engine oil. 3) Drain coolant. 4) Remove oil pan and oil pump strainer referring to “Oil Pan and Oil Pump Strainer” in this section. 5) Remove cylinder head cover referring to “Cylinder Head Cover”...
Page 520 ENGINE MECHANICAL (J20 ENGINE) 6A4-31 CAUTION: After 2nd timing chain is removed, never turn intake cam- shaft, exhaust camshaft and crankshaft independently more than such an extent as shown. If turned, interfer- ence may occur between piston and valves and valves themselves, and parts related to piston and valves may be damaged.
Page 521 6A4-32 ENGINE MECHANICAL (J20 ENGINE) Tensioner Adjuster No.2 • Check shoe (1) for wear or damage. INSTALLATION 1) Check that crank timing sprocket key (1) is in match with tim- ing mark (2) on cylinder block as shown in figure. 2) Check that arrow mark on idler sprocket (1) faces upward as shown in figure.
Page 522 ENGINE MECHANICAL (J20 ENGINE) 6A4-33 5) Install sprockets to intake and exhaust camshafts by aligning dark blue plate (1) of 2nd timing chain with arrow marks on intake sprocket and exhaust sprocket respectively. CAUTION: Do not turn camshaft more than allowable turning range. If turned excessively, valve and piston may get damaged.
Page 523 6A4-34 ENGINE MECHANICAL (J20 ENGINE) 10) Turn crankshaft clockwise at two rotations, then align timing mark on crankshaft and timing mark on cylinder block as shown in figure. Check that timing marks of cylinder head and cylinder block are in match with match marks on sprockets respectively. 1.
Page 524: 1St Timing Chain And Chain Tensioner
ENGINE MECHANICAL (J20 ENGINE) 6A4-35 1st Timing Chain and Chain Tensioner 1. 1st timing chain 6. Timing chain tensioner adjuster No.1 11. Timing chain guide bolt 2. Idler sprocket 7. Timing chain guide No.1 Tightening torque 3. Idler sprocket shaft 8.
Page 525 6A4-36 ENGINE MECHANICAL (J20 ENGINE) 7) For reinstallation of timing chain, turn crankshaft so that tim- ing marks on cylinder head and cylinder block match with those on sprockets as shown in figure. 8) Remove 2nd timing chain referring to “2nd Timing Chain and Chain Tensioner”...
Page 526 ENGINE MECHANICAL (J20 ENGINE) 6A4-37 Timing Chain Tensioner • Check shoe (1) for wear or damage. Crankshaft Timing Sprocket • Check teeth of sprocket for wear or damage. Idler Sprocket • Check teeth and bush (1) of sprocket for wear or damage. 1st Timing Chain •...
Page 527 6A4-38 ENGINE MECHANICAL (J20 ENGINE) Timing Chain Tensioner Adjuster No.1 • Check that latch (1) and tooth surface (2) are free from dam- age and latch functions properly. INSTALLATION 1) Check that crank timing sprocket key (1) is in match with tim- ing mark (2) on cylinder block.
Page 528 ENGINE MECHANICAL (J20 ENGINE) 6A4-39 6) Match yellow plate (4) of 1st timing chain (3) to match mark (2) on crankshaft timing sprocket (1). 7) Install timing chain tensioner (1) as shown in figure. Tightening torque Timing chain tensioner nut (a) : 25 N·m (2.5 kg-m, 18.5 lb-ft) 2.
Page 529 6A4-40 ENGINE MECHANICAL (J20 ENGINE) 12) Check that dark blue plate (2) and yellow plate (4) of 1st tim- ing chain are in match with match marks on sprockets respectively. 1. Match mark on idler sprocket 3. Match mark on crank timing sprocket 13) Install 2nd timing chain referring to “2nd Timing Chain and Chain Tensioner”...
Page 530: Camshafts And Valve Lash Adjusters
ENGINE MECHANICAL (J20 ENGINE) 6A4-41 Camshafts and Valve Lash Adjusters CAUTION: • Don’t turn camshafts or start engine (i.e., valves should not be operated) for about half an hour after reinstalling hydraulic valve lash adjusters and camshafts. As it takes time for valves to settle in place, operating engine within half an hour after their installation may cause interference to occur between valves themselves or valves and piston.
Page 531 6A4-42 ENGINE MECHANICAL (J20 ENGINE) COMPONENTS 1. Intake camshaft 6. Valve lash adjuster Tightening torque 2. Exhaust camshaft 7. CMP sensor Apply engine oil to sliding surface of each part. 3. Camshaft housing 8. Oil relief valve 4. Intake camshaft housing 9.
Page 532 ENGINE MECHANICAL (J20 ENGINE) 6A4-43 REMOVAL 1) Disconnect negative cable at battery. 2) Drain engine oil. 3) Drain coolant. 4) Remove oil pan and oil pump strainer referring to “Oil Pan and Oil Pump Strainer” in this section. 5) Remove cylinder head cover referring to “Cylinder Head Cover”...
Page 533 6A4-44 ENGINE MECHANICAL (J20 ENGINE) 13) Remove valve lash adjusters (2). NOTE: • Never disassemble hydraulic valve lash adjuster. • Don’t apply force to body of adjuster, oil in high pres- sure chamber in adjuster will leak. • Immerse removed adjuster in clean engine oil (1) and keep it there till reinstalling it so as to prevent oil leak- age.
Page 534 ENGINE MECHANICAL (J20 ENGINE) 6A4-45 Camshaft Journal Wear Check camshaft journals and camshaft housings for pitting, scratches, wear or damage. If any malcondition is found, replace camshaft or cylinder head with housing. Never replace cylinder head without replacing hous- ings. Check clearance by using gaging plastic.
Page 535 6A4-46 ENGINE MECHANICAL (J20 ENGINE) If measured camshaft journal clearance exceeds limit, measure journal (housing) bore and outside diameter of camshaft journal. Replace camshaft or cylinder head assembly whichever the differ- ence from specification is greater. Camshaft journal bore dia. (intake and exhaust) Standard : 26.000 –...
Page 536 ENGINE MECHANICAL (J20 ENGINE) 6A4-47 Oil Relief Valve Check oil relief valve for clogging and ball for being stuck. INSTALLATION 1) Before installing valve lash adjuster to cylinder head (1), fill oil passage of cylinder head with engine oil according to fol- lowing procedure.
Page 537 6A4-48 ENGINE MECHANICAL (J20 ENGINE) 4) Install camshafts. Apply oil to sliding surface of each camshaft and camshaft journal then install them by aligning match marks on cylinder head and pins on camshafts as shown in figure. NOTE: Install camshaft in such direction that its end with groove for CMP sensor installation comes to exhaust side.
Page 538 ENGINE MECHANICAL (J20 ENGINE) 6A4-49 9) Install CMP sensor referring to “CMP Sensor” in Section 6F2. 10) Install 2nd timing chain referring to “2nd Timing Chain and Chain Tensioner” in this section. 11) Install timing chain cover referring to “Timing Chain Cover” in this section.
Page 539: Valves And Cylinder Head
6A4-50 ENGINE MECHANICAL (J20 ENGINE) Valves and Cylinder Head COMPONENTS “A” : Apply sealant (SUZUKI BOND No. 1215, 8. Valve spring (outer) 16. Cylinder head bolt 99000-31110) to thread 1. Cylinder block 9. Valve spring (inner) 17. Cylinder head bolt (M6) 2.
Page 540 ENGINE MECHANICAL (J20 ENGINE) 6A4-51 5) Remove strut tower bar. 6) Remove air cleaner outlet hose. 7) Disconnect the following electric lead wires : • EGR valve coupler • IAC valve coupler • TP sensor coupler • EVAP canister purge valve coupler •...
Page 541 6A4-52 ENGINE MECHANICAL (J20 ENGINE) 13) Disconnect exhaust No. 1 pipe (1) from exhaust manifold (2). 14) Remove exhaust manifold stiffener (1) (if equipped). 15) Loosen cylinder head bolts in such order as indicated in fig- ure and remove them. NOTE: Don’t forget to remove bolt (M6) shown in figure.
Page 542 ENGINE MECHANICAL (J20 ENGINE) 6A4-53 DISASSEMBLY 1) When servicing cylinder head, remove intake manifold, injec- tors, exhaust manifold, water outlet pipe and water outlet cap from cylinder head. 2) Using special tools, compress valve springs and then remove valve cotters (1). Special tool (A) : 09916-14510 (B) : 09916-14910...
Page 543 6A4-54 ENGINE MECHANICAL (J20 ENGINE) 6) Using special tool (valve guide remover), drive valve guide out from combustion chamber side to valve spring side. Special tool (A) : 09916-44910 NOTE: Do not reuse valve guide once disassembled. Be sure to use new valve guide (oversize).
Page 544 ENGINE MECHANICAL (J20 ENGINE) 6A4-55 • Inspect valve stem end face for pitting and wear. If pitting or wear is found there, valve stem end may be resurfaced, but not too much to grind off its chamber. When it is worn out too much that its chamber is gone, replace valve.
Page 545 6A4-56 ENGINE MECHANICAL (J20 ENGINE) • Valve seat repair : A valve seat not producing a uniform contact with its valve or showing width of seating contact that is out of specified range must be repaired by regrinding or by cutting and regrinding and finished by lapping.
Page 546 ENGINE MECHANICAL (J20 ENGINE) 6A4-57 • Check cylinder head for cracks on intake and exhaust ports, combustion chambers, and head surface. Using straightedge and thickness gauge, check flatness of gasketed surface at a total of 6 locations. If distortion limit, given below, is exceeded, correct gasketed surface with a surface plate and abrasive paper of about #400 (Waterproof silicon carbide abrasive paper) : Place abrasive paper on...
Page 547 6A4-58 ENGINE MECHANICAL (J20 ENGINE) Valve Springs • Referring to data given below, check to be sure that each spring is in sound condition, free of any evidence of break- age 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 548 ENGINE MECHANICAL (J20 ENGINE) 6A4-59 2) Install valve guide to cylinder head. Heat cylinder head uniformly to a temperature of 80 to 100°C (176 to 212°F) so that head will not be distorted, and drive new valve guide into hole with special tools. Drive in new valve guide until special tool (Valve guide installer) contacts cylinder head.
Page 549 6A4-60 ENGINE MECHANICAL (J20 ENGINE) 5) Install new valve stem seal (1) to valve guide. After applying engine oil to seal and spindle of special tool (Valve guide installer handle), fit oil seal to spindle, and then install seal to valve guide by pushing special tool by hand. After installing, check to be sure that seal is properly fixed to valve guide.
Page 550 ENGINE MECHANICAL (J20 ENGINE) 6A4-61 9) Install intake manifold, injectors, exhaust manifold, water out- let pipe (2) and water outlet cap to cylinder head (1). NOTE: When installing water outlet pipe, apply sealant to the thread of the bolt shown in figure. “A”...
Page 551 6A4-62 ENGINE MECHANICAL (J20 ENGINE) d) Tighten all bolts to 53 N·m (5.3 kg-m, 38.5 lb-ft) according to numerical order in figure. e) In the same manner as in 4) again, tighten them to speci- fied torque. Tightening torque Cylinder head bolt (a) : 105 N·m (10.5 kg-m, 76.0 lb-ft) Cylinder head bolt (M6) (b) : 11 N·m (1.1 kg-m, 8.0 lb-ft) NOTE: Be sure to tighten M6 bolt (3) after securing the other...
Page 552: Pistons, Piston Rings, Connecting Rods And Cylinders
ENGINE MECHANICAL (J20 ENGINE) 6A4-63 Pistons, Piston Rings, Connecting Rods and Cylinders COMPONENTS 1. Top ring 7. Connecting rod bearing 13. Connecting rod bearing cap nut : Do not apply engine oil between rod big end and bearing, between cap and bearing. 2.
Page 553 6A4-64 ENGINE MECHANICAL (J20 ENGINE) REMOVAL 1) Relieve fuel pressure referring to “Fuel Pressure Relief Pro- cedure” in Section 6. 2) Disconnect negative cable at battery. 3) Drain engine oil. 4) Drain coolant. 5) Remove cylinder head with intake manifold, exhaust mani- fold and water outlet pipe referring to “Valves and Cylinder Head”...
Page 554 ENGINE MECHANICAL (J20 ENGINE) 6A4-65 • Force piston pin out. CLEANING Clean carbon deposits from piston head and ring grooves, using a suitable tool. INSPECTION Cylinder • Inspect cylinder walls for scratches, roughness, or ridges which indicate excessive wear. If cylinder bore is very rough or deeply scratched, or ridged, rebore cylinder and use over size piston.
Page 555 6A4-66 ENGINE MECHANICAL (J20 ENGINE) Pistons • Inspect piston for faults, cracks or other damages. Damaged or faulty piston should be replaced. • Piston diameter : As indicated in figure, piston diameter should be measured at a position 26.5 mm (1.04 in.) from piston skirt end in the direction perpendicular to piston pin.
Page 556 ENGINE MECHANICAL (J20 ENGINE) 6A4-67 Piston Pin • Check piston pin, connecting rod small end bore and piston bore for wear or damage, paying particular attention to con- dition of small end bore bush. If pin, connecting rod small end bore or piston bore is badly worn or damaged, replace pin, connecting rod or piston.
Page 557 6A4-68 ENGINE MECHANICAL (J20 ENGINE) Connecting Rod • Big-end side clearance : Check big-end of connecting rod for side clearance, with rod fitted and connected to its crank pin in the normal manner. If measured clearance is found to exceed its limit, replace con- necting rod.
Page 558 ENGINE MECHANICAL (J20 ENGINE) 6A4-69 • Connecting rod bearing visual inspection: Inspect bearing shells for signs of fusion, pitting, burn or flak- ing and observe contact pattern. Bearing shells found in defective condition must be replaced. • Connecting rod bearing clearance 1) Before checking bearing clearance, clean bearing and crank pin.
Page 559 6A4-70 ENGINE MECHANICAL (J20 ENGINE) 5) Remove cap and using a scale (2) on gaging plastic (1) envelope, measure gaging plastic (1) width at the widest point (clearance). If clearance exceed its limit, use a new standard size bearing referring to “Selection of Connecting Rod Bearings” in this section.
Page 560 ENGINE MECHANICAL (J20 ENGINE) 6A4-71 1) Check stamped numbers on connecting rod and its cap as shown. Three kinds of numbers (“1”, “2” and “3”) represent the fol- lowing connecting rod big end inside diameters. For example, stamped number “1” indicates that correspond- ing connecting rod big end inside diameter is 53.0000 –...
Page 561 6A4-72 ENGINE MECHANICAL (J20 ENGINE) 3) There are five kinds of standard bearings differing in thick- ness. To distinguish them, they are painted in the following colors at the position as indicated in figure. Each color indicated the following thickness at the center of bearing.
Page 562 ENGINE MECHANICAL (J20 ENGINE) 6A4-73 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. a) Each piston (1) has stamped number (7) 1 or 2 as shown.
Page 563 6A4-74 ENGINE MECHANICAL (J20 ENGINE) 1) Install piston pin to piston (1) and connecting rod : After applying engine oil to piston pin and piston pin holes in piston and connecting rod (3), fit connecting rod to piston as shown in figure and insert piston pin to piston and connect- ing rod, and install piston pin circlips.
Page 564 ENGINE MECHANICAL (J20 ENGINE) 6A4-75 2) Install guide hoses over connecting rod bolts. These guide hoses protect crank pin and threads of rod bolt from damage during installation of connecting rod and piston assembly. 3) When installing piston and connecting rod assembly into cyl- inder bore, point arrow mark on piston head to crankshaft pulley side (1).
Page 565 6A4-76 ENGINE MECHANICAL (J20 ENGINE) 6) Reverse removal procedure for installation. 7) Adjust cooling fan belt tension referring to “Cooling Fan Belt Tension Check and Adjustment” in Section 6B. 8) Adjust accelerator cable play and A/T throttle cable play (for vehicle with A/T) referring to “Accelerator Cable Adjustment”...
Page 566: Engine Mountings
ENGINE MECHANICAL (J20 ENGINE) 6A4-77 Engine Mountings COMPONENTS 1. Engine side mounting bracket nut and bolt 2. Engine mounting frame side bracket bolt 3. Engine mounting frame side bracket nut Tightening torque...
Page 567: Unit Repair Overhaul
6A4-78 ENGINE MECHANICAL (J20 ENGINE) Unit Repair Overhaul Engine Assembly REMOVAL 1) Release fuel pressure in fuel feed line referring to “Fuel Pressure Relief Procedure” in Section 6-1. 2) Disconnect negative cable at battery. 3) Remove engine hood. 4) Remove strut tower bar. 5) Drain coolant.
Page 568 ENGINE MECHANICAL (J20 ENGINE) 6A4-79 8) Disconnect the following electric lead wires : • Injector wire harness coupler • CMP sensor coupler • Ignition coil couplers • TP sensor coupler • MAF sensor coupler • IAT sensor coupler • IAC valve coupler •...
Page 569 6A4-80 ENGINE MECHANICAL (J20 ENGINE) 17) Remove exhaust No.1 pipe bolt or exhaust No.1 pipe (1). 18) Release A/T fluid hoses from clamps (for A/T vehicle). 19) Remove right side transmission stiffener (1) (if equipped). 20) Remove clutch housing lower plate. 21) Remove torque converter bolts (for A/T vehicle).
Page 570 ENGINE MECHANICAL (J20 ENGINE) 6A4-81 25) Install lifting device. 26) Remove engine side mounting bracket nuts from engine mountings. 27) Before lifting engine, check to ensure all hoses, wires and cables are disconnected from engine. 28) Remove engine assembly from chassis and transmission by lifting a little, sliding toward front, and then, carefully hoist engine assembly.
Page 571 6A4-82 ENGINE MECHANICAL (J20 ENGINE) 6) Tighten transmission stiffener bolts to specified torque if equipped. Tightening torque Transmission stiffener bolt (a) : 50 N·m (5.0 kg-m, 36.5 lb-ft) 1. Right side transmission stiffener 7) Tighten bolts or nuts of exhaust No.1 pipe (1) to specified torque.
Page 572: Main Bearings, Crankshaft And Cylinder Block
ENGINE MECHANICAL (J20 ENGINE) 6A4-83 Main Bearings, Crankshaft and Cylinder Block COMPONENTS...
Page 573 6A4-84 ENGINE MECHANICAL (J20 ENGINE) 1. Cylinder block 10. Flywheel (M/T) 19. Crankcase bolt with 10 mm thread Drive plate (A/T) diameter 2. Lower crankcase 11. Clutch housing plate 20. Crankcase bolt with 8 mm thread : Apply sealant 99000-31250 to lower crankcase diameter mating surface referring to Step 5) of “Installation”.
Page 574 ENGINE MECHANICAL (J20 ENGINE) 6A4-85 REMOVAL 1) Remove engine assembly from vehicle referring to “Engine Assembly” in this section. 2) Remove clutch and flywheel (for M/T vehicle) or drive plate (for A/T vehicle). For clutch removal, refer to “Clutch Cover, Clutch Disc and Flywheel”...
Page 575 6A4-86 ENGINE MECHANICAL (J20 ENGINE) 14) Loosen crankcase bolts, follow sequence in figure and remove them. 1. Lower crankcase 2. Bolt (10 mm thread diameter) 3. Bolt (8 mm thread diameter) 15) Remove crankshaft from cylinder block. INSPECTION Crankshaft Crankshaft runout Using a dial gauge, measure runout at center journal.
Page 576 ENGINE MECHANICAL (J20 ENGINE) 6A4-87 Thickness of crankshaft thrust bearing Bearing size Thickness Standard 2.500 mm (0.984 in.) Oversize (0.125 mm (0.0049 in.)) 2.563 mm (0.1009 in.) 1. Thrust bearing 2. Oil groove Out-of-round and taper (uneven wear) of journals An unevenly worn crankshaft journal shows up as a difference in diameter at a cross section or along its length (or both).
Page 577 6A4-88 ENGINE MECHANICAL (J20 ENGINE) 3) Place a piece of gaging plastic (1) the full width of bearing (parallel to crankshaft) on journal, avoiding oil hole. 4) Install lower crankcase (1) to cylinder block. Tighten crankcase bolts, following sequence in figure. Tighten crankcase bolts to specified torque.
Page 578 ENGINE MECHANICAL (J20 ENGINE) 6A4-89 Selection of main bearings STANDARD BEARING : NOTE: • If bearing is in malcondition, or bearing clearance is out of specification, select a new standard bearing according to following procedure and install it. • When replacing crankshaft or cylinder block and lower crankcase due to any reason, select new standard bearings to be installed by referring to number stamped on new crankshaft and/or alphabets stamped...
Page 579 6A4-90 ENGINE MECHANICAL (J20 ENGINE) 2) Next, check crankcase (bearing cap) bore diameter without bearing. On lower crankcase five alphabets are stamped as shown in figure. Three kinds of alphabets (“A”, “B” and “C”) represent follow- ing cap bore diameters. Crankshaft bearing cap bore diameter specification Bearing cap bore diameter Stamped alphabet...
Page 580 ENGINE MECHANICAL (J20 ENGINE) 6A4-91 4) From number stamped on crank web No.2 and alphabets stamped on lower crankcase, determine new standard bear- ing to be installed to journal, by referring to table shown below. For example, if number stamped on crank web No.2 is “1” and alphabet stamped on lower crankcase is “B”, install a new standard bearing painted in “Black”...
Page 581 6A4-92 ENGINE MECHANICAL (J20 ENGINE) • If necessary, regrind crankshaft journal and select under- size bearing to use with it as follows. a) Regrind journal to following finished diameter. Finished diameter of crankshaft journal 57.7439 – 57.7560 mm (2.2734 – 2.2738 in.) b) Using micrometer, measure reground journal diameter.
Page 582 ENGINE MECHANICAL (J20 ENGINE) 6A4-93 Rear Oil Seal Carefully inspect oil seal for wear or damage. If lip portion is worn or damaged, replace oil seal. Flywheel • If ring gear is damaged, cracked or worn, replace flywheel. • If the surface contacting clutch disc is damaged, or exces- sively worn, replace flywheel.
Page 583 6A4-94 ENGINE MECHANICAL (J20 ENGINE) 3) Using micrometer, measure piston diameter. 4) Calculate cylinder bore diameter to be rebored as follows. D = A + B – C D : Cylinder bore diameter to be rebored. A : Piston diameter as measured. B : Piston clearance = 0.02 –...
Page 584 ENGINE MECHANICAL (J20 ENGINE) 6A4-95 1) Fit main bearings (4) to cylinder block (1). One of two halves of main bearing, has oil groove (3). Install this half with oil groove to cylinder block, and another half without oil groove to lower crankcase. Make sure that two halves are painted in the same color.
Page 585 6A4-96 ENGINE MECHANICAL (J20 ENGINE) 6) Install lower crankcase (1) to cylinder block. After applying engine oil to all crankcase bolts ((1) – (22)), tighten them gradually as follows. a) Tighten bolts (1) – (10) to 42 N·m (4.2 kg-m, 30.5 lb-ft) according to numerical order as shown.
Page 586 ENGINE MECHANICAL (J20 ENGINE) 6A4-97 8) Install flywheel (M/T vehicle) or drive plate (A/T vehicle). Using special tool, lock flywheel or drive plate, and tighten flywheel or drive plate bolts (1) applied with sealant to speci- fication. “A” : Sealant 99000-31110 Special tool (A) : 09924-17811 Tightening torque...
Page 587: Special Tool
6A4-98 ENGINE MECHANICAL (J20 ENGINE) Special Tool 09911-97710 09911-97811 09913-75510 09915-47330 Oil seal guide Oil seal installer Bearing installer Oil filter wrench 09915-67311 See NOTE “A”. Vacuum gauge See NOTE “B”. See NOTE “C”. 09916-34542 09916-37810 09916-38210 09916-44910 Reamer handle Reamer (6 mm) Reamer (11 mm) Valve guide remover...
Page 588 ENGINE MECHANICAL (J20 ENGINE) 6A4-99 09917-87810 09917-98221 09918-08210 09919-28610 Valve guide installer Valve stem seal installer Vacuum gauge hose joint Protective sleeve 09924-17811 09926-58010 09944-36011 09927-56010 Flywheel holder Bearing puller attachment Steering wheel remover Gear stopper NOTE: • “A” : This kit includes the following items. 1.
Page 589: Required Service Material
6A4-100 ENGINE MECHANICAL (J20 ENGINE) Required Service Material Recommended SUZUKI product Material (Part Number) Sealant SUZUKI BOND No.1207F • To apply to mating surfaces of cylinder block 99000-31250 and oil pan. • To apply to mating surfaces of cylinder block and timing chain cover.
Page 590 ENGINE MECHANICAL (J20 ENGINE) 6A4-101 Tightening Torque Specifications Tightening torque Fastening part N•m kg-m lb-ft Oil pressure switch 10.5 Cylinder head cover nut Exhaust No.1 pipe bolt or nut 36.5 Heated oxygen sensor-1 32.5 Timing chain cover bolt Crankshaft pulley bolt 108.5 Oil pump strainer bolt Oil pump strainer bracket bolt...
Page 591 6A4-102 ENGINE MECHANICAL (J20 ENGINE)
Page 592 ENGINE COOLING 6B-1 SECTION 6B ENGINE COOLING CONTENTS General Description........6B-2 Cooling Fan Belt Tension Check and Adjustment ..........6B-15 Cooling System Component ......6B-3 For G16 engine model.......6B-3 On-Vehicle Service ........6B-17 For J20 engine model........6B-4 Coolant Draining ......... 6B-17 For H25 engine model.......6B-5 Cooling Water Pipes or Hoses....
Page 593: General Description
6B-2 ENGINE COOLING General Description The cooling system consists of the radiator cap, radiator, coolant reservoir, hoses, water pump, cooling fan, and thermostat. The radiator is of tube-and-fin type. WARNING: • Do not remove radiator cap to check engine coolant level; check coolant visually at the see-through coolant reservoir.
Page 594: Cooling System Component
ENGINE COOLING 6B-3 Cooling System Component For G16 engine model 1. Radiator 5. Water inlet pipe 9. Radiator outlet hose 13. Heater outlet hose 2. Radiator inlet hose 6. O-ring 10. Water outlet cap gasket 14. Heater inlet hose 3. Thermostat cap 7.
Page 595: For J20 Engine Model
6B-4 ENGINE COOLING For J20 engine model 1. Radiator 7. Radiator outlet hose 13. Water bypass No.2 hose 19. Heater circulation pipe 2. Radiator inlet hose 8. Thermostat cap 14. Heater inlet hose 20. Heater hose 3. Water outlet pipe 9.
Page 596: For H25 Engine Model
ENGINE COOLING 6B-5 For H25 engine model 1. Radiator 7. Thermostat 13. Water head LH hose 19. Water outlet cap gasket 2. Radiator outlet hose 8. Blank 14. Heater outlet pipe 20. Water circulation hose 3. Radiator inlet hose 9. O-ring 15.
Page 597: Cooling System Circulation
6B-6 ENGINE COOLING Cooling System Circulation 1) While the engine is warmed up (thermostat closed), coolant circulates as follows. [A] : For J20 and H25 engine models [B] : For G16 engine model 2) When coolant is warmed up to normal temperature and the thermostat opens, coolant passes through the radiator core to be cooled as well as the above flow circuit.
Page 598 ENGINE COOLING 6B-7...
Page 599: Thermostat
6B-8 ENGINE COOLING [A] : G16 engine 2. Cooling fan 6. Radiator outlet way 10. Heater outlet way 14. Heater unit [B] : J20 engine 3. Thermostat 7. Outlet pipe 11. Heater inlet way [C] : H25 engine 4. Water pump 8.
Page 600: Cooling Fan Clutch
ENGINE COOLING 6B-9 Cooling Fan Clutch Fluid is enclosed in the cooling fan clutch (2) and at its center front, there is a bimetal (3) whose thermal reaction and the engine speed control the cooling fan (1) speed. CAUTION: Do not disassemble fan clutch. WARNING: Keep hands, tools, and clothing away from engine cool- ing fan (1) to help prevent personal injury.
Page 601 6B-10 ENGINE COOLING Anti-freeze proportioning chart: °C –36 Freezing temperature °F –33 Antifreeze/Anticorrosion coolant concentration Itr. 2.8/2.8 G16 engine US pt 5.8/5.8 Imp. pt. 4.9/4.9 Itr. 3.3/3.3 Ratio of compound to cooling water J20 engine US pt 6.9/6.9 Imp. pt. 5.7/5.7 Itr.
Page 602: Diagnosis
ENGINE COOLING 6B-11 Diagnosis Diagnosis Table Condition Possible Cause Correction Engine overheats Loose or broken water pump belt Adjust or replace. Not enough coolant Check coolant level and add as necessary. Faulty thermostat Replace. Faulty water pump Replace. Dirty or bent radiator fins Clean or remedy.
Page 603: Maintenance
6B-12 ENGINE COOLING Maintenance Coolant Level Check WARNING: To help avoid danger of being burned: • Do not remove reservoir cap while coolant is “boiling”, • Do not remove radiator cap while engine and radiator are still hot. Scalding fluid and steam can be blown out under pres- sure if either cap is taken off too soon.
Page 604: Cooling System Service
ENGINE COOLING 6B-13 Cooling System Service WARNING: To help avoid danger of being burned, do not remove radiator cap while engine and radiator are still hot. Scalding fluid and steam can be blown out under pres- sure if cap is taken off too soon. Cooling system should be serviced as follows.
Page 605: Cooling System Flush And Refill
6B-14 ENGINE COOLING Cooling System Flush and Refill 1) Remove radiator cap when engine is cool. Turn cap slowly to the left until it reaches a “stop” (Do not press down while turning it). Wait until pressure is relieved (indicated by a hissing sound) then press down on cap and continue to turn it to the left.
Page 606: Cooling Fan Belt Tension Check And Adjustment
ENGINE COOLING 6B-15 Cooling Fan Belt Tension Check and Adjust- ment WARNING: Disconnect negative cable at battery before checking and adjusting belt tension. For G16 and H25 engines 1) Inspect belt for cracks, cuts, deformation, wear and cleanli- ness. If so, replace belt. 2) Check belt for tension.
Page 607 6B-16 ENGINE COOLING For J20 engine 1) Inspect belt for cracks, cuts, deformation, wear and cleanli- ness. If so, replace belt. 2) Check belt for tension. Belt is in proper tension when it deflects the following specifications under thumb pressure (about 10 kg or 22 lbs).
Page 608: On-Vehicle Service
ENGINE COOLING 6B-17 On-Vehicle Service WARNING: • Check to make sure that engine coolant temperature is cold before removing any part of cooling system. • Also be sure to disconnect negative cable from battery terminal before removing any part. Coolant Draining 1) Remove radiator cap.
Page 609 6B-18 ENGINE COOLING 5) Disconnect ECT sensor (4) coupler. 6) Disconnect heater inlet hose (5) from water outlet cap (3). 1. Thermostat case 2. Water outlet pipe 7) Remove water outlet cap (3) from cylinder heads. 8) Remove water outlet pipe (2) from thermostat case (1). 9) Remove thermostat case (1) from cylinder block.
Page 610 ENGINE COOLING 6B-19 For H25 engine 1) Install thermostat case (1) to cylinder block with new O-ring (4). 2) Install water outlet pipe (2) to thermostat case (1) with new O-rings (4). 3) Install water outlet cap (3) to cylinder heads with new gas- kets.
Page 611: Thermostat
6B-20 ENGINE COOLING Thermostat REMOVAL 1) Drain cooling system and tighten drain plug. 2) Remove fan shroud with cooling fan after disconnecting radi- ator inlet hose from radiator (H25 engine only). 3) Remove thermostat cap (1). 4) Remove thermostat. [A] : G16 engine [B] : J20 engine [C] : H25 engine INSPECTION...
Page 612 ENGINE COOLING 6B-21 4) Check thermostatic movement of wax pellet as follows : a) Immerse thermostat (1) in water, and heat water gradually. b) Check that valve starts to open at specific temperature. If valve starts to open at a temperature substantially below or above specific temperature, thermostat unit should be replaced with a new one.
Page 613: Cooling Fan Belt
6B-22 ENGINE COOLING Cooling Fan Belt REMOVAL For G16 and H25 engines 1) Disconnect negative (–) cable at battery. 2) Loosen P/S pump drive belt adjusting bolt and then remove P/S pump belt. 3) Loosen adjusting bolt (1) and pivot bolt. 4) Slacken belt by displacing generator and then remove it.
Page 614: Cooling Fan And Fan Clutch
ENGINE COOLING 6B-23 Cooling Fan and Fan Clutch REMOVAL 1) Disconnect negative (–) cable at battery. 2) Drain cooling system by loosing drain plug (1) of radiator. 3) Disconnect radiator inlet hose from radiator. 4) Loosen cooling fan/clutch nuts. 5) Remove P/S fluid reserver stay bolts (1) from radiator stay (G16 and H25 engines only).
Page 615: Radiator
6B-24 ENGINE COOLING Radiator REMOVAL 1) Disconnect negative (–) cable at battery. 2) Drain cooling system by loosening drain plug (1) of radiator. 3) When servicing A/T vehicle, place oil pan under radiator (1) and disconnect A/T fluid hoses (2), (3) from radiator. 4) Loosen cooling fan/clutch nuts (1).
Page 616 ENGINE COOLING 6B-25 9) Disconnect water inlet and outlet hose (1), (2) and reservoir tank hose (3) from radiator. 10) Remove radiator (4). INSPECTION Check radiator for leakage or damage. Straighten bent fins, if any. CLEAN Clean frontal area of radiator cores. INSTALLATION Reverse removal procedures, noting the following.
Page 617: Water Pump
6B-26 ENGINE COOLING Water Pump REMOVAL For G16 engine 1) Disconnect negative (–) cable at battery. 2) Drain cooling system. 3) Remove timing belt and tensioner referring to “Timing Belt and Belt Tensioner” in Section 6A1. 4) Remove rubber seal (1) between oil pump and water pump. 5) Remove oil level gauge guide (1) with oil level gauge.
Page 618 ENGINE COOLING 6B-27 For J20 engine 1) Disconnect negative (–) cable at battery. 2) Drain coolant. 3) Remove radiator outlet hose from thermostat cap (2). 4) Remove heater outlet pipe bolt (1). 5) Remove generator belt by loosening tensioner pulley. Refer to “Generator Belt”...
Page 619 6B-28 ENGINE COOLING INSPECTION For G16 engine Rotate water pump by hand to check for smooth operation. If pump does not rotate smoothly or makes abnormal noise, replace it. For J20 engine CAUTION: Do not disassemble water pump. If any repair is required on pump, replace it as assembly. •...
Page 620 ENGINE COOLING 6B-29 INSTALLATION For G16 engine 1) Install new pump gasket (2) to cylinder block. 2) Install water pump (1) to cylinder block. Tightening torque Water pump bolt (G16 engine) (a) : 12 N·m (1.2 kg-m, 8.5 lb-ft) 3) After installing water pump, install rubber seal (1) between water pump and oil pump.
Page 621 6B-30 ENGINE COOLING For J20 engine 1) Install new O-ring (1) to water pump (2). NOTE: Do not forget to install dowel pins on water pump side before mounting water pump to engine block. 2) Install water pump (1) by using new bolts (2) to cylinder block and tighten to specified torque.
Page 622: Engine Coolant Temperature (Ect) Sensor
Ethylene glycol base coolant – Additive to engine cooling system for (Anti-freeze/Anti-corrosion improving cooling efficiency and for coolant) protection against rusting. Sealant SUZUKI BOND NO. 1215 Water outlet pipe bolt (99000-31110) Tightening Torque Specifications Tightening torque Fastening part N•m kg-m...
Page 623 6B-32 ENGINE COOLING...
Page 624: Fuel System
ENGINE FUEL 6C-1 SECTION 6C ENGINE FUEL CONTENTS General Description........6C-1 Fuel Pump.............6C-3 Fuel Filter ............6C-3 Fuel System ..........6C-1 Fuel Lines .............6C-4 Diagnosis............6C-2 Fuel Filler Cap..........6C-5 Diagnosis Table ..........6C-2 Fuel Tank ............6C-5 On-Vehicle Service..........6C-2 Tightening Torque Specification....6C-8 Precautions ...........6C-2 General Description Fuel System The main components of the fuel system are fuel tank, fuel pump, fuel filter and fuel level gauge and it includes three lines, fuel feed line, fuel return line and fuel vapor line.
Page 625: Diagnosis
6C-2 ENGINE FUEL Diagnosis Diagnosis Table Refer to “Engine Diagnosis” in Section 6. On-Vehicle Service Precautions WARNING: Before attempting service of any type on fuel system, fol- lowing cautions should be always observed. • Disconnect negative cable at battery. • DO NOT smoke, and place “NO SMOKING” signs near work area.
Page 626: Fuel Pump
ENGINE FUEL 6C-3 Fuel Pump REMOVAL 1) Remove fuel tank. Refer to “Fuel Tank” in this section. 2) Remove fuel pump assembly (1) from fuel tank. INSPECTION Check fuel pump filter for evidence of dirt and contamination. If present, clean and check for presence of dirt in fuel tank. INSTALLATION Reverse removal procedure for installation noting the followings.
Page 627: Fuel Lines
6C-4 ENGINE FUEL INSTALLATION Reverse removal procedure noting the following. • Upon completion of installation, verify that there is no fuel leakage at each connection referring to Section 6 or Section 6-1. 1. Fuel filter 2. Fuel filter outlet hose 3.
Page 628: Fuel Filler Cap
ENGINE FUEL 6C-5 INSPECTION Visually inspect fuel lines for evidence of fuel leakage, hose cracking and deterioration, or damage. Make sure all clamps are secure. Replace parts as needed. 1. Fuel feed hose (if equipped) 2. Fuel return hose 3. Fuel vapor hose 4.
Page 629 6C-6 ENGINE FUEL 4) Remove fuel tank filler hose protector. 5) Disconnect filler hose (3) from fuel tank (1) and breather hose (2) from fuel filler neck. 6) Remove fuel tank inlet valve (4). Use care not to damage inlet valve when removing. 7) Drain fuel tank by pumping fuel out through fuel tank filler.
Page 630 ENGINE FUEL 6C-7 INSPECTION After removing fuel tank, check hoses and pipes connected to fuel tank for leaks, loose connections, deterioration or damage. Also check fuel pump and level gauge gaskets for leaks, visually inspect fuel tank for leaks and damage. Replace any damaged or malconditioned parts.
Page 631: Tightening Torque Specification
6C-8 ENGINE FUEL 8) Connect fuel filter inlet hose (3) to fuel filter (1). 2. Fuel filter outlet hose 9) Connect coupler to fuel pump assembly and tank pressure sensor respectively. 10) Connect negative (–) cable to battery. 11) Upon completion of installation, check fuel system for leak- age.
Page 632: Engine And Emission Control System (G16/J20 Engines)
• Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
Page 633 6E1-2 ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINES) Camshaft position sensor A/C compressor relay and condenser (CMP sensor) ........6E1-47 fan motor relay (other than canvas Crankshaft position sensor top model)..........6E1-55 (G16 engine) ......... 6E1-48 Fuel cut operation ......... 6E1-56 Crankshaft position sensor Emission Control System......
Page 634: General Description
ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINES) 6E1-3 General Description ENGINE AND EMISSION CONTROL SYSTEM INTRODUCTION The engine and emission control system has 4 major sub-systems : air intake system, fuel delivery system, electronic control system and emission control system. Air intake system includes air cleaner, mass air flow sensor, throttle body, idle air control valve and intake mani- fold.
Page 635 6E1-4 ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINES) ENGINE AND EMISSION CONTROL SYSTEM DIAGRAM FOR G16 ENGINE...
Page 636 ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINES) 6E1-5 1. Air cleaner 32. Malfunction indicator lamp 2. Intake air temp. sensor 33. “O/D OFF” lamp 3. Mass air flow sensor 34. “POWER” lamp 4. Throttle body 35. Starter 5. Idle air control valve 36.
Page 637 6E1-6 ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINES) ENGINE AND EMISSION CONTROL SYSTEM DIAGRAM FOR J20 ENGINE...
Page 638 ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINES) 6E1-7 1. Air cleaner 33. Vehicle speed sensor 2. Intake air temp. sensor 34. Combination meter 3. Mass air flow sensor 35. A/C condenser fan relay (if equipped) 4. EVAP canister purge valve 36.
Page 639: Air Intake System Description
6E1-8 ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINES) Air Intake System Description The main components of the air intake system are air cleaner (1), mass air flow sensor (2), air cleaner outlet hose (3), throttle body (4), idle air control valve (6) and intake manifold (7). The air (by the amount corresponding to the throttle valve (5) opening and engine speed) is filtered by the air cleaner, passes through the throttle body, is distributed by the intake manifold and finally drawn into each com- bustion chamber.
Page 640 ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINES) 6E1-9 [A]: G16 engine 8. Cylinder head 14. Air cut valve 20. Engine coolant flow [B]: J20 engine 9. Exhaust manifold 15. Fuel delivery pipe 21. EGR flow (if equipped) C. Air 10. Bypass air flow 16.
Page 641: Fuel Delivery System Description
6E1-10 ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINES) Fuel Delivery System Description The fuel delivery system consists of the fuel tank (1), fuel pump (2), fuel filter (4), fuel pressure regulator, deliv- ery pipe (5) and fuel injectors (6). The fuel in the fuel tank is pumped up by the fuel pump, filtered by the fuel filter and fed under pressure to each injector through the delivery pipe.
Page 642: Electronic Control System Description
ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINES) 6E1-11 Electronic Control System Description The electronic control system consists of 1) various sensors which detect the state of engine and driving condi- tions, 2) ECM (PCM) which controls various devices according to the signals from the sensors and 3) various controlled devices.
Page 643 6E1-12 ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINES) ELECTRONIC CONTROL SYSTEM COMPONENT LOCATION FOR G16 ENGINE...
Page 644 ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINES) 6E1-13 [A]: Other than canvas top model [B]: Canvas top model INFORMATION SENSORS CONTROLLED DEVICES OTHERS 1. MAF sensor a : Fuel pump relay A : PCM/ECM 2. VSS b : Injectors B : EVAP canister 3.
Page 645 6E1-14 ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINES) ELECTRONIC CONTROL SYSTEM COMPONENT LOCATION FOR J20 ENGINE...
Page 646 ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINES) 6E1-15 [A]: Other than canvas top model [B]: Canvas top model INFORMATION SENSORS CONTROLLED DEVICES OTHERS 1. IAT sensor a : Idle air control valve A : ECM (PCM) 2. MAF sensor b : A/C condenser fan motor relay (if equipped) B : EVAP canister 3.
Page 647 6E1-16 ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINES) ELECTRONIC CONTROL SYSTEM WIRING CIRCUIT (CANVAS TOP MODEL) WHT/BLU C51-2-19 C51-2-2 ORN/BLU C51-2-20 C51-2-1 PNK/BLK C51-2-30 C51-2-9 PNK/GRN YEL/BLU C51-2-26 C51-2-8 PNK/BLU PPL/RED C51-3-26 C51-3-10 PPL/WHT C51-2-16 LT GRN C51-3-5 PPL/GRN C51-2-15 LT GRN/WHT C51-2-14 LT GRN/YEL...
Page 648 ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINES) 6E1-17 1. Fuel injector No.1 30. Data link connector 2. Fuel injector No.2 31. TCC solenoid (A/T) 3. Fuel injector No.3 32. Shift solenoid-B (A/T) 4. Fuel injector No.4 33. Shift solenoid-A (A/T) 5.
Page 649 6E1-18 ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINES) ELECTRONIC CONTROL SYSTEM WIRING CIRCUIT (OTHER THAN CANVAS TOP MODEL) WHT/BLU C51-2-19 C51-2-2 ORN/BLU C51-2-20 C51-2-1 PNK/BLK C51-2-30 C51-2-9 PNK/GRN YEL/BLU C51-2-26 C51-2-8 PNK/BLU PPL/RED C51-3-26 PPL/WHT C51-3-10 C51-2-16 LT GRN C51-3-5 PPL/GRN C51-2-15 LT GRN/WHT...
Page 650 ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINES) 6E1-19 1. Fuel injector No.1 34. TCC solenoid (A/T) 2. Fuel injector No.2 35. Shift solenoid-B (A/T) 3. Fuel injector No.3 36. Shift solenoid-A (A/T) 4. Fuel injector No.4 37. Transmission range switch (sensor) (A/T) 5.
Page 651 6E1-20 ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINES) TERMINAL ARRANGEMENT OF ECM (PCM) CONNECTOR (VIEWED FROM HARNESS SIDE) TERMINAL WIRE COLOR CIRCUIT TERMINAL WIRE COLOR CIRCUIT Output of 5 V power source for CO adjusting resistor Selector switch signal of Power mode/Normal mode GRY/RED ORN/BLU (if equipped)
Page 652 ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINES) 6E1-21 TERMINAL WIRE COLOR CIRCUIT BLU/GRN A/T input shaft speed sensor signal (–) BLU/YEL A/T input shaft speed sensor signal (+) – – – – – – “D” position signal for transmission range selector YEL/GRN switch (A/T) “N”...
Page 653 6E1-22 ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINES) ENGINE AND EMISSION CONTROL SYSTEM FLOW CHART “A” : Air “B” : Exhaust gas “C” : Vapor “D” : Fuel...
Page 654: Diagnosis
ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINES) 6E1-23 ENGINE & EMISSION CONTROL INPUT/OUTPUT TABLE Diagnosis Diagnosis Table Refer to “Engine Diagnosis Table” in Section 6. On-Vehicle Service Engine and Emission Control System Description When hoses are disconnected and system components are removed for service, reinstall components properly, and route and connect hoses correctly after service.
Page 655 6E1-24 ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINES) [A] : G16 engine 4. A/T throttle cable (A/T) 11. Fuel feed hose [B] : J20 engine 5. Throttle cable 12. Tank pressure control valve [C] : Vehicle without immobilizer indicator lamp 6.
Page 656: Accelerator Cable Adjustment
ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINES) 6E1-25 Accelerator Cable Adjustment 1) With throttle valve closed, check accelerator pedal play which should be within following specification. If measured value is out of specification, adjust it to specifi- cation with cable adjusting nut (2). Accelerator pedal play “a”...
Page 657: Idle Speed/Idle Air Control (Iac) Duty Inspection
Before starting engine, place transmission gear shift lever in “Neutral” (shift selector lever to “P” range for A/T vehicle), and set parking brake and block drive wheels. 1) Connect SUZUKI scan tool to DLC (1) with ignition switch OFF. Special tool (A) : SUZUKI scan tool 2) Warm up engine to normal operating temperature.
Page 658: Idle Mixture Inspection/Adjustment (Vehicle Without Heated Oxygen Sensor)
ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINES) 6E1-27 Idle mixture inspection/adjustment (vehicle without heated oxygen sensor) All vehicles not equipped with heated oxygen sensor are shipped with their CO% factory adjusted as follows. Engine idle mixture (CO%) at specified idle speed 0.8 –...
Page 659: Air Intake System
6E1-28 ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINES) Air Intake System Throttle body THROTTLE BODY COMPONENTS 1. Cable bracket 3. TP sensor 5. O-ring 2. Throttle body 4. Idle air control valve Do not reuse ON-VEHICLE INSPECTION • Check that throttle valve lever moves smoothly. REMOVAL 1) Disconnect negative cable at battery.
Page 660 ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINES) 6E1-29 5) Disconnect electric coupler from TP sensor (1) and IAC valve (2). 6) Disconnect coolant hoses (3) from throttle body. 7) Remove throttle body from intake manifold. CLEANING 1) Remove IAC valve from throttle body. 2) Clean throttle body bore and bypass air passages (1) by blowing compressed air.
Page 661: Idle Air Control Valve (Iac Valve)
6E1-30 ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINES) 6) Connect accelerator cable (1) and A/T throttle cable (2), and adjust each cable play to specification. 7) Refill cooling system. 8) Connect negative cable at battery. Idle air control valve (IAC valve) INSPECTION 1) Disconnect connector from IAC valve.
Page 662: Fuel Delivery System
ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINES) 6E1-31 INSTALLATION 1) Install new O-ring to throttle body. 2) Install IAC valve to throttle body. Tighten IAC valve screws to specified torque. Tightening torque IAC valve screw (a) : 3.5 N·m (0.35 kg-m, 2.5 lb-ft) 3) Connect IAC valve connector securely.
Page 663 6E1-32 ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINES) Fuel pressure specification CONDITION FUEL PRESSURE With fuel pump operating and 250 – 300 kPa engine stopped (2.5 – 3.0 kg/cm 35.6 – 42.7 psi) At specified idle speed 210 – 260 kPa (2.1 –...
Page 664: Fuel Pump
ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINES) 6E1-33 Fuel pump ON-VEHICLE INSPECTION CAUTION: When fuel filler cap is removed in any procedure, work must be done in a well-ventilated area, keep away from any open flames and without smoking. 1) Remove filler cap and turn ON ignition switch (2). Then fuel pump operating sound be heard from fuel filler (1) for about 3 seconds and stop.
Page 665: Fuel Pressure Regulator
6E1-34 ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINES) Fuel pressure regulator REMOVAL 1) Relieve fuel pressure according to procedure described on “Fuel Pressure Relief Procedure” in Section 6. 2) Disconnect battery negative cable from battery. 3) Disconnect vacuum hose (1) from fuel pressure regulator (2).
Page 666: Fuel Injector
ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINES) 6E1-35 Fuel injector ON-VEHICLE INSPECTION 1) Using sound scope (1) or such, check operating sound of injector when engine is running or cranking. Cycle of operating sound should vary according to engine speed. If no sound or an unusual sound is heard, check injector cir- cuit (wire or coupler) or injector.
Page 667 6E1-36 ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINES) 5) Remove clamp bolt for fuel feed pipe and return pipe. 6) Remove fuel delivery pipe bolts (3). 7) Remove fuel injector(s) (1) from delivery pipe and intake manifold or cylinder head. WARNING: A small amount of fuel may be released when fuel injec- tor is removed.
Page 668 6) Operate fuel pump and apply fuel pressure to injector as fol- lows : a) When SUZUKI scan tool can be used : i) Connect SUZUKI scan tool to DLC with ignition switch OFF. ii) Turn ignition switch ON, clear DTC and select “MISC TEST”...
Page 669 6E1-38 ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINES) INSTALLATION 1) Replace injector O-ring (3) with new one using care not to damage it. Install grommet (2) to injector. 2) Check if insulator (1) is scored or damaged. If it is, replace with new one.
Page 670: Electronic Control System
ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINES) 6E1-39 Electronic Control System Engine control module (ECM)/powertrain control module (PCM) CAUTION: As ECM/PCM consists of precision parts, be careful not to expose it to excessive shock. REMOVAL 1) Disconnect battery negative cable from battery. 2) Disable air bag system (if equipped) referring to “Disabling the Air Bag System”...
Page 671: Mass Air Flow Sensor (Maf Sensor)
6E1-40 ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINES) Mass air flow sensor (MAF sensor) INSPECTION NOTE: Ω Use voltmeter with high-impedance (10 k /V minimum) or digital type voltmeter. 1) Connect voltmeter to “B +” terminal of MAF sensor coupler disconnected and ground.
Page 672: Intake Air Temperature (Iat) Sensor
ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINES) 6E1-41 REMOVAL 1) Disconnect negative cable at battery and coupler (1) from MAF sensor (2). 2) Remove air cleaner outlet hose from throttle body and MAF sensor. 3) Remove MAF sensor from air cleaner case. NOTE: Don’t disassemble MAF sensor.
Page 673 6E1-42 ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINES) INSPECTION Immerse temperature sensing part of IAT sensor in water (or ice) and measure resistance between sensor terminals while heating water gradually. If measured resistance doesn’t show such characteristic as shown in figure, replace IAT sensor. [A] : Resistance [B] : Temperature INSTALLATION...
Page 674: Throttle Position Sensor (Tp Sensor)
ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINES) 6E1-43 Throttle position sensor (TP sensor) INSPECTION 1) Disconnect negative cable at battery and coupler from TP sensor. 2) Using ohmmeter, check resistance between terminals under each condition given in table below. If check result is not satisfactory, replace TP sensor. TP sensor resistance TERMINALS RESISTANCE...
Page 675: Engine Coolant Temperature Sensor (Ect Sensor)
6E1-44 ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINES) Engine coolant temperature sensor (ECT sensor) REMOVAL 1) Disconnect negative cable from battery. 2) Drain cooling system. 3) Disconnect coupler from ECT sensor. 4) Remove ECT sensor (1) from intake manifold or water outlet cap (3).
Page 676: Heated Oxygen Sensor-1 And -2 (Ho2S-1 And Ho2S-2)
ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINES) 6E1-45 INSTALLATION Reverse removal procedure noting the following. • Clean mating surfaces of sensor and intake manifold. • Check O-ring for damage and replace if necessary. • Tighten ECT sensor to specified torque. Tightening torque ECT sensor (a) : 15 N·m (1.5 kg-m, 11.0 lb-ft)
Page 677 6E1-46 ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINES) REMOVAL WARNING: To avoid danger of being burned, do not touch exhaust system when system is hot. Oxygen sensor removal should be performed when system is cool. 1) Disconnect negative cable from battery. 2) Remove connector from bracket (3) and disconnect coupler of oxygen sensor.
Page 678: Vehicle Speed Sensor (Vss)
ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINES) 6E1-47 Vehicle speed sensor (VSS) ON-VEHICLE INSPECTION 1) Hoist vehicle. 2) Release parking brake lever, set transmission in neutral and transfer in “2H”. 3) Remove ECM/PCM cover. 4) Connect voltmeter between VSS terminal of ECM/PCM con- nector and body ground.
Page 679: Crankshaft Position Sensor (G16 Engine)
6E1-48 ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINES) INSTALLATION (G16 ENGINE) 1) Check that O-ring is free from damage. 2) Check that CMP sensor and signal rotor tooth are free from any metal particles and damage. 3) Install CMP sensor to sensor case. Tightening torque CMP sensor bolt (a) : 9 N·m (0.9 kg-m, 6.5 lb-ft)
Page 680: Crankshaft Position Sensor (J20 Engine)
ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINES) 6E1-49 2) Install crankshaft position sensor to oil pan. Tightening torque Crankshaft position sensor bolt (a) : 10 N·m (1.0 kg-m, 7.5 lb-ft) CAUTION: Be sure to tighten to specified torque. CKP sensor will be deformed if overtightened and correct CKP sensor signal will not be fed if loosened.
Page 681 6E1-50 ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINES) INSPECTION 1) Check vacuum passage on intake manifold, and vacuum passage for clog. Clean if clogged. CAUTION: Do not put wires into air vent hole for cleaning. It causes damage in sensor. 2) Check sensor O-ring (1) for damage and deterioration.
Page 682: Fuel Level Sensor (Sender Gauge)
ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINES) 6E1-51 INSTALLATION 1) Confirm that vacuum passage on intake manifold is free from clog. 2) Apply engine oil to O-ring of sensor. 3) Install sensor to intake manifold. 4) Connect connector to sensor securely. Fuel level sensor (Sender gauge) Refer to “Fuel Level Gauge (Sender Gauge)”...
Page 683: Main Relay
6E1-52 ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINES) Main relay INSPECTION 1) Disconnect negative cable at battery. 2) Remove main relay (1) from connector. [A-1] : Left-hand steering vehicle except for canvas top model [A-2] : Right-hand steering vehicle except for canvas top model [B-1] : Left-hand steering vehicle for canvas top model [B-2] : Right-hand steering vehicle for canvas top model 2.
Page 684 ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINES) 6E1-53 3) Check resistance between each two terminals as in table below. If check results are as specified, proceed to next operation check. If not, replace. Main relay resistance TERMINALS RESISTANCE ∞ Between A and B (Infinity) Ω...
Page 685: Fuel Pump Relay
6E1-54 ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINES) Fuel pump relay INSPECTION 1) Disconnect negative cable at battery. 2) Remove fuel pump relay (1) from connector. 3) Structure of fuel pump relay is the same as that of main relay. Check its resistance and operation using the same proce- dure as that for main relay.
Page 686: A/C Compressor Relay And Condenser Fan Motor Relay (Other Than Canvas Top Model)
ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINES) 6E1-55 A/C compressor relay and condenser fan motor relay (other than canvas top model) INSPECTION 1) Disconnect negative (–) cable at battery. 2) Remove A/C compressor relay (1) or A/C condenser fan motor relay (2) from fuse/relay box (3). 3) Structure of A/C compressor relay or A/C condenser relay is the same as that of main relay.
Page 687: Fuel Cut Operation
2,000 r/min. Emission Control System EGR system SYSTEM INSPECTION [USING SUZUKI SCAN TOOL] 1) Connect SUZUKI scan tool to data link connector (DLC) (1) with ignition switch OFF. Special tool (A) : SUZUKI scan tool 2) Start engine and warm up it to normal operating tempera- ture.
Page 688 ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINES) 6E1-57 REMOVAL 1) Disconnect negative cable at battery. 2) Disconnect EGR valve coupler (2). 3) Remove EGR valve (1) and gasket from intake manifold (3). INSPECTION 1) Check resistance between following terminals of EGR valve (1) in each pair.
Page 689: Evaporative Emission Control System
6E1-58 ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINES) INSTALLATION Reverse removal procedure noting following. • Clean mating surface of EGR valve (1) and intake manifold (3). • Use new gasket (2). [A] : G16 Engine [B] : J20 Engine Evaporative emission control system VACUUM PASSAGE INSPECTION Start engine and run it at idle speed.
Page 690 ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINES) 6E1-59 EVAP CANISTER INSPECTION WARNING: DO NOT SUCK nozzles on EVAP canister. Fuel vapor inside EVAP canister is harmful. 1) Disconnect vacuum hoses from EVAP canister and remove EVAP canister. 2) When air is blown into tank pipe (1), there should be no restriction of flow through purge pipe (2) and air pipe (3).
Page 691: Pcv System
6E1-60 ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINES) PCV system NOTE: Be sure to check that there is no obstruction in PCV valve or its hoses before checking engine idle speed/IAC duty for obstructed PCV valve or hose hampers its accu- rate checking.
Page 692 09930-88530 See NOTE “A”. Vacuum pump gauge Injector test lead Tech 2 kit (Suzuki scan tool) (See NOTE “B”.) NOTE: • “A” : This kit includes the following items. 1. Pressure gauge 09912-58441, 2. Pressure hose 09912-58431, 3. Attachment 09919-46010, 4.
Page 693 6E1-62 ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINES)
Page 694 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
Page 695 6E2-2 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) Vehicle speed sensor (VSS) ....6E2-42 Emission Control System......6E2-46 Manifold absolute pressure sensor ..6E2-43 EGR system (if equipped)..... 6E2-46 Crankshaft position sensor....6E2-43 Evaporative emission control Main relay..........6E2-44 system ..........6E2-48 Fuel pump relay ........
Page 696: General Description
ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) 6E2-3 General Description ENGINE AND EMISSION CONTROL SYSTEM INTRODUCTION The engine and emission control system has 4 major sub-systems : air intake system, fuel delivery system, electronic control system and emission control system. Air intake system includes air cleaner, mass air flow sensor, throttle body, idle air control valve and intake mani- fold.
Page 697 6E2-4 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) ENGINE AND EMISSION CONTROL SYSTEM DIAGRAM...
Page 698 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) 6E2-5 1. Air cleaner 23-1. Diag. switch terminal 42. Main relay 2. Intake air temp. sensor 23-2. Test switch terminal 43. Ignition switch 3. Mass air flow sensor 23-3. Output duty select switch terminal 44.
Page 699: Air Intake System Description
6E2-6 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) Air Intake System Description The main components of the air intake system are air cleaner (1), mass air flow sensor (16), air cleaner intake air pipe (9), throttle body (10), intake collector (5), idle air control valve (17) and intake manifold (4). The air (by the amount corresponding to the throttle valve opening and engine speed) is filtered by the air cleaner, passes through the throttle body, is distributed by the intake manifold and finally drawn into each com- bustion chamber.
Page 700: Fuel Delivery System Description
ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) 6E2-7 Fuel Delivery System Description The fuel delivery system consists of the fuel tank (1), fuel pump (2), fuel filter (3), fuel pressure regulator (6), delivery pipe (10) and fuel injectors (9). The fuel in the fuel tank is pumped up by the fuel pump, filtered by the fuel filter and fed under pressure to each injector through the delivery pipe.
Page 701: Electronic Control System Description
6E2-8 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) Electronic Control System Description The electronic control system consists of 1) various sensors which detect the state of engine and driving condi- tions, 2) ECM (PCM) which controls various devices according to the signals from the sensors and 3) various controlled devices.
Page 702 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) 6E2-9 INFORMATION SENSORS CONTROLLED DEVICES OTHERS 1. IAT sensor a : A/C condenser fan motor relay (if equipped) A : Main fuse box 2. MAP sensor (if equipped) b : Ignition coil assemblies B : ECM (PCM) 3.
Page 703: Engine And Emission Control System Flow Chart
6E2-10 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) Engine and Emission Control System Flow Chart “A” : Air “B” : Exhaust gas “C” : Vapor “D” : Fuel...
Page 704 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) 6E2-11 ELECTRONIC CONTROL SYSTEM WIRING CIRCUIT C51-2-7 C51-3-3 WHT/BLU C51-2-6 PNK/BLK C51-3-2 ORN/BLU C51-2-19 PNK/GRN C51-2-18 PNK/BLU C51-2-28 GRY/GRN C51-3-9 YEL/GRN GRY/BLK C51-2-27 C51-3-10 YEL/BLU LT GRN C51-2-5 C51-2-4 LT GRN/WHT C51-2-17 LT GRN/YEL PPL/WHT C51-3-23 C51-2-16...
Page 705 6E2-12 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) 1. Fuel injector No.1 26. Power/Normal change switch 51. ABS control module (if equipped) 2. Fuel injector No.2 27. O/D cut switch 52. HO2S Bank 2 Sensor 2 (if equipped) 3. Fuel injector No.3 28.
Page 706 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) 6E2-13 TERMINAL ARRANGEMENT OF ECM (PCM) CONNECTOR (VIEWED FROM HARNESS SIDE) WIRE WIRE TERMINAL CIRCUIT TERMINAL CIRCUIT COLOR COLOR Fuel pump relay output (without immobilizer Output of 5 V power source for CO adjusting E61-1 WHT/GRN E61-33...
Page 707 6E2-14 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) WIRE WIRE TERMINAL CIRCUIT TERMINAL CIRCUIT COLOR COLOR C51-1-1 GRN/RED Shift solenoid-B output for A/T C51-2-3 BLK/WHT Ignition switch signal Torque converter clutch (TCC) solenoid out- C51-1-2 GRN/YEL put for A/T LT GRN/ EGR valve (stepper motor coil 2) output (if C51-2-4 “R”...
Page 708: Diagnosis
ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) 6E2-15 ENGINE & EMISSION CONTROL INPUT/OUTPUT TABLE Diagnosis Diagnosis Table Refer to “Engine Diagnosis Table” in Section 6-1.
Page 709: On-Vehicle Service
6E2-16 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) On-Vehicle Service Engine and Emission Control System Description When hoses are disconnected and system components are removed for service, reinstall components properly, and route and connect hoses correctly after service. Refer to figure for proper routing of hoses. 1.
Page 710: Accelerator Cable Adjustment
ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) 6E2-17 Accelerator Cable Adjustment 1) Warm up engine to normal operating temperature. And check to make sure that fast idle control cam is off cam fol- lower lever, if not check fast idle control system referring to “Throttle Body”...
Page 711: A/T Throttle Cable Adjustment
6E2-18 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) A/T Throttle Cable Adjustment 1) Make sure that accelerator cable is adjusted as specified. 2) With throttle valve closed, check clearance “c” which should be within following specification. If it is out of specification, adjust it by turning cable adjusting nut (2).
Page 712 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) 6E2-19 a) Using SUZUKI scan tool i) Connect SUZUKI scan tool to DLC (1) with ignition switch OFF. Special tool (A) : SUZUKI scan tool ii) Warm up engine to normal operating temperature.
Page 713 IAC duty through duty output terminal in mon- itor coupler. First of all, check label on ECM (PCM) for part No. if so, check IAC duty by using SUZUKI scan tool. i) Disconnect scan tool from DLC if connected.
Page 714: Idle Mixture Inspection/Adjustment
ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) 6E2-21 viii) Remove service wire from diagnosis connector. ix) Check that specified engine idle speed is obtained with A/ C ON if vehicle is equipped with A/C. If not, check A/C ON signal circuit and idle air control sys- tem.
Page 715: Air Intake System
6E2-22 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) Air Intake System Throttle body THROTTLE BODY COMPONENTS 1. Throttle body 3. Breather hose 5. MAF sensor 7. Fast idle up thermo wax 2. Intake collector 4. Water hose 6. TP sensor ON-VEHICLE INSPECTION 1) Check that throttle valve lever moves smoothly.
Page 716 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) 6E2-23 REMOVEL 1) Disconnect negative cable at battery. 2) Drain cooling system. 3) Remove strut tower bar. 4) Disconnect accelerator cable (1) and or A/T throttle cable (2) from throttle body. 5) Disconnect water hose (3) from throttle body. 6) Remove surge tank cover.
Page 717 6E2-24 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) 15) Remove throttle body (3) and intake collector (2) from intake manifold (1). 16) Disconnect hoses of IAC valve and PCV from throttle body. 17) Remove throttle body from intake collector. NOTE: •...
Page 718: Idle Air Control Valve (Iac Valve)
ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) 6E2-25 Idle air control valve (IAC valve) REMOVAL 1) Disconnect battery negative cable at battery. 2) Disconnect IAC valve connector. 3) Remove IAC valve (1) from intake collector (2). ON-VEHICLE INSPECTION 1) Disconnect connector from IAC valve (1). 2) Check each coil of IAC valve for resistance.
Page 719: Fuel Delivery System
6E2-26 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) INSTALLATION For installation, reverse removal procedure and note following precautions. • Use new gaskets (1). Fuel Delivery System Fuel pressure inspection 1) Relieve fuel pressure in fuel feed line referring to “Fuel Pres- sure Relief Procedure”...
Page 720 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) 6E2-27 5) Turn ignition switch ON to operate fuel pump and after 3 sec- onds turn it OFF. Repeat this 3 or 4 times and then check fuel pressure. 6) Start engine. 7) Measure fuel pressure at idling. If measure pressure doesn’t satisfy specification, refer to “Diagnostic Flow Table B-3”...
Page 721: Fuel Pump
6E2-28 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) Fuel pump ON-VEHICLE INSPECTION CAUTION: When fuel filler cap is removed in any procedure, work must be done in a well-ventilated area, keep away from any open flames and without smoking. 1) Remove filler cap and turn ON ignition switch (2). Then fuel pump operating sound should be heard from fuel filler (1) for about 3 seconds and stop.
Page 722: Fuel Pressure Regulator
ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) 6E2-29 Fuel pressure regulator REMOVAL 1) Relieve fuel pressure in fuel feed line referring to “Fuel Pres- sure Relief Procedure” in Section 6-1. 2) Disconnect battery negative cable from battery. 3) Disconnect vacuum hose (1) from fuel pressure regulator. 4) Remove fuel pressure regulator (1) from fuel delivery pipe (3).
Page 723: Fuel Injector
6E2-30 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) • Tighten fuel pressure regulator (1) bolts to specified torque. Tightening torque Fuel pressure regulator bolt (a) : 11 N·m (1.1 kg-m, 8.0 lb-ft) • With engine “OFF” and ignition switch “ON”, check for fuel leaks around fuel line connection.
Page 724 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) 6E2-31 3) Disconnect fuel feed hose (1) and fuel return hose (2). 4) Disconnect vacuum hose (4) and fuel return hose from fuel pressure regulator (5). 5) Remove fuel feed pipe (8) and fuel connect pipe (7) from delivery pipes (6) (right and left).
Page 725 6E2-32 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) 4) Install suitable vinyl tube onto injector (4) nozzle to prevent fuel from splashing out when injecting. 5) Put graduated cylinder under injector as fan apart as possi- ble. 6) Disconnect fuel pump relay (6). 7) To operate fuel pump and apply fuel pressure to injector, using wire harness as thick as the one used for fuel pump circuit, connect two terminals of relay connector as shown in...
Page 726 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) 6E2-33 INSTALLATION 1) Replace injector O-ring (1) with new one using care not to damage it. Install grommet (2) to injector. 2) Check if insulator (1) is scored or damaged. If it is, replace with new one.
Page 727: Electronic Control System
6E2-34 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) 5) Install fuel connect pipe (1) and tighten union bolts to speci- fied torque with new gaskets (3). Tightening torque Fuel connect pipe union bolt (b) : 30 N·m (3.0 kg-m, 22.0 lb-ft) 6) Install fuel feed pipe (2) and tighten union bolt to specified torque with new gaskets.
Page 728: Mass Air Flow Sensor (Maf Sensor)
ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) 6E2-35 4) Disconnect connectors from ECM (PCM). 5) Remove ECM (PCM) with bracket. INSTALLATION 1) Install ECM (PCM) with bracket to vehicle. 2) Connect connectors to ECM (PCM) securely. 3) Install ECM (PCM) cover to bracket. 4) Enable air bag system (if equipped) referring to “Enabling Air Bag System”...
Page 729: Intake Air Temperature (Iat) Sensor
6E2-36 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) 6) Turn ignition switch ON and check voltage between C51-3- 23 and C51-3-21 terminal. MAF sensor output signal standard voltage 0.5 – 1.0 V [A] : Terminal arrangement of ECM (PCM) coupler viewed from harness side. 7) Start engine and check that voltage is lower than 5 V and it rises as engine speed increases.
Page 730: Throttle Position Sensor (Tp Sensor)
ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) 6E2-37 INSPECTION Immerse temperature sensing part of IAT sensor in water (or ice) and measure resistance between sensor terminals while heating water gradually. If measured resistance doesn’t show such characteristic as shown in figure, replace IAT sensor. [A] : Resistance [B] : Temperature INSTALLATION...
Page 731 6E2-38 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) 3) Using ohmmeter, check resistance between terminals under each condition given in table below. If check result is not satisfactory, replace TP sensor. TP sensor resistance TERMINALS RESISTANCE Ω Between 1 and 3 terminals 4 –...
Page 732: Engine Coolant Temperature Sensor
TP sensor screw at a position where voltage as spec- ified below is obtained at coupler terminal C51-3-12. NOTE: If SUZUKI scan tool is available, make an adjustment by using SUZUKI scan tool while observing TP sensor volt- age.
Page 733: Heated Oxygen Sensor (Sensor 1)
6E2-40 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) INSPECTION Immerse temperature sensing part of ECT sensor in water and measure resistance between sensor terminals while heating water gradually. If measured resistance doesn’t shown such characteristic as shown, replace ECT sensor. [A] : Resistance [B] : Temperature [C] : ( ) for reference...
Page 734: Heated Oxygen Sensor (Sensor 2)
ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) 6E2-41 3) Remove oxygen sensor(s) from exhaust manifold(s). NOTE: Be careful not to expose it to excessive shock. INSTALLATION Reverse removal procedure noting the followings. • Tighten oxygen sensor(s) to specified torque. Tightening torque Heated oxygen sensor 1 (a) : 45 N·m (4.5 kg-m, 32.5 lb-ft) •...
Page 735: Vehicle Speed Sensor (Vss)
6E2-42 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) INSTALLATION Reverse removal procedure noting the followings. • Tighten oxygen sensor(s) to specified torque. Tightening torque Heated oxygen sensor 1 (a) : 45 N·m (4.5 kg-m, 32.5 lb-ft) • Connect connector of oxygen sensor(s) and clamp wire har- ness securely.
Page 736: Crankshaft Position Sensor
ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) 6E2-43 Manifold absolute pressure sensor INSPECTION 1) Disconnect coupler from MAP sensor (1). 2) Remove MAP sensor (1). 3) Arrange 3 new 1.5 V batteries (2) in series (check that total voltage is 4.5 – 5.0 V) and connect its positive terminal to “Vin”...
Page 737: Main Relay
6E2-44 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) Main relay INSPECTION 1) Disconnect negative cable at battery. 2) Remove main relay (1) from connector. [A] : Left-hand steering vehicle [B] : Right-hand steering vehicle 3) Check resistance between each two terminals as in table below.
Page 738: Fuel Pump Relay
ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) 6E2-45 Fuel pump relay INSPECTION 1) Disconnect negative cable at battery. 2) Remove fuel pump relay (1) from connector. 3) Structure of fuel pump relay is the same as that of main relay. Check its resistance and operation using the same proce- dure as that for main relay.
Page 739: Fuel Cut Operation
2,000 r/min. Emission Control System EGR system (if equipped) SYSTEM INSPECTION [USING SUZUKI SCAN TOOL] 1) Connect SUZUKI scan tool to data link connector (DLC) (1) with ignition switch OFF. Special tool (A) : SUZUKI scan tool 2) Start engine and warm up it to normal operating tempera- ture.
Page 740 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) 6E2-47 REMOVAL 1) Disconnect negative cable at battery. 2) Disconnect EGR valve coupler. 3) Remove EGR valve (1) and gasket from intake collector. INSPECTION 1) Check resistance between following terminals of EGR valve (1) in each pair.
Page 741: Evaporative Emission Control System
6E2-48 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) Evaporative emission control system EVAP CANISTER PURGE INSPECTION 1) Warm up engine to normal operating temperature and keep idling 5 min. or more. 2) Disconnect purge hose (1) from EVAP canister when engine is running at idle speed.
Page 742 09930-88521 (See NOTE “A”.) Vacuum pump gauge Injector test lead Tech 2 kit SUZUKI scan tool (See NOTE “B”.) NOTE: • “A” : This kit includes the following items. 1. Pressure gauge 09912-58441, 2. Pressure hose 09912-58431, 3. 3-way joint & hose 09912-58490, 4.
Page 743 6E2-50 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE)
Page 744 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
Page 745: General Description
6F1-2 IGNITION SYSTEM (FOR G16 ENGINE) General Description The ignition system is a distributorless ignition system. Its consists of the parts as described below and has an electronic ignition control system. • ECM (or PCM) It detects the engine condition through the signals from the sensors, determines the most suitable ignition timing and time for electricity to flow to the primary coil and sends a signal to the igniter (in ignition coil assembly).
Page 746: System Wiring
IGNITION SYSTEM (FOR G16 ENGINE) 6F1-3 System Wiring BLK/WHT BLK/BLU WHT/GRN C51-3-20 BLK/WHT E61-9 C51-2-24 C51-3-4 BLU/BLK BLK/RED C51-3-15 BLU/BLK BLK/ORN C51-2-23 BRN/BLK BLU/BLK C51-2-26 YEL/BLU C51-3-3 GRY/BLK C51-3-26 C51-3-25 BLU/WHT PPL/RED 1. Ignition switch 7. Ignition timing adjusting resistor (if equipped) 2.
Page 747: Components
6F1-4 IGNITION SYSTEM (FOR G16 ENGINE) Components 1. Ignition coil assembly for No.1 and No.4 cylinders 5. ECM (or PCM) (*) 9. Ignition timing adjusting resistor (*) (if equipped) 2. Ignition coil assembly for No.2 and No.3 cylinders 6. High-tension cord 10.
Page 748: Diagnosis
IGNITION SYSTEM (FOR G16 ENGINE) 6F1-5 Diagnosis Condition Possible Cause Correction Engine cranks, but will No spark not start or hard to • Blown fuse for ignition coil Replace. start • Loose connection or disconnection of lead Connect securely. wire or high-tension cord(s) •...
Page 749 6F1-6 IGNITION SYSTEM (FOR G16 ENGINE) Step Action Ignition Coil Assembly Check Go to Step 8. Replace ignition coil 1) Check ignition coil assembly for damage, assembly. deterioration and terminal corrosion, refer- ring to “Ignition Coil Assembly” in this sec- tion.
Page 750: On-Vehicle Service
Section 6E1.) 4) Fix ignition timing as follows. [Using SUZUKI scan tool] Connect SUZUKI scan tool to DLC (1) with ignition switch OFF, restart engine and fix ignition timing by using fixed spark mode of SUZUKI scan tool. Special tool...
Page 751 6F1-8 IGNITION SYSTEM (FOR G16 ENGINE) [Not using SUZUKI scan tool] (for vehicle with monitor connector) • Ground test switch terminal (2) in diagnosis connector (white color) (1) by using service wire so that ignition timing is fixed on initial one.
Page 752 – Signal rotor on camshaft – TP sensor – VSS – Crankshaft pulley/timing belt cover installation 8) After checking, end fixed spark mode of SUZUKI scan tool or remove service wire from diagnosis connector. CAUTION: Driving with test switch terminal grounded will cause damage to catalyst.
Page 753: High-Tension Cord
6F1-10 IGNITION SYSTEM (FOR G16 ENGINE) 9) With engine idling (closed throttle position and vehicle stopped), check that ignition timing is about BTDC 6° – 10°. Also, check that increasing engine speed advances ignition timing. If above check results are not satisfactory, check input signals related to ignition system.
Page 754: Ignition Coil Assembly (Igniter And Ignition Coil)
IGNITION SYSTEM (FOR G16 ENGINE) 6F1-11 INSTALLATION 1) Install high-tension cord (2) to spark plug and ignition coil assembly (1) while gripping its cap. CAUTION: • Never attempt to use metal conductor high-tension cord(s) as replacing parts. • Insert each cap potion fully when installing high-ten- sion cords.
Page 755: Spark Plug
6F1-12 IGNITION SYSTEM (FOR G16 ENGINE) INSTALLATION 1) Install ignition coil assembly (2). 2) Tighten ignition coil bolt (1), and then connect ignition coil coupler. 3) Install high-tension cord (3) to ignition coil assembly (2) while gripping its cap. Spark Plug REMOVAL 1) Pull out high-tension cord while gripping its cap.
Page 756 IGNITION SYSTEM (FOR G16 ENGINE) 6F1-13 INSPECTION CAUTION: When servicing the iridium/platinum spark plugs (slender center electrode type plugs), do not touch the center electrode to avoid damage to it. The electrode is not strong enough against mechanical force as it is slender and its material is not mechanically tough.
Page 757: Ignition Timing Adjusting Resistor (If Equipped)
6F1-14 IGNITION SYSTEM (FOR G16 ENGINE) Ignition Timing Adjusting Resistor (If Equipped) REMOVAL 1) With ignition switch OFF, remove ECM (or PCM), referring to “Engine Control Module (ECM)/Power Train Control Module (PCM)” in Section 6E1. 2) Remove ignition timing adjusting resistor (2). 1.
Page 758: Noise Suppressor
IGNITION SYSTEM (FOR G16 ENGINE) 6F1-15 Noise Suppressor REMOVAL 1) Disconnect coupler of noise suppressor (1). 2) Remove noise suppressor (1). 2. Engine harness INSPECTION Using ohmmeter, check to be sure that capacitor (condenser) in noise suppressor is not conductive. If check result is not satisfactory, replace noise suppressor.
Page 759: Tightening Torque Specification
Spark plug 18.0 Special Tool 09930-76420 Timing light (Dry cell type) Tech 2 kit (SUZUKI scan tool) (See NOTE “A”.) NOTE: “A” : This kit includes the following items and substitutes for the Tech 1A kit. 1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5. Cigarette cable, 6.
Page 760 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
Page 761: General Description
6F2-2 IGNITION SYSTEM (FOR J20/H25 ENGINES) General Description The ignition system is a direct ignition system. It consists of the parts as described below and has an electronic ignition control system. • ECM (or PCM) It detects the engine condition through the signals from the sensors, determines the most suitable ignition timing and time for electricity to flow to the primary coil and sends a signal to the igniter (in ignition coil assembly).
Page 762: System Wiring
IGNITION SYSTEM (FOR J20/H25 ENGINES) 6F2-3 System Wiring BLK/BLU BLK/WHT WHT/GRN C51-3-20 BLK/WHT C51-2-24 E61-9 C51-3-4 BLU/BLK BLK/RED C51-2-23 BRN/BLK C51-3-15 BLU/BLK C51-2-22 BRN/WHT BLU/BLK C51-2-26 YEL/BLU C51-3-21 BRN/YEL C51-3-26 PPL/RED BLK/ORN BLK/BLU BLK/WHT C51-2-3 BLK/WHT WHT/GRN C51-2-13 C51-2-12 BRN/BLK E-61-8 C-51-2-20 BLU/BLK...
Page 763: Components
6F2-4 IGNITION SYSTEM (FOR J20/H25 ENGINES) Components [A] : J20 Engine 1. Ignition coil assembly (Igniter and ignition coil) 3. Noise suppressor 5. Spark plug [B] : H25 Engine 2. CMP sensor 4. ECM (or PCM) (*) 6. Diagnosis connector NOTE: Above figure shows left hand steering vehicle.
Page 764: Diagnosis
IGNITION SYSTEM (FOR J20/H25 ENGINES) 6F2-5 Diagnosis Condition Possible Cause Correction Engine cranks, but will No spark not start or hard to • Blown fuse for ignition coil assembly Replace start • Loose connection or disconnection of lead Connect securely wire •...
Page 765 6F2-6 IGNITION SYSTEM (FOR J20/H25 ENGINES) Step Action CMP Sensor Check Substitute a known-good Tighten CMP sensor bolt 1) Check CMP sensor. ECM (or PCM) and then or replace CMP sensor. Refer to Step 6 or 7 of DTC P0340 Diag. repeat Step 2.
Page 766: On-Vehicle Service
IGNITION SYSTEM (FOR J20/H25 ENGINES) 6F2-7 On-Vehicle Service Ignition Spark Check 1) For H25 engine, remove surge tank cover. 2) Disconnect injector coupler (1). WARNING: Without disconnection of injector coupler, combustible gas may come out from spark plug holes during this test and may get ignited in engine room.
Page 767 6) Using timing light, check that timing observed from viewpoint (1) is within specification. Initial ignition timing of viewpoint (when it is fixed by SUZUKI scan tool or service wire) : 5 ± 1° BTDC Ignition order : 1-3-4-2 (J20 engine)
Page 768 8) After tightening bolt(s), recheck that ignition timing is within specification. 9) After checking and/or adjusting, end fixed spark mode of SUZUKI scan tool or disconnect service wire from diagnosis connector. CAUTION: Driving with test switch terminal grounded will cause damage to catalyst.
Page 769: Ignition Coil Assembly (Igniter And Ignition Coil)
6F2-10 IGNITION SYSTEM (FOR J20/H25 ENGINES) Ignition Coil Assembly (Igniter and Ignition Coil) REMOVAL 1) For H25 engine, remove ignition coil cover. 2) Disconnect ignition coil coupler. 3) Remove ignition coil bolt (1), and then pull out ignition coil assembly (2). [A] : J20 Engine [B] : H25 Engine INSPECTION...
Page 770: Spark Plug
IGNITION SYSTEM (FOR J20/H25 ENGINES) 6F2-11 Spark Plug REMOVAL 1) For H25 engine, remove ignition coil cover. 2) Disconnect ignition coil coupler. 3) Remove ignition coil bolt (1), and then pull out ignition coil assembly (2). 4) Remove spark plug (3). [A] : J20 Engine [B] : H25 Engine INSPECTION...
Page 771: Cmp Sensor
6F2-12 IGNITION SYSTEM (FOR J20/H25 ENGINES) INSTALLATION 1) Install spark plug(s) (3) and tighten them to specified torque. Tightening torque Spark plug (a) : 25 N·m (2.5 kg-m, 18.0 lb-ft) 2) Install ignition coil assembly (2) securely. 3) Tighten ignition coil bolt (1), and then connect ignition coil coupler.
Page 772 IGNITION SYSTEM (FOR J20/H25 ENGINES) 6F2-13 INSTALLATION NOTE: After installing CMP sensor, adjust ignition timing. (Refer to “Ignition Timing Check And Adjustment” in this sec- tion.) 1) Install a new O-ring (2) with engine oil applied to CMP sen- sor (1). 2) Install CMP sensor (1) to camshaft (3).
Page 773: Noise Suppressor
6F2-14 IGNITION SYSTEM (FOR J20/H25 ENGINES) 3) Tighten CMP sensor bolts (3). Tightening torque CMP sensor bolt (a) : 15 N·m (1.5 kg-m, 11.0 lb-ft) 4) Connect CMP sensor coupler (2). [A] : J20 Engine [B] : H25 Engine 1. CMP sensor Noise Suppressor REMOVAL 1) Disconnect coupler of noise suppressor (1).
Page 774 IGNITION SYSTEM (FOR J20/H25 ENGINES) 6F2-15 INSPECTION Using ohmmeter, check to be sure that capacitor (condenser) in noise suppressor is not conductive. If check result is not satisfactory, replace noise suppressor. INSTALLATION For installation, reverse removal procedure.
Page 775: Tightening Torque Specification
CMP sensor bolt 11.0 Special Tool 09930-76420 Timing light (Dry cell type) Tech 2 kit (SUZUKI scan tool) (See NOTE.) NOTE: This kit includes the following items and substitutes for the Tech 1A kit. 1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5. Cigarette cable, 6.
Page 776 CRANKING SYSTEM (0.9 kW, 1.2 kW and 1.4 kW Reduction Type) 6G-1 SECTION 6G CRANKING SYSTEM (0.9 kW, 1.2 kW and 1.4 kW Reduction Type) NOTE: Starting motor vary depending on specifications, etc. Therefore, be sure to check model and specification of the vehicle being serviced before replacing parts.
Page 777: General Description
6G-2 CRANKING SYSTEM (0.9 kW, 1.2 kW and 1.4 kW Reduction Type) General Description Cranking Circuit The cranking circuit consists of the battery, starting motor, ignition switch, and related electrical wiring. These components are connected electrically. Only the starting motor will be covered in this section. Starting Motor Circuit •...
Page 778: Starting Motor
CRANKING SYSTEM (0.9 kW, 1.2 kW and 1.4 kW Reduction Type) 6G-3 Starting Motor 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 779: Diagnosis
6G-4 CRANKING SYSTEM (0.9 kW, 1.2 kW and 1.4 kW Reduction Type) Diagnosis 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 780 CRANKING SYSTEM (0.9 kW, 1.2 kW and 1.4 kW Reduction Type) 6G-5 Condition Possible Cause Correction Starting motor run- If battery and wiring are satisfactory, inspect ning but too slow starting motor (small torque) • Insufficient contact of magnetic switch main Replace magnetic switch.
Page 781: Unit Repair Overhaul
6G-6 CRANKING SYSTEM (0.9 kW, 1.2 kW and 1.4 kW Reduction Type) Unit Repair Overhaul Dismounting and Remounting Use following procedure to remove starter : 1) Disconnect negative battery lead at battery. 2) Disconnect magnetic switch lead wire and battery cable from starting motor terminals.
Page 782 CRANKING SYSTEM (0.9 kW, 1.2 kW and 1.4 kW Reduction Type) 6G-7 2) Remove bolts shown in left figure, then separate reduction gear assembly from starting motor assembly. 1. Bolts 2. Reduction gear assembly 3) To overhaul reduction gear assembly, remove packing and planetary gears.
Page 783 6G-8 CRANKING SYSTEM (0.9 kW, 1.2 kW and 1.4 kW Reduction Type) 7) Remove snap ring, then pull out pinion stop ring and over- running clutch and internal gear. Special tool (A) : 09900-06107 1. Internal gear 2. Snap ring 3.
Page 784: Reassembly
CRANKING SYSTEM (0.9 kW, 1.2 kW and 1.4 kW Reduction Type) 6G-9 12) Remove rear bracket cap, and then remove rear bush, as required. 1. Rear bush 2. Rear bracket cap 3. Rear bracket Reassembly CAUTION: • Washing, adjusting and disassembling of shock absorber (clutch plate) are not allowed.
Page 785 6G-10 CRANKING SYSTEM (0.9 kW, 1.2 kW and 1.4 kW Reduction Type) 9) Install over-running clutch assembly to gear shaft, using care for installing direction of pinion stop ring. 1. Over-running clutch 2. Pinion stop ring 3. Snap ring 4. Gear shaft 10) Insert shaft ass’y into front housing with lever positioned as shown left figure.
Page 786: Inspection
CRANKING SYSTEM (0.9 kW, 1.2 kW and 1.4 kW Reduction Type) 6G-11 16) Install magnetic switch assembly and protector (if equipped). Connect wire (switch to motor) to switch terminal. 17) Upon completion of assembly, carry out “Performance Test”. (Refer to page 6G-16.) 1.
Page 787 6G-12 CRANKING SYSTEM (0.9 kW, 1.2 kW and 1.4 kW Reduction Type) • Hold-In Coil Open Circuit Test Check for continuity across magnetic switch ‘S’ terminal and coil case. If no continuity exists, coil is open and should be replaced. 3.
Page 788 CRANKING SYSTEM (0.9 kW, 1.2 kW and 1.4 kW Reduction Type) 6G-13 6. BRUSH HOLDER • Check movement of brush in brush holder. If brush move- ment within brush holder is sluggish, check brush holder for distortion and sliding faces for contamination. Clean or cor- rect as necessary.
Page 789 6G-14 CRANKING SYSTEM (0.9 kW, 1.2 kW and 1.4 kW Reduction Type) • Inspect commutator for insulator depth. Correct or replace if below limit. Commutator insulator depth “a” Standard : 0.4 – 0.6 mm (0.015 – 0.023 in.) Limit : 0.2 mm (0.008 in.) 1.
Page 790: Performance Test
CRANKING SYSTEM (0.9 kW, 1.2 kW and 1.4 kW Reduction Type) 6G-15 9. PINION AND OVER-RUNNING CLUTCH • Inspect pinion for wear, damage or other abnormal condi- tions. Check that clutch locks up when turned in direction of drive and rotates smoothly in reverse direction. Replace if neces- sary.
Page 791 6G-16 CRANKING SYSTEM (0.9 kW, 1.2 kW and 1.4 kW Reduction Type) Hold-In Test While connected as above with plunger out, disconnect negative lead from terminal ‘M’. Check that plunger and pinion remain out. If plunger and pinion return inward, replace magnetic switch. Plunger and Pinion Return Test Disconnect negative lead from switch body.
Page 792: Specifications
CRANKING SYSTEM (0.9 kW, 1.2 kW and 1.4 kW Reduction Type) 6G-17 Specifications 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 12.3 mm (0.44 in.) (16.5 mm (0.65 in.)) Number of pinion teeth Performance...
Page 793: Required Service Material
6G-18 CRANKING SYSTEM (0.9 kW, 1.2 kW and 1.4 kW Reduction Type) Required Service Material Recommended SUZUKI product Material (Part Number) Lithium grease SUZUKI SUPER GREASE A • Front and rear bush. (99000-25010) • Plunger. • Pinion drive lever. • Internal gear.
Page 794: Charging System
• Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
Page 795: General Description
6H-2 CHARGING SYSTEM General Description Battery 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. • It can, for a limited time, provide energy when the electrical load exceeds the output of the generator.
Page 796: Built-In Indicator (If Equipped)
CHARGING SYSTEM 6H-3 Built-in indicator (If equipped) The battery has a built-in temperature compensated indicator in the top of the battery. This indicator is to be used with the follow- ing diagnostic procedure. When checking the indicator, make sure that the battery has a clean top. A light may be needed in some poorly-lit areas.
Page 797: Care Of Battery
6H-4 CHARGING SYSTEM Care of battery WARNING: • Never expose battery to open flame or electric spark because of battery generate gas which is flammable and explosive. • Do not allow battery fluid to contact eyes, skin, fabrics, or painted surfaces as fluid is a corrosive acid. Flush any contacted area with water immediately and thor- oughly.
Page 798: Generator
CHARGING SYSTEM 6H-5 Generator The generator is a small and high performance type with an IC regulator incorporated. The internal components are connected electrically as shown below figure. The generator features are as follows : • Solid state regulator is mounted inside the generator. •...
Page 799 6H-6 CHARGING SYSTEM [A] : 60 A type 1. Pulley 6. Field coil 11. Front housing F : Field coil terminal [B] : 70 A type 2. Pulley nut 7. Regulator 12. Rear housing IG : Ignition terminal [C] : 80 A type 3.
Page 800: Diagnosis
CHARGING SYSTEM 6H-7 Diagnosis Battery Common causes of failure A battery is not designed to last indefinitely; however, with proper care, it will provide many years of service. If the battery performs satisfactorily during test but fails to operate properly for no appar- ent reason, the following are some factors that may point to the cause of trouble : •...
Page 801: Hydrometer Test
6H-8 CHARGING SYSTEM Hydrometer test The direct method of checking the battery for state of charge is to carry out a high rate discharge test, which involves a special pre- cise voltmeter and an expensive instrument used in the service shops, but not recommendable to the user of the vehicle.
Page 802: Generator
CHARGING SYSTEM 6H-9 Generator CAUTION: • Do not mistake polarities of IG terminal and L terminal. • Do not create a short circuit between IG and L termi- nals. Always connect these terminals through a lamp. • Do not connect any load between L and E. •...
Page 803: Undercharged Battery
6H-10 CHARGING SYSTEM Undercharged battery This condition, as evidenced by slow cranking or indicator clear with red dot can be caused by one or more of the following condi- tions even though indicator lamp may be operating normal. Following procedure also applies to cars with voltmeter and ammeter.
Page 804 CHARGING SYSTEM 6H-11 Higher Voltage If voltage is higher than standard value, check ground of brushes. If brushes are not grounded, replace IC regulator. Lower Voltage [60 A type] If voltage is below or in standard value, increase engine speed up to 2000 –...
Page 805: Overcharged Battery
6H-12 CHARGING SYSTEM Overcharged battery 1) To determine battery condition, refer to “Battery” section. 2) If obvious overcharge condition exists as evidenced by excessive spewing of electrolyte, measure generator B ter- minal voltage at engine 2000 rpm. 3) If measured voltage is higher than upper limit value, proceed to disassembly section of generator service.
Page 806: On-Vehicle Service
CHARGING SYSTEM 6H-13 On-Vehicle Service Battery Jump starting in case of emergency WITH AUXILIARY (BOOSTER) BATTERY CAUTION: If vehicle is manual transmission model and has a catalytic converter, do not push or tow it to start. Damage to its emission system and/or to other parts may result. Both booster and discharged battery should be treated carefully when using jumper cables.
Page 807: Dismounting
6H-14 CHARGING SYSTEM Dismounting 1) Disconnect negative (–) cable. 2) Disconnect positive (+) cable. 3) Remove retainer. 4) Remove battery. Handling When handling battery, following safety precautions should be fol- lowed : • Hydrogen gas is produced by battery. A flame or spark near battery may cause the gas to ignite.
Page 808: Generator
CHARGING SYSTEM 6H-15 Generator Generator belt [G16 and H25 engines] Refer to “Cooling Fan Belt” in Section 6B “Engine Cooling”. [J20 engine] INSPECTION Refer to “Water Pump, Generator, Power Steering and/or A/C Compressor (If Equipped) Drive Belt (J20 Engine)” in section 0B- 7 “Maintenance and Lubrication”.
Page 809: Unit Repair Overhaul
6H-16 CHARGING SYSTEM REMOVAL WARNING: Disconnect negative cable at battery before removing and installing generator belt. 1) Loosen tensioner by turning the tensioner pulley clock wise. 2) While holding the tensioner and belt loose, remove generator belt. INSTALLATION 1) Loosen tensioner by turning the tensioner pulley clockwise. 2) While holding the tensioner, install generator belt.
Page 810: Remounting
CHARGING SYSTEM 6H-17 4) Disconnect “B” terminal wire and coupler from generator. 1. Generator 2. Coupler 3. “B” terminal 5) Remove generator belt. Refer to Section 6B “Engine Cool- ing” (G16 and H25 engines) or “Generator Belt” (J20 engine) in this section. 6) Remove generator.
Page 811: Disassembly [60 A Type]
6H-18 CHARGING SYSTEM Disassembly [60 A type] 1. Pulley 3. Bearing 5. Rotor 7. IC regulator 9. Rear housing 2. Front housing 4. Retainer 6. Stator 8. Rectifier 10. Brush 1) For easier reinstallation, provide match marks on both front and rear housings as shown in left figure before separating them.
Page 812 CHARGING SYSTEM 6H-19 3) With lever inserted between stator core and front housing, separate generator into front and rear sides. 1. Rear housing 2. Stator core 3. Front housing 4. Lever 4) Loosen pulley nut by using vise and take off pulley. NOTE: •...
Page 813 6H-20 CHARGING SYSTEM 7) When removing rear bearing, use oil hydraulic press. 1. Rear bearing 2. Oil hydraulic press 3. General rod 4. General tool 8) Remove three screws and generator “B” terminal nut. 1. Screw 2. Generator “B” terminal nut 3.
Page 814: Disassembly [70 A And 80 A Types]
CHARGING SYSTEM 6H-21 Disassembly [70 A and 80 A types]...
Page 815 6H-22 CHARGING SYSTEM [A] : 70A type 8. Rotor 16. Brush holder [B] : 85 A type 8. Rotor 16. Regulator 1. Pulley nut 9. End housing bearing 17. Rear end cover 1. Pulley nut 9. End housing bearing 17. Brush 2.
Page 816 CHARGING SYSTEM 6H-23 8) Hold shaft by using hexagonal box wrench and remove pul- ley nut, and then pull out pulley. CAUTION: • To hold shaft, use hexagonal box. Duodecimal box may cause slipping and consequential shaft or tool dam- age.
Page 817: Inspection [60 A Type]
6H-24 CHARGING SYSTEM Inspection [60 A type] Rotor 1) Using an ohmmeter, check for continuity between slip rings of rotor. If there is no continuity, replace rotor. Ω Standard resistance : 2.5 – 2.9 1. Rotor 2) Using an ohmmeter, check that there is no continuity between slip ring and rotor core.
Page 818 CHARGING SYSTEM 6H-25 Brush and Brush Holder Check each brush for wear by measuring its length. If brush is found worn down to service limit, replace brush. Brush length “a” Standard : 16 mm (0.63 in.) Service limit : 2 mm (0.08 in.) Rectifier 1) Using an ohmmeter, check continuity between each of upper and lower rectifier bodies and each diode lead.
Page 819: Inspection [70 A And 80 A Types]
6H-26 CHARGING SYSTEM Inspection [70 A and 80 A types] Rotor • Using an ohmmeter, check for continuity between slip rings of rotor. If there is no continuity, replace rotor. Ω Standard resistance : About 2.9 • Using an ohmmeter, check that there is no continuity between slip ring and rotor.
Page 820 CHARGING SYSTEM 6H-27 • Using an ohmmeter, check that there is no continuity between coil leads and stator core. If there is continuity, replace stator. Brush and Brush Holder Check each brush for wear by measuring its length as shown. If brush is found worn down to service limit, replace brush.
Page 821: Replace Brush
6H-28 CHARGING SYSTEM Bearing • Check that drive and bearing is not rough or worn. • Check that end housing bearing is not rough or worn. Replace brush [60 A type] Refer to “Disassembly” and “Reassembly” of 60 A type. [70 A and 80 A types] 1) Remove rear end cover and then brush holder.
Page 822: Reassembly [60 A Type]
CHARGING SYSTEM 6H-29 Reassembly [60 A type] Assemble in reverse order of DISASSEMBLY, noting the follow- ing. 1) Be sure to install brushes in the proper direction and solder brush wires and stator leads. 1. Stator 2. Brush 3. Brush holder 4.
Page 823: Reassembly [70 A And 80 A Types]
6H-30 CHARGING SYSTEM Reassembly [70 A and 80 A types] 1) If end housing bearing is removed, install it. 2) Check end housing bearing turns smoothly. 1. End housing bearing 2. Rotor 3. Bearing cover 3) If stator is removed, install stator and tighten stud bolts. 4) If drive end bearing is removed, install it.
Page 824 CHARGING SYSTEM 6H-31 9) Install pulley and tighten pulley nut with holding shaft by using hexagonal box wrench to specified torque. Tightening torque (a) : 111 N·m (11.1 kg-m, 80.5 lb-ft) 1. Pulley 2. Hexagonal box wrench 3. Offset wrench 10) Install 4 rubber insulators.
Page 825 6H-32 CHARGING SYSTEM 13) Place the IC regulator together with the brush holder hori- zontally on the rear end frame. 14) Install the 5 screws until there is a clearance of approx. 1 mm (0.04 in.) between the brush holder and connector. Tightening torque (a) : 2.0 N·m (0.2 kg-m, 1.5 lb-ft) 1.
Page 826: Specifications
CHARGING SYSTEM 6H-33 Specifications Battery NOTE: The battery used in each vehicle is one of the following four types, depending on specification. Battery type 38B20L 55B24L (S) 55D23L 75D23L Rated capacity AH/5HR, 12 Volts Electrolyte L (US/Imp. pt) 2.8 (5.92/4.93) 3.1 (6.55/5.46) 3.9 (8.24/6.86) 3.9 (8.24/6.86)
Page 827 6H-34 CHARGING SYSTEM...
Page 828 EXHAUST SYSTEM 6K-1 SECTION 6K EXHAUST SYSTEM CAUTION: Be sure to use UNLEADED FUEL for the catalytic converter equipped vehicle. Use of LEADED FUEL will affect performance of the catalytic converter adversely to a great extent. CONTENTS General Description........6K-2 On-Vehicle Service .........6K-5 Components..........6K-2 Exhaust Manifold ..........
Page 829: General Description
6K-2 EXHAUST SYSTEM General Description The exhaust system of the vehicle consists of the exhaust manifold, exhaust No.1 pipe (with Warm Up Three- Way Catalytic Convertor, WU-TWC, if equipped), exhaust No.2 pipe (with Three-Way Catalytic Converter, TWC), muffler, seals, gasket, etc. The three way catalytic converter is an emission control device added to the exhaust system to lower the level of Hydrocarbon (HC), Carbon Monoxide (CO) and Oxides of Nitrogen (NOx) pollutants in the exhaust gas.
Page 830 EXHAUST SYSTEM 6K-3 For H25 engine model 45 N·m (4.5 kg-m) 60 N·m (6.0 kg-m) 45 N·m (4.5 kg-m) 60 N·m (6.0 kg-m) 50 N·m (5.0 kg-m) 45 N·m (4.5 kg-m) 45 N·m (4.5 kg-m) 60 N·m (6.0 kg-m) 50 N·m (5.0 kg-m) 45 N·m (4.5 kg-m) 50 N·m (5.0 kg-m)
Page 831: Maintenance
6K-4 EXHAUST SYSTEM Maintenance WARNING: To avoid the danger of being burned, do not touch the exhaust system when the system is hot. Any service on the exhaust system should be performed when the sys- tem is cool. At every interval of periodic maintenance service, and when vehi- cle is raised for other service, check exhaust system as follows: •...
Page 832: On-Vehicle Service
EXHAUST SYSTEM 6K-5 On-Vehicle Service WARNING: To avoid the danger of being burned, do not touch the exhaust system when the system is hot. Any service on the exhaust system should be performed when the sys- tem is cool. Exhaust Manifold Refer to “Exhaust Manifold”...
Page 833 6K-6 EXHAUST SYSTEM...
Page 834 Prepared by 1st Ed. Dec, 2002 Printed in Japan...

This manual is also suitable for:

Engine 2002 grand vitara sq416 Engine 2002 grand vitara sq625

Suzuki Engine 2002 GRAND VITARA SQ420 Service Manual

Engine General Information and Diagnosis (G16/J20 Engines)

Engine General Information and Diagnosis (G16/J20 Engines)

Exhaust System

Engine Diagnosis

Engine Cooling

Engine Fuel

Table of Contents

Section 6A1 Engine Mechanical (G16 Engine)

Engine Mechanical (G16 Engine)

General Description

On-Vehicle Service

Unit Repair Overhaul

Special Tool

Required Service Material

Tightening Torque Specifications

Section 6A2 Engine Mechanical (H25 Engine)

General Description

On-Vehicle Service

Unit Repair Overhaul

Special Tool

Required Service Material

Section 6A4 Engine Mechanical (J20 Engine)

Engine Mechanical (J20 Engine)

General Description

On-Vehicle Service

Unit Repair Overhaul

Special Tool

Required Service Material

Section 6B Engine Cooling

General Description

Diagnosis

Maintenance

On-Vehicle Service

Tightening Torque Specifications

Required Service Materials

Section 6C Engine Fuel

General Description

Diagnosis

On-Vehicle Service

Tightening Torque Specification

Section 6E1 Engine and Emission Control System (G16/J20 Engines)

Engine and Emission Control System (G16/J20 Engines)

General Description

On-Vehicle Service

Diagnosis

Section 6E2 Engine and Emission Control System (H25 Engine)

General Description

Diagnosis

On-Vehicle Service

Quick Links

Chapters

Related Manuals for Suzuki Engine 2002 GRAND VITARA SQ420

Summary of Contents for Suzuki Engine 2002 GRAND VITARA SQ420