Suzuki 2000 Grand Vitara SQ625 Service Manual

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IMPORTANT

WARNING/CAUTION/NOTE

Please read this manual and follow its instructions

carefully. To emphasize special information, the

words WARNING, CAUTION and NOTE have spe-

cial meanings. Pay special attention to the messages

highlighted by these signal words.

WARNING:

Indicates a potential hazard that could result

in death or injury.

CAUTION:

Indicates a potential hazard that could result

in vehicle damage.

NOTE:

Indicates special information to make mainte-

nance easier or instructions clearer.

WARNING:

This service manual is intended for authorized

SUZUKI dealers and qualified service me-

chanics only. Inexperienced mechanics or

mechanics without the proper tools and

equipment may not be able to properly per-

form the services described in this manual.

Improper repair may result in injury to the me-

chanic and may render the vehicle unsafe for

the driver and passengers.

WARNING:

For vehicles equipped with a Supplemental

Restraint (Air Bag) System:

D 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 De-

scription" in air bag system section in order

to confirm whether you are performing ser-

vice on or near the air bag system compo-

nents or wiring. Please observe all WARN-

INGS and "Service Precautions" under "On-

Vehicle Service" in air bag system section

before performing service on or around the

air bag system components or wiring. Fail-

ure to follow WARNINGS could result in

unintentional activation of the system or

could render the system inoperative. Either

of these two conditions may result in severe

injury.

D If the air bag system and another vehicle

system both need repair, SUZUKI recom-

mends that the air bag system be repaired

first, to help avoid unintended air bag sys-

tem activation.

D Do not modify the steering wheel, instru-

ment panel or any other air bag system com-

ponent (on or around air bag system compo-

nents or wiring). Modifications can adverse-

ly affect air bag system performance and

lead to injury.

D If the vehicle will be exposed to tempera-

tures over 93 C (200 F) (for example, during

a paint baking process), remove the air bag

system components (air bag (inflator) mod-

ule, sensing and diagnostic module (SDM),

seat belt pretensioner (if equipped) before-

hand to avoid component damage or unin-

tended activation.

Table of Contents

Chapters

Table of Contents

Summary of Contents for Suzuki 2000 Grand Vitara SQ625

Page 1 D Service on and around the air bag system cial meanings. Pay special attention to the messages components or wiring must be performed highlighted by these signal words. only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and WARNING: Wiring Location View” under “General De- Indicates a potential hazard that could result scription”...
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 SQ416/SQ420/SQ625 99501-65D01-xxx Transmission, Transfer and Differentials Unit Repair Manual (Front and Rear) of SQ series. SQ416/SQ420/SQ625 99512-65D10-015 Applicable model mentioned in FOREWORD Wiring Diagram Manual of this manual. SQ416/SQ420/SQ625 99500-65D00-xxx Vehicles before the vehicle identification number Service Manual mentioned in FOREWORD of this manual.
Page 4 TABLE OF CONTENTS SECTION TABLE OF CONTENTS SECTION ENGINE GENERAL INFORMATION General Information and General Information Diagnosis (G16/J20) Maintenance and Lubrication General Information and HEATING AND AIR Diagnosis (H25) CONDITIONING Engine Mechanical (G16) Heater and Ventilation Engine Mechanical (H25) Air Conditioning Engine Mechanical (J20) STEERING, SUSPENSION, Engine Cooling...
Page 5 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 6: Table Of Contents
6-2 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16 / J20 ENGINES) CONTENTS GENERAL INFORMATION ....DTC P0136 HO2S-2 Circuit Malfunction ......6- 62 ENGINE DIAGNOSIS .
Page 7: General Information
ENGINE GENERAL INFORMATION (G16 / J20 ENGINES) 6-3 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). Accordingly, when any internal engine parts are serviced, care and cleanliness are important.
Page 8 6-4 ENGINE GENERAL INFORMATION (G16 / J20 ENGINES) PRECAUTION ON FUEL SYSTEM SERVICE D Work must be done with no smoking, in a well-ventilated area and away from any open flames. D As fuel feed line (between fuel pump and fuel pressure regulator) is still under high fuel pressure even after engine was stopped, loosening or disconnecting fuel feed line directly may cause dan- gerous spout of fuel to occur where loosened or disconnected.
Page 9 ENGINE GENERAL INFORMATION (G16 / J20 ENGINES) 6-5 FUEL PRESSURE RELIEF PROCEDURE CAUTION: This work must not be done when engine is hot. If done so, it may cause adverse effect to catalyst. After making sure that engine is cold, release fuel pressure as fol- lows.
Page 10: Engine Diagnosis
ECM (PCM) memory as freeze frame data. (For the details, refer to description on Freeze frame data.) D It is possible to communicate by using not only SUZUKI scan tool (Tech-1) but also generic scan tool. (Diagnostic information can be accessed by using a scan tool.)
Page 11 ENGINE DIAGNOSIS (G16 / J20 ENGINES) 6-7 Warm-Up Cycle A “warm-up cycle” means sufficient vehicle operation such that the coolant temperature has risen by at least 22_C (40_F) from engine starting and reaches a minimum temperature of 70_C (160_F). Driving Cycle A “driving cycle”...
Page 12 DLC in compliance with SAE J1962 in its installation position, the serial data line shape of connector and pin assignment. K line of ISO 9141 is used for SUZUKI scan tool (Tech-1) or generic scan tool to communication with ECM (PCM) and ABS control mod- ule. Body ground...
Page 13 ENGINE DIAGNOSIS (G16 / J20 ENGINES) 6-9 ON-BOARD DIAGNOSTIC SYSTEM (VEHICLE WITHOUT MONITOR CONNECTOR) ECM diagnosis troubles which may occur in the area including the following parts when the ignition switch is ON and the engine is run- ning, and indicates the result by turning on or flashing malfunction indicator lamp (1).
Page 14 K line of ISO 9141 is used for SUZUKI scan tool (Tech-1) to commu- nicate with ECM and ABS control module. SUZUKI serial data line is used for SUZUKI scan tool (Tech-1) to communicate with an electronic control unit (Airbag SDM, etc.).
Page 15: Precaution In Diagnosing Trouble
(DTC, freeze frame data, etc.) stored in ECM (PCM) memory. D Diagnostic information stored in ECM (PCM) memory can be cleared as well as checked by using SUZUKI scan tool (Tech-1) or generic scan tool. Before using scan tool, read its Operator’s (Instruction) Manual carefully to have good understanding as to what functions are available and how to use it.
Page 16: Engine Diagnostic Flow Table
6-12 ENGINE 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 1) Perform customer complaint analysis. complaint analysis. Was customer complaint analysis performed? Diagnostic Trouble Code (DTC) and Freeze Frame 1) Print DTC and...
Page 17 ENGINE DIAGNOSIS (G16 / J20 ENGINES) 6-13 1. CUSTOMER COMPLAINT ANALYSIS Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form will facilitate collecting information to the point required for proper analysis and diagnosis.
Page 18: Customer Problem Inspection Form
6-14 ENGINE DIAGNOSIS (G16 / J20 ENGINES) CUSTOMER PROBLEM INSPECTION FORM (EXAMPLE) User name: Model: VIN: Date of issue: Date Reg. Date of problem: Mileage: PROBLEM SYMPTOMS VDifficult Starting VPoor Driveability VNo cranking VHesitation on acceleration VNo initial combustion VBack fire/After fire VPoor starting at (VCold/VWarm/VAlways) VLoss of power VOther ______________...
Page 19 “Diagnostic Flow Table A-2” for troubleshooting. DIAGNOSTIC TROUBLE CODE (DTC) CHECK [Using SUZUKI scan tool] 1) Prepare generic scan tool or SUZUKI scan tool (Tech-1). 2) Connect it to data link connector (DLC) located on underside of instrument panel at driver’s seat side.
Page 20: Diagnostic Trouble Code (Dtc Clearance
6-16 ENGINE DIAGNOSIS (G16 / J20 ENGINES) DIAGNOSTIC TROUBLE CODE (DTC) CLEARANCE [Using scan tool] 1) Connect generic scan tool or SUZUKI scan tool (Tech-1) to data link connector in the same manner as when making this connec- tion for DTC check.
Page 21: Fail-Safe Table
ENGINE DIAGNOSIS (G16 / J20 ENGINES) 6-17 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 22: Diagnostic Trouble Code (Dtc) Table
6-18 ENGINE DIAGNOSIS (G16 / J20 ENGINES) DIAGNOSTIC TROUBLE CODE (DTC) TABLE (vehicle (vehicle DETECTING CONDITION without with DETECTING ITEM (DTC will set when detecting:) monitor monitor connec- connec- tor) tor) P0100 Sensor output low voltage (or MAF sensor (No.34) circuit shorted to ground) Mass air flow circuit 1 driving...
Page 23 ENGINE DIAGNOSIS (G16 / J20 ENGINES) 6-19 (vehicle (vehicle DETECTING CONDITION DETECTING ITEM with without (DTC will set when detecting:) valve) valve) flashing Misfire of such level as to cause damage to P0300 Random misfire detected during three way catalyst applicable P0301 Cylinder 1 misfire detected...
Page 24 6-20 ENGINE DIAGNOSIS (G16 / J20 ENGINES) DETECTING CONDITION DETECTING ITEM (DTC will set when detecting:) P0705 Transmission Range Switch Circuit (No.72) Malfunction P0715 Input/Turbine Speed Sensor (No.76) Circuit Malfunction P0720 Output Speed Sensor Circuit Malfunction (No.75) Torque Converter Clutch Circuit P0741 Performance or Stuck off P0743...
Page 25: Scan Tool Data
NOTE: D For asterisk (:) marked item in OTHER column, item can be read only SUZUKI scan tool. D When checking the data with the engine running at idle or racing, be sure to shift M/T gear to the neutral gear position and A/T gear to the “Park”...
Page 26 6-22 ENGINE DIAGNOSIS (G16 / J20 ENGINES) NORMAL CONDITION/ SCAN TOOL DATA CONDITION OTHER REFERENCE VALUE OXYGEN SENSOR B1 S1 At specified idle speed after warming up. 0.01 – 0.95 V (HO2S-1 Output Voltage) OXYGEN SENSOR B1 S2 When engine is running at 2000 r/min. for 3 min. 0.01 –...
Page 27 ENGINE DIAGNOSIS (G16 / J20 ENGINES) 6-23 NORMAL CONDITION/ SCAN TOOL DATA CONDITION OTHER REFERENCE VALUE VSS (for 4-A/T) At stop. 0 km/h 0 MPH (Vehicle Speed Sensor) GEAR POSITION (for 4-A / T) Ignition switch ON, selector lever is shifted at “R”, “D”, “2”...
Page 28 6-24 ENGINE DIAGNOSIS (G16 / J20 ENGINES) SCAN TOOL DATA DEFINITIONS COOLANT TEMP (ENGINE COOLANT TEMP., CALC LOAD (CALCULATED LOAD VALUE, %) _C/_F) Engine load displayed as a percentage of maximum It is detected by engine coolant temp. sensor. possible load. Value is calculated mathematically us- ing the formula: actual (current) intake air volume B INTAKE AIR TEMP (_C/_F) maximum possible intake air volume x 100%.
Page 29 ENGINE DIAGNOSIS (G16 / J20 ENGINES) 6-25 TOTAL FUEL TRIM (%) EGR VALVE (%) The value of total fuel trim is obtained by putting val- This parameter indicates opening rate of EGR valve ues of short term fuel trim and long term fuel trim to- which controls the amount of EGR flow.
Page 30 6-26 ENGINE DIAGNOSIS (G16 / J20 ENGINES) VSS (4-A/T) (km/h, MPH) TCC SOL CON/MON (TORQUE CONVERTER CLUTCH SOLENOID COMMAND/MONITOR, It is computed by using pulse signals from vehicle ON/OFF) (output) speed sensor on 4-speed automatic trans- CON-ON: ON command being output to TCC sole- mission.
Page 31: Visual Inspection
ENGINE DIAGNOSIS (G16 / J20 ENGINES) 6-27 VISUAL INSPECTION Visually check following parts and systems. INSPECTION ITEM REFERRING SECTION D Engine oil – – – – – level, leakage Section 0B D Engine coolant – – – – – level, leakage Section 0B D Fuel –...
Page 32: Engine Basic Check
6-28 ENGINE 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 33: Engine Diagnosis Table
ENGINE DIAGNOSIS (G16 / J20 ENGINES) 6-29 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 Reference Item Hard starting Engine and emission control system...
Page 34 6-30 ENGINE DIAGNOSIS (G16 / J20 ENGINES) Condition Possible Cause Reference Item Improper engine Ignition system out of order. D Faulty spark plug idling or engine fails Spark plugs in Ignition System to idle Section. D Faulty ignition coil with ignitor Ignition coil in Ignition System Section.
Page 35 ENGINE DIAGNOSIS (G16 / J20 ENGINES) 6-31 Condition Possible Cause Reference Item Surges Ignition system out of order. D Defective spark plug (excess carbon (Engine power variation Spark plugs in Ignition System under steady throttle or deposits, improper gap, and burned Section.
Page 36 6-32 ENGINE DIAGNOSIS (G16 / J20 ENGINES) Condition Possible Cause Reference Item D Inoperative thermostat Overheating Thermostat in Engine Cooling Section. D Poor water pump performance Water pump in Engine Cooling Section. D Clogged or leaky radiator Radiator in Engine Cooling Section. D Improper engine oil grade Engine oil and oil filter change in Maintenance and Lubrication...
Page 37 ENGINE DIAGNOSIS (G16 / J20 ENGINES) 6-33 Condition Possible Cause Reference Item D Improper oil viscosity Low oil pressure Engine oil and oil filter change in Maintenance and Lubrication Section. D Malfunctioning oil pressure switch Oil pressure switch inspection in Body Electrical System Section.
Page 38 6-34 ENGINE 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 and resistance. CAUTION: PCM/ECM cannot be checked by itself. It is strictly prohib- ited to connect voltmeter or ohmmeter to PCM (ECM) with couplers disconnected from it.
Page 39 ENGINE DIAGNOSIS (G16 / J20 ENGINES) 6-35 TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION Power source for CO adjusting 4.75 – 5.25 V Ignition switch ON resistor (if equipped) Power source for back up 10 – 14 V Ignition switch ON and OFF 10 –...
Page 40 6-36 ENGINE DIAGNOSIS (G16 / J20 ENGINES) TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION ——— —— ——— Heated oxygen sensor-2 While engine running at 2000 r / min. 0.01 – 0.95 V (if equipped) for 3 min. or longer after warming up. ———...
Page 41 ENGINE DIAGNOSIS (G16 / J20 ENGINES) 6-37 TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION Ground for HO2S-1 shield wire —— ——— Power source for TP sensor 4 75 4.75 – 5.25 V 5 25 V Ignition switch ON Ignition switch ON Power source for MAP sensor Power source 10 –...
Page 42 6-38 ENGINE DIAGNOSIS (G16 / J20 ENGINES) TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION A / T output speed sensor (–) About 2.5 V Ignition switch ON A / T output speed sensor (+) About 2.5 V Ignition switch ON 24-25 ——— ——...
Page 43 ENGINE DIAGNOSIS (G16 / J20 ENGINES) 6-39 TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION Deflects between Ignition switch ON, Rear right tire Vehicle speed sensor 0 – 1 V and over 4 V turned slowly with rear left tire locked Deflects between Camshaft position sensor (+) Ignition switch ON, crankshaft turned slowly 0 –...
Page 44: Resistance Check
6-40 ENGINE 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 voltmeter or ohmmeter. 2) Check resistance between each pair of terminals of discon- nected couplers as listed in the following table.
Page 45 ENGINE DIAGNOSIS (G16 / J20 ENGINES) 6-41 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 1. ECM (PCM) 2. To ignition switch 3. Main fuse 4.
Page 46 6-42 ENGINE DIAGNOSIS (G16 / J20 ENGINES) TABLE A-2 MALFUNCTION INDICATOR LAMP CIRCUIT CHECK – MIL REMAINS “ON” AFTER ENGINE STARTS WIRING DIAGRAM/CIRCUIT DESCRIPTION Refer to TABLE A-1. INSPECTION STEP ACTION DTC Check: Go to Step 2 of Go to Step 2. 1) With ignition switch OFF, install scan tool.
Page 47: Table A-5 Ecm (Pcm) Power And Ground Circuit Check
ENGINE DIAGNOSIS (G16 / J20 ENGINES) 6-43 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 1. To ignition switch 2. Main fuse 3.
Page 48 6-44 ENGINE DIAGNOSIS (G16 / J20 ENGINES) TABLE A-5 INSPECTION STEP ACTION Main Relay Operating Sound Check: Go to Step 5. Go to Step 2. Is operating sound of main relay heard at ignition switch ON? Fuse Check: Go to Step 3. Check for short in Is main “FI”...
Page 49 ENGINE DIAGNOSIS (G16 / J20 ENGINES) 6-45 DTC P0100 (DTC No.33, 34) MASS AIR FLOW CIRCUIT MALFUNCTION WIRING DIAGRAM 1. Main fuse 2. Main relay 3. Mass air flow sensor DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA D MAF sensor circuit open or short Following conditions are detected for 5 sec.
Page 50 6-46 ENGINE 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 switch OFF. Check for intermit- 2) Start engine and check MAF value displayed on scan tent referring to...
Page 51: Dtc P0110 (Dtc No
ENGINE DIAGNOSIS (G16 / J20 ENGINES) 6-47 DTC P0110 (DTC No.23, 25) INTAKE AIR TEMP. (IAT) CIRCUIT MALFUNCTION WIRING DIAGRAM 1. IAT sensor DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA D IAT sensor circuit short Following conditions are detected. D Engine running D IAT sensor D High intake air temperature or low temperature...
Page 52 6-48 ENGINE 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 53: Coolant Temp. Sensor Circuit Malfunction
ENGINE DIAGNOSIS (G16 / J20 ENGINES) 6-49 DTC P0115 (DTC No.14,15) ENGINE COOLANT TEMP. SENSOR CIRCUIT MALFUNCTION WIRING DIAGRAM 1. ECT sensor 2. To combination (ECT) meter DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA D ECT sensor circuit short Following conditions are detected for 5 sec.
Page 54 6-50 ENGINE 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 55 ENGINE DIAGNOSIS (G16 / J20 ENGINES) 6-51 DTC P0120 (DTC No.21, 22) THROTTLE POSITION CIRCUIT MALFUNCTION WIRING DIAGRAM 1. Throttle position sensor C51-3-13 DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA D TP sensor circuit open or short Following conditions are detected for 5 sec.
Page 56 6-52 ENGINE 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 switch Check for intermittent OFF and then turn ignition switch ON.
Page 57 ENGINE DIAGNOSIS (G16 / J20 ENGINES) 6-53 DTC P0121 THROTTLE POSITION RANGE/PERFORMANCE PROBREM WIRING DIAGRAM Refer to previous page (DTC P0120). DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA D TP sensor Throttle opening change is smaller than specification D ECM (PCM) while intake air volume changes and engine is D High resistance in circuit...
Page 58 If voltmeter was Go to Step 4. When using SUZUKI scan tool: used, check 1) Turn ignition switch OFF and connect SUZUKI terminal C51-3-9 for scan tool to DLC. poor connection. 2) Turn ignition switch ON and check TP sensor output...
Page 59: Dtc P0130 (Dtc No.13)
ENGINE DIAGNOSIS (G16 / J20 ENGINES) 6-55 DTC P0130 (DTC No.13) HO2S-1 CIRCUIT MALFUNCTION WIRING DIAGRAM 1. To ignition switch 2. HO2S-1 3. Fuse box DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA D HO2S-1 or its circuit Following conditions are detected in idle state D Fuel system while running under driving conditions described...
Page 60 6-56 ENGINE DIAGNOSIS (G16 / J20 ENGINES) DTC CONFIRMATION PROCEDURE WARNING: D When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. D Road test should be carried out with 2 persons, a driver and a tester, on a level road.
Page 61 ENGINE DIAGNOSIS (G16 / J20 ENGINES) 6-57 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 62 6-58 ENGINE DIAGNOSIS (G16 / J20 ENGINES) DTC P0133 HO2S-1 CIRCUIT SLOW RESPONSE WIRING DIAGRAM Refer to page (DTC P0130). DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA D HO2S-1 Following conditions are detected in idle state D ECM (PCM) while running under driving conditions described for DTC CONFIRMATION PROCEDURE.
Page 63 ENGINE DIAGNOSIS (G16 / J20 ENGINES) 6-59 DTC P0134 HO2S-1 NO ACTIVITY DETECTED WIRING DIAGRAM Refer to page (DTC P0130). DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA D HO2S-1 or its circuit Following conditions are detected in vehicle running D Fuel system state while running under driving conditions described D ECM (PCM)
Page 64 6-60 ENGINE DIAGNOSIS (G16 / J20 ENGINES) DTC P0135 HO2S-1 HEATER CIRCUIT MALFUNCTION WIRING DIAGRAM Refer to DTC P0130 section. DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA D HO2S-1 heater circuit Following condition is detected when HO2S D HO2S-1 heater heater is electrically live.
Page 65 ENGINE DIAGNOSIS (G16 / J20 ENGINES) 6-61 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 66 6-62 ENGINE DIAGNOSIS (G16 / J20 ENGINES) DTC P0136 HO2S-2 CIRCUIT MALFUNCTION WIRING DIAGRAM 1. To ignition switch DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA D HO2S-2 or its circuit DTC will set when any one of following conditions D Fuel system is detected.
Page 67 ENGINE DIAGNOSIS (G16 / J20 ENGINES) 6-63 DTC CONFIRMATION PROCEDURE WARNING: D When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. D Road test should be carried out with 2 persons, a driver and a tester, on a level road.
Page 68 6-64 ENGINE DIAGNOSIS (G16 / J20 ENGINES) DTC P0141 HO2S-2 HEATER CIRCUIT MALFUNCTION WIRING DIAGRAM Refer to DTC P0136 section. DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA D HO2S-2 heater or its circuit Following condition is detected when HO2S-2 D ECM (PCM) heater operates.
Page 69 ENGINE DIAGNOSIS (G16 / J20 ENGINES) 6-65 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 70 6-66 ENGINE DIAGNOSIS (G16 / J20 ENGINES) DTC P0171 FUEL SYSTEM TOO LEAN DTC P0172 FUEL SYSTEM TOO RICH SYSTEM DIAGRAM Refer to Section 6E1. DTC DETECTING CONDITION AND POSSIBLE CAUSE DTC DETECTING CONDITION POSSIBLE CAUSE D Vacuum leaks (air inhaling) When running after engine warmed D Short term fuel trim exceeding 15 % or long term D Exhaust gas leakage...
Page 71 ENGINE DIAGNOSIS (G16 / J20 ENGINES) 6-67 TROUBLESHOOTING (DTC P0171/P0172) STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG FLOW DIAG. FLOW TABLE”. Is there DTC(s) other than “DTC P0171/P0172”? Go to applicable Go to Step 3.
Page 72 6-68 ENGINE 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 73 ENGINE DIAGNOSIS (G16 / J20 ENGINES) 6-69 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, 1) Check spark plug and ignition spark of cylinder wire harness, or other where misfire occurs, referring to “IGNITION system parts.
Page 74 6-70 ENGINE DIAGNOSIS (G16 / J20 ENGINES) DTC P0325 (DTC No.43) KNOCK SENSOR CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION 1. Knock sensor DTC DETECTING CONDITION TROUBLE AREA D Knock sensor output voltage: 3.98 V or more D “B” circuit open or shorted to ground D Knock sensor output voltage: 0.90 V or less D Knock sensor malfunction D ECM malfunction...
Page 75 ENGINE DIAGNOSIS (G16 / J20 ENGINES) 6-71 Fig. 1 for Step 3...
Page 76 6-72 ENGINE DIAGNOSIS (G16 / J20 ENGINES) DTC P0335 CRANKSHAFT POSITION SENSOR CIRCUIT MALFUNCTION WIRING DIAGRAM G16 Engine J20 Engine 1. CKP sensor 2. Crankshaft timing belt pulley 3. Sensor plate on crankshaft 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 77 ENGINE DIAGNOSIS (G16 / J20 ENGINES) 6-73 DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA D CKP sensor circuit CKP sensor signal is not input while 20 pulses of D CKP sensor CMP sensor signal are input after engine start. D ECM (PCM) DTC CONFIRMATION PROCEDURE NOTE:...
Page 78 6-74 ENGINE DIAGNOSIS (G16 / J20 ENGINES) TROUBLESHOOTING (DTC P0335) 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. 1) With ignition switch OFF, disconnect ECM (PCM) coupler (C51-2).
Page 79 ENGINE DIAGNOSIS (G16 / J20 ENGINES) 6-75 DTC P0340 (DTC No.42) CAMSHAFT POSITION SENSOR CIRCUIT MALFUNCTION WIRING DIAGRAM G16 Engine J20 Engine 1. Signal rotor on camshaft 2. CMP sensor 3. To main relay 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 80 6-76 ENGINE DIAGNOSIS (G16 / J20 ENGINES) DTC CONFIRMATION PROCEDURE NOTE: Check to make sure that the following conditions are satisfied when using this DTC CONFIRMATION PRO- CEDURE. D Intake air temp.: –8_C, 18_F or higher D Engine coolant temp.: –8 – 110_C (18 – 230_F) D Altitude (barometric pressure): 2400 m, 8000 ft or less (560 mmHg, 75 kPa or more) 1) Connect scan tool to DLC with ignition switch OFF.
Page 81 ENGINE DIAGNOSIS (G16 / J20 ENGINES) 6-77 TROUBLESHOOTING (DTC P0340/DTC No.42) STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. Is engine cranked? Go to Step 3. Go to “CRANKING SYSTEM” section. Is there DTC P1500 (Engine starter signal circuit)? Go to DTC P1500 Go to Step 4.
Page 82 6-78 ENGINE DIAGNOSIS (G16 / J20 ENGINES) STEP ACTION G16 Engine: Intermittent trouble or G16 Engine: Check signal rotor for the following, using mirror. faulty ECM (PCM). Clean rotor teeth or D Damage Check for intermittent replace camshaft. D No foreign material attached referring to “Intermittent J20 Engine: Is it in good condition?
Page 83 ENGINE DIAGNOSIS (G16 / J20 ENGINES) 6-79 DTC P0400 EXHAUST GAS RECIRCULATION FLOW MALFUNCTION SYSTEM/WIRING DIAGRAM 1. EGR valve 2. Intake manifold 3. Exhaust gas 4. Sensed information 5. Main fuse 6. Main relay (PCM) 7. MAP sensor 8. Fuse box...
Page 84 6-80 ENGINE DIAGNOSIS (G16 / J20 ENGINES) DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA D EGR valve During deceleration (engine speed high with closed D EGR passage throttle position) in which fuel cut is involved, difference D Manifold absolute pressure sensor in intake manifold pressure between when EGR valve D ECM (PCM)
Page 85 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 Section 6E1. Is it in good condition? MAP Sensor Check: Intermittent trouble Repair or replace.
Page 86 6-82 ENGINE DIAGNOSIS (G16 / J20 ENGINES) DTC P0403 (DTC No.51) EXHAUST GAS RECIRCULATION CIRCUIT MALFUNCTION WIRING DIAGRAM 1. Main fuse 2. Main relay 3. EGR valve 4. Fuse box DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Low voltage is detected at EGR valve stepping motor EGR valve (stepping motor) or its circuit electrical circuit for specified time continuously.
Page 87 ENGINE DIAGNOSIS (G16 / J20 ENGINES) 6-83 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 1) With ignition switch OFF, disconnect connector malfunction.
Page 88 6-84 ENGINE DIAGNOSIS (G16 / J20 ENGINES) DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD SYSTEM DIAGRAM 1. Heated oxygen sensor-1 2. Heated oxygen sensor-2 3. Warm up three way catalytic converter (WU-TWC, if equipped) 4. Three way catalytic converter CIRCUIT DESCRIPTION Exhaust oxygen concentration at the pre-TWC and the post-TWC is detected from HO2S-1 and HO2S-2 respec- tively and accordingly ECM (PCM) controls the closed loop which then controls the fuel injection volume.
Page 89 ENGINE DIAGNOSIS (G16 / J20 ENGINES) 6-85 DTC CONFIRMATION PROCEDURE WARNING: D When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. D Road test should be carried out with 2 persons, a driver and a tester, on a level road.
Page 90 6-86 ENGINE DIAGNOSIS (G16 / J20 ENGINES) DTC P0443 EVAP CONTROL SYSTEM PURGE CONTROL VALVE CIRCUIT MALFUNCTION WIRING DIAGRAM 1. Main relay 2. Main fuse 3. EVAP canister purge valve 4. Fuse box DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA D EVAP canister purge valve and its circuit Monitor signal of EVAP canister purge valve is different...
Page 91 ENGINE DIAGNOSIS (G16 / J20 ENGINES) 6-87 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 operation Intermittent trouble or Go to Step 3. referring to “EVAP Canister Purge System Check”.
Page 92 6-88 ENGINE DIAGNOSIS (G16 / J20 ENGINES) 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 from EVAP canister.
Page 93 ENGINE DIAGNOSIS (G16 / J20 ENGINES) 6-89 DTC P0500 (DTC No.24) VEHICLE SPEED SENSOR MALFUNCTION WIRING DIAGRAM 1. Speedometer 2. To main relay 3. Vehicle speed sensor DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA D Vehicle speed sensor circuit open or short Vehicle speed signal not inputted although fuel is kept D Vehicle speed sensor cut for longer than 5 seconds.
Page 94 6-90 ENGINE 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 “Bl/Y” wire or Go to Step 3. poor C51-2-25 connection.
Page 95 ENGINE DIAGNOSIS (G16 / J20 ENGINES) 6-91 DTC P0505 IDLE AIR CONTROL SYSTEM MALFUNCTION SYSTEM/WIRING DIAGRAM 1. Throttle body 2. Idle air control valve 3. ECM (PCM) 4. Sensed information 5. Main fuse 6. Main relay 7. Fuse box DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA D Engine idle speed is 100 r/min.
Page 96 6-92 ENGINE DIAGNOSIS (G16 / J20 ENGINES) 1) Connect scan tool to DLC with ignition switch OFF. 2) Turn ON ignition switch and clear DTC, pending DTC and freeze frame data by using scan tool and warm up engine completely. 3) Run engine at idle speed for 1 min.
Page 97 ENGINE DIAGNOSIS (G16 / J20 ENGINES) 6-93 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 1) Connect scan tool to DLC with ignition switch OFF.
Page 98 6-94 ENGINE DIAGNOSIS (G16 / J20 ENGINES) DTC P1408 MANIFOLD ABSOLUTE PRESSURE SENSOR CIRCUIT MALFUNCTION WIRING DIAGRAM 1. Manifold absolute pressure sensor DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA D While engine is running after being warmed up and D Manifold absolute pressure sensor D Manifold absolute pressure sensor vacuum with throttle opening smaller than specification, high-...
Page 99 ENGINE DIAGNOSIS (G16 / J20 ENGINES) 6-95 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 Go to Step 3. 1) Remove ECM (PCM) cover. or faulty ECM 2) Check voltage between C51-3-8 and C51-3-22 (PCM).
Page 100 6-96 ENGINE DIAGNOSIS (G16 / J20 ENGINES) 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 D Barometric pressure sensor in ECM (PCM) DTC P1450:...
Page 101 ENGINE DIAGNOSIS (G16 / J20 ENGINES) 6-97 DTC P1500 ENGINE STARTER SIGNAL CIRCUIT MALFUNCTION WIRING DIAGRAM 1. Starting motor 2. Transmission range sensor (switch) 3. Engine start switch in ignition (main) switch DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA D Engine start signal circuit Engine starts even though vehicle is at stop and engine...
Page 102 6-98 ENGINE DIAGNOSIS (G16 / J20 ENGINES) DTC P1510 ECM BACK-UP POWER SUPPLY MALFUNCTION WIRING DIAGRAM 1. Fuse box 2. Main fuse box 3. To DLC 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 103 ENGINE DIAGNOSIS (G16 / J20 ENGINES) 6-99 TABLE B-1 FUEL PUMP CIRCUIT INSPECTION WIRING DIAGRAM 1. Main relay 2. Fuel pump relay 3. Main fuse 4. To ignition switch 5. Fuel pump 6. Fuse box INSPECTION STEP ACTION Fuel Pump Operation Check: Fuel pump circuit Go to Step 2.
Page 104 6-100 ENGINE DIAGNOSIS (G16 / J20 ENGINES) TABLE B-2 FUEL INJECTORS AND CIRCUIT INSPECTION WIRING DIAGRAM 1. Main relay 2. Injector No.1 3. Injector No.2 4. Injector No.3 5. Injector No.4 6. To ignition switch INSPECTION STEP ACTION Check Injector for Operating Sound. Go to Step 2.
Page 105 ENGINE DIAGNOSIS (G16 / J20 ENGINES) 6-101 TABLE B-3 FUEL PRESSURE INSPECTION SYSTEM DIAGRAM 1. Injector 2. Delivery pipe 3. Fuel pressure regulator 4. Fuel filter 5. Fuel pump (A): Gauge (B): Hose (C): Attachment INSPECTION NOTE: Before using following flow table, check to make sure that battery voltage is higher than 11 V. If battery voltage is low, pressure becomes lower than specification even if fuel pump and line are in good condition.
Page 106 6-102 ENGINE DIAGNOSIS (G16 / J20 ENGINES) STEP ACTION With fuel pump operated and fuel return hose Faulty fuel pressure Shortage of fuel or fuel blocked by pinching it, is fuel pressure regulator. pump or its circuit defective applied? (Refer to Table B-1 “Fuel Pump Circuit Inspection”).
Page 107 ENGINE DIAGNOSIS (G16 / J20 ENGINES) 6-103 TABLE B-4 IDLE AIR CONTROL SYSTEM INSPECTION WIRING DIAGRAM 1. Throttle body 2. Idle air control valve 3. ECM (PCM) 4. Sensed information 5. Main relay INSPECTION STEP ACTION Check engine idle speed and IAC duty Go to Step 2.
Page 108 6-104 ENGINE DIAGNOSIS (G16 / J20 ENGINES) STEP ACTION Was idle speed within specification in Check for following: Go to Step 5. Step 1? – Vacuum leaks – Air inhaling – EVAP canister purge control system – Accessory engine load –...
Page 109 ENGINE DIAGNOSIS (G16 / J20 ENGINES) 6-105 TABLE B-5 A/C SIGNAL CIRCUITS INSPECTION (IF EQUIPPED) WIRING DIAGRAM control module (amplifier) INSPECTION STEP ACTION Check A/C Signal Circuit. Go to Step 2. “Y/B” circuit open or 1) Check voltage at terminal E61-17 with short, Evaporative ignition switch ON.
Page 110 6-106 ENGINE DIAGNOSIS (G16 / J20 ENGINES) TABLE B-6 A/C CONDENSER FAN MOTOR RELAY CONTROL SYSTEM INSPECTION (IF EQUIPPED) WIRING DIAGRAM To ignition switch A/C condenser Rear def fan motor relay fuse in J/B Main fuse fuse condenser fan motor INSPECTION WARNING: Keep hands, tools, and clothing away from A/C condenser fan to help prevent personal injury.
Page 111 4. DLC cable 5. Test lead/probe 6. Power source cable 7. DLC cable adaptor 8. Self–test adaptor 09917-47010 09930-88530 09931-76011 Vacuum pump gauge Injector test lead SUZUKI scan tool (tech 1) kit 09931-76030 Mass storage cartridge 16 / 14 pin DLC cable...
Page 112 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 113 6-1-2 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) Fuel Pressure Relief Procedure ..6-1- 7 DTC P0141 HO2S (Bank-1 Sensor-2) Heater Circuit Malfunction ..6-1-71 Fuel Leakage Check Procedure .
Page 114 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-3 DTC P1408 Manifold Absolute Table B-1 Fuel Pump Circuit Check 6-1-121 Pressure Sensor Circuit Malfunction 6-1-114 Table B-2 Fuel Injector Circuit Check 6-1-123 DTC P1450 Barometric Pressure Table B-3 Fuel Pressure Check .
Page 115 6-1-4 ENGINE (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). Accordingly, when any internal engine parts are serviced, care and cleanliness are important.
Page 116 ENGINE (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 PRE- VENTING DAMAGE, AND IN CONTRIBUTING TO RELIABLE EN- GINE PERFORMANCE. D When raising or supporting engine for any reason, do not use a jack under oil pan.
Page 117 6-1-6 ENGINE (H25 ENGINE) PRECAUTION ON FUEL SYSTEM SERVICE D Work must be done with no smoking, in a well-ventilated area and away from any open flames. With short pipe, fit hose as far as it reaches pipe joint as shown. D As fuel feed line (between fuel pump and fuel pressure regulator) Hose is still under high fuel pressure even after engine was stopped,...
Page 118: Fuel Pressure Relief Procedure
ENGINE (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 follows. Left hand steering vehicle 1) Place transmission gear shift lever in “Neutral”...
Page 119: Fuel Leakage Check Procedure
6-1-8 ENGINE (H25 ENGINE) FUEL LEAKAGE CHECK PROCEDURE After performing any service on fuel system, check to make sure that there are no fuel leakages as follows. 1) Turn ON ignition switch for 3 seconds (to operate fuel pump) and then turn it OFF.
Page 120: Engine Diagnosis
ECM (PCM) memory as freeze frame data. (For the details, refer to description on Freeze frame data.) D It is possible to communicate by using not only SUZUKI scan tool (Tech-1) (2) but also generic scan tool. (Diagnostic information...
Page 121 6-1-10 ENGINE (H25 ENGINE) Warm-Up Cycle A warm-up cycle means sufficient vehicle operation such that the coolant temperature has risen by at least 22_C (40_F) from engine starting and reaches a minimum temperature of 70_C (160_F). Driving Cycle A “Driving Cycle” consists of engine startup and engine shutoff. 2 Driving Cycles Detection Logic The malfunction detected in the first driving cycle is stored in ECM (PCM) memory (in the form of pending DTC and freeze frame data)
Page 122 Serial data line (K line of ISO 9141) is used for SUZUKI scan tool (Tech-1) or generic scan tool to communicate with ECM (PCM) and ABS control module. SUZUKI serial data line is used for SUZUKI...
Page 123: On-Board Diagnostic System (Vehicle With Monitor Connector)
6-1-12 ENGINE (H25 ENGINE) ON-BOARD DIAGNOSTIC SYSTEM (VEHICLE WITH MONITOR CONNECTOR) ECM diagnosis troubles which may occur in the area including the following parts when the ignition switch is ON and the engine is run- ning, and indicates the result by turning on or flashing malfunction indicator lamp (1).
Page 124 K line of ISO 9141 is used for SUZUKI scan tool to communication with ECM (PCM) and ABS control module. SUZUKI serial data line is used for SUZUKI scan tool to communicate with an electronic control units (Airbag SDM, etc.).
Page 125: Precaution In Diagnosing Trouble
ECM (PCM) memory. D Diagnostic information stored in ECM (PCM) memory can be cleared as well as checked by using SUZUKI scan tool (Tech-1) or generic scan tool. Before using scan tool, read its Operator’s (Instruction) Manual carefully to have good understanding as to what functions are available and how to use it.
Page 126: Engine Diagnostic Flow Table
ENGINE (H25 ENGINE) 6-1-15 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 1) Perform customer complaint analysis. complaint analysis. Was customer complaint analysis performed? DTC(s) /Freeze Frame Data Check 1) Record DTC(s)/ Go to Step 4.
Page 127 6-1-16 ENGINE (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 128 ENGINE (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, re- cord DTC and freeze frame data. D After that clear DTC referring to “DIAGNOSTIC TROUBLE CODE CLEARANCE” in this section. DTC indi- cates malfunction that occurred in the system but does not indicate whether it exists now or it occurred in the past and the normal condition has been restored now.
Page 129 6-1-18 ENGINE (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 130 ENGINE (H25 ENGINE) 6-1-19 9. TROUBLESHOOTING FOR DTC Based on the DTC indicated in Step 6 or 7 and referring to the applicable DTC diag. flow table in this section, locate the cause of the trouble, namely in a sensor, switch, wire harness, connector, actuator, ECM (PCM) or other part and repair or replace faulty parts.
Page 131: Malfunction Indicator Lamp (Mil) Check
DIAGNOSTIC TROUBLE CODE (DTC) CHECK [Using scan tool] 1) Prepare generic scan tool (2) or SUZUKI scan tool (Tech-1). 2) With ignition switch OFF, connect it to data link connector (DLC) (3) located on underside of instrument panel at driver’s seat side.
Page 132: Diagnostic Trouble Code (Dtc) Clearance
ENGINE (H25 ENGINE) 6-1-21 DIAGNOSTIC TROUBLE CODE (DTC) CLEARANCE [Using scan tool] 1) With ignition switch OFF, connect generic scan tool or SUZUKI scan tool (Tech-1) to data link connector (DLC). 2) Turn ignition switch ON. 3) Erase DTC according to instructions displayed on scan tool.
Page 133: Diagnostic Trouble Code (Dtc) Table
6-1-22 ENGINE (H25 ENGINE) DIAGNOSTIC TROUBLE CODE (DTC) TABLE (vehicle (vehicle DETECTING CONDITION DETECTING ITEM without with (DTC will set when detecting:) monitor monitor connector connector P0100 Sensor output too low (No.34) Mass air flow circuit 1 driving 1 driving malfunction cycle cycle...
Page 134 ENGINE (H25 ENGINE) 6-1-23 (vehicle (vehicle DETECTING CONDITION DETECTING ITEM without with (DTC will set when detecting:) monitor monitor connector connector Output voltage of HO2S-1 fails to go P0154 HO2S (Bank 2 – Sensor 1) 2 driving 2 driving above specification (or HO2S-1 circuit (No.26) no activity detected cycles...
Page 135 6-1-24 ENGINE (H25 ENGINE) (vehicle (vehicle DETECTING CONDITION DETECTING ITEM without with (DTC will set when detecting:) monitor monitor connector connector Output waveforms of HO2S-1 and HO2S-2 are similar. Catalyst system efficiency 2 driving P0420 (Time from output voltage change of below threshold (Bank 1) cycles applicable...
Page 136 ENGINE (H25 ENGINE) 6-1-25 DETECTING CONDITION DETECTING ITEM (DTC will set when detecting:) P0705 Transmission range circuit (No.72) malfunction P0715 Input/turbine speed sensor (No.76) circuit malfunction P0720 A/T VSS signal circuit malfunction (No.75) Torque converter clutch circuit P0741 performance or stuck off P0743 No.65 Torque converter clutch circuit electrical...
Page 137: Fail-Safe Table
6-1-26 ENGINE (H25 ENGINE) 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 REACTIVATION TROUBLE AREA FAIL SAFE OPERATION CONDITION...
Page 138: Scan Tool Data
NOTE: D For asterisk (:) marked item in OTHER column, item can be read only SUZUKI scan tool. D When checking the data with the engine running at idle or racing, be sure to shift M/T gear to the neutral gear position and A/T gear to the “Park”...
Page 139 6-1-28 ENGINE (H25 ENGINE) NORMAL CONDITION / SCAN TOOL DATA CONDITION OTHER REFERENCE VALUE THROTTLE POS Ignition switch Accelerator pedal released. 10 + 5 % (Absolute Throttle Position) (Absolute Throttle Position) ON / warmed up ON / warmed u Accelerator pedal depressed fully. 80 + 10 % engine stopped.
Page 140 ENGINE (H25 ENGINE) 6-1-29 SCAN TOOL DATA CONDITION NORMAL CONDITION/ OTHER REFERENCE VALUE ELECTRIC LOAD Ignition ON, small light OFF Ignition switch ON, small light ON VSS (for 4-A/T) At stop. 0 km/h 0 MPH (Vehicle Speed Sensor) GEAR POSITION (for 4-A/T) Ignition switch ON, selector lever is shifted at “R”, “D”, “2”...
Page 141: Scan Tool Data Definitions
6-1-30 ENGINE (H25 ENGINE) SCAN TOOL DATA DEFINITIONS COOLANT TEMP (ENGINE COOLANT TEMP., BATTERY VOLTAGE (V) _C/_F) This parameter indicates battery positive voltage in- It is detected by engine coolant temp. sensor. putted from main relay to ECM (PCM). INTAKE AIR TEMP (_C/_F) MAF (MASS AIR FLOW RATE, g/s, lb/min.) It is detected by intake air temp.
Page 142 ENGINE (H25 ENGINE) 6-1-31 FUEL SYSTEM B1 (FUEL SYSTEM BANK 1 EGR VALVE (%) STATUS) This parameter indicates opening rate of EGR valve FUEL SYSTEM B2 (FUEL SYSTEM BANK 2 which controls the amount of EGR flow. STATUS) Air/fuel ratio feedback loop status displayed as one A/C SWITCH (ON/OFF) of the followings.
Page 143 6-1-32 ENGINE (H25 ENGINE) GEAR POSITION (1ST, 2ND, 3RD or 4TH) TRANS RANGE (TRANSMISSION RANGE, R, N, D, 2 or L) The gear position is determined on the basis of the It indicates transmission range according to transmis- command state signals generated from PCM to shift sion range switch signal.
Page 144: Engine Diagnosis Table
ENGINE (H25 ENGINE) 6-1-33 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 Reference Item Hard starting Engine and emission control system (Engine cranks OK.) out of order.
Page 145 6-1-34 ENGINE (H25 ENGINE) Condition Possible Cause Reference Item Improper engine Ignition system out of order. D Faulty spark plug idling or engine fails Spark plugs in Ignition System to idle section. D Faulty ignition coil with ignitor Ignition coil in Ignition System section.
Page 146 ENGINE (H25 ENGINE) 6-1-35 Condition Possible Cause Reference Item Surges Ignition system out of order. D Defective spark plug (excess carbon (Engine power variation Spark plugs in Ignition System under steady throttle or deposits, improper gap, and burned section. cruise. electrodes, etc.) Feels like the vehicle Fuel system out of order.
Page 147 6-1-36 ENGINE (H25 ENGINE) Condition Possible Cause Reference Item D Inoperative thermostat Overheating Thermostat in Engine Cooling section. D Poor water pump performance Water pump in Engine Cooling section. D Clogged or leaky radiator Radiator in Engine Cooling section. D Improper engine oil grade Engine oil and oil filter change in Maintenance and Lubrication section.
Page 148 ENGINE (H25 ENGINE) 6-1-37 Condition Possible Cause Reference Item D Improper oil viscosity Low oil pressure Engine oil and oil filter change in Maintenance and Lubrication section. D Malfunctioning oil pressure switch Oil pressure switch inspection in BODY ELECTRICAL SYSTEM section.
Page 149: Ecm (Pcm) Substitution
6-1-38 ENGINE (H25 ENGINE) 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 respec- tively. –...
Page 150 ENGINE (H25 ENGINE) 6-1-39 TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION For 3 sec. after ignition switch ON or while engine 0 – 2.5 V running. E61 1 E61-1 Fuel pump relay Fuel pump relay After 3 sec. from ignition switch ON with engine 10 –...
Page 151 6-1-40 ENGINE (H25 ENGINE) TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION E61-21, 22 ——— ——— ——— 0 – 1 V Ignition switch ON Immobilizer indicator lamp (vehicle without monitor connector) 10 – 14 V Engine running E61-23 E61-23 Duty output terminal (vehicle with 0 –...
Page 152 ENGINE (H25 ENGINE) 6-1-41 TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION Deflects between C51-3-9 Camshaft position sensor (POS) Ignition switch ON, crankshaft turned slowly. 0 – 1 V and 4 – 6 V Deflects between C51-3-10 Camshaft position sensor (REF) Ignition switch ON, camshaft turned slowly. 0 –...
Page 153 6-1-42 ENGINE (H25 ENGINE) TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION C51-1-6 Shift solenoid A (A / T VEHICLE) 10 – 14 V Ignition switch ON 10 – 14 V Ignition switch ON, Transfer lever: N or 2H range C51 1 7 C51-1-7 4WD lamp (if equipped) 4WD lamp (if equipped)
Page 154 ENGINE (H25 ENGINE) 6-1-43 TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION C51-2-14 IAC valve (stepper motor coil 2) ——— ——— C51-2-15 IAC valve (stepper motor coil 1) ——— ——— EGR valve (stepper motor coil 4) C51-2-16 0 – 1 V (if equipped) Ignition switch ON Ignition switch ON EGR valve (stepper motor coil 3)
Page 155: Resistance Check
6-1-44 ENGINE (H25 ENGINE) 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 156 ENGINE (H25 ENGINE) 6-1-45 STANDARD TERMINAL CIRCUIT CONDITION RESISTANCE C51-1-1 – Body ground Shift solenoid-B 11 – 15 W C51-1-2 – Body ground TCC solenoid — C51-1-6 – Body ground Shift solenoid-A A/T input speed 560 – 680 W C51-1-8 – C51-1-16 —...
Page 157 6-1-46 ENGINE (H25 ENGINE) 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 1. Battery 2. Ignition switch 3. ECM / PCM 4. MIL 5. Fuse box 6.
Page 158: Check
ENGINE (H25 ENGINE) 6-1-47 TROUBLESHOOTING STEP ACTION Test Switch Terminal check (vehicle with monitor Go to Step 2. Test switch terminal connector): circuit is shorted to (1) Check test switch terminal of monitor connector for ground. being grounded. Repair or correct. (2) With ignition switch ON leaving engine OFF, measure voltage between E61-16 and ground.
Page 159 6-1-48 ENGINE (H25 ENGINE) 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 Go to Step 2. (1) With ignition switch OFF, install scan tool. “ENGINE DIAG.
Page 160 ENGINE (H25 ENGINE) 6-1-49 TABLE A-4 MALFUNCTION INDICATOR LAMP CHECK MIL DOES NOT FLASH OR JUST REMAINS ON EVEN WITH GROUNDING DIAGNOSIS SWITCH TERMINAL (vehicle with monitor connector) WIRING DIAGRAM/CIRCUIT DESCRIPTION Refer to TABLE A-1. TROUBLESHOOTING STEP ACTION MIL Circuit check: “V/Y”...
Page 161 6-1-50 ENGINE (H25 ENGINE) 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 1. Battery 2. Ignition switch 3. Main fuse 4.
Page 162 ENGINE (H25 ENGINE) 6-1-51 TROUBLESHOOTING STEP ACTION Main Relay Operating Sound check: Go to Step 5. Go to Step 2. Is operating sound of main relay heard at ignition switch Fuse check: Go to Step 3. Check for short in Is fuse 8 in good condition? circuits connected to this fuse.
Page 163: Dtc P0100 (Dtc No.33, 34) Mass Air Flow Sensor Circuit Malfunction
6-1-52 ENGINE (H25 ENGINE) DTC P0100 MASS AIR FLOW SENSOR CIRCUIT MALFUNCTION (DTC No.33, 34) WIRING DIAGRAM 1. Main relay 2. Mass air flow sensor TERMINAL ARRANGEMENT OF ECM (PCM) COUPLER (VIEWED FROM HARNESS SIDE) DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA D Engine running and more than 5.0 V MAF sensor output...
Page 164 ENGINE (H25 ENGINE) 6-1-53 DTC CONFIRMATION PROCEDURE NOTE: Check to make sure that following conditions are satisfied when using this DTC CONFIRMATION PROCE- DURE. WARNING: D When performing a road test, select a place where there is no traffic or possibility of a traffic accident and very careful during to avoid occurrence of an accident.
Page 165: Dtc P0110 (Dtc No.23, 25) Intake Air Temp. Circuit Malfunction
6-1-54 ENGINE (H25 ENGINE) DTC P0110 INTAKE AIR TEMP. CIRCUIT MALFUNCTION (DTC No.23, 25) WIRING DIAGRAM 1. IAT sensor TERMINAL ARRANGEMENT OF ECM (PCM) COUPLER (VIEWED FROM HARNESS SIDE) DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA D Less than 0.16 V IAT sensor output voltage continues for IAT sensor circuit 5 sec.
Page 166 ENGINE (H25 ENGINE) 6-1-55 D Intake air temperature: between –14_C and 70_C (68_F and 158_F) D 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. (3) Start engine and run it for 10 sec.
Page 167: Dtc P0115 (Dtc No.14, 15) Engine Coolant Temp. Circuit Malfunction
6-1-56 ENGINE (H25 ENGINE) DTC P0115 ENGINE COOLANT TEMP. CIRCUIT MALFUNCTION (DTC No.14, 15) WIRING DIAGRAM 1. ECT sensor 2. Combination meter TERMINAL ARRANGEMENT OF ECM (PCM) COUPLER (VIEWED FROM HARNESS SIDE) DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA D ECT sensor signal terminal voltage is less than 0.16 V for ECT sensor...
Page 168 ENGINE (H25 ENGINE) 6-1-57 D Atmospheric pressure: higher than 560 mmHg (Altitude: lower than 2790 m (9150 ft)) D 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. (3) Start engine and run it for 10 sec.
Page 169: Dtc P0120 (Dtc No.21, 22) Throttle Position Circuit Malfunction
6-1-58 ENGINE (H25 ENGINE) DTC P0120 THROTTLE POSITION CIRCUIT MALFUNCTION (DTC No.21, 22) WIRING DIAGRAM 1. Throttle position sensor TERMINAL ARRANGEMENT OF ECM (PCM) COUPLER (VIEWED FROM HARNESS SIDE) DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA TP sensor signal terminal voltage continues less than 0.1 V for TP sensor 1 sec.
Page 170 ENGINE (H25 ENGINE) 6-1-59 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. “Gr/R” wire open or (1) Wit ignition switch OFF, disconnect C30-3 coupler. shorted to ground (2) Check voltage between C30-3 and ground.
Page 171: Dtc P0121 Throttle Position Circuit Performance Problem
6-1-60 ENGINE (H25 ENGINE) 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 or as large (rationality-high) while engine is running under low...
Page 172 ENGINE (H25 ENGINE) 6-1-61 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. (2) Start engine and warm up for normal operating temperature then stop engine.
Page 173: Dtc P0130 Ho2S (Bank-1 Sensor-1) Circuit Malfunction
6-1-62 ENGINE (H25 ENGINE) DTC P0130 HO2S (BANK-1 SENSOR-1) CIRCUIT MALFUNCTION WIRING DIAGRAM 1. HO2S heater relay 2. HO2S TERMINAL ARRANGEMENT OF ECM (PCM) COUPLER (VIEWED FROM HARNESS SIDE) DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA D Minimum HO2S voltage is 0.4 V or higher.
Page 174 ENGINE (H25 ENGINE) 6-1-63 NOTE: Check to make sure that following conditions are satisfied when using this DTC CONFIRMATION PROCE- DURE. D Intake air temperature: between –14_C and 70_C (6.8_F and 158_F) D Atmospheric pressure: higher than 560 mmHg (Altitude: lower than 2790 m (9150 ft)) D Following DTC is not detected: P0135 (1) With ignition switch OFF, connect scan tool.
Page 175: Dtc P0133 Ho2S (Bank-1 Sensor-1)
6-1-64 ENGINE (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 HO2S 5 sec.
Page 176: Detected
ENGINE (H25 ENGINE) 6-1-65 DTC P0134 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. HO2S HO2S circuit Fuel injector Fuel pressure control system ECM (PCM)
Page 177 6-1-66 ENGINE (H25 ENGINE) STEP ACTION HO2S Voltage check: Poor C51-3-4 and/or Go to Step 4. (1) Remove ECM (PCM) cover. C51-3-21 terminal (2) Start engine and check voltage between C51-3-4 connection. and C51-3-21 while repeating racing engine. If OK, substitute a Does the voltage indicate 0.5 V or more even at once? known-good ECM (PCM) and recheck.
Page 178: Dtc P0135 Ho2S (Bank-1 Sensor-1) Heater Circuit Malfunction
ENGINE (H25 ENGINE) 6-1-67 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 179 6-1-68 ENGINE (H25 ENGINE) Fig. for STEP 2, 3 a. HO2S heater relay...
Page 180: Dtc P0136 Ho2S (Bank-1 Sensor-2) Circuit Malfunction
ENGINE (H25 ENGINE) 6-1-69 DTC P0136 HO2S (BANK-1 SENSOR-2) CIRCUIT MALFUNCTION WIRING DIAGRAM 1. HO2S heater relay 2. HO2S TERMINAL ARRANGEMENT OF ECM (PCM) COUPLER (VIEWED FROM HARNESS SIDE) DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTION CONDITION TROUBLE AREA Maximum HO2S voltage is higher than 2.0 V for 20 sec.
Page 181 6-1-70 ENGINE (H25 ENGINE) D Intake air temperature: between –14_C and 70_C (6.8_F and 158_F) D Atmospheric pressure: higher than 560 mmHg (Altitude: lower than 2790 m (9150 ft)) D Following DTCs are not detected: P0110 (No.23, 25), P0335, P0460, P1450 and P1451 (1) With ignition switch OFF, connect scan tool.
Page 182: Dtc P0141 Ho2S (Bank-1 Sensor-2) Heater Circuit Malfunction
ENGINE (H25 ENGINE) 6-1-71 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 lower HO2S than specified value.
Page 183 6-1-72 ENGINE (H25 ENGINE) STEP ACTION HO2S Heater Control Circuit check: Substitute a known- Faulty HO2S heater (1) With ignition switch OFF, install HO2S heater relay. good ECM (PCM) relay or “W/B” wire (2) With ignition switch ON leaving engine OFF, check and recheck.
Page 184: Dtc P0150 Ho2S (Bank-2 Sensor-1) Circuit Malfunction
ENGINE (H25 ENGINE) 6-1-73 DTC P0150 HO2S (BANK-2 SENSOR-1) CIRCUIT MALFUNCTION WIRING DIAGRAM 1. HO2S heater relay 2. HO2S TERMINAL ARRANGEMENT OF ECM (PCM) COUPLER (VIEWED FROM HARNESS SIDE) DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA D Minimum HO2S voltage is 0.4 V or higher.
Page 185 6-1-74 ENGINE (H25 ENGINE) WARNING: D When performing a road test, select a place where there is no traffic or possibility of a traffic accident and very careful during to avoid occurrence of an accident. D Road test, should be carried out with 2 person, a driver and tester, on a level road. D Intake air temperature: between –14_C and 70_C (6.8_F and 158_F) D Atmospheric pressure: higher than 560 mmHg (Altitude: lower than 2790 m (9150 ft)) D Following DTC is not detected: P0135...
Page 186: Dtc P0153 Ho2S (Bank-2 Sensor-1) Circuit Slow Response
ENGINE (H25 ENGINE) 6-1-75 DTC P0153 HO2S (BANK-2 SENSOR-1) CIRCUIT SLOW RESPONSE WIRING DIAGRAM Refer to DTC P0150 (DTC No.26). DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Hi/Low switch cycle average of HO2S voltage is longer than HO2S 5 sec.
Page 187: Detected
6-1-76 ENGINE (H25 ENGINE) DTC P0154 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. HO2S HO2S circuit Fuel injector Fuel pressure control system ECM (PCM)
Page 188 ENGINE (H25 ENGINE) 6-1-77 STEP ACTION HO2S Voltage check: Poor C51-3-15 and/ Go to Step 4. (1) Remove ECM (PCM) cover. or C51-3- 21 terminal (2) Start engine and check voltage between C51-3-15 connection. and C51-3-21 while repeating racing engine. If OK, substitute a Does the voltage indicate 0.5 V or more even at once? known-good ECM...
Page 189: Dtc P0155 Ho2S (Bank-2 Sensor-1) Heater Circuit Malfunction
6-1-78 ENGINE (H25 ENGINE) 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 190 ENGINE (H25 ENGINE) 6-1-79 Fig. for STEP 2, 3 a. HO2S heater relay...
Page 191: Dtc P0156 Ho2S (Bank-1 Sensor-2) Circuit Malfunction
6-1-80 ENGINE (H25 ENGINE) DTC P0156 HO2S (BANK-2 SENSOR-2) CIRCUIT MALFUNCTION WIRING DIAGRAM 1. HO2S heater relay 2. HO2S TERMINAL ARRANGEMENT OF ECM (PCM) COUPLER (VIEWED FROM HARNESS SIDE) DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTION CONDITION TROUBLE AREA Maximum HO2S voltage is higher than 2.0 V for 20 sec.
Page 192 ENGINE (H25 ENGINE) 6-1-81 D Intake air temperature: between –14_C and 70_C (6.8_F and 158_F) D Atmospheric pressure: higher than 560 mmHg (Altitude: lower than 2790 m (9150 ft)) D Following DTCs are not detected: P0110 (No.23, 25), P0335, P0460, P01450 and P01451 (1) With ignition switch OFF, connect scan tool.
Page 193: Dtc P0161 Ho2S (Bank-2 Sensor-2) Heater Circuit Malfunction
6-1-82 ENGINE (H25 ENGINE) 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 lower HO2S than specified value.
Page 194 ENGINE (H25 ENGINE) 6-1-83 STEP ACTION HO2S Heater Control Circuit check: Substitute a known- Faulty HO2S heater (1) With ignition switch OFF, install HO2S heater relay. good ECM (PCM) relay or “P/W” wire (2) With ignition switch ON leaving engine OFF, check and recheck.
Page 195: Dtc P0171 Fuel System Too Lean (Bank-1)
6-1-84 ENGINE (H25 ENGINE) 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 196 ENGINE (H25 ENGINE) 6-1-85 STEP ACTION Check fuel injector circuit referring to “TABLE B-3” Go to Step 7. Repair or replace. in this section. Is it in good condition? Check fuel level sensor referring to “ENGINE AND Go to Step 8. Faulty fuel level EMISSION CONTROL”...
Page 197: Dtc P0174 Fuel System Too Lean (Bank-2)
6-1-86 ENGINE (H25 ENGINE) 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 198 ENGINE (H25 ENGINE) 6-1-87 STEP ACTION Check fuel injector circuit referring to “TABLE B-3” Go to Step 7. Repair or replace. in this section. Is it in good condition? Check fuel level sensor referring to “ENGINE AND Go to Step 8. Faulty fuel level EMISSION CONTROL”...
Page 199: Dtc P0300 Random Misfire Detected
6-1-88 ENGINE (H25 ENGINE) 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 sensor for each cylinder.
Page 200 ENGINE (H25 ENGINE) 6-1-89 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, (1) Check spark plug and ignition spark of cylinder wire harness or spark where misfire occurs, referring to “IGNITION plug.
Page 201: Dtc P0335 Crankshaft Position Sensor Circuit Malfunction
6-1-90 ENGINE (H25 ENGINE) DTC P0335 CRANKSHAFT POSITION SENSOR CIRCUIT MALFUNCTION WIRING DIAGRAM 1. CKP sensor TERMINAL ARRANGEMENT OF ECM (PCM) COUPLER (VIEWED FROM HARNESS SIDE) DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA CKP sensor signal is not input for 3 sec. after engine start. CKP sensor CKP sensor circuit ECM (PCM)
Page 202 ENGINE (H25 ENGINE) 6-1-91 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. (1) With ignition switch OFF, disconnect ECM (PCM) coupler (C51-3).
Page 203: Dtc P0340 (Dtc No.42) Camshaft Position Sensor Circuit Malfunction
6-1-92 ENGINE (H25 ENGINE) DTC P0340 CAMSHAFT POSITION SENSOR CIRCUIT MALFUNCTION (DTC No.42) WIRING DIAGRAM 1. CMP sensor 2. Main relay TERMINAL ARRANGEMENT OF ECM (PCM) COUPLER (VIEWED FROM HARNESS SIDE) SYSTEM DESCRIPTION CMP sensor detects REF signal and POS signal. _ REF signal: 6 pulses/1 revolution of camshaft.
Page 204 ENGINE (H25 ENGINE) 6-1-93 DTC CONFIRMATION PROCEDURE NOTE: Check to make sure that following conditions are satisfied when using this DTC CONFIRMATION PROCE- DURE. D Intake air temperature: between –14 C and 70 C (6.8 F and 158 F) D Atmospheric pressure: higher than 560 mmHg (Altitude: lower than 2790 m (9150 ft)) D Following DTC is not detected: P0335 (1) With ignition switch OFF, connect scan tool.
Page 205 6-1-94 ENGINE (H25 ENGINE) Fig. for STEP 4 1. Disconnected CMP sensor coupler 2. “BI / B” wire terminal 3. “Gr / Y” wire terminal...
Page 206: Dtc P0400 (Dtc No.51) Exhaust Gas Recirculation Flow Malfunction
ENGINE (H25 ENGINE) 6-1-95 DTC P0400 EXHAUST GAS RECIRCULATION FLOW MALFUNCTION (DTC No.51) SYSTEM/WIRING DIAGRAM 1. EGR valve 2. Intake manifold 3. Exhaust gas 1. EGR valve (stepper motor) 2. Main relay TERMINAL ARRANGEMENT OF ECM (PCM) COUPLER (VIEWED FROM HARNESS SIDE)
Page 207 Go to Step 4. EGR Valve Operation check: Intermittent trouble. Go to Step 4. (1) With ignition switch OFF, install SUZUKI scan tool. If OK, substitute a (2) Check EGR system referring to “ENGINE AND known-good ECM EMISSION CONTROL” section.
Page 208 ENGINE (H25 ENGINE) 6-1-97 STEP ACTION EGR Valve Stepper Motor Coil Circuit check: Stuck or faulty EGR Faulty “Lg”, “Lg/W”, (1) With ignition switch OFF, connect EGR coupler and valve. “Lg/R”, “Lg/Y” wire disconnect ECM (PCM) couplers. Clogged EGR gas or EGR valve.
Page 209: Dtc P0420 Catalyst System (Bank-1) Efficiency Below Threshold
6-1-98 ENGINE (H25 ENGINE) DTC P0420 CATALYST SYSTEM (BANK-1) EFFICIENCY BELOW THRESHOLD DTC P0430 CATALYST SYSTEM (BANK-2) EFFICIENCY BELOW THRESHOLD SYSTEM/WIRING DIAGRAM 1. Warm up TWC converter (Bank 2) 5. HO2S (Bank 2, Sensor 1) 2. Warm up TWC converter (Bank 1) 6.
Page 210 ENGINE (H25 ENGINE) 6-1-99 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: Check to make sure that following conditions are satisfied when using this DTC CONFIRMATION PROCE-...
Page 211: Dtc P0443 Evap Control System Purge Control Valve Circuit Malfunction
6-1-100 ENGINE (H25 ENGINE) DTC P0443 EVAP CONTROL SYSTEM PURGE CONTROL VALVE CIRCUIT MALFUNCTION WIRING DIAGRAM 1. Main fuse 2. Main relay 3. EVAP canister purge valve DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA D EVAP canister purge valve and its circuit Monitor signal of EVAP canister purge valve is different D ECM (PCM) from command signal.
Page 212 ENGINE (H25 ENGINE) 6-1-101 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 operation Intermittent trouble or Go to Step 3. referring to “EVAP Canister Purge System” check. faulty ECM (PCM).
Page 213 2) With ignition switch ON, blow into hose “A”. Air should not come out of hose “B”. Using SUZUKI scan tool Connect SUZUKI scan tool (1) to DLC (2) with ignition switch OFF. 3-1) Turn ON EVAP canister purge valve by using SUZUKI scan tool with ignition switch ON.
Page 214 ENGINE (H25 ENGINE) 6-1-103 4) With ignition switch OFF, disconnect coupler from EVAP canis- ter purge valve. 5) Check resistance between two terminals of EVAP canister purge valve. Resistance of EVAP canister purge valve: 28 – 36 W at 20_C (68_F) If resistance is as specified, proceed to next operation check.
Page 215 6-1-104 ENGINE (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 from EVAP canister. 5) Place finger against the end of disconnected hose and check that vacuum is not felt there when engine is running at idle speed.
Page 216: Dtc P0460 Fuel Level Sensor Circuit High Input
ENGINE (H25 ENGINE) 6-1-105 DTC P0460 FUEL LEVEL SENSOR CIRCUIT HIGH INPUT WIRING DIAGRAM/CIRCUIT DESCRIPTION 1. Fuel level meter in combination meter 2. Fuel level sensor DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Fuel level sensor voltage higher than specified value. Fuel level sensor and/or its circuit Fuel level meter and/or its circuit ECM (PCM)
Page 217 6-1-106 ENGINE (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. “Bl/W” wire shorted (1) With ignition switch OFF, disconnect G10 of to power circuit.
Page 218: Dtc P0500 (Dtc No.24) Vehicle Speed Sensor Malfunction
ENGINE (H25 ENGINE) 6-1-107 DTC P0500 VEHICLE SPEED SENSOR MALFUNCTION (DTC No.24) WIRING DIAGRAM 1. Vehicle speed sensor 2. Main relay 3. Speedometer TERMINAL ARRANGEMENT OF ECM (PCM) COUPLER (VIEWED FROM HARNESS SIDE) CIRCUIT DESCRIPTION Refer to “ENGINE AND EMISSION CONTROL” section. DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA...
Page 219 6-1-108 ENGINE (H25 ENGINE) WARNING: D When performing a road test, select a place where there is no traffic or possibility of a traffic accident and very careful during to avoid occurrence of an accident. D Road test, should be carried out with 2 person, a driver and tester, on a level road. D Intake air temperature: between –14 C and 70 C (6.8 F and 158 F) D Atmospheric pressure: higher than 560 mmHg (Altitude: lower than 2790 m (9150 ft)) (1) With ignition switch OFF, connect scan tool.
Page 220 ENGINE (H25 ENGINE) 6-1-109 STEP ACTION Speedometer Circuit check: Substitute a known- Faulty “Bl/Y” wire. (1) With ignition switch OFF, disconnect G11 coupler good combination If OK, substitute a from combination meter. meter and recheck. known-good ECM (2) With ignition switch ON leaving engine OFF, check (PCM) and recheck.
Page 221: Dtc P0505 Idle Air Control System Malfunction
6-1-110 ENGINE (H25 ENGINE) DTC P0505 IDLE AIR CONTROL SYSTEM MALFUNCTION SYSTEM/WIRING DIAGRAM 1. IAC valve 2. Fast idle control system 3. Bypass air 4. Engine coolant COLD HOT 5. Main relay TERMINAL ARRANGEMENT OF ECM (PCM) COUPLER (VIEWED FROM HARNESS SIDE)
Page 222 ENGINE (H25 ENGINE) 6-1-111 SYSTEM/CIRCUIT DESCRIPTION Refer to “ENGINE AND EMISSION CONTROL” section. 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. though IAC valve opening is about 100 %. Air intake system Idle engine speed is higher than desired engine speed 200 r/min.
Page 223 6-1-112 ENGINE (H25 ENGINE) STEP ACTION Air Intake System check: Go to Step 7. Repair or replace. (1) Check air intake system for clog and air inhabit. (2) Check fast idle up system referring to “ENGINE AND EMISSION CONTROL” section. Are they in good condition? VSS check: Go to DTC P0500...
Page 224: Dtc P0601 Internal Control Module Memory Check Sum Error
ENGINE (H25 ENGINE) 6-1-113 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 225: Dtc P1408 Manifold Absolute Pressure Sensor Circuit Malfunction
6-1-114 ENGINE (H25 ENGINE) DTC P1408 MANIFOLD ABSOLUTE PRESSURE SENSOR CIRCUIT MALFUNCTION WIRING DIAGRAM 1. MAP sensor TERMINAL ARRANGEMENT OF ECM (PCM) COUPLER (VIEWED FROM HARNESS SIDE) CIRCUIT DESCRIPTION Refer to “ENGINE AND EMISSION CONTROL” section. DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA MAP sensor signal voltage continues more than 2.7 V for 5 sec.
Page 226 ENGINE (H25 ENGINE) 6-1-115 D Intake air temperature: between 5 C and 70 C (6.8 F and 158 F) D 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 227: Dtc P1450 Barometric Pressure Sensor Circuit Malfunction
6-1-116 ENGINE (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 228 ENGINE (H25 ENGINE) 6-1-117 DTC TROUBLESHOOTING STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. 1) Connect scan tool to DLC with ignition switch OFF. Substitute a known- Go to Step 2. 2) Turn ignition switch ON and select “DATA LIST”...
Page 229: Dtc P1500 Engine Start Signal Circuit Malfunction
6-1-118 ENGINE (H25 ENGINE) DTC P1500 ENGINE START SIGNAL CIRCUIT MALFUNCTION WIRING DIAGRAM 1. Ignition switch 2. Transmission range switch TERMINAL ARRANGEMENT OF ECM (PCM) COUPLER (VIEWED FROM HARNESS SIDE) 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 230 ENGINE (H25 ENGINE) 6-1-119 DTC CONFIRMATION PROCEDURE NOTE: Check to make sure that following conditions are satisfied when using this DTC CONFIRMATION PROCE- DURE. D Intake air temperature: between –14 C and 70 C (6.8 F and 158 F) D Atmospheric pressure: higher than 560 mmHg (Altitude: lower than 2790 m (9150 ft)) (1) With ignition switch OFF, connect scan tool.
Page 231: Dtc P1510 Ecm Back-Up Power Supply Malfunction
6-1-120 ENGINE (H25 ENGINE) DTC P1510 ECM BACK-UP POWER SUPPLY MALFUNCTION WIRING DIAGRAM TERMINAL ARRANGEMENT OF ECM (PCM) COUPLER (VIEWED FROM HARNESS SIDE) 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 232 ENGINE (H25 ENGINE) 6-1-121 TABLE B-1 FUEL PUMP CIRCUIT CHECK WIRING DIAGRAM 1. Fuel pump 2. Fuel pump relay 3. Main relay TERMINAL ARRANGEMENT OF ECM (PCM) COUPLER VIEWED FROM HARNESS SIDE CIRCUIT DESCRIPTION Fuel pump relay is turned ON _ for 3 sec.
Page 233 6-1-122 ENGINE (H25 ENGINE) TROUBLESHOOTING STEP ACTION Fuel Pump Operation check: Fuel pump circuit Go to Step 2. (1) Remove fuel filler cap. is in 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 234 ENGINE (H25 ENGINE) 6-1-123 TABLE B-2 FUEL INJECTOR CIRCUIT CHECK WIRING DIAGRAM 1. Fuel injector 2. Main relay TERMINAL ARRANGEMENT OF ECM (PCM) COUPLER VIEWED FROM HARNESS SIDE...
Page 235 6-1-124 ENGINE (H25 ENGINE) 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 Go to Step 3.
Page 236 ENGINE (H25 ENGINE) 6-1-125 TABLE B-3 FUEL PRESSURE CHECK SYSTEM DIAGRAM 1. Injector 2. Delivery pipe 3. Fuel pressure regulator 4. Fuel filter 5. Fuel pump (A): Gauge (B): Hose (C): Attachment SYSTEM DESCRIPTION Fuel pressure regulator keeps the fuel pressure applied to injector 290 kPa higher than that in intake manifold at all times.
Page 237 6-1-126 ENGINE (H25 ENGINE) STEP ACTION Is there fuel leakage from fuel feed line hose, pipe or Fuel leakage from Fuel leakage from joint? fuel feed line hose, injector, fuel pressure pipe or joint. regulator or fuel pump. Was fuel pressure higher than specification in Step 2? Go to Step 7.
Page 238 ENGINE (H25 ENGINE) 6-1-127 TABLE B-4 A/C SIGNAL CIRCUIT CHECK (IF EQUIPPED) CIRCUIT DIAGRAM 1. A / C control module TERMINAL ARRANGEMENT OF ECM (PCM) COUPLER VIEWED FROM HARNESS SIDE CIRCUIT DESCRIPTION ECM (PCM) outputs A/C ON signal (one of the signals for A/C control module to control the A/C) to A/C control module when A/C switch signal inputted to ECM (PCM) and engine conditions are specified.
Page 239 6-1-128 ENGINE (H25 ENGINE) STEP ACTION A/C ON Signal check: A/C signal circuit is Faulty “Gr/W”, poor (1) Check voltage between E61-27 and ground under in good condition. performance of ECT following conditions. sensor, TP sensor, Engine running and A/C switch and/or heater inputted engine blower switch OFF 0 –...
Page 240: (If Equipped)
ENGINE (H25 ENGINE) 6-1-129 TABLE B-5 A/C CONDENSER FAN MOTOR RELAY CONTROL SYSTEM CHECK (IF EQUIPPED) CIRCUIT DIAGRAM 1. Condenser fan 2. Condenser fan relay TERMINAL ARRANGEMENT OF ECM (PCM) COUPLER VIEWED FROM HARNESS SIDE CIRCUIT DESCRIPTION A/C condenser fan is turned ON by ECM (PCM) when engine coolant temperature is higher than specified value regardless A/C ON or OFF.
Page 241 6-1-130 ENGINE (H25 ENGINE) STEP ACTION A/C Condenser Fan Control Signal check: Fuse 29 blown, Fuse 23 blown, (1) Remove ECM (PCM) cover. faulty “R/B”, “R/Bl”, faulty “Y/G”, “Y/Bl” (2) Check voltage between E61-5 and ground under or “B” wire, faulty wire or A/C following conditions.
Page 242: Special Tools
5. Test lead / probe 6. Power source cable 7. DLC cable adaptor 8. Self-test adaptor 09917-47010 09930-88521 09931-76011 Vacuum pump gauge Injector test lead SUZUKI scan tool (Tech 1) SUZUKI scan tool 09931-76030 mass storage cartridge 16 / 14 pin DLC cable...
Page 243 _ Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 244: General Description
6A1-2 ENGINE MECHANICAL (G16 ENGINE) GENERAL DESCRIPTION ENGINE The engine is a water-cooled, in line 4 cylinders, 4 The single overhead camshaft is mounted over the stroke cycle gasoline unit equipped with its S.O.H.C. cylinder head: it is driven from crankshaft through tim- (Single Overhead Camshaft) valve mechanism ar- ing belt and opens and closes its valves via the rocker ranged for “V”-type valve configuration and 16 valves...
Page 245 ENGINE MECHANICAL (G16 ENGINE) 6A1-3 ENGINE LUBRICATION The oil pump is of a trochoid type, and mounted on In another path, oil goes up to cylinder head and lubri- crankshaft at crankshaft pulley side. cates camshaft journals, rocker arms, camshaft, etc., Oil is drawn up through oil pump strainer and passed passing through oil gallery in rocker arm shaft.
Page 246: 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 le- ver in “Neutral” (shift selector lever to “P” range for A/T model), and set parking brake and block drive wheels.
Page 247 ENGINE MECHANICAL (G16 ENGINE) 6A1-5 7) 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 1400 kPa Standard (14.0 kg/cm , 199.0 psi)
Page 248: Engine Vacuum Check
(vacuum gauge and joint) between intake man- ifold and vacuum hose disconnected. Special Tool (A): 09915-67310 (B): 09918-08210 SUZUKI GENUINE PARTS (C): Hose 09343-03087 (D): 3-way joint 09367-04002 3) Run engine at specified idle speed, and read vacuum gauge. Vacuum should be within following specification.
Page 249: Oil Pressure Check
ENGINE MECHANICAL (G16 ENGINE) 6A1-7 OIL PRESSURE CHECK NOTE: Prior to checking oil pressure, check following items. _ Oil level in oil pan. If oil level is low, add oil up to Full level mark on oil level gauge. _ Oil quality. If oil is discolored, or deteriorated, change it.
Page 250 6A1-8 ENGINE MECHANICAL (G16 ENGINE) 6) Before reinstalling oil pressure switch, be sure to wrap its screw threads with sealing tape and tighten switch to specified torque. NOTE: If sealing tape edge is bulged out from screw threads of switch, cut it off. Tightening Torque (a): 14 N m (1.4 kg-m, 10.5 lb-ft)
Page 251: Valve Lash (Clearance)
ENGINE MECHANICAL (G16 ENGINE) 6A1-9 VALVE LASH (CLEARANCE) 1) Remove negative cable at battery. 2) Remove cylinder head cover referring to item “Cylinder Head cover”. 3) Using 17 mm socket, turn crankshaft pulley clockwise until “V” mark (in white paint) on pulley aligns with “0” (zero) calibrated on timing belt cover.
Page 252 6A1-10 ENGINE MECHANICAL (G16 ENGINE) 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 253: Air Cleaner Element
ENGINE MECHANICAL (G16 ENGINE) 6A1-11 AIR CLEANER ELEMENT REMOVAL 1) Remove air cleaner case clamps. 2) Remove air cleaner element from case. INSPECTION Check air cleaner element for dirt. Replace excessively dirty ele- ment. CLEAN Blow off dust by compressed air from air outlet side of element. INSTALLATION Reverse removal procedure for installation.
Page 254: Cylinder Head Cover
6A1-12 ENGINE MECHANICAL (G16 ENGINE) 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. 4) Detach accelerator cable from clamp. 5) Remove cylinder head cover with cylinder head cover gasket and O-rings.
Page 255: Throttle Body And Intake Manifold
ENGINE MECHANICAL (G16 ENGINE) 6A1-13 THROTTLE BODY AND INTAKE MANIFOLD 1. Intake manifold 2. Gasket 3. Intake manifold No.2 stiffener 4. Intake manifold stiffener (Front) 5. Engine hook 6. Fuel delivery pipe 7. Throttle body 8. Intake manifold stiffener (Rear) 9.
Page 256 6A1-14 ENGINE MECHANICAL (G16 ENGINE) 6) Disconnect accelerator cable and A/T throttle cable (for A/T) from throttle body. 7) Disconnect following hoses: _ Brake booster hose from intake manifold _ Canister purge hose from EVAP canister purge valve _ Engine cooling water (coolant) hose (outlet side) from throttle body _ Radiator inlet hose from thermostat cap _ PCV hoses from intake manifold and throttle body...
Page 257 ENGINE MECHANICAL (G16 ENGINE) 6A1-15 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. _ Adjust accelerator cable play and A/T throttle cable (for A/T) play, referring to section 6E1.
Page 258: Exhaust Manifold
6A1-16 ENGINE MECHANICAL (G16 ENGINE) EXHAUST MANIFOLD Vehicle not equipped with warm Vehicle equipped with warm up up three way catalytic converter three way catalytic converter 1. Exhaust manifold 2. Upper cover 3. Gasket 4. Heated oxygen sensor-1 5. Lower cover 6.
Page 259 ENGINE MECHANICAL (G16 ENGINE) 6A1-17 INSTALLATION 1) Install new gasket to cylinder head. 2) Install exhaust manifold and stiffener (if equipped). Tighten bolts and nuts to specified torque. 1. Exhaust manifold gasket 3) Install pipe gasket and install exhaust pipe to exhaust manifold. Before installing pipe gasket, check it for deterioration or dam- age, and replace as necessary.
Page 260: Timing Belt And Belt Tensioner
6A1-18 ENGINE MECHANICAL (G16 ENGINE) TIMING BELT AND BELT TENSIONER 1. Timing belt 2. Tensioner 3. Tensioner plate 4. Tensioner spring 5. Camshaft timing pulley 6. Tensioner bolt 7. Pulley bolt 8. Seal 9. Inside cover seal 10. Inside cover 11.
Page 261 ENGINE MECHANICAL (G16 ENGINE) 6A1-19 7) For installation of timing belt, align 4 timing marks as shown in figure by turning crankshaft. 1. “V” mark on cylinder head cover 2. Timing mark by “E” on camshaft timing belt pulley 3. Arrow mark on oil pump case 4.
Page 262 6A1-20 ENGINE MECHANICAL (G16 ENGINE) _ Inspect tensioner for smooth rotation. INSTALLATION 1) Install tensioner plate to tensioner. Insert lug of tensioner plate into hole in tensioner. 1. Lug 2. Hole 2) Install tensioner and tensioner plate: Do not tighten tensioner bolt with wrench yet. Hand tighten only at this time.
Page 263 ENGINE MECHANICAL (G16 ENGINE) 6A1-21 5) Install timing belt and tensioner spring. 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 is free from any slack. And then install tensioner spring as shown in figure, and hand- tighten tensioner stud.
Page 264 6A1-22 ENGINE MECHANICAL (G16 ENGINE) 9) Install radiator fan shroud, water pump pulley, cooling fan and water pump drive belt. Adjust water pump drive belt tension, referring to “ENGINE COOLING” section. 10) Install power steering pump belt or A/C compressor belt, if equipped.
Page 265: Oil Pan And Oil Pump Strainer
ENGINE MECHANICAL (G16 ENGINE) 6A1-23 OIL PAN AND OIL PUMP STRAINER 1. Oil pan 2. Oil pump strainer 3. Seal 4. Drain plug gasket 5. Drain plug 6. CKP sensor REMOVAL 3. Oil pan 1) Raise vehicle. 2) Remove front differential housing (1) with differential (2), refer- ring to “DIFFERENTIAL”...
Page 266 6A1-24 ENGINE MECHANICAL (G16 ENGINE) 6) Remove oil pan and then oil pump strainer. 1. Cylinder block 2. Strainer 3. Oil pan CLEANING _ Clean mating surfaces of oil pan and cylinder block. Remove oil, old sealant, and dusts from mating surfaces and oil pan inside.
Page 267 ENGINE MECHANICAL (G16 ENGINE) 6A1-25 INSTALLATION 1) Apply sealant to oil pan mating surface continuously as shown in figure. “A” Sealant: 99000-31150 2) Install oil pump strainer (1) and oil pan (3). Install seal (2) in the position as shown in figure. Tighten strainer bolt first and then bracket bolt to specified torque.
Page 268 6A1-26 ENGINE MECHANICAL (G16 ENGINE) 5) Install CKP sensor (1) and connect its coupler. Tightening Torque (a): 10 N m (1.0 kg-m, 7.5 lb-ft) 6) Install front differential housing with differential according to installation procedure described in “DIFFERENTIAL” section. 7) Refill front differential housing with gear oil, referring to “DIF- FERENTIAL”...
Page 269: Oil Pump
ENGINE MECHANICAL (G16 ENGINE) 6A1-27 OIL PUMP 1. Rotor plate 6. Pin 2. Inner rotor 7. Relief valve 3. Outer rotor 8. Spring 4. Gasket 9. Retainer 5. Pin 10. Retainer ring REMOVAL 1) Disconnect negative cable at battery. 2) Remove timing belt as previously outlined. 3) Remove generator and its bracket.
Page 270 6A1-28 ENGINE MECHANICAL (G16 ENGINE) 6) Remove oil pump assembly (1) after removing bolts (2). DISASSEMBLY 2. Oil level gauge guide 1) Remove oil level gauge guide bolt (3) and pull out guide from oil 4. Guide seal pump (1). 2) Remove rotor plate (1).
Page 271 ENGINE MECHANICAL (G16 ENGINE) 6A1-29 NOTE: When installing oil seal, press-fit it till its end face is flush with oil pump case end face. 1. Oil seal 2. Oil pump case _ Check outer and inner rotors, rotor plate, and oil pump case for excessive wear or damage.
Page 272 6A1-30 ENGINE MECHANICAL (G16 ENGINE) 4) Install rotor plate. Tighten 5 screw securely. After installing plate, check to be sure that gears turn smoothly by hand. 5) Apply engine oil to guide seal and install guide seal and guide. 1. Oil pump 2.
Page 273 ENGINE MECHANICAL (G16 ENGINE) 6A1-31 5) Install timing pulley key and crank timing belt pulley. Refer to figure for proper installation of these parts. With crankshaft locked, tighten crank timing belt pulley bolt to specified torque. Tightening Torque (a): 130 N m (13.0 kg-m, 94.0 lb-ft) Special Tool 1.
Page 274: Rocker Arms, Rocker Arm Shaft And Camshaft
6A1-32 ENGINE MECHANICAL (G16 ENGINE) ROCKER ARMS, ROCKER ARM SHAFT AND CAMSHAFT -11. Camshaft -12. Camshaft oil seal -13. Rocker arm shaft -14. O-ring -15. Rocker shaft bolt -16. Rocker arm (IN) -17. Rocker arm No. 1 (EX) -18. Rocker arm No. 2 (EX) -19.
Page 275 ENGINE MECHANICAL (G16 ENGINE) 6A1-33 5) Remove camshaft timing belt pulley by using special tool. Special Tool (A): 09917-68220 6) Remove cylinder head cover as previously outlined. 1. Camshaft pulley 7) Disconnect CMP sensor connector and remove CMP sensor case from cylinder head. Place a container or rag under CMP sensor case, for a small amount of oil flows out during removal of case.
Page 276 6A1-34 ENGINE MECHANICAL (G16 ENGINE) 11) Remove intake rocker arm with clip from rocker arm shaft. NOTE: Do not bend clip when removing intake rocker arm. 1. Rocker arm (IN) 2. Clip 3. Rocker arm shaft 12) Remove rocker arm shaft bolts. 1.
Page 277 ENGINE MECHANICAL (G16 ENGINE) 6A1-35 Rocker Arm Shaft Runout Using “V” blocks and dial gauge, check runout. If runout exceeds its limit, replace rocker arm shaft. Runout limit: 0.20 mm (0.008 in.) Rocker Arm-to-Rocker Arm Shaft Clearance Using a micrometer and a bore gauge, measure rocker shaft dia. and rocker arm l.D.
Page 278 6A1-36 ENGINE MECHANICAL (G16 ENGINE) 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 housing. Check clearance by using gaging plastic. The procedure is as follows.
Page 279 ENGINE MECHANICAL (G16 ENGINE) 6A1-37 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 dif- ference from specification is greater. Item Standard 28.000 – 28.021 mm Camshaft Journal bore dia.
Page 280 6A1-38 ENGINE MECHANICAL (G16 ENGINE) 5) Install rocker arm shaft bolts and tighten them to specified torque. Tightening Torque (a): 11 N m (1.1 kg-m, 8.0 lb-ft) 6) Fill small amount of engine oil into arm pivot holding part of rock- er arm shaft.
Page 281 ENGINE MECHANICAL (G16 ENGINE) 6A1-39 8) Install camshaft oil seal. After applying engine oil to oil seal lip, press-fit camshaft oil seal till oil seal surface becomes flush with housing surface. 1. Camshaft oil seal 9) Install rocker arm shaft plug and timing belt inside cover. Then tighten rocker arm shaft plug to specified torque.
Page 282 6A1-40 ENGINE MECHANICAL (G16 ENGINE) 14) Adjust valve clearance as previously outlined. 15) Install cylinder head cover. 16) Install radiator and refill cooling system referring to “ENGINE COOLING” section. 17) Install hood lock to front upper member and adjust lock position referring to “BODY SERVICE”...
Page 283: Valves And Cylinder Head
ENGINE MECHANICAL (G16 ENGINE) 6A1-41 VALVES AND CYLINDER HEAD 1. Valve cotters 2. Valve spring retainer 3. Valve spring 4. Valve stem seal 5. Valve spring seat 6. Exhaust valve 7. Intake valve REMOVAL 1) Relieve fuel pressure according to fuel pressure relief procedure described in section 6.
Page 284 6A1-42 ENGINE MECHANICAL (G16 ENGINE) 5) Remove air intake hose. 6) Disconnect following electric wires: D Throttle position sensor D Manifold differential D Idle air control valve pressure sensor D Engine coolant temp. sensor D EVAP canister purge valve D Camshaft position sensor D Injector wires at the D Ground wires from intake coupler...
Page 285 ENGINE MECHANICAL (G16 ENGINE) 6A1-43 13) Disconnect exhaust pipe from exhaust manifold and remove exhaust manifold stiffener or exhaust pipe bracket bolt. 14) Loosen cylinder head bolts in such order as indicated in figure and remove them. 15) Check all around cylinder head for any other parts required to be removed or disconnected and remove or disconnect what- ever necessary.
Page 286 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 intake rocker arm with clip from rocker arm shaft, re- move rocker arm shaft bolts and remove exhaust rocker arms and springs by pulling its shaft out to transmission side.
Page 287 ENGINE MECHANICAL (G16 ENGINE) 6A1-45 INSPECTION Valve Guides Using a micrometer and bore gauge, take diameter readings on valve stems and guides to check stem-to-guide clearance. Be sure to take reading at more than one place along the length of each stem and guide.
Page 288 6A1-46 ENGINE MECHANICAL (G16 ENGINE) D Inspect valve stem end face for pitting and wear. If pitting or wear is found there, valve stem end may be resurfaced, but not so much as to grind off its chamfer. When it is worn so much that its chamfer is gone, replace valve.
Page 289 ENGINE MECHANICAL (G16 ENGINE) 6A1-47 D 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 290 6A1-48 ENGINE MECHANICAL (G16 ENGINE) D Flatness of gasketed surface: Using a straightedge and thickness gauge, check surface at a to- tal of 6 locations. If distortion limit, given below, is exceeded, cor- rect gasketed surface with a surface plate and abrasive paper of about #400 (Waterproof silicon carbide abrasive paper): place paper on and over surface plate, and rub gasketed surface against paper to grind off high spots.
Page 291 ENGINE MECHANICAL (G16 ENGINE) 6A1-49 Valve Springs D Referring to data given below, check to be sure that each spring is in sound condition, free of any evidence of breakage or weak- ening. Remember, weakened valve springs can cause chatter, not to mention possibility of reducing power output due to gas leakage caused by decreased seating pressure.
Page 292 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 293 ENGINE MECHANICAL (G16 ENGINE) 6A1-51 5) Install new valve stem seal 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 294 6A1-52 ENGINE MECHANICAL (G16 ENGINE) 9) Install rocker arms, springs and rocker arm shaft as previously outlined. 10) Install intake manifold and exhaust manifold. INSTALLATION 1) Remove old gasket and oil on mating surfaces and install new head gasket as shown in figure, that is, “TOP” mark provided on gasket comes to crankshaft pulley side, facing up (toward “2”...
Page 295 ENGINE MECHANICAL (G16 ENGINE) 6A1-53 4) Reverse removal procedure for installation. 5) Adjust water pump drive belt tension, referring to “ENGINE COOLING” section. 6) Adjust power steering pump belt tension or A/C compressor belt tension, if equipped. Refer to section 0B. 7) Adjust intake and exhaust valve lashes as previously outlined.
Page 296: Piston, Piston Rings, Connecting Rods And Cylinders
6A1-54 ENGINE MECHANICAL (G16 ENGINE) PISTON, PISTON RINGS, CONNECTING RODS AND CYLINDERS 1. Top ring 6. Connecting rod 2. 2nd ring bearing cap 3. Oil ring 7. Connecting rod 4. Piston bearing 5. Connecting rod 8. Piston pin 9. Piston pin circlip REMOVAL 1) Remove cylinder head from cylinder block as previously out- lined.
Page 297 ENGINE MECHANICAL (G16 ENGINE) 6A1-55 DISASSEMBLY 1) Using piston ring expander, remove two compression rings (Top and 2nd) and oil ring from piston. 2) Remove piston pin from connecting rod. D Ease out piston pin circlips, as shown. 1. Piston pin circlip D Force piston pin out.
Page 298 6A1-56 ENGINE MECHANICAL (G16 ENGINE) INSPECTION Cylinders D Inspect cylinder walls for scratches, roughness, or ridges which indicate excessive wear. If cylinder bore is very rough or deeply scratched, or ridged, rebore cylinder and use oversize piston. D Using a cylinder gauge, measure cylinder bore in thrust and axial directions at two positions as shown in figure.
Page 299 ENGINE MECHANICAL (G16 ENGINE) 6A1-57 D Piston clearance: Measure cylinder bore diameter and piston diameter to find their difference which is piston clearance. Piston clearance should be within specification as given below. If it is out of specification, re- bore cylinder and use oversize piston. Piston clearance: 0.02 –...
Page 300 6A1-58 ENGINE MECHANICAL (G16 ENGINE) Piston Rings To measure end gap, insert piston ring into cylinder bore and then measure the gap by using thickness gauge. If measured gap is out of specification, replace ring. NOTE: Decarbon and clean top of cylinder bore before inserting pis- ton ring.
Page 301 ENGINE MECHANICAL (G16 ENGINE) 6A1-59 Crank Pin and Connecting Rod Bearings D Inspect crank pin for uneven wear or damage. Measure crank pin for out-of-round or taper with a micrometer. If crank pin is damaged, or out-of-round or taper is out of limit, replace crankshaft or regrind crank pin referring to following step 6).
Page 302 6A1-60 ENGINE MECHANICAL (G16 ENGINE) 5) Remove cap and using a scale on gaging plastic envelope, measure gaging plastic width at the widest point (clearance). If clearance exceeds its limit, use a new standard size bearing and remeasure clearance. Item Standard Limit Bearing...
Page 303 ENGINE MECHANICAL (G16 ENGINE) 6A1-61 c) Stamped number on piston and that on cylinder block should correspond. That is, install number 2 stamped piston to cylinder which is identified with number 2 and a number 1 piston to cylin- der with number 1. Piston Cylinder Piston-to-cylinder...
Page 304 6A1-62 ENGINE MECHANICAL (G16 ENGINE) INSTALLATION OR CONNECTION 1) Apply engine oil to pistons, rings, cylinder walls, connecting rod bearings and crankpins. NOTE: Do not apply oil between connecting rod and bearing or be- tween bearing cap and bearing. 2) Install guide hoses over connecting rod bolts. These guide hoses protect crankpin and threads of rod bolt from damage during installation of connecting rod and piston assem- bly.
Page 305 ENGINE MECHANICAL (G16 ENGINE) 6A1-63 6) Reverse removal procedure for installation, as previously out- lined. 7) Adjust water pump drive belt tension, referring to section 0B. 8) Adjust power steering pump belt tension or A/C compressor belt tension, if equipped. Refer to section 0B. 9) Adjust intake and exhaust valve lashes as previously outlined.
Page 306: Unit Repair Overhaul
6A1-64 ENGINE MECHANICAL (G16 ENGINE) UNIT REPAIR OVERHAUL ENGINE ASSEMBLY REMOVAL 1) Release fuel pressure in fuel feed line by referring to Fuel Pres- sure Relief Procedure in section 6. 2) Disconnect negative cable from battery. 3) Remove engine hood. 4) Drain cooling system.
Page 307 ENGINE MECHANICAL (G16 ENGINE) 6A1-65 9) Disconnect following hoses: D Canister purge hose from EVAP canister purge valve D Radiator outlet hose from inlet pipe D Brake booster hose from intake manifold D Vacuum hose from intake manifold D Heater inlet and outlet hose from pipe D Fuel feed hose and return hose from each pipe D A/T fluid hose clamp from bracket 10) Disconnect accelerator cable and A/T throttle cable (if...
Page 308 6A1-66 ENGINE MECHANICAL (G16 ENGINE) 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 309 ENGINE MECHANICAL (G16 ENGINE) 6A1-67 INSTALLATION 1) Lower engine assembly into engine compartment and connect engine to transmission. Hand-tighten bolts and nuts fastening cylinder block and trans- mission. 2) Tighten engine mounting bracket nuts (R & L). Tightening Torque (a): 50 N m (5.0 kg-m, 36.5 lb-ft) 3) Tighten bolts fastening cylinder block and transmission to speci- fied torque.
Page 310 6A1-68 ENGINE MECHANICAL (G16 ENGINE) D Tighten bolts of exhaust pipes to specified torque. Tightening Torque (a): 50 N m (5.0 kg-m, 36.5 lb-ft) D Tighten transmission stiffener bolts (right side) to specified torque (A/T). Tightening Torque (a): 50 N m (5.0 kg-m, 36.5 lb-ft) 6) Adjust water pump drive belt tension, referring to “ENGINE COOLING”...
Page 311: Main Bearings, Crankshaft And Cylinder Block
ENGINE MECHANICAL (G16 ENGINE) 6A1-69 MAIN BEARINGS, CRANKSHAFT AND CYLINDER BLOCK 1. Cylinder block 7. Crankshaft 13. Housing bolt 2. Front oil seal 8. Thrust bearing 14. Input shaft bearing 3. Main bearing 9. Rear oil seal 15. Flywheel 4. Bearing cap 10.
Page 312 6A1-70 ENGINE MECHANICAL (G16 ENGINE) REMOVAL 1) Remove engine assembly from body as previously outlined. 2) Remove clutch cover, clutch disc and flywheel (drive plate for A/T). Special Tool (A): 09924-17810 1. Flywheel bolt 3) Remove crankshaft pulley, timing belt and crankshaft timing pulley.
Page 313 ENGINE MECHANICAL (G16 ENGINE) 6A1-71 INSPECTION Crankshaft Crankshaft runout Using a dial gauge, measure runout at center journal. Rotate crank- shaft slowly. If runout exceeds its limit, replace crankshaft. Limit on runout: 0.06 mm (0.0023 in.) Crankshaft thrust play Measure this play with crankshaft set in cylinder block in the normal manner, that is, with thrust bearing and journal bearing caps installed.
Page 314 6A1-72 ENGINE MECHANICAL (G16 ENGINE) Main Bearings General information D Service main bearings are available in standardsize and 0.25 mm (0.0098 in.) undersize, and each of them has 5 kinds of bearings differing in tolerance. D Upper half of bearing has oil groove as shown in figure. Install this half with oil groove to cylinder block.
Page 315 ENGINE MECHANICAL (G16 ENGINE) 6A1-73 5) Remove cap and using scale on gaging plastic envelope, mea- sure 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 316 6A1-74 ENGINE MECHANICAL (G16 ENGINE) 2) Next, check bearing cap bore diameter without bearing. On mat- ing surface of cylinder block, four alphabets are stamped as shown in figure. Three kinds of alphabets (“A”, “B” and “C”) represent following cap bore diameters. Bearing cap bore diameter Alphabet stamped (without bearing)
Page 317 ENGINE MECHANICAL (G16 ENGINE) 6A1-75 4) From numerals stamped on crank webs of No.2 and No.3 cylin- ders 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 318 6A1-76 ENGINE MECHANICAL (G16 ENGINE) D If necessary, regrind crankshaft journal and select under-size bearing to use with it as follows. 1) Regrind journal to following finished diameter. Finished diameter:51.732 – 51.750 mm (2.0367 – 2.0373 in.) 2) Using micrometer, measure reground journal diameter. Measurement should be taken in two directions perpendicular to each other in order to check for out-of-round.
Page 319 ENGINE MECHANICAL (G16 ENGINE) 6A1-77 Flywheel D If ring gear is damaged, cracked or worn, replace flywheel. D If the surface contacting clutch disc is damaged, or excessively worn, replace flywheel. D Check flywheel for face runout with dial gauge. If runout exceeds its limit, replace flywheel.
Page 320 6A1-78 ENGINE MECHANICAL (G16 ENGINE) 5) Rebore and hone cylinder to calculated dimension. NOTE: Before reboring, install all main bearing caps in place and tighten to specification to avoid distortion of bearing bores. 6) Measure piston clearance after honing. INSTALLATION NOTE: D All parts to be installed must be perfectly clean.
Page 321 ENGINE MECHANICAL (G16 ENGINE) 6A1-79 3) Install crankshaft to cylinder block. 4) Install bearing cap to cylinder block, making sure to point arrow mark (on each cap) to crankshaft pulley side. Fit them sequen- tially in ascending order, 1, 2, 3, 4 and 5, starting from pulley side. After installing bearing cap stiffeners, tighten bearing cap bolts in such order as shown in figure a little at a time and repeat it till they are tightened to specified torque.
Page 322 6A1-80 ENGINE MECHANICAL (G16 ENGINE) 8) Install pistons and connecting rods as previously outlined. 9) Install oil pump strainer and oil pan as previously outlined. 10) Install cylinder head assembly to cylinder block as previously outlined. 11) Install camshaft, crankshaft timing belt pulley, timing belt, crankshaft pulley, water pump pulley, etc., as previously out- lined.
Page 323: Special Tools
ENGINE MECHANICAL (G16 ENGINE) 6A1-81 SPECIAL TOOLS 1. 09915-64510-001 Compression gauge 2. 09915-64510-002 Connector 3. 09915-64530 Hose 09915-67310 09918-08210 09915-77310 4. 09915-67010 Attachment Vacuum gauge Vacuum gauge hose joint Oil pressure gauge 09926-18210 09917-18210 09927-56010 Oil seal guide 09917-68220 Tappet adjuster wrench Gear stopper (Vinyl resin) Camshaft pulley holder...
Page 324: Required Service Materials
Flywheel holder Oil filter wrench REQUIRED SERVICE MATERIALS RECOMMENDED MATERIALS SUZUKI PRODUCT SUZUKI BOND NO.1207C D Mating surfaces of cylinder block and oil pan. Sealant (99000-31150) D Mating surfaces of camshaft housings (No.6). SUZUKI BOND NO.1215 D Mating surfaces of camshaft position sensor case and...
Page 325 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 326: General Description
6A2-2 ENGINE MECHANICAL (H25 ENGINE) GENERAL DESCRIPTION ENGINE The engine is a water-cooled, 60_ V6 cylinders, 4 The double overhead camshaft is mounted over the stroke cycle gasoline unit with its DOHC (Double cylinder head; it is driven from crankshaft through tim- overhead camshaft) valve mechanism arranged for ing chains, and no push rods are provided in the valve “V”...
Page 327 ENGINE MECHANICAL (H25 ENGINE) 6A2-3 ENGINE LUBRICATION The oil pump is of a trochoid type, and mounted under In other paths oil goes up to the cylinder heads and the crankshaft. Oil is drawn up through the oil pump lubricates valves and camshafts, etc., after passing strainer and passed through the pump to the oil filter.
Page 328: 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 and spark plugs.
Page 329: Engine Vacuum Check
Special Tool (A): 09915-67310 (B): 09918-08210 SUZUKI GENUINE PARTS (C): Hose 09343-03087 (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 330: Oil Pressure Check
6A2-6 ENGINE MECHANICAL (H25 ENGINE) OIL PRESSURE CHECK NOTE: Prior to checking oil pressure, check the followings. D Oil level in oil pan If oil level is low, add oil up to Full level hole on oil level gauge. D Oil quality If oil is discolored, or deteriorated, change it.
Page 331: Air Cleaner Element
ENGINE MECHANICAL (H25 ENGINE) 6A2-7 AIR CLEANER ELEMENT This air cleaner element is of dry type. Note that it needs cleaning according to the following method. REMOVAL 1) Remove air cleaner upper case. 2) Remove air cleaner element. INSPECTION Check element for dirt. CLEAN Blow off dust by blowing compressed air from air outlet side of ele- ment (i.e., the side facing up when installed in air cleaner case).
Page 332: Throttle Body And Intake Manifold
6A2-8 ENGINE MECHANICAL (H25 ENGINE) THROTTLE BODY AND INTAKE MANIFOLD 1. Air cleaner box 2. Intake air hose 3. Intake air pipe 4. Surge tank pipe 5. Intake manifold 6. Throttle body 7. Intake collector 8. Intake air temperature sensor 9.
Page 333 ENGINE MECHANICAL (H25 ENGINE) 6A2-9 6) Remove surge tank cover. 1. Surge tank cover 7) Remove air cleaner upper case, intake air hose, intake air pipe and surge tank pipe as one component. Do not disassemble them, when removing and reinstalling. 1.
Page 334 6A2-10 ENGINE MECHANICAL (H25 ENGINE) 15) Disconnect couplers from manifold absolute pressure (MAP) sensor, EVAP canister purge valve and EGR valve. 16) Disconnect PCV hose from cylinder head cover. Disconnect breather hoses from throttle body or cylinder head cover. 17) Disconnect hoses of EVAP canister purge valve and heater. 18) Remove EGR pipe.
Page 335 ENGINE MECHANICAL (H25 ENGINE) 6A2-11 INSTALLATION 1) Install new intake manifold gaskets to cylinder heads. 1. Gasket 2) Install intake manifold. 1. Intake manifold Tighten bolts and nuts to specified torque. Tightening Torque (a): 23.0 N m (2.3 kg-m, 16.5 lb-ft) 3) Install throttle body to intake collector with new throttle body gas- 1.
Page 336 6A2-12 ENGINE MECHANICAL (H25 ENGINE) 7) Install EGR pipe with new gaskets. 8) Connect hoses of EVAP canister purge valve and heater. 9) Connect hoses of PCV, breather and water. 10) Connect couplers of manifold absolute pressure (MAP) sen- sor, EVAP canister purge valve and EGR valve. Fix wire harness with clamps.
Page 337 ENGINE MECHANICAL (H25 ENGINE) 6A2-13 19) Install surge tank cover. 1. Surge tank cover 20) Install air cleaner upper case. 21) Connect coupler to intake air temp. sensor. 22) Install strut tower bar. 1. Strut tower bar 23) Check to ensure that all removed parts are back in place. Reinstall any necessary parts which have not been reinstalled.
Page 338: Exhaust Manifold
6A2-14 ENGINE MECHANICAL (H25 ENGINE) EXHAUST MANIFOLD Type 1 WARNING: To avoid danger of being burned, do not service exhaust system while it is still hot. Service should be performed af- ter system has cooled off. Type 2 1. Exhaust manifold 2.
Page 339 ENGINE MECHANICAL (H25 ENGINE) 6A2-15 7) Hoist vehicle. 8) For 4WD vehicle, before disconnecting front propeller shaft, put match mark on joint flange and propeller shaft to facilitate their installation as shown in figure. 9) For 4WD vehicle, disconnect propeller shaft from front differen- tial.
Page 340 6A2-16 ENGINE MECHANICAL (H25 ENGINE) 4) Install exhaust No.1 pipe and stiffener. Tighten exhaust No.1 pipe bolts and nuts to specified torque. Tightening Torque (b): 50 N m (5.0 kg-m, 36.5 lb-ft) 1. Exhaust No.1 pipe 2. Catalytic converter 3. Stiffener Tightening Torque Type 1 (b): 50 N...
Page 341 ENGINE MECHANICAL (H25 ENGINE) 6A2-17 6) Connect EGR pipe to left (No.1) bank exhaust manifold. 1. Exhaust manifold 2. Exhaust manifold cover 7) Install exhaust manifold covers. 3. Oil level gauge guide 8) Install oil level gauge guide using new O-ring. 9) Connect oxygen sensor lead wire couplers.
Page 342: Cylinder Head Covers
6A2-18 ENGINE MECHANICAL (H25 ENGINE) CYLINDER HEAD COVERS REMOVAL 1) Remove throttle body and intake manifold. Refer to item “THROTTLE BODY AND INTAKE MANIFOLD” in this section for removal. 2) Remove ignition coil covers. 3) Disconnect ignition coil couplers and remove ignition coils. 4) Remove cylinder head covers.
Page 343: Oil Pan And Oil Pump Strainer
ENGINE MECHANICAL (H25 ENGINE) 6A2-19 OIL PAN AND OIL PUMP STRAINER 1. Upper oil pan 2. Lower oil pan 3. Oil pump strainer 4. Bracket 5. O-ring 6. Drain plug 7. Gasket REMOVAL 1) Remove oil level gauge guide. 2) Raise vehicle and remove both front wheels. 3) Remove rack and pinion assembly.
Page 344 6A2-20 ENGINE MECHANICAL (H25 ENGINE) CLEAN D Inside of oil pan and oil pump strainer screen. 1. Oil strainer 2. Screen D Clean sealing surface on upper oil pan, lower oil pan and lower crankcase. Remove oil, old sealant, and dust from sealing surface. INSTALLATION 1) Install new O-ring to lower crankcase as shown in figure.
Page 345 ENGINE MECHANICAL (H25 ENGINE) 6A2-21 5) Install upper oil pan to lower crankcase. 1. Upper oil pan Tightening Torque (b): 11.0 N m (1.1 kg-m, 8.0 lb-ft) (c): 27.0 N m (2.7 kg-m, 19.5 lb-ft) 6) Install bracket to oil pump strainer and upper oil pan. 1.
Page 346: Timing Chain Cover
6A2-22 ENGINE MECHANICAL (H25 ENGINE) TIMING CHAIN COVER REMOVAL 1) Disconnect negative cable at battery. 2) Drain engine oil. 3) Drain coolant. 4) Remove throttle body and intake manifold. Refer to item “THROTTLE BODY AND INTAKE MANIFOLD” 1. Timing chain cover 2.
Page 347 ENGINE MECHANICAL (H25 ENGINE) 6A2-23 CLEAN Clean sealing surface on timing chain cover, crankcase, cylinder block and cylinder heads. Remove oil, old sealant, and dust from sealing surface. INSPECTION Check oil seal lip for damages or deterioration. Replace as necessary. NOTE: When installing new oil seal, top it in until its surface is flash with edge of timing chain cover.
Page 348: Oil Pump
6A2-24 ENGINE MECHANICAL (H25 ENGINE) OIL PUMP REMOVAL 1) Disconnect negative cable at battery. 2) Drain engine oil. 3) Drain coolant. 4) Remove oil pan, oil pump strainer and timing chain cover. Refer to item “TIMING CHAIN COVER” in this section. 5) Loosen oil pump chain guide bolts.
Page 349 ENGINE MECHANICAL (H25 ENGINE) 6A2-25 D Measure free length and tension of oil relief spring. Item Standard 63.5 mm Spring free length (2.5 in.) 86.0 N for 52.0 mm 8.6 kg for Spring preload 52.0 mm 62.2 lb/ 2.05 in. D Measure clearance of oil pump rotor and oil pump case.
Page 350 6A2-26 ENGINE MECHANICAL (H25 ENGINE) 3) Assemble oil pump. After assembling oil pump check to be sure that rotor turns smoothly by hand. Tightening Torque (a): 12.0 N m (1.2 kg-m, 8.5 lb-ft) INSTALLATION 1) Install oil pump to crankcase. Tightening Torque (c), (d): 27.0 N m (2.7 kg-m, 19.5 lb-ft)
Page 351: Lh (No.1) Bank 2Nd Timing Chain And Chain Tensioner
ENGINE MECHANICAL (H25 ENGINE) 6A2-27 LH (NO.1) BANK 2ND TIMING CHAIN AND CHAIN TENSIONER 1. LH bank 2nd timing chain 2. Timing chain tensioner adjuster No.3 3. LH bank intake camshaft sprocket 4. LH bank exhaust camshaft sprocket 5. Camshaft sprocket bolt 6.
Page 352 6A2-28 ENGINE MECHANICAL (H25 ENGINE) 6) Remove timing chain tensioner adjuster No.3. To remove it, slacken LH bank 2nd timing chain by turning in- take camshaft counterclockwise a little while pushing back pad. 1. Timing chain tensioner adjuster No.3 2. LH bank intake camshaft 7) Remove LH bank intake and exhaust camshaft sprocket bolts.
Page 353 ENGINE MECHANICAL (H25 ENGINE) 6A2-29 INSPECTION Timing chain guide No.4 and No.5 Check shoe for wear or damage. 1. Timing chain guide No.4 2. Timing chain guide No.5 3. Shoe Camshaft sprocket Check teeth of sprocket for wear or damage. Timing chain Check timing chain for wear or damage.
Page 354 6A2-30 ENGINE MECHANICAL (H25 ENGINE) 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 as shown in figure. 1. Idler sprocket No.2 mark 3.
Page 355 ENGINE MECHANICAL (H25 ENGINE) 6A2-31 6) Install sprockets to intake and exhaust camshafts by aligning silver plate of LH bank 2nd timing chain, match marks on intake sprocket and exhaust sprocket respectively. CAUTION: Do not turn camshaft more than necessary. If turned excessively, valve and piston may get dam- aged.
Page 356 6A2-32 ENGINE MECHANICAL (H25 ENGINE) 11) Turn crankshaft two rotations clockwise then align timing mark on crankshaft and timing mark on cylinder block as shown in figure. Check each other timing marks that align them shown in figure. 1. Crank timing pulley key 2.
Page 357: 1St Timing Chain And Chain Tensioner
ENGINE MECHANICAL (H25 ENGINE) 6A2-33 1ST TIMING CHAIN AND CHAIN TENSIONER 1. 1st timing chain 2. Timing chain tensioner adjuster No.1 3. RH bank 1st timing chain intake camshaft sprocket 4. 1st timing chain crankshaft sprocket 5. Idler sprocket No.2 6.
Page 358 6A2-34 ENGINE MECHANICAL (H25 ENGINE) 5) For reinstallation of timing chain, align 8 timing marks as shown in figure by turning crankshaft. 6) Remove LH bank 2nd timing chain. Refer to item “LH (NO.1) BANK 2ND TIMING CHAIN AND CHAIN TENSIONER” in this section for removal. 7) Remove timing chain guide No.1.
Page 359 ENGINE MECHANICAL (H25 ENGINE) 6A2-35 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 for wear or damage. 1. Shoe 1st timing chain crankshaft sprocket Check teeth of sprocket for wear or damage.
Page 360 6A2-36 ENGINE MECHANICAL (H25 ENGINE) Idler sprocket No.2 Check teeth of sprocket for wear or damage. 1. Bush 1st timing chain Check timing chain for wear or damage. Timing chain tensioner adjuster No.1 Check that latch and tooth surface are free from damage and latch functions properly.
Page 361 ENGINE MECHANICAL (H25 ENGINE) 6A2-37 3) Check timing mark on RH bank intake camshaft as shown in fig- 1. Knock pin of intake camshaft ure. 2. Match mark 4) Install RH bank 1st timing chain intake camshaft sprocket noting following points. D The sprocket should be set in such way that its RH mark can be seen.
Page 362 6A2-38 ENGINE MECHANICAL (H25 ENGINE) 9) Install idler sprocket No.2 by aligning match marks on LH silver plate of 1st timing chain. 1. Silver plate 2. Match mark on intake sprocket 3. RH bank cylinder head 10) Install crankshaft sprocket by aligning match marks on gold or yellow plate of 1st timing chain and crankshaft timing sprocket.
Page 363: Tightening Torque
ENGINE MECHANICAL (H25 ENGINE) 6A2-39 16) Install timing chain guide No.1 and No.2. Tightening Torque (e): 9 N m (0.9 kg-m, 6.5 lb-ft) 1. Timing chain guide No.2 2. Timing chain guide No.1 3. Guide bolts 17) Check each aligned timing marks as shown in figure. 3.
Page 364 6A2-40 ENGINE MECHANICAL (H25 ENGINE) 18) Install LH bank 2nd timing chain. Refer to item “LH (NO.1) BANK 2ND TIMING CHAIN AND TENSIONER” in this section for installation. 19) Install timing chain cover. Refer to item “TIMING CHAIN COVER” in this section for instal- lation.
Page 365: Rh (No.2) Bank 2Nd Timing Chain And Chain Tensioner
ENGINE MECHANICAL (H25 ENGINE) 6A2-41 RH (NO.2) BANK 2ND TIMING CHAIN AND CHAIN TENSIONER 1. RH bank 2nd timing chain 2. Timing chain tensioner adjuster No.2 3. RH bank exhaust camshaft sprocket 4. RH bank 2nd timing chain intake camshaft sprocket 5.
Page 366 6A2-42 ENGINE MECHANICAL (H25 ENGINE) 2) Remove LH bank 2nd timing chain. Refer to item “LH (NO.1) BANK 2ND TIMING CHAIN AND CHAIN TENSIONER” in this section for removal. 3) Remove 1st timing chain. Refer to item “1ST TIMING CHAIN AND CHAIN TENSIONER” in this section for removal.
Page 367 ENGINE MECHANICAL (H25 ENGINE) 6A2-43 RH bank 2nd timing chain sprockets Check teeth of sprocket for wear or damage. RH bank 2nd timing chain Check timing chain for wear or damage. Timing chain tensioner adjuster No.2 D Check shoe for wear or damage. D Check that plunger slides smoothly.
Page 368 6A2-44 ENGINE MECHANICAL (H25 ENGINE) 4) Apply oil to sliding surface of each camshafts and camshaft jour- nals. 5) Install RH bank 2nd timing chain by aligning match marks on yel- low or silver plates of RH bank 2nd timing chain, RH bank 2nd timing chain intake camshaft sprocket and RH bank 2nd timing chain exhaust camshaft sprocket as shown in figure.
Page 369 ENGINE MECHANICAL (H25 ENGINE) 6A2-45 9) Install timing chain guide No.3. Tightening Torque (c): 11 N m (1.1 kg-m, 7.5 lb-ft) 1. Timing chain guide No.3 10) Install 1st timing chain. Refer to item “1ST TIMING CHAIN AND CHAIN TENSIONER” in this section for installation.
Page 370: Oil Pump Chain
6A2-46 ENGINE MECHANICAL (H25 ENGINE) OIL PUMP CHAIN 1. Oil pump chain 2. Oil pump drive sprocket 3. Oil pump chain tensioner (oil pump guide) REMOVAL 1) Disconnect negative cable at battery. 2) Drain engine oil. 3) Drain coolant. 4) Remove timing chain cover. Refer to item “TIMING CHAIN COVER”...
Page 371 ENGINE MECHANICAL (H25 ENGINE) 6A2-47 7) Put match marks to oil pump chain and oil pump sprocket. 1. Oil pump drive chain 2. Oil pump sprocket 3. Match mark 8) Remove oil pump chain guide. 9) Remove oil pump chain. 10) Remove oil pump drive sprocket.
Page 372 6A2-48 ENGINE MECHANICAL (H25 ENGINE) INSPECTION Oil pump chain guide Check shoe for wear or damage. 1. Shoe Oil pump drive sprocket Check teeth of sprocket for wear or damage. Oil pump sprocket Check teeth of sprocket for wear or damage. Oil pump chain Check oil pump chain for wear or damage.
Page 373 ENGINE MECHANICAL (H25 ENGINE) 6A2-49 2) Install oil pump chain by aligning match marks on oil pump chain and oil pump sprocket. 1. Oil pump drive chain 2. Oil pump sprocket 3. Match mark 3) Install oil pump chain guide and hand-tighten oil pump chain 1, (c) guide bolts.
Page 374: Camshaft And Valve Lash Adjuster
6A2-50 ENGINE MECHANICAL (H25 ENGINE) CAMSHAFT AND VALVE LASH ADJUSTER 1. RH bank 2nd timing chain 2. RH bank exhaust camshaft 3. RH bank intake camshaft 4. RH bank exhaust camshaft holder 5. RH bank intake camshaft holder 6. LH bank intake camshaft 7.
Page 375 ENGINE MECHANICAL (H25 ENGINE) 6A2-51 REMOVAL 1) Disconnect negative cable at battery. 2) Drain engine oil. 3) Drain coolant. 4) Remove timing chain cover. Refer to item “TIMING CHAIN COVER” in this section for re- moval. 5) Remove LH bank 2nd timing chain. Refer to item “LH (NO.1) BANK 2ND TIMING CHAIN AND CHAIN TENSIONER”...
Page 376 6A2-52 ENGINE MECHANICAL (H25 ENGINE) Camshaft Runout Set camshaft between two “V” blocks, and measure its runout by using a dial gauge. If measured runout exceeds below specified limit, replace cam- shaft. Runout limit 0.10 mm (0.0039 in.) “a” Camshaft Journal Wear Check camshaft journals and camshaft housings for pitting, scratches, wear or damage.
Page 377 ENGINE MECHANICAL (H25 ENGINE) 6A2-53 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. Standard Camshaft journal 26.000 – 26.033 mm bore dia.
Page 378 6A2-54 ENGINE MECHANICAL (H25 ENGINE) INSTALLATION 1) Before installing valve lash adjuster to cylinder head, fill oil pas- sage of cylinder head with engine oil according to following pro- cedure. Pour engine oil through oil holes and check that oil comes out from oil holes in sliding part of valve lash adjuster.
Page 379 ENGINE MECHANICAL (H25 ENGINE) 6A2-55 6) Install LH bank camshaft housing pins as shown in figure. 7) Apply sealant “A” to LH bank exhaust camshaft housing No.5 sealing surface area as shown in figure. “A”: Sealant 99000-31150 1. LH bank intake camshaft 2.
Page 380 6A2-56 ENGINE MECHANICAL (H25 ENGINE) 10) Install 1st timing chain. Refer to item “1ST TIMING CHAIN AND CHAIN TENSIONER” in this section for installation. 11) Install LH bank 2nd timing chain. Refer to item “LH (NO.1) BANK 2ND TIMING CHAIN AND CHAIN TENSIONER”...
Page 381: Valve Lash Adjuster Noise Diagnosis
ENGINE MECHANICAL (H25 ENGINE) 6A2-57 VALVE LASH ADJUSTER NOISE DIAGNOSIS In case of the followings, valve lash adjuster noise may be caused by air trapped into valve lash adjusters. D Vehicle is left for 24 hours or more. D Engine oil is changed. D Hydraulic lash adjuster is replaced or reinstalled.
Page 382: Valves And Cylinder Heads
6A2-58 ENGINE MECHANICAL (H25 ENGINE) VALVES AND CYLINDER HEADS 1. Cylinder block 2. RH bank cylinder head 3. LH bank cylinder head 4. RH bank cylinder head gasket 5. LH bank cylinder head gasket 6. Exhaust valve 7. Intake valve 8.
Page 383 ENGINE MECHANICAL (H25 ENGINE) 6A2-59 REMOVAL 1) Relieve fuel pressure according to procedure described in Sec- tion 6. 2) Disconnect negative cable at battery. 3) Drain engine oil. 4) Drain coolant. 5) Remove CMP sensor, camshaft and valve lash adjuster. Refer to Section 6F2 for CMP sensor removal and item “CAM- SHAFT AND VALVE LASH ADJUSTER”...
Page 384 6A2-60 ENGINE MECHANICAL (H25 ENGINE) DISASSEMBLY 1) Using special tools (A), (B) & (C), compress valve springs and then remove valve cotters 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 385 ENGINE MECHANICAL (H25 ENGINE) 6A2-61 INSPECTION Valve Guides Using a micrometer and bore gauge, take diameter readings on valve stems and guides to check stem-to-guide clearance. Be sure to take reading at more than one place along the length of each stem and guide.
Page 386 6A2-62 ENGINE MECHANICAL (H25 ENGINE) D Seating contact width: Create contact pattern one each valve in the usual manner, i.e., by giving uniform coat of marking compound to valve seat and by rotatingly tapping seat with valve head. Valve lapper (tool used in valve lapping) must be used.
Page 387 ENGINE MECHANICAL (H25 ENGINE) 6A2-63 Cylinder Head D Remove all carbon from combustion chambers. NOTE: Do not use any sharp-edged tool to scrape off carbon. Be careful not to scuff or nick metal surfaces when decarbon- ing. The same applies to valves and valve seats, too. D Check cylinder head for cracks on intake and exhaust ports, com- bustion chambers, and head surface.
Page 388 6A2-64 ENGINE MECHANICAL (H25 ENGINE) Valve Springs D Referring to data given below, check to be sure that each spring is in sound condition, free of any evidence of breakage or weak- ening. Remember, weakened valve springs can cause chatter, not to mention possibility of reducing power output due to gas leakage caused by decreased seating pressure.
Page 389 ENGINE MECHANICAL (H25 ENGINE) 6A2-65 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. 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 390 6A2-66 ENGINE MECHANICAL (H25 ENGINE) 5) Install new valve stem seal 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 391 ENGINE MECHANICAL (H25 ENGINE) 6A2-67 INSTALLATION RH (No.2) bank 1) Clean mating surface on cylinder head and cylinder block. Re- move oil, old gasket and dust from mating surface. 2) Install knock pin to cylinder block. 3) Apply sealant “A” to cylinder head gasket as shown in figure. “A”: Sealant 99000-31150 Width “w”: Min.
Page 392 6A2-68 ENGINE MECHANICAL (H25 ENGINE) 8) Install valve lash adjuster, camshaft, CMP sensor and RH bank 2nd timing chain. Refer to item “CAMSHAFT AND VALVE LASH ADJUSTER” and “RH (NO.2) BANK 2ND TIMING CHAIN AND CHAIN TEN- SIONER” in this section. For CMP sensor, refer to Section 6F2 for installation.
Page 393: Piston, Piston Rings, Connecting Rods And Cylinders
ENGINE MECHANICAL (H25 ENGINE) 6A2-69 PISTON, PISTON RINGS, CONNECTING RODS AND CYLINDERS 1. Top ring 2. 2nd ring 3. Oil ring 4. Piston 5. Connecting rod 6. Connecting rod bearing cap 7. Connecting rod bearing 8. Piston pin 9. Piston pin circlip 10.
Page 394 6A2-70 ENGINE MECHANICAL (H25 ENGINE) 6) Mark cylinder number on all pistons, connecting rods and con- necting rod caps. 7) Remove rod bearing caps. 8) Install guide hose over threads of rod bolts. This prevents damage to bearing journal and rod bolt threads when removing connecting rod.
Page 395 ENGINE MECHANICAL (H25 ENGINE) 6A2-71 INSPECTION Cylinders D Inspect cylinder walls for scratches, roughness, or ridges which indicate excessive wear. If cylinder bore is very rough or deeply scratched, or ridged, rebore cylinder and use over size piston. D Using a cylinder gauge, measure cylinder bore in thrust and axial directions at two positions as shown in figure.
Page 396 6A2-72 ENGINE MECHANICAL (H25 ENGINE) D Piston clearance: Measure cylinder bore diameter and piston diameter to find their difference which is piston clearance. Piston clearance should be within specification as given below. If it is out of specification, re- bore cylinder and use oversize piston. Piston clearance: 0.02 –...
Page 397 ENGINE MECHANICAL (H25 ENGINE) 6A2-73 Piston Rings To measure end gap, insert piston ring into cylinder bore and then measure the gap by using thickness gauge. If measure gap is out of specification, replace ring. NOTE: Clean carbon and any other dirt from top of cylinder bore be- fore inserting piston ring.
Page 398 6A2-74 ENGINE MECHANICAL (H25 ENGINE) Crank Pin and Connecting Rod Bearings D Inspect crank pin for uneven wear or damage. Measure crank pin for out-of-round or taper with a micrometer. If crank pin is dam- aged, or out-of-round or taper is out of limit, replace crankshaft or regrind crank pin referring to following step 6).
Page 399 ENGINE MECHANICAL (H25 ENGINE) 6A2-75 5) Remove cap and using a scale on gaging plastic envelope, measure gaging plastic width at the widest point (clearance). If clearance exceeds its limit, use a new standard size bearing and remeasure clearance. Item Standard Limit Bearing...
Page 400 6A2-76 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 401 ENGINE MECHANICAL (H25 ENGINE) 6A2-77 1) Install piston pin to piston and connecting rod: After applying engine oil to piston pin and piston pin holes in pis- ton and connecting rod, fit connecting rod to piston as shown in figure and insert piston pin to piston and connecting rod, and install piston pin circlips.
Page 402 6A2-78 ENGINE MECHANICAL (H25 ENGINE) INSTALLATION 1) Apply engine oil to pistons, rings, cylinder walls, connecting rod bearings and crank pins. NOTE: Do not apply oil between connecting rod and bearing or be- tween bearing cap and bearing. 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 assem- bly.
Page 403 ENGINE MECHANICAL (H25 ENGINE) 6A2-79 6) Install cylinder heads and oil pump to cylinder block. Refer to item “VALVES AND CYLINDER HEADS” and “OIL PUMP” in this section. 7) Install valve lash adjusters, camshafts and RH bank 2nd timing chain. Refer to item “CAMSHAFT AND VALVE LASH ADJUSTER”...
Page 404: Unit Repair Overhaul
6A2-80 ENGINE MECHANICAL (H25 ENGINE) UNIT REPAIR OVERHAUL ENGINE ASSEMBLY REMOVAL 1) Release fuel pressure in fuel feed line. Refer to Section 6. 2) Disconnect negative cable at battery. 3) Remove engine hood. 4) Drain engine oil. 5) Drain coolant. 6) Remove radiator, radiator fan shroud, cooling fan and radiator reservoir.
Page 405 ENGINE MECHANICAL (H25 ENGINE) 6A2-81 16) Disconnect following hoses at the location shown in figure: D Fuel feed hose from fuel feed pipe D Fuel return hose from fuel return pipe 17) Remove EVAP canister. 1. Fuel feed hose FRONT 2.
Page 406 6A2-82 ENGINE MECHANICAL (H25 ENGINE) 32) Install lifting device. 33) Disconnect engine side mounting brackets to engine mount- ings. 1. Engine side mount bracket 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 assembly.
Page 407 ENGINE MECHANICAL (H25 ENGINE) 6A2-83 6) Tighten bolts and nuts of exhaust No.1 pipe to specified torque. Type 1 Tightening Torque (d): 50 N m (5.0 kg-m, 36.5 lb-ft) Type 2 1. Exhaust No.1 pipe 7) Install front differential housing with differential to chassis if re- moved.
Page 408: Main Bearings, Crankshaft And Cylinder Block
6A2-84 ENGINE MECHANICAL (H25 ENGINE) MAIN BEARINGS, CRANKSHAFT AND CYLINDER BLOCK 1. Cylinder block 2. Lower crankcase 3. Crankshaft 4. Main bearing 5. Thrust bearing 6. Rear oil seal 7. Flywheel (M / T) Drive plate (A / T) 8. Water pump 9.
Page 409 ENGINE MECHANICAL (H25 ENGINE) 6A2-85 REMOVAL 1) Remove engine assembly from vehicle as previously outlined. 2) Remove clutch and flywheel (for M/T vehicle) or drive plate (for A/T vehicle). For clutch removal, refer to Section 7C1. Using special tool (flywheel holder), remove flywheel (M/T ve- hicle) or drive plate (A/T vehicle).
Page 410 6A2-86 ENGINE MECHANICAL (H25 ENGINE) Use a dial gauge to read displacement in axial (thrust) direction of crankshaft. If its limit is exceeded, replace thrust bearing with new standard one or oversize one to obtain standard thrust play. Crankshaft Thrust Play Standard: 0.11 –...
Page 411 ENGINE MECHANICAL (H25 ENGINE) 6A2-87 Inspect Check bearings for pitting, scratches, wear or damage. If any malcondition is found, replace both upper and lower halves. Never replace either half without replacing the other half. Main bearing clearance Check clearance by using gaging plastic according to following pro- cedure.
Page 412 6A2-88 ENGINE MECHANICAL (H25 ENGINE) Selection of main bearings STANDARD BEARING: If bearing is in malcondition, or bearing clearance is out of specifica- tion, select a new standard bearing according to following proce- dure and install it. 1) First check journal diameter. As shown in figure, crank web has stamped numbers and alphabet at the center.
Page 413 ENGINE MECHANICAL (H25 ENGINE) 6A2-89 3) There are five kinds of standard bearings differing in thickness. To distinguish them, they are painted in following colors at the position as indicated in figure. Each color indicates following thickness at the center of bearing. Color painted Bearing thickness 2.493 –...
Page 414 6A2-90 ENGINE MECHANICAL (H25 ENGINE) UNDERSIZE BEARING (0.25 mm): D 0.25 mm undersize bearing is available, in five kinds varying in thickness. To distinguish them, each bearing is painted in following colors at such position as indicated in figure. Each color represents following thickness at the center of bear- ing.
Page 415 ENGINE MECHANICAL (H25 ENGINE) 6A2-91 Rear Oil Seal Carefully inspect oil seal for wear or damage. If lip portion is worn or damaged, replace oil seal. Flywheel D If ring gear is damaged, cracked or worn, replace flywheel. D If the surface contacting clutch disc is damaged, or excessively worn, replace flywheel.
Page 416 6A2-92 ENGINE MECHANICAL (H25 ENGINE) 5) Rebore and hone cylinder to calculated dimension. NOTE: Before reboring, install all main bearing caps in place and tighten to specification to avoid distortion of bearing bores. 6) Measure piston clearance after honing. INSTALLATION NOTE: D All parts to be installed must be perfectly clean.
Page 417 ENGINE MECHANICAL (H25 ENGINE) 6A2-93 6) Install crankcase to cylinder block. Apply oil to crankcase bolts be- 2, (a) fore installing them. Tighten crankcase bolts, following sequence in figure. Tighten crankcase bolts to specified torque. NOTE: Tighten 10 mm thread diameter bolts first (following the order shown in figure), then tighten 8 mm thread diameter bolts.
Page 418: Special Tools
6A2-94 ENGINE MECHANICAL (H25 ENGINE) SPECIAL TOOLS 09911-97810 09913-75510 09915-47310 09915-64510 Oil seal installer Bearing installer Oil filter wrench Compression gauge 09915-67010 09915-64530 Compression gauge 09915-67310 09915-77310 Compression gauge hose attachment (c) Vacuum gauge Oil pressure gauge 1. 09916-14510 Valve lifter 2.
Page 419: Required Service Material
Oil pressure gauge Oil seal guide attachment REQUIRED SERVICE MATERIAL RECOMMENDED SUZUKI PRODUCT D To apply to mating surfaces of cylinder block and oil pan. D To apply to mating surfaces of cylinder block and timing Sealant 1207C 99000-31150 chain cover.
Page 420 _ Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 421: General Description
6A4-2 ENGINE MECHANICAL (J20 ENGINE) GENERAL DESCRIPTION ENGINE The engine is water-cooled, in line 4 cylinders, 4 The double overhead camshaft is mounted over the stroke cycle gasoline unit with its DOHC (Double cylinder head; it is driven from crankshaft through tim- overhead camshaft) valve mechanism arranged for ing chains, and no push rods are provided in the valve “V”...
Page 422 ENGINE MECHANICAL (J20 ENGINE) 6A4-3 ENGINE LUBRICATION The oil pump is of a trochoid type, and mounted under In other path oil goes up to the cylinder head and lubri- the crankshaft. Oil is drawn up through the oil pump cates valves and camshafts, etc., after passing through strainer and passed through the pump to the oil filter.
Page 423: 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 le- ver in “Neutral” (shift selector lever to “P” range for A/T model), and set parking brake and block drive wheels.
Page 424 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 1400 kPa Standard (14.0 kg/cm , 199.0 psi)
Page 425: Engine Vacuum Check
Special Tool (A): 09915-67310 (B): 09918-08210 SUZUKI GENUINE PARTS (C): Hose 09343-03087 (D): 3-way joint 09367-04002 4) Start engine and run engine at specified idle speed (see section 6E1), and read vacuum gauge. Vacuum should be within specifi- cation.
Page 426: Oil Pressure Check
ENGINE MECHANICAL (J20 ENGINE) 6A4-7 OIL PRESSURE CHECK WARNING: To avoid danger of being burned, do not touch exhaust man- ifold when exhaust system is hot. When servicing, be sure to perform it after exhaust system has cooled down. NOTE: Prior to checking oil pressure, check the followings.
Page 427: Air Cleaner Element
6A4-8 ENGINE MECHANICAL (J20 ENGINE) AIR CLEANER ELEMENT REMOVAL 1) Remove air cleaner case clamps. 2) Remove air cleaner element from case. INSPECT Check air cleaner element for dirt. Replace excessively dirty ele- ment. CLEAN Blow off dust by compressed air from air outlet side of element. INSTALLATION Reverse removal procedure for installation.
Page 428: Throttle Body And Intake Manifold
ENGINE MECHANICAL (J20 ENGINE) 6A4-9 THROTTLE BODY AND INTAKE MANIFOLD 1. Intake manifold 2. Intake manifold gasket 3. Throttle body 4. Fuel delivery pipe 5. EGR valve 6. Intake manifold rear stiffener 7. Intake manifold front stiffener 8. Manifold differential pressure sensor REMOVAL 1) Relieve fuel pressure according to fuel pressure relief procedure...
Page 429 6A4-10 ENGINE MECHANICAL (J20 ENGINE) 6) Disconnect accelerator cable and A/T throttle cable (For A/T vehicle) from throttle body. 7) Disconnect following hoses: _ Brake booster hose from intake manifold _ PCV hose from intake manifold _ Fuel pressure regulator vacuum hose from intake manifold _ Canister purge hose from EVAP canister purge valve _ Vacuum hose from intake manifold _ Water hoses from throttle body and water bypass pipe...
Page 430 ENGINE MECHANICAL (J20 ENGINE) 6A4-11 _ Check to ensure that all removed parts are back in place. Reinstall any necessary parts which have not been reinstalled. _ Refill cooling system, referring to Section 6B. _ Upon completion of installation, turn ignition switch ON but en- gine OFF and check for fuel leaks.
Page 431: Exhaust Manifold
6A4-12 ENGINE MECHANICAL (J20 ENGINE) EXHAUST MANIFOLD Vehicle not equipped Vehicle equipped with warm up with warm up three three way catalytic converter way catalytic converter 1. Exhaust manifold 2. Exhaust manifold gasket 3. Heated oxygen sensor-1 4. Exhaust manifold upper cover 5.
Page 432 ENGINE MECHANICAL (J20 ENGINE) 6A4-13 5) Remove exhaust pipe bolts or nuts and exhaust pipe bracket bolt (if equipped). 1. Exhaust No.1 pipe 6) Remove exhaust manifold and its gasket from cylinder head. 1. Exhaust manifold 2. Exhaust manifold gasket INSTALLATION 1) Install new gasket to cylinder head.
Page 433 6A4-14 ENGINE MECHANICAL (J20 ENGINE) 4) Install exhaust manifold stiffener if equipped. Tighten exhaust manifold stiffener nut and bolt to specified torque. 1. Exhaust manifold stiffener (if equipped) 5) Install upper cover to exhaust manifold. 6) Connect heated oxygen sensor-1 coupler and fit coupler to bracket securely.
Page 434: 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 ve- hicle only). 5) Remove oil level gauge. 6) Disconnect breather hose and PCV hose from cylinder head cover.
Page 435: Oil Pan And Oil Pump Strainer
6A4-16 ENGINE MECHANICAL (J20 ENGINE) OIL PAN AND OIL PUMP STRAINER 1. Oil pan 2. Strainer 3. O-ring 4. Gasket 5. Drain plug REMOVAL 1. Differential housing 3. Oil pan 2. Differential 4. Steering gear box 1) Remove oil level gauge. 2) Raise vehicle and remove both front wheels.
Page 436 ENGINE MECHANICAL (J20 ENGINE) 6A4-17 CLEAN 1) Inside of oil pan and oil pump strainer screen. 2) Clean sealing surface on oil pan and crankcase. Remove oil, old sealant, and dust from sealing surface. INSTALLATION 1) To facilitate and ensure installation of oil pan, increase clearance between engine and vehicle body according to following proce- dure.
Page 437 6A4-18 ENGINE MECHANICAL (J20 ENGINE) 3) Install O-rings in the position as shown in figure and install oil pump strainer to oil pump. Tighten strainer bolts first and then bracket bolt to specified torque. Tightening Torque (a): 11 N m (1.1 kg-m, 8.0 lb-ft) (b): 11 N m (1.1 kg-m, 8.0 lb-ft) 4) After fitting oil pan to cylinder block, run in securing bolts and...
Page 438: Oil Pump
ENGINE MECHANICAL (J20 ENGINE) 6A4-19 OIL PUMP 1. Cylinder block 2. Oil pump 3. Oil pump sprocket 4. Oil pump sprocket cover REMOVAL 1) Disconnect negative cable at battery. 2) Drain engine oil. 3) Remove oil pan and oil pump strainer. Refer to item “OIL PAN AND OIL PUMP STRAINER”...
Page 439 6A4-20 ENGINE MECHANICAL (J20 ENGINE) _ Measure free length and tension of oil relief spring. Item Standard 63.5 mm Spring free length (2.5 in.) 86.0 N for 52.0 mm 8.6 kg for Spring preload 52.0 mm 62.2 lb/ 2.05 in. _ Measure clearance of oil pump rotor and oil pump case.
Page 440 ENGINE MECHANICAL (J20 ENGINE) 6A4-21 4) Install relief valve, relief spring and retainer to oil pump case No.2. Tighten retainer to specified torque. Tightening Torque (a): 29 N m (2.9 kg-m, 21.0 lb-ft) 5) Install oil pump case pins to oil pump case No.2. 1.
Page 441: Timing Chain Cover
6A4-22 ENGINE MECHANICAL (J20 ENGINE) TIMING CHAIN COVER 1. Cylinder head cover 2. Cylinder head cover gasket 3. Cylinder head side seal 4. O-ring 5. Oil pan 6. Oil pump strainer 7. Timing chain cover 8. Crankshaft pulley 9. Crankshaft pulley bolt 10.
Page 442 ENGINE MECHANICAL (J20 ENGINE) 6A4-23 11) Remove generator belt idler pulley. 12) Disconnect radiator outlet hose from thermostat cap. 13) With hoses connected, detach A/C compressor from com- pressor bracket if equipped. 14) Remove A/C compressor bracket if equipped. 1. Generator belt idler pulley 2.
Page 443 6A4-24 ENGINE MECHANICAL (J20 ENGINE) INSTALLATION Reverse removal sequence to install timing chain cover noting fol- lowing points. 1) Apply sealant “A” and “B” to area as shown in figure. “A”: Sealant 99000-31150 “B”: Sealant 99000-31140 1. Timing chain cover 2.
Page 444 ENGINE MECHANICAL (J20 ENGINE) 6A4-25 4) Install A/C compressor bracket if equipped. Tighten bracket bolts to specified torque. Tightening Torque (a): 55 N m (5.5 kg-m, 40.0 lb-ft) 5) Install generator belt idler pulley. Tighten nut to specified torque. 1. Generator belt Tightening Torque idler pulley (b): 45 N...
Page 445: 2Nd Timing Chain And Chain Tensioner
6A4-26 ENGINE MECHANICAL (J20 ENGINE) 2ND TIMING CHAIN AND CHAIN TENSIONER 1. 2nd timing chain 2. Timing chain tensioner adjuster No.2 3. Intake camshaft timing sprocket 4. Exhaust camshaft timing sprocket 5. Idler sprocket 6. Timing chain guide No.2 7. Tensioner adjuster No.2 gasket REMOVAL 1) Disconnect negative cable at battery.
Page 446 ENGINE MECHANICAL (J20 ENGINE) 6A4-27 8) Remove timing chain tensioner adjuster No.2. To remove it, slacken 2nd timing chain by turning intake cam- shaft counterclockwise a little while pushing back pad. 1. Timing chain tensioner adjuster No.2 9) Remove intake and exhaust camshaft timing sprocket bolts. To remove it, fit a spanner to hexagonal part at the center of camshaft to hold it stationary.
Page 447 6A4-28 ENGINE MECHANICAL (J20 ENGINE) INSPECTION Timing Chain Guide No.2 _ Check shoe for wear or damage. 1. Timing chain guide No.2 2. Shoe Camshaft Sprocket _ Check teeth of sprocket for wear or damage. Timing Chain _ Check timing chain for wear or damage. Tensioner Adjuster No.2 _ Check shoe for wear or damage.
Page 448 ENGINE MECHANICAL (J20 ENGINE) 6A4-29 INSTALLATION 1) Check that crank timing sprocket key is in match with timing mark on cylinder block as shown in figure. 1. Crank timing sprocket key 2. Timing mark 2) Check that arrow mark on idler sprocket faces upward as shown in figure.
Page 449 6A4-30 ENGINE MECHANICAL (J20 ENGINE) 6) Install intake and exhaust camshaft timing sprocket bolts. To install it, fit a spanner to hexagonal part at the center of cam- shaft to hold stationary. Tightening Torque (a): 80 N m (8.0 kg-m, 57.5 lb-ft) 1.
Page 450 ENGINE MECHANICAL (J20 ENGINE) 6A4-31 10) Turn crankshaft two rotations clockwise 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 451: 1St Timing Chain And Chain Tensioner
6A4-32 ENGINE MECHANICAL (J20 ENGINE) 1ST TIMING CHAIN AND CHAIN TENSIONER 1. 1st timing chain 2. Idler sprocket 3. Idler sprocket shaft 4. Crankshaft timing sprocket 5. Timing chain tensioner 6. Timing chain tensioner adjuster No.1 7. Timing chain guide No.1 REMOVAL 1) Disconnect negative cable at battery.
Page 452 ENGINE MECHANICAL (J20 ENGINE) 6A4-33 7) For reinstallation of timing chain, turn crankshaft so that timing marks on cylinder head and cylinder block match with those on sprockets as shown in figure. 8) Remove 2nd timing chain. Refer to item “2ND TIMING CHAIN AND CHAIN TENSIONER” in this section for removal.
Page 453 6A4-34 ENGINE MECHANICAL (J20 ENGINE) Crankshaft Timing Sprocket _ Check teeth of sprocket for wear or damage. Idler Sprocket _ Check teeth and bush of sprocket for wear or damage. 1. Bush 1st Timing Chain _ Check timing chain for wear or damage. Timing Chain Tensioner Adjuster No.1 _ Check that latch and tooth surface are free from damage and latch functions properly.
Page 454 ENGINE MECHANICAL (J20 ENGINE) 6A4-35 INSTALLATION 1) Check that crank timing sprocket key is in match with timing mark on cylinder block. 1. Crank timing sprocket key 2. Timing mark 2) Install crankshaft timing sprocket as shown in figure. Match mark faces to chain cover. 1.
Page 455 6A4-36 ENGINE MECHANICAL (J20 ENGINE) 8) With latch of tensioner adjuster No.1 returned and plunger pushed back into body, hold it at the position by inserting stop- per between latch and body. 1. Plunger 2. Latch 3. Body 4. Stopper 9) Install timing chain tensioner adjuster No.1.
Page 456 ENGINE MECHANICAL (J20 ENGINE) 6A4-37 13) Install 2nd timing chain. Refer to item “2ND TIMING CHAIN AND CHAIN TENSIONER” in this section for installation. 14) Install timing chain cover. Refer to item “TIMING CHAIN COVER” in this section for instal- lation.
Page 457: Camshafts And Valve Lash Adjusters
6A4-38 ENGINE MECHANICAL (J20 ENGINE) CAMSHAFTS AND VALVE LASH ADJUSTERS 1. Intake camshaft 2. Exhaust camshaft 3. Camshaft housing 4. Intake camshaft housing 5. Exhaust camshaft housing 6. Valve lash adjuster 7. CMP sensor 8. Oil relief valve 9. Timing chain guide No.2 REMOVAL 1) Disconnect negative cable at battery.
Page 458 ENGINE MECHANICAL (J20 ENGINE) 6A4-39 9) After removing 2nd timing chain, set key on crankshaft in posi- tion as shown by turning crankshaft. This is to prevent interfer- ence between valves and piston. 10) Loosen camshaft housing bolts in such order as indicated in figure and remove them.
Page 459 6A4-40 ENGINE MECHANICAL (J20 ENGINE) Camshaft Runout Set camshaft between two “V” blocks, and measure its runout by using a dial gauge. If measured runout exceed below specified limit, replace camshaft. Runout limit 0.10 mm (0.0039 in.) Camshaft Journal Wear Check camshaft journals and camshaft housings for pitting, scratches, wear or damage.
Page 460 ENGINE MECHANICAL (J20 ENGINE) 6A4-41 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. Item Standard Camshaft journal 26.000 –...
Page 461 6A4-42 ENGINE MECHANICAL (J20 ENGINE) Oil Relief Valve Check oil relief valve for clogging and ball for being stuck. INSTALLATION 1) Before installing valve lash adjuster to cylinder head, fill oil pas- sage of cylinder head with engine oil according to following pro- cedure.
Page 462 ENGINE MECHANICAL (J20 ENGINE) 6A4-43 5) Install camshaft housing pins as shown in figure. 6) Apply sealant “A” to exhaust camshaft end housing sealing surface area as shown in figure. “A”: Sealant 99000-31150 1. Intake camshaft 2. Exhaust camshaft 3. Pin installation position 7) Check position of camshaft housings.
Page 463: Valve Lash Adjuster Noise Diagnosis
6A4-44 ENGINE MECHANICAL (J20 ENGINE) CAUTION: D 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 464: Valves And Cylinder Head
10. Valve spring retainer 11. Valve cotter 12. Hydraulic valve lash adjuster 13. Valve guide “A”: Apply sealant (SUZUKI BOND 14. Water outlet pipe 15. Water outlet cap No. 1215, 99000-31110) to thread REMOVAL 1) Relieve fuel pressure according to procedure described in Sec- tion 6.
Page 465 6A4-46 ENGINE MECHANICAL (J20 ENGINE) 7) Disconnect following electric lead wires: D EGR valve coupler D IAC valve coupler D TP sensor coupler D EVAP canister purge valve coupler D Ground terminal from intake manifold D Heated oxygen sensor-1 and/or -2 coupler D CMP sensor coupler D ECT sensor coupler D Injector wire harness coupler...
Page 466 ENGINE MECHANICAL (J20 ENGINE) 6A4-47 13) Disconnect exhaust No. 1 pipe from exhaust manifold. 1. Exhaust No.1 pipe 14) Remove exhaust manifold stiffener (if equipped). 1. Exhaust manifold stiffener 15) Loosen cylinder head bolts in such order as indicated in figure and remove them.
Page 467 6A4-48 ENGINE MECHANICAL (J20 ENGINE) 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 by using special tool. Special Tool (A): 09916-14510 (B): 09916-14910...
Page 468 ENGINE MECHANICAL (J20 ENGINE) 6A4-49 INSPECTION Valve Guides Using a micrometer and bore gauge, take diameter readings on valve stems and guides to check stem-to-guide clearance. Be sure to take reading at more than one place along the length of each stem and guide.
Page 469 6A4-50 ENGINE MECHANICAL (J20 ENGINE) D Seating contact width: Create contact pattern on each valve in the usual manner, i.e. by giving uniform coat of marking compound to valve seat and by ro- tatingly tapping seat with valve head. Valve lapper (tool used in valve lapping) must be used.
Page 470 ENGINE MECHANICAL (J20 ENGINE) 6A4-51 Cylinder Head D Remove all carbon deposits from combustion chambers. NOTE: Do not use any sharp-edged tool to scrape off carbon depos- its. Be careful not to scuff or nick metal surfaces when decar- boning. The same applies to valves and valve seats, too. D Check cylinder head for cracks on intake and exhaust ports, com- bustion chambers, and head surface.
Page 471 6A4-52 ENGINE MECHANICAL (J20 ENGINE) Valve Springs D Referring to data given below, check to be sure that each spring is in sound condition, free of any evidence of breakage or weak- ening. Remember, weakened valve springs can cause chatter, not to mention possibility of reducing power output due to gas leakage caused by decreased seating pressure.
Page 472 ENGINE MECHANICAL (J20 ENGINE) 6A4-53 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 (A): 09916-34542 (B): 09916-38210 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.
Page 473 6A4-54 ENGINE MECHANICAL (J20 ENGINE) 5) Install new valve stem seal 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 474 ENGINE MECHANICAL (J20 ENGINE) 6A4-55 9) Install intake manifold, injectors, exhaust manifold, water outlet pipe and water outlet cap to cylinder head. NOTE: When installing water outlet pipe, apply sealant to the thread of the bolt shown in figure. “A”: Sealant 99000-31110 1.
Page 475 6A4-56 ENGINE MECHANICAL (J20 ENGINE) 5) Check that key on crankshaft aligns with timing mark as shown in figure. 1. Timing mark 2. Crank timing sprocket key 6) Reverse removal procedure for installation. 7) Adjust cooling fan belt tension. Refer to Section 6B for adjusting procedure. 8) Adjust accelerator cable play and A/T throttle cable play (for vehicle with A/T).
Page 476: Pistons, Piston Rings, Connecting Rods And Cylinders
ENGINE MECHANICAL (J20 ENGINE) 6A4-57 PISTONS, PISTON RINGS, CONNECTING RODS AND CYLINDERS 1. Top ring 2. 2nd ring 3. Oil ring 4. Piston 5. Connecting rod 6. Connecting rod bearing cap 7. Connecting rod bearing 8. Piston pin 9. Piston pin circlip 10.
Page 477 6A4-58 ENGINE MECHANICAL (J20 ENGINE) DISASSEMBLY 1) Using piston ring expander, remove two compression rings (Top and 2nd) and oil ring from piston. 2) Remove piston pin from connecting rod. D Ease out piston pin circlips, as shown. 1. Piston pin circlip D Force piston pin out.
Page 478 ENGINE MECHANICAL (J20 ENGINE) 6A4-59 INSPECTION Cylinder D Inspect cylinder walls for scratches, roughness, or ridges which indicate excessive wear. If cylinder bore is very rough or deeply scratched, or ridged, rebore cylinder and use over size piston. D Using a cylinder gauge, measure cylinder bore in thrust and axial directions at two positions as shown in figure.
Page 479 6A4-60 ENGINE MECHANICAL (J20 ENGINE) D Piston clearance: Measure cylinder bore diameter and piston diameter to find their difference which is piston clearance. Piston clearance should be within specification as given below. If it is out of specification, re- bore cylinder and use oversize piston. Piston clearance: 0.02 –...
Page 480 ENGINE MECHANICAL (J20 ENGINE) 6A4-61 Piston Rings To measure end gap, insert piston ring into cylinder bore and then measure the gap by using thickness gauge. If measured gap is out of specification, replace ring. NOTE: Clean carbon deposits and any other dirt from top of cylinder bore before inserting piston ring.
Page 481 6A4-62 ENGINE MECHANICAL (J20 ENGINE) Crank Pin and Connecting Rod Bearings D Inspect crank pin for uneven wear or damage. Measure crank pin for out-of-round or taper with a micrometer. If crank pin is dam- aged, or out-of round or taper is out of limit, replace crankshaft or regrind crank pin referring to following step 6).
Page 482 ENGINE MECHANICAL (J20 ENGINE) 6A4-63 5) Remove cap and using a scale on gaging plastic envelope, mea- sure gaging plastic width at the widest point (clearance). If clearance exceeds its limit, use a new standard size bearing and remeasure clearance. Item Standard Limit...
Page 483 6A4-64 ENGINE MECHANICAL (J20 ENGINE) ASSEMBLY 1 or 2 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. No.
Page 484 ENGINE MECHANICAL (J20 ENGINE) 6A4-65 1) Install piston pin to piston and connecting rod: After applying engine oil to piston pin and piston pin holes in pis- ton and connecting rod, fit connecting rod to piston as shown in figure and insert piston pin to piston and connecting rod, and install piston pin circlips.
Page 485 6A4-66 ENGINE MECHANICAL (J20 ENGINE) INSTALLATION 1) Apply engine oil to pistons, rings, cylinder walls, connecting rod bearings and crank pins. NOTE: Do not apply oil between connecting rod and bearing or be- tween bearing cap and bearing. 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 assem- bly.
Page 486: Engine Mountings
ENGINE MECHANICAL (J20 ENGINE) 6A4-67 6) Reverse removal procedure for installation, as previously out- lined. 7) Adjust cooling fan belt tension. Refer to Section 6B for adjusting procedure. 8) Adjust accelerator cable play and A/T throttle cable play (for vehicle with A/T). Refer to Section 6E1. 9) Check to ensure that all removed parts are back in place.
Page 487: Unit Repair Overhaul
6A4-68 ENGINE MECHANICAL (J20 ENGINE) UNIT REPAIR OVERHAUL ENGINE ASSEMBLY REMOVAL 1) Release fuel pressure in fuel feed line. Refer to Section 6. 2) Disconnect negative cable at battery. 3) Remove engine hood. 4) Remove strut tower bar. 5) Drain coolant. 6) Remove radiator, radiator fan shroud and cooling fan.
Page 488 ENGINE MECHANICAL (J20 ENGINE) 6A4-69 12) With hoses connected, detach power steering pump and A/C compressor from cylinder block if equipped. 13) Raise vehicle. 14) Drain engine oil if necessary. 15) Remove front differential housing with differential from chassis. Refer to Section 7E for removal. 16) Remove exhaust pipe bolt or exhaust pipe.
Page 489 6A4-70 ENGINE MECHANICAL (J20 ENGINE) 23) Remove bolt and nuts fastening cylinder block and transmis- sion. 24) Install lifting device. 25) Remove engine side mounting bracket nuts from engine mountings. 26) Before lifting engine, check to ensure all hoses, wires and cables are disconnected from engine.
Page 490 ENGINE MECHANICAL (J20 ENGINE) 6A4-71 5) Tighten torque converter bolts to specified torque (for A/T ve- hicle). Tightening Torque (a): 65 N m (6.5 kg-m, 47.0 lb-ft) 6) Tighten transmission stiffener bolts to specified torque if equipped. Tightening Torque (a): 50 N m (5.0 kg-m, 36.5 lb-ft) 1.
Page 491: Main Bearings, Crankshaft And Cylinder Block
6A4-72 ENGINE MECHANICAL (J20 ENGINE) MAIN BEARINGS, CRANKSHAFT AND CYLINDER BLOCK 1. Cylinder block 10. Flywheel (M / T) 2. Lower crankcase Drive plate (A / T) 3. Crankshaft 11. Clutch housing plate 4. O-ring 12. Blank 5. Oil pump drive chain 13.
Page 492 ENGINE MECHANICAL (J20 ENGINE) 6A4-73 REMOVAL Remove engine assembly from vehicle as previously out- lined. Remove clutch and flywheel (for M/T vehicle) or drive plate (for A/T vehicle). For clutch removal, refer to Section 7C1. Special Tool (A): 09924-17810 1. Flywheel bolt Remove throttle body, intake manifold, exhaust manifold.
Page 493 6A4-74 ENGINE MECHANICAL (J20 ENGINE) INSPECTION Crankshaft Crankshaft runout Using a dial gauge, measure runout at center journal. Rotate crank- shaft slowly. If runout exceeds its limit, replace crankshaft. Limit on runout: 0.06 mm (0.0023 in.) Crankshaft thrust play Measure this play with crankshaft set in cylinder block in the normal manner, that is, with thrust bearing and journal bearing caps installed.
Page 494 ENGINE MECHANICAL (J20 ENGINE) 6A4-75 Main Bearings General information D Service main bearings are available in standard size and 0.25 mm (0.0098 in.) undersize, and each of them has 5 kinds of bear- ings differing in tolerance. D Upper half of bearing has oil groove as shown in figure. Install this half with oil groove to cylinder block.
Page 495 6A4-76 ENGINE MECHANICAL (J20 ENGINE) 5) Remove lower crankcase and using scale on gaging plastic en- velop, measure gaging plastic width at its widest point. If clear- ance exceeds its limit, replace bearing. Always replace both up- per and lower inserts as a unit. A new standard bearing may produce proper clearance.
Page 496 ENGINE MECHANICAL (J20 ENGINE) 6A4-77 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 following cap bore diameters. [For Bearing cap No.1, No.2, No.3 and No.5] Bearing cap bore diameter Stamped alphabet (without bearing)
Page 497 6A4-78 ENGINE MECHANICAL (J20 ENGINE) 4) From number stamped on crank web No.2 and alphabets stamped on lower crankcase, determine new standard bearing to be installed to journal, by referring to table shown below. For example, if number stamped on crank web No.2 is “1” and alphabet stamped on lower crankcase is “B”, install a new stan- dard bearing painted in “Black”...
Page 498 ENGINE MECHANICAL (J20 ENGINE) 6A4-79 UNDERSIZE BEARING (0.25 mm): D 0.25 mm undersize bearing is available, in five kinds varying in thickness. To distinguish them, each bearing is painted in following colors at such position as indicated in figure. Each color represents following thickness at the center of bear- ing.
Page 499 6A4-80 ENGINE MECHANICAL (J20 ENGINE) Oil Pump Sprocket D Check teeth of sprocket for wear or damage. If any damage or wear is found, replace crankshaft. 1. Crankshaft 2. Oil pump sprocket Oil Pump Drive Chain D Check oil pump drive chain for wear or damage. Rear Oil Seal Carefully inspect oil seal for wear or damage.
Page 500 ENGINE MECHANICAL (J20 ENGINE) 6A4-81 Cylinder Block Distortion of gasketed surface D Using straightedge and thickness gauge, check gasketed sur- face for distortion and, if flatness exceeds its limit, correct it. Flatness Limit: 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 501 6A4-82 ENGINE MECHANICAL (J20 ENGINE) INSTALLATION NOTE: D All parts to be installed must be perfectly clean. D Be sure to oil crankshaft journals, journal bearings, thrust bearings, crank pins, connecting rod bearings, pistons, pis- ton rings and cylinder bores. D Journal bearings, crankcase (bearings caps), connecting rods, rod bearings, rod bearing caps, pistons and piston rings are in combination sets.
Page 502 ENGINE MECHANICAL (J20 ENGINE) 6A4-83 Install lower crankcase to cylinder block. Apply oil to crank- case bolts before installing them. Tighten crankcase bolts to 70% torque of specified torque, following sequence in figure and then tighten crankcase bolts to specified torque accord- ing to numerical order in figure.
Page 503 6A4-84 ENGINE MECHANICAL (J20 ENGINE) 9) Install engine side mounting brackets (right and left). Tighten bracket bolts to specified torque. Tightening Torque (d): 50 N m (5.0 kg-m, 36.5 lb-ft) 10) Install water pump and heater outlet pipe. Refer to Section 6B. 11) Install pistons and connecting rods as previously outlined.
Page 504: Special Tools
ENGINE MECHANICAL (J20 ENGINE) 6A4-85 SPECIAL TOOLS 09911-97710 09911-97810 09913-75510 09915-47330 Oil seal guide Oil seal installer Bearing installer Oil filter wrench 1. 09915-64510-001 Compression gauge 2. 09915-64510-002 Connector 1. 09915-77310 3. 09915-64530 Oil pressure gauge 1. 09916-14510 Hose 2. 09915-78211 Valve lifter 4.
Page 505: Required Service Materials
Bearing puller attachment Steering wheel remover Gear stopper REQUIRED SERVICE MATERIALS RECOMMENDED SUZUKI PRODUCT D To apply to mating surfaces of cylinder block and oil pan. D To apply to mating surfaces of cylinder block and timing Sealant 1207C 99000-31150 chain cover.
Page 506: Engine Cooling
ENGINE COOLING 6B-1 SECTION 6B ENGINE COOLING CONTENTS GENERAL DESCRIPTION ..............6B- 2 Cooling System Circulation .
Page 507: 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 508 ENGINE COOLING 6B-3 [A]: G16 engine [B]: J20 engine [C]: H25 engine 1. Radiator 2. Cooling fan 3. Thermostat 4. Water pump 5. Radiator inlet way 6. Radiator outlet way 7. Outlet pipe 8. Outlet cap 9. Throttle body 10. Heater outlet way 11.
Page 509: Thermostat
6B-4 ENGINE COOLING THERMOSTAT [G16 & J20 engines] J20 and Temp. at which H25 engines : 82 + 2_C (179 + 3.6_F) valve begins to open G16 engine : 88 + 2_C (190 + 3.6_F) J20 and Temp. at which valve H25 engines: 95_C (203_F) becomes fully open G16 engine : 100_C (212_F)
Page 510: Coolant
ENGINE COOLING 6B-5 COOLANT The coolant recovery system is standard. The coolant in the radiator expands with heat, and the overflow is col- lected in the reservoir. When the system cools down, the coolant is drawn back into the radiator. The cooling system has been filled at the factory with a quality coolant that is a 50/50 mixture of water and ethylene glycol antifreeze.
Page 511: Diagnosis
6B-6 ENGINE COOLING DIAGNOSIS DIAGNOSIS TABLE Condition Possible Cause Correction _ Loose or broken water pump belt Engine overheats Adjust or replace. _ Not enough coolant Check coolant level and add as necessary. _ Faulty thermostat Replace. _ Faulty water pump Replace.
Page 512: Cooling System Service
ENGINE COOLING 6B-7 COOLING SYSTEM SERVICE WARNING: To help avoid danger of being burned, do not remove radia- tor cap while engine and radiator are still hot. Scalding fluid and steam can be blown out under pressure if cap is taken off too soon. Cooling system should be serviced as follows.
Page 513 6B-8 ENGINE COOLING 3) Stop engine and open radiator drain plug to drain coolant. 4) Close drain plug (1). Add water until system is filled and run en- gine until upper radiator hose is hot again. 5) Repeat steps 3) and 4) several times until drained liquid is nearly colorless.
Page 514: Cooling Fan Belt Tension Check And Adjustment
ENGINE COOLING 6B-9 COOLING FAN BELT TENSION CHECK AND [G16 engine] ADJUSTMENT 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 cleanliness. If so, replace belt. 2) Check belt for tension.
Page 515 6B-10 ENGINE COOLING For J20 engine [J20 engine] 1) Inspect belt for cracks, cuts, deformation, wear and cleanliness. If so, replace belt. 2) Check belt for tension. Belt is in proper tension when it deflects 5 to 7 mm (0.20 – 0.27 in.) under thumb pressure (about 10 kg or 22 lbs).
Page 516: On-Vehicle Service
ENGINE COOLING 6B-11 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 517 6B-12 ENGINE COOLING 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. 4. O-ring 5. Heater hose 6. Water hose (To throttle body) INSTALLATION For G16 and J20 engines Install removed parts in reverse order of removal procedure, noting...
Page 518: Thermostat
ENGINE COOLING 6B-13 6) Install throttle body and intake manifold. Refer to Section 6A2 for installation. 7) Install radiator outlet pipe (3) to thermostat case with new O-ring. 8) Install radiator inlet and outlet hoses (1), (2). 9) Refill cooling system with proper coolant, referring to description on “COOLANT”...
Page 519 6B-14 ENGINE COOLING _ Check thermostatic movement of wax pellet as follows: a) Immerse thermostat 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 re- placed with a new one.
Page 520: Cooling Fan Belt
ENGINE COOLING 6B-15 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 521: Cooling Fan And Fan Clutch
6B-16 ENGINE COOLING COOLING FAN BELT TENSION INSPECTION Inspect belt and check belt tension. Refer to “COOLING FAN BELT TENSION CHECK AND ADJUSTMENT” in this section. 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.
Page 522: Radiator
ENGINE COOLING 6B-17 INSTALLATION Install removed parts in reverse order of removal procedure. _ After installation, adjust belt tension for specification and tighten each bolt and nut securely. Tightening Torque Cooling fan/dutch nut (G16 engine) (a): 11 N m (1.1 kg-m, 8.0 lb-ft) Cooling fan/dutch nut (H25 and J20 engines) (a): 25 N m (2.5 kg-m, 18.0 lb-ft)
Page 523 6B-18 ENGINE COOLING 6) Remove P/S oil tank stay bolts (1) from radiator stay. 7) Remove radiator shroud securing clips. 8) Then remove cooling fan/clutch and radiator shroud. 9) Disconnect water inlet and outlet hose (1), (2) and reservoir tank hose (3) from radiator. 10) Remove radiator (4).
Page 524 ENGINE COOLING 6B-19 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 525 6B-20 ENGINE COOLING 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 Section 6H.
Page 526: Water Pump
ENGINE COOLING 6B-21 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 For J20 engine CAUTION: Do not disassemble water pump. If any repair is required on pump, replace it as assembly. _ Rotate water pump by hand to check for smooth operation.
Page 527 6B-22 ENGINE COOLING 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 wa- ter pump and oil pump.
Page 528 ENGINE COOLING 6B-23 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 be- fore 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 529: Engine Coolant Temperature (Ect) Sensor
Ethylene glycol base coolant Additive to engine cooling system (Anti-freeze/Anti-corrosion ——— for improving cooling efficiency and coolant) for protection against rusting. SUZUKI BOND NO. 1215 Sealant Water outlet pipe bolt (99000-31110) TIGHTENING TORQUE SPECIFICATION Tightening torque Fastening parts Fastening arts...
Page 530: Engine Fuel
ENGINE FUEL 6C-1 SECTION 6C ENGINE FUEL CONTENTS GENERAL DESCRIPTION ....6C-1 Fuel Filter ......6C-3 Fuel System .
Page 531 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. D Disconnect negative cable at battery. D DO NOT smoke, and place “NO SMOKING” signs near work area.
Page 532 ENGINE FUEL 6C-3 FUEL PUMP REMOVAL 1) Remove fuel tank. Refer to “FUEL TANK” in this section. 2) Remove fuel pump assembly 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 533: Fuel Lines
6C-4 ENGINE FUEL INSTALLATION Reverse removal procedure noting the following. D 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 534: Fuel Filler Cap
ENGINE FUEL 6C-5 FUEL FILLER CAP INSPECTION Remove cap, and check gasket for even filler neck imprint, and de- terioration or any damage. If gasket is in malcondition, replace cap. CAUTION: If cap requires replacement, only a cap with the same fea- tures should be used.
Page 535 6C-6 ENGINE FUEL 8) Disconnect fuel filter inlet hose from filter. 1. Fuel filter 2. Fuel filter outlet hose 3. Fuel filter inlet hose 9) Disconnect fuel vapor hose (1) and return hose (2) from pipes. 10) Remove fuel tank protector from vehicle. 11) Lower fuel tank gradually while holding it horizontally and pull out each coupler from fuel pump (1) and fuel tank pressure sensor (2).
Page 536 ENGINE FUEL 6C-7 INSTALLATION 1) Install fuel pump assembly and fuel cut valve to fuel tank. Refer to “FUEL PUMP” in this section. 2) Connect fuel hoses to fuel tank, fuel cut valve and fuel pump as- sembly. Rear After connecting, clamp hoses securely. side 3) Install inlet valve to fuel tank.
Page 537 6C-8 ENGINE FUEL 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 leakage. FUEL TANK PURGING PROCEDURE CAUTION: This purging procedure will NOT remove all fuel vapor. Do not attempt any repair on tank where heat or flame is re- quired, as an explosion resulting in personal injury could occur.
Page 538 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 539 6E1-2 ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINES) HO2S -1 and -2 ..... . 6E1-37 Fuel Cut Operation (Inspection) .
Page 540 ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINES) 6E1-3 GENERAL DESCRIPTION The engine and emission control system has 4 major Electronic control system includes ECM (PCM), vari- sub-systems: air intake system, fuel delivery system, ous sensors and controlled devices. electronic control system and emission control sys- Emission control system includes EGR, EVAP and tem.
Page 541 6E1-4 ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINES) G16 ENGINE...
Page 542 ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINES) 6E1-5...
Page 543 6E1-6 ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINES) J20 ENGINE...
Page 544 ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINES) 6E1-7...
Page 545: Air Intake System
6E1-8 ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINES) AIR INTAKE SYSTEM The main components of the air intake system are air When the idle air control valve is opened according to cleaner, mass air flow sensor, air cleaner outlet hose, the signal from PCM (ECM), the air bypasses the throttle body, idle air control valve and intake man- throttle valve through bypass passage and is finally...
Page 546: Fuel Delivery System
ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINES) 6E1-9 FUEL DELIVERY SYSTEM The fuel delivery system consists of the fuel tank, fuel amount higher than the pressure in the intake man- pump, fuel filter, fuel pressure regulator, delivery pipe ifold by the fuel pressure regulator, the fuel is injected and fuel injectors.
Page 547: Electronic Control System
6E1-10 ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINES) ELECTRONIC CONTROL SYSTEM D Idle air control system The electronic control system consists of 1) various D Fuel pump control system sensors which detect the state of engine and driving D Evaporative emission control system conditions, 2) ECM (PCM) which controls various de- D Ignition control system...
Page 548 ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINES) 6E1-11 J20 ENGINE 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 B : EVAP canister 3.
Page 549 6E1-12 ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINES) C51-1-22 C51-1-23 Bl / G C51-1-10 Bl / Y C51-1-11...
Page 550 ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINES) 6E1-13 6-1. Fuel injector No.1 -24. Starter magnetic switch 2. Fuel injector No.2 -25. Vehicle speed sensor 3. Fuel injector No.3 26. Combination meter -4. Fuel injector No.4 26-1. Fuel level sensor -5.
Page 551 6E1-14 ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINES) TERMINAL ARRANGEMENT OF ECM (PCM) CONNECTOR (VIEWED FROM HARNESS SIDE) CIRCUIT CIRCUIT CIRCUIT TERMINAL TERMINAL TERMINAL A / T output speed sensor (–) Ground for MAF sensor Power source for CO adjusting resistor Ground A / T output speed sensor (+)
Page 552 ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINES) 6E1-15...
Page 553: Engine & Emission Control Input/Output Table
6E1-16 ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINES) ENGINE & EMISSION CONTROL INPUT/OUTPUT TABLE Input Function Output Main relay control Main relay Fuel pump control Fuel pump relay f f f f f f f f f f f Injection control Injectors f f f f f...
Page 554: On-Vehicle Service
ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINES) 6E1-17 ON-VEHICLE SERVICE G16 ENGINE J20 ENGINE [A]: Vehicle without immobilizer indicator lamp [B]: Vehicle with immobilizer indicator lamp 1. Brake booster hose 2. Engine ground 3. Vacuum hose for fuel pressure regulator 4.
Page 555: General
6E1-18 ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINES) GENERAL When hoses are disconnected and system components are re- moved for service, reinstall components properly, and route and connect hoses correctly after service. Refer to Emission Control In- formation Label or figure on previous page for proper routing of hoses.
Page 556: Idle Speed/Idle Air Control Duty
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 with ignition switch OFF. Special Tool (A): SUZUKI scan tool, Tech 1...
Page 557: Idle Mixture Inspection/Adjustment
6E1-20 ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINE) 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%) 0.8 – 1.3% at specified idle speed Idle mixture adjustment should never be changed from the original factory setting.
Page 558: Air Intake System
ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINES) 6E1-21 AIR INTAKE SYSTEM THROTTLE BODY 1. Cable bracket 2. Throttle body 3 TP sensor 4. Idle air control valve 5. O-ring On-Vehicle Inspection D Check that throttle valve lever moves smoothly. Removal 1) Disconnect negative cable at battery.
Page 559 6E1-22 ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINES) Cleaning 1) Remove IAC valve from throttle body. 2) Clean throttle body bore and bypass air passages by blowing compressed air. CAUTION: D Do not blow compressed air through bypass air pas- sage with IAC valve installed to throttle body.
Page 560: Idle Air Control Valve
ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINES) 6E1-23 IDLE AIR CONTROL VALVE (IAC VALVE) Inspection 1) Disconnect connector from IAC valve. 2) Check each coil of IAC valve for resistance. Terminals Resistance Between “1” and “2” “3” and “2” 35 –...
Page 561: Fuel Delivery System
6E1-24 ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINES) FUEL DELIVERY SYSTEM FUEL PRESSURE INSPECTION 1) Relieve fuel pressure in fuel feed line referring to p. 6-4. 2) Using backup wrench, loosen plug bolt on fuel delivery pipe and remove it.
Page 562: Fuel Pump
ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINES) 6E1-25 8) Install plug bolt to fuel delivery pipe. Use new gasket. Tighten it to specified torque, using backup wrench. Tightening Torque (a): 30 N m (3.0 kg-m, 22.0 lb-ft) 9) With engine “OFF” and ignition switch “ON”, check for fuel leaks. FUEL PUMP On-Vehicle Inspection CAUTION:...
Page 563: Fuel Pressure Regulator
6E1-26 ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINES) Installation 1) Install fuel pump to its bracket. 2) Install fuel pump to fuel tank and then install fuel tank to body ac- cording to procedure described in “Fuel System” section. FUEL PRESSURE REGULATOR Removal 1) Relieve fuel pressure according to procedure described on p.
Page 564 ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINES) 6E1-27 FUEL INJECTOR On-Vehicle Inspection 1) Using sound scope or such, check operating sound of injector when engine is running or cranking. Cycle of operating sound should vary according to engine speed.
Page 565: Fuel Injector
6E1-28 ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINES) 6) Remove fuel delivery pipe bolts. 7) Remove fuel injector(s) 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 566 6) Operate fuel pump and apply fuel pressure to injector as follows: When SUZUKI scan tool can be used: (1) Connect SUZUKI scan tool to DLC with ignition switch OFF. (2) Turn ignition switch ON, clear DTC and select “MISC TEST”...
Page 567 6E1-30 ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINES) Installation 1) Replace injector O-ring with new one using care not to damage it. Install grommet to injector. 2) Check if insulator is scored or damaged. If it is, replace with new one.
Page 568: Electronic Control System
ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINES) 6E1-31 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 569: Maf Sensor
6E1-32 ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINES) MASS AIR FLOW SENSOR (MAF SENSOR) Inspection NOTE: Use voltmeter with high-impedance (10 kW/V minimum) or digital type voltmeter. 1) Connect voltmeter to “B +” terminal of MAF sensor coupler dis- connected and ground.
Page 570 ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINES) 6E1-33 Removal 1) Disconnect negative cable at battery and coupler from MAF sen- sor. 2) Remove air cleaner outlet hose from throttle body and MAF sen- sor. 3) Remove MAF sensor from air cleaner case. NOTE: Don’t disassemble MAF sensor.
Page 571: Iat Sensor
6E1-34 ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINES) INTAKE AIR TEMPERATURE (IAT) SENSOR Removal 1) Disconnect negative cable from battery. 2) Disconnect IAT sensor coupler. 3) Remove IAT sensor from air cleaner case. Inspection Immerse temperature sensing part of IAT sensor in water (or ice) and measure resistance between sensor terminals while heating water gradually.
Page 572: Tp Sensor
ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINES) 6E1-35 THROTTLE POSITION SENSOR (TP SENSOR) Inspection 1) Disconnect negative cable at battery and coupler from TP sen- sor. 2) Using ohmmeter, check resistance between terminals under each condition given in table below. TERMINALS RESISTANCE Between 1 and...
Page 573: Ect Sensor
6E1-36 ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINES) ENGINE COOLANT TEMPERATURE SENSOR G16 Engine (ECT SENSOR) Removal 1) Disconnect negative cable from battery. 2) Drain cooling system. 3) Disconnect coupler from ECT sensor. 4) Remove ECT sensor from intake manifold or water outlet cap. J20 Engine 1.
Page 574 ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINES) 6E1-37 Installation G16 Engine Reverse removal procedure noting the following. D Clean mating surfaces of sensor and intake manifold. D Check O-ring for damage and replace if necessary. D Tighten ECT sensor to specified torque. Tightening Torque (a): 15 N m (1.5 kg-m, 11.0 lb-ft)
Page 575 6E1-38 ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINES) Removal Sensor-1 WARNING: To avoid danger of being burned, do not touch exhaust sys- tem 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 and disconnect coupler of oxy- gen sensor.
Page 576: Vehicle Speed Sensor
ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINES) 6E1-39 VEHICLE SPEED SENSOR (VSS) On-Vehicle Inspection 1) Hoist vehicle. 2) Release parking brake lever, set transmission in neutral and “VSS, C51-2-25” transfer in “2H”. 3) Remove ECM/PCM cover. 4) Connector voltmeter between VSS terminal of ECM/PCM con- nector and body ground.
Page 577: Crankshaft Position Sensor
6E1-40 ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINES) CRANKSHAFT POSITION SENSOR (G16 Engine) Inspection Check crankshaft position sensor referring to Steps 2 and 3 of DTC P0335 Diag. Flow Table in “Engine Diagnosis” section. If malfunc- tion is found, replace. Removal 1) Hoist vehicle.
Page 578 ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINE) 6E1-41 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR Removal 1) Disconnect negative cable at battery. 2) Disconnect connector from MAP sensor. 3) Remove MAP sensor from intake manifold. Inspection 1) Check vacuum passage on intake manifold, and vacuum pas- sage for clog.
Page 579: Fuel Level Sensor
6E1-42 ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINES) 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 Section 8C.
Page 580: Main Relay
ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINE) 6E1-43 MAIN RELAY [A-1] Inspection 1) Disconnect negative cable at battery. 2) Remove main relay (1) from connector. [A-2] [B-1] 1. Main relay [B-2] 2. Junction (Fuse) box [A-1]: Left-hand steering hard top model [A-2]: Right-hand steering hard top model [B-1]: Left-hand steering canvas top model [B-2]: Right-hand steering canvas top model...
Page 581: Fuel Pump Relay
6E1-44 ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINES) 4) Check that there is continuity between terminals “A” and “B” when battery is connected to terminals “C” and “D”. If malfunction is found, replace. FUEL PUMP RELAY [A-1] Inspection 1) Disconnect negative cable at battery.
Page 582: Fuel Cut Operation (Inspection) 6E1-45
ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINES) 6E1-45 FUEL CUT OPERATION Inspection NOTE: Before inspection, check to make sure that gear shift lever is in Neutral position (with A/T model, selector lever in “P” range) and that parking brake lever is pulled all the way up. 1) Warm up engine to normal operating temperature.
Page 583: Emission Control System
6E1-46 ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINES) EMISSION CONTROL SYSTEM EGR SYSTEM System Inspection [Using SUZUKI scan tool (Tech 1)] 1) Connect Tech 1 to data link connector (DLC) with ignition switch OFF. Special tool (A):SUZUKI scan tool, Tech 1...
Page 584 ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINES) 6E1-47 Inspection 1) Check resistance between following terminals of EGR valve in each pair. TERMINALS STANDARD RESISTANCE A – B C – B 20 – 24 W at 20_C, 68_F F – E D –...
Page 585: Evaporative Emission Control System
6E1-48 ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINES) EVAPORATIVE EMISSION CONTROL SYSTEM Evap Canister Purge System Check 1) Warm up engine to normal operating temperature. 2) Stop engine and hoist vehicle so that all wheels rotate freely. 3) Start engine, release parking brake lever, set transfer in “2H” and M/T in “5th”...
Page 586 ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINES) 6E1-49 3) Disconnect vacuum hoses from intake manifold and its EVAP canister. 4) With coupler disconnected, blow into hose “A”. Air should not come out of hose “B”. 1. Hose “A” 2.
Page 587: Pcv System
6E1-50 ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINES) Tank Pressure Control Valve Inspection 1) Remove tank pressure control valve installed around EVAP can- ister. 2) Air should pass through valve smoothly from fuel tank side (black side of tank pressure control valve) to orange side when blown hard.
Page 588: Tightening Torque Specifications
4. DLC cable 5. Test lead/probe 6. Power source cable 7. DLC cable adaptor 8. Self–test adaptor 09917-47010 09930-88530 09931-76011 Vacuum pump gauge Injector test lead Suzuki scan tool kit 09931-76030 16 / 14 pin DLC (OBD-II Mass storage cartridge adapter) cable...
Page 589 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 590: Special Tools
6E2-2 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) ....... . 6E2-40 EGR System (if equipped) .
Page 591: General Description
ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) 6E2-3 GENERAL DESCRIPTION The engine and emission control system has 4 major Electronic control system includes ECM (PCM), vari- sub-systems: air intake system, fuel delivery system, ous sensors and controlled devices. electronic control system and emission control sys- Emission control system includes EGR, EVAP and tem.
Page 592 6E2-4 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE)
Page 593 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) 6E2-5...
Page 594: Air Intake System
6E2-6 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) AIR INTAKE SYSTEM The main components of the air intake system are air When the idle air control valve is opened according to cleaner, mass air flow sensor, air cleaner intake air the signal from ECM (PCM), the air bypasses the pipe, throttle body, intake collector, idle air control throttle valve through bypass passage and is finally...
Page 595: Fuel Delivery System
ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) 6E2-7 FUEL DELIVERY SYSTEM The fuel delivery system consists of the fuel tank, fuel amount higher than the pressure in the intake man- pump, fuel filter, fuel pressure regulator, delivery pipe ifold by the fuel pressure regulator, the fuel is injected and fuel injectors.
Page 596: Electronic Control System
6E2-8 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) ELECTRONIC CONTROL SYSTEM D Idle air control system The electronic control system consists of 1) various D Fuel pump control system sensors which detect the state of engine and driving D Evaporative emission control system conditions, 2) ECM (PCM) which controls various de- D Ignition control system vices according to the signals from the sensors and...
Page 597 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) 6E2-9...
Page 598 6E2-10 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) TERMINAL ARRANGEMENT OF ECM (PCM) CONNECTOR (VIEWED FROM HARNESS SIDE) C51-3 C51-1 C51-2...
Page 599 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) 6E2-11 1. Fuel injector No.1 CIRCUIT CIRCUIT TERMINAL TERMINAL 2. Fuel injector No.2 E61-1 Fuel pump relay C51-3-18 —— 3. Fuel injector No.3 E61-2 —— C51-3-19 —— 4. Fuel injector No.4 E61-3 —— C51-3-20 Ground 5.
Page 600: Engine & Emission Control Input/Output Table
6E2-12 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) ENGINE & EMISSION CONTROL INPUT/OUTPUT TABLE Input Function Output Main relay control Main relay Fuel pump control Fuel pump relay f f f f Injection control Injectors f f f f f f f f f f f f f f f Idle air control...
Page 601: On-Vehicle Service
ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) 6E2-13 ON-VEHICLE SERVICE 1. Brake booster hose pipe 7. Breather hose 13. IAC valve 2. Vacuum hose for fuel pressure regulator 8. EGR pipe 14. IAC hose 3. Fuel pressure regulator 9. Exhaust manifold 15.
Page 602: General
6E2-14 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) GENERAL When hoses are disconnected and system components are re- moved for service, reinstall components properly, and route and connect hoses correctly after service. Refer to figure on previous page for proper routing of hoses. ACCELERATOR CABLE ADJUSTMENT 1) Warm up engine to normal operating temperature.
Page 603: Idle Speed/Idle Air Control Duty Inspection
“Neutral” (shift selector lever to “P” range for A/T vehicle), and set parking brake and block drive wheels. [Using SUZUKI scan tool, Tech 1] 1) Connect SUZUKI scan tool to DLC with ignition switch OFF. Special Tool (A): SUZUKI scan tool, Tech 1...
Page 604 6E2-16 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) [Not using SUZUKI scan tool] (vehicle with monitor connector) NOTE: If ECM (PCM) parts No. ends with “0”, ECM (PCM) does not out- put IAC duty through duty output terminal in monitor coupler.
Page 605 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) 6E2-17 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 0.8 – 1.3% at specified idle speed (CO%) Idle mixture adjustment should never be changed from the original factory setting.
Page 606: Air Intake System
6E2-18 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) AIR INTAKE SYSTEM THROTTLE BODY 1. Throttle body 2. Intake collector 3. Breather hose 4. Water hose 5. MAF sensor 6. TP sensor 7. Fast idle up thermo wax On-Vehicle Inspection 1) Check that throttle valve lever moves smoothly. 2) Measure plunger (1) protrusion “a”...
Page 607 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) 6E2-19 Removal 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 608 6E2-20 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) 15) Remove throttle body (3) and intake collector (2) from intake manifold (1). 15) Disconnect hoses of IAC valve and PCV from throttle body. 16) Remove throttle body from intake collector. NOTE: D MAF sensor (4), TP sensor (5), or other components con- taining rubber must not be placed in a solvent or cleaner bath.
Page 609: Idle Air Control Valve
ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) 6E2-21 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 610 6E2-22 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) Installation For installation, reverse removal procedure and note following pre- cautions. D Use new gaskets (1).
Page 611: Fuel Delivery System
ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) 6E2-23 FUEL DELIVERY SYSTEM FUEL PRESSURE INSPECTION 1) Relieve fuel pressure in fuel feed line referring to “Fuel Pres- sure Relief Procedure” in “ENGINE GENERAL INFORMA- TION” section. 2) Disconnect fuel feed hose (3) from delivery fuel feed pipe (1). CAUTION: A small amount of fuel may be released when fuel feed hose is removed.
Page 612: Fuel Pump
6E2-24 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 613: Fuel Pressure Regulator
ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) 6E2-25 FUEL PRESSURE REGULATOR Removal 1) Relieve fuel pressure in fuel feed line referring to “Fuel Pressure Relief Procedure” in “ENGINE” section. 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 614: Fuel Injector
6E2-26 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) FUEL INJECTOR On-Vehicle Inspection 1) Using sound scope (1) or such, check operating sound of injec- tor when engine is running or cranking. Cycle of operating sound should vary according to engine speed.
Page 615 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) 6E2-27 7) Remove delivery pipes (1) (right and left) from intake manifold. 8) Remove fuel injector(s). Inspection WARNING: As fuel is injected in this inspection, perform in a well venti- lated area and away from open flames. Use special care to prevent sparking when connecting and disconnecting test lead to and from battery.
Page 616 6E2-28 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) 4) Install suitable vinyl tube onto injector (4) nozzle to prevent fuel Left hand Right hand from splashing out when injecting. steering vehicle steering vehicle 5) Put graduated cylinder under injector as fan apart as possible. 6) Disconnect fuel pump relay.
Page 617 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) 6E2-29 2) Check if insulator (1) is scored or damaged. If it is, replace with new one. Install insulators and cushions (2) to intake manifold. 3) Apply thin coat of fuel to O-rings (1) and then install injectors into delivery pipes (right and left) and intake manifold.
Page 618 6E2-30 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) 8) Connect fuel feed hose (1) and fuel return hose (2). 9) Connect connectors (3) to injectors. 10) Install throttle body and intake collector, refer to “THROTTLE BODY INSTALLATION” in this section. 11) With engine “OFF”...
Page 619: Electronic Control System
ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) 6E2-31 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 620: Ecm (Pcm)
6E2-32 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) MASS AIR FLOW SENSOR (MAF SENSOR) Inspection NOTE: Use voltmeter with high-impedance (10 kW/V minimum) or dig- ital type voltmeter. 1) Remove ECM (PCM) cover from bracket. 2) With ignition switch OFF, disconnect MAF sensor connector (1). 3) Connect voltmeter to C32-3 terminal (2) of MAF sensor connec- tor disconnected and ground.
Page 621 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) 6E2-33 Removal 1) Disconnect negative cable at battery and coupler from MAF sen- sor (2). 2) Remove throttle body (1), referring to “THROTTLE BODY RE- MOVAL” in this section. NOTE: Don’t remove MAF sensor. CAUTION: D Do not expose MAF sensor (throttle body) to any shock.
Page 622: Iat Sensor
6E2-34 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) INTAKE AIR TEMPERATURE (IAT) SENSOR Removal 1) Disconnect negative cable from battery. 2) Disconnect IAT sensor coupler. 3) Remove IAT sensor from air cleaner case. Inspection Immerse temperature sensing part of IAT sensor in water (or ice) and measure resistance between sensor terminals while heating water gradually.
Page 623 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) 6E2-35 THROTTLE POSITION SENSOR (TP SENSOR) Inspection 1) Warm up engine and stop it when its temperature has reached normal operating temperature (Check to make sure that they have some clearance between fast idle cam and cam follow le- ver.).
Page 624: Tp Sensor
6E2-36 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) Adjustment 1) Warm up engine to normal operating temperature. 2) Check to make sure that fast idle cam and cam follower lever are not in contact with each other. If they are, check fast idle control system.
Page 625: Ect Sensor
ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) 6E2-37 ENGINE COOLANT TEMPERATURE SENSOR (ECT SENSOR) Removal 1) Disconnect negative cable from battery. 2) Drain cooling system. 3) Disconnect coupler from ECT sensor (1). 4) Remove ECT sensor from water outlet cap (2). Inspection Immerse temperature sensing part of ECT sensor in water and measure resistance between sensor terminals while heating water...
Page 626 6E2-38 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) HEATED OXYGEN SENSOR (SENSOR 1) Removal WARNING: To avoid danger of being burned, do not touch exhaust sys- tem when system is hot. Oxygen sensor removal should be performed when system is cool. 1) Disconnect negative cable from battery.
Page 627 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) 6E2-39 HEATED OXYGEN SENSOR (SENSOR 2) Removal WARNING: To avoid danger of being burned, do not touch exhaust sys- tem when system is hot. Oxygen sensor removal should be performed when system is cool. 1) Disconnect negative cable from battery.
Page 628 6E2-40 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) 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) Connector voltmeter between VSS terminal C51-3-1 of ECM (PCM) connector and body ground.
Page 629 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) 6E2-41 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 volt- age is 4.5 – 5.0 V) and connect its positive terminal to “Vin” termi- nal of sensor and negative terminal to “Ground”...
Page 630 6E2-42 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) MAIN RELAY Left-hand steering vehicle Inspection 1) Disconnect negative cable at battery. 2) Remove main relay (1) from relay box (2). Right-hand steering vehicle 3) Check resistance between each two terminals as in table below. TERMINALS RESISTANCE 8 (Infinity)
Page 631: Fuel Pump Relay
ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) 6E2-43 FUEL PUMP RELAY Left-hand steering vehicle Inspection 1) Disconnect negative cable at battery. 2) Remove fuel pump relay (1) from relay box. 3) Structure of fuel pump relay is the same as that of main relay. Check its resistance and operation using the same procedure as that for main relay.
Page 632: Emission Control System
6E2-44 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) EMISSION CONTROL SYSTEM EGR SYSTEM (IF EQUIPPED) System Inspection [Using SUZUKI scan tool (Tech 1)] 1) Connect Tech 1 to data link connector (DLC) with ignition switch OFF. Special tool (A): SUZUKI scan tool, Tech 1...
Page 633 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) 6E2-45 Inspection 1) Check resistance between following terminals of EGR valve in each pair. Terminals Standard resistance A – B C – B 20 – 24 W at 20_C, 68F F – E D –...
Page 634: Evaporative Emission Control System
6E2-46 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 id- ling 5 min. or more. 2) Disconnect purge hose from EVAP canister when engine is run- ning at idle speed.
Page 635 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) 6E2-47 PCV VALVE 1) Disconnect PCV valve (1) from cylinder head cover and plug head cover hole. 2) Run engine at idle. 3) Place your finger over end of PCV valve to check for vacuum. If there is no vacuum, check for clogged valve.
Page 636: Tightening Torque Specifications
5. Test lead / probe 6. Power source cable 7. DLC cable adaptor 8. Self-test adaptor 09917-47010 09930-88521 09931-76011 Vacuum pump gauge Injector test lead SUZUKI scan tool (Tech 1A) SUZUKI scan tool mass 09931-76030 storage cartridge 16 / 14 pin DLC cable...
Page 637 _ Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 638: 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 639: Components
IGNITION SYSTEM (FOR G16 ENGINE) 6F1-3 COMPONENTS 1. Ignition coil assembly for No.1 and No.4 cylinders 2. Ignition coil assembly for No.2 and No.3 cylinders 3. Monitor coupler ( 4. CMP sensor NOTE: 5. ECM (or PCM) ( Above figure shows left hand steering vehicle. For right hand 6.
Page 640: Diagnostic Flow Table
6F1-4 IGNITION SYSTEM (FOR G16 ENGINE) DIAGNOSTIC FLOW TABLE STEP ACTION Was “Engine Diagnostic Flow Table” in SECTION Go to Step 2. Go to “Engine Diag- 6 performed ? nostic Flow Table” in SECTION 6. Ignition Spark Test Go to Step 10 on the Go to Step 3.
Page 641: Ignition Spark Check
IGNITION SYSTEM (FOR G16 ENGINE) 6F1-5 STEP ACTION Ignition Timing Check System is in good Adjust ignition timing 1) Check initial ignition timing and ignition timing condition. if adjustable or check advance, referring to “Ignition Timing Check” in CMP sensor, signal this section.
Page 642: Ignition Timing Check
4) Fix ignition timing as follows. [Using SUZUKI scan tool (Tech 1)] Connect SUZUKI scan tool (Tech 1) to DLC (1) with ignition switch OFF, restart engine and fix ignition timing by using fixed spark mode of SUZUKI scan tool (Tech 1).
Page 643 – 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 re- move service wire from monitor connector. CAUTION: Driving with test switch terminal grounded will cause damage to catalyst.
Page 644: On-Vehicle Service
6F1-8 IGNITION SYSTEM (FOR G16 ENGINE) ON-VEHICLE SERVICE HIGH-TENSION CORD REMOVAL 1) Remove high-tension cord from ignition coil assembly while gripping its cap. 2) Pull out high-tension cord from spark plug while gripping its cap. CAUTION: _ Removal of high-tension cords together with clamps will be recommended so as to damage their inside wire (resistive conductor).
Page 645: Ignition Coil Assembly (Igniter And Ignition Coil)
IGNITION SYSTEM (FOR G16 ENGINE) 6F1-9 IGNITION COIL ASSEMBLY (IGNITER AND IGNITION COIL) REMOVAL 1) Disconnect ignition coil coupler. 2) Disconnect high-tension cord from ignition coil assembly. 3) Remove ignition coil bolt, and then pull out ignition coil assem- bly. 1.
Page 646: Spark Plug
6F1-10 IGNITION SYSTEM (FOR G16 ENGINE) SPARK PLUG REMOVAL 1) Pull out high-tension cord while gripping its cap. 2) Remove ignition coil assembly, referring to “Ignition Coil Assem- bly” under “On-Vehicle Service” earlier in this section. 3) Remove spark plug 1.
Page 647: Cmp Sensor
IGNITION SYSTEM (FOR G16 ENGINE) 6F1-11 INSPECTION Measure resistance of ignition timing adjusting resistor by using ohmmeter. NOTE: Depending on number marked on ignition timing adjusting re- sistor, resistor value varies as follows. 980 – 1020 W 80 – 84 W 7: 1.35 –...
Page 648: Tightening Torque Specification
4. DLC cable 5. Test lead / probe 6. Power source cable 7. DLC cable adapter 8. Self-test adapter 09930-76420 09931-76011 09931-76030 Timing light (Dry cell type) SUZUKI scan tool (Tech 1A) kit 16 / 14 pin DLC cable Mass storage cartridge...
Page 649 _ Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 650: 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 651: Components
IGNITION SYSTEM (FOR J20 / H25 ENGINES) 6F2-3 COMPONENTS J20 Engine H25 Engine 1. Ignition coil assembly (Igniter and ignition coil) 2. Monitor coupler (*) (if equipped) NOTE: 3. CMP sensor Above figure shows left hand steering vehicle. 4. Noise suppressor For right hand steering vehicle, parts with (*) are 5.
Page 652: Diagnosis
6F2-4 IGNITION SYSTEM (FOR J20 / H25 ENGINES) DIAGNOSIS Condition Possible Cause Correction Engine cranks, but will not No spark _ Blown fuse for ignition coil assembly start or hard to start Replace _ Loose connection or disconnection of lead Connect securely wire _ Faulty spark plug(s)
Page 653 IGNITION SYSTEM (FOR J20 / H25 ENGINES) 6F2-5 STEP ACTION Ignition Coil Assembly Check Malfunction of igni- Go to Step 7. 1) Substitute a known-good ignition coil assembly tion coil assembly. and then repeat Step 2. Is check result of Step 2 satisfactory? CMP Sensor Check Substitute a known- Tighten CMP sensor...
Page 654: Ignition Spark Check
Refer to SECTION 6E1 or 6E2. 4) [Using SUZUKI scan tool (Tech 1)] Connect SUZUKI scan tool (Tech 1) to DLC (1) with ignition switch OFF, restart engine and fix ignition timing by using fixed spark mode of SUZUKI scan tool (Tech 1).
Page 655 IGNITION SYSTEM (FOR J20 / H25 ENGINES) 6F2-7 5) Set timing light to ignition harness for No.1 cylinder. J20 Engine 6) Using timing light, check that timing observed from viewpoint is within specification. Initial ignition timing of viewpoint (when it is fixed by Tech 1 or service wire): 5 + 1_ BTDC Ignition order: 1-3-4-2 (J20 engine) : 1-6-5-4-3-2 (H25 engine) Special Tool...
Page 656 6F2-8 IGNITION SYSTEM (FOR J20 / H25 ENGINES) 9) After checking and/or adjusting, end fixed spark mode of SU- J20 Engine ZUKI scan tool or disconnect service wire from monitor cou- pler. CAUTION: Driving with test switch terminal grounded will cause damage to catalyst.
Page 657: On-Vehicle Service
IGNITION SYSTEM (FOR J20 / H25 ENGINES) 6F2-9 ON-VEHICLE SERVICE J20 Engine 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, and then pull out ignition coil assem- bly.
Page 658 6F2-10 IGNITION SYSTEM (FOR J20 / H25 ENGINES) INSPECTION CAUTION: When servicing the iridium/platinum sparkplugs (slender center electrode type plugs), do not touch the center elec- trode to avoid damage to it. The electrode is not strong enough against mechanical force as it is slender and its ma- terial is not mechanically tough.
Page 659: Cmp Sensor
IGNITION SYSTEM (FOR J20 / H25 ENGINES) 6F2-11 CMP SENSOR J20 Engine CAUTION: Disassembly is prohibited. If anything faulty is found, re- place as an assembly unit. REMOVAL 1) Disconnect CMP sensor coupler. 2) Remove CMP sensor by removing bolt(s). H25 Engine 1.
Page 660: Noise Suppressor
6F2-12 IGNITION SYSTEM (FOR J20 / H25 ENGINES) 3) Tighten CMP sensor bolts. J20 Engine Tightening Torque (a): 15 N m (1.5 kg-m, 11.0 lb-ft) 4) Connect CMP sensor coupler. 3, (a) H25 Engine 1. CMP sensor 2. CMP sensor coupler 3.
Page 661 IGNITION SYSTEM (FOR J20 / H25 ENGINES) 6F2-13 INSTALLATION For installation, reverse removal procedure.
Page 662: Tightening Torque Specifications
4. DLC cable 5. Test lead / probe 6. Power source cable 7. DLC cable adapter 8. Self-test adapter 09930-76420 09931-76011 09931-76030 Timing light (Dry cell type) SUZUKI scan tool (Tech 1A) kit 16 / 14 pin DLC cable Mass storage cartridge...
Page 663: Special Tools
CRANKING SYSTEM 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. CONTENTS GENERAL DESCRIPTION .
Page 664: General Description
6G-2 CRANKING SYSTEM GENERAL DESCRIPTION CRANKING CIRCUIT The cranking circuit consists of the battery, starting motor, ignition switch, and related electrical wiring. These com- ponents are connected electrically. Only the starting motor will be covered in this section. STARTING MOTOR CIRCUIT _ The magnetic switch coils are magnetized when the ignition switch is closed.
Page 665: Starting Motor
CRANKING SYSTEM 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 666: Diagnosis
6G-4 CRANKING SYSTEM 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 _ Abnormal noise is heard Proper diagnosis must be made to determine exactly where the cause of each trouble lies..in battery, wiring har- ness, (including starting motor switch), starting motor or engine.
Page 667 CRANKING SYSTEM 6G-5 Condition Possible Cause Correction _ Burnt commutator Motor not running Replace armature. _ Layer short-circuit of armature Replace. _ Crankshaft rotation obstructed Repair. Starting motor running If battery and wiring are satisfactory, but too slow (small torque) inspect starting motor _ Insufficient contact of magnetic switch Replace magnetic switch.
Page 668: Unit Repair Overhaul
6G-6 CRANKING SYSTEM 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. 3) Remove two starting motor mount bolts. 4) Remove starting motor.
Page 669 CRANKING SYSTEM 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 plan- 1. Planetary gear etary gears. 2.
Page 670 6G-8 CRANKING SYSTEM 7) Remove snap ring, then pull out pinion stop ring and over-run- ning clutch and internal gear. Special Tool (A): 09900-06107 1. Internal gear 2. Snap ring 3. Pinion stop ring 4. Over-running clutch 8) Remove rear bracket and brush holder. 1.
Page 671 CRANKING SYSTEM 6G-9 11) Remove brush springs and brushes. 12) Remove rear bracket cap, and then remove rear bush, as re- quired. 1. Rear bush 2. Rear bracket cap 3. Rear bracket...
Page 672: Reassembly
6G-10 CRANKING SYSTEM REASSEMBLY CAUTION: _ Washing, adjusting and disassembling of shock absorber (clutch plate) are not allowed. _ New oilless bearing have been lubricated when they are supplied as spare parts. DO NOT wash with grease dis- solving solvent nor lubricate them with other lubricant. 1) Inspect component parts (Refer to page 6G-12) and replace with new ones as necessary.
Page 673 CRANKING SYSTEM 6G-11 11) Install packing so that cuts in packing align with holes for through bolts in front housing. 12) Install plate and seal rubber to front housing. 1. Packing 2. Planetary gear 3. Bolt hole 4. Seal rubber 13) Apply grease to ball and install ball into shaft hole.
Page 674: Inspection
6G-12 CRANKING SYSTEM INSPECTION 1. PLUNGER Inspect plunger for wear. Replace if necessary. 2. MAGNETIC SWITCH Push in plunger and release it. The plunger should return quickly to its original position. Replace if necessary. _ Pull-In Coil Open Circuit Test Check for continuity across magnetic switch ‘S’...
Page 675 CRANKING SYSTEM 6G-13 4. BRUSH _ Check brushes for wear. Measure length of brushes and if below limit, replace brush. Brush length 0.9 kW and 1.2 kW types 1.4 kW type 16.5 mm Standard 12.3 mm (0.44 in.) (0.65 in.) Limit 7 mm (0.28 in.) _ Install brushes to each brush holder and check for smooth...
Page 676 6G-14 CRANKING SYSTEM _ Check commutator for uneven wear with armature supported 1. Armature 2. V-block on V-blocks. If deflection of dial gauge pointer exceeds limit, 3. Magnetic stand repair or replace. 4. Dial gauge NOTE: Below specification presupposes that armature is free from bend.
Page 677 CRANKING SYSTEM 6G-15 _ Open Circuit Test Check for continuity between segments. If there is no continuity at any test point, there is an open circuit and armature must be replaced. 8. GEARS Inspect internal gear and planetary gears for wear, damage or other abnormal conditions.
Page 678: Performance Test
6G-16 CRANKING SYSTEM PERFORMANCE TEST CAUTION: Each test must be performed within 3 – 5 seconds to avoid coil from burning. 1) Pull-In Test Connect battery to magnetic switch as shown. Check that plunger and pinion move outward. If plunger and pinion don’t move, replace magnetic switch. NOTE: Before testing, disconnect lead wire from terminal M.
Page 679: Specifications
CRANKING SYSTEM 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 Condition...
Page 680: Required Service Material
6G-18 CRANKING SYSTEM REQUIRED SERVICE MATERIAL RECOMMENDED MATERIAL SUZUKI PRODUCT _ Front and rear bush. _ Plunger. _ Pinion drive lever. SUZUKI SUPER GREASE A _ Internal gear. Lithium grease (99000-25010) _ Planetary carrier shaft. _ Planetary gear _ Ball SPECIAL TOOL...
Page 681 CRANKING SYSTEM 6G1-1 SECTION 6G1 CRANKING SYSTEM (0.9 kW No-Reduction Type) CONTENTS GENERAL DESCRIPTION ....6G1-2 Inspection ......6G1- 8 Cranking Circuit .
Page 682: General Description
6G1-2 CRANKING SYSTEM GENERAL DESCRIPTION CRANKING CIRCUIT The cranking circuit consists of the battery, starting motor, ignition switch, and related electrical wiring. These com- ponents are connected electrically as shown below. Only the starting motor will be covered in this section. To distributor Pull in coil Magnetic switch...
Page 683 CRANKING SYSTEM 6G1-3 1. Drive housing cover 2. Drive bush 3. Drive housing 4. Armature ring 5. Armature stop ring 6. Over running clutch 7. Pinion drive lever 8. Magnetic switch 9. Commutator end cover 10. Brush spring 11. Brush holder 12.
Page 684: Diagnosis
6G1-4 CRANKING SYSTEM DIAGNOSIS Possible symptoms due to starting system trouble would be as follows: D Starting motor does not run (or runs slowly) D Starting motor runs but fails to crank engine D Abnormal noise is heard Proper diagnosis must be made to determine exactly where the cause of each trouble lies ..in battery, wiring harness, (including ignition and starter switch), starting motor or engine.
Page 685 CRANKING SYSTEM 6G1-5 Condition Possible Cause Correction Starting motor running If battery and wiring are satisfactory, but too slow (small inspect starting motor D Insufficient contact of magnetic switch torque) Replace magnetic switch. main contacts D Layer short-circuit of armature Replace.
Page 686: Unit Repair Overhaul
6G1-6 CRANKING SYSTEM UNIT REPAIR OVERHAUL 1. Starting motor 2. Clutch housing upper plate 3. Transmission case 4. Starting motor mounting bolt 5. Starting motor mounting nut 6. Magnetic switch lead wire 7. Battery cable DISMOUNTING 1) Disconnect negative battery lead at battery. 2) Disconnect magnetic switch lead wire and battery cable from starting motor.
Page 687: Disassembly
CRANKING SYSTEM 6G1-7 DISASSEMBLY NOTE: D Before disassembling starting motor, be sure to put match marks at two locations (A and B) as shown in the left figure so that any possible mistakes can be avoided. D Do not clamp yoke in a vise or strike it with a hammer during 1.
Page 688: Reassembly
6G1-8 CRANKING SYSTEM 6) Draw off over running clutch, as follows: (1) Draw stop ring toward clutch side. (2) Remove armature ring and side off clutch. 1. Stop ring 2. Snap ring 3. Pinion gear 4. Clutch REASSEMBLY Assemble in reverse order of Disassembly, noting the following. 1) Apply grease.
Page 689 CRANKING SYSTEM 6G1-9 D Inspect commutator for insulator depth. Correct or replace if be- 0.4 – 0.8 mm (0.015 – 0.023 in.) Insulator low limit. Commutator segments Commutator mica depth Standard: 0.4 – 0.6 mm (0.015 – 0.023 in.) Limit: 0.2 mm (0.0078 in.) CORRECT INCORRECT...
Page 690 6G1-10 CRANKING SYSTEM 4. BRUSH HOLDER Check movement of brush in brush holder. If brush movement within brush holder is sluggish, check brush holder for distortion and sliding faces for correct contamination. Clean or correct as necessary. Clean for continuity across insulated brush holder (positive side) and grounded brush holder (negative side).
Page 691 CRANKING SYSTEM 6G1-11 D Inspect spline teeth for wear or damage. Replace if necessary. Inspect pinion for smooth movement. 8. ARMATURE SHAFT BUSH Inspect bushes for wear or damage. Replace if necessary. 9. MAGNETIC SWITCH Push in plunger and release it. Plunger should return quickly to its original position.
Page 692: Performance Test
6G1-12 CRANKING SYSTEM PERFORMANCE TEST CAUTION: These tests must be performed within 3 - 5 seconds to avoid coil from burning. D PULL-IN TEST ‘BAT’ Connect battery to magnetic switch as shown. Check that pinion moves outward. If pinion does not move, replace magnetic switch. NOTE: ‘S’...
Page 693: Specifications
Magnetic switch operating voltage 8 volts maximum REQUIRED SERVICE MATERIAL RECOMMENDED MATERIAL SUZUKI PRODUCT D Armature shaft. D Over-running clutch. SUZUKI SUPER GREASE A Lithium grease D Commutator end cap. (99000-25010) D Drive lever. SPECIAL TOOL 09900-06107 Snap ring pliers...
Page 694: Charging System
_ Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 695: 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 696 CHARGING SYSTEM 6H-3 CARE OF BATTERY WARNING: _ Never expose battery to open flame or electric spark be- cause of battery generate gas which is flammable and ex- plosive. _ Do not allow battery fluid to contact eyes, skin, fabrics, or painted surfaces as fluid is a corrosive acid.
Page 697: Generator
6H-4 CHARGING SYSTEM 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. _ All regulator components are enclosed into a solid mold.
Page 698 CHARGING SYSTEM 6H-5 [60 A type] [70 A type] [85 A type] 1. Pulley 7. Regulator : Generator output (Battery terminal) 2. Pulley nut 8. Brush : Dummy terminal 3. Rotor fan 9. Rear end frame : Ground 4. Stator coil 10.
Page 699: Diagnosis
6H-6 CHARGING SYSTEM 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 apparent reason, the following are some factors that may point to the cause of trouble: _ Accessories left on overnight or for an extended period without...
Page 700 CHARGING SYSTEM 6H-7 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 701: Generator
6H-8 CHARGING SYSTEM GENERATOR [60 A type] CAUTION: _ Do not mistake polarities of IG terminal and L terminal. _ Do not create a short circuit between IG and L terminals. Always connect these terminals through a lamp. _ Do not connect any load between L and E. _ When connecting a charger or a booster battery to vehicle battery, refer to this section describing battery charging.
Page 702 CHARGING SYSTEM 6H-9 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 amme- ter.
Page 703 6H-10 CHARGING SYSTEM 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 704: On-Vehicle Service
CHARGING SYSTEM 6H-11 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 emis- sion system and/or to other parts may result.
Page 705: Dismounting
6H-12 CHARGING SYSTEM WITH CHARGING EQUIPMENT CAUTION: When jump starting engine with charging equipment, be sure equipment used is 12-volt and negative ground. Do not use 24-volt charging equipment. Using such equipment can cause serious damage to electrical system or electronic parts.
Page 706: Generator
CHARGING SYSTEM 6H-13 GENERATOR GENERATOR BELT [G16 and H25 engines] Refer to “COOLING FAN BELT” in SECTION 6B “ENGINE COOL- ING”. [J20 engine] INSPECTION _ Inspect belt for cracks, cuts, deformation, wear and cleanliness. If any of above conditions are found replace generator belt. _ Check to make sure that tension indicators are as follows in the left figure by using mirror.
Page 707: Unit Repair Overhaul
6H-14 CHARGING SYSTEM UNIT REPAIR OVERHAUL GENERATOR DISMOUNTING 1) Disconnect negative (–) cable at battery. 1. Battery 2. Negative (–) battery cable 2) Remove air cleaner outlet hose. 3) Remove canister from its bracket. 1. Air cleaner outlet hose 2. Canister 4) Disconnect “B”...
Page 708: Remounting
CHARGING SYSTEM 6H-15 REMOUNTING 1) Mount generator on the generator bracket. 2) Tighten generator bolts. Tightening Torque (a): 23 N m (2.3 kg-m, 16.5 lb-ft) 3) Install generator (cooling fan) belt. Refer to SECTION 6B “EN- GINE COOLING” (G16 and H25 engines) or “GENERATOR BELT”...
Page 709: Disassembly
6H-16 CHARGING SYSTEM DISASSEMBLY [60 A type] 1. Pulley 2. Front housing 3. Bearing 4. Retainer 5. Rotor 6. Stator 7. IC regulator 8. Rectifier 9. Rear housing 10. Brush 1) For easier reinstallation, provide match marks on both front and rear housings as shown in left figure before separating them.
Page 710 CHARGING SYSTEM 6H-17 3) With lever inserted between stator core and front housing, sepa- rate 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. 1.
Page 711 6H-18 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 3. “B” terminal 2. Generator “B” terminal nut 9) Unsolder stator leads and remove stator from rear housing and regulator assembly.
Page 712 CHARGING SYSTEM 6H-19 DISASSEMBLY [70 A and 85 A types] [70A type] 1. Pulley nut 2. Pulley 3. Drive end frame 4. Stator 5. Stud bolt 6. Drive end bearing 7. Bearing retainer 8. Rotor 9. End housing bearing 10. Bearing cover 11.
Page 713 6H-20 CHARGING SYSTEM 1) Remove “B” terminal inner nut and insulator. 2) Remove rear end cover. 1. Rear end cover 2. Insulator 3. “B” terminal inner nut 3) Remove 2 screws and pull out brush holder assembly. 4) Remove 3 screws and IC regulator. 5) Remove brush holder cover from brush holder.
Page 714 CHARGING SYSTEM 6H-21 9) Remove 4 rear end frame nuts. 10) Drive out rear end frame with rotor tapping shaft lightly by using plastic hammer. 11) Separate rear end frame from rotor evenly by using plastic hammer. CAUTION: Do not hit shaft at slip ring side, when separating rotor and rear end frame.
Page 715: Inspection
6H-22 CHARGING SYSTEM INSPECTION [60 A type] Rotor 1) Using ohmmeter, check for continuity between slip rings of rotor. If there is no continuity, replace rotor. Standard resistance: 2.5 – 2.9 W 1. Rotor 2) Using ohmmeter, check that there is no continuity between slip ring and rotor core.
Page 716 CHARGING SYSTEM 6H-23 Rectifier 1) Using ohmmeter, check continuity between each of upper and lower rectifier bodies and each diode lead. Check both directions by reversing probes of ohmmeter and there should be only one-way continuity in each case. If check result is not satisfactory, replace rectifier. 2) In the same manner as described in above step 1), check that there is only one-way continuity between both leads of diode trio.
Page 717 6H-24 CHARGING SYSTEM INSPECTION [70 A and 85 A types] Rotor _ Using ohmmeter, check for continuity between slip rings of rotor. If there is no continuity, replace rotor. Standard resistance: About 2.9 W _ Using ohmmeter, check that there is no continuity between slip ring and rotor.
Page 718 CHARGING SYSTEM 6H-25 Brush and brush holder Check each brush for wear by measuring its length as shown. If “a” brush is found worn down to service limit, replace brush. Refer to “Replace Brush” in this section. Exposed brush length “a” Standard: 10.5 mm (0.413 in.) Limit : 4.5 mm (0.351 in.)
Page 719: Replace Brush
6H-26 CHARGING SYSTEM REPLACE BRUSH [60 A type] Refer to “DISASSEMBLY” and “REASSEMBLY” of 60 A type. [70 A and 85 A types] 1) Remove rear end cover and then brush holder. 2) Unsolder and remove the brush and spring. 3) Run the wire of a new brush through the spring and the hole in the brush holder, and insert the spring and brush into the brush holder.
Page 720: Reassembly
CHARGING SYSTEM 6H-27 REASSEMBLY [60 A type] Assemble in reverse order of DISASSEMBLY, noting the following. 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 721 6H-28 CHARGING SYSTEM REASSEMBLY [70 A and 85 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. 1, (a) 4) If drive end bearing is removed, install it.
Page 722 CHARGING SYSTEM 6H-29 10) Install 4 rubber insulators. 1. Rectifier insulators 11) Install rectifier. CAUTION: When installing rectifier, check to confirm that stator leads have enough clearance with cooling fan blades. Tightening Torque (a): 2.0 N m (0.2 kg-m, 1.5 lb-ft) (b): 3.9 N m (0.39 kg-m, 3.0 lb-ft) 1.
Page 723 6H-30 CHARGING SYSTEM 17) Make sure that rotor turns smoothly.
Page 724: Specifications
CHARGING SYSTEM 6H-31 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) (5.92/4.93) (6.55/5.46) (8.24/6.86) (8.24/6.86) Electrolyte S.G.
Page 725: Exhaust System
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-1 MAINTENANCE .
Page 726 6K-2 EXHAUST SYSTEM COMPONENTS NOTE: Tighten bolts and nuts ((a), (b), (c)) to specified torque, referring to “MUFFLER” in this section. 1-1. Exhaust manifold (J20 engine without WU-TWC) 1-6. Exhaust No.2 pipe 1-2. Exhaust manifold (G16 engine without WU-TWC) 1-7. Gasket 1-3.
Page 727 EXHAUST SYSTEM 6K-3 MAINTENANCE WARNING: To avoid the danger of being burned, do not touch the ex- haust system when the system is hot. Any service on the ex- haust system should be performed when the system is cool. At every interval of periodic maintenance service, and when vehicle is raised for other service, check exhaust system as follows: D Check rubber mountings for damage, deterioration, and out of position.
Page 728 6K-4 EXHAUST SYSTEM ON-VEHICLE SERVICE WARNING: To avoid the danger of being burned, do not touch the ex- haust system when the system is hot. Any service on the ex- haust system should be performed when the system is cool. EXHAUST MANIFOLD Refer to Section 6A1, 6A2 or 6A4 for removal and installation proce- dures.
Page 729 Prepared by Overseas Service Department 1st Ed. April, 2000 Printed in Japan Printing: April, 2000...

This manual is also suitable for:

2000 grand vitara sq416 2000 grand vitara sq420

Suzuki 2000 Grand Vitara SQ625 Service Manual

Table of Contents

Table of Contents

Engine Diagnosis

Special Tools

Engine Mechanical (G16 Engine)

General Description

On-Vehicle Service

Unit Repair Overhaul

Special Tools

Required Service Materials

(H25 Engine)

General Description

On-Vehicle Service

Unit Repair Overhaul

Special Tools

Required Service Material

Section 6A4 Engine Mechanical (J20 Engine)

General Description

On-Vehicle Service

Unit Repair Overhaul

Special Tools

Required Service Materials

Section 6B Engine Cooling

General Description

Maintenance

Diagnosis

On-Vehicle Service

Required Service Material

Tightening Torque Specification

Section 6E1 Engine and Emission Control System (Sequential Multiport Fuel Injection for G16/J20 Engines)

On-Vehicle Service

Tightening Torque Specifications

Section 6E2 Engine and Emission Control System (Sequential Multiport Fuel Injection for H25 Engine)

Special Tools

General Description

On-Vehicle Service

Tightening Torque Specifications

Section 6F1 Ignition System (for G16 Engine)

General Description

Diagnosis

On-Vehicle Service

Special Tools

Tightening Torque Specification

Section 6F2 Ignition System (for J20/H25 Engines)

General Description

Diagnosis

On-Vehicle Service

Tightening Torque Specifications

Section 6G Cranking System (0.9 Kw, 1.2 Kw and 1.4 Kw Reduction Type)

Special Tools

General Description

Diagnosis

Unit Repair Overhaul

Specifications

Required Service Material

Special Tool

Quick Links

Chapters

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Summary of Contents for Suzuki 2000 Grand Vitara SQ625